Servis Manual 590ST, 695ST

580ST
590ST
695ST
Backhoe Loaders
Service Manual
Print No. 84568047A

TO THE READER
This manual has been printed for a skilful engi- CNH ITALIA S.p.A.
neer to supply necessary technical information to Technical Information
carry out service operations on this machine. Via Plava, 80
10135 Torino - Italy
Carefully read this manual to collect correct infor-
mation relevant to repair procedures.
For any question or remark, or in case of any
error relevant the contents of this manual, please
contact:
REFERENCES
Beyond this Service Manual, also refer to the
documents listed below:
- Operator’s Manual
- Service Parts Catalogue
SERVICE MANUAL The Service Manuals for “Backhoe loader” and

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

Service Manual - “Backhoe loader” 580ST - 590ST - 695ST 84568047A
Service Manual - “Engine” 580ST - 590ST - 695ST 84496807
PREVENT ACCIDENTS
The majority of accidents and injuries which occur in the workshop, at the worksite or on the road, are caused
by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason
most accidents can be prevented by recognizing the real cause and taking the necessary precautions, before
the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be conditions
that cannot be completely safeguarded against, without interfering with reasonable accessibility and efficient
operation.
A careful operator and / or technician is the best insurance against accidents.

The careful observance of this single safety rule would be sufficient to prevent serious injuries:
Never attempt to clean, lubricate or adjust a machine while it is in motion.
S WARNING S
Before carrying out any maintenance operation, adjustment and or repair on machines equipped with attach-
ments, controlled hydraulically or mechanically, make sure that the attachment is lowered and safely set on
the ground. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be
sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and /or
mechanical device used for controlling the equipment.
CNH ITALIA S.p.A.

Technical Information
Via Plava, 80
10135 Torino - Italy
All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.
BACKHOE LOADER MODELS
The complete range of Backhoe Loader models described in this manual are identified below:
580ST 590ST 695ST

Powershift / / O
Powershuttle O O /
Sideshift stabilizers / / O
Center pivot stabilizers / / O
Cab O O O
Rops / / /
2WD / / /
4WD O O O
4WS / / O
Pilot control O O O
Mechanical control O O O
Engine Iveco 72 kW - 97 HP model

O / /
CASE 434T/E (electronic)
/ O O
Short backhoe dipper / / /
Long backhoe dipper O O O
INDEX
SECTION 00 - SAFETY RULES

FOREWORD..................................................................................................................................................... 4
SAFETY INSTRUCTIONS ................................................................................................................................ 6
PREVENTION OF FIRE OR EXPLOSIONS..................................................................................................... 8
PREVENTION OF BURNS ............................................................................................................................... 9
PRECAUTIONS FOR WASTE DISPOSAL..................................................................................................... 10
SECTION 01 - MAINTENANCE
SECTION 02 - TECHNICAL SPECIFICATIONS

MODELS........................................................................................................................................................... 3
IDENTIFICATION OF MAIN COMPONENTS................................................................................................... 4
TECHNICAL SPECIFICATIONS....................................................................................................................... 6
DIESEL ENGINE ......................................................................................................................................... 6
TRANSMISSION.......................................................................................................................................... 8
AXLES ......................................................................................................................................................... 9
BRAKES .................................................................................................................................................... 10
STEERING................................................................................................................................................. 10
HYDRAULIC SYSTEM .............................................................................................................................. 11
FRONT COUNTERWEIGHT ..................................................................................................................... 11
BUCKETS .................................................................................................................................................. 12
TYRES ....................................................................................................................................................... 13
DPF SYSTEM ............................................................................................................................................ 14
DIMENSIONS AND PERFORMANCE............................................................................................................ 18

DIMENSIONS - 2WS SIDESHIFT ............................................................................................................. 18
DIMENSIONS - 4WS CENTER PIVOT...................................................................................................... 20
LOADER ATTACHMENT PERFORMANCE.............................................................................................. 21
PERFORMANCE OF LOADER BUCKET WITH FORKS .......................................................................... 23
BACKHOE ATTACHMENT PERFORMANCE........................................................................................... 24
MAXIMUM LIFTING LOADS........................................................................................................................... 27

LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE .................................................................. 27
BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................... 28
SUPPLY SUMMARY TABLE .......................................................................................................................... 29

INDEX
SECTION 10 - ENGINE
REMOVAL AND INSTALLATION THE ENGINE HOOD, THE RADIATOR AND ENGINE .............................. 3
PRELIMINARY OPERATIONS .................................................................................................................... 3
BATTERY.......................................................................................................................................................... 4
DISCONNECT ............................................................................................................................................. 4
ENGINE HOOD................................................................................................................................................. 6
REMOVE...................................................................................................................................................... 6
RADIATOR........................................................................................................................................................ 9
REMOVE...................................................................................................................................................... 9
ENGINE .......................................................................................................................................................... 16
REMOVE.................................................................................................................................................... 16
INSTALL..................................................................................................................................................... 26
RADIATOR...................................................................................................................................................... 35
INSTALL..................................................................................................................................................... 35
ENGINE HOOD............................................................................................................................................... 41
INSTALL..................................................................................................................................................... 41
BATTERY........................................................................................................................................................ 44
CONNECT ................................................................................................................................................. 44
ENGINE ERROR CODES............................................................................................................................... 46
SECTION 21 - TRANSMISSION
POWERSHUTTLE TRANSMISSION................................................................................................................ 3
TECHNICAL SPECIFICATIONS.................................................................................................................. 4
CONTROLS ................................................................................................................................................. 8
LUBRICATION ........................................................................................................................................... 12
GREASING ................................................................................................................................................ 15
REMOVAL FROM MACHINE .................................................................................................................... 17
DISASSEMBLY AND ASSEMBLY............................................................................................................. 20
TROUBLESHOOTING ............................................................................................................................. 132
TRANSMISSION ERROR CODES .......................................................................................................... 136
REPAIR TIMES........................................................................................................................................ 140
SPECIAL TOOLS..................................................................................................................................... 141
POWERSHIFT TRANSMISSION.................................................................................................................. 142

TECHNICAL SPECIFICATIONS.............................................................................................................. 142
CONTROLS ............................................................................................................................................. 153
LUBRICATION ......................................................................................................................................... 155
GREASING .............................................................................................................................................. 157
REMOVAL FROM MACHINE .................................................................................................................. 158
DISASSEMBLY AND ASSEMBLY........................................................................................................... 161
TRANSMISSION ERROR CODES .......................................................................................................... 329
REPAIR TIMES........................................................................................................................................ 333
SPECIAL TOOLS..................................................................................................................................... 334
INDEX
SECTION 25 - FRONT AXLE

2WS FRONT AXLE........................................................................................................................................... 3
LUBRICATION AND GREASING ................................................................................................................ 4
REMOVAL FROM MACHINE ...................................................................................................................... 6
DISASSEMBLY AND ASSEMBLY............................................................................................................... 7
TROUBLESHOOTING................................................................................................................................. 7
4WD - 2WS FRONT AXLE ............................................................................................................................. 10

TECHNICAL SPECIFICATIONS................................................................................................................ 10
LUBRICATION AND GREASING .............................................................................................................. 11
TROUBLESHOOTING............................................................................................................................... 57
SPECIAL TOOLS....................................................................................................................................... 61
4WS FRONT AXLE......................................................................................................................................... 62

SECTION 27 - REAR AXLE

2WS REAR AXLE (580ST) ............................................................................................................................... 3
REPAIR TIMES.......................................................................................................................................... 67
SPECIAL TOOLS....................................................................................................................................... 68
2WS REAR AXLE (590ST) ............................................................................................................................. 69

TROUBLESHOOTING............................................................................................................................. 127
REPAIR TIMES........................................................................................................................................ 133
SPECIAL TOOLS..................................................................................................................................... 134
4WS REAR AXLE (695ST) ........................................................................................................................... 135

LUBRICATION AND GREASING ............................................................................................................ 138
REPAIR TIMES........................................................................................................................................ 225
SPECIAL TOOLS..................................................................................................................................... 227
INDEX
SECTION 33 - BRAKE SYSTEM

PARKING BRAKE............................................................................................................................................. 3
OPERATION ................................................................................................................................................ 3
ADJUSTMENT ............................................................................................................................................. 4
SERVICE BRAKE ........................................................................................................................................... 15

OPERATION .............................................................................................................................................. 15
BRAKE PUMP - Remove ........................................................................................................................... 16
BRAKE PUMP - Install ............................................................................................................................... 18
SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS ................................................................................................................................. 3
HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS ....................................................... 3
HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .................................................................... 9
HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS ..................................................... 13
HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS .................................................................. 15
HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .......................................................... 17
HYDRAULIC PUMP ........................................................................................................................................ 19

HYDRAULIC FIXED-FLOW-RATE GEAR PUMP...................................................................................... 19
HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP............................................................................ 30
CONTROL VALVES........................................................................................................................................ 44
LOADER CONTROL VALVE ..................................................................................................................... 53
BACKHOE ATTACHMENT CONTROL VALVE......................................................................................... 57
RELIEF VALVES........................................................................................................................................ 69
BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE .................................................. 78
ACCUMULATOR “AUTO GLIDE RIDE” PARKER .......................................................................................... 81

MAINTENANCE ......................................................................................................................................... 81
SAFETY ..................................................................................................................................................... 81
CHECKING AND ADJUSTING THE PRECHARGE PRESSURE ............................................................. 82
HYDRAULIC SWING SYSTEM ...................................................................................................................... 84

OPERATION .............................................................................................................................................. 84
HYDRAULIC CYLINDERS.............................................................................................................................. 87
LOADER ATTACHMENT BOOM CYLINDER............................................................................................ 88
LOADER BUCKET CYLINDER.................................................................................................................. 93
4X1 LOADER BUCKET CYLINDER .......................................................................................................... 97
BACKHOE BOOM CYLINDER ................................................................................................................ 100
BACKHOE ATTACHMENT DIPPER CYLINDER .................................................................................... 104
BACKHOE BUCKET CYLINDER............................................................................................................. 108
TELESCOPIC CYLINDER ....................................................................................................................... 112
STABILIZER CYLINDER - CENTER PIVOT (695ST).............................................................................. 115
STABILIZER CYLINDER - SIDESHIFT ................................................................................................... 119
SWING CYLINDER.................................................................................................................................. 123
INDEX
BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT.................................................................. 127

SPECIAL TOOLS..................................................................................................................................... 128
HYDRAULIC CONTROL LEVERS ............................................................................................................... 129

CONTROLS AND OPERATION .............................................................................................................. 130
COMPONENTS ....................................................................................................................................... 131
CONTROL LEVER VALVE ...................................................................................................................... 136
TROUBLESHOOTING.................................................................................................................................. 138
PRELIMINARY CHECKS......................................................................................................................... 138
TROUBLESHOOTING (WITH “REXROTH” CONTROL VALVES).......................................................... 139
SWING..................................................................................................................................................... 141
HYDRAULIC PUMP................................................................................................................................. 142
SECTION 39 - CHASSIS
DESCRIPTION ................................................................................................................................................. 3
REMOVAL AND INSTALLATION OF COMPONENTS .................................................................................... 5

COMPONENTS WITHIN THE CHASSIS .................................................................................................... 5
COMPONENTS OF THE LOWER PART OF THE CHASSIS ..................................................................... 6
COMPONENTS ATTACHED OUTSIDE THE CHASSIS........................................................................... 10
COMPONENTS OF THE UPPER PART ................................................................................................... 11
SECTION 41 - STEERING SYSTEM

DESCRIPTION ................................................................................................................................................. 3
2WS STEERING SYSTEM ............................................................................................................................... 4
POWER STEERING ....................................................................................................................................... 11

COMPONENTS ......................................................................................................................................... 13
DISASSEMBLY.......................................................................................................................................... 15
ASSEMBLY................................................................................................................................................ 18
INDEX
SECTION 50 - CAB HEATING AND AIR CONDITIONING

GENERAL .................................................................................................................................................... 3
CAB HEATING.................................................................................................................................................. 5
CONTROLS ................................................................................................................................................. 5
OPERATION ................................................................................................................................................ 6
AIR FLOW DIFFUSERS .............................................................................................................................. 7
OVERHAUL ................................................................................................................................................. 9
TROUBLESHOOTING ............................................................................................................................... 11
AIR CONDITIONING....................................................................................................................................... 12
PRINCIPLES OF AIR CONDITIONING ..................................................................................................... 12
CONTROLS ............................................................................................................................................... 17
OPERATION .............................................................................................................................................. 18
TROUBLESHOOTING AND TESTING...................................................................................................... 25
FLUSHING THE SYSTEM ......................................................................................................................... 43
DRAINING THE SYSTEM.......................................................................................................................... 45
CHARGING THE SYSTEM........................................................................................................................ 46
OVERHAUL ............................................................................................................................................... 47
COMPRESSOR .............................................................................................................................................. 52
REMOVAL AND INSTALLATION .............................................................................................................. 53
TROUBLESHOOTING ............................................................................................................................... 65
INDEX
SECTION 55 - ELECTRIC SYSTEM

ELECTRIC DIAGRAMS .................................................................................................................................... 3
ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580ST - 590ST electronic engine) ............................. 3
ELECTRIC DIAGRAMS - POWERSHIFT CAB (2WS) .............................................................................. 21
CONTROLS AND INSTRUMENTS ................................................................................................................ 59

FRONT CONTROL PANELS (580ST - 590ST) ......................................................................................... 59
FRONT CONTROL PANELS (695ST)....................................................................................................... 61
CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST electronic engine) ............. 63
SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST)....................................................................... 65
ANTI-START SYSTEM .............................................................................................................................. 67
DIAGNOSTIC DISPLAY (580ST - 590ST - 695ST)........................................................................................ 68

SYMBOLS.................................................................................................................................................. 70
SETUP MENU ........................................................................................................................................... 71
PROCEDURE ABOUT SELF TEST .......................................................................................................... 72
ON BOARD ERROR CODE RETRIEVAL ................................................................................................. 73
BACKLIGHTING AND DIMMING............................................................................................................... 74
WORK HOURS.......................................................................................................................................... 75
OPERATION.............................................................................................................................................. 76
WARNING SYSTEM.................................................................................................................................. 80
MAINTENANCE......................................................................................................................................... 81
WARNING MESSAGES ............................................................................................................................ 82
STARTING SYSTEM ...................................................................................................................................... 88

OPERATION.............................................................................................................................................. 88
STARTER MOTOR.................................................................................................................................... 91
ALTERNATOR................................................................................................................................................ 98
OPERATION.............................................................................................................................................. 99
BATTERY ..................................................................................................................................................... 101

OPERATION............................................................................................................................................ 101
REPLACEMENT ...................................................................................................................................... 102
CHARGE AND ELECTROLYTE LEVEL CHECK .................................................................................... 103
CONNECTING A BOOSTER BATTERY ................................................................................................. 104
BATTERY MASTER SWITCH ................................................................................................................. 104
TROUBLESHOOTING.................................................................................................................................. 105
INDEX
SECTION 82 - LOADER ATTACHMENT

LOADER ATTACHMENT CONTROLS............................................................................................................. 3
LOADER ATTACHMENT OPERATION....................................................................................................... 3
4x1 LOADER BUCKET CONTROL (Optional)............................................................................................. 6
LOADER ATTACHMENT CONTROL LOCK (Specific to certain countries) ................................................ 7
BUCKET SELF-LEVELLING............................................................................................................................. 8
LOADER ATTACHMENT SAFETY STRUT...................................................................................................... 9

LOADER ATTACHMENT SAFETY STRUT (2WS)...................................................................................... 9
LOADER ATTACHMENT SAFETY STRUT (4WS).................................................................................... 10
REMOVAL AND INSTALLATION OF LOADER BUCKET .............................................................................. 11

STANDARD LOADER BUCKET ................................................................................................................ 11
LOADER BUCKET WITH FORKS (Optional) ............................................................................................ 12
BUCKET TEETH REPLACEMENT............................................................................................................ 13
LOADER REMOVAL....................................................................................................................................... 14
SECTION 84 - BACKHOE ATTACHMENT

DESCRIPTION AND OPERATION................................................................................................................... 3
BACKHOE ATTACHMENT CONTROLS .......................................................................................................... 6

BACKHOE ATTACHMENT MECHANICAL CONTROLS ............................................................................ 7
BACKHOE ATTACHMENT HYDRAULIC CONTROLS ............................................................................. 18
BACKHOE ATTACHMENT SIDESHIFT (Sideshift version) ...................................................................... 24
BACKHOE ATTACHMENT DISASSEMBLY................................................................................................... 26

DIPPER EXTENSION - REPLACE - WEAR PLATES - EXTENDABLE DIPPER -
580ST-590ST-695ST ................................................................................................................................. 28
BACKHOE BUCKET REPLACEMENT ...................................................................................................... 31
BACKHOE BUCKET .................................................................................................................................. 32
BACKHOE ATTACHMENT HYDRAULIC HANDLING.................................................................................... 33

CONTROLS ............................................................................................................................................... 33
HYDRAULIC DIAGRAM............................................................................................................................. 34
580ST
590ST
695ST
SECTION 00 - SAFETY RULES

2 SECTION 00 - SAFETY RULES
SECTION 00 - SAFETY RULES 3
SAFETY INSTRUCTIONS
S WARNING S
This warning symbol points out important mes-
sages involving your safety.
Carefully read the safety rules contained herein
and follow advised precautions to avoid potential
hazards and to safeguard your safety and personal
integrity.
In this manual you will find this symbol together
with the following keywords:
S WARNING S
This symbol warns about the possibility of potential
damages to the machine that can involve the oper-
ator’s safety.
S WARNING S
With specific warnings about potential dangers for
the operator’s or other persons integrity directly or
indirectly involved.
The non-compliance with the warnings preceded by

the above-mentioned keywords (WARNING and
DANGER) can cause serious accidents or even the
death of the persons involved.
Moreover, in the present Manual, some instructions
are given with text in italics, preceded by the words
NOTE and CAUTION.
NOTE: it emphasizes and underlines to the operator
the correct technique or correct procedure to follow.
S WARNING S
This symbol warns about the possibility of potential
damages to the machine that can involve the oper-
ator’s safety.
FOREWORD
Backhoe loaders 580ST - 590ST - 695ST have been
designed to perform most earth-moving operations.
If you use this machine for duties involving the use
of attachments, accessories, or special tools, con-
sult your Dealer to make sure that the adaptations or
modifications carried out are in conformity with the
machine’s technical specifications and with current
regulations on safety.
Any modifications or adaptations which are not
approved by the manufacturer may invalidate the
machine’s original conformity with safety require-
ments.
The machine must be used according to its intended 1
use, respecting the safety and precautionary rules
and strictly following the operating instructions.
Any functional disorders, especially those affecting
the safety of the machine, should therefore be recti-
fied immediately.
S DANGER S
A different use of the excavator or of its working
equipment:
- for lifting or transporting persons;
- as a working platform;
- for lifting loads without the attachment being
approved for this purpose;
- for pulling loads;
- is considered unintended use.
Unintended use may cause injury or life-threatening
risks for the operator and for other persons.
The manufacturer/supplier cannot be held responsi-

ble for any damage resulting from unintended use.
The risk involved in such misuse lies entirely with
the user.
S DANGER S
It is absolutely forbidden to tamper with and/or
change the setting of any of the hydraulic system
valves to avoid damaging machine components,
with a consequent risk for personal safety.
The current Operator’s Manual is the user’s guide

for correct run-in, use and maintenance of the
machine.
Carefully read this Operator’s Manual and store it in SPARE PARTS

the cab for quick location and reference. The “non-genuine” spare parts have not been
Instructions concerning safety, operation and main- checked and authorized by the Manufacturer.
tenance have been developed to permit safe serv- The assembly and/or use of such products may
ice and repair of this machine without any risk. have negative effects on the machine design fea-
In the event of queries or suggestions relevant to tures and could impair its operation safety.
your machine do not hesitate to address to your
The Manufacturer is not liable for any damage
Dealer.
caused by “non-genuine” spare parts or accesso-
Dealers have qualified and trained personnel at dis- ries.
posal as well as Original Spares, means and equip-
ment suitable to carry out all necessary
maintenance. WARRANTY
Any modifications or adaptations which are not ap- This machine is under warranty according to the
proved by the manufacturer may invalidate the ma- regulations in force in Your Country and in compli-
chine’s original conformity with safety requirements. ance with the sales agreement drawn up with the
IMPORTANT: the engine and fuel system on your Dealer.
machine are designed and built to government The warranty, however, expires if the operation and
emissions standards. Tampering by dealers, cus- maintenance instruction for this machine and con-
tomers, operators and users is strictly prohibited by tained in this manual, have not been followed.
law. Failure to comply with this prohibition could
result in government fines, rework charges, invalid
warranty, legal action and possible confiscation of
the machine until rework to original condition is
completed. Engine service and/or repairs must be
carried out by a certified technician only.
NOTE: each machine is supplied complete with a
copy of this Manual. Descriptions and illustrations
provided herein are not binding. The Manufacturer,
provided that the basic characteristics of machine
types described and shown in this Manual remain
the same, reserves the right to change compo-
nents, parts and accessories supplied without any
commitment to timely update this publication; and
this any time it deems it convenient for improve-
ment purposes or due to commercial or manufac-
turing requirements. For exact information, please
consult your Dealer or contact the Manufacturer’s
Branch Offices, who remain at your disposal for fur-
ther help.
SAFETY INSTRUCTIONS
Carefully read the safety rules contained herein and
follow advised precautions to avoid potential haz-
ards and to safeguard your safety and personal
integrity.
Your safety and that of the people around you
depends on you.
It is essential that you understand this manual for a
correct inspection, lubrication and repair of this
machine.
Read this manual carefully and check that:
- you understand fully the symbols on the controls
and the safety signs used in this manual and on
the machine;
- you understand fully the speed, stability, braking
and steering characteristics of the machine. If you
are in any doubt, consult your Dealer.
The safety messages in this section concern situa-
tions which may arise during normal machine opera-
tion, servicing and repair. These safety messages
also indicate the different ways of coping with these
situations. Other safety messages are used
throughout the manual to indicate specific dangers.
The information given in this chapter is a summary
of the basic rules to respect at all times and does
not exempt you from observing traffic regulations or
the requirements of insurance companies.
The presence of grease, oil, mud or (in winter) ice
on the steps and access handles can cause acci-
dents. Make sure they are always clean.
When mounting or dismounting from the machine
always face the machine and use the steps and
access handles on the left-hand side of the
machine.
Wear close fitting clothing and safety equipment

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

The engine fuel can originate an explosion or a fire.
Never refuel when the engine is running.
Do not smoke during refuelling.
Take all the necessary safety measures when weld-
ing, grinding or when working near a naked flame.
Use a non-inflammable product for cleaning parts.
A spark or a flame can cause the electrolyte of the

battery to explode.
To prevent any risk of explosion, observe the follow-
ing instructions:
- when disconnecting the battery cables, always
disconnect the negative (-) cable first;
- to reconnect the battery cables, always connect
the negative (-) cable last;
- never short-circuit the battery clamps with metal
objects;
- do not weld, grind or smoke near a battery.
The engine exhaust may produce sparks.
Before using the machine in an area which may con-
tain inflammable vapours, ensure that there is good
ventilation.
Always keep a fire extinguisher available on the ma-
chine.
Make sure that it is properly maintained in conformity
with the manufacturer’s instructions.
PREVENTION OF BURNS
The battery electrolyte generates severe burns.
The battery contains sulphuric acid.
Avoid any contact with the skin, eyes or clothing.
Antidote:
- EXTERNAL: rinse well with water, removing any
soiled clothing.
- INTERNAL: avoid vomiting. Drink water to rinse
your mouth. Consult a doctor.
- EYES: rinse thoroughly with water for 15 minutes
and get prompt medical attention.
When the electrolyte of a battery is frozen, it can
explode if you attempt to charge the battery or if you
try to start the engine using a booster battery.
Always keep the battery charged to prevent the elec-
trolyte freezing.
Batteries generate explosive gases.
Keep all flames, sparks and cigarettes away.
Provide good ventilation when changing a battery or
using a battery in an enclosed space.
Always protect your eyes when working near a bat-
tery.
Never touch the battery terminals with your hands.
This can induce a state of electrolysis and impair the
main organs of the body.
Hot coolant could spray out if the radiator cap is

removed while the system is still hot.
To remove the cap: allow the system to cool down,
turn the cap to the first notch and wait until there is
no more pressure.
Then remove the cap.
PRECAUTIONS FOR WASTE DISPOSAL

Improperly disposing of waste can threaten the envi-
ronment.
Each country has its own Regulations on this sub-
ject. It is therefore advisable to prepare suitable con-
tainers to collect and store momentarily all solid and
fluid materials that must not be scattered in the envi-
ronment to avoid pollution.
At preset intervals these products will be delivered
to disposal stations legally recognized and present
in this Country.
Here below is a list of the products in the machine
which require disposal:
- hydraulic oil;
- brake system oil;
- coolant mixture, condensation residue and pure
anti-freeze;
- diesel oil;
- oil and diesel oil filter elements;
- engine and air conditioning air filter elements;
- battery.
Also polluting rags, paper, sawdust and gloves must
be disposed in compliance with the same proce-
dures.
Do not use food or beverage containers that may
mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain, or
into any water source.
Air conditioning coolant escaping into the air can
damage the Earth’s atmosphere.
Government regulations may require a certified air
conditioning service centre to recover and recycle
used air conditioning coolant.
Obtain information on the proper way to recycle or
dispose of waste from your local environmental or
recycling centre, or from your Dealer.
580ST
590ST
695ST
SECTION 01 - MAINTENANCE
2 SECTION 01 - MAINTENANCE
SECTION 01 - MAINTENANCE 3
Do not carry out any service operation until you

have read and understood the instructions and
warnings given in this manual.
Observe the adjusting, maintenance and inspection
activities and intervals set out in the operating
instructions, including information on the replace-
ment of parts and equipment as this service con-
cerns exclusively the qualified personnel.
Wear safety equipment and suitable clothing to per-
form maintenance operations on the machine.
During maintenance operations, apply a warning
plate.
Always wear eye protection when using a tool which

might project metal particles. Use a hammer with a
soft face, such as copper, for pin assembly.
Incorrectly performed maintenance or adjustments
can cause serious injury. If you do not understand a
maintenance or adjustment procedure, consult your
Dealer.
Before performing any maintenance operation on
this machine, make sure it is in a safety condition.
Move the machine to a level and firm ground, away

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

vent the machine from moving.
Unauthorized modifications of the machine can
cause serious injuries.
Do not carry out any modification on this machine
without obtaining prior authorization from your
Dealer.
Any modification carried out must be in conformity
with the machine’s technical specifications and must
conform to current safety regulations.
Do not carry out any welding operation on the
machine without prior authorization from your
Dealer.
Some of the machine’s components are subject to
type approvals. It is mandatory when replacing
those components to ensure that they are in con-
formity with regulations.
Hydraulic fluid or grease under pressure which pen-
etrates the skin can cause serious injury.
Take the necessary safety precautions (protective
clothing and face and hand protection) to prevent all
such risks.
In addition, before handling these products, read the
manufacturer’s specific instructions for their use.
If hydraulic fluid penetrates the skin a doctor must
be called immediately.
When carrying out a welding operation on the
machine, as authorized by the manufacturer and in
accordance with his specifications, disconnect the
electric system by means of the battery master
switch, connect the welding set earth lead to the
component on which the welding is to be carried out
(never connect the ground lead to a hydraulic sys-
tem component) and disconnect the electric cables
of the motor control unit (in case of electronic
motors).
A burst tyre can cause serious injury.
Regularly check the condition of tyres and always
observe the inflation pressures defined in accord-
ance with the type of tyre and ground conditions.
SECTION 01 - MAINTENANCE 5
When checking the tyre pressure or during an infla-

tion operation, never stay in front of the tyre but
always keep to the tread side.
Always use an inflation cage when the wheel is
removed from the machine.
Keep all other persons away from the area.
Never weld near a tyre. It is essential to remove the
tyre before any welding operation.
Take the necessary safety measures to protect your
face when using compressed air.
The machine’s structure is in conformity with the
FOPS and ROPS protection standards.
Any modification (drilling, welding, etc.) may cause
that conformity to be invalidated.
NOTE:
580ST
590ST
695ST
SECTION 02 - TECHNICAL
SPECIFICATIONS
MODELS........................................................................................................................................................... 3
IDENTIFICATION OF MAIN COMPONENTS................................................................................................... 4
DIESEL ENGINE ......................................................................................................................................... 6
TRANSMISSION.......................................................................................................................................... 8
AXLES ......................................................................................................................................................... 9
BRAKES .................................................................................................................................................... 10
STEERING................................................................................................................................................. 10
HYDRAULIC SYSTEM .............................................................................................................................. 11
FRONT COUNTERWEIGHT ..................................................................................................................... 11
BUCKETS .................................................................................................................................................. 12
TYRES ....................................................................................................................................................... 13
DPF SYSTEM ............................................................................................................................................ 14
DIMENSIONS AND PERFORMANCE............................................................................................................ 18

DIMENSIONS - 4WS CENTER PIVOT...................................................................................................... 20
LOADER ATTACHMENT PERFORMANCE.............................................................................................. 21
PERFORMANCE OF LOADER BUCKET WITH FORKS .......................................................................... 23
BACKHOE ATTACHMENT PERFORMANCE........................................................................................... 24
MAXIMUM LIFTING LOADS........................................................................................................................... 27

LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE .................................................................. 27
BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................... 28
SUPPLY SUMMARY TABLE .......................................................................................................................... 29

2 SECTION 02 - TECHNICAL SPECIFICATIONS
1.
SECTION 02 - TECHNICAL SPECIFICATIONS 3
MODELS
580ST 590ST 695ST

Powershift / / O
Powershuttle O O /
Sideshift stabilizers / / O
Center pivot stabilizers / / O
Cab O O O
Rops / / /
2WD / / /
4WD O O O
4WS / / O
Pilot control O O O
Mechanical control O O O

O / /
/ O O
Short backhoe dipper / / /
Long backhoe dipper O O O
IDENTIFICATION OF MAIN COMPONENTS

2WS
7
2
1
5
13
14
3
10
11
4
12
TBR00107
1. Loader bucket 9. Dipper / telescopic dipper of backhoe

2. Loader attachment attachment
3. Front axle 10. Backhoe bucket
4. Fuel tank 11. Backhoe attachment sideshift carriage
5. Rear axle 12. Stabilizers
6. Cab 13. Battery box
7. Engine guard 14. Hydraulic oil tank
8. Backhoe attachment boom
4WS
7
2
1
5
13
14
3
10
11
4
12
TBR00108
1. Loader bucket 9. Dipper / telescopic dipper of backhoe

2. Loader attachment attachment
3. Front axle 10. Backhoe bucket
4. Fuel tank 11. Backhoe attachment sideshift carriage
5. Rear axle 12. Stabilizers
6. Cab 13. Battery box
7. Engine guard 14. Hydraulic oil tank
8. Backhoe attachment boom
TECHNICAL SPECIFICATIONS
DIESEL ENGINE
72 kW - 97 HP ENGINE (580ST)
Specifications (EEC 88/195) .................................................................................. 72 kW - 97 HP @ 2200 rpm
Model ...........................................................................................................................................CASE 434T/E
Type ........................................................................................................................................ diesel, electronic
No. of cylinders ................................................................................................................................................ 4
Valves per cylinder ........................................................................................................................................... 2
Bore............................................................................................................................................. 99 mm (3.9 in)
Stroke ...................................................................................................................................... 110 mm (4.33 in)
Displacement .................................................................................................................. 4485 cm3 (237.69 in3)
Compression ratio .................................................................................................................................... 16.5:1
Maximum torque (EC) ......................................................................................453 Nm (334 lbf·ft) @ 1400 rpm
Low idle speed at no load ........................................................................................................... 1000 ± 50 rpm
High idle speed at no load........................................................................................................... 2380 ± 60 rpm
Maximum speed at full load ................................................................................................................ 2200 rpm
Air intake ....................................................................................................TAA (turbocharged with aftercooler)
Supply
Type ........................................................................................................................high-pressure, common rail
Injection pump............................................................................................................ CP3 high-pressure pump
Control unit..............................................................................................................................................EDC17
Injection sequence ..................................................................................................................................1-3-4-2
Cold-start device ............................................................................................................. Glow plugs (standard)
Cooling
Pump type ......................................................................................................................................... H2O pump
Pump drive ...........................................................................................................................................belt drive
Temperature switch (opening start) ......................................................................... 81 ± 2 °C (177.8 ± 35.6 °F)
82 kW - 110 HP ENGINE (590ST / 695ST)

Specifications (EEC 88/195) ................................................................................. 82 kW - 110 HP @ 2200 rpm
Model ............................................................................................................................................ CASE 434T/E
Type ..........................................................................................................................................diesel, electronic
No. of cylinders ................................................................................................................................................. 4
Valves per cylinder ............................................................................................................................................ 4
Bore ............................................................................................................................................. 99 mm (3.9 in)
Stroke........................................................................................................................................110 mm (4.33 in)
Displacement ................................................................................................................... 4485 cm3 (237.69 in3)
Compression ratio..................................................................................................................................... 16.5:1
Maximum torque (EC).................................................................................. 516 Nm (380.58 lbf·ft) @ 1400 rpm
Low idle speed at no load ............................................................................................................ 1000 ± 50 rpm
High idle speed at no load ........................................................................................................... 2380 ± 60 rpm
Maximum speed at full load ................................................................................................................. 2200 rpm
Air intake .....................................................................................................TAA (turbocharged with aftercooler)
Supply
Type ......................................................................................................................... high-pressure, common rail
Injection pump............................................................................................................. CP3 high-pressure pump
Control unit............................................................................................................................................... EDC17
Injection sequence ................................................................................................................................... 1-3-4-2
Cold-start device ..............................................................................................................“grid heater” (optional)
Cooling
Pump type.......................................................................................................................................... H2O pump
Pump drive............................................................................................................................................ belt drive
Temperature switch (opening start).......................................................................... 81 ± 2 °C (177.8 ± 35.6 °F)
TRANSMISSION
4WD/2WS TRANSMISSION - POWERSHUTTLE (580ST - 590ST)
Model ..................................................................................................................... CARRARO TLB1 MPB 4WD
Type (4x4) ................................................................................................. 4 forward and 4 reverse travel gears
Torque converter ratio .................................................................................................................................. 2.38
Transmission ratios:
1st gear .........................................................................forward travel 5.603:1 reverse travel 4.643:1
2nd gear ........................................................................forward travel 3.481:1 reverse travel 2.884:1
3rd gear.........................................................................forward travel 1.585:1 reverse travel 1.313:1
4th gear .........................................................................forward travel 0.793:1 reverse travel 0.657:1
4WD/4WS TRANSMISSION - POWERSHIFT (695ST)

Model ..................................................................................................................... CARRARO TLB2 MPB 4WS
Torque converter ratio .................................................................................................................................. 2.38
AXLES
FRONT AXLES
4WD/2WS front axle (580ST - 590ST)
Model ...........................................................................................................................................................CNH
Type ........................................................................................................................................................steering
4WD/4WS front axle (695ST)
Model ...................................................................................................................................... CARRARO 26.32
Type ........................................................................................................................................................steering
REAR AXLES
2WS rear axle
Model (580ST) ........................................................................................................................ CARRARO 28.44
Model (590ST) ........................................................................................................................ CARRARO 28.50
Type ..............................................................................................................................................................rigid
4WS rear axle (695ST)
Model ................................................................................................................................... CARRARO 26.32M
Type ........................................................................................................................................................steering
Differential lock ........................................................................................................................................ electric
BRAKES
SERVICE BRAKES
2WS
Type .......................................................................................................wet multi-discs, 4 x axle (2 x half axle)
Braking surface ..................................................................................................................... 1236 cm2 (191 in2)
4WS
Type .......................................................................................................wet multi-discs, 6 x axle (3 x half axle)
Braking surface .................................................................................................................... 1092 cm2 (169 in2)
PARKING BRAKE
Type ....................................................................................................................................... manual, with lever
Maximum lever pull ................................................................................................................... 1650 N (371 lbf)
Lever stroke ............................................................................................................................... 21 mm (0.87 in)
Maximum torque - POWERSHUTTLE ...............................................................................2000 Nm (1475 lbf·ft)
Maximum torque - POWERSHIFT .....................................................................................1500 Nm (1106 lbf·ft)
STEERING
2WS ............................................................................................................................................... 2 wheel steer
4WS ............................................................................................................................................... 4 wheel steer
System pressure .............................................................................................. 170 ÷ 175 bar (2465 ÷ 2538 psi)
POWER STEERING
2WS (with variable-flow-rate pump)
Model .........................................................................................................................EATON P/N 403 -8754-04
Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev)
Shock valve adjustment ......................................................................................................... 235 bar (3408 psi)
Load-sensing pressure relief valve adjustment...................................................................... 175 bar (2538 psi)
2WS (with gear pump)
Model .........................................................................................................................EATON P/N 403 -8754-08
Load-sensing pressure relief valve adjustment...............................................................................................No
4WS
Model .........................................................................................................................EATON P/N 403 -7754-04
HYDRAULIC SYSTEM
GEAR PUMP
Pump 72 kW - 97 HP (580ST)
Model ........................................................................................................... CASAPPA KP 30.34 - 05 S6 - LMF
Type ....................................................................................................................................... double gear pump
Flow rate ..................................................................................... 35.427 + 35.427 cm3/rev (2.16 + 2.16 in3/rev)
Pump 82 kW - 110 HP (590ST - 695ST)
Model ........................................................................................................... CASAPPA KP 30.38 - 05 S6 - LMF
Type ....................................................................................................................................... double gear pump
Flow rate ..................................................................................... 40.258 + 35.427 cm3/rev (2.45 + 2.16 in3/rev)
VARIABLE-FLOW-RATE PUMP
Pump 72 kW - 97 HP (580ST)
Model ....................................................................................................................... DANFOSS J71C Series 45
Type ......................................................................................................................................... with axial pistons
Flow rate ...................................................................................................................... 71 cm3/rev (4.33 in3/rev)
Pump 82 kW - 110 HP (590ST - 695ST)
Flow rate ...................................................................................................................... 75 cm3/rev (4.57 in3/rev)
FRONT COUNTERWEIGHT
COUNTERWEIGHT - 2WS
Standard...................................................................................................................................... 159 kg (350 lb)
Medium ....................................................................................................................................... 330 kg (727 lb)
COUNTERWEIGHT - 4WS
Standard...................................................................................................................................... 160 kg (352 lb)
BUCKETS
LOADER BUCKETS
2WS Type 1 m3 (35.3 ft3) 4x1 6x1 (with forks)

standard
Heaped capacity 1.0 m3 (35.3 ft3) 1.0 m3 (35.3 ft3) 1.0 m3 (35.3 ft3)
Width 2250 mm (88.58 in) 2250 mm (88.58 in) 2250 mm (88.58 in)
Weight 410 kg (902 lb) 800 kg (1760 lb) 960 kg (2112 lb)
4WS Heaped capacity 1.15 m3 (40.61 ft3) 1.15 m3 (40.61 ft3) 1.15 m3 (40.61 ft3)
Width 2400 mm (94.4 in) 2400 mm (94.4 in) 2400 mm (94.4 in)
Weight 426 kg (937 lb) 830 kg (1826 lb) 990 kg (2178 lb)
BACKHOE BUCKETS
Type Width [mm (in)] Weight [kg (lb)]
300 (11.81) 89 (196)
400 (15.75) 104 (229)
450 (17.71) 112 (247)

Normal operation
600 (23.62) 130 (286)
750 (29.53) 151 (333)
900 (35.43) 171 (377)
406 (15.98) 139 (306)
457 (17.9) 149 (328)

Heavy Duty
610 (24) 176 (388)
914 (35.9) 228 (503)

TYRES
TYRE TYPES
Tyres - 2WS
Front tyres Rear tyres
12.5/80 - 18 L3 10PR 18.4-26 R4 10PR
4WD 12.5/80 - 18 L3 10PR 16.9-28 R4 10PR
320/80 R18 IT 520 480/80 R26 IT520
Tyres - 4WS
Front and rear tyres
16.9/24 R4 12PR
16.9/28 R4 12PR
440/80 R28 IT520
440/80 R28 IT530
NUT TORQUES
Front nuts (2WS)....................................................................................................................330 Nm (243 lbf·ft)
Rear nuts (2WS) ....................................................................................................................540 Nm (398 lbf·ft)
Front and rear nuts (4WS) .....................................................................................................700 Nm (516 lbf·ft)
DPF SYSTEM
A diesel particulate filter (or DPF) is a device designed to remove diesel particulate matter or soot from the
exhaust gas of a diesel engine.
The manufacturer has chosen high efficiency DPF (Diesel Particulate Filter) technology for its own light
engine, medium engine and heavy engine portfolio to meet, starting from current Euro IV up to Euro VI / Tier4,
emission standards.
DPF technology is typically coupled with an engine-based NOx emission reduction strategy, mainly leveraging
on EGR (exhaust gas recirculation):
- DPF is today a widely used technology for removing particulate matter (both in mass and number, which-
ever is the raw soot particles quantity and distribution);
- filtration efficiency is close to 100%, up to the maintenance or substitution target;
- modern common-rail based Diesel engines are capable to safely regenerate by post-injections DPF, even
with very high soot mass loading;
- DPF regeneration at high temperature by common-rail could yield, in some very severe applications, to an
accelerated deterioration of the lube oil quality (oil dilution caused by late post-injections), so that, if both
passive and active DPF regenerations are not working, unit will de-rate and DPF replacement may be
required;
- lube oil ashes are collected in the filter and cause an increase of the average pressure drop (i.e. higher fuel
consumption).
Technical description
Application:
- engine type: Engine FPT;
- emission level: Tier4i.
Aftertreatment concept:
- flow-through DOC;
- high efficiency DPF (ceramic wall-flow monolith).
DPF regeneration:
- mixed passive and active regeneration.
Engine layout:
- HPL cooled EGR.
Canning / substrate main details
2 W
4 3
TBR00086
1. Metallic can
2. Ceramic fibre mat
3. SIC substrate
4. Ceramic substrate
S. Repeat distance
W. Wall thickness
N. Cell density
N. 1/S2
S. Cell pitch
NOTE: when the level of soot exceeds a certain level, the DPF filter have to be replaced or regenerated in a
specialized centre which has a regeneration station (thermal regenerator / pulse cleaner).
Functional sketch (1)
10
8
7
4
2 1
6 5
4
3
TBR00087
1. DPF
2. DOC
3. Delta P sensor
4. Temperature sensor
5. Outlet flange
6. Inlet flange
7. EGR valve
8. Air flow meter
9. Turbine
10. ECU
Functional sketch (2)
1
3
TBR00088
1. DPF
2. DOC
3. Delta P sensor
4. Temperature sensor
5. Outlet flange
6. Inlet flange
DOC = Diesel Oxidant Catalyst

+ CRT = Continuous Regenerating Trap
DPF = Diesel Particulate Filter
DIMENSIONS AND PERFORMANCE
DIMENSIONS - 2WS SIDESHIFT
Front tyres ..................................................................................................................................... 12.5/80-18 I3

Rear tyres.......................................................................................................................................... 18.4-26 R4
Standard loader bucket .................................................................................................................1 m3 (35.3 ft3)
Standard backhoe bucket....................................................................................................... 914 mm (35.98 in)
A Overall machine length 5865 mm (230.90 in)

B Loader bucket reach 2060 mm (81.10 in)
C Wheel base 2175 mm (85.62 in)
D Backhoe bucket dimensions 1630 mm (64.17 in)
E Rear wheel base - backhoe attachment swing axis 1325 mm (52.16 in)
F Machine maximum height (upper part of backhoe attachment boom) 3680 mm (144.88 in)
G Stabilizer width 2430 mm (95.66 in)
H Cab height 2950 mm (116.14 in)
I Loader bucket width 2250 mm (88.58 in)
DIMENSIONS - 4WS SIDESHIFT
Front and rear tyres ............................................................................................................... 440/80-R28 IT530

Standard loader bucket .......................................................................................................... 1.15 m3 (40.61 ft3)
Standard backhoe bucket ...................................................................................................... 914 mm (35.98 in)

F Machine maximum height (upper part of backhoe attachment boom) 3650 mm (143.70 in)
G Stabilizer width 2480 mm (97.63 in)
DIMENSIONS - 4WS CENTER PIVOT
Front and rear tyres ............................................................................................................... 440/80 R28 IT530


F Machine maximum height (with standard dipper) 3712 mm (146.14 in)
2380 mm - 2580 mm
G Standard stabilizer width - reversible
(93.70 in - 101.57 in)
LOADER ATTACHMENT PERFORMANCE

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

Rear tyres ..........................................................................................................................................18.4-26 R4
Standard loader bucket ................................................................................................................. 1 m3 (35.3 ft3)
A Maximum height/dimensions 4255 mm (167.52 in)

B Maximum height of loader bucket pin/pivot 3460 mm (136.22 in)
C Maximum dumping height 2625 mm (103.35)
D Digging depth 120 mm (4.72 in)
Loader attachment reach when raised in dumping position (according to
E 830 mm (32.68 in)
front counterweight)
α Angle of lowered closed bucket 45°
β Dumping angle 45°

695ST

A Maximum height/dimensions 4350 mm (171.26 in)

B Maximum height of loader bucket pin/pivot 3490 mm (137.40 in)
C Maximum dumping height 2715 mm (106.89 in)
D Digging depth 113 mm (4.44 in)
Loader attachment reach when raised in dumping position (according to
E 745 mm (29.33 in)
front counterweight)
α Angle of lowered closed bucket 45°
β Dumping angle 45°

PERFORMANCE OF LOADER BUCKET WITH FORKS

580ST - 590ST
A Maximum height of loader bucket pin/pivot with lifted forks 4245 mm (167.13 in)
B Fork maximum height 3460 mm (136.22 in)
C Height of loader bucket pin/pivot of loader bucket with lowered forks 460 mm (18.11 in)
D Fork reach when raised 2320 mm (91.34 in)
E Fork reach when lowered 3185 mm (125.39 in)
695ST
A Maximum height of loader bucket pin/pivot with lifted forks 3520 mm (138.58 in)
B Fork maximum height 3060 mm (120.47 in)
C Height of loader bucket pin/pivot of loader bucket with lowered forks 460 mm (18.11 in)
D Fork reach when raised 2195 mm (86.42 in)
E Fork reach when lowered 3185 mm (125.39 in)
BACKHOE ATTACHMENT PERFORMANCE

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

Rear tyres.......................................................................................................................................... 18.4-26 R4
Telescopic dipper
Standard dipper
extended
A Maximum digging height 5875 mm (231.30 in) 6790 mm (267.32 in)
B Maximum height at full load 3925 mm (154.53 in) 4835 mm (190.35 in)
C Maximum digging depth 4370 mm (172.05 in) 5435 mm (213.98 in)
D Maximum digging reach with lowered bucket 5230 mm (205.90 in) 6240 mm (245.67 in)
E Maximum reach when loaded 870 mm (34.25 in) 1425 mm (56.10 in)
α Bucket digging angle 200° 195°
695ST SIDESHIFT
Front and rear tyres ...............................................................................................................440/80 R28 IT530

Standard backhoe bucket ...................................................................................................... 914 mm (35.98 in)
Telescopic dipper
Standard dipper
extended
α Bucket digging angle 198° 195°
695ST CENTER PIVOT

Telescopic dipper
Standard dipper
extended
α Angle of lowered closed bucket 198° 195°
MAXIMUM LIFTING LOADS
LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE

2WS
4WS
BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE

2WS ( 580ST)
2WS (590ST)
4WS (695ST)
SUPPLY SUMMARY TABLE
RECOMMENDED FLUIDS AND CASE INTERNATIONAL MODELS QUANTITY

APPLICATION Specifications Specifications Litres Gal
ENGINE - OIL
Unitek CJ-4 MAT 3521 API CJ-4, ACEA E9, 2WS - with filter 8 2.11
15W40 4WS - with filter
COOLING SYSTEM
Akcela Premium Anti-freeze MS 1710 ASTM D6210 ALL 24 6.30
antifreeze 50% water 50%
HYDRAULIC SYSTEM
Akcela Nexplore MAT 3525 API GL4 ISO VG 32/46 2WS 140 36.90
10W-30 4WS 118 31.10
Akcela Hydraulic Excavator Fluid Bio MS 1230 ISO VG 46 2WS 140 36.90
DIN 51524 - part II 4WS 118 31.10
POWERSHUTTLE MS1209 API GL4, 80W - 140
TRANSMISSION 4WD 20.8 4.57
Akcela Hy-tran Ultra
POWERSHIFT TRANSMISSION
Akcela Hy-tran Ultra ALL 20.8 4.57
FRONT AXLE (2WS) MS1317
Akcela Transaxle fluid 80W -140 4WD Differential 6.5 1.70
Wheel 0.7 0.20
reduction
gear (each)
FRONT AXLE (4WS) Differential 10.5 2.80
Akcela Transaxle fluid 80W -140 Wheel reduction gear 1.3 0.34
(each)
REAR AXLE (2WS) Differential 580ST
Akcela Transaxle fluid 80W -140 15.5 3.41
590ST 17 3.74
REAR AXLE (4WS) Differential 11 2.90
Akcela Transaxle fluid 80W -140 Wheel reduction gear 1.3 0.34
(each)
FUEL
Decanted and filtered diesel fuel 2WS 145 38.20
4WS 124 32.70
VARIOUS JOINTS
Akcela Multi-purpose grease 251H EP NLGI 2 ALL As required
TELESCOPIC DIPPER
Akcela Moly Grease 251 H EP-M NLGI 2 ALL As required
AIR CONDITIONING
COMPRESSOR ALL 240 14.6
PAG SP 20 oil cm3 in3
NOTE:
580ST
590ST
695ST
SECTION 10 - ENGINE
REMOVAL AND INSTALLATION THE ENGINE HOOD, THE RADIATOR AND ENGINE .............................. 3
PRELIMINARY OPERATIONS .................................................................................................................... 3
BATTERY ......................................................................................................................................................... 4
DISCONNECT ............................................................................................................................................. 4
ENGINE HOOD ................................................................................................................................................ 6

REMOVE ..................................................................................................................................................... 6
RADIATOR ....................................................................................................................................................... 9
REMOVE ..................................................................................................................................................... 9
ENGINE .......................................................................................................................................................... 16
REMOVE ................................................................................................................................................... 16
INSTALL .................................................................................................................................................... 26
RADIATOR ..................................................................................................................................................... 35
INSTALL .................................................................................................................................................... 35
ENGINE HOOD .............................................................................................................................................. 41

INSTALL .................................................................................................................................................... 41
BATTERY ....................................................................................................................................................... 44
CONNECT ................................................................................................................................................. 44
ENGINE ERROR CODES .............................................................................................................................. 46

2 SECTION 10 - ENGINE
SECTION 10 - ENGINE 3
REMOVAL AND INSTALLATION OF THE ENGINE HOOD, THE RADIATOR AND ENGINE
Preliminary operations
Z Position the machine on a flat and compact sur-
face.
Z Apply the parking brake and chock the wheels
with wedges.
Z Use only the recommended tools.
Z Do not insert hands or extraneous components
between parts.
Z Disconnect the battery before proceeding.
S WARNING S
Do not allow unauthorized persons to repair or
service this machine. Be certain to read the Use
and Maintenance Manual with care before starting,
operating, servicing, refuelling or repairing this
machine.
Turn the STARTER SWITCH to the OFF position

and display the “DO NOT START” warning notice.
IMPORTANT: From this point onwards, mark all

electrical connections and hydraulic pipes to facili-
tate the process of RESTORING CONNECTIONS
DURING REFITMENT.
Z Unscrew the cap of the hydraulic oil tank slowly to

release the air pressure from inside the tank.
Z Move the control lever repeatedly back and forth
to release pressure in the hydraulic circuit.
Z With oil warm, remove plug from the bottom of the
machine and drain the oil into a receptacle of suit-
able capacity.
S DANGER S
Fluid under pressure; Before removing the plug or
cap, turn slowly to release pressure from the sys-
tem. See the Use and Maintenance Manual.
Put a container below radiator drain. Remove radia-

tor cap. Remove cap and drain coolant into con-
tainer. Install cap after coolant has drained. Install
radiator cap.
Put a container below engine oil drain. Remove cap
and drain oil into container. Install cap after oil has
drained.
Battery - Disconnect
S WARNING S
Explosive gas!
Batteries emit explosive hydrogen gas and other
fumes while charging. Ventilate the charging area.
Keep the battery away from sparks, open flames,
and other ignition sources. Never charge a frozen
battery. Failure to comply could result in death or
serious injury.
S WARNING S
Hazardous chemicals!
Battery electrolyte contains sulfuric acid. Contact
with skin and eyes could result in severe irritation
and burns. Always wear splash-proof goggles and
protective clothing (gloves and aprons). Wash
hands after handling.Failure to comply could result
in death or serious injury.
Remove the battery cover hardware.
TBR00002
Remove the battery cover.
TBR00003
Disconnect the negative battery cable from the

negative battery terminal.
TBR00004
Engine hood - Remove

Raise the loader in the full upright position. Lock
the support strut to hold the loader in the upright
position.
TBR00005
Remove grill hardware.
TBR00007
Remove grill bumpers.
TBR00008
Remove the grill.
TBR00006
Open hood and remove hood struts.
TBR00009
Remove hood straps.
TBR00010
Lower hood and attach lifting device.
TBR00011
Remove hood pivot point hardware.
TBR00012
Remove pivot point tubes.
TBR00013
Remove hood.
TBR00014
Radiator - Remove
Discharge the A/C system, (if present).
NOTICE: Use appropriate reclaiming devices when
recovering A/C refrigerant.
TBR00020
Disconnect the electrical connection X2 from the

horn.
TBR00044
Disconnect the hoses and electrical connection

X70 from the filter drier air conditioned (if present)
and remove the filter.
TBR00015
Disconnect the exhaust gas pipe.
TBR00016
Remove the four screws that secure the top cover

of the engine hood to the frame of the machine.
TBR00017
Remove the top cover of the engine hood from the

machine.
TBR00018
Remove hood hinge plates.
TBR00027
Remove the screws that secure the radiator wrap-

per of the engine hood to the frame of the machine.
TBR00019
Remove the radiator wrapper.
TBR00026
Remove the radiator purge hose.
TBR00021
Remove the upper radiator hose.
TBR00022
Remove the charge air cooler hoses and pipes.
TBR00023
Cap (seal) all open ports to keep contaminates

from entering the system.
TBR00024
Remove the lower radiator hose.
TBR00025
Tag and disconnect the four front cooler lines and

cap all open ports.
TBR00029
Disconnect the duct air intake from air cleaner.
TBR00030
Remove the duct air intake.
TBR00028
Tag and disconnect the two cooler lines right hand

and cap open ports.
TBR00035
Tag and disconnect the two cooler lines left hand

and cap open ports.
TBR00031
Attach a suitable device.
TBR00032
Remove cooling package mounting hardware.
TBR00033
Slowly raise cooling package from chassis. Be sure

all harness connections and hoses have been dis-
connected and are clear of the cooling package.
Remove cooling package from machine.
TBR00034
2 7
TBR00084
1. Cooler charged air

2. Condenser
3. Radiator
4. Oil cooler
5. Cooler fuel
6. Washer
7. M12X30 hex screw
[tightening torque 90÷110 Nm (66÷81 lbf•ft)]
Engine - Remove
Remove and disconnect compressor electrical con-
nection X473 (if present).
TBR00036
Identify, tag and disconnect the high pressure and

low pressure A/C lines, (if present).
TBR00037
Disconnect the air temperature sensor X474.
TBR00038
Remove the electrical connection X4 from 2-way

aircleaner connector.
TBR00045
Remove the pipe connecting the aircleaner with tur-

bocharger.
TBR00039
Remove the aspirator tube.
TBR00040
Remove crank case vent.
TBR00041
Remove the hoses right and left from delta pres-

sure sensor and the electrical connection X475.
TBR00042
Disconnect the connecting exhaust pipe from the

turbocharger with a silencer/DPF opening the
clamp.
TBR00043
Remove from electronic module control the electri-

cal connection X469.
TBR00046
Remove from the engine electronic control unit the

electrical connection X470 (1) and X471 (2).
TBR00047
Remove the connection X468.
TBR00048
Remove the ground cable and ground strap.
TBR00049
Remove the connection X69.
TBR00050
Remove the connection X477 from temperature

sensor DPF.
TBR00051
Remove the alternator connection X67 and connec-

tion X10.
TBR00052
Disconnect the electrical connection X508 from

starter motor and the ignition connection.
TBR00053
Remove the connection X476 from temperature

sensor DPF.
TBR00054
Remove the connection from heated Lambda sen-

sor.
TBR00058
Attach the aircleaner/DPF a lifting device suitable

and remove the screws (q.ty 4, two on each side).
TBR00055
Carefully remove the aircleaner/DPF from the chas-

sis and be rest on a special support.
TBR00056
Remove the four screws that secure the aircleaner

support of the DPF devise.
TBR00057
Remove the four screws that secure the aircleaner

to the support plate.
Remove the aircleaner from the support.
TBR00059
Remove the silencer/DPF from its mounting by

removing the four screws (1) securing the two half 1
flanges (2), firstly measuring and making a note of 2
distances A, B and C shown in the diagram in order
to ensure a precise connection between the com-
ponent pipes when reassembling.
TBR00060
Remove the flywheel access cover.
TBR00061
Rotate the engine to access flywheel flexplate

hardware. Use hardware tool 380000988.
TBR00062
Remove flywheel to flex plate hardware.
TBR00063
Attach a suitable lifting device.
TBR00064
Remove motor mount hardware.
TBR00065
Remove engine to transmission hardware.
TBR00066
Slowly raise engine fromchassis. Be sure all har-

ness connections and hoses have been discon-
nected and are clear of the engine. Remove engine
from machine.
TBR00067
3
4
TBR00085
1. Bracket RH engine mount 8. Washer

2. Bracket LH engine mount 9. M16 nut
3. Washer [tightening torque 210÷240 Nm (156÷178 lbf•ft)]
4. M12X35 hex screw
5. Anti-vibration devise
6. Washer
7. M16X120 hex screw
Engine - Install
Carefully lower the engine into the chassis.
TBR00067
Install engine to transmission hardware.

[Tightening torque 52÷57 Nm (38÷42 lbf•ft)]
TBR00066
Install engine mount hardware.

[Tightening torque 210÷240 Nm (155÷177 lbf•ft)]
TBR00065
Remove the lifting device.
TBR00064
Rotate the engine to access flywheel. Use hard-

ware tool 380000988.
TBR00062
Reinstall the flywheel to flex plate hardware.

[Tightening torque 52÷57 Nm (38÷42 lbf•ft)].
TBR00063
Install the flywheel access cover.
TBR00061
Fit the silencer/DPF on its mounting using the four

screws (1) securing the two half flanges (2), com- 1
plying with the distances A, B and C shown in the 2
diagram and noted during the dismantling in order
to ensure a precise connection between the com-
ponent pipes.
TBR00060
Install the aircleaner on the support and secure it

with four screws.
TBR00059
Assembly the aircleaner with a silencer/DPF and

secure using the four screws.
TBR00057
Attach a suitable lifting device and carefully install

on the frame.
TBR00056
Assembly the aircleaner/DPF to the plate mounted

on the frame using the four screws (two on each
side).
TBR00055
Connect the exhaust pipe of the silencer/DPF to the

turbocharger with the clamp.
TBR00043
Connecting the hose aircleaner to the turbocharger.
TBR00039
Connect the heated Lambda sensor connection.
TBR00058
Connect the connection X476 of temperature sen-

sor DPF.
TBR00054
Connect the connection X477 of temperature sen-

sor DPF.
TBR00051
Connect the hoses right and left on delta pressure

sensor and connect the electrical connection X475.
TBR00042
Connect the high pressure and low pressure A/C

lines (if present).
TBR00037
Connect the electrical connection X473 on the

compressor (if present).
TBR00036
Connect the air temperature sensor.
TBR00038
Connect the electrical connection X508 on the

starter motor and the ignition connection.
TBR00053
Connect the electrical connections X67 and X10 on

the alternator.
TBR00052
Connect the electrical connection X69.
TBR00050
Connect the ground cable and ground strap.
TBR00049
Connect the electrical connection X468.
TBR00048
Connect the connections X470 (1) and X471 (2) on

the electronic control unit.
TBR00047
Connect the electrical connection X469 on the elec-

tronic module control.
TBR00046
Connect crank case vent.
TBR00041
Connect the aspirator tube.
TBR00040
Connect the electrical connection X4 on 2-way air-

cleaner connector.
TBR00045
Top up the engine oil to the level indicated, using

the specific recommended lubricant.
Top up the hydraulic oil to the level indicated, using
the specific recommended lubricant.
Radiator - Install
Carefully lower the cooling package into place.
TBR00034
Install the cooling package with the existing mount-

ing hardware.
TBR00033
Remove the lifting device.
TBR00032
Connect the two cooler lines left hand.
TBR00031
Connect the two cooler lines right hand.
TBR00035
Connect the duct air intake on aircleaner.
TBR00030
Connect the four front cooler lines.
TBR00029
Install the lower radiator hose.
TBR00025
Remove the caps from the open ports.
TBR00024
Install the charge air cooler hoses and pipes.
TBR00023
Install the upper radiator hose.
TBR00022
Install the radiator purge hose.
TBR00021
Install the radiator wrapper.
TBR00026
Install the radiator wrapper mounting bolts.
TBR00019
Install hood hinge plates.
TBR00027
Install the top cover of the engine hood on the

machine.
TBR00018
Install the four screws that secure the top cover of

the engine hood to the frame of the machine.
NOTE: Exhaust cone on the hood must be concen-
tric with DPF exhaust tube to within ± 6 mm (0.23 in).
Insufficient gap between DPF and fixed hood cone
will result in damage to the fixed hood finish.
TBR00017
Install the exhaust gas pipe.
TBR00016
Install filter drier air conditioning (if present), con-

nect the hoses and electrical connection X70.
TBR00015
Connect the electrical connection X2 on the horn.
TBR00044
Recharge the A/C system.
TBR00020
Refill the system with coolant.
TBR00068
Engine hood - Install

Lower the hood into place.
TBR00014
Install pivot point tubes.
TBR00013
Install the hood pivot point hardware.
TBR00012
Remove the lifting straps.
TBR00011
Install the hood straps.
TBR00010
Open hood and install the hood struts.
TBR00009
Install the grill.
TBR00006
Install the grill bumpers.
TBR00008
Install all grill hardware.
TBR00007
Remove the support strut that are holding the

loader in the upright position.
TBR00005
Battery - Connect
S WARNING S
Explosive gas!
Batteries emit explosive hydrogen gas and other
fumes while charging. Ventilate the charging area.
Keep the battery away from sparks, open flames,
and other ignition sources. Never charge a frozen
battery. Failure to comply could result in death or
serious injury.
S WARNING S
Hazardous chemicals!
Battery electrolyte contains sulfuric acid. Contact
with skin and eyes could result in severe irritation
and burns. Always wear splash-proof goggles and
protective clothing (gloves and aprons). Wash
hands after handling. Failure to comply could result
in death or serious injury.
Connect the negative battery cable to the negative

battery terminal.
TBR00004
Install the battery cover.
TBR00003
Install the battery cover hardware.
TBR00002
ENGINE ERROR CODES
CODE SHORT FAILURE DESCRIPTION AMBER RED STOP

WARNING
One second
alarm upon
activation for
key cycle
Coolant Temperature Sensor - Signal Not

3006 Plausible (Compared with Engine Oil X
Temperature).
Coolant Temperature Sensor - Signal Below
3008 X
Range Min.
Coolant Temperature Sensor - (via CAN) No
3009 X
Signal.
Fuel Temperature Signal - Signal Above Range
3015 X
Max.
Fuel Temperature Signal - Signal Below Range
3016 X
Min.
Boost Pressure Sensor - Signal Above Range
3019 X
Max.
3021 Boost Pressure Sensor - (via CAN) No Signal. X
3022 Boost Pressure Sensor - Signal Not Plausible. X
Atmospheric Pressure Sensor - Signal Not
3023 X
Plausible Compared with Boost Pressure.
Atmospheric Pressure Sensor - Signal Above
3024 X
Range Max.
Atmospheric Pressure Sensor - Signal Below
3025 X
Range Min.
3028 Oil Pressure Too Low. X***
3029 Oil Pressure Sensor – Short circuit to Battery. X
3030 Oil Pressure Sensor – Short circuit to Ground. X
3031 Oil Pressure Sensor - Hardware Error. X
3032 Oil Pressure Sensor - Value Too High. X
Oil Temperature Sensor - Signal Not Plausible
3033 X
(Compared with Coolant Temperature).
Oil Temperature Sensor - Signal Above Range
3034 X
Max.
Oil Temperature Sensor - Signal Below Range
3035 X
Min.
3036 Oil Temperature Sensor - (via CAN) No Signal. X
3037 Boost Pressure Sensor - Signal Low. X
3051 Battery Voltage to ECM too High. X
3052 Battery Voltage to ECM too Low X
*** Note: Per direction from Engineering group this amber flag will be overriden by Cluster to a Red.

WARNING
One second
alarm upon
activation for
key cycle
3060 Cylinder1 - Unclassifiable Error in Injector. X

Cylinder1 - Injector Cable Short circuit
3061 X
(Low Side to Battery).
3063 X
(High Side to Ground).
3069 X
3071 X
3077 X
3079 X
3081 X
3083 X
3088 Crankshaft Sensor - No Signal. X
3089 Crankshaft Sensor - Invalid Signal. X
3090 Camshaft Sensor - No Signal. X
3091 Camshaft Sensor - Invalid Signal. X
Offset Between Camshaft and Crankshaft -
3093 X
Outside Boundaries.
Operating with Camshaft Sensor Only -
3095 X
Backup Mode.
Rail Pressure Sensor CP3 - Signal Below Range
3102 X
Min.
3104 Rail Pressure Relief Valve – Open. X
Rail Pressure Relief Valve - Pressure Shock
3105 X
Requested.
Rail Pressure Relief Valve - Did Not Open After
3106 X
Pressure Shock.
3107 Metering Unit – Short circuit to Battery. X
Rail Pressure Sensor Monitoring - Signal Above
3110 X
Range Max.

WARNING
One second
alarm upon
activation for
key cycle
Rail Pressure Sensor Monitoring - Signal Below

3111 X
Range Min.
Rail Pressure Sensor CP3 - Signal Above Range
3112 X
Max.
3113 Main Relay 1 – Short circuit to Battery. X
3114 Main Relay 1 – Short circuit to Ground. X
3118 ECM 12V Sensor Supply Voltage High. X
3119 ECM 12V Sensor Supply Voltage Low. X
3131 Grid Heater Always Switched On X
3137 Metering Unit - Open Load. X
3138 Metering Unit - Temperature Too High. X
3141 Fuel Flow Set point Too Low. X
3147 Oil Temperature Too High. X
3154 Grid Heater Relay – Short circuit to Battery. X
3155 Grid Heater Relay – Short circuit to Ground. X
3156 Grid Heater Relay - No Load. X
Rail Pressure Governor Deviation Exceeded
3171 X
Max. Limit with Fuel Delivery Quantity on Limit.
Rail Pressure Governor Deviation Exceeded Min.
3172 X
Limit with Fuel Delivery Quantity on Limit.
Rail Pressure Governor Deviation Below Min.
3173 X
Limit for Speed.
Rail Pressure Governor Deviation Exceeded
3174 X
Max. Limit.
3175 Rail Pressure Drop Rate is higher then expected. X
3176 Set point of Metering Unit Not Plausible in Overrun. X
3188 Cylinder 1 Warning - Open Load. X
3210 Bank1 - General Short circuit on Injection Cable. X
Bank1 - Injection Cable Short circuit Low Side to
3211 X
Ground.
3213 Bank1 - Unclassifiable Error. X
3218 Bank2- General Short circuit on Injection Cable X

WARNING
One second
alarm upon
activation for
key cycle
Bank2 - Injection Cable Short circuit Low Side to

3219 X
Ground.
3221 Bank2 - Unclassifiable Error. X
Injection Processor (CY33X) Error - Internal
3227 X
Reset / Voltage Too Low.
Injection Processor (CY33X) Error - Unlocked /
3228 X
Initialization Failure.
Injection Processor (CY33X) Error -
3229 X
Injections Limited By Software.
Injection Processor (CY33X) Error - SPI
3230 X
Communication Failure.
Injection Processor Error - Internal Reset / Clock
3231 X
Loss / Voltage Too Low.
Injection Processor Error - Unlocked /
3232 X
Initialization Failure.
3233 Injection Processor Error - Test Mode. X
Injection Processor Error - SPI Communication
3234 X
Failure.
3238 ECM Internal SPI Communication Error - CJ940. X
3242 ECM (Locked) Recovery Occurred. X
ECM Recovery (Suppressed) - Recovery
3243 X
Occurred.
3244 ECU Recovery (Visible) - Recovery Occurred. X
3245 ECM Processor - Watchdog Not Plausible. X
3246 Shutoff Paths During Initialization - Watchdog. X
Shutoff Paths During Initialization -
3247 X
Supply Voltage Too High.
Shutoff Paths During Initialization -
3248 X
Supply Voltage Too Low.
TPU Monitoring - Time Deviation between TPU
3249 X
and System Not Plausible.
3250 Dataset - Variant Defective. X
3251 Dataset - Requested Variant Could Not Be Set. X
3252 Controller Watchdog - SPI Communication Failure. X
3253 ADC Monitoring - Reference Voltage Too Low. X
3254 ADC Monitoring - Reference Voltage Too High. X
3255 ADC Monitoring - Test Impulse Error. X

WARNING
One second
alarm upon
activation for
key cycle
3256 ADC Monitoring - Queue Error. X

3258 High Side Power – Short circuit to Battery. X
3259 High Side Power – Short circuit to Ground. X
3260 Low Side Power - Open Load. X
Low Side Power – Short circuit to Battery of
3261 X
Excess Temperature.
3262 Low Side Power – Short circuit to Ground. X
3265 Overrun Monitoring - Injection Time Too Long. X
Redundant Engine Speed in Overrun Monitoring -
3266 X
Speed Signal Not Plausible.
ECM Internal Supply Voltage Too High -
3278 X
CJ940 Above Limit.
ECM Internal Supply Voltage Too Low -
3279 X
CJ940 Below Limit.
3280 Sensor Supply Voltage 1 – High. X
3281 Sensor Supply Voltage 1 – Low. X
3284 Sensor Supply Voltage 2 – Low. X
3286 Sensor Supply Voltage 3 - Low. X
3334 Timeout of CAN message TSC1-PE Torque. See note below X
3339 Timeout of CAN message TSC1-VE Speed. See note below X
Atmospheric Pressure Sensor - Processed via
3363 X
ADC (no CAN Plausibility Performed).
3856 Coolant Temperature signal test failure. X
3998 Unknown error code with amber lamp from ECU. X
Possible unknown error code with red lamp from
3999 X
ECU.
Note: 3334, 3339 initial visualize as amber due to ECU coding in DM1 message. Message then turns to red
based on rules above.
580ST
590ST
695ST
SECTION 21 - TRANSMISSION
POWERSHUTTLE TRANSMISSION................................................................................................................ 3
CONTROLS ................................................................................................................................................. 8
LUBRICATION........................................................................................................................................... 12
GREASING ................................................................................................................................................ 15
TRANSMISSION ERROR CODES.......................................................................................................... 136
REPAIR TIMES........................................................................................................................................ 140
SPECIAL TOOLS..................................................................................................................................... 141
POWERSHIFT TRANSMISSION.................................................................................................................. 142

CONTROLS ............................................................................................................................................. 153
LUBRICATION......................................................................................................................................... 155
GREASING .............................................................................................................................................. 157
TRANSMISSION ERROR CODES.......................................................................................................... 329
REPAIR TIMES........................................................................................................................................ 333
SPECIAL TOOLS..................................................................................................................................... 334
2 SECTION 21 - TRANSMISSION
SECTION 21 - TRANSMISSION 3
POWERSHUTTLE TRANSMISSION
This transmission is used on powershuttle backhoe
loader models 580ST - 590ST.
4WD/2WS TRANSMISSION - POWERSHUTTLE (580ST - 590ST)
Torque converter ratio.................................................................................................................................. 2.38
DIMENSIONS
4WD
PORTS
Ref. Dimension Use Notes - Miscellaneous

1 7/8” - 14 UNF Oil inlet from cooler
2 7/8” - 14 UNF Oil outlet to cooler
3 1/2” - 14 UNF Transmission temperature switch
4 Oil drain plug
0.5 + 3.5 bar (7.3 + 50 psi) ON forward /
5 1/8” - 28 BSP ISO 228 Oil cooler return reverse travel position
0.5 + 3.5 bar (7.3 + 50 psi) ON neutral position
11 + 13 bar (159 + 188 psi)
6 1/8” - 28 BSP ISO 228 Forward gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in neutral
position
11 + 13 bar (159 + 188 psi)
7 1/8” - 28 BSP ISO 228 Reverse gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in neutral
position
11 + 13 bar (159 + 188 psi)
Forward / reverse gear pressure
8 1/8” - 28 BSP ISO 228 0.3 bar (4.3 psi) = maximum pressure in neutral
check port
position
9 1/8” - 28 BSP ISO 228 Converter pressure check port 0.5 + 0.9 bar (7.3 + 13 psi)
10 9/16” - 18 UNF Oil inlet / outlet for differential lock
13 bar (188 psi) at 900 rpm
11 9/16” - 18 UNF Brake oil outlet / inlet
14.5 bar (210 psi) at 2200 rpm
12 9/16” - 18 UNF Oil inlet from the brake
Oil inlet from service pump to
13 9/16” - 18 UNF Brake pressure switch = 10 ± 1 bar (145 ± 14 psi)
brake release
13 + 14 bar (188 + 203 psi) at 900 rpm
14 4WD pressure check port
13 + 15.5 bar (188 + 225 psi) at 2200 rpm
CONTROLS
1. GEARSHIFT LEVER: it is possible to select

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

speeds. A torque converter is used to couple the
engine with the transmission.
The reverse travel lever (3) allows shifting between
forward and reverse travel without disengaging the
gear ratios.
A device for “transmission disconnection” is activated
by pushing button (2), placed on the gearshift lever
(1) or by pushing button (5), placed on the loader
attachment (3) control lever.
S WARNING S
Always apply the parking brake whenever the
machine is parked as the machine is free to roll
even though the transmission gearshift lever and
power reversing lever may be “In Gear” and the
engine is turned OFF.
GEARSHIFT LEVER
The gearshift lever (1) is used to select any of the 4
gear ratios.
The transmission disconnect button (2) is
depressed and held as the lever is shifted from one
gear to another. The button is then released to re-
establish the power of transmission drive.
FORWARD/REVERSE POWERSHUTTLE LEVER

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

temperatures with cold transmission oil, allow the oil
to warm up before attempting to shift the powershut-
tle lever. The transmission can be shifted normally
after the oil warms up.
IMPORTANT: the horn will sound if the powershuttle
lever is operated with the parking brake engaged.
IMPORTANT: The powershuttle lever can be acti-
vated with any engine speed.
As a safety and precautionary measure, the engine
must run at approximately 1200 rpm.
This action is easily controlled by means of the foot
accelerator to control engine and ground speed.
TRANSMISSION DISCONNECTION
The 4x4 transmission provides for easy upward and
downward gear ratio changes on the move.
However, as a clutch is not used between the
engine and transmission, the power flow from the
engine to the transmission must be interrupted to
shift from one gear ratio to another. This is accom-
plished by means of a transmission disconnect
(dump) button.
The finger operated button (2) on the main gearshift
lever knob (1) is easy to operate.
S WARNING S
Do not use the disconnect switch control down hill,
because excessive speed may cause loss of con-
trol, personal injury or the failure of transmission.
To make upward gear ratio changes, simply depress

and hold button (2) on the gearshift lever (1), while
shifting the same from one gear ratio to another.
When the desired gear ratio has been selected
release the button and allow the unit to gain engine
speed and ground speed. If another higher ratio is
required repeat the procedure.
IMPORTANT: to prevent possible damages to the

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

2. Oil drain plug
3. Breather
LEVEL CHECK
The oil level check should be carried out with the
engine running at low speed and at normal operat-
ing temperature.
Move the machine to a level and firm ground.
Raise the loader attachment and assemble the
safety support strut.
Place the backhoe attachment in the road travel
position.
Place the direction-of-travel lever and gearshift
lever in neutral position.
brake.
Open and raise the engine guard and lock it in
opened position by means of the safety lock on the
left-hand gas spring.
Extract the dipstick (1), clean it with a clean cloth
and completely insert it into the tube, then take it out
again.
If the oil level is below the mini mark, top up.
Stop the engine.
Unlock the safety lock and close the engine guard.
OIL CHANGE
position.
brake.
Remove the dipstick (1).
NOTE: change the oil while the transmission is still
warm; the oil will flow more easily.
Place a container with suitable capacity under the
drain plug (2).
Unscrew and remove the drain plug.
Let the transmission oil drain.
Re-install the drain plug (2).

Fill with new oil of specified type through the dipstick
hole.
NOTE: transmission oil capacity 20.8 litres (4.57 gal)
(4WD).
Reassemble the dipstick (1).
Check the oil level by means of the dipstick and, if
necessary, add more oil.
Drive the machine for a few minutes in first and sec-
ond gear, then stop the engine.
Check the oil level again by means of the dipstick
and, if necessary, add more oil.
GREASING
Tecnolube POLYMER 400 grease
Transmission oil
*: no grease, no oil
REMOVAL FROM MACHINE
3 1
8
9
6
5 4
6
5
2
13
12
11
7
10
TBR00071
TABLE 1
1. Transmission 8. M16x120 hex screw
2. Anti-vibration 9. Washer
3. Left transmission support 10. M16 nut
4. Right transmission support [tightening torque 210÷240 Nm (156÷178 lbf·ft)]
5. Washer 11. Washer
6. M12x30 hex screw 12. M12x30 hex screw
[tightening torque 90÷110 Nm (66÷81 lbf·ft)] [tightening torque 90÷110 Nm (66÷81 lbf·ft)]
7. Washer 13. Bracket transmission mounting
NOTE: ensure chassis bolt on mount is seated against locating block on chassis.
6
7
2
3
4
5
TBR00072
TABLE 2
1. Transmission 6. Washer
2. Torque converter 7. M10x20 hex screw
3. Plate [tightening torque 52÷57 Nm (38÷42 lbf·ft)]
4. Plate 8. M10x30 hex screw
[tightening torque 52÷57 Nm (38÷42 lbf·ft)]
5. Snap ring
TBR00073
TABLE 3
1. Fitting (apply Loctite 577) 4. M10x30 hex screw
2. Dipstick tube [tightening torque 52÷57 Nm (38÷42 lbf·ft)]
3. Dipstick 5. Washer
DISASSEMBLY AND ASSEMBLY

Some of the following pictures could not exactly
show your transmission, but the procedure is cor-
rect.
TIGHTENING TORQUES AND APPLICATION OF SEALANTS / ADHESIVES

A. Loctite 510 C. Loctite 638
B. Loctite 518 D. Loctite 542
PLUGS AND FILTERS
Disassembly
Remove the oil drain plug (5) and drain the oil from
the transmission.
Loosen and remove the 2 screws (1).

Remove the cap (2).
Remove the oil filter (4) and the O-ring (3).
Unscrew and remove the oil filter (6).
Remove fitting (7).
Remove the spool (8).

Remove the spring (9).
Use a puller to remove the pressure relief valve

(10).
NOTE: the pressure relief valve is adjusted by the
Manufacturer. Never disassemble nor adjust it. If
any of its parts are damaged, replace the valve with
a new one.
Do not remove the plug unless there are leaks.

The plug is sealed with Loctite 542 and is difficult to
remove.
If the removal is necessary, clean it and apply Loc-
tite 542 prior to assembly.
If necessary, remove the plugs (13) or the breather

(11).
Assembly
Assemble the plugs (13) and the breather (11).
Assemble valve (10).
Assemble the spring (9).
Assemble the spool (8).

Assemble fitting (7).

Tighten to the prescribed torque of 80 Nm (59 lbf·ft).
Assemble a new oil filter (6).

Lubricate the gasket.
Tighten clockwise until the gasket makes contact
with its seat, then tighten further 2/3 of a turn.
Assemble the oil filter (4) and the O-ring (3).
Assemble the cover (2).

Screw in and tighten the screws (1) to a tightening
torque of 23 Nm (17 lbf·ft).
Assemble the plug (5).

OIL PUMP
Disassembly
Loosen and remove the screws (1).
Mark the oil pump position with respect to the bell
housing before loosening the screws.
Use two levers (A) to pull out the oil pump (2).
Remove the oil pump (2).

The pump seal ring can be damaged during this
operation.
If necessary, remove the O-ring (3).
S WARNING S
Do not disassemble the pump or its operation may
be compromised.
If necessary, remove the seal ring (4).

Assembly
Assemble the seal ring (4) onto the oil pump (2).
Use tool 380200218.
Lubricate the seal ring.
Assemble the O-ring (3).
Before pump assembly (if new), check that the oil

passage holes (between pump and half box) or the
visual marks coincide.
Lubricate the seal ring (4) to keep it centred, in

order to facilitate its introduction onto the oil pump.
Lubricate the matching seat with the front half box.

Assemble the oil pump (2).

Check that the mark on the oil pump and on the bell
housing coincide.
TUBES
Disassembly
Drain transmission oil.
Loosen and remove the screws (1) and (2).
Remove the tube (3).
Collect the gaskets (4).
Assembly
Assemble the tube (3) with the gaskets (4).
Screw in and tighten the screws (1) and (2) to the
prescribed torque of 40 Nm (30 lbf·ft).
HYDRAULIC CONTROL VALVE
Disassembly
Disconnect all electric connections.
Drain the transmission oil.
Remove the hydraulic control valve (53).
Remove the gasket (49).
Remove the screws (48), and the plate (50).
Lock the hydraulic control valve with a clamp.

Remove the plug (1) and the O-ring (2).
Push piston (4) downwards and remove the snap

ring (3).
Remove the piston (4) and the spring (5).
Verify the wear condition of the piston (4) and of the

spring (5).
Do not disassemble the piston (8) from the control

valve body.
If the piston is to be disassembled (8), the control
valve body must be replaced (47).
If the piston (8) is to be replaced, also order the
control valve body (47).
Remove the washer (10).

Remove the valve cover (34).
Remove the plate (36).
Remove the outer piston (38), the springs (39), (40)

and (41), the pin (42) and the inner piston (43).
Verify the wear condition of the springs (39), (40)

and (41) and of the pin (42).
Remove the ball (26).

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

(29).

(27).
Unscrew the solenoid tube (24).

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

(24).
Remove the spring (23) and the washer (22).

Verify the wear condition of the piston (21) and of
the solenoid tube (24).
Unscrew and remove the nut (20).

Remove the O-ring (19).

(17).
Unscrew the solenoid tube (18).
Remove the O-rings (17).
Verify the wear condition of the solenoid tube (18),

of the O-ring (19) and of the nut (20).
Assembly
Assemble the O-rings (17).
Assemble the solenoid tube (18).

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

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

torque of 5 ÷ 7 Nm (3.6 ÷ 5 lbf·ft).
Assemble the solenoid tube (24), the spring (23),

the piston (21) and the washer (22).
Assemble the solenoid tube (24) and the piston

(21).
Screw in and tighten the solenoid tube (24) to a

tightening torque of 21.5 ÷ 24.5 Nm (15.9 ÷ 18 lbf·ft).


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

(5 ÷ 7.4 lbf·ft).
Insert the spring (25).
Insert the ball (26).

Position the gasket (37).
Pre-assemble the springs (39), (40) and (41) and

the pin (42) with the pistons (38) and (43).
Assemble the outer piston (38), the springs (39),

(40) and (41), the pin (42) and the inner piston (43).
Position the plate (36).

Position and lubricate the gasket (35).
Assemble the valve cover (34).

torque of 9.8 ÷ 11.8 Nm (7 ÷ 8.7 lbf·ft).
Turn the hydraulic control valve (47).

Assemble the washer (10).

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

ring (3).

Assemble the plate (50).


Lubricate the gasket (49).
Assemble the hydraulic control valve (53).

torque of 15 ÷ 24.2 Nm (11 ÷ 17.9 lbf·ft).
4WD SOLENOID VALVE
Disassembly
Prior to disassembling the 4WD solenoid valve, dis-
connect all electric connections.
Remove the solenoid body (2).
Remove the nut (8).

Remove the solenoid valve coil (7).
Remove the shaft (6).

Remove the O-rings (5).
If necessary, remove the valve (3).

Do not disassemble the valve (3).
There are no serviceable parts.
If there is a problem, use a new valve.
Assembly
Assemble valve (3).
Assemble the O-rings (5) on the shaft (6).
Assemble the 4WD solenoid coil (7).

Screw in and tighten the nut (8) to the tightening
torque of 5 ÷ 8 Nm (3.6 ÷ 5.9 lbf·ft).
Position the gasket (4).

Remove the solenoid body (2).

PARKING HANDBRAKE
Disassembly
Unscrew the screw (1).

Use a screwdriver and 2 screws to lock the flange.
Remove the screw (1) and the washer (2).
Remove the flange (4) and the O-ring (3).
Loosen and remove the screws (5), (6) and (7).

Remove the brake (8) assembly.
Remove the O-ring (9) from the brake (8).
Remove the seal ring (15).

Remove the plug (16).
S WARNING S
The seal ring can be damaged.
Remove the rings (10), the 5 brake discs (11) and

the 5 counterdiscs (12).
Remove the hub (13).

Assembly
Assemble the hub (13).
Use a gauge to check that each counterdisc (12)

and each brake disc (11) is flat.
If necessary, replace them.
If the brake discs (11) are nearly smooth, replace
them.
If the friction material is damaged or appears
burned, replace it.
Check the grooves for wear.
Check counterdiscs (12) for pitting, scoring, or other
damage.
If you will be using new brake discs, soak them in oil
for at least an hour before assembly.
If you are using the old friction discs, make sure that
the contact surfaces are coated with oil before
assembly, check the wear condition.
If this is 50% compared to the nominal value, we
suggest its replacement.
Brake disc kit
Brake disc number 5

Counterdisc number 5
Nominal brake disc 3.6 ± 0.05 mm
thickness (0.14 ± 0.002 in)
Brake disc kit nominal
37.40 ÷ 37.60 mm
thickness [with 163 kg
(1.47 ± 1.48 in)
(359.34 lbs) of load]
Brake disc maximum wear 0.65 mm
(each side) (0.02 in)
Assemble the counterdisc (12), the brake disc (11)

and the ring (10).
Repeat this operation until the brake disc kit is com-
plete.

Assemble the seal ring (15) onto the brake (8), use
tool 380200226.
Insert the O-ring (9) on the brake (8).

Assemble the brake assy (8) on transmission.
Screw in and tighten the screws (5), (6) and (7) to a
tightening torque of 50 Nm (37 lbf·ft).
Assemble the flange (4) and the O-ring (3).

Lubricate the O-ring (3).
Assemble the washer (2) and the screw (1).
Use a screwdriver and 2 screws to lock the flange (A).
Tighten the screw (1) to a tightening torque of 139 Nm
(102.5 lbf·ft).
4WD - TRANSMISSION BOX
Disassembly
Remove the snap ring (1).
Loosen and remove flange retaining screw (2).

Use a screwdriver and 2 screws to prevent the
flange rotation.

Remove cover (7).
Remove the O-ring (8) from the cover (7).
Remove the seal ring (9) from rear cover (7).

Remove the gearshift control assy (11) and the O-ring
(12).
Loosen and remove the 7 screws (13) and the

flange (14).
Loosen and remove the screws (15) fastening the

cover (16).
Use a prybar to loosen the rear cover from the
housing.
Remove the rear cover (16).
Remove the pins (18) by means of a punch.

Remove the retainers (20).
Remove the 2 balls (23).

Loosen and remove the screws (24) and the wash-

ers (25).
Remove the springs (26).
Remove the balls (27).
Pull the secondary shaft to the rear so that there is

backlash between the snap ring and the rear hous-
ing.
Remove transmission shaft PTO (29) by pushing

lightly on the opposite side.
If necessary, replace the seal ring (30) by cutting it.
Take out the bearing (32) with tool 380200190.

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

Raise the front half box.
The outer rings of the bearings on the primary shaft

(36) and on the secondary shaft (37) can either stay
on the shafts or on the front box seat.
Remove the 2 bearings (36) and (37).
Remove the bearing (38).
If necessary, replace the O-rings (39).
Assembly
Push the secondary shaft toward the back of the
rear box, so that there is backlash between the
snap ring seat and the rear box.
Assemble the snap ring (28).

Apply a thin film of sealant on the edge of the rear

half box.
Lubricate the primary shaft bearing (36) and the

secondary shaft bearing (37).
Assemble the 2 bearings (36) and (37).
Assemble the front half box (35) on the rear one.

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


Lubricate the bearing of the 4WD shaft.

Assemble the bearing (38) on 4WD shaft by means
of tool 380200230.
By means of tool 380200213 assemble the seal ring

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

Screw in the 3 screws (6) fastening the cover to the

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

flange.
Assemble the 4WD flange (5).

Screw in the screw (2).

Use a screwdriver to prevent the flange rotation.
(102.5 lbf·ft).
Insert the ball (27).

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

(59 lbf·ft).
Insert the ball (27) and the spring (26).

Assemble the screw (24) and the washer (25).
(59 lbf·ft).
Assemble the bearing (32) on the transmission

shaft PTO (29).
To assemble the teflon seal ring (30) perform follow-

ing operations by means of the listed tools in
sequence:
380200257 (without shim);
380200225;
380200214.
Insert transmission shaft PTO (29) to stroke end.
Grease the balls.

Insert the 2 balls (23).
Assemble the plate (22).
Apply sealant on the threads of the 2 screws.

Screw in the 2 screws (21) to fasten the plate cor-
rectly and tighten them to the prescribed torque of
50 Nm (37 lbf·ft).
Assemble the retainers (20) on the gearbox pins.
Assemble the pins (18) to fasten the retainers on

the gearshift pins.
Apply a thin film of sealant on the edge of the rear

cover (16).
Do not grease the O-ring.
Place the rear cover (16).

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

(14).
Place the flange (14).
Assemble a new O-ring (12) on the gearshift control

assy (11).
Use clean oil to lubricate the ring and assembly it
on the rear box.
Screw in the 3 screws (10) fastening the gearshift
control assy to the rear cover and tighten to the pre-
scribed torque of 23 Nm (17 lbf·ft).
SHAFTS A, D
Disassembly
Grab the shaft with the (A) pliers and pull out the
shaft assy (D).
Shaft (A)
Assemble a bearing separator under the gear (do

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

Remove the spacer (4).
Remove the gear (6).
Remove the roller retainer (7).
Remove the thrust washer (8).

Remove the pin (9).
Lift and remove the snap ring (11).
Remove the discs (18) and the counterdiscs (17).

Place a mark below the groove on the clutch bell.
Mark the snap ring (11), the discs (18) and the
counterdiscs (17).
These marks will be used as a reference during
assembly.
Lower the cover (13) by means of tool 380200215.

Loosen the knobs of the threaded bars to clear the

spring tension.
Remove the upper part of tool 380200215.
Remove the cover (13) and the spring (15).
Remove the sleeve (5).
Remove the clutch piston (19) by blowing in com-

pressed air through the delivery hole.
If necessary, remove the seal ring (20) with the

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

If necessary, remove the seal rings (22).
Use a puller to remove the bearing (24).

Remove the bearing (24) and the thrust washer

(25).
Remove the gear (26) and the roller retainer (12).
For the disassembly of other parts, repeat the oper-

ations described previously.
Check the seal ring grooves (large and small) for

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

assembly order.

and each clutch disc (18) is flat.
If they are not flat, replace them with new ones.
If the clutch discs (18) are nearly smooth, or if their
friction faces are damaged or burnt, they must be
replaced.
damage.
If you will be using new clutch discs, soak them in
oil for at least an hour before assembly.
If you are using the old clutch discs, make sure that
the contact surfaces are coated with transmission
oil before assembly, check their wear condition (see
chart below).
If the wear exceeds the 50% of the rated value,
replace them.
Verify the bore and the housing of the input shaft for
damage that will cause leakage during the assembly
of the clutch.
Check if the slots in the housing of the input shaft
are damaged by the tangs of the counterdiscs.
Forward - reverse gear clutch
Disc number (each side) 6

Counterdisc number (each side) 7
Counterdisc rated thickness 2.5 ± 0.05 mm (0.10 ± 0.002 in)
Rated thickness of disc 1.75 ± 0.05 mm (0.07 ± 0.002 in)
Disc maximum wear (each side) 0.2 mm (0.009 in)

Disc kit nominal thickness [with 163 kg (359.34 lbs) of load] 29.00 ÷ 29.20 mm (1.14 ± 1.15 in)
Shaft (D)
Remove the bearing (16) from the shaft (D) by
means of a puller.

means of a puller.
Assembly
Shaft (A)
Assemble the seal ring (20) with the relevant O-ring
and the seal ring (21) with the relevant inner O-ring,
respectively in the outer and inner seat of the pis-
ton.
Apply a thin film of oil on the seal rings.
Insert the piston (19) with tool (T) 380001926.

Assemble the sleeve (5).
Assemble the spring (15) and the cover (13).
Lower the cover (13) and insert the snap ring (14)
by means of tool 380200215.
Remove the 380200215 tool and fit the pin (9).

Insert the thrust washer (8).
Insert the roller retainer (7).
To assemble the clutch discs start with the gear (6)

on the bench.
Assemble the thrust washer (11) so that the refer-
ence mark on top of the plate, made during disas-
sembly, is facing towards the gear.
Assemble the discs (18) and the counterdiscs (17)

on the gear (6).
The assembled clutch disc kit must contain 6
counterdiscs and 6 friction discs.
Use 2 screwdrivers to position the disc kit.
Assemble the spacer (4).
Heat the bearing (3) to 80 ÷ 100 °C (176 ÷ 212 °F).

Assemble the bearing (3) with tool 380200190.
NOTE: for clarity of the seal ring installation proce-

dure, the following photos do not show the disc kit,
gear, spacer, bearing, and snap ring installed on the
input shaft.
Insert the seal ring (1).
Assemble the 380200224 tool onto the input shaft

with the chamfered end facing inwards.
Let tool 380200224 slide on the input shaft and

above the spacer.
The tool will stop in the correct position to install the
seal ring in the groove.
Heat the seal ring to 60 ÷ 80 °C (140 ÷ 176 °F) for 5

minutes.
Assemble the seal ring on tool 380200224.
Assemble tool 380200225 over tool 380200224 and

slide the seal ring until it reaches the groove in the
shaft.
Remove tools 380200224 and 380200225, the
expander/protector and the spacer from the shaft.
Assemble the end of seal compressor 380200214

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

with the narrow chamfer over the shaft and over the
seal ring.
Leave the seal compressor in place for 15 minutes
until the seal ring has cooled and is properly seated
in the groove.
After the seal ring has cooled, remove the seal
compressor from the shaft.
Turn the shaft upside down to carry out the opera-

tions described previously.
Lubricate the thrust washer (25).
Assemble the thrust washer so that the notch in the
inner edge fits over the pin.
Make sure that the side with the oil grooves is
down.

By means of tool 380200197 place the bearing (24)
onto the input shaft until it makes contact with the
thrust washer.

Assemble the snap rings and place the spacer in

the protection (tool 380001933).
Place tool 380001933 and the spacer on the shaft.


minutes.

shaft.
Remove tools 380001928 and 380001933.

seal ring.

seal ring.
in the groove.
In order to insert the other 3 rings, repeat the opera-

tions described previously, by means of following
spacer rings:
380001933/3 for the 2nd ring;
380001933/2 for the 3rd ring;
380001933/1 for the 4th ring.
1. Lubrication oil passage

2. Forward gear clutch passage
3. Reverse gear clutch passage
4. Forward gear engagement
5. Forward gear clutch disc kit
6. Reverse gear clutch disc kit
7. Reverse gear engagement
8. Input shaft
Apply compressed air of approximately 6 bar (87 psi)

to the forward clutch passage.
Listen for the forward gear piston to move and to
lock the relevant clutch disc kit.
Try to shift the forward travel gear.
It must not turn on the input shaft.
Try to shift the reverse travel gear.
It must turn freely on the input shaft.
If the clutches do not work correctly, disassemble
them to find the problem.
Carry out the check procedure of the clutch disc kit

play on both sides of the clutch.
Position the shaft on a suitable support (S) and
apply load F on the counterdisc (11) surface by
means of a proper buffer (T), as shown.
This operation clears any possible play.
To check the backlash, supply the piston chamber

with compressed air at 6 bar (87 psi) and verify the
actual stroke “X” with a dial indicator.
Determine clearance “X”.
The piston stroke (19) and (38) must be such to

ensure a play corresponding to (according to the
clutch disc kit)
X = 2.15 ÷ 4.10 mm (0.08 ÷ 0.16 in)
X = 1.60 ÷ 2.45 mm (0.06 ÷ 0.10 in)
If the distance is not within specification, the clutch
is probably wrongly installed.
Turn the clutch shaft upside down and repeat the
operation for the other clutch disc kit.
Shaft (D)
Assemble the bearing (16) on shaft (D) by means of
tool 380200230.

tool 380200230.
Lubricate with oil the shaft seat (A).
Insert shaft (D) and shaft (A).

The operation is correct only if the 2 shafts are fitted
at the same time.
SHAFTS B, C
Disassembly
Remove the shafts (B) and (C).
Remove the gearshift control yokes.

To remove the shaft (C) use tool 380200246.
Shaft (C)
By means of a puller remove the bearing (1).
Remove the thrust washer (2) and 3rd speed gear

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

Remove the ring (5) from each side of the synchro-

nizer assy.
The components of the synchronizer assy are serv-
iced as a complete unit.
The synchronizer assy may be disassembled for
inspection and cleaning.
If some parts are damaged, replace the synchro-
nizer assy.
Use a suitable gauge to measure the backlash

between the bottom of the teeth on the synchro-
nizer ring and the edge of the sleeve on the outside
of the synchronizer assy.
The backlash (S) should be approximately 1.0 mm
(0.04 in) with used parts in good condition.
If the backlash (S) is 0.5 mm (0.02 in) or less, use a
new synchronizer assy.
Before disassembly, repeat the measurement on
the opposite side of the synchronizer.
Remove the ring (6) from each side of the synchro-

nizer.
Remove the sleeve (7) from the synchronizer hub.

When the sleeve is removed from the hub, the
spring plates, the hub pins and the hub springs will
be released from the hub.
Be careful not to lose any of these parts.
Remove the blocks (8), the balls (9), the springs

(10) and the synchronizer hub (11).
The synchronizer hub contains 3 blocks (8), 3 balls
(9) and 3 springs (10).
Remove the 4th speed gear (12).
Turn the shaft.

Remove outer ring of bearing (15).
Use a puller to remove inner ring of bearing (15).

NOTE: do not try to remove the bearing by pulling
the gear since it is locked by snap ring (16).
Remove the shims (20) and the thrust washer (17).
Remove the pin (19).
Remove the 2nd speed gear (18).

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

Remove the synchronizer ring (22).
Remove the steel ring (24) and the sintered ring

(25) together.
Install the synchronizer with the synchronizer assy.
Use a suitable gauge to measure the backlash
between the bottom of the teeth on the synchro-
nizer ring and the edge of the sleeve on the outside
of the synchronizer assy.
The backlash (S1) should be approximately 1.0 mm

(0.04 in) with used parts in good condition.
If the backlash (S1) is 0.5 mm (0.02 in) or less, use
a new synchronizer assy.
Repeat the measurement on the opposite side.
Remove the ring (26).
Overturn the synchronizer and remove the ring (27)

from the other side.
Remove the steel ring (28) and the sintered ring

(29) together.
Remove the ring (30).

Support the sleeve on blocks.

Push it down and, at the same time, extract the
detent devices of sleeve and hub.
Remove the balls (32), the blocks (33), the springs

(34) and the hub (35).
Remove the 1st speed gear (37).

Remove the 4WD gear (14).

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

Assembly
Shaft (C)
Put the secondary shaft on the bench so that the
first-second gear end is up.
You can use a vice with soft jaws to hold the shaft in
position.
Install the snap ring (13).
Assemble the 4WD gear (14).

Assemble the 1st speed gear (37).
Assemble the 1st/2nd speed synchronizer (23).

Before final assembly, check the correct location of
the hub (35), sleeve (31), springs (34), blocks (33)
and balls (32).
The springs are installed on the hub.
The blocks are not yet pushed down into the sleeve
and are holding the hub outside the sleeve.
The balls are loose in the recesses of the blocks.
Use a punch or a screwdriver to push the balls (32)

into the blocks and push these latter downwards, so
that the balls are on the flat faces of the teeth, but
not into the detent grooves.
When all the balls are in position, push the hub and
the blocks downwards until the balls move into the
detent groove.
Assemble the ring (30).
Lubricate the sintered ring (29) and the steel ring

(28).
Assemble the sintered ring (29) and the steel ring
(28).
Assemble the ring (27).

The flat sides of the teeth must be directed
upwards.
Overturn the synchronizer and assemble the ring

(26) from the other side.
Lubricate the sintered ring (25) and the steel ring

(24) with oil.
Assemble the sintered ring (25) and the steel ring
(24).
Install the top synchronizer ring on the synchronizer
assy.
Make sure that the teeth on the top synchronizer
ring are aligned with the teeth inside the sleeve.
Push the sleeve upwards until it engages with the
teeth on top of synchronizer ring.
To do this, you must use enough force to overcome
the strength of the detent springs and balls.
When the synchronizer ring and the sleeve are
engaged, the detent must hold the sleeve in this
position.
Push the sleeve back to neutral position, turn over
the synchronizer assy and repeat the procedure
with the lower synchronizer ring.
If the sleeve does not engage with the teeth or does
not hold the position to which it was shifted, the syn-
chronizer assy is damaged or was not correctly
assembled.
Disassemble the synchronizer assy to find the prob-
lem.
Install the ring (22) so that the flat sides of the teeth
are directed upwards.
Assemble the 1st/2nd speed synchronizer (23).
Install the spacer (21) on the 2nd speed gear (18).

Assemble the 2nd speed gear (18).
Assemble the pin (19).
Assemble the thrust washer (17) and the shims

(20).

Measure the backlash “X” between gear (18) and
thrust washer (17):
the value must be between 0.2 ÷ 0.42 mm (0.01 ÷ 0.02 in).
Use a thickness gauge.
If backlash “X” is more than the prescribed value,

remove the snap ring and the thrust washer from
their seats and, using the shims shown in the chart,
reach the prescribed value.
Correctly assemble the shims (20) between the
thrust washer (17) and the snap ring (16).
SHIM RANGE
Shims mm (in) 0.05 0.1 0.3 0.5
(0.002) (0.004) (0.012) (0.02)
Heat the inner ring of the bearing (15) to 80 ÷ 100 °C

(176 ÷ 212 °F).
Assemble the inner ring of the bearing (15) by
means of tool 380200203.
Assemble the outer ring of bearing (15).

Turn the shaft.

Assemble the 4th speed gear (12).
Assemble the 3rd/4th speed synchronizer (4).

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

(10) onto the hub (11).
Use a punch or a screwdriver to push the spring
plates as the synchronizer hub is installed into the
sleeve (7).
Be sure that the spring plates are aligned with the
grooves of the sleeve.
Assemble the ring (6) on each side of the synchro-

nizer assy.
Use oil to lubricate the ring (5) and install it on each

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

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

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

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

Heat the bearing to 80 ÷ 100 °C (176 ÷ 212 °F).
Re-position the shaft assemblies (B) and (C) into

the half box.
Use tool 380200246.
S WARNING S
The shaft assemblies must be inserted with pins
and yokes.
Insert the pre-fitted yokes for 3rd and 4th speed and
for 1st and 2nd speed as shown.
Position the assy with care, paying attention that the

ends of the yoke pins are correctly seated.
4WD - E SHAFT
Disassembly
Remove the shaft (E).
Remove the 4WD clutch gear (10).
Use tool 380200258 to compress the spring retainer

downwards in order to reach the snap ring. Remove
the snap ring (1).
Release the tension and remove the tool.

Remove the springs (4).
Remove the 2 O-rings (6) and (9).
Remove the seal rings (8).

Remove the 4WD clutch tube (7) from the front box.
If necessary, or if the tube is leaking or damaged,
replace the front box.
Assembly
Assemble and lubricate the O-rings (6) and (9).
Assemble the springs (4).

Position the washer (2) and the snap ring (1).
Use tool 380200258 to press the spring retainer

down until you have access to the snap ring.
Release the tension and remove the tool.
Make sure that the snap ring (1) is seated correctly
in the recess of the spring retainer.
Place tool 380200207 on the shaft.

Heat the seal ring (8) to 60 ÷ 80 °C (140 ÷ 176 °F).
Assemble the seal ring on the tool.
Assemble tool 380200225 on tool 380200207 and

slide the seal ring until it reaches the groove of the
shaft.
Remove tools 380200225 and 380200207 and the
spacer from the shaft.

seal ring.

seal ring.
in the groove.
Insert tool 380200208.

Repeat the previously described operations to
insert the second ring.
Lubricate the seal rings.
Apply compressed air at about 6 bar (87 psi) to 4WD

clutch oil passage (see arrow) by plugging the oppo-
site hole with a finger.
The sleeve (5) should move when compressing the
springs (4).
The 4WD gear (10) should turn freely on 4WD shaft.
If the operation is not correct, dismantle to find the
problem.
Assemble the bearing (11).
Assemble the gear (10).
Assemble the shafts (B) and (C).

Assemble shaft (E).
Reassemble the 4WD clutch tube (7), if previously

removed from the front box.
Assemble the front half box on the rear half box.
SPEED CONTROLS
Disassembly
For the disassembly of the two half boxes it is nec-
essary to remove the gearshift control assy.
Remove the gearshift control assy (2) and the O-ring
(3).
Use proper pliers to release the catch on the collar

fastening the boot.
Remove the collar (4).
Remove the protection boot (5).
Remove the 2 pins (7).

Remove the bushing (9).
Remove the gearshift lever (6).
If disassembly is required, remove the pins (11) and

separate the yokes from the shift rods.
Make sure that you remember how the parts are
assembled and which parts go together.
Inspect all parts for burrs or excessive wear.
Assembly is the reverse procedure of disassembly.
Assembly
Apply grease to the ball of the gearshift lever.
Assemble the gearshift lever (6).
Check for the correct position of the control lever (6)

according to the gearbox cover (2):
- direct the recess (A) towards the straight side of
cover (B);
- the slots (C) aligned with the cover holes (D).
Assemble the bushing (9).

Insert the pins (7) through the holes of the cover

flange, so that they engage in the slots of the gear-
shift lever.
Assemble the protection boot (5) so that its end is

correctly positioned over the pin ends.
Be careful so that the pins do not fall out during this
step.
Assemble the collar (4) on the protection.

Use proper pliers to engage the collar block.
Assemble and lubricate the O-ring (3) in the seat of

the cover flange.
Put the gearshift control assy behind the rear cover.
Insert the two pins (11) to lock the 3rd and 4th
speed control yoke (13) and the 1st and 2nd speed
control yoke (14).
TROUBLESHOOTING
FAULT POSSIBLE CAUSE ACTION
The vehicle does not Control valve supply problem. Check and, if necessary, replace the
move. control valves.
Damaged connections of transmission Repair and, if necessary, replace the

and vehicle wiring harness. wiring harness.
Oxidation in the contacts of the Clean the contacts.

electric cables of the wiring harness.
Interruption of the electric cable. Replace the electric cable.
Damage to the solenoids/solenoid Replace the solenoids.

valves.
Damage to sensors. Replace sensors.
Short circuits or bad contact. Check and, if necessary, replace the

fuses.
Incorrect oil level. Restore the oil level.
Check for possible oil leaks. Eliminate the leaks and restore the oil
level.
Suction strainer restriction. Clean the suction strainer.
Damaged oil pump. Replace the oil pump.
Damaged oil pump pressure relief Replace the oil pump.

valve.
Damaged/restricted filter. Replace the filter.
Damaged / stuck control valve. Replace the control valve.
Damaged converter. Replace the converter.
Oil temperature below 0 °C (32 °F). Wait for the operating temperature to
be reached (stall test).
Damaged rotary seal rings. Replace the rotary seal rings.
Synchronizers damaged. Replace the synchronizers.
Stuck shuttle lever. Repair the shuttle lever.
Excessively worn-out clutch assembly. Repair and, if necessary, replace the

clutch disc kit.
Lack of motion transmission (broken Check, repair and, if necessary,

gears, shafts, bearings, etc.). replace.
The brake does not release. Check the general pressure of

transmission.
Check voltage.
Check the operation of the solenoid

valve.
Check the mounting of the brake

solenoid valve block after operating on
the brake.
After the above-described

verifications, disassemble the brake
cover and check the condition of the
parts for unlocking/locking the brake
(seal rings, belleville washers, brake
disc deformation, etc.).
The vehicle has a reduced Incorrect oil temperature. Wait for the operating temperature to
power transmission. be reached (stall test).
Transmission oil overheating. Restore acceptable temperature

values.
Incorrect operating pressures. Check the hydraulic circuit and

replace (oil pump, filters, control
valve).
Worn-out clutch assembly. Replace/repair.
4WD fails to engage. Repair/replace the 4WD shaft assy.
Overheated solenoids/solenoid Replace.

valves.
Overheating. Damaged cooling system. Repair the cooling system.
Dirty heat exchanger. Clean the heat exchanger.
Unintentionally activated parking Deactivate the parking brake.

brake.
Excessive soil deposit on axle wheel Clean the axle wheel hubs.
hubs.
Seizure (broken gears, shafts, Check, repair and, if necessary,

bearings, etc.). replace.
Braking force external to transmission: Check and repair the axle.

axle operating problem.
Dragging of clutch discs. Repair and, if necessary, replace the

clutch discs.
Damaged oil thermostat. Replace the oil thermostat.
Worn-out oil pump. Replace the oil pump.
Wheel rotation with lifted Dragging of clutch discs. Repair and, if necessary, replace the
vehicle. clutch discs.
Low oil temperature (high oil Wait for the operating temperature to
viscosity). be reached (stall test).
Incorrect oil gradient. Change oil and filters.
Damaged control valve. Replace the control valve.
Stuck shuttle lever. Repair and, if necessary, replace the

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

Check the oil gradient.

Worn-out clutch discs. Replace the clutch discs.
Synchronizer coupling wear. Replace the synchronizer coupling.
Damaged 4WD coupling assy. Replace the 4WD coupling assy.
Irregular coupling. Damaged hydraulic control valve. Replace the control valves.
Electric system fault. Repair the electric system.
Overheating. See “overheating”.
Damaged hydraulic system. Repair the hydraulic system.

The gear remains Damaged/stuck shuttle lever. Repair and, if necessary, replace the
engaged. shuttle lever.
Damaged clutch assembly. Repair and, if necessary, replace the

clutch assembly.
Gearshift lever damaged. Replace gearshift lever.
Lack of 4WD power Damaged 4WD connection assy. Replace the 4WD coupling assy.
transmission.
Hydraulic system fault. Repair the hydraulic system.
Braking sensor fault. Check and, if necessary, replace the

braking sensors.
Gear fails to engage. Gearshift lever damaged. Replace the gearshift lever.

TRANSMISSION ERROR CODES
CODE DESCRIPTION Amber Red

Telltale LED Telltale LED
STOP
Power supply (pin 2), forward FWD drive (pin 3),

4000 X
or RVS (pin 4) drive shorted to ground.
Power supply for digital outputs (pin 8) does not
4002 X
have power.
Battery voltage (Pin 34) voltage below 10 volts for
4004 X
2.5 seconds with engine speed above 900 rpm.
Downshift delayed due to possible engine
4005 X
overspeed condition.
FWD input (Pin 12) feedback circuit is reading too
4006 X
much current with command. (>1.1 A for 1ms).
FWD input (Pin 12) current is less than 0.05 A
4007 with more than 0.1 A commanded for more than X
250 ms.
FWD solenoid is drawing more current than
4008 X
commanded.
FWD solenoid is drawing less current than
4009 X
commanded.
RVS input (pin 40) feedback circuit is reading too
4011 X
RVS input (pin 40) current is less than 0.05 A with
4012 X
more than 0.1 A commanded for more than 250 ms.
RVS solenoid is drawing more current than
4013 X
commanded (Error=20% of command or more).
RVS solenoid is drawing less current than
4014 X
commanded (Error=20% of command or more).
Differential lock or 4 wheel drive solenoid shorted
4028 X
to ground.
Shift lever improperly connected, no power to pin
4029 X
16, pin 18, or pin 46 for more than 3 seconds.
Shift lever malfunction; transmission in neutral
4030 receives forward and neutral together more than X
5 seconds.
4031 receives reverse and neutral together more than X
5 seconds.
Shift lever malfunction; transmission in forward
4032 receives forward and reverse together more than X
5 seconds.
Shift lever malfunction; transmission in reverse
4033 X
receives forward and reverse together more than 5.

STOP

4034 receives neutral and forward together more than X
5 seconds.
Shifter lever malfunction; transmission in reverse
4035 receives neutral and reverse together more than X
5 seconds.
During transition from second to third gear, and
4036 X
GearCMD_01 signal erratic or incorrect.
During transition from first to second gear, and
4037 X
During transition from third to fourth gear, and
4038 X
4040 Transmission Controller Driveline Configuration. X
Transmission output shaft frequency above 3000
4041 X
Hz detected. (0.5 second debouce).
Temperature signal erratic or incorrect
4042 X
(Consecutive samples differ by more than 50°C).
Temperature sensor input (Pin 43) is shorted to a
4043 X
ground.
Temperature sensor input (Pin 43) is open
4044 X
circuited or shorted to a voltage above 5 volts.
Charge pressure is not detected when engine
4045 X
speed is above 700 rpm for 10 seconds.
Charge pressure is not detected for 0.5 seconds
4046 X
and vehicle speed is over 10 km/hr.
Charge pressure switch is closed with no
4047 X
frequency input to the TRAX controller.
Unknown vehicle model value from VCM. Verify
4054 model in VCM or upgrade transmission controller X
software.
Internal TRAX failure, hardware measurement,
4101 X
replace TRAX controller if reoccurring.
Internal TRAX failure, software timing, replace
4102 X
TRAX controller if reoccurring.
Internal TRAX failure, software not running,
4103 X
Internal TRAX failure, redundant flash memory,
4105 X
Internal TRAX failure, sensor supply high, replace
4106 X

STOP
Internal TRAX failure, sensor supply low, replace

4107 X
4200 First shift solenoid shorted to ground. X
4201 Second or Third shift solenoid shorted to ground. X
4203 Fourth shift solenoid shorted to ground. X
4204 System detects different gear than commanded. X
System can not engage required gear. (Engaged
4205 X
gear is different than requested gear).
4206 Gear engagement failed. X
1ST/2ND gear shift rail position reporting first
4207 X
gear at startup.
1ST/2ND gear shift rail position reporting second
4208 X
gear at startup.
3RD/4TH gear shift rail position reporting third
4209 X
gear at startup.
3RD/4TH gear shift rail position reporting forth
4210 X
gear at startup.
First and second gear sensor input shorted to
4211 X
ground.
First and second gear sensor input voltage too
4212 X
high.
Third and forth gear sensor input shorted to
4213 X
ground.
4214 Third and forth gear sensor input voltage too high. X
4300 CANBus speed sensor message missing. X
CANBus speed sensor frequency input out of
4301 X
range.
4302 CANBus speed sensor frequency input erratic. X
CANBus speed sensor frequency input abnormal
4303 X
rate of change.
4304 CANBus speed sensor supply voltage too low. X
4305 CANBus speed sensor supply voltage too high. X
4306 CANBus speed sensor can not recover. X
4825 Loss of TC1 message after 15 seconds. X
Possible detection wrong transmission type for
4850 X
installed software.
Incorrect VCM configuration of transmission type.
4995 X
Electronic is transmission present.

STOP
Electronic transmission offline or incorrect VCM

4996 X
configuration of transmission type.
4997 Loss of message from TRAX controller. X
Generic error code for a SPN/FMI combination
4998 X
that is not stored in this list.
4999 X
REPAIR TIMES
The times are referred to average values of mainte-
nance performed by skilled personnel in workshops
equipped with all necessary fixtures for a proper
execution of the required works.
The repair and/or replacement times are indicated in
minutes.
We assume that the transmission assy has already
been removed from the machine.
ASSY OPERATION TIME (minutes)

Plugs and filters Oil filter replacement 5
Oil pump Oil pump replacement 20
Replacement of lubrication tube 5
Lines Replacement of supply tube for solenoid valve of
5
parking brake
Control valve replacement 15
Control valve
Control valve overhauling 60
4WD solenoid valve
Solenoid valve replacement 10
(only with 4WD models)
PTO shaft replacement 60
Replacement of seal rings on input shaft 20
Transmission box
Half box replacement 80
Open, clean, close the half boxes 50
Replacement of shaft A / bearings 60
Overhauling of shaft A 150
Shafts A and D
Replacement of seal rings on shaft A 120
Replacement of shaft D / bearings 60
Replacement of shaft B 60
Overhauling/replacement of shaft C 150
Shafts B and C
Replacement of bearings of shaft B 60
Replacement of bearings of shaft C 60
Overhauling/replacement of shaft E 100
Shaft E Replacement of bearings of shaft E 70

(only with 4WD models) Replacement of seal rings 70
Gear/sleeve replacement 90
Gearshift control Gearshift lever replacement 20
Disc kit replacement 40
Parking brake
Brake overhauling/replacement 40
SPECIAL TOOLS
PN CNH DESCRIPTION USE
380002211 Handle To be used with the various pushers and buffers
380200190 Buffer Assembly / disassembly of several bearings
380200197 Buffer Assembly of bearings of shaft A
380200203 Buffer Assembly of bearings of shaft B and C
380200207 Protection Assembly of shaft seal ring
380200208 Protection Assembly of shaft seal ring
380200213 Protection Assembly of shaft cover seal ring
380200214 Calibrator Assembly of seal ring on PTO shaft
380200215 Attachment Disassembly / assembly of clutch
380200218 Buffer Assembly of oil pump seal ring
380200224 Cover and shims Assembly of seal ring on shaft A
380200225 Plunger Assembly of seal ring on PTO shaft
380001926 Protection Clutch piston assembly
380200226 Buffer Assembly of SAHR seal ring for parking brake
380200230 Buffer Assembly of bearings of shaft D
380001933 Cover and shims Assembly of seal ring on shaft A
380001927 Calibrator Assembly of seal ring on shaft A
380001928 Plunger Assembly of seal ring on shaft A
380200246 Hook Lifting of shafts B and C and of gear control yokes
380200257 Protection Assembly of seal ring on PTO shaft
380200258 Tool Disassembly / Assembly of snap ring on shaft

POWERSHIFT TRANSMISSION
This transmission is used on powershift backhoe
loader models 580ST - 590ST - 695ST.
4WD/2WS TRANSMISSION - POWERSHIFT (580ST - 590ST)
4WD/4WS TRANSMISSION - POWERSHIFT (695ST)

Model ..................................................................................................................... CARRARO TLB2 MPB 4WS

2/3 proportional solenoid valve specifications
Absorption:.................................................................................................................................................. 10 W
Protection degree:......................................................................................................................................IP69K
Solenoid resistance:......................................................................................................... 7.25 Ω [20 °C (68 °F)]
Power supply voltage:............................................................................................................................12 V DC
2/3 solenoid valve specifications

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

Absorption:........................................................................................................................ 1.68 A [20 °C (68 °F)]
Diagram
A. 2/3 proportional solenoid 2nd - 4th speed actuation
B. 2/3 proportional solenoid reverse speed
C. 2/3 proportional solenoid forward speed
D. 2/3 proportional solenoid 1st - 3rd speed actuation
E. 2/3 solenoid valve 4WD engagement
F. 2/4 solenoid valve 2nd or 4th speed selection
G. 2/3 solenoid valve differential lock engagement
H. 2/4 solenoid valve 1st or 3rd speed selection
PS. Supply pressure check port
HDL2. Differential lock engagement control port
DIMENSIONS
2WS
4WS
HYDRAULIC DIAGRAM
2WS
REF. DESCRIPTION NOTES

1 Suction filter 250 Nm (184.39 lbf·ft)
2 Pump 36 cm3/rev (2.20 in3/rev)
3 Oil filter relief valve 23 bar (333 psi)
4 Filter 10 Nm (7.4 lbf·ft)
5 Torque converter
6 Oil cooler
7 Torque converter relief valve 3.5 ÷ 5.5 bar (50 ÷ 80 psi)
8 Pressure regulator for sequential valve
9 Air breather
10 Forward gear pressure check port
11 Reverse gear pressure check port
12 Forward gear clutch
13 Reverse gear clutch
14 4WD clutch
15 HDL
16 Shaft lubrication inlet
17 Brake oil return port
18 Transfer oil return port
19 Main pressure check port
20 Pressure check port of 1st gear clutch
21 Pressure check port of 2nd gear clutch
22 1st gear clutch
23 2nd gear clutch
24 3rd gear clutch
25 4th gear clutch
26 Main shaft lubrication
27 Output shaft lubrication
28 Temperature thermostat
29 Parking brake lubrication
4WS
REF. DESCRIPTION NOTES

1 Suction filter 250 Nm (184.39 lbf·ft)
2 Pump 36 cm3/rev (2.20 in3/rev)
3 Oil filter relief valve 23 bar (333 psi)
4 Spin-on filter 10 Nm (7.4 lbf·ft)
5 Torque converter
6 Oil cooler
7 Torque converter relief valve 3.5 ÷ 5.5 bar (50 ÷ 80 psi)
8 Pressure regulator for sequential valve
9 Air breather
10 Forward gear pressure check port
11 Reverse gear pressure check port
12 Forward gear clutch
13 Reverse gear clutch
14 4WD clutch
15 HDL
16 Shaft lubrication inlet
17 Brake oil return port
18 Transfer oil return port
19 Main pressure check port
20 Pressure check port of 1st gear clutch
21 Pressure check port of 2nd gear clutch
22 1st gear clutch
23 2nd gear clutch
24 3rd gear clutch
25 4th gear clutch
26 Main shaft lubrication
27 Output shaft lubrication
28 Temperature thermostat
29 Parking handbrake lubrication
PORTS
2WS
REF. DIMENSION USE NOTES - MISCELLANEOUS

Check port for torque converter input
3 9/16” - 18 UNF 3 ÷ 9 bar (43.5 ÷ 130 psi)
pressure
13.5 ÷ 16.5 bar (196 ÷ 239 psi)
4 9/16” - 18 UNF Forward gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in
neutral position
13.5 ÷ 16.5 bar (196 ÷ 239 psi)
5 9/16” - 18 UNF Reverse gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in
neutral position
6 Oil drain plug
7 9/16” - 18 UNF Oil pressure delivery to differential lock 14 ÷ 17 bar (203 ÷ 246 psi)
Lubrication pressure check port (from cooler) 1 ÷ 5 bar (14.5 ÷ 72.5 psi) forward/reverse gear
8 9/16” - 18 UNF
Oil outlet to brake tank 1 ÷ 5 bar (14.5 ÷ 72.5 psi) neutral position
9 9/16” - 18 UNF Brake oil pressure delivery 14 ÷ 17 bar (203 ÷ 246 psi)
10 9/16” - 18 UNF Oil return
11 9/16” - 18 UNF Oil level check port
12 9/16” - 18 UNF Oil main pressure check port 14 ÷ 17 bar (203 ÷ 246 psi)
13 1/8” - BSP Lubrication check port
14 1/8” - BSP Check port of 1st gear
15 1/8” - BSP Check port of 2nd gear
16 1/8” - BSP Check port of 4th gear
4WS
REF. DIMENSION USE NOTES - MISCELLANEOUS

Check port for torque converter input
3 9/16” - 18 UNF 3 ÷ 9 bar (43.5 ÷ 130 psi)
pressure
13.5 ÷ 16.5 bar (196 ÷ 239 psi)
4 9/16” - 18 UNF Forward gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in
neutral position
13.5 ÷ 16.5 bar (196 ÷ 239 psi)
5 9/16” - 18 UNF Reverse gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in
neutral position
6 Oil drain plug
7 9/16” - 18 UNF Oil pressure delivery to differential lock 14 ÷ 17 bar (203 ÷ 246 psi)
Lubrication pressure check port (from cooler) 1 ÷ 5 bar (14.5 ÷ 72.5 psi) forward/reverse gear
8 9/16” - 18 UNF
Oil outlet to brake tank 1 ÷ 5 bar (14.5 ÷ 72.5 psi) neutral position
9 9/16” - 18 UNF Brake oil pressure delivery 14 ÷ 17 bar (203 ÷ 246 psi)
10 9/16” - 18 UNF Oil return
11 9/16” - 18 UNF Oil level check port
12 9/16” - 18 UNF Oil main pressure check port 14 ÷ 17 bar (203 ÷ 246 psi)
13 1/8” - BSP Lubrication check port
14 1/8” - BSP Check port of 1st gear
15 1/8” - BSP Check port of 2nd gear
16 1/8” - BSP Check port of 4th gear
CONTROLS
1. GEARSHIFT AND DIRECTION CONTROL 2. KICKDOWN SWITCH: if the machine is in sec-

LEVER: it is possible to select four forward and ond gear and it is necessary to shift to the first
four rearward travel gears. gear to work with the loader attachment, acti-
The lever has 3 positions, according to which vating the kickdown switch to a lower ration
the travel direction is defined: allows the machine to instantly shift from sec-
F = forward travel ond to first gear.
N = idle/neutral When the reverse travel is activated, transmis-
R = reverse sion reverts to second gear.
By turning the knob, instead, the following 3. TRANSMISSION DISCONNECT BUTTON (on
gears are selected: loader attachment control lever)
1 = 1st gear
2 = 2nd gear
3 = 3rd gear
4 = 4th gear
KICKDOWN (QUICK SHIFTING TO LOWER

GEAR RATIO)
The kickdown function (2nd to 1st gear only)
instantly increases the torque on the driving wheels
and, hence, the digging power. For example when
the loader is pushing into a pile and more torque is
required at the wheels.
This is achieved by an instant gearshift from 2nd to
1st gear by means of button (2).
TRANSMISSION DISCONNECTION
The disconnect feature is useful when loading, for
example; when pushing the loader into a pile and
you have sufficient dirt in the bucket press the dis-
connect switch (3) which disengages the transmis-
sion and allows the full power of the engine to be
directed to the hydraulic oil pump.
Disconnection is available in 1st and 2nd gear.
NOTE: transmission disconnection is selectable
when the machine speed is lower than 5 km/h, by
depressing the button on the loader lever, and
remains active until the switch is released.
2
LUBRICATION
1. Hole for filling and fastening of oil dipstick

2. Oil level plug
3. Oil drain plug
4. Breather
LEVEL CHECK
The oil level check should be carried out with the
engine running at low speed and at normal operat-
ing temperature.
position.
Place the direction-of-travel lever and gearshift
lever in neutral position.
brake.
Extract the dipstick (1), clean it with a clean cloth
and completely insert it into the hose, then take it
out again.
If the oil level is below the mini mark, top up.
Stop the engine.
Unlock the safety lock and close the engine guard.
OIL CHANGE
position.
brake.
Remove the dipstick (1).
NOTE: change the oil while the transmission is still
warm; the oil will flow more easily.
Place a container with suitable capacity under the
drain plug (2).
Loosen and remove the drain plug (2).
Let the transmission oil drain.
Re-install the drain plug (2).

Fill with new oil of specified type through the dipstick
hole.
NOTE: transmission oil capacity 20.8 litres
(4.57 gal).
Reassemble the dipstick (1).
Check the oil level by means of the dipstick and, if
necessary, add more oil.
Drive the machine for a few minutes in first and sec-
ond gear, then stop the engine.
Check the oil level again by means of the dipstick
and, if necessary, add more oil.
GREASING
Transmission oil
4WS
F45638
3 1
8
6 5
9
4
2 5
6
13
12
11 7
10
TBR00074
TABLE 1
2. Anti-vibration 9. Washer
3. Left transmission support 10. M16 nut
4. Right transmission support [tightening torque 210÷240 Nm (156÷178 lbf·ft)]
7. Washer 13. Bracket transmission mounting
NOTE: ensure chassis bolt on mount is seated against locating block on chassis.
2
3
4
5
10
6 11
7
9
8
12
13
TBR00075
TABLE 2
2. Torque converter [tightening torque 52÷57 Nm (38÷42 lbf·ft)]
3. Plate 9. O-Ring
4. Plate 10. Dipstick tube
5. Snap ring 11. Dipstick
1 2
TBR00076
TABLE 3
1. Washer 4. Washer
3. Clamp

show your transmission, but the procedure is cor-
rect.

A. Loctite 510
B. Loctite 542
C. Loctite 518
D. Loctite 638
Only 4WS
PLUGS AND FILTERS
Disassembly
Remove the oil drain plug (1) and drain the oil from
the transmission.
Remove cover (3).

Remove the oil filter (4) and the O-ring (5).
Unscrew and remove the oil filter (6).

If necessary, remove the fitting (7).
Loosen and remove the valve (8).

Check the valve (8).

Clean the valve.
If necessary, replace the O-rings (9) and (10).
If necessary, remove the breather (11).
NOTE: this port enables you to check the supply

pressure for forward gear engagement.
NOTE: this port enables you to check the supply

pressure for reverse gear engagement.
NOTE: this port enables you to check the lubrica-

tion pressure.
Remove the revolution sensor (15).
Remove the oil thermostat (16).

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

Assemble the plugs (12) and (13).

Assemble and tighten the breather (11) by hand.

Clean the valve (8).

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

Assemble fitting (7).

Assemble the oil filter (6).

Lubricate the gasket.
Tighten clockwise until the gasket makes contact
with its seat, then tighten further 2/3 of a turn.
Assemble the O-ring (5) on the filter (4).

Insert the filter (4).

Screw in the 2 screws (2) and tighten to the pre-
Assemble the oil drain plug (1).

OIL PUMP
Disassembly
Mark the oil pump position with respect to the bell
housing before loosening the screws.
Pull out the oil pump (2) by means of two levers (A).
Remove the oil pump (2).
S WARNING S
The O-ring can be damaged.
S WARNING S
Do not disassemble the pump or its operation may
be compromised.
S WARNING S
Assembly
Assemble the seal ring (4) onto the oil pump (2).
Use tool 380200218.
Lubricate the seal ring (4).
Before pump assembly (if new), check that the oil

passage holes (between pump and half box) or the
visual marks coincide.
Lubricate the seal ring (4) to keep it centred, in

order to facilitate its introduction onto the oil pump.
Lubricate the matching seat with the front half box.

Assemble the oil pump (2).

Check that the mark on the oil pump and on the bell
housing coincide.
Disassembly
Disconnect cable (12).

Disconnect the electric connections.
Loosen all the fittings of the delivery pipes con-
nected with the control valve (2).
Remove the control valve (2).
Remove the pressure switch (4).

Place the control valve on a workbench.

Loosen and remove the screws (5) of the valves.
Pull out the valves (6), (7) and (8) with a screw-
driver.
Check the valves (6), (7) and (8).
Loosen and remove the valve (9).

Check the valve (9).

Clean the valve and, if necessary, replace the O-rings
(10) and (11).
Assembly
Clean the valve (9).

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

(18 ÷ 22 lbf·ft).
Assemble the valves ON/OFF (6) and (7) and the

proportional valves (8) by observing the shown
positions.
Assemble the pressure switch (4).

torque of 3 ÷ 4 Nm (2 ÷ 3 lbf·ft).
Assemble the gasket (3).
Assemble the control valve (2).

HYDRAULIC SYSTEM LINES
Disassembly
Remove the tube (1) (2nd gear).
Remove the tube (2) (4th gear).
Remove the tube (3) (3rd gear).
Remove the tube (4) (1st gear).
Remove the tube (5) (4WD).

Remove the tube (6) (lubrication).
Remove the tube (7) (lubrication).

Assembly
Assemble the tube (7) (lubrication) by tightening the

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

Assemble the tube (5) (4WD) by tightening the fit-

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

Assemble the tube (3) (3rd gear) by tightening the

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

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

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

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

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

the 5 counterdiscs (12).
Only 4WS
Remove the brake and the disc kit.
Do not remove the plug (16).
Only 4WS
Remove the screw (17), the washer (18) and the
hub (19).
Assembly

and each brake disc (11) is flat.
If the brake discs (11) are nearly smooth, replace
them.
If the friction material is damaged or appears
burned, replace it.
damage.
If you will be using new brake discs, soak them in oil
for at least an hour before assembly.
If you are using the old friction discs, make sure that
the contact surfaces are coated with oil before
assembly, check the wear condition.
If this is 50% compared to the nominal value, we
suggest its replacement.
Brake disc kit
Brake disc number 5

Counterdisc number 5
3.6 ± 0.05 mm
Nominal brake disc thickness
(0.14 ± 0.002 in)
Brake disc kit nominal
37.40 ÷ 37.60 mm
thickness [with 163 kg
(1.47 ± 1.48 in)
(359.34 lbs) of load]
Brake disc maximum wear 0.65 mm
(each side) (0.02 in)
Assemble the counterdisc (12), the brake disc (11)

and the ring (10).
Repeat this operation until the brake disc kit is com-
plete.

Assemble the seal ring (15) onto the brake (8), use
tool 380200226.
Insert the O-ring (9) on the brake (8).

Assemble the brake assy (8) on transmission.
Assemble the flange (4) and the O-ring (3).

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

Unscrew and remove the screw (1) for flange fas-
tening (2).
If necessary, use a screwdriver and 2 screws to lock

the flange.
Collect the washer (3).

S WARNING S
Only 4WS
Loosen and remove the screw (A) and the washer
(B).
If necessary, replace the O-ring (E).
Remove the flange (D).
If necessary, replace the seal ring (G).
Loosen and remove the screws (C).
Remove the hub (F).
Unscrew and remove the screws (6) for flange fas-

tening (7).
Remove the flange (7).

Pull out the transmission shaft PTO (8).
If necessary, replace the seal ring (9) by cutting it.
Take out the bearing (11) with tool 380200190.

Loosen and remove the screws (12) from the rear

(13) and the front half box (14).
Insert a lever (L) in the special slot and remove the

cover.
NOTE: the surfaces are attached with some seal-
ant.
If necessary, use a plastic hammer to facilitate the

separation of the half box.
S WARNING S
Do not lift the transmission shafts; the removal of
the shafts from their housings can damage the seal
rings.
Lift the front half box (14).

Remove the 4 O-rings (15).
Seal all oil recirculation holes with rubber plugs (T).
Assembly
Clean the edge of the rear half box.
Carefully verify the box and its inner components for
the possible presence of debris (dirt, filings or
burrs).
Thoroughly clean all possible dirt.
S WARNING S
Only after a careful inspection of the whole trans-
mission, proceed with the re-assembly.
Remove the old sealant from the mating surface of
the rear half box by means of a proper scraper.
We suggest the use of a sealant solvent.
Carefully clean the O-ring seats.
Degrease and dry accurately the mating surface of

the rear half box.
NOTE: we suggest the use of a proper solvent.
Apply sealant on the mating surface of the rear half

box.
Spread the sealant uniformly.
Prevent the penetration of the sealant in the O-ring

seats.
Carefully clean the O-ring seats.

Do not lubricate the O-rings.
Place the 4 O-rings (15) into their seats with a

buffer.
Assemble the front half box (14) on the rear one.

Make sure that the bearings of the shafts go straight
into the bores in the front box.
Push the front half box onto the rear one.
Tighten the screws (12) to the rear half box (13) and
to the front half box (14).
Tighten the screws (12) to a tightening torque of
50 Nm (37 lbf·ft).
Assemble the seal ring (5) on the output of the front

shaft by means of tool 380200226.
Assemble the flange (2) and a new O-ring (4).
Assemble the washer (3) and tighten the screw (1).

(102.5 lbf·ft).
Assemble the bearing (11) on the transmission shaft

PTO (8).
To assemble the seal ring (9) perform following

operations by means of the listed tools in sequence:
380200257;
380200225;
380200214.
Insert transmission shaft PTO (8) to stroke end.

Smear a thin layer of sealant on the flange (7).
S WARNING S
During flange assembly, the 2 holes for the oil pas-
sage (P) should coincide.

Only 4WS
Assemble the hub (F).
Screw in and tighten the screws (C) to the tighten-
ing torque of 50 Nm (37 lbf·ft).
Assemble the seal ring (G) by means of tool
380200226.
Assemble O-ring (E).
Assemble the flange (D).
Place the washer (B), screw in and tighten the screw
(A) to the tightening torque of 139 Nm (102.5 lbf·ft).
A, D SHAFTS
Disassembly
Grab the shaft with the (A) pliers and pull out the
shaft assy (D).
Shaft (A)
Assemble a bearing separator under the gear (do

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


Remove the pin (9).
Lift and remove the snap ring (11).

Place a mark below the groove on the clutch bell.
Mark the snap ring (11), the discs (18) and the
counterdiscs (17).
These marks will be used as a reference during
assembly.


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

air through the delivery hole.

Turn the shaft.

If necessary, remove the seal rings (22).
Remove the bearing (24) by means of a puller.

Remove the bearing (24) and the thrust washer

(25).
Remove the gear (26) and the roller retainer (12).
For the disassembly of other parts, repeat the oper-

ations described previously.

wear or damage.
assembly order.
At each disassembly check with a gauge that the

total thickness of the clutch discs remains in the
wear limits; otherwise replace the clutch disc kit (18)
with a new one.
Verify that all clutch discs are free from burns, that
the friction surfaces are not damaged and that the
grooves of the friction surfaces are well outlined.
Moreover, verify that the counterdiscs (17) are per-
fectly flat, without scrapes or pittings.
In case any of the discs shows even just one of the
above-mentioned faults, replace the clutch disc kit
with a new one.
If you are to use a new kit of clutch discs, let it soak
into a bath of oil for at least one hour before its use.
In any case, prior to assembling the clutch disc kit,
lubricate the contact surfaces of the counterdiscs
with oil.
Check that the hole of the input shaft on the rear half
box does not show damages that could cause leaks
when the clutch is assembled.
Check that the grooves of the input shaft are not
damaged by the steel discs.
2WS forward - reverse gear clutch

A. Reverse
B. Forward
1. Clutch disc (no. 6)
2. Clutch counterdisc (no. 3)
3. Clutch counterdisc (no. 3)
4WS forward gear clutch

A. Reverse
B. Forward
1. Reverse clutch disc (no. 6)
2. Reverse clutch counterdisc (no. 2)
3. Reverse clutch counterdisc (no. 2)
4. Forward clutch disc (no. 7)
5. Forward clutch counterdisc (no. 3)
6. Forward clutch counterdisc (no. 4)
Shaft (D)
means of a puller.

means of a puller.
Assembly
Shaft (A)
and the seal ring (21) with the relevant inner O-ring,
respectively in the outer and inner seat of the pis-
ton.
Apply a thin film of oil on the seal rings.
Insert the piston (19) by means of tool (T)

380001926 to protect the seal rings (21).
Insert the snap ring (14).

NOTE: make sure that the snap ring (14) is cor-
rectly fitted into its seat.

spring tension.
Insert the thrust washer (8).
Insert the roller retainer (7).

To assemble the clutch discs start with the gear (6)

on the bench.
Assemble the thrust washer (11) so that the refer-
ence mark on top of the plate, made during disas-
sembly, is facing towards the gear.
Assemble the discs (18) and the counterdiscs (17)

on the gear (6).
The assembled clutch disc kit must contain 6
counterdiscs and 6 friction discs.
Use 2 screwdrivers to position the disc kit.


NOTE: for clarity of the seal ring installation proce-

dure, the following photos do not show the disc kit,
gear, spacer, bearing, and snap ring installed on the
input shaft.
Insert the seal ring (1).
Assemble the 380200224 tool onto the input shaft

with the chamfered end facing inwards.
Let tool 380200224 slide on the input shaft and

above the spacer.

minutes.

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

seal ring.

seal ring.
in the groove.
Turn the shaft upside down to carry out the opera-

tions described previously.
Assemble the thrust washer so that the notch in the
inner edge fits over the pin.
Make sure that the side with the oil grooves is
down.

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

the protection (tool 380001933).
Place tool 380001933 on the shaft.


minutes.

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

chamfer onto the shaft and over the seal ring.

seal ring.
in the groove.
In order to insert the other 3 rings, repeat the opera-

tions described previously, by means of following
spacer rings:
380001933 for the 2nd ring;
380001933 for the 3rd ring;
380001933 for the 4th ring.

2. Forward gear clutch passage
3. Reverse gear clutch passage
4. Forward gear engagement
5. Forward gear disc kit
6. Reverse gear disc kit
7. Reverse gear engagement
8. Input shaft
Apply compressed air of approximately 6 bar (87 psi)

to the forward clutch passage.
Listen for the forward gear piston to move and to
lock the relevant disc kit.
Try to shift the forward travel gear.
It must not turn on the input shaft.
Try to shift the reverse travel gear.
It must turn freely on the input shaft.

play on both sides of the clutch.
Position the shaft on a suitable support (S) and
apply load F on the counterdisc (11) surface by
means of a proper buffer (T), as shown.

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

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

ensure a play corresponding to
X = 1.60 ÷ 2.45 mm (0.06 ÷ 0.10 in)
Y = 1.90 ÷ 2.75 mm (0.07 ÷ 0.11 in)
Shaft (D)
tool 380200230.

tool 380200230.
Lubricate the shaft seat (A).
Assemble shaft (D) and shaft (A).

The operation is correct only if the 2 shafts are fitted
at the same time.
SHAFT B
Disassembly
Unscrew and remove the screws (28) and remove
the 4WD oil bulkhead (29).
Assemble on the rear end of the shaft (C) the hub

(27) and tool 380200256.
Lift the 3 shafts (B), (C) and (E) simultaneously by

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

(V).
Remove the seal rings (1) and (2).
S WARNING S
The seal rings can be damaged.
Remove the bearing (3) and the gear (4) by means

of a puller.
Remove the bearing (3) and the gear (4).

Remove the roller retainer (7) and the thrust washer

(13).
Remove the pin (24) and the spacer (14).

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

screwdrivers.


spring tension.





wear or damage.
assembly order.

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

Disc kit nominal thickness [with 163 kg (359.34 lbs) of load] 30.50 ÷ 30.70 mm (1.20 ÷ 1.21 in)
Pack maximum wear (each side) 3.2 mm (0.126 in)
Assembly
Assemble the seal ring (26).

In order to fit the ring (26), repeat the following
operations by means of spacer ring 380200224.
Assemble the seal ring (20) with the relevant inner

O-ring and the snap ring (21) with the relevant inner
O-ring, respectively in the outer and inner seat of
the piston.
Apply a thin film of oil on the seal rings recently fit-

ted.
Insert the piston (19) by means of tool 380001926

to protect the seal rings (21).


spring tension.
Assemble the disc kit.
Assemble the spacer (14) and the pin (24).
Insert the thrust washer (13) and the roller retainer

(7).
Assemble the thrust washer (10) and push it to end

stroke on disc kit.
Supply compressed air at low pressure to the deliv-

ery hole to push the thrust washer (10) against the
snap ring (9) and align the disc teeth.
Assemble the gear (8) by paying attention not to let

it slide to stroke end.

Assemble the thrust washer (6) and the snap ring

(5).
Assemble the gear (4) paying attention to direct the

protruding end of the groove towards the clutch and
the bearing (3).
Use tool 380200203.

2. Oil passage for 2nd gear clutch
3. 2nd gear engagement
4. 2nd gear clutch disc kit
5. Input shaft
Try to turn the 2nd travel gear. It must turn on the

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

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

The piston stroke (19) must be such to ensure a
play corresponding to:
X = 2.20 ÷ 3.05 mm (0.09 ÷ 0.12 in)
Insert the seal rings (1) and (2).

In order to insert the seal rings, repeat the following
operations by means of:
- spacer 380200240 for 1st and 2nd ring;
- pusher 380200242 and compressor 380200241.
Assemble the bulkhead (29) and tighten the screws

(28).
SHAFT C
Disassembly
Unscrew and remove the screws (V1) to detach the
4WD oil bulkhead (P1).

(61) and tool 380200256.

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

(V2).
Remove tool 380200256 and sleeve (62).

Overturn the assembly.

Push the thrust washer (39) downwards.

screwdrivers.
Remove the disc kit (40).
Lower the cover (42) in order to allow the extraction

of the snap ring (41) by means of tool 380200215.

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

If necessary, remove the seal ring (45) with the rele-

vant O-ring from the outer seat of piston (44).
If necessary, remove the seal ring (53) with the rele-

vant O-ring from the gear seat (54).
Remove the gear (37) by means of a puller.
Remove the 2 bushings (47) and (56), the 2 roller

retainers (46) and (55) and the spacer (50).
Verify the condition of the removed components
(46), (47), (50), (55) and (56).
Remove the O-rings (48) and (52) from the bushing

(50).
Verify the wear condition of the seal rings (49) and

(51).
If necessary, cut the seal rings (49) and (51) to
remove them from bushing (50).

Remove the feather (32).
Lower the counterdisc (33) slightly to release the

snap ring (34).

screwdrivers.


spring tension.
spring (28).
Pull out the piston (26) from its seat by blowing in

compressed air through the delivery hole.
Remove the bushing (27) and the piston (26).

Overturn the shaft (23).

Remove the seal rings (16), (17), (18) and (19) by
cutting them.


(8).

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

snap ring (4).
Remove the thrust washer (5) by means of 2 screw-

drivers.


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

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


wear or damage.

assembly order.

wear limits; otherwise replace the clutch disc kit (B)
with a new one.
Moreover, verify that the counterdiscs (A) are per-
with a new one.
with oil.
1st gear clutch

3rd gear clutch

4th gear clutch

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

380200250.
Assemble the seal ring (45) and the relevant O-ring

on piston (44).
Apply a thin film of grease on the outer edge and in

the inner part of the piston (44) and fit it to the gear
(54).
Insert the spring (43), the cover (42) and the snap
ring (41).

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

spring tension.
Insert the kit (40) and the thrust washer (39) into the
gear (54).
Assemble the snap ring (38) making sure it is cor-

rectly seated.

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

ted.

to protect the seal rings.


into its seat.

spring tension.
Insert the thrust washer (31) on the shaft (23).

Apply a thin film of grease under the thrust washer
(31) to prevent its falling when overturning the shaft.
Assemble the thrust washer (31) by inserting it on

pin (22).
Assemble the feather (22) and the thrust washer

(31).
Apply a thin film of grease under the thrust washer
(31) to prevent its falling when overturning the shaft.
Insert the disc and counterdisc kit (32) onto the

main shaft (23).
Assemble the roller retainer (36) and the thrust

washer (33).
Supply compressed air at low pressure into hole (a)

to push the thrust washer (33) against the snap ring
(34).
Assemble the gear (35) by paying attention not to

let it slide to stroke end.
Insert the gear (37) on the shaft (23).

Insert the gear (54) on the shaft (23).
Assemble the bushing (47) and the bearing (46)

with tool 380200190.
Assemble the O-rings (48) and (52) on the bushing

(50).
Assemble new seal rings (49) and (51) on bushing

(50) by means of tools 380200251, 380200252 and
380200253.
Assemble the bushing (50) and the shaft (23) with

tool 380200190.
The reference marks must be directed upwards.
Assemble the bushing (56) and the bearing (55)

with tool 380200190.
Assemble the hub (61) and tool 380200256.
Turn the shaft.

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

ted.

to protect the seal rings.


into its seat.

spring tension.

Insert the disc kit (6) on the shaft (23).
Assemble the thrust washer (5).
Supply compressed air at low pressure into the sup-

ply hole to push the thrust washer (5) against the
snap ring (4).
Assemble the thrust washer (8) and the roller

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

and the roller retainer (7).

Assemble the seal rings (16), (17), (18) and (19) by

1. 1st gear clutch oil passage

2. 3rd gear clutch oil passage
3. 4th gear clutch oil passage
4. 3rd gear engagement
5. 3rd gear disc kit
6. 4th gear disc kit
7. 4th gear engagement
8. 1st gear engagement
9. 1st gear disc kit
10. Main shaft
Check that all gears turn freely on main shaft. Listen for the 3rd gear piston to move and to lock
the related clutch disc kit.
to the 1st gear clutch passage. Try to shift the 3rd travel gear.
Listen for the 1st gear piston to move and to lock It must not turn on the main shaft.
the related clutch disc kit. If the clutch does not work correctly, disassemble it
Try to shift the 1st travel gear. to find the problem.
It must not turn on the main shaft. Apply compressed air at approximately 6 bar (87 psi)
to the 4th gear clutch passage.
to find the problem. Listen for the 4th gear piston to move and to lock
the related clutch disc kit. Try to shift the 4th travel
gear.
to the 3rd gear clutch passage.
It must not turn on the main shaft.
to find the problem.

play.
Position the shaft on a suitable support and apply
load F on the surface of the clutch counterdisc by
means of a proper buffer (T).

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

X = 0.5 ÷ 1.95 mm (0.020 ÷ 0.077 in)

X = 2.20 ÷ 3.05 mm (0.09 ÷ 0.12 in)

X = 1.725 ÷ 2.375 mm (0.068 ÷ 0.093 in)
Hook the 3 shafts (B), (C) and (E) by means of tool

380200239.
Lift the shafts (B), (C) and (E) at the same time and
insert the assy into the half box.
Assemble the bulkhead (P1) and tighten the screws

(V1).
E SHAFT
(Only for 2WS)
* = 4WD shaft set
Disassembly
Unscrew and remove the screws to detach the 4WD
oil bulkhead.

and tool 380200256.


(V).

Remove the bearings (21) and (1) by means of a

puller.
Overturn the shaft.

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

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

counterdisc kit (15).
Remove the counterdisc (14).
Take out the piston (8).
Remove the inner (7) and outer O-ring (9) from the
piston (8).
Remove the pins (10) and the O-rings (11).


assembly order.

with a new one.
with a new one.
with oil.
4WD clutch

Assembly
Insert the inner O-ring (7) and the outer O-ring (9)
on the piston (8).
Insert the O-rings (11) on the related pins (10).
Insert the pins (10) on the piston (8).
Apply a thin film of grease on the O-rings and posi-

tion the pins on piston (8) in order to match the
holes of the output shaft.
Overturn the shaft (12) and insert the piston (8).
Insert the counterdisc (14) with the chamfer down-

wards into the shaft (12).
Assemble the disc and counterdisc kit starting with

a counterdisc (A) followed by a disc (B).
Assemble the thrust washer (16) on the shaft (12).

Assemble the roller retainer (19) and the spacer

(20).


Make sure that the disc, counterdisc kit and the pis-
ton are correctly seated.
Pre-assemble the spacer (6), the thrust washer (4)

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

between the thrust washer (4) and the snap ring (2).
To value “X” subtract the fixed measure “S1” of

1.80 mm (0.071 in) corresponding to the piston
stroke.
The resulting measure “S” corresponds to the height
of the shim that must be inserted between the thrust
washer (4) and the snap ring (2).
S = X - S1 = X - 1.80 mm (0.071 in)
Choose the shim with value “S” from the shim range
available.
NOTE: in any case, choose the shim ensuring a
piston stroke of 1.70 ÷ 1.90 mm (0.067 ÷ 0.075 in).
SHIM RANGE
Shims mm 0.1 0.3 0.5
(in) (0.004) (0.012) (0.02)
Remove the thrust washer (4) and the snap ring (2).
Insert the belleville washers (5).

Check the proper orientation of the belleville wash-
ers (5).
Assemble the thrust washer (4) and the shims (3)

with size “S” previously calculated.
Press the belleville washers and fit the snap ring (2)
The springs can cause damages to persons if the
snap ring is not assembled correctly.
Assemble the seal rings (22) and (23).

Use tool 380200224.
Use tool 380200223 to check piston operation and

verify correct adjustment.
In order to check the sealing of rings (7) and (9), put

the piston chamber under pressure with oil at 10 bar
(145 psi) and verify with a dial gauge that the actual
stroke is 1.70 ÷ 1.90 mm (0.067 ÷ 0.075 in).
1. 4WD oil passage

2. 4WD gear
3. 4WD lubricant oil passage
4. Shaft
5. Belleville washers
Apply compressed oil pressure of approximately

10 bar (145 psi) to the 4WD clutch passage.
Listen for the piston to move and to unlock the
related clutch disc kit.
The belleville washers compress themselves. Try to
shift the 4WD gear.
It must turn freely on the 4WD shaft.
Lift the 3 shafts (B), (C) and (E) at the same time
and insert the assy into the half box by means of
tool 380200239.
Assemble the bulkhead and tighten the screws.

E SHAFT
(Only for 2WS)
* = 4WD shaft set
Disassembly
oil bulkhead.

and tool 380200256.


(V).

Remove the bearings (1) and (24) by means of a

puller.


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

(6).

Remove the bell housing assy from the shaft.

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

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


assembly order.

with a new one.
with a new one.
with oil.
4WD clutch

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

holes of the output shaft (12).
Overturn the bell housing (12) and insert the piston

(8).
Insert the brake counterdisc (16) with the chamfer

downwards into the bell housing (12).
Assemble the disc and counterdisc kit (17) starting

with a counterdisc (A) followed by a disc (B).

Assemble the shaft (13).
Turn the shaft (13) and the bell housing (12).

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



stroke.
The resulting measure “S” corresponds to the
height of the shim that must be inserted between
the thrust washer (4) and the snap ring (2).
S = X - S1 = X - 1.80 mm (0.071 in)
available.
SHIM RANGE
Shims mm 0.1 0.3 0.5
(in) (0.004) (0.012) (0.02)

ers (5).


Assemble the roller retainer (22) and the spacer

(23).
Assemble the seal rings (25) and (26) by means of

tool 380200224.

In order to check the sealing of the rings, put the

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

2. 4WD gear
3. 4WD lubricant oil passage
4. Shaft

shift the 4WD gear.
tool 380200239.

E SHAFT
(Only 4WS)
Disassembly
oil bulkhead.


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





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

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

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

assembly order.

wear limits; otherwise replace the clutch disc kit with
a new one.
Verify that all clutch discs (b) are free from burns,
that the friction surfaces are not damaged and that
the grooves of the friction surfaces are well out-
lined.
Moreover, verify that the counterdiscs (a) are per-
with a new one.
with oil.
4WD clutch

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

holes of the output shaft (12).
Overturn the bell housing (12) and insert the piston

(8).
Insert the brake counterdisc (13) with the chamfer

downwards into the clutch bell housing (12).
Assemble the disc and counterdisc kit (14) starting

with a counterdisc (A) followed by a disc (B).

Assemble the O-ring (18) on the shaft (17).

Turn the shaft (17) on the bell housing (12).

Make sure that the disc, counterdisc kit and the pis-
ton are correctly seated.



stroke.
The resulting measure “S” corresponds to the height
of the shim that must be inserted between the thrust
washer (4) and the snap ring (2).
S = X - S1 = X - 1.80 mm (0.071 in)
available.
SHIM RANGE
Shims mm 0.1 0.3 0.5
(in) (0.004) (0.012) (0.02)

ers (5).



Fitting diagram of bearing (23).
Assemble the seal rings (24), (25) and (26).
Use tools 380200264, 380001927 and 380001928.
Fitting diagram of tool (T) 380200264.


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

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

2. 4WD gear
3. Bearing lubrication
4. Shaft
6. Bearing

shift the 4WD gear.
tool 380200239.

TROUBLESHOOTING
The vehicle does not Control valve supply problem. Check and, if necessary, replace the
move. control valves.

Oxidation in the contacts of the Clean the contacts.

electric cables of the wiring harness.
Interruption of the electric cable. Replace the electric cable.
Damage to the solenoids/solenoid Replace the solenoids.

valves.
Short circuits or bad contact. Check and, if necessary, replace the

fuses.
EGM/ECU gearshift electronic control Replace the electronic control of the

operation fault. EGM/ECU gearshift.
Check for possible oil leaks. Eliminate the leaks and restore the oil
level.
Suction strainer restriction. Clean the suction strainer.
Damaged oil pump pressure relief Replace the oil pump.

valve.
Damaged/restricted filter. Replace the filter.
Damaged / stuck control valve. Replace the control valve.
Oil temperature below 0 °C (32 °F). Wait for the operating temperature to
be reached (stall test).
Damaged rotary seal rings. Replace the rotary seal rings.
Stuck shuttle lever. Repair the shuttle lever.
Excessively worn-out clutch assembly. Repair and, if necessary, replace the

clutch discs.
Lack of motion transmission (broken Check, repair and, if necessary,

gears, shafts, bearings, etc.). replace.
The brake does not release. Check the general pressure of

transmission.
Check voltage.
Check the operation of the solenoid
valve.
Check the mounting of the brake
solenoid valve block after operating on
the brake.
After the above-described
verifications, disassemble the brake
cover and check the condition of the
parts for unlocking/locking the brake
(seal rings, belleville washers, brake
disc deformation, etc.).
The vehicle has a reduced Incorrect oil temperature. Wait for the operating temperature to
power transmission. be reached (stall test).
Transmission oil overheating. Restore acceptable temperature

values.
Incorrect operating pressures. Check the hydraulic circuit and

replace (oil pump, filters, control
valve).
Worn-out clutch assembly. Replace/repair.
4WD fails to engage. Repair/replace the 4WD shaft assy.
Overheated solenoids/solenoid Replace.

valves.

Software of EGM/ECU gearshift Replace EGM/ECU.

electronic control faulty.
Overheating. Damaged cooling system. Repair the cooling system.
Dirty heat exchanger. Clean the heat exchanger.
Unintentionally activated parking Deactivate the parking brake.

brake.
Excessive soil deposit on axle wheel Clean the axle wheel hubs.
hubs.

Braking force external to transmission: Check and repair the axle.

axle operating problem.
Dragging of clutch discs. Repair and, if necessary, replace the

clutch discs.
Damaged oil thermostat. Replace the oil thermostat.
Worn-out oil pump. Replace the oil pump.
Wheel rotation with lifted Dragging of clutch discs. Repair and, if necessary, replace the
vehicle. clutch discs.
Incorrect oil gradient. Change oil and filters.
Stuck shuttle lever. Repair and, if necessary, replace the

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

Check the oil gradient.

Irregular coupling. Damaged hydraulic control valve. Replace the control valves.
Overheating. See “overheating”.
EGM/ECU gearshift electronic control Replace EGM/ECU.

operation fault.

The gear remains Damaged/stuck shuttle lever. Repair and, if necessary, replace the
engaged. shuttle lever.
Damaged clutch assembly. Repair and, if necessary, replace the

clutch assembly.

operation fault.
Lack of 4WD power Damaged 4WD connection assy. Replace the 4WD coupling assy.
transmission.
Hydraulic system fault. Repair the hydraulic system.
Braking sensor fault. Check and, if necessary, replace the

braking sensors.

operation fault.
Gear fails to engage. Damaged clutch engagement assy. Replace the clutch engagement assy.
Damaged pressure sensors. Check and, if necessary, replace the

sensors.

operation fault.
TRANSMISSION ERROR CODES

STOP
Power supply (pin 2), forward FWD drive (pin 3),

4000 X
or RVS (pin 4) drive shorted to ground.
Power supply (pin 5), PWM 1 drive (pin 6), or
4001 X
reverse PWM2 drive (pin 7) shorted to ground.
Power supply for digital outputs (pin 8) does not
4002 X
have power.
Battery voltage (Pin 34) voltage below 10 volts for
4004 X
2.5 seconds with engine speed above 900 rpm.
Downshift delayed due to possible engine
4005 X
overspeed condition.
FWD input (Pin 12) feedback circuit is reading too
4006 X
FWD input (Pin 12) current is less than 0.05 A
4007 with more than 0.1 A commanded for more than X
250 ms.
FWD solenoid is drawing more current than
4008 X
commanded.
FWD solenoid is drawing less current than
4009 X
commanded.
RVS input (pin 40) feedback circuit is reading too
4011 X
RVS input (pin 40) current is less than 0.05 A with
4012 X
more than 0.1 A commanded for more than 250 ms.
RVS solenoid is drawing more current than
4013 X
commanded.
RVS solenoid is drawing less current than
4014 X
commanded.
First and third shift modulation solenoid input (pin
4016 13) feedback circuit is reading too much current X
with command. (>1.1 A for 1ms).
First and third shift modulation solenoid input (pin
4017 13) current is less than 0.05 A with more than 0.1 X
A commanded for more than 250 ms.
First and third shift modulation solenoid is
4018 X
drawing more current than commanded.
First and third shift modulation solenoid is
4019 X
drawing less current than commanded.
Second and fourth shift modulation solenoid input
4021 (pin 41) feedback circuit is reading too much X
current with command. (>1.1 A for 1ms).

STOP
Second and fourth shift modulation solenoid input

4022 (pin 41) current is less than 0.05 A with more than X
0.1 A commanded for more than 250 ms.
Second and fourth shift modulation solenoid is
4023 X
drawing more current than commanded.
Second and fourth shift modulation solenoid is
4024 X
drawing less current than commanded.
4026 First / Third shift solenoid shorted to ground. X
4027 Second / Fourth shift solenoid shorted to ground. X
Differential lock or 4 wheel drive solenoid shorted
4028 X
to ground.
Shift lever improperly connected, no power to pin
4029 X
16, pin 18, or pin 46 for more than 3 seconds.
4030 receives forward and neutral together more than X
5 seconds.
4031 receives reverse and neutral together more than X
5 seconds.
4032 receives forward and reverse together more than X
5 seconds.
Shift lever malfunction; transmission in reverse
4033 X
receives forward and reverse together more than 5.
4034 receives neutral and forward together more than X
5 seconds.
Shifter lever malfunction; transmission in reverse
4035 receives neutral and reverse together more than X
5 seconds.
During transition from second to third gear, and
4036 X
During transition from first to second gear, and
4037 X
During transition from third to fourth gear, and
4038 X
Vehicle speed exceeding 12 km/hr limit
4039 in crab or circle mode. LCD display shall X
be 4ws symbol.
4040 Transmission Controller Driveline Configuration. X
Transmission output shaft frequency above 3000
4041 X
Hz detected. (0.5 second debouce).

STOP
Temperature signal erratic or incorrect

4042 X
(Consecutive samples differ by more than 50°C).
Temperature sensor input (Pin 43) is shorted to a
4043 X
ground.
Temperature sensor input (Pin 43) is open
4044 X
circuited or shorted to a voltage above 5 volts.
Charge pressure is not detected when engine
4045 X
speed is above 700 rpm for 10 seconds.
Charge pressure is not detected for 0.5 seconds
4046 X
and vehicle speed is over 10 km/hr.
Charge pressure switch is closed with no
4047 X
frequency input to the TRAX controller.
4100 Missing EEC1 message on CAN. X
Internal TRAX failure, hardware measurement,
4101 X
Internal TRAX failure, software timing, replace
4102 X
Internal TRAX failure, software not running,
4103 X
Internal TRAX failure, redundant flash memory,
4105 X
Internal TRAX failure, sensor supply high, replace
4106 X
Internal TRAX failure, sensor supply low, replace
4107 X
4300 CANBus speed sensor message missing. X
CANBus speed sensor frequency input out of
4301 X
range.
4302 CANBus speed sensor frequency input erratic. X
CANBus speed sensor frequency input abnormal
4303 X
rate of change.
4304 CANBus speed sensor supply voltage too low. X
4305 CANBus speed sensor supply voltage too high. X
4306 CANBus speed sensor can not recover. X
4825 Loss of TC1 message after 15 seconds. X
Possible detection wrong transmission type for
4850 X
installed software.
Incorrect VCM configuration of transmission type.
4995 X
Electronic is transmission present.

STOP
Electronic transmission offline or incorrect VCM

4996 X
configuration of transmission type.
4997 Loss of message from TRAX controller. X
4998 X
4999 X
REPAIR TIMES
minutes.
We assume that the transmission assy has already
been removed from the machine.

Oil filter replacement 5
Plugs and filters Oil temperature sensor replacement 5
Revolutions sensor replacement 5
Converter replacement 10
Oil pump
Oil pump replacement 20
Lines Replacement of lubrication and gearshift lines (each) 5
Control valve replacement 20
Control valve Control valve overhauling 40
Solenoid valve replacement (each) 5
PTO shaft replacement 30
Replacement of seal rings on input shaft 20
Transmission box
Half box replacement 80
Open, clean, close the half boxes 50
Replacement of shaft A / bearings 60
Overhauling of shaft A 150
Shafts A and D
Replacement of seal rings on shaft A 120
Replacement of shaft D / bearings 60
Overhauling/replacement of shaft B 150
Shafts B
Replacement of bearings of shaft B 60
Overhauling/replacement of shaft B 180
Shafts C
Replacement of bearings of shaft C 60
Overhauling/replacement of shaft E 100
Shaft E Replacement of bearings of shaft E 60
Replacement of seal rings on shaft E 70
Solenoid valve replacement 10
Parking brake Disc kit replacement 40
Replacement of seal rings on piston 20
SPECIAL TOOLS
PN CNH DESCRIPTION USE 2WS 4WS
380002211 Handle To be used with the various pushers and buffers • •
380200190 Buffer Assembly / disassembly of several bearings • •
380200197 Buffer Assembly of shaft A bearings • •
380200203 Buffer Assembly of several bearings and of 2nd travel gear • •
380200214 Calibrator Assembly of seal ring on PTO shaft • •
380200215 Attachment Disassembly / assembly of clutch • •
380200218 Buffer Assembly of oil pump seal ring • •
380200223 Check Piston check • •
380200224 Cover and shims Several seal ring assembly • •
380200225 Plunger Several seal ring assembly • •
380001926 Protection Clutch piston assembly • •
380200226 Buffer Assembly of SAHR seal ring for parking brake • •
380200230 Buffer Assembly of bearings of shaft D • •
380200240 Cover and shims Seal ring assembly • •
380001933 Cover and shims Assembly of seal ring on shaft A • •
380001927 Calibrator Assembly of seal ring on shaft A • •
380001928 Plunger Assembly of seal ring on shaft A • •
380200241 Calibrator Assembly of seal ring on shaft • •
380200239 Hook Lifting of shafts B, C, E and of gear control yokes • •
380200257 Protection Assembly of seal ring on PTO shaft • •
380200242 Plunger Seal ring assembly • •
380200248 Protection Assembly of seal ring on shaft C • •
380200250 Calibrator Assembly of seal ring on shaft C • •
380200251 Cover and shims Assembly of seal ring on shaft C • •
380200252 Plunger Assembly of seal ring on shaft C • •
380200253 Calibrator Assembly of seal ring on shaft C • •
380200256 Sleeve Shaft disassembly • •
380200275 Tool Assembly of snap ring on shaft E • •
380200258 Puller Disassembly of snap ring on shaft E • •
380200220 Drift Assembly of bearings of shaft E / •
380200229 Drift Assembly of bearings of shaft E / •

580ST
590ST
695ST
SECTION 25 - FRONT AXLE
2WS FRONT AXLE........................................................................................................................................... 3

TROUBLESHOOTING................................................................................................................................. 7
4WD - 2WS FRONT AXLE ............................................................................................................................. 10

SPECIAL TOOLS....................................................................................................................................... 61
4WS FRONT AXLE......................................................................................................................................... 62

2 SECTION 25 - FRONT AXLE
SECTION 25 - FRONT AXLE 3
2WS FRONT AXLE
Manufacturer CNH
Model Steering
LUBRICATION AND GREASING
Oil capacity 0.2 litres (0.044 gal)

Oil type Akcela Transaxle fluid 80W -140
1. Level and fill plug for differential oil

2. Air breather
3. Level, fill and drain plug for reduction gear oil
4. Oil drain plug
5. Greasing points
Before draining the oil from the axle body, use the
breather (2) to release any possible internal pres-
sure.
S WARNING S
Risk of violent oil ejection.
To drain the oil from the central body remove the

level plug (1) and the drain plug (4).
S WARNING S
Drain all oil.

Clean, screw in and tighten the drain plug (4).
Fill through the hole of the plug (1).
Check the level and, if necessary, top up.
Clean, screw and tighten the plug (1).
Before draining the oil from the reduction gear,

rotate it so that the plug (3) is in the highest position
(position A) and partially unscrew the plug to
release any possible internal pressure.
Turn and bring the plug to the lowest position (posi-
tion B).
Remove the plug and drain the oil.
Now turn again and bring the hole of the plug (3) to
check and oil filling position (position C).
Carry out the filling.

shored cavity.
Rest the loader attachment on the ground in order to
unload the weight of the machine from the 2 front
wheels, then lift the front part, thus ensuring the
safety of the subsequent operations.
Use the locking pin (if provided) to lock the loader
attachment controls.
position.
brake.
mechanically.
control levers in all directions.
On hydraulically controlled machines, turn the key to
ON and release the pressure by moving the hydrau-
lic control levers in all directions.
Fasten the front axle (3) to a lifting hoist or to a sup-
port.
Now it is possible to carry out the disassembly of
the 2 front tyres by loosening and removing the rel-
evant fixing nuts (7) [tightening torque = 330 Nm
(243 lbf·ft)].
Disconnect the hoses of the steering cylinder, pay-
ing attention to possible oil leaks, preventing spill-
age over the ground using a container.
Remove the snap ring (6) from the machine side,
and keep the shims (4).
Using a soft hammer, tap the pin (5) in order to
extract it from the relevant hole, on the front side of
the machine.
Once the pin (5) has been disassembled, it is possi-
ble to remove the front axle (3).

(See 4WD front axle)
TROUBLESHOOTING
Bent axle beam body. Overloaded vehicle. Replace the axle beam body.
Damaged vehicle. Replace the axle beam body.
Worn out or pitted bearings. Insufficient lubrication. Replace the bearings and top up oil.
Contaminated oil. Change the oil, fill up to right level

and replace at recommended
intervals.
Excessive use. Replace the bearings.
Normal wear. Replace the bearings.
Oil leakage form the seals. Prolonged operation with oil at a Replace the gasket or seal and
high temperature. matching surface if damaged.
Incorrectly installed seal. Correctly lubricate and change oil

and seals at recommended
intervals.
Damaged seal lip. Replace the seal.

intervals.
Bent or broken axle beam. Intensive use of the vehicle or Replace the axle beam.
overloaded vehicle.
Axle shaft broken on wheel Loose wheel support. Replace the axle beam and check if
side. the wheel support is worn out or
wrongly adjusted.
Bent axle beam body. Replace the axle beam and check if
the wheel support is worn out or
wrongly adjusted.
Wheel vibration and tyre Incorrect installation. Correct the installation.

resistance.
Faulty differential. Inspect and repair the axle.
Wrong weight distribution. Distribute the weight differently.
Overload. Remove the excessive load.
Incorrect tyre rotation radius. Replace the tyre or adjust pressure

on both tyres.
Bent or broken axle shaft. Replace the axle beam.

Difficult steering; the machine Incorrect installation. Correct the installation.

travels in a straight line while
steering. Faulty differential. Replace the differential.

on both tyres.
Excessive noise. Incorrect installation. Correct the installation.
Faulty differential. Replace the differential.

on both tyres.
Incorrect wheel alignment. Replace the parts and check that the
bearings are in good conditions.
Incorrect axle part installation. Check the installation.
Uneven wear of tyre. Incorrect installation. Correct the installation.

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

that the bearings are in good
conditions.
Friction noise. Incorrect installation. Correct the installation.
Damaged or worn axle parts. Replace the parts and check that the
Presence of foreign objects. Discard.

Vibrations during travel. Incorrect installation. Correct the installation.

on both tyres.
Intermittent noise. Damaged ring gear. Replace bevel gear.
Differential box screws loose. Tighten the screws to torque.
Incorrect installation. Correct the installation.

on both tyres.

4WD - 2WS FRONT AXLE
Manufacturer CNH
Model Steering
Steering angle According to the type
Total reduction ratio According to the type
Lubrication angle 35° maximum (front and rear) - 35° maximum (from side to side)
Differential 6.5 litres (1.43 gal)

Oil capacity
Final drive (each) 0.7 litres (0.15 gal)

2. Air breather
4. Oil drain plug
5. Greasing points
sure.
S WARNING S

S WARNING S
Drain all oil.


tion B).

shored cavity.
position.
brake.
mechanically.
port.
the 2 front tyres by loosening and removing the rel-
evant fixing nuts (5) [tightening torque = 330 Nm
(243 lbf·ft)].
Disconnect the cardan joint (1).
Loosen and remove the screws (2) with the rele-
vant washers (3) [tightening torque = 460 ÷ 540 Nm
(339 ÷ 398 lbf·ft)].
Remove the front axle (4).

MOUNTING SCREW TORQUE
Tie rod nut, standard 111 ÷ 137 Nm (82 ÷ 101 lbf·ft)

Tie rod nut, HD 213 ÷ 263 Nm (157 ÷ 194 lbf·ft)
Tie rod ball joint nut, standard 129 ÷ 160 Nm (95 ÷ 118 lbf·ft)
Ball joint nut, HD 162 ÷ 200 Nm (119 ÷ 147 lbf·ft)
Tie rod ball joint nut, standard 255 ÷ 315 Nm (188 ÷ 232 lbf·ft)
Breather 11 ÷ 14 Nm (8 ÷ 10 lbf·ft)
Oil drain plug 54 ÷ 66 Nm (40 ÷ 49 lbf·ft)
Lubrication fitting, king pin 20 ÷ 30 Nm (15 ÷ 22 lbf·ft)
Planet carrier retention screw 21 ÷ 26 Nm (15.5 ÷ 19 lbf·ft)
King pin screw 154 ÷ 188 Nm (114 ÷ 139 lbf·ft)
Differential cover screw 96 ÷ 118 Nm (71 ÷ 87 lbf·ft)
Steering cylinder screw 358 ÷ 442 Nm (264 ÷ 326 lbf·ft)
Steering stop nut 200 ÷ 244 Nm (148 ÷ 178 lbf·ft)
Shaft retaining nut 358 ÷ 442 Nm (264 ÷ 326 lbf·ft)
Ring gear support screw, standard 88 ÷ 108 Nm (65 ÷ 80 lbf·ft)
Ring gear support screw, HD 96 ÷ 118 Nm (71 ÷ 87 lbf·ft)
Gear pin screw 95 ÷ 105 Nm (70 ÷ 77 lbf·ft)
Oil drain plug 72 ÷ 88 Nm (53 ÷ 65 lbf·ft)
Bearing cup screw 96 ÷ 118 Nm (71 ÷ 87 lbf·ft)
Ring nut retainer screw 21 ÷ 26 Nm (15.5 ÷ 19 lbf·ft)
Ring gear screw 96 ÷ 118 Nm (71 ÷ 87 lbf·ft)
Pinion 1.7 ÷ 2.2 Nm (1.2 ÷ 1.6 lbf·ft)
Differential 1.5 ÷ 2.5 Nm (1.1 ÷ 1.8 lbf·ft)
Wheel bearing with seal, standard 8 ÷ 25 Nm (6 ÷ 18 lbf·ft)
Wheel bearing with seal, HD 12 ÷ 25 Nm (9 ÷ 18 lbf·ft)
Standard differential 0 ÷ 1 Nm (0 ÷ 0.7 lbf·ft)
Limited slip differential 1 ÷ 5 Nm (0.7 ÷ 4 lbf·ft)
WHEEL HUB
Disassembly
Unscrew and remove the plug (1) and drain the oil.
Separate the planetary carrier (3) from the axle

using the two slots for prying.
Remove the planetary gear carrier assy (3).

Mark the washers and grease the pins.
Remove the washers (18).
Inspect the washers (18) for dents or damage in

roller contact area.
If necessary, remove the gears.

Wipe off any contamination on the drain plug.
Loosen the caulking on the nut (5).
Unscrew the ring nut (5) by means of tool

380000468.
Remove the ring nut (5).

Tighten the 2 screws (10) in the 2 threaded holes in

the hub.
Tighten the 2 screws evenly until the ring gear car-
rier (11) is free of the swivel housing.
Remove the ring gear (6).
Remove the wheel hub (13) complete with swivel

housing using a puller.
Remove the outer bearing (15).
Separate the wheel hub (13) from the swivel hous-

ing.
Remove the inner bearing (16).

Remove the snap ring (12) which fastens the ring

gear (6) in the ring gear carrier (11).
Separate the ring gear carrier (11) and the ring gear
(6).
If necessary, remove the bushings (14).
Remove the bearing cups (15) and (16), if neces-

sary.
Checks
Clean all parts in cleaning solvent.
Inspect the bearing cup and the rollers in the bear-
ings for flat areas, pitting, scoring, and other dam-
age. Also check the inner race for damage. If any of
these defects are found, new bearings and new
bearing cups must be installed.
Inspect the pins for wear and damage.
Inspect the teeth of the gears and of the ring gear
for wear, pitting, scoring or other damage.
Use new parts as required.
Assembly
If bearing cups were removed, use an acceptable
driver to press new bearing cups into the wheel
hub.
The word “OUTSIDE” on the seal ring (17) must be

facing up.
Use tool DMT100004 to insert the new seal ring into
the wheel hub.
Do not damage the seal ring.
Insert the new rollers using tool DMT100002.
Apply grease to help retain the rollers.
Make sure that all required rollers have been

installed.
Install the gears (8) onto the pins, respecting the

reference marks traced during disassembly.
Remove tool DMT100002.
Check the correct assembly of all rollers.
Install the washers (18).

Where possible, match the washers with the rele-
vant pins, respecting the reference marks traced
during disassembly.
Screw in and tighten the screws (9).

Press the bushings (14) into the ring gear carrier

(11).
Assemble the ring gear carrier (11) and the ring

gear (6).
Assemble the cup of the inner bearing into the

swivel housing.
Installation will be easier if you heat the bearing
slightly.
Do not heat the bearing more than 149 °C (300 °F).
Assemble the wheel hub (13).
Install the outer bearing (15).

Installation will be easier if you heat the bearing
slightly.
Do not heat the wheel bearing more than 149 °C
(300 °F).
Align the holes in the ring gear carrier (11) with the
holes in the swivel housing and install the ring gear
carrier.
Install and tighten the screws (10) evenly to pull the

hub against the swivel housing.
Tighten the screws (10) to a tightening torque
of 358 ÷ 442 Nm (264 ÷ 326 lbf·ft).
Tighten the ring nut (5) using tool 380000468, to a tight-

ening torque of 358 ÷ 442 Nm (264 ÷ 326 lbf·ft).
Assemble a new O-ring (4).
Assemble the planetary carrier (3).
Screw in and tighten the 2 screws (2) to a tightening

torque of 21 ÷ 26 Nm (15.5 ÷ 19 lbf·ft).
Screw on the plug (1) after oil filling.
SWIVEL HOUSING
Disassembly
Unscrew and remove the tie rod nut (1).
Use a two-jaw puller to loosen the ball joint.
Remove the ball joint (2).
Remove the steering cylinder (3).

Fasten the swivel housing (10) to an appropriate lift-

ing tool.
Loosen the screws (6).
Remove the screws (6) and the top king pin (7).
Repeat the same operations to remove the bottom

king pin.
Remove the swivel housing (10) together with the

cardan joint (14).
Remove the belleville washer (9) from the top and

bottom of the axle body.
Remove the bearing (8) from the top and bottom of

the axle body by means of a puller.
Remove the seal (15) by means of a puller.
Remove the bushing (16) by means of a puller.
Remove the bearing cup (8) from the king pin (7)
using a hammer and a chisel.
Assembly
Install the bushing (16) by means of tool
DMT100005.
Install the seal (15) by means of tool DMT100006.
Assemble the bearing (8).
Assemble the swivel housing (10) together with the

cardan joint (14).
Assemble the belleville washers (9).

Fasten the swivel housing (10).
Assemble the top king pin (7).

154 ÷ 188 Nm (114 ÷ 139 lbf·ft).
Assemble the bottom king pin (7).

154 ÷ 188 Nm (114 ÷ 139 lbf·ft).
Assemble the ball joint (2) and the nut (1).
Tighten the nut (1) to 162 ÷ 200 Nm (119 ÷ 147

lbf·ft).
CARDAN JOINT
Disassembly
Remove the 4 snap rings (3).
Use the CAS1980 V-block to support the coupling (5).

Adjust the screws in the V-block to hold the coupling
level.
Use a driver and press the bottom bearing cup
against the V-block.
Fasten the bearing cup in a vice and drive the cou-

pling off the bearing cup.
Use the V-block to support the coupling and press

the other bearing cup against the V-block.
Remove the long axle shaft (2) from the coupling (5).
Remove the coupling (5) from the bearing cup.
Press the bottom bearing cup out of the yoke.
Remove the yoke from the bearing cup. DO NOT hit

the axle shaft in the seal area.
Press the other bearing cup out of the yoke.

Remove the cross (4).
Press the bearing cup out of the yoke.
Press the bearing cup into the yoke until the top of
the bearing cup is 6 mm (0.24 in) above the top of
the yoke.
Carefully install the cross (4) in the bearing cup.

Press the other bearing cup into the yoke until the
top of the bearing cup is 9 mm (0.35 in) above the
top of the yoke.
Carefully remove the cross (4) from the bearing cup

so that the cross is in both bearing cups.
Hold the cross and press the bearing cups into the
yoke.
Press a bearing cup into the yoke so that a snap

ring can be installed.
Repeat the same operations for the other bearing

cup.
Use the V-block to support the coupling and press
the bearing cup into the coupling evenly with the
outer diameter of the coupling.
Carefully install the cross (4) into the bearing cup.
Press the other bearing cup into the coupling until

the bearing cup is 6 mm (0.24 in) above the top of
the yoke.
Carefully raise the cross into the top bearing cup so

that the cross is in both bearing cups.
Hold the cross and press the bearing cup into the
coupling so that a snap ring can be installed.
Repeat the same operations for the other bearing

cup.
DIFFERENTIAL
Disassembly
Loosen and remove the differential carrier screws
(1).
Remove the differential carrier (2) by means of a

suitable lifting device.
Place the differential on an approved working area.
Prevent the pinion from turning.

Measure the backlash of the ring gear.
Record the reading.
Make an identification mark on the supports and

ring nut on one side of the differential carrier.
Loosen and remove the screws (29) and the wash-

ers (28).
Loosen both adjusting ring nuts (15) by means of

tool DMT100002.
Remove the screws (26) and the supports (27).
Remove the differential assy.

Remove the seal (4) and the cover (3).
Loosen and remove the nut (5) of the pinion using

tool 380000468 and tool 380100102.
Extract the pinion (13) using a press.

Remove the washers (8) and (10) and the spacer

(9).
Separate the pinion (13) from the inner bearing (11).
Remove the shim (12).
Use a soft punch to remove the bearing cups only if

the inspection indicates the need for new parts.
Remove the seal (30) from the cover (3).
Remove the O-ring (4) from the cover (3).

Remove the retaining pin (19).
Remove the pin (20) and the gears (22).

Remove the thrust washer (24) and the gear (23).
Checks
Inspect the bearing cups and the bearings for flat
areas, pitting, scoring and other damage.
Also check the inner race for damage. If any of
these defects are found, new bearings and bearing
cups must be installed.
Inspect the teeth on the pinion and of the ring gear
for pitting, scoring and broken teeth. The ring gear
and pinion gear must be replaced as a set.
Inspect the gears, the pins and the teeth of the pin-
ion gears for pitting, scoring and other damage.
Also inspect the thrust surfaces and the bores of
each gear. Check the splines in the gears for wear.
Inspect the thrust washers for pitting, scoring and
other damage.
Assembly
Assemble the thrust washer (24) and the gear (23).
Install the pin (20) and the gears (22).
Install the retaining pin (19).
NOTE: before assembly, grease all gear contact

surfaces.
Make sure that the mounting surfaces of the ring

gear (17) are clean and install the ring gear.
Assemble the bearing cup(s) into the differential

carrier.
Use a feeler to ensure cups are fully seated.
Install the shim (12).

The chamfer of the shim must be towards the pin-
ion.
Press the bearing (11) against the shim.

Use a feeler gauge to ensure bearing is fully
seated.
Lubricate the bearing (11).
Install a new spacer (9) and the washers (8) and

(10).
Insert the pinion (13).

Install the bearing (7).
Install a new nut (5).

Use a yoke and the wrench 380000468 to tighten
the nut.
The pinion and bearings will still be loose.

Progressively tighten the nut until the bearings
become seated.
NOTE: If the nut is tightened too much (rotating
torque higher than specified), the pinion must be
removed and a new spacer must be installed on the
pinion.
Use tool 380100102 and a torque wrench to check
the rotating torque of the pinion.
It must be rotated while tightening the nut. Final
reading to be verified after 3 complete revolu-
tions. The rotating torque must be 1.7 ÷ 2.2 Nm
(1.2 ÷ 1.6 lbf·ft).
If the rotating torque is lower than specified, further
tighten the nut and check the rotating torque again.
When the rotating torque is as specified, use a

hammer and punch and partially drive the nut (5)
into the slot in the pinion.
Assemble a new O-ring (4) on the cover (3).
Assemble a new seal (30) in the cover (3) using tool

DMT100001.
The seal will be approximately 1/16 from the inner
face of the cover.
Lubricate the O-ring and the seal.

Install the differential carrier assy and lubricate the

bearings.
Assemble the supports (27) with the alignment

marks.
Tighten the screws (26) to 20 Nm (15 lbf·ft) to pull
the supports against the differential carrier (do not
overtighten).
The bearings must be able to rotate.
Assemble the adjusting ring nuts (15).

Tighten both adjusting ring nuts (15), making sure
there is some backlash between the ring gear and
the pinion.
Rotate the pinion by approx. 3 or 4 turns and ensure

proper seating.
Check in 3 places, approximately 120° apart.
The value of the rolling torque must be
0.0009 ÷ 0.0015 Nm (0.0006 ÷ 0.0011 lbf·ft).
If values vary more than 0.001 Nm (0.0007 lbf·ft),
then replace bevel set.
If backlash value is too large, loosen the ring nut by
one slot on gear side and tighten the ring nut slot on
the back face of the ring gear.
If backlash value is too small, do the opposite of the
above-described operations.
Make the final adjustments of the ring nuts to align

locking devices and confirm the rolling torque.
Apply the yellow compound on the bevel set in 3
places, 120° apart, on 3 teeth each.
Rotate bevel set enough to see pattern in yellow
compound.
Pattern should be per chart above.
Normal wear will flatten (elongate) the contact pat-
tern.
NOTE: this is a non-adjustable bevel set. If pattern
is significantly different from specifications, then
replace bevel set.
If the original ring gear and pinion gear are being
used, the backlash must be equal to the measure-
ment made during disassembly.
Tighten the screws (26) to the prescribed torque
of 266 Nm (196 lbf·ft).
Screw in the lock screw (29) which blocks the
ring gear and tighten to a tightening torque of
162 ÷ 200 Nm (119 ÷ 147 lbf·ft).
Apply some sealant.

Assemble the differential carrier (2).

TROUBLESHOOTING
Ring gear tooth broken on the Excessive gear load compared to Replace bevel gear set.
outer side. the one expected.
Incorrect ring gear adjustment Follow carefully the recommended

(excessive backlash). operations for the adjustment of the
bevel gear set backlash.
Loose pinion nut. Tighten the pinion nut.
Ring gear tooth side broken. Load bump. Replace bevel gear set.
Incorrect ring gear adjustment Follow carefully the recommended

(insufficient backlash). operations for the adjustment of the
bevel gear set backlash.
Loose pinion nut. Tighten the pinion nut.
Worn pinion or ring gear teeth. Insufficient lubrication. Replace bevel gear set.
Contaminated oil. Follow carefully the recommended

operations for the adjustment of the
Incorrect lubrication or depleted bevel gear set backlash.
additives.
Worn out pinion bearings that cause Use proper lubricants, fill up to the
an incorrect pinion axle backlash right levels and replace at
and wrong contact between pinion recommended intervals.
and ring gear.
Overheated ring gear and Prolonged operation at high Replace bevel gear set.
pinion teeth. temperatures.
Check if ring gear teeth are
damaged. Inappropriate lubricant. Use proper lubricants, fill up to the
right level and replace at
Low oil level. recommended intervals.
Contaminated oil.
Pinion teeth pitting. Excessive use. Replace bevel gear set.
Insufficient lubrication. Use correct lubrication, fill up to the

right level and substitute at
recommended intervals.
Bent axle beam body. Overloaded vehicle. Replace the axle beam body.
Damaged vehicle. Replace the axle beam body.
Worn out or pitted bearings. Insufficient lubrication. Replace the bearings and top up oil.

intervals.
Excessive use. Replace the bearings.
Normal wear. Replace the bearings.

Oil leakage form the seals. Prolonged operation with oil at a Replace the gasket or seal and
high temperature. matching surface if damaged.
Incorrectly installed seal. Correctly lubricate and change oil

and seals at recommended
intervals.
Damaged seal lip. Replace the seal.

intervals.
Excessive wear of input Use until worn. Replace the flange.

flange spline.
Loose pinion nut. Check that the pinion spline is not
excessively worn out.
Pinion axle backlash. Replace bevel gear set if required.
Fatigue failure of pinion teeth. Use until worn. Replace bevel gear set.
See if the fracture line is well
defined (wave lines, straight Continuous overload.
lines).
Pinion and ring gear teeth Crash load of differential Check and/or replace other
breakage. components. differential components.
Worn out side gear spline. Excessive use. Replace differential gear group.
Replace all scratched
washers (excessive Replace the axle shaft if required.
backlash).
Worn out or scored thrust Excessive use. Use correct lubrication and fill up to
washer surface. right level.
Inappropriate lubricant. Replace at intervals recommended.
Contaminated oil. Replace all scratched washers and

those with a thickness by 0.1 mm
(0.004 in) lower than the new ones.
Worn out inner diameter of Excessive use. Replace bearing.

tapered roller bearing.
Excessive pinion axial backlash. Check pinion axial backlash.
Insufficient lubrication Use proper lubrication, fill up to right

Contaminated oil. level and replace at recommended
intervals.
Bent or broken axle beam. Intensive use of the vehicle or Replace the axle beam.
overloaded vehicle.
Axle shaft broken on wheel Loose wheel support. Replace the axle beam and check if
side. the wheel support is worn out or
wrongly adjusted.
Bent axle beam body. Replace the axle beam and check if
the wheel support is worn out or
wrongly adjusted.
Wheel vibration and tyre Incorrect installation. Correct the installation.

resistance.
Faulty differential. Inspect and repair the axle.

on both tyres.

steering. Faulty differential. Replace the differential.

on both tyres.

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

Uneven wear of tyre. Incorrect installation. Correct the installation.

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

that the bearings are in good
conditions.
Damaged or worn axle parts. Replace the parts and check that the
Presence of foreign objects. Discard.

on both tyres.
Incorrect installation. Correct the installation.

on both tyres.

SPECIAL TOOLS
CAS-1980 V-block Support for cardan joint disassembly
380100103 Protection Assembly of differential carrier seal ring
DMT100001 Protection Pinion seal ring assembly
DMT100002 Tool Assembly of bearings
DMT100004 Buffer Wheel hub seal ring assembly
DMT100005 Buffer Assembly of bushing into the axle body
DMT100006 Buffer Assembly of seal ring in axle body
DMT100007 Tool Assembly of pinion bearing
380000468 Wrench Pinion nut tightening
380100102 Wrench Pinion nut tightening

4WS FRONT AXLE
Manufacturer CARRARO
Model 26.32
Differential ratio 2.75
Planetary hub ratio 6.92
Total reduction ratio 19.04
Lubrication angle 35° maximum (front and rear) - 35° maximum (from side to side)
Differential 10.5 litres (2.31 gal)

Oil capacity
1. Oil level plug

2. Air breather
4. Oil drain plug
5. Greasing points
sure.
S WARNING S

S WARNING S
Drain all oil.


tion B).

shored cavity.
position.
brake.
mechanically.
port.
Now it is possible to carry out the disassembly of the 2
front tyres by loosening and removing the relevant fix-
ing nuts (7) [tightening torque = 700 Nm (516 lbf·ft)].
Disconnect the cardan joint (1) by unlocking and
removing the screws (2) and the bracket (3).
Loosen and remove the screws (5) with the relevant
washers (4).
Remove the front axle (6).
NOTES:
580ST
590ST
695ST
SECTION 27 - REAR AXLE
2WS REAR AXLE (580ST) ............................................................................................................................... 3

REPAIR TIMES.......................................................................................................................................... 67
SPECIAL TOOLS....................................................................................................................................... 68
2WS REAR AXLE (590ST) ............................................................................................................................. 69

REPAIR TIMES........................................................................................................................................ 133
SPECIAL TOOLS..................................................................................................................................... 134
4WS REAR AXLE (695ST) ........................................................................................................................... 135

LUBRICATION AND GREASING ............................................................................................................ 138
REPAIR TIMES........................................................................................................................................ 225
SPECIAL TOOLS..................................................................................................................................... 227
2 SECTION 27 - REAR AXLE
SECTION 27 - REAR AXLE 3
2WS REAR AXLE

(580ST)
Model 28.44
Bevel gear reduction ratio 2.75/1
Epicyclic gear ratio 6.40/1
Total reduction ratio 17.6/1
Input rotation clockwise
420 kg
Dry weight
(926 lb)
Differential type Mechanical and driven
12 ÷ 35 bar
Pressure for differential lock
(174 ÷ 508 psi)
0.20 ÷ 0.28 mm
Bevel gear set backlash
(0.0079 ÷ 0.0110 in)
Pinion bearing preload (1) FP = 115 ÷ 138 N
(measured on Ø = 34.8 mm (1.37 in) without seal ring) (26 ÷ 31 lbf)
Ring gear-pinion bearing total preload (1) FT = (FP + 33) ÷ (FP + 50) N
(measured on Ø = 34.8 mm (1.37 in) without seal ring) [FT = (FP + 7.4) ÷ (FP + 11.2) lbf]
MP = 2.0 ÷ 2.4 Nm
Pinion bearing rolling torque (1) measured without seal ring
(1.47 ÷ 1.77 lbf·ft)
Total pinion-ring gear bearing rolling torque (1) measured without MT = (MP + 0.58) ÷ (MP + 0.87) Nm
seal ring [MT = (MP + 0.43) ÷ (MP + 0.64) lbf·ft]
(*) Only for new bearings
SERVICE BRAKE
Brake type Wet disc brake

Brake operating temperature -20 °C ÷ 150 °C (-4 ÷ 5.9 °F)
Maximum operating pressure 43 bar (624 psi)
Oil displacement for brake actuation (each side) 16 cm3 (0.98 in3)
A. New counterdisc thickness = 8.0 ± 0.05 mm

(0.31 ± 0.002 in)
B. New friction disc thickness = 6.73 ± 0.1 mm
(0.26 ± 0.004 in)
Worn disc minimum thickness = 5.8 mm (0.23 in)
C. New counterdisc thickness = 5.0 ± 0.05 mm
(0.20 ± 0.002 in)
Oil capacity (differential) 17 litres (3.74 gal)


2. Differential oil drain plug
3. Oil breather
4. Oil drain plug
5. Brake breather
sure.
S WARNING S

S WARNING S
Drain all oil.

Clean the plug (2), screw it and tighten to the pre-

shored cavity.
Lower the loader attachment to the ground.
Lower the backhoe attachment to the ground.
brake.
Lower the stabilizers until the rear wheels are
slightly lifted from the ground (they are free from
machine weight).
Fasten the rear axle to a lifting hoist or to a support.
Now it is possible to carry out the disassembly of the
2 rear tyres by loosening and removing the relevant
fixing nuts (9) [tightening torque = 700 Nm (516 lbf·ft)].
Unscrew and remove the screws (4) with the nuts
(2) and the washers (3) and (5) [tightening torque
= 610 ÷ 678 Nm (445 ÷ 500 lbf·ft)].
Remove the rear axle (1).

show your axle, but the procedure is correct.

A. Loctite 510
B. Loctite 270
C. Loctite 638
GREASE POINTS
FRONT FLANGE
Disassembly
Remove the stop ring (1) and the front flange (2).
Remove the O-ring (4) and the shim (5).

Assembly
Assemble the seal ring (3) into the central body with
a drift 380200228 and a hammer.
Insert the shim (5) and a new O-ring (4) into the pin-
ion shaft.
Insert the front flange (2) on the shaft end.
Fasten the pieces as soon as assembled by fitting
the snap ring (1).
BRAKES
Disassembly
Drain the oil completely from the differential.
Loosen and remove all screws (1) except for 2 as a

safety measure.
Connect the wheel hub (2) to a lifting device and

tension the rope.
Insert 2 opposed threaded rods to enable removal.
Remove the 2 last screws (1) and separate the

wheel hub assy (2) from the axle body (3).
Slowly remove the wheel hub assy and the half axle
(4), make sure that the braking discs (5) and the
counterdiscs (6) stay on the wheel hub assy.
Place the wheel hub assy vertically and mark the

counterdisc (5) assembled to the axle body side (3).
Remove the discs (6), the counterdiscs (5) and the
dowel pins (7).
Remove the half axle (4) from the wheel hub assy
(2).
In some cases the axle shaft can be delivered

already assembled in 2 parts.
Remove the screws (8) and the belleville washers

(9) from the brake cylinder (10).
Check screws (8) and belleville washers (9) for

damage.
NOTE: if brake discs are replaced, also replace
screws and springs.
Remove the snap ring (11) and the self adjust kit
assy (12).
Place the self adjust kit (12) on tool 380200245 and

remove the snap rings (13).
Check bushing (14) for wear.

Repeat the procedure for the remaining 2 self
adjust kits.
Remove the brake cylinder assy (10).

Remove the brake piston (15) from the brake cylin-

der (10).
Remove the O-rings (16) and (17) from the brake

cylinder (10).
Remove the O-ring (18) from the brake piston (15).

Assembly
Assemble the O-ring (18) onto the brake piston

(15).
Assemble the O-rings (16) and (17) onto the brake

cylinder (10).
Lubricate the O-rings (16), (17) and (18).

Assemble the brake piston (15) into the brake cylin-
der (10).
Lubricate the seat of the brake cylinder on the

wheel hub (2) and assemble the dowel pins (7).
Assemble the brake cylinder assy (10) and remove

the dowel pins (7).
Place the bushing (14) into tool 380200245 paying

attention to direct it with the chamfer edge upwards.
Assemble the snap rings (13) by turning them by

90° with respect to the ring mounted before.
Assemble the snap rings (13) until they are seated

against the calibrated disc and using a drift
380200245.
adjust kits.
Assemble the self adjust kits (12) into the brake cyl-
inder, paying attention to direct the chamfer edge of
the bushing (14) upwards.
Assemble the snap rings (11).

Make sure that the teeth of the snap ring are
directed towards the self adjust kit.
Snap ring (11) orientation.

Assemble the belleville washers (9) on the screws

(8) paying attention to orient them correctly.
Assemble the screws (8) and the belleville washers

(9).
15.3 Nm (11 lbf·ft).
Make sure that the 4 belleville washers are correctly
aligned before tightening the screws.
Assemble half shaft (4) and the dowel pins (7).
Using the reference mark made during disassem-

bly, assemble the counterdisc (5) paying attention to
direct it with the mark towards the axle body (3).
Assemble the first braking disc (6) and the counter-

disc (5).
If using new brake discs (6), they must be soaked in
oil for at least 24 hours prior to installation.
Assemble the last brake disc (6) and make sure that
its slots are aligned with those of the first disc.

assemble it on the beam (3).
Support and turn the axle beam (4), while pushing
the wheel hub onto it.
Screw in screws (1) applying the prescribed sealant

and tighten to tightening torque of 226 Nm (167 lbf·ft).
WHEEL HUB
Disassembly
Remove the brake assy.
If disassembly of the planetary gear carrier for over-

hauling is not necessary, use a bearing puller to lift
the planetary gear carrier assy.
Enlarge the snap ring (2) and simultaneously

extract the gear carrier (1).
If necessary, remove the snap rings (3) and by

means of a puller the gears (4) with the bearings (5)
from the gear carrier (1).
NOTE: the bearing (5) cannot be removed from the
gear (4).
If one gear must be replaced, replace the whole
pair.
Unscrew and remove the ring nut (6) fastening the

ring gear retaining hub using tool 380200244.
Separate the wheel hub (7) from the wheel flange

(8) with a puller.
Connect the wheel hub (7) to a hoisting tool to

remove it.
Collect the bearing (9).
Remove the bearing cup (9) from the wheel hub (7).
Remove the seal ring (10) from the wheel hub (7).
Remove the bearing cup (11) from the wheel hub

(7).
Remove the spacer (12) from the wheel flange (8).
To remove the bearing (11), use a disc grinder to cut

the cage and to engrave the ring.
Then use a chisel to cut and to remove the ring.
Assembly
Assemble the bearing cup (11) onto wheel hub (7)
with the buffer 380200211.
Assemble the bearing cup (9) with the buffer
380002222.
Assemble the seal ring (10) on the wheel hub (7)
Use tool 380200254 (T) to assemble the seal ring

(10) onto the wheel hub (7).
Assemble the bearing (11) onto wheel flange (8)

with a pusher and a press.
Place the spacer (12) on the wheel flange (8).

place it on the wheel flange (8).
Clean the sealing surface of the flange.
Pay attention not to damage the seal ring (10).
Assemble the bearing cup (9) with a pusher and a

hammer.
Assemble the ring nut (6).
Screw in and tighten the ring nut (6) with tool

380200244 at tightening torque of 1000 Nm (738
lbf·ft).
Assemble the bearing (5) with tool 380200255 (T).
Assemble the gears (4) and the snap rings (3) on

the gear carrier (1).
Ensure that the chamfer of the bearings (5) is
directed towards the gear carrier (1).
Connect the gear carrier (1) to a hoisting tool to

remove it.
Lift it and then place it on the wheel hub (7).
Orient the gear carrier (1) so that the tooth engages

into the ring nut (6).
In order to simplify the installation, align the hole on

the gear carrier with the ring nut (6).
NOTE: it may take several attempts to find the right
combination of alignment between teeth and hole of
the gear carrier and the ring nut, to get the locking
tooth to engage.
Enlarge the snap ring (2) to complete the gear car-

rier (1) assembly.
DIFFERENTIAL SUPPORT ASSY
Disassembly

Separate the axle support (3) from the axle body (2)
using pry bars in slots.
Connect the differential support (3) to a lifting

device to remove it.
Measure the rolling torque MT0 of the bearings (pin-

ion-ring gear system), using wrench 380200269.
Note value MT0 that is necessary for assembling the
bearings.
NOTE: the total rolling torque must be determined
without the pinion seal ring.
It is possible to measure the total starting preload

FT0 of the bearings (pinion-ring gear system) using
a dynamometer whose cord is wound on the end of
the pinion shaft.
Note value FT0 that is necessary for assembling the
bearings.
Unscrew and remove the screws (4) fastening the

ring nuts (5) and (6).
Unscrew the ring nuts (5) and (6) using tool

380200243.
Remove the differential box (7).

The bearing cups (8) and (9) must be removed
together with the differential box.
Assembly
Assemble the bearing cups (8) and (9) on the differ-
ential box (7) with drift 380200218.
Assemble the differential box (7) with bearings onto

the differential support (3).
Tighten both ring nuts (5) and (6) with special tool
380200243, till the backlash is eliminated and the
bearings are slightly preloaded.
Check that the bearings are correctly seated.
Position a magnetic-base dial gauge on the differ-

ential support, so that the feeler touches the surface
of one tooth of the ring gear with a 90° angle.
Lock the pinion and alternately move the ring gear,

and note the backlash between pinion and ring
gear, measured with the dial gauge.
Repeat the operation on two or more points (teeth),
rotating the ring gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.20 ÷ 0.28 mm (0.0079 ÷ 0.0110 in)
Carry out the adjustment by operating on the ring
nuts (5) and (6) with tool 380200243.
Adjust the ring nuts (5) and (6), remembering that:

- if the measured backlash is less than the pre-
scribed tolerance range, unscrew the ring nut (6)
and screw in the ring nut (5) by the same meas-
ure;
- if the measured backlash is more than the pre-
ure.
Repeat the whole sequence of the above men-

tioned operations until the requested conditions are
reached.
Once the pinion-ring gear backlash has been

adjusted, if the bearings have not been replaced,
measure the total preload FTm of the bearings (pin-
ion-ring gear system), using a dynamometer whose
cord is wound on the end of the pinion shaft.
Use this method only if the bearings are already run
in.
The measured value FTm should be within the fol-
lowing range:
FTm = FT0 ÷ (FT0 + 10) N
FTm = FT0 ÷ (FT0 + 2.25) lbf

measure the total rolling torque MTm of the bearings
(pinion-ring gear system) with a torque meter and
the special wrench 380200269.
The measured value MTm should be the same of
the starting:
MTm = MT0
If the bearings have been replaced, measure the

total preload FTm of the bearings (pinion-ring gear
system), using a dynamometer whose cord is
wound on tool 380200272 inserted on the pinion
splined end.
The total preload FTm is measured by tool

380200237.
The measured value should be within the following
range:
FTm = (FPm + 11) ÷ (FPm + 16.7) N
[FTm = (FPm + 2.47) ÷ (FPm + 3.75) lbf]
where FPm is the actual preload measured on tool
380200237 [gauge diameter Dm = 104.4 mm
(4.11 in)].
NOTE: if you do not use the prescribed tool to

measure the total preload FTm, the reference diam-
eter is the diameter of pinion shaft splined end.
range:
FTm = (FPm + 33) ÷ (FPm + 50) N
[FTm = (FPm + 7.42) ÷ (FPm + 11.24) lbf]
where FPm is the preload of the pinion bearings.

adjusted, if the bearings have been replaced, meas-
ure the total rolling torque MTm of the bearings (pin-
ion-ring gear system) with a torque meter and the
wrench 380200269.
S WARNING S
All preloads must be measured without seal rings.
The total torque MTm should be within the following

range:
MTm = (MPm + 0.58) ÷ (MPm + 0.87) Nm
[MTm = (MPm + 0.43) ÷ (MPm + 0.64) lbf·ft]
where MPm is the preload of the pinion bearings.
If the measure is not within the requested range,

check the assembly of each component and oper-
ate on the ring nuts (5) and (6) of the differential
support:
- if the total preload is less than the given range,
screw on the ring nuts (5) and (6) by the same
measure, keeping the pinion-ring gear backlash
value unchanged;
screw on the ring nuts (5) and (6) with the same
value unchanged.
Once all the adjustment operations have been com-

pleted, lock the ring nuts (5) and (6) with the screws
(4).
Tighten the screws (4) to a tightening torque of 10 Nm
(7.4 lbf·ft).
Before matching worked surfaces, make sure they

are perfectly clean, if not, clean with proper deter-
gents.
Apply a film of sealant on the contact surface of the
axle body (2) and the differential support.
Place the differential support (3) on the axle body

(2).

Check of the bevel gear

To test the marks of the bevel gear teeth, paint the
ring gear with red lead paint.
The contact mark test should always be carried out
on the ring gear teeth and on both sides.
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in
order to adjust the backlash.
X -> Excessive contact at the tooth base:
move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in
Movements to correct:
1 -> move the pinion for type X contact adjustment;
2 -> move the pinion for type Z contact adjustment.
DIFFERENTIAL LOCKING ASSY
Disassembly
Loosen plug (1) without removing it.
Push the yoke (2) downwards using the differential

support as a retainer, then remove the plug (1).

Remove tool 380200259.

Extract the rod assy (3) from the differential support.
Remove the yoke (2), the spring (7) and the spacer
(8) from the rod (3).
Remove the O-ring (9) from the plug (1).

Remove the O-rings (11) and (12) from the piston
(10).
Assembly
Assemble the O-rings (11) and (12) onto the piston
(10).
Lubricate the O-rings.
Lubricate the rod (3).

Assemble the yoke (2) on the rod (3).
Assemble the spacer (8) and the spring (7).
Orient the spacer (8) with the flat side towards the
snap ring (13).
Assemble the rod assy (3) onto the differential sup-

port.

Assemble the bushing (6), making sure that its flat

end faces outwards.
Insert tool 380200259 (T1).
Assemble the snap ring (5) with tool 380200260

(T2).
Remove tools 380200259 (T1) and 380200260
(T2).

support as a retainer.
Screw in the plug (1) by hand.
Tighten the plug (1) to the requested torque of 80 Nm

(59 lbf·ft).
DIFFERENTIAL
Disassembly
If differential bearings must be replaced, remove
the bearing cups (1) and (2).
Take out the cover (5) and collect the anti-rotation

pin (6) and the shoulder ring (7).
Remove the dowels (9).

Take out the pins (10).
Unscrew and remove the screws (11) and the ring

gear (12).
Slip off pin (13) until the gear is free (14).

NOTE: the pin can be slipped off only in one direc-
tion.
Assemble the planetary gear (14) and the relevant

shoulder ring (15).
Remove the pin (13), the planetary gear (16) and

the relevant shoulder ring (17).
Pull out partially the pins (18) and remove the

spacer (19).
Remove the pins (18), the gears (20) and the rele-
vant shoulder rings (21).
Remove the gear (22) and the relevant ring (23).

Remove the pins (25) locking the differential box

(24).
Assembly
Assemble the O-rings (26) on the pins (25).
Assemble the pins (25) into the differential box (24).
Assemble the gear (22) and the relevant ring (23).

Assemble the gears (20) and the relevant shoulder

rings (21). Insert pins (18) far enough to hold them.
NOTE: orient the pins with the flat side upwards.
Assemble the spacer (19) and the pins (18), make

sure to align the pin holes with those of the differen-
tial box (24).
Lubricate and assemble the gear (16) and the rele-

vant shoulder ring (17).
Insert pin (13).
Orient the pin (13) with the flat side upwards.
Assemble the planetary gear (14) and the relevant

shoulder ring (15) and insert the pin (13) and make
sure to align the pin hole with that of the differential
box (24).
Assemble the ring gear (12), apply some sealant

and tighten the screws (11) to a tightening torque of
165 Nm (122 lbf·ft).
Insert the pins (10) and tighten the plugs (9) to the
prescribed torque.
Apply a thin film of grease on the cover (5) and

assemble the ring (7).
Assemble the anti-rotation pin (6) on the cover (5).

Assemble the cover (5) onto the differential box.
Lock the cover (5) with the snap ring (4).
Assemble the sleeve (3) and make sure that it seats

correctly.
NOTE: to ease the fitting, turn the gear (22).
Assemble the bearing cups (1) and (2) with drift

380200218.
Take care not to mix the bearing cups.
PINION ASSY
Disassembly
Measure the starting preload FP0 of the pinion bear-
ings using a dynamometer whose cord is wound on
the end of the pinion shaft.
S WARNING S
Note value FP0 that is necessary for assembling the
bearings.
Measure the rolling torque MP0 of the bearings,

using a torque wrench and tool 380200269.
S WARNING S
Note value MP0 that is necessary for assembling
the bearings.
Lock the differential assy in a vice.

Unscrew the ring nut (1) using special tools
380000021 and 380000020.
NOTE: this operation will irretrievably damage the
lock nut (1).
Remove the ring nut (1) and collect its washer (2).
Tap the shaft end with a soft hammer to remove the

pinion (3).
Collect the washers (4) and (5), the spacer (6) and
the bearing (7).
Remove the bearing cups (7) and (8) from the differ-
ential support (9) using a buffer and a hammer.
Remove the bearing (8) from the pinion (3) by

means of a puller.
Collect the shim (10).
Check the conditions of all pinion parts.

The ring nut (1) and the spacer (6) must be
replaced during assembly.
Assembly
Place the differential support (9) on a workbench.
Insert the bearing cups (7) and (8) with the buffers
380200200 and 380002215 and a hammer.
Insert the bearings (7) and (8) into the relevant

seats.
Assemble the false pinion kit 380200273 (a1) and
the ring nut (1).
Tighten without exceeding the ring nut, until the
backlash is eliminated.
Assemble tool 380200187 (T) on the differential box

seats (9).
Use a depth gauge to measure dimension “X” (dis-

tance between bearing axis of differential box and
leaning point of pinion head or bearing base).
To adjust the bevel gear measure the distance “A”

with a depth gauge.
Determine the value “X” as follows:
X = (A + C) - B mm (in)
where “B” and “C” are known values.
In order to determine the value (S) of the shim to be

placed between pinion and bearing, subtract from
the measured value (X) the value (V) engraved on
pinion head (V = prescribed distance).
S = (X - V) mm (in)
Select the shim (10) with value (S) from the range
of available shims, and fit it onto the shaft end under
the pinion head.
SHIM RANGE
Shims
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm
(0.098) (0.102) (0.106) (0.110) (0.114) (0.118) (0.122) (0.126) (0.130) (0.134)
(in)
Q.ty - - - - - - - - - -
Remove tool 380200187 from the seats (9) of the

differential box.
Disassemble the ring nut (10), the false pinion
380200202 (a1) and the bearings (7) and (8).
Once you have chosen the suitable shim (10), insert

it on the pinion shaft with the chamfer against the
pinion head.
Insert the bearing (8) into the pinion (3) using a

press and a buffer 380200204.
Insert the pinion (3) into the differential box (9).

Insert the shims (4) and (5) and the spacer (6).
NOTE: always use a new spacer (6).
Check the right assembly sequence.

Assemble the bearing (7) on pinion shaft, using

buffer 380200204 and a hammer.
Insert the washer (2) and tighten the new ring nut
(1) on the pinion shaft.
Lubricate the ring nut thread (1) and the supporting
face with the washer (2) with oil.
Screw in the ring nut (1) using the wrench for ring
nut 380200268 and the pinion retainer 380200269.
S WARNING S
The tightening torque is given by the measure of
the preload on bearings (7) and (8); gradually
tighten the ring nut (1).
NOTE: if the tightening is excessive, the spacer (6)

must be replaced and the procedure repeated.
When you check the preload, strike the pinion end
(3) with a soft hammer to favour the bearings (7)
and (8) settlement.
If the bearings have not been replaced, to measure

the preload FPm of the bearings (7) and (8), use a
dynamometer whose cord is wound on the end of
pinion shaft (3).
S WARNING S
Use this method only if the bearings are not to be
replaced, otherwise go to next step.

range:
FPm = FP0 ÷ (FP0 + 10) N
[FPm = FP0 ÷ (FP0 + 2.25) lbf]
If the bearings have not been replaced, it is possible

to measure the rolling torque MPm of the bearings
(7) and (8), using a torque wrench and tool
380000020.
NOTE: use this method only if the bearings are not
replaced.
S WARNING S
The measured value should be the same of the

starting:
MPm = MP0
If the bearings (7) and (8) are new, to measure the
preload FPm of the bearings, use a dynamometer
whose cord is wound on tool 380200237, inserted
on the end of pinion shaft.
The actual preload FPm is measured on tool

380200237 [gauge diameter Dm = 114.4 mm (4.50
in)].
range:
FPm = 38.3 ÷ 46 N
[FPm = 8.61 ÷ 10.34 lbf]
S WARNING S
Values for new bearings.
In case you do not use the prescribed tool to meas-

ure the preload, the reference diameter is the diam-
eter of pinion shaft splined end.
range:
FPm = 115 ÷ 138 N
[FPm = 25.85 ÷ 31.02 lbf]
If the bearings are new, measure the rolling torque

MPm of the pinion shaft bearings with a torque
meter and the wrench 380000020.
S WARNING S
The measured value MPm should be within the fol-

lowing range:
MPm = 2.0 ÷ 2.4 Nm
[MPm = 1.47 ÷ 1.77 lbf·ft]
Once the prescribed preload value is achieved,

caulk the ring nut (1) using a hammer and a punch.
TROUBLESHOOTING
Wheel vibrations. Incorrect installation. Correct the installation.
Axle faulty. Inspect and repair the axle.

on both tyres.
Axle beam bent. Replace the axle beam.
Tyre resistance. Incorrect installation. Correct the installation.
Axle faulty. Inspect and repair.

on both tyres.
Broken axle shaft. Incorrect installation. Correct the installation.

on both tyres.

steering. Axle faulty. Inspect and repair.

on both tyres.
No differential action; jams Incorrect installation. Correct the installation.

during steering.

on both tyres.
Incorrect wheel alignment. Check that the structure and the

Excessive wear of the tyre. Incorrect installation. Correct the installation.

on both tyres.
Differential locked. Check the installation.
Excessive steering angle. Reduce the steering angle.

Damaged or worn axle parts. Replace the damaged axle parts.
Incorrect adjustment of the bevel Adjust the bevel gear set.

gear set.

Outer tip of ring gear tooth is Excessive gear load compared to Replace bevel gear.
broken. the one expected. Follow carefully recommended
Gear adjustment wrong (excessive adjustment operations of ring gear
backlash). and pinion backlash and of tooth
marks detection.
Pinion nut loose.
Inner tip of ring gear tooth is Crash load. Replace bevel gear.
broken.
Gear adjustment wrong (insufficient Follow carefully recommended
backlash). adjustment operations of ring gear
and pinion backlash and of tooth
Pinion nut loose.
marks detection.
Ring gear teeth or pinion teeth Insufficient lubrication. Replace bevel gear.
damaged or scored.
Contaminated lubricant. Replace worn out pinion bearings
that cause an incorrect pinion axle
Incorrect lubrication or poor
backlash and wrong contact
additives.
between pinion and ring gear.
Worn out pinion bearings that cause
Use proper lubricant, fill up to right
an incorrect pinion axle backlash
level and replace at recommended
and wrong contact between pinion
intervals.
and ring gear.
Ring gear teeth or pinion teeth Prolonged operation at high Replace bevel gear.
overheated. Check if gear temperature.
teeth have faded.
Unsuitable lubricant. level and replace at recommended
intervals.
Oil level low.
Contaminated lubricant.
Drive pinion teeth pitted. Extremely intense use. Replace bevel gear.
Insufficient lubrication. Use proper lubricant, fill up to right
intervals.
Bent axle beam body. Machine overloaded. Replace the axle beam body.
Damaged vehicle.
Crash load.
Bearings worn or pitted. Insufficient lubrication. Replace the bearings.

Contaminated lubricant. Use proper lubricant, fill up to right
Extremely intense use.
intervals.
Normal wear.
Pinion nut loose.
Gaskets leak oil. Prolonged operation at excessive oil Replace the gasket and matching
temperature. surface if damaged.
Oil gasket wrongly installed. Use proper lubricant, fill up to right
Gasket edge cut or scored.
intervals.
Excessive wear of input Intense use. Replace the flange.

flange spline.
Pinion nut loose. Check that the pinion spline is not
Pinion axial backlash.
Replace bevel gear, if necessary.
Pinion gear tooth fatigue Intense use. Replace bevel gear.

break.
Continuous overload.
Check if the fracture line is
wavy or clearly delineated
(stop line).
Break of pinion teeth and ring Crash load of differential Check and/or replace other
gear teeth. components. differential components.
Splines of planetary gear worn Intense use. Replace differential gear assy.
(excessive backlash).
Replace axle beam, if necessary.
Worn or scored surfaces of Insufficient lubrication. Replace all scratched washers and
the scraper thrust washer. those with a 0.1 mm (0.004 in)
Lubrication wrong.
thickness lower than the new ones.
intervals.
Inner diameter of pinion Intense use. Replace bearing.

tapered roller bearing worn
Excessive pinion end play. Check pinion axial backlash.
out.
Unsuitable lubrication. Use proper lubricant, fill up to right
intervals.
Broken or bent axle beam. Intense vehicle operation, overload. Replace the axle beam.
Broken axle beam at wheel Loose wheel support. Replace the axle beam.
flange.
Bent axle beam body. Check bending of axle beam body.
Ensure that wheel support is not
worn out or wrongly adjusted.
Noise during travel. Excessive backlash between ring Adjust the backlash between the ring
gear and pinion. gear and the pinion.
Pinion and ring gear worn. Replace pinion and ring gear.
Worn-out pinion bearings Replace pinion bearings.
Loose pinion bearings. Adjust pinion bearings.
Excessive pinion end play. Adjust the axial play of the pinion.
Differential bearings worn out. Replace differential bearings.
Loose differential bearings. Adjust the bearings.
Ring gear excessively off-set. Replace the ring gear.
Low lubricant level. Restore the level.
Poor or wrong lubricant grade. Change lubricant.
Noise during idling. Noises emitted by the axle when the Adjust the backlash between the ring
vehicle is moving are usually heard gear and the pinion or replace pinion
during idling, even though they are and ring gear.
not too loud.
Wrong backlash between pinion and Adjust the play between the pinion
ring gear (the noise heard while and the ring gear.
decelerating disappears when speed
is increased).
Pinion spline or input flange worn. Replace the pinion.
Constant noise. Ring gear teeth or pinion teeth Replace bevel gear.
damaged.
Worn bearings. Replace the bearings.
Pinion splines worn. Replace the pinion.

Noise while bending. Differential planetary gears Replace the planetary gears.
damaged.
Differential box and/or pins worn. Replace the differential box.
Worn differential thrust washers. Replace the thrust washers.
Worn-out axle beam splines Replace the axle beam.

REPAIR TIMES
minutes.
We assume that the axle has already been removed
from the machine.

Connection flange Pinion sealing ring 30
Replacement / overhauling of wheel flange (x 1) 240
Replacement of wheel hub with ring gear (x 1) 240
Wheel hub Replacement of bearings and wheel hub seal ring (x 1) 210
O-ring replacement (x 1) 30
Gear carrier assy replacement (x 1) 50
Replacement of discs and counterdiscs and zero setting of
40
self-adjust (for each side)
Overhauling / replacement of brake piston seals (x 1) 90
Brake
Overhauling / replacement of brake cylinder (for each side) 105
Self-adjust replacement (for each side) 60
Axle shaft replacement (x 1) 30
Differential bearing replacement 180
Differential support
Bevel gear / differential replacement 150
Differential Differential gear replacement 240
Differential locking O-ring / piston replacement 30
Pinion Pinion bearings replacement 180
SPECIAL TOOLS
380000021 Wrench Screw / unscrew the pinion ring nut
380200187 False differential box Differential and pinion assembly
380002215 Buffer Pinion bearing cups assembly
380000020 Wrench Measure of pinion rolling torque
380002222 Buffer Wheel hub seal ring and bearing assembly
380200200 Buffer Pinion bearing cups assembly
380200202 False pinion Differential and pinion assembly
380200204 Buffer Assembly of pinion bearings
380200218 Buffer Assembly of bearing cups into the differential box
380200228 Drift Pinion seal ring assembly
380200237 Tool Measure of pinion preload
380200243 Wrench Screw / unscrew the pinion ring nuts
380200244 Wrench Screw / unscrew the wheel hub ring nuts
380200245 Buffer Assembly / disassembly of self-adjust kit
380200255 Buffer Assembly of bearings into gears
380200259 Plunger Assembly / disassembly of differential locking yoke
380200260 Guide Assembly / disassembly of differential locking yoke

2WS REAR AXLE

(590ST)
Model 28.50
472 kg
Dry weight
(1040 lb)
Differential type Mechanical and driven
12 ÷ 35 bar
Pressure for differential lock
(174 ÷ 508 psi)
0.20 ÷ 0.35 mm
(0.008 ÷ 0.014 in)
Pinion bearing preload (*) FPm = 10.0 ÷ 12.0 daN
(measured on Ø = 39.7 mm (1.56 in) without seal ring) (22.48 ÷ 26.98 lbf)
Ring gear-pinion bearing total preload (*) FTm = (FPm + 2.76) ÷ (FPm + 4.16) daN
(measured on Ø = 39.7 mm (1.56 in) without seal ring) [FTm = (FPm + 6.20) ÷ (FPm + 9.35) lbf]
MPm = 2.0 ÷ 2.4 Nm
Pinion bearing rolling torque (*) measured without seal ring
(MPm = 1.47 ÷ 1.77 lbf·ft)
Total pinion-ring gear bearing rolling torque (*) measured MTm = (MPm + 0.55) ÷ (MPm + 0.83) Nm
without seal ring [MTm = (MPm + 0.40) ÷ (MPm + 0.61) lbf·ft]
SERVICE BRAKE

Maximum operating pressure 55 bar (798 psi)

(0.31 ± 0.002 in)
(0.26 ± 0.004 in)
C. New counterdisc thickness = 5.0 ± 0.05 mm
(0.20 ± 0.002 in)
Oil capacity (differential) 15.5 litres (3.41 gal)


3. Oil breather
4. Oil drain plug
5. Brake breather
sure.
S WARNING S

S WARNING S
Drain all oil.


shored cavity.
brake.
machine weight).
the 2 rear tyres by loosening and removing the
relevant fixing nuts (9) [tightening torque = 700 Nm
(516 lbf·ft)].
(2) and the washers (3) and (5) [tightening torque =
610 ÷ 678 Nm (445 ÷ 500 lbf·ft)].


A. Loctite 510
B. Loctite 270
C. Loctite 638
GREASE POINTS
FRONT FLANGE
Disassembly
Remove the stop ring (1) and the front flange (2).
Collect shim (4) and the O-ring (3).
Take out the seal ring (5) from the central body (6).
S WARNING S
If necessary, remove protection (7) from the front

flange (2).
Assembly
On the front flange (2), assemble the protection (7)
using tool 380200277.
Use tool 380200277 to assemble the protection (7)

on the front flange (2).
Insert a new seal ring (5) into the central body (6)
using tool 380200276.
Use tool 380200276 to fit the seal ring (5) into the
central body (6).
Grease the O-ring (3).

Insert the washer (4), the O-ring (3) and the front
flange (2) into the pinion.
Fasten the pieces as soon as assembled by fitting
the snap ring (1).
BRAKES
Disassembly
Loosen and remove all screws (1) except for 2 as a

safety measure.

tension the rope.
Insert 2 opposed threaded rods to enable removal.
Remove the 2 last screws (1) and separate the

wheel hub assy (2) from the axle body (3).
Slowly remove the wheel hub assy and the half axle
(4), make sure that the discs (5) and the counter-
discs (6) stay on the wheel hub assy.
Place the wheel hub assy vertically and mark the

counterdisc (5) assembled to the axle body side (3).
Remove the discs (6), the counterdiscs (5) and the
dowel pins (7).
Remove the half axle (4) from the wheel hub assy
(2).
Remove the screws (8) and the belleville washers

(9) from the brake cylinder (10).
Check screws (8) and belleville washers (9) for

damage.
NOTE: if brake discs are replaced, also replace
screws and springs.
Remove the snap ring (11) and the self adjust kit
assy (12).
Place the self adjust kit (12) on tool 380200245 and

remove the snap rings (13).
Check bushing (14) for wear.

adjust kits.
Remove the brake cylinder assy (10).
Remove the brake piston (15) from the brake cylin-

der (10).
Remove the O-rings (16) and (17) from the brake

cylinder (10).
Remove the O-ring (18) from the brake piston (15).

Assembly
Assemble the new O-ring (19).
Assemble the O-ring (18) onto the brake piston

(15).
Assemble the O-rings (16) and (17) onto the brake

cylinder (10).
Lubricate the O-rings (16), (17) and (18).

Assemble the brake piston (15) into the brake cylin-
der (10).
Lubricate the seat of the brake cylinder on the

wheel hub (2) and assemble the dowel pins (7).
Assemble the brake cylinder assy (10) and remove

the dowel pins (7).
Place the bushing (14) into tool 380200245 paying

attention to direct it with the chamfer edge upwards.
Assemble the snap rings (13) by turning them by

90° with respect to the ring mounted before.
Assemble the snap rings (13) until they are seated

against the calibrated disc and using a drift
380200245.
adjust kits.
Assemble the self adjust kits (12) into the brake cyl-
inder, paying attention to direct the chamfer edge of
the bushing (14) upwards.
Assemble the snap rings (11).

Make sure that the teeth of the snap ring are
directed towards the self adjust kit.
Snap ring (11) orientation.

Assemble the belleville washers (9) on the screws

(8) paying attention to orient them correctly.
Assemble the screws (8) and the belleville washers

(9).
15.3 Nm (11 lbf·ft).
Make sure that the 4 belleville washers are correctly
aligned before tightening the screws.
Assemble half shaft (4) and the dowel pins (7).
Using the reference mark made during disassem-

bly, assemble the counterdisc (5) paying attention to
direct it with the mark towards the axle body (3).
Assemble the first braking disc (6) and the counter-

disc (5).
If using new brake discs (6), they must be soaked in
oil for at least 24 hours prior to installation.
Assemble the last brake disc (6) and make sure that
its slots are aligned with those of the first disc.

assemble it on the beam (3).
Support and turn the axle beam (4), while pushing
the wheel hub onto it.
Screw in screws (1) applying the prescribed seal-

ant and tighten to tightening torque of 226 Nm
(167 lbf·ft).
WHEEL HUB
Disassembly
Remove the brake assy.
If disassembly of the planetary gear carrier for over-

hauling is not necessary, use a bearing puller to lift
the planetary gear carrier assy.
Enlarge the snap ring (2) and simultaneously

extract the gear carrier (1).
If necessary, remove the snap rings (3) and by

means of a puller the gears (4) with the bearings (5)
from the gear carrier (1).
NOTE: the bearing (5) cannot be removed from the
gear (4).
If one gear must be replaced, replace the whole
pair.
Unscrew and remove the ring nut (6) fastening the

ring gear retaining hub using tool 380200244.
Separate the hub (7) from the wheel flange (8) with
a puller.
Connect the hub (7) to a hoisting tool to remove it.

Collect the bearing (9).
Remove the bearing cup (9) from the wheel hub (7).
Remove the seal ring (10) from the wheel hub (7).
Remove the bearing cup (11) from the wheel hub

(7).
Remove the spacer (12) from the wheel flange (8).
To remove the bearing (11), use a disc grinder to cut

the cage and to engrave the ring.
Then use a chisel to cut and to remove the ring.
Assembly
Assemble the bearing cup (11) onto wheel hub (7)
Assemble the bearing cup (9) with the buffer
380002222.
Assemble the seal ring (10) on the wheel hub (7)
Use tool 380200254 (T) to assemble the seal ring

(10) onto the wheel hub (7).
Assemble the bearing (11) onto wheel flange (8)

with a press.
Place the spacer (12) on the wheel flange (8).

place it on the wheel flange (8).
Clean the sealing surface of the flange.
Pay attention not to damage the seal ring (10).
Assemble the bearing (9) and the ring nut (6).

Screw in and tighten the ring nut (6) with tool

380200244 at tightening torque of 1000 Nm (738 lbf·ft).
Assemble the bearing (5) with tool 380200255 (T).
Assemble the gears (4) and the snap rings (3) on

the gear carrier (1).
Ensure that the chamfer of the bearings (5) is
directed towards the gear carrier (1).
Connect the gear carrier (1) to a hoisting tool to

remove it.
Lift it and then place it on the wheel hub (7).
Orient the gear carrier so that the tooth engages

into the ring nut (6).
In order to simplify the installation, align the hole on

the gear carrier with the ring nut (6).
NOTE: it may take several attempts to find the right
combination of alignment between teeth and hole of
the gear carrier and the ring nut, to get the locking
tooth to engage.
Enlarge the snap ring (2) to complete the gear car-

rier (1) assembly.
DIFFERENTIAL SUPPORT ASSY
Disassembly

Separate the axle support (3) from the axle body (2)
using pry bars in slots.
Connect the differential support (3) to a lifting

device to remove it.
Measure the rolling torque MT0 of the bearings (pin-

ion-ring gear system), using wrench 380200269.
Note value MT0 that is necessary for assembling the
bearings.
NOTE: the total rolling torque must be determined
without the pinion seal ring.
It is possible to measure the total starting preload

FT0 of the bearings (pinion-ring gear system) using
a dynamometer whose cord is wound on the end of
the pinion shaft.
bearings.
Unscrew and remove the screws (4) fastening the

ring nuts (5) and (6).
Unscrew the ring nuts (5) and (6) using tool

380200243.
Remove the differential box (7).

The bearing cups (8) and (9) must be removed
together with the differential box.
Assembly
Assemble the bearing cups (8) and (9) on the differ-
ential box (7) with drift 380200218.
Assemble the differential box (7) with bearings onto

the differential support (3).
Tighten both ring nuts (5) and (6) with special tool
380200243, till the backlash is eliminated and the
bearings are slightly preloaded.
Check that the bearings are correctly seated.
Position a magnetic-base dial gauge on the differ-

ential support, so that the feeler touches the surface
of one tooth of the ring gear with a 90° angle.
Lock the pinion and alternately move the ring gear,

and note the backlash between pinion and ring
gear, measured with the dial gauge.
Repeat the operation on two or more points (teeth),
rotating the ring gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.20 ÷ 0.35 mm (0.008 ÷ 0.014 in)
Carry out the adjustment by operating on the ring
nuts (5) and (6) with tool 380200243.
Adjust the ring nuts (5) and (6), remembering that:

- if the measured backlash is less than the pre-
ure;
- if the measured backlash is more than the pre-
ure.

tioned operations until the requested conditions are
reached.

in.
lowing range:
FTm = FT0 ÷ (FT0 + 10) N
[FTm = FT0 ÷ (FT0 + 2.25) lbf]

measure the total rolling torque MTm of the bearings
(pinion-ring gear system) with a torque meter and
the special wrench 380200269.
The measured value MTm should be the same of
the starting:
MTm = MT0

splined end.

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

ure the total rolling torque MTm of the bearings (pin-
wrench 380200269.
S WARNING S

check the assembly of each component and oper-
ate on the ring nuts (5) and (6) of the differential
support:
screw on the ring nuts (5) and (6) by the same
value unchanged;
screw on the ring nuts (5) and (6) with the same
value unchanged.
NOTE: To test the marks of the bevel gear teeth,

paint the ring gear with red lead paint.
The contact mark test should always be carried out
on the ring gear teeth and on both sides.
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in
X -> Excessive contact at the tooth base:
move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in
Movements to correct:
1 -> move the pinion for type X contact adjustment;
2 -> move the pinion for type Z contact adjustment.
Once all the adjustment operations have been com-

pleted, fit the ring nuts (5) and (6) by tightening the
screws (4).
Tighten the screws (4) to a tightening torque of 10 Nm
(7.4 lbf·ft).

gents.
Apply a film of sealant on the contact surface of the
axle body (2) and the differential support.
Place the differential support (3) on the axle body

(2).

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


Remove tool 380200259.

Remove the springs (4) and (8) and the spacer (9).
Extract the rod assy (3) from the differential support.

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

(11).
Assemble the rod (3) and the yoke (2) in the differ-
ential support.
NOTE: orient the rod (3) with the outer groove (A)
directed towards the yoke (2).
Insert the springs (4) and (8) and the spacer (9).
Screw in and tighten the plug (1) to the prescribed

Assemble the bushing (6).
Insert tool 380200259 (T1).

Assemble the snap ring (5) with tool 380200260

(T2).
Remove tools 380200259 (T1) and 380200260
(T2).

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

(22 lbf·ft).
DIFFERENTIAL
Disassembly
If necessary, replace the differential bearings.

Remove the bearing cups (3) and (4).
Take out the cover (7) and collect the anti-rotation

pin (8) and the ring (9).

Remove the dowels (11).
Take out the pins (12).
Slip off pin (13) until the gear is free (14).
Assemble the gear (14) and the relevant shoulder

ring (15).
Remove the pin (13), the gear (16) and the relevant
shoulder ring (17).
Pull out partially the pins (18) and remove the

spacer (19).
Remove the pins (18), the gears (20) and the rele-
vant shoulder rings (21).
Remove the gear (22) and the relevant ring (23).

Remove the pins (25) locking the differential box

(24).
Assembly
Assemble the O-rings (26) on the pins (25).
Assemble the pins (25) into the differential box (24).
Assemble the gear (22) and the relevant ring (23).

Assemble the gears (20) and the relevant shoulder

rings (21). Insert pins (18) far enough to hold them.
NOTE: orient the pins with the flat side upwards.
Assemble the spacer (19) and the pins (18), make

sure to align the pin holes with those of the differen-
tial box (24).

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

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

Screw in and tighten the plugs (11) to the pre-
scribed torque of 25 Nm (18.4 lbf·ft).
Apply a thin film of grease on the cover (7) and

assemble the ring (9).
Assemble the anti-rotation pin (8) on the cover (7).

Assemble the cover (7) onto the differential box.
Lock the cover (7) with the snap ring (6).
Assemble the sleeve (5) and make sure that it seats

correctly.
NOTE: to ease the fitting, turn the gear (22).
Assemble the bearing cups (3) and (4) with drift

380200218.
Take care not to mix the bearing cups.
Assemble the ring gear (2).

Apply some sealant and tighten the screws (1) to
the prescribed torque of 190 Nm (140 lbf·ft).
PINION ASSY
Disassembly
S WARNING S
bearings.
Measure the rolling torque MP0 of the bearings,

using a torque wrench and tool 380200269.
S WARNING S
Note value MP0 that is necessary for assembling
the bearings.
Lock the differential assy in a vice.

Unscrew the ring nut (1) using special tools
380200268 and 380200269.
NOTE: this operation will irretrievably damage the
lock nut (1).
Remove the ring nut (1) and collect its washer (2).

pinion (3).
Collect the washers (4) and (5), the spacer (6) and
the bearing (7).
Remove the bearing cups (7) and (8) from the differ-
ential support (9) using a buffer and a hammer.

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

replaced during assembly.
Assembly
Place the differential support (9) on a workbench.
Insert the bearing cups (7) and (8) with buffer
380200274 and a hammer.
Insert the bearings (7) and (8) into the relevant

seats.
Assemble the false pinion kit 380200273 (a1) and
the ring nut (1).
Tighten without exceeding the ring nut, until the
backlash is eliminated.
Assemble tool 380200187 (T) on the differential box

seats (9).
Use a depth gauge to measure dimension “X” (dis-

tance between bearing axis of differential box and
leaning point of pinion head or bearing base).

with a depth gauge.
X = (A + C) - B mm (in)
In order to determine the value (S) of the shim to be

placed between pinion and bearing, subtract from
the measured value (X) the value (V) engraved on
pinion head (V = prescribed distance).
S = (X - V) mm (in)
Select the shim (10) with value (S) from the range
of available shims, and fit it onto the shaft end under
the pinion head.
NOTE: orient the shim (10) with the chamfered end
towards the pinion head (3).
SHIM RANGE
Shims
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm (0.098) (0.102) (0.106) (0.110) (0.114) (0.118) (0.122) (0.126) (0.130) (0.134)
(in)
Q.ty - - - - - - - - - -
Remove tool 380200187 from the seats (9) of the

differential box.
Disassemble the ring nut, the spacer, the false pin-
ion 380200273 and the bearings (7) and (8).

pinion head.
Insert the bearing (8) on the pinion (3) using a press

and a buffer 380200220.
Insert the pinion (3) into the differential box (9).

Insert the shims (4) and (5) and the spacer (6).

Assemble bearing (7) on pinion shaft, using buffer

Insert the washer (2) and tighten the new ring nut
(1) on the pinion shaft.
Lubricate the ring nut thread (1) and the supporting
face with the washer (2) with oil.
Screw in the ring nut (1) using the wrench for ring
nut 380200268 and the pinion retainer 380200269.
S WARNING S
The tightening torque is given by the measure of
the preload on bearings (7) and (8); gradually
tighten the ring nut (1).
NOTE: if the tightening is excessive, the spacer (6)

must be replaced and the procedure repeated.
When you check the preload, strike the pinion end
(3) with a soft hammer to favour the bearings (7)
and (8) settlement.

the preload FPm of the bearings (7) and (8), use a
dynamometer whose cord is wound on the end of
pinion shaft (3).
S WARNING S
Use this method only if the bearings are not to be
replaced, otherwise go to next step.

range:
FPm = FP0 ÷ (FP0 + 10) N
[FPm = FP0 ÷ (FP0 + 2.25) lbf]
If the bearings have not been replaced, it is possible

to measure the rolling torque MPm of the bearings
(7) and (8), using a torque wrench and tool
380200269.
NOTE: use this method only if the bearings are not
replaced.
S WARNING S
The measured value should be the same of the

starting:
MPm = MP0
If the bearings (7) and (8) are new, to measure the
preload FPm of the bearings, use a dynamometer
whose cord is wound on tool 380200272, inserted
on the end of pinion shaft.

(4.69 in)].
range:
FPm = 33.3 ÷ 40 N
(FPm = 7.49 ÷ 8.99 lbf)
S WARNING S
Values for new bearings.

range:
FPm = 100 ÷ 120 N
(FPm = 22.48 ÷ 2.02 lbf)
If the bearings are new, measure the rolling torque

MPm of the pinion shaft bearings with a torque
meter and the wrench 380200269.
S WARNING S
The measured value MPm should be within the fol-

lowing range:
MPm = 1.6 ÷ 2.4 Nm
(MPm = 1.18 ÷ 1.77 lbf·ft)

caulk the ring nut (1) using a hammer and a punch.
TROUBLESHOOTING

on both tyres.

on both tyres.

on both tyres.


on both tyres.


during steering.

on both tyres.


on both tyres.


gear set.

broken. the one expected. Follow carefully recommended
marks detection.
Pinion nut loose.
broken.
Pinion nut loose.
marks detection.
damaged or scored. Contaminated lubricant. Replace worn out pinion bearings
additives.
intervals.
and ring gear.
overheated. Check if gear temperature. Use proper lubricant, fill up to right
teeth have faded. Unsuitable lubricant. level and replace at recommended
intervals.
Oil level low.
intervals.
Damaged vehicle.
Crash load.

intervals.
Normal wear.
Pinion nut loose.
intervals.

flange spline.

break.
(stop line).
Lubrication wrong.
intervals.

out.
intervals.
flange.
not too loud.
is increased).
damaged.

damaged.

REPAIR TIMES
minutes.
from the machine.

Connection flange Pinion sealing ring 30
Replacement / overhauling of wheel flange (x 1) 240
Replacement of wheel hub with ring gear (x 1) 240
Wheel hub Replacement of bearings and wheel hub seal ring (x 1) 210
Gear carrier assy replacement (x 1) 50
Replacement of discs and counterdiscs and zero setting of
40
self-adjust (for each side)
Overhauling / replacement of brake piston seals (x 1) 90
Brake
Overhauling / replacement of brake cylinder (for each side) 105
Self-adjust replacement (for each side) 60
Differential bearing replacement 180
Bevel gear / differential replacement 150
Differential Differential gear replacement 240
Differential locking O-ring / piston replacement 30
Pinion Pinion bearings replacement 180
SPECIAL TOOLS
380200220 Buffer Assembly of pinion bearings
380200272 Tool Measure of pinion preload
380200274 Buffer Assembly of bearings into the differential box
380200243 Wrench Screw / unscrew the pinion ring nuts
380200244 Wrench Screw / unscrew the wheel hub ring nuts
380200276 Buffer Assembly of seal ring into front flange
380200254 Buffer Disassembly of bearings and wheel hub seal ring
380200277 Buffer Assembly of protection onto front flange
380200255 Buffer Assembly of bearings into gears
380200259 Plunger Assembly / disassembly of differential locking yoke
380200260 Guide Assembly / disassembly of differential locking yoke

4WS REAR AXLE

(695ST)
Model 26.32M
Maximum steering angle 21° 0-1
Toe-in A±1
538 kg
Dry weight
(1186 lb)
Differential type Limited slip or open
0.15 ÷ 0.30 mm
(0.006 ÷ 0.012 in)
Pinion bearing preload (*) FP = 92 ÷ 138 N
(measured on Ø = 34.8 mm without seal ring) (FP = 21 ÷ 31 lbf)
Ring gear-pinion bearing total preload (*) FT = (FP + 33.4) ÷ (FP + 50.2) N
(measured on Ø = 34.8 mm without seal ring) [FT = (FP + 7.5) ÷ (FP + 11.29) lbf]
MP = 1.6 ÷ 2.4 Nm
Pinion bearing rolling torque (*) measured without seal ring
(MP = 1.18 ÷ 1.77 lbf·ft)
Total pinion-ring gear bearing rolling torque (*) measured without MT = (MP + 0.58) ÷ (MP + 0.87) Nm
seal ring [MT = (MP + 0.43) ÷ (MP + 0.64) lbf·ft]

SERVICE BRAKE

Brake actuation Hydraulic
Maximum operating pressure Mineral oil
Standard brake discs

(0.20 ± 0.002 in)
(0.19 ± 0.002 in)
C. New counterdisc thickness = 8.9 ÷ 9.0 mm
(0.350 ÷ 0.354 in)
“Limited slip” brake discs

(0.051 ± 0.001 in)
(0.063 ± 0.001 in)
C. New friction disc thickness = 2.7 ± 0.05 mm
(0.106 ± 0.002 in)
Worn disc minimum thickness = 2.6 ± 0.05 mm
(0.102 ± 0.002 in)
Differential 11 litres (2.42 gal)

Oil capacity

3. Oil breather
4. Filler, level and drain plug for reduction gear oil
5. Greasing points
sure.
S WARNING S

S WARNING S
Drain all oil.

Before draining the oil from the reduction gear, turn

the gear so that the plug (4) is in the highest possi-
ble position [position A].
Partially unscrew the plug (4) to release any possi-
ble internal pressure.
Turn the plug (4) and bring it to its lowest position
[position B].
Rotate again to bring the hole of the plug (4) to
Clean, screw in and tighten the plug (4).

shored cavity.
brake.
machine weight).
the 2 rear tyres by loosening and removing the
relevant fixing nuts (9) [tightening torque = 700 Nm
(516 lbf·ft)].
(4) and the washers (3) and (5) [tightening torque
= 830 ÷ 970 Nm (612 ÷ 715 lbf·ft)].


B. Loctite 270
C. Loctite 638
GREASE POINTS
grease AGIP GR MU EP2

FRONT FLANGE
Disassembly
Drain oil from the central body.
Remove the snap ring (1) from the pinion shaft (6)
and slip off the front flange (2).


Collect the washer (4).
Assembly
Insert the washer (4) into the pinion shaft.
Assemble and lubricate the new O-ring (3).
Assemble the new seal ring (5) with tool 380200267

and a hammer.
Assemble the seal ring (5) by means of tool

380200267 (T1).
Assemble the front flange (2).

Refill the central body with oil.
STEERING CYLINDER
Disassembly
Loosen and remove the nuts (1) and (14) and slip
off the tie rods (3) and (12) from the swivel housings
(2) and (13).
S WARNING S
Do not damage the end of the threaded pins.
If necessary, replace the nuts (1) and (14).

Remove the clamps (15) and (18).

Disassemble the sensor (17), the connector bracket
(16) and the 2 clamps (15) and (18).
Remove the tie rods (3) and (12) from the cylinder
rods by loosening the nuts (4) and (11), then check
their conditions.
Remove the ball joints (5) and (9).
Loosen and remove the 2 screws (6) and the 2

screws (9).
Take out the bushings (7) by means of a puller.
Remove the steering cylinder (8).

Remove the snap rings (19) and (27) from the

steering cylinder (8).
Push the two cylinder heads (21) and (25) inside

the cylinder.
Collect the 2 snap rings (20) and (26).
Pull out the rod (23) as necessary to collect the cyl-

inder head (25).
NOTE: do not extract the piston from the cylinder
(22).
Push the rod (23) in the opposite direction and

remove it from the cylinder (22) with the head (21).
Extract the head (21) from the rod (23).
Remove and, if necessary, replace all different seal

rings from the rod (23) and from the 2 cylinder
heads (21) and (25).
Assembly
Assemble the seal rings (24) onto the 2 heads (21)
and (25).
Assemble the seal rings (24) onto rod (23).

Check the proper assembly of the seal rings.
Assemble the 2 heads (21) and (25) with rod (23).
The 2 heads (21) and (25) must be positioned cor-

rectly.
Insert the pre-assembled assy, consisting in the rod

(23) and the two cylinder heads (21) and (25) into
the cylinder body (22).
Push the cylinder heads (21) and (25) into the cylin-
der body (22).
Insert the 2 snap rings (20) and (26) into the rele-
vant seats in the cylinder body (22).
Pull outward the rod (23) on each side pulling the

cylinder heads (21) and (25) to the end of the
stroke.
Assemble the 2 snap rings (19) and (27) on the

heads (21) and (25).
Check the correct assembly of the heads and snap

rings.
Assemble the steering cylinder (8).
Cool the bushes (7) down to a temperature

lower than -100 °C (-148 °F) with liquid nitro-
gen.
Assemble the bushes (7) by means of a punch and
a hammer.

Screw in the ball joints (5) and (10) to the ends of the
rod to the prescribed torque of 300 Nm (221 lbf·ft).
Screw in the nuts (4) and (11) and the tie rods (3)
and (12) to the ball joints (5) and (10).
Align the swivel housing (2) with the axle.

Screw the tie rod (3) so that its ball joint can be
inserted into the swivel housing (2) arm.
It is important to unscrew the nut (4) to carry out this
operation.
Repeat the mentioned operations on the other side.
Insert the ball joint of the tie rod (12) into its seat on
the swivel housing (13).
Screw in and tighten the nut (14) to a tightening
Repeat the mentioned operations on the other side.
Screw in the nuts (4) and (11) of the tie rods (3) and
(12) only after the toe-in adjustment has been car-
ried out.
Assemble the sensor (17) and the connector

bracket (16) with the clamps (15) and (18) to the
steering cylinder (8).
Tighten the clamps (7) and (8) only after the toe-in
adjustment has been carried out.
STEERING SENSOR ADJUSTMENT
S WARNING S
The steering sensor adjustment operations can be
carried out only after toe-in adjustment has been
carried out.
Connect, by means of the relevant connector (C),

the steering sensor (17) to a control device that can
detect the presence of voltage generated by the
sensor. The tool is usually provided with a led that
turns on only when voltage is present.
Respect the steering sensor electric specifications

and the connection diagram.
It is also possible to use a common tester or to con-
nect the steering sensor to the vehicle control
panel.
The picture shows the connector (C) diagram.
Align the wheels to rectilinear driving direction.

Move the steering sensor (17) and relative clamps
to a side of the cylinder.
Fix the clamps (15) and (18) so that they can slide
on the cylinder surface.
Slide horizontally the steering sensor till the led is

on (position “A”) and measure XA dimension,
between the differential support and the rear part of
the sensor shown in the figure.
The red led (L) of the sensor (17) is located as illus-

trated.
Slide horizontally the steering sensor till the led is

on (position “B”) and measure XB dimension,
between the differential support and the rear part of
the sensor.
Move the steering sensor backwards by a distance

of (XB - XA)/2 as shown in the figure [maximum tol-
erance ± 1.0 mm (0.04 in)].
Before tightening the hose clamps, check the right

position of the steering sensor (17) in the appropri-
ate seat fixed on the steering cylinder (the steering
sensor must be oriented as shown in the figure).
Position the fastening screws (S) of the 2 hose

clamps (15) and (18).
Tighten the fastening screws (S) to lock the sensor
(17).
REDUCTION GEAR
Disassembly
Unscrew the plug (1) and drain oil from the reduc-
tion gear.
Loosen and remove the 2 fixing screws (2).

Remove the gear carrier (3) from the wheel hub

(10) and remove the relevant O-ring (9).
Position the gear carrier (3) on a workbench and
check its wear conditions.
To carry out any possible replacement of the gears

(6):
- loosen and remove the screw (8) of each gear (6);
- remove the washer (7);
- take out the gears (6) from the pins;
- collect the bearings (5) and check their condi-
tions;
- collect the thrust washer (4).
Assembly
Collect all reduction gear parts: the gear carrier, the
thrust washers (4), the gears (6) with the relevant
needle bearings (5), the washers (7) and the
screws (8).
With new gears (6), it is advisable to assemble new
bearings (5).
Position the planetary gears carrier (3) on a work-

bench.
Insert the needles (5) into the gears (6).
Grease the needles (5).
Insert the pin of the planetary gear carrier (3), the
thrust washer (4) and the gears (6) with needles.
Assemble the washers (7) into the pins of the plane-

tary gear carrier (3).
Install the new O-ring (9) on the wheel hub (10).
Assemble the reduction gear assy on the wheel

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

WHEEL HUB
Disassembly
Insert a lever between the swivel housing and the
axle body and fit it into the double joint.
With the lever push the double joint in the direction
of the wheel hub to allow the snap ring removal.
Do not damage the double joint.

Collect the washer (2) and the thrust washer (3).
In order to remove the ring gear carrier hub from its

housing, screw two of the just removed screws (5)
in the threaded extraction holes.
Remove the ring gear carrier hub (7) together with
the ring gear (4).
Remove the snap ring (8) and separate the ring

gear carrier hub (7) from the ring gear (4).
Only if necessary, remove the centering bushes (6)
from the ring gear carrier by means of tool
Remove the wheel hub (11) from the swivel housing

(14) and collect the bearing (9).
Slide out the wheel hub (11), using levers and a

hammer to facilitate the operation.
Position the wheel hub (11) on a flat surface and

remove the seal ring (13).
Take out the bearing cups (9) and (12) with a drift
and a hammer.
Remove the bearing (12) from the swivel housing

(14) by means of a puller.
Unscrew and remove the screws (15) and (19) from

the upper (16) and lower (18) king pins.
S DANGER S
Before removing the king pins (16) and (18), secure
the swivel housing (14) with a rope or a hoist or any
other supporting device to guarantee operator’s
safety.
Remove the king pins (16) and (18).
Loosen and remove the swivel housing (14).
Position the swivel housing (14) on a flat surface

and take the seal ring (25) out with a puller.
Rivet the swivel housing and take out the bronze
bushing (24), using a buffer and a hammer.
Assembly
If previously removed, assemble the steering stop
screw (23), the nut (22) and the bushings (20) and
(21).
Do not tighten the nut (22) until the steering angle
adjustment has been carried out.
Insert the bronze bushing (24) into the swivel hous-

ing (14) by means of tool 380000024 and a ham-
mer.
Assemble the new seal ring (25) into the swivel
housing (14) with tool 380200266 and a hammer.
If the ball bearing (17) has been previously

removed, reassemble it to the lower king pin (18) by
means of tool 380200195 and a press.
Grease the king pin seats (16) and (18).
Position the belleville washers (27) and (28) on the
king pin seats (16) and (18).
Secure the swivel housing (14) with a rope to a

hoist or any other supporting device.
Protect the splined end of the axle shaft by winding
it with protective tape, to avoid damaging the seal
ring.
Assemble the swivel housing (14) to the axle and,
after assembly, completely remove the protective
tape.
Assemble the lower (18) and the upper (16) king

pins.
Make sure that the belleville washers stay in the
correct position.
The special operation “Set Right” of the bearings

does not require preload or backlash adjustment.
Anyway, before assembling new components,
check the indicated dimensions.
A = 10.090 ÷ 10.140 mm (0.397 ÷ 0.399 in)
B = 64.275 ÷ 64.325 mm (2.530 ÷ 2.532 in)
C = 27.000 ÷ 27.100 mm (1.063 ÷ 1.066 in)
Insert the bearing cups (9) and (12) into the wheel
hub (11) by means of tool 380200211 and a press.
Insert the new seal ring (13) into the wheel hub (11)
using tool 380200210 and a hammer.
Assemble the bearing (12) in the swivel housing

(14).
Assemble the wheel hub (11) on the swivel housing
(14) and fit the bearing (9).
Position the ring gear hub (7) on a workbench and

insert the bushings (6) at surface level with tool
380200192.
At least two bushings (diametrically-opposed)
should be set slightly higher than the carrier surface
level to be used as dowel pins.
Preassemble the ring gear carrier hub (7) and the

ring gear (4) with the snap ring (8).
Assemble the ring gear carrier hub assy on the

wheel hub using the two projecting bushings as
dowel pins.
Screw the relevant screws in order to put in contact
the assembly with the wheel hub.
Assemble all bushings (6) up to stroke end with tool

Insert a lever between the swivel housing (14) and

the axle body and fit it into the double joint.
With the lever push the double joint in the direction
of the wheel hub to allow the snap ring introduction.
Insert the thrust washer (3) and the washer (2).

Assemble the snap ring (1) at the end of the splined
hub.
BEAM ASSY
Disassembly
Drain axle oil completely.
Loosen and remove the two screws (13).
Unscrew the nuts (11) of the oil recirculation line
(12).
Remove the oil recirculation line (12).
If necessary, remove the cover (1) from the double

joint (2).
Remove the double joint (2).
Put alignment marks on the beam trumpets, on the

brake cylinders and on the axle central body, in
order to identify the coupling parts during reassem-
bly.
Position the axle on supports suitable to hold it or

secure the assemblies separately to a lifting device.
Remove the beam (8) and the O-ring (9).

If the beam is removed, the brake assy is released.
Extract the seal ring (3).

If necessary, remove the bushing (4), paying atten-
tion not to damage its seat.
If necessary, remove the bushing (5) and the race

(6) of the ball joint from the seats using a puller.
Assembly
Cool down the bushing (5) and the cup (6) to a tem-
perature lower than -100 °C (-148 °F) with liquid
nitrogen.
Assemble the bushing (5) in the upper king pin seat
with buffer 380200196 and a hammer.
Assemble the cup (6) on the lower king pin seat
with buffer 380200196 and a hammer.
Assemble the bushing (4) by means of tool

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

Support the assemblies properly as already pointed

out for disassembly phase.
Assemble the beam (8) on the central axle body
(10) respecting the reference marks applied during
disassembly.

Tighten the screw (7) respecting the sequence

shown.
Insert the double joint (2).

Assemble the oil recirculation line (12).

Tighten the nuts (11) to the tightening torque of
60 Nm (44 lbf·ft).
BRAKES
Disassembly
Remove the beam and the axle shaft.
Remove the brake components: the counterdiscs

(11), discs (12), the brake disc carrier hub (10), the
brake disc (9) and the brake counterdisc (8).
NOTE: mark the position of the hub for assembly.
Remove the brake piston return kit (7) and the self-
adjust kit (6).
Take out the brake piston (4) from the brake cylin-
der (1).
If necessary, remove the plug (14) and the relevant
O-ring (13).
Blow some air through the oil supply hole for the
brake to eject the piston (4), using the minimum
pressure required.
Remove the O-rings (2) and (3) from the piston (4).
If necessary, remove the bushings (5) of the self-

adjust kit from the piston (4), using tool 380200194
and a hammer.
Assembly
Collect the piston (4).
Push the washers (5) into the self-adjust seats
using tool 380200194 and a hammer, till they are
aligned with the piston supporting inner surface.
The bushings (5) must be aligned with the inner

supporting surface of the piston (4).
Assemble the new O-rings (2) and (3) into the pis-
ton (4).
Insert the piston (4) into the brake cylinder (1).
Place tool 380200238 onto the piston (4).

Place the piston (4) with one slot aligned with the oil
recirculation hole or with the brake inspection hole
in the brake cylinder (1).
Use a prybar to insert the piston into the brake
flange with a light pressure.
Insert the big spring, the small spring and the bush-
ing of the piston return kit (7) into the bigger hole of
the piston.
Assemble the cover and the screw of the piston

return kit (7).
Assemble the bushing, the washer and the screw of

the self-adjust kit (6).
Screw and tighten the screws of the 2 kits.
If you are to replace the brake discs, you have to

restore the initial piston position.
Remove the connections, the breathers and possi-
ble plugs from the brake oil inlets.
Bring the piston (4) to stroke end, using tool

Place the tool carefully so as not to damage the pis-
ton.
Check that the brake discs and the counterdiscs do

not show any sign of burning (otherwise replace
them).
If new brake discs are installed, soak them into pre-
scribed oil before assembly.
Reassemble all elements of the brake assy: the

brake counterdisc (8), the brake disc (9), the brake
disc carrier hub (10), the counterdiscs (11) and the
discs (12).
Orient the teeth correctly i.e. to the outside of the

brake disc carrier hub (10).
Reassemble the beam with the axle central body.
BRAKE DISC REPLACEMENT

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

Remove the brake components: the counterdiscs

(11), discs (12), the brake disc carrier hub (10), the
brake disc (9) and the brake counterdisc (8).
Check that the brake discs and the counterdiscs do

not show any sign of burning (otherwise replace
them).
If new brake discs are installed, soak them into pre-
scribed oil before assembly.
If you are to replace the brake discs, you have to

restore the initial piston position.
Remove the connections, the breathers and possi-
ble plugs from the brake oil inlets.
Bring the brake piston (4) to stroke end, using tool

place the special tool carefully so as not to damage
the piston.
Reassemble all brake elements: the brake counter-

disc (8), the brake disc (9), the brake disc carrier
hub (10), the counterdiscs (11) and the discs (12).
Orient the teeth correctly i.e. to the outside of the

brake disc carrier hub (10).
Reassemble the beam with the axle central body.

DIFFERENTIAL SUPPORT
Disassembly
Remove the brake.
Measure the starting preload FT0 of the bearings

(pinion-ring gear system) using a dynamometer
whose cord is wound on the end of the pinion shaft.
bearings.
Ensure the brake cylinder (6) to a lifting device

using its holes.
Loosen and remove the screw (7).
Remove the brake cylinder (6).

This operation releases the differential assy.
Disassemble the brake cylinder (6) and remove the
relevant O-ring (4).
Remove the differential (3) from the central body

(1).
Unscrew and remove the screw (10) and the ring

nut retainer (9) from the brake cylinder (6).
Unscrew and remove the ring nut (8) from the brake
cylinder (6) using tool 380200209.
Pull out the bearing cup (5) from the brake cylinder
(6) using a buffer and a hammer.
Assembly
Before assembling the differential, install the pinion
assy.
Lubricate and insert the new O-ring (2) on each side

of the central body (1).
Place the brake cylinder (6) on a flat surface and

force the bearing cup (5) using buffer 380200218.
Measure the outer diameter C of the ring gear

installed on the differential.
Calculate the value:
R = C/2 mm (in)
NOTE: this datum is required for the backlash
adjustment between pinion and ring gear.
Lubricate or assemble a new O-ring (4) into the seat

of the 2 brake cylinders (6).
Assemble the left brake cylinder into the central

body (1).
Check that the reference marks applied during dis-
assembly between the brake cylinders and the cen-
tral body coincide.
Insert the differential (3) into the central body (1).
The ring gear must be placed on the left side.
Assemble the right brake cylinder (6) into the cen-

tral body (1).
Check that the reference marks applied during dis-
assembly between the brake cylinders and the cen-
tral body coincide.
Tighten screw (7) in place (A).

Tighten the screw to the prescribed torque of 80 Nm
(59 lbf·ft).
Screw in the 2 screws M16 x 130 (S) in place (B)
and tighten them to the 80 Nm (59 lbf·ft) torque.
Tighten both ring nuts (8) with tool 380200209, till

the backlash is eliminated and slightly preload the
differential bearings.
Assemble tool 380200222 on the hole of the differ-

ential box.
Place a dial gauge and a feeler in contact and to
90° with respect to the surface of the tool and in cor-
respondence of value R.
Shift manually and alternately tool 380200222

bracket installed on the hole of the differential box.
Determine and note the backlash between pinion
and ring gear.
Turn the ring gear 1/4 of turn, determine and note
the backlash between pinion and ring gear.
Repeat this operation to get several values of the
backlash.
Check if the average backlash is within the
requested range:
0.15 ÷ 0.30 mm (0.006 ÷ 0.012 in)
If the backlash is not within the requested range,
carry out adjustment as follows.
Adjust the ring nuts (8) with tool 380200209.
Unscrew and tighten both ring nuts of about 30°
each, then check the backlash.
Adjust the ring nuts (8) remembering that:

- if the measured backlash is higher than the pre-
scribed tolerance range, tighten the ring nut on
the opposite side of the ring gear and loosen the
opposite ring nut by the same measure (A);
- if the measured backlash is lower than the pre-
scribed tolerance range, tighten the ring nut on
the ring gear side and loosen the opposite ring nut
by the same measure (B).
After pinion-ring gear backlash adjustment, check

that there is a minimum preload on the differential
box bearings.
tioned operations until the indicated conditions are
reached.

in.
lowing range:
FTm = FT0 ÷ (FT0 + 10) N
[FTm = FT0 ÷ (FT0 + 2.25) lbf]

splined end.
S WARNING S
All preloads must be measured without seal ring.

380200237.
range:
FTm = (FPm + 11.1) ÷ (FPm + 16.7) N
[FTm = (FPm + 2.5) ÷ (FPm + 3.7) lbf]
380200237 [gauge diameter Dm = 104.4 mm (4.11 in)].
NOTE: if you do not use the prescribed tool to

measure the total preload FTm, the reference diam-
eter is the diameter of pinion shaft splined end.
range:
FTm = (FPm + 33.4) ÷ (FPm + 50.2) N
[FTm = (FPm + 7.5) ÷ (FPm + 11) lbf]
where FPm is the preload of the pinion bearings.

ure the total rolling torque MT of the bearings (pin-
wrench 380000020.
S WARNING S
The total torque MT should be within the following

range:
MTm = (MP + 0.58) ÷ (MP + 0.87) Nm
[MTm = (MP + 0.43) ÷ (MP + 0.64) lbf·ft]
where MP is the preload of the pinion bearings.

check the assembly of each single component and
operate on the ring nuts of the differential support:
screw on the adjusting ring nuts by the same
value (A) unchanged;
- if the total preload is more than the given range,
unscrew the adjusting ring nuts by the same
value (B) unchanged.
Once all adjustment operations have been per-

formed, assemble the ring nut retainers (9), fasten-
ing them with the relevant screws (10).
13 Nm (9 lbf·ft).
Turn the ring nuts (8) as little as possible to allow
their assembly.
Remove the 2 additional screws M16 x 130 (S) from

both sides.
NON-SELF-LOCKING DIFFERENTIAL
Disassembly
Lock the differential with a clamp.
Loosen the screws (1) and remove the ring gear (2).
This operation releases also the two half boxes of
the differential.
Disassemble the 2 half boxes (4) and (12).

Apply reference marks on the 2 half boxes before
separating them.
Disassemble all parts and check their operating sta-
tus and wear condition.
Take out the bearings (3) and (13) from the half
boxes (4) and (12) using a puller.
Assembly
Assemble the bearings (3) and (13) on the half
boxes (4) and (12), using tool 380200188 and a
hammer.
Place the half boxes (4) and (12) on a workbench

and carefully assemble the inner elements: the dif-
ferential locking counterdiscs (5), the gear (6), the 2
pins (7), the planetary gears (8) and the thrust
washers (9).
Join the two half boxes (4) and (12), aligning the
reference marks made during disassembly.

gents.
Place the ring gear (2) on the differential box.
Apply sealant on the screw thread (1).
“LIMITED SLIP” DIFFERENTIAL
Disassembly
Lock the differential with a clamp.
Loosen the screws (1) and remove the ring gear (2).
This operation releases also the two half boxes of
the differential.
Disassemble the 2 half boxes (4) and (12).

Apply reference marks on the 2 half boxes before
separating them.
Disassemble all parts and check their operating sta-
tus and wear condition.
Take out the bearings (3) and (13) from the half
boxes (4) and (12) using a puller.
If necessary, take out the bushings (14) from the

half boxes (4) and (12).
Do not damage the bushing seats.
Assembly
If previously removed, insert bushings (14) into the
half boxes (4) and (12) using tool 380200205 and a
hammer.
Assemble the bearings (3) and (13) on the half

boxes (4) and (12), using tool 380200188 and a
hammer.
Place the half boxes (4) and (12) on a workbench

and carefully assemble the inner elements: differen-
tial locking counterdiscs (5), differential locking
discs (6) and (7), gears (8), 2 pins (9), planetary
gears (10) and thrust washers (11).
The first disc (7) must be oriented with friction face
towards the discs and with smooth face towards the
gear (8).
Join the 2 half boxes (4) and (12), aligning the refer-
ence marks made during disassembly.

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

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

pinion (1).
Once the pinion (1) has been removed, collect the

washers (4), (6) and (9), the spacer (5) and the
bearing (8).
Check the wear condition of the bearing cups.

Take out the bearing cups (3) and (8), if necessary.

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

replaced during reassembly.
Assembly
Position the axle central body onto a workbench.
Insert the bearing cups (3) and (8) into their seats
using kit 380200216.
Use the false pinion 380200202 and false differen-

tial box 380200217.
Insert the bearing and the false pinion into the
seats.
Tighten the ring nut, until the backlash is eliminated.
Check the correct place of the differential box sup-

ports at the right and left side, using the reference
marks applied on the same and on the central body.
Assemble the 2 brake cylinders, fastening them
with the relevant screws.
Insert the false differential box 380200217 into the

central axle body.
Check that the false differential box is inserted in
both seats of the differential supports.

with a depth gauge.
X = (A + C) - B mm (in)
From the value “X” deduct the value “V” (stamped

on the pinion head) to get the value “S”.
S = X - V mm (in)
Choose the shim with value (S) from the shim range
available.
SHIM RANGE
Shims
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm
(0.098) (0.102) (0.106) (0.110) (0.114) (0.118) (0.122) (0.126) (0.130) (0.134)
(in)
Q.ty - - - - - - - - - -
Loosen and remove the ring nut (10).

Remove the false pinion 380200202 and the bear-
ings (3) and (8) from the central body (7).
Disassemble the false differential box 380200217
from the brake cylinders and then unscrew the
screws to remove the brake cylinders.

pinion head.
Insert the bearing (3) on the pinion shaft (1) using a

press and tool 380200190.
Insert the shim (4) and a new spacer (5) and the
shim (6).

Insert the preassembled pinion (1) into the central

body and the bearing (8) into the pinion shaft.
Assemble the bearing (8) with tool 380200190 and
a hammer.
Insert the ring nut retaining washer and tighten the

new ring nut (10) on the pinion shaft.
Tighten the ring nut (10) using wrench (T1)
380000021 and the pinion retainer (T2) 380000020
with 3/4” standard connection.
The torque setting is given by the preload measure-
ment on bearings.
Tighten the ring nut (10) gradually.
Excessive tightening could damage the spacer (5),
that would need to be replaced and the procedure
to be repeated.
When you check the preload, strike the pinion ends
(1) with a soft hammer to favour the seating of the
bearings.
the preload FPm, use a dynamometer whose cord is
wound on the end of the pinion shaft.
S WARNING S
Use this method only if the bearings are not
replaced.

range:
FPm = FP0 ÷ (FP0 + 10) N
[FPm = FP0 ÷ (FP0 + 2.25) lbf]
If the bearings are new, to measure the preload

FPm, use a dynamometer whose cord is wound on
tool 380200237, inserted on the end of pinion shaft.

(4.50 in)].
range:
FPm = 31 ÷ 46 N
[FPm = 6.97 ÷ 10.34 lbf]

range:
FPm = 92 ÷ 138 N
[FPm = 20.68 ÷ 31.02 lbf]
It is possible to measure the rolling torque MP of the

pinion shaft bearings with a torque meter and the
wrench 380000020.
S WARNING S
The measured value MP should be within this

range:
MP = 1.6 ÷ 2.4 Nm
[MP = 1.18 ÷ 1.77 lbf·ft]

caulk the ring nut (10) using a hammer and a
punch.
Assemble the differential assy (3).

TOE-IN / STEERING ANGLE
Toe-in check
Assemble 2 identical, 1 m long linear bars on the
wheel sides and lock them with 2 nuts on the wheel
hub stud screws.
S WARNING S
The 2 bars should be fixed on their middle so that
they are perfectly perpendicular to the supporting
surface and parallel to the pinion axis; align the 2
bars.
Measure with a tape measure the distance (M)

between bar ends.
NOTE: keep the minimum value, swinging the
measurement point.
Check that the difference between the measure-

ments at the ends of the wheel hub diameters is
within the required tolerance range.
The nominal toe-in (A) value is referred to the exter-
nal diameter of the wheel hubs flange, therefore the
measured toe-in value (M) at the bar ends must be
related to the ratio between length of the bar and
flange diameter:
nominal toe-in = A±1 J measured toe-in = M±3
If toe-in is not correct, operate with two wrenches

on the rods (1) screwing in and out the two tie rods
(3) equally, till the toe-in is within the requested tol-
erance.
Once this adjustment has been performed, screw

in the nuts (2) of the bars (1) and tighten them to
a 250 Nm (184 lbf·ft) torque.
Steering angle adjustment

Use the same bars assembled for toe-in adjustment
and a long bar perfectly rested on the machined
part of the central body (pinion side), so that, at
maximum steering, the two bars form an acute
angle.
In order to set the steering angle, adjust a goniome-

ter according to the angle measure (C), calculated
as follows:
C = 90° - S
Where (S) is the prescribed steering angle set.
Place the goniometer on the long bar.
Orient the left wheel assy until the calculated angle
(C) is obtained between the two bars.
Apply the prescribed sealant on the screw thread

(4).
Carry out the adjustment of the mechanical lock,
screwing in and out the relevant screws (4), locking
them afterwards with the nuts (5).
Check that the locks on the opposite sides are both

in contact with the axle beam.
Completely steer to the opposite side and repeat

the same operations described previously.
Check that the locks on the opposite sides are both

in contact with the axle beam.
SPECIAL INTERVENTIONS
Disassembly of wheel assy and double joint

Drain the oil from the differential.
Loosen and remove the nut (1) and disconnect the
tie rod (3) from the swivel housing.
S WARNING S
Do not hit the end of the threaded pin of the tie rod
(3) during disassembly.
Do not unscrew the tie rod (3) and the relevant nut
(4) so as not to impair the wheel toe-in.
Ensure the swivel housing to a lifting device with a

rope.
Unscrew and remove the screws (5) and (9) from
the upper (6) and lower (10) king pins.
Remove the king pins (6) and (10).
Remove the wheel hub assy.

Assembly of wheel assy and double joint

Assemble the wheel hub assy.
Grease the king pin seats (6) and (10).

Position the belleville washers on the king pin seats.
Assemble the lower (10) and the upper (6) king
pins.
Assemble the upper (6) and lower (10) and king

pins by fastening the screws (9) and (5) to the pre-
Insert the ball joint of the tie rod (3) into its seat on
the swivel housing (1) by turning the swivel housing
as much as necessary.
Do not unscrew the tie rod (3) and the relevant nut
(4) so as not to impair the wheel toe-in.
Screw in and tighten the nut (2) to a tightening

Check the differential oil level from the hole of the

oil inlet plug (14) and top up if necessary.
Screw in and tighten the plug (14) to the tighten-
Replacement of the seal ring of the double joint

Remove the wheel assy and the double joint.
Take out the seal ring (11), paying attention not to
damage its seat.
Assemble the new seal ring (11) with the buffer

Check the correct place of the seal ring (11) accord-

ing to the axle type.
Replacement of the bronze bushing of the dou-

ble joint
Remove the wheel assy and the double joint.
Extract the seal ring (11).
Remove the bronze bushing (13) with a puller, pay-
ing attention not to damage its seat.
Insert the new bronze bushing (13) with the buffer

Assemble the seal ring (11).

Brake wear check

Actuate the service brake with machine stopped.
Unscrew the breather to release the inner pressure.
Unscrew and remove the plug (1).
Check the wear condition of the brake disc friction

face by trying to insert between the counterdiscs a
dowel with 4.08 mm (0.16 in) of diameter.
If the dowel cannot be inserted, the brake discs
must be replaced because worn out.
If the dowel can be inserted, the brake discs must
not be replaced.
Screw in the plug (1) with a dynamometric wrench.

Carry out the check of the other brake assy.
TROUBLESHOOTING

on both tyres.

on both tyres.

on both tyres.


on both tyres.

during steering.

on both tyres.


on both tyres.


gear set.

broken. the one expected.
Follow carefully recommended
marks detection.
Pinion nut loose.
broken.
Pinion nut loose.
marks detection.
damaged or scored.
Contaminated lubricant. Replace worn out pinion bearings
additives.
intervals.
and ring gear.
overheated. Check if gear temperature. Use proper lubricant, fill up to right
teeth have faded.
Unsuitable lubricant. level and replace at recommended
intervals.
Oil level low.
intervals.
Damaged vehicle.
Crash load.

intervals.
Normal wear.
Pinion nut loose.
intervals.

flange spline.

break.
(stop line).
Lubrication wrong.
intervals.

out.
intervals.
flange.
not too loud.
is increased).
damaged.

damaged.

REPAIR TIMES
minutes.
from the machine.

Flange Replacement of pinion seal ring 30
Rod replacement (x 1) 30
Ball joint replacement (x 1) 15
Tie rod replacement (x 1) 30
Ball joint boot replacement (x 1) 15
Steering cylinder Tie rod boot replacement (x 1) 15
Sensor replacement 15
Steering cylinder replacement 120
Steering cylinder overhauling 240
Sensor replacement and adjustment 60
Gear carrier replacement 20
Reduction gear assy Gear carrier overhaul (3 planetary gears) 35
Gear carrier overhaul (4 planetary gears) 45
Standard wheel hub replacement 30
Seal ring + wheel hub bearing replacement 75
Stud bolt replacement (x 1) 5
Swivel housing overhauling 90
Swivel housing replacement 70
Wheel hub
Double joint replacement 30
Double joint overhauling 60
King pin replacement (x 1) 30
King pin bearing replacement (x 1) 45
Ring gear replacement (x 1) 30
Ball joint replacement (x 1) 45
Replacement of the seal rings of the double joint 45
Axle shaft Cardan joint bronze bushing replacement 60
Disc and counterdisc replacement (for each side) 60
Overhaul / replacement of piston seal rings (for each side) 90
Brake Self-adjust kit replacement (for each side) 60
Overhaul / replacement of piston (for each side) 90
Overhaul / replacement of O-ring (for each side) 30
Replacement of differential assy 150
Differential box bearings 120

Differential replacement 150
Differential Overhaul / replacement of bevel gear, planetary gears, pins 240
Overhauling / replacement of differential box bearings 120
Overhauling / replacement of pinion bearings 180
Pinion
Overhaul / replacement of bevel gear, planetary gears, pins 240
SPECIAL TOOLS
380200190 Buffer Assembly of pinion bearing cups
380200192 Buffer Assembly / disassembly of bushings in the ring gear carrier hub
380200195 Buffer Ball bearing assembly of the lower king pin
380200196 Buffer Ball bearing assembly of the upper king pin
380000024 Buffer Bushing assembly into the swivel housing
380200205 Buffer Assembly of bushings into the differential box
380200209 Wrench Tighten / loosen the brake cylinder ring nut
380200210 Buffer Wheel hub seal ring assembly
380200211 Buffer Assembly of bearing cups into the wheel hub
380200216 Kit Assembly of pinion bearing cups
380200218 Buffer Assembly of bearing cup into the brake cylinder
380200222 Tool Backlash measure between pinion and ring gear
380200227 Buffer Assembly of bushing in the half-beam
380002226 Buffer Assembly of seal ring in the half-beam
380200237 Tool Preload measure
380200238 Buffer Brake piston assembly
380200266 Buffer Seal ring assembly into the swivel housing
380200267 Buffer Pinion seal ring assembly

NOTES:
580ST
590ST
695ST
SECTION 33 - BRAKE SYSTEM
PARKING BRAKE............................................................................................................................................. 3
OPERATION................................................................................................................................................ 3
ADJUSTMENT............................................................................................................................................. 4
SERVICE BRAKE ........................................................................................................................................... 15

OPERATION.............................................................................................................................................. 15
BRAKE PUMP - Remove........................................................................................................................... 16
BRAKE PUMP - Install............................................................................................................................... 18
2 SECTION 33 - BRAKE SYSTEM
SECTION 33 - BRAKE SYSTEM 3
PARKING BRAKE
This device allows the immobilization of the
machine each time it must be parked or stopped to
carry out maintenance work.
Type ....................................................................................................................................... manual, with lever
Maximum lever pull ....................................................................................................................1650 N (371 lbf)
Lever stroke ............................................................................................................................... 21 mm (0.87 in)
Maximum torque - Powershuttle ..........................................................................................2000 Nm (450 lbf·ft)
Maximum torque - Powershift ..............................................................................................1500 Nm (337 lbf·ft)
OPERATION
The parking brake essentially consists of:
- manual control lever;
- transmission brake.
The lever (1) is located on the right side of the cab

(seat placed to loader attachment).
The lever position (1) is controlled by the sensor (2),
when the lever is lifted to immobilize the machine,
the lamp (3) indicating the parking brake activation
and placed on the side instrument panel (4), lights
on.
IMPORTANT: if the gear is engaged when the park-
ing brake is activated, it will actuate the warning
buzzer and the symbol “parking brake alarm” will
appear on the display.
By lifting the lever (1), by means of cable (5) and of
the relevant yoke (7), the brake is actuated inside
transmission (6).
NEGATIVE PARKING BRAKE OPERATION

Negative parking brake applied (A)
When the system is not under pressure, the bel-
leville washers (1) push on the parking brake piston
(2) compressing the brake discs (3).
This happens when the machine motor is stopped
or because the operator has actuated the parking
brake.
In order to move the machine disable the parking
brake.
Negative brake released (B)

When the brake oil reaches the disengagement
pressure, the parking brake piston (2) is pushed
against the belleville washers (1) and the brake
discs (3) are free.
This happens under normal operating condition,
when the operator disengages the parking brake.
ADJUSTMENT
The parking brake can be adjusted by placing the
brake pad in contact with the disc, now you have to
block the brake cable.
The brake cable movement (1) can be adjusted by
handling on the locknut (2).
Adjust the parking brake so as to brake the machine
completely by lifting the brake lever up to the 4th
ratchet.
MECHANICAL PARKING BRAKE ADJUSTMENT PROCEDURE

Check operation of parking brake (the lever has to
do 4/5 shots and the car should start moving into 3rd
gear at 1700 rpm).
TBR00125
Step 10 - Bring the parking brake adjustment nut
(Ref. 1) from the position 1 to position 2 (nearly 50
mm).
Step 20 - Insert a 50 mm calibrated shim (Ref. 2)
and set the adjustment nut at end stroke position (to
reach the calibrated shim wall).
Step 30 - Lock the adjustment nut in that position
tightening the lock nut (Ref. 3)

These procedures deal with the parking brake sec-
tion and leave off the control lever and the relevant
connection cable.
1. Screw 10. Piston

2. Washer 11. Snap ring
3. O-ring 12. O-ring
4. Flange 13. Stop plate
5. Screw 14. O-ring
6. Brake cover 15. Disc
7. O-ring 16. Brake discs
8. Belleville washer 17. Hub
9. O-ring
DISASSEMBLY
Loosen the screw (1).
Remove the O-ring (3) and the flange (4).
Loosen the screws (5).

Remove all screws (5), the screws (A) and alter-

nately loosen the screws (B) to release the load
from the belleville washers.
NOTE: the housing is under spring pressure, failure
to follow the instructions will result in serious injury
or damage to the equipment.
Remove the brake cover (6).

Remove the brake discs (16).

Remove the retaining plate (13).
Remove the O-rings (12) and (14) from the retaining

plate.
Compress the belleville washers, to remove the

snap ring (11).
Remove the piston (10) from the brake cover (6).

Remove the O-ring (9) from the piston (10).
Remove the belleville washers (8) from the brake

cover (6).
INSPECTION
Inspect the brake discs and plates for pitting, scor-
ing, excessive surface wear and other damage.
Inspect the belleville washer for cracking and exces-
sive surface wear at contact points.
Inspect brake pistons and housing for scratches on
their sliding surfaces, and contact surfaces for pit-
ting or excessive wear.
Replace the O-rings.
ASSEMBLY
Assemble the new O-ring (7) on the brake cover (6).
Assemble the belleville washers (8).
Assemble the new O-ring (9) on the piston (10).
Lubricate and install the piston (10) into the brake

cover (6).
Compress the belleville washers, to assemble the

snap ring (11).
Assemble new O-rings (12) and (14) onto the

retaining plate.
Lubricate and install the retaining plate (13) into the

brake cover (6).

Assemble the brake discs (16).
Assemble the brake cover assembly.

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

Screw in the screw (1) with the washer (2).

(102 lbf·ft).
SERVICE BRAKE
During operation, the brake system of the machine
can stop the machine at any time.
2WS
Type ........................................................................................................ wet multi-discs, 4 x axle (2 x half axle)
4WS
Type ........................................................................................................ wet multi-discs, 6 x axle (3 x half axle)
OPERATION
This system essentially consists of:
- brake pedals (in the cab);
- wet disc brakes hydraulically operated in the rear
axle.
NOTE: this drawing represents the 2WS rear axle; By pushing the pedals (1) you activate the brake
the operation of the 4WS rear axle is the same. pump (3) delivering hydraulic oil to the 2 brake
discs (5) fitted in the rear axle (6).
The two pedals (1) located in the cab underneath
the steering wheel, can be matched with the locking In this way, pressure is generated against the brake
pin (2). pistons (7), which, on their turn, compress the discs
(9) and the counterdiscs (8), thus locking the axle
This enables:
and therefore the machine.
- the machine braking (pedals locked together);
- the machine turning (by pushing just one pedal).
BRAKE PUMP - Remove

Park the machine on a level surface. Raise the
loader and lock the support strut to hold the loader.
Open the engine hood and remove the DPF system
from the machine following the procedure
described in section 10, Engine Remove.
TBR00094
Tag and disconnect from brakes pump (1) the

hydraulic hoses in (2), and (3), the hydraulic hoses
brake right (4) and left (5).
5
4
TBR00093
From inside cab operator remove the steering

wheel column cover.
TBR00095
Remove the cotter pins (1) and clevis pins (2).
1 2
TBR00096
From the engine side secure the brake pump to a

lifting equipment.
Loosen and remove the nuts (1) and washers (2)
that fasten the brake pump (3) to the frame (4). 4
Remove the brake pump (3) from the frame (4).
1
TBR00097
BRAKE PUMP - Install

Hold the brake pump (3) in alignment with the holes
in the frame (4) and install the washers (2) and nuts
(1) that fasten the brake pump (3) to the frame (4).
Remove the lifting equipment. 4
TBR00097
Connect to the brake pump (1) the hydraulic hoses

(2) and (3), the hydraulic hoses brake right (4) and
left (5).
5
4
TBR00093
Put the clevis on the brake pump in position on the

brake pedal. Install the clevis pins (2) that fastens
the clevis to the brake pedal. Install the cotter pins
(1) in the clevis pins.
1 2
TBR00096
Using the adjustment bolts, adjust left and right pedals

to the height H shown:
H = 106÷108 mm (4.17÷4.25 in) for non-floormat units;
H = 126÷128 mm (4.96÷5 in) for floormat units.
Then tighten the adjustment bolt nuts.
Dimensions apply before floormat installation.
The brake valve pushrods (1) should then be
rotated in order to achieve 1÷2 mm (0.039÷0.078
in) of free play measured at the pedal pad.
Then tighten the nuts on each pushrod to lock the 1
clevises.
After proper adjustment, when the pedals are in
their at-rest position, the clevis pins should be free.
TBR00098
From inside cab operator install the steering wheel

column cover.
TBR00095
Install the DPF system on the machine by following

the procedure described in section 10, Engine -
Install.
TBR00099
NOTE:
580ST
590ST
695ST
SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC DIAGRAMS ................................................................................................................................. 3

HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS....................................................... 3
HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .................................................................... 9
HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS..................................................... 13
HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS .................................................................. 15
HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .......................................................... 17
HYDRAULIC PUMP........................................................................................................................................ 19
HYDRAULIC FIXED-FLOW-RATE GEAR PUMP...................................................................................... 19
HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP ........................................................................... 30
CONTROL VALVES ....................................................................................................................................... 44

LOADER CONTROL VALVE ..................................................................................................................... 53
BACKHOE ATTACHMENT CONTROL VALVE......................................................................................... 57
RELIEF VALVES ....................................................................................................................................... 69
BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE .................................................. 78
ACCUMULATOR “AUTO GLIDE RIDE” PARKER.......................................................................................... 81

MAINTENANCE......................................................................................................................................... 81
SAFETY ..................................................................................................................................................... 81
CHECKING AND ADJUSTING THE PRECHARGE PRESSURE ............................................................. 82
HYDRAULIC SWING SYSTEM ...................................................................................................................... 84

OPERATION.............................................................................................................................................. 84
HYDRAULIC CYLINDERS.............................................................................................................................. 87
LOADER ATTACHMENT BOOM CYLINDER ........................................................................................... 88
LOADER BUCKET CYLINDER ................................................................................................................. 93
4X1 LOADER BUCKET CYLINDER .......................................................................................................... 97
BACKHOE BOOM CYLINDER ................................................................................................................ 100
BACKHOE ATTACHMENT DIPPER CYLINDER .................................................................................... 104
2 SECTION 35 - HYDRAULIC SYSTEM
BACKHOE BUCKET CYLINDER............................................................................................................. 108

TELESCOPIC CYLINDER ....................................................................................................................... 112
STABILIZER CYLINDER - CENTER PIVOT (695ST).............................................................................. 115
STABILIZER CYLINDER - SIDESHIFT ................................................................................................... 119
SWING CYLINDER.................................................................................................................................. 123
BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT .................................................................. 127
SPECIAL TOOLS..................................................................................................................................... 128
HYDRAULIC CONTROL LEVERS................................................................................................................ 129

CONTROLS AND OPERATION .............................................................................................................. 130
COMPONENTS ....................................................................................................................................... 131
CONTROL LEVER VALVE ...................................................................................................................... 136
TROUBLESHOOTING .................................................................................................................................. 138

PRELIMINARY CHECKS......................................................................................................................... 138
TROUBLESHOOTING (WITH “REXROTH” CONTROL VALVES).......................................................... 139
SWING ..................................................................................................................................................... 141
HYDRAULIC PUMP ................................................................................................................................. 142
SECTION 35 - HYDRAULIC SYSTEM 3
HYDRAULIC DIAGRAMS
HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS

WITH FIXED-FLOW-RATE GEAR PUMP
* Alternative diagram for non-reactive steering

1. Front axle steering cylinder

2. Power steering
3. 4x1 bucket cylinders
3A. Lock valve
3B. 4x1 EH valve
4. Loader bucket cylinders
4A. Lock valve
5. Boom cylinders
5A. Lock valve
6. Ride control valve (optional)
7. Ride control accumulator (optional)
8. Loader attachment control valve
9. Hand hammer control valve (optional)
10. Backhoe hammer control valve (optional)
11. Hand hammer (optional)
12. Backhoe hammer (optional)
13. Hydraulic fixed-flow-rate gear pump
14. Priority valve
15. Oil cooler
16. Hydraulic tank
17. Air filter
18. Oil filter
19. Backpressure valve
20. Return manifold
21. Backhoe attachment travel lock cylinders (sideshift)
22. Stabilizer right cylinder
22A.Lock valve
23. Stabilizer left cylinder
23A.Lock valve
24. Dipper cylinder
24A.Lock valve
25. Bucket cylinder
26. Swing cylinders
27. Swing control valve
28. Boom cylinder
28A.Lock valve
29. Telescopic cylinder
30. Backhoe attachment control valve
31. Backhoe quick coupler (optional)
32. Backhoe quick coupler control valve (optional)
33. Diagnostic
WITH FIXED-FLOW-RATE GEAR PUMP - WITHOUT BACKHOE ATTACHMENT SWING CONTROL VALVE

2. Power steering
3A. Lock valve
4A. Lock valve
5. Boom cylinders
5A. Lock valve
13. Hydraulic fixed-flow-rate gear pump
14. Priority valve
15. Oil cooler
16. Hydraulic tank
17. Air filter
18. Oil filter
20. Return manifold
22A.Lock valve
23A.Lock valve
24. Dipper cylinder
24A.Lock valve
25. Bucket cylinder
26. Swing cylinders
27. Diagnostic
28. Boom cylinder
28A.Lock valve
WITH VARIABLE-FLOW-RATE PISTON PUMP


2. Power steering
3A. Lock valve
3B. 4x1 EH valve
4A. Lock valve
5. Boom cylinders
5A. Lock valve
13. Hydraulic variable-flow-rate piston pump
14. Priority valve
15. Oil cooler
16. Hydraulic tank
17. Air filter
18. Oil filter
20. Return manifold
22A.Lock valve
23A.Lock valve
24. Dipper cylinder
24A.Lock valve
25. Bucket cylinder
26. Swing cylinders
27. Diagnostic
28. Boom cylinder
28A.Lock valve
31. Bidirectional auxiliary attachment (optional)
HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS

WITH FIXED-FLOW-RATE GEAR PUMP


2. Power steering
3A. Lock valve
3B. 4x1 EH valve
4A. Lock valve
5. Boom cylinders
5A. Lock valve
13. Hydraulic fixed-flow-rate piston pump
14. Priority valve
15. Oil cooler
16. Hydraulic tank
17. Air filter
18. Oil filter
20. Return manifold
22A.Lock valve
23A.Lock valve
24. Dipper cylinder
24A.Lock valve
25. Bucket cylinder
26. Swing cylinders
28. Boom cylinder
28A.Lock valve
34. Diagnostic
35. Left-hand hydraulic control lever
35A.Left hydraulic control lever - boom - dipper
35B.Left hydraulic control lever - swing
36. Right-hand hydraulic control lever
36A.Right hydraulic control lever - boom - dipper
36B.Right hydraulic control lever - swing
37. Pilot control manifold
WITH VARIABLE-FLOW-RATE PISTON PUMP


2. Power steering
3A. Lock valve
3B. 4x1 EH valve
4A. Lock valve
5. Boom cylinders
5A. Lock valve
14. Priority valve
15. Oil cooler
16. Hydraulic tank
17. Air filter
18. Oil filter
20. Return manifold
22A.Lock valve
23A.Lock valve
24. Dipper cylinder
24A.Lock valve
25. Bucket cylinder
26. Swing cylinders
28. Boom cylinder
28A.Lock valve
35A.Left hydraulic control lever - boom - dipper
36A.Right hydraulic control lever - boom - dipper
36B.Right hydraulic control lever - swing
HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS
5B

2. Rear axle steering cylinder
3. 4WS steering control valve
4. Power steering
5A. Lock valve
5B. 4x1 EH valve
6A. Lock valve
7. Boom cylinders
7A. Lock valve
15. Hydraulic variable-flow-rate pump
16. Priority valve
17. Oil cooler
18. Hydraulic tank
19. Air filter
20. Oil filter
21. Return manifold
26A.Lock valve
27A.Lock valve
28. Dipper cylinder
28A.Lock valve
29. Bucket cylinder
30. Swing cylinders
32. Boom cylinder
32A.Lock valve
33. Telescopic dipper cylinder (optional)
HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS


4. Power steering
5A. Lock valve
5B. 4x1 EH valve
6A. Lock valve
7. Boom cylinders
7A. Lock valve
16. Priority valve
17. Oil cooler
18. Hydraulic tank
19. Air filter
20. Oil filter
22. Return manifold
25A.Lock valve
26A.Lock valve
27. Dipper cylinder
27A.Lock valve
28. Bucket cylinder
29. Swing cylinders
31. Boom cylinder
31A.Lock valve
32. Telescopic dipper cylinder (optional)
36A.Boom or dipper right hydraulic control lever
36B.Hydraulic control lever right-bucket
37. Backhoe attachment control valve solenoid valve
37A.Boom or dipper left hydraulic control lever
HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS


4. Power steering
5A. Lock valve
6A. Lock valve
7. Boom cylinders
7A. Lock valve
16. Priority valve
17. Oil cooler
18. Hydraulic tank
19. Air filter
20. Oil filter
22. Return manifold
25A.Lock valve
26A.Lock valve
27. Dipper cylinder
27A.Lock valve
28. Bucket cylinder
29. Swing cylinders
31. Boom cylinder
31A.Lock valve
35A.Boom or dipper left hydraulic control lever
36A.Boom or dipper right hydraulic control lever
36B.Hydraulic control lever right-bucket
HYDRAULIC PUMP
The machine can be provided with 2 types of
hydraulic pump:
- fixed-flow-rate gear pump;
- variable-flow-rate piston pump.
Further to the type, pumps differentiate according to
the motor:
- 72 kW (97 HP) motor;
- 82 kW (110 HP) motor.
HYDRAULIC FIXED-FLOW-RATE GEAR

PUMP
The hydraulic pump is mounted on the rear part of
the transmission and is driven by a shaft directly
connected to the engine splined to the torque con-
verter.
The pump consists of two pumping elements, the
front pump (1) and the rear pump (2), and a load-
sensing flow divider valve (3) for the steering sys-
tem.
Oil is drawn through the common inlet port into both
pumping elements.
The front pump flow is directed to the loader and
backhoe attachment control valve and also to the
sideshift carriage lock cylinders.
The rear pump flow passes through the flow divider
valve, which maintains priority oil flow to the steer-
ing system, with the remaining flow used for the
loader and backhoe control valves.
Pump 72 kW - 97 HP (580ST)
Model .......................................................................................................... CASAPPA KP 30.34 - 05 S6 - LMF
Type ...................................................................................................................................... double gear pump
Displacement ............................................................................. 35.427 + 35.427 cm3/rev (2.16 + 2.16 in3/rev)
Pump 82 kW - 110 HP (590ST - 695ST)
Model .......................................................................................................... CASAPPA KP 30.38 - 05 S6 - LMF
Type ...................................................................................................................................... double gear pump
Displacement ............................................................................. 40.258 + 35.427 cm3/rev (2.45 + 2.16 in3/rev)
PUMP (97 HP ENGINE) 1st PUMP 2nd PUMP

Direction of rotation (looking on drive
Clockwise (D)
shaft)
35.427 cm3/rev 35.427 cm3/rev
Displacement
(2.16 in3/rev) (2.16 in3/rev)
Inlet pressure range for pump 0.7 - 3 bar (10 - 43 psi)
Maximum continuous pressure P1 260 bar (3771 psi) 260 bar (3771 psi)
Maximum intermittent pressure P2 280 bar (4061 psi) 280 bar (4061 psi)
Maximum peak pressure P3 300 bar (4351 psi) 300 bar (4351 psi)
Operating temperature -25 to +80 °C (-13 to +176 °F)
min P1 350 rpm
Speed
max P1 3000 rpm
recommended 2
12 to 100 mm /s (0.47 to 3.93 in/s²) (cSt)
Viscosity range
permitted max 750 mm2/s (29.53 in/s²) (cSt)
Dp > 200 bar (2900 psi) 8 - Nas 1638
bx = 75 - 10 mm (3.0 - 0.39 in) 19 / 17 /14 - ISO 4406
Contamination class
Dp < 200 bar (2900 psi) 10 - Nas 1638
bx = 75 - 25 mm (3.0 - 0.98 in) 21 / 19 /16 - ISO 4406
Relief valve 177 ± 3 bar (2567 - 43 psi)
Stand by pressure load sensing valve 7 bar (102 psi)
Weight 30 kg (66 lb)
PUMP (110 HP ENGINE) 1st PUMP 2nd PUMP

Direction of rotation (looking on drive
Clockwise (D)
shaft)
40.258 cm3/rev 35.427 cm3/rev
Displacement
(2.45 in3/rev) (2.16 in3/rev)
Inlet pressure range for pump 0.7 - 3 bar (10 - 43 psi)
Maximum continuous pressure P1 260 bar (3771 psi) 260 bar (3771 psi)
Maximum intermittent pressure P2 280 bar (4061 psi) 280 bar (4061 psi)
Maximum peak pressure P3 300 bar (4351 psi) 300 bar (4351 psi)
Operating temperature -25 to +80 °C (-13 to +176 °F)
min P1 350 rpm
Speed
max P1 3000 rpm
recommended 12 to 100 mm2/s (0.47 to 3.93 in/s²) (cSt)
Viscosity range
permitted max 750 mm2/s (29.53 in/s²) (cSt)
Dp > 200 bar (2900 psi) 8 - Nas 1638
bx = 75 - 10 mm (3.0 - 0.39 in) 19 / 17 /14 - ISO 4406
Contamination class
Dp < 200 bar (2900 psi) 10 - Nas 1638
bx = 75 - 25 mm (3.0 - 0.98 in) 21 / 19 /16 - ISO 4406
Relief valve 177 ± 3 bar (2567 - 43 psi)
Stand by pressure load sensing valve 7 bar (102 psi)
Weight 30 kg (66 lb)
Tightening torques
TBR00109
Hydraulic diagram
LOAD-SENSING VALVE
1. Orifice 8. Steering relief valve

2. Rear systems (EF) 9. Relief valve adjuster
3. Filter 10. Poppet
4. Spool 11. Return to inlet pump port
5. To steering priority flow (CF) 12. Lock plug
6. Orifice 13. Load sensing signal (LS)
7. Inlet port from rear pump (IN) 14. Orifice
When the steering is in neutral the LS port is con-

nected to the unload (through the steering) and the
steering inlet port (CF) is open.
Load sensing valve with pump running - Steering in neutral

Return to oil tank
Trapped oil
Pressure oil
1. Orifice 5. To steering priority flow (CF)
2. Rear systems (EF) 6. Orifice
3. Filter 7. Inlet port (from rear port)
4. Spool
The pressure on (CF) increases until the pressure value (stand-by pressure) is sufficient to move the spool
valve in a way to divert the flow toward (EF).
Load sensing valve with pump running - Steering working

Trapped oil
Return to oil tank
1. Orifice 5. To steering priority flow (CF)
2. Rear systems (EF) 6. Orifice
3. Filter 7. Inlet port (from rear port)
4. Spool
During steering two actions are performed:

1. The fluid moves to the steering through (CF).
2. The (LS) signal is in communication to the steering.
COMPONENTS
1. Screw 19. Bushing

2. Steering control valve 20. Gasket
3. Spool 21. Bushing
4. O-ring 22. Elastic retainer
5. Plug 23. Bearing
6. Valve 24. Gear
7. Filter 25. Gear
8. Fitting 26. Front pump body
9. Spring seat 27. Gasket
10. Spring 28. Gear
11. O-ring 29. Flange
12. Cover 30. Seal ring
13. Relief valve 31. Seal ring
14. O-ring 32. Snap ring
15. Poppet 33. Pressure seal
16. Spring 34. Gear
17. Seat 35. O-ring
18. Rear pump body 36. Screw

Disassembly of the steering control valve
To aid reassembly draw an alignment line along the
total length of the pump assembly.
Remove the screws (1).
Remove the load-sensing steering control valve (2).

Check and replace the O-rings (35), if necessary.
Disassembly of the steering control valve

Do not disassemble the steering system relief valve
(A) if the valve’s pressure is to specification when
pressure-testing the pump prior to overhaul.
NOTE: if the steering system pressure relief valve is
disassembled, the valve must be reset as described
in Chapter “Troubleshooting, pressure and flow test-
ing”.
Wash all components in an approved degreaser
and check the following:
- the valve bore must be free from scoring or dam-
age to metering edges;
- the spool (3) should slide freely in the bore and
must be free from scoring or damage;
- ensure all orifices are clean;
- the valve seat must not show cavities or damage
(a small chamfer at the entrance of the bore is
allowed);
- examine the filter (7) mounted inside the outlet
and relief valves and replace the filter if dirty.
Pressure and flow test the pump.
Rear pump disassembly

Remove the rear pump assembly (18).
IMPORTANT: prior to disassembly and to ensure

correct reassembly identify the position of each
bearing block in the pump body as described below.
Write an identifying letter “A” and “B”, “C” and “D” on
the pump housing and in the channel of each bear-
ing block.
NOTE: orientation of bearing block seals relative to

oil port.
If scribe is not available take care to keep bearing
blocks in pairs.
Disassemble the gears (24), the seals (33), the

elastic retainers (22) and the bearings (23).
Wash all components in approved degreaser.
Inspect the wear track cut by the gears in pump

body. The body can be reused if the track is bright
and polished and does not exceed 0.08 ÷ 0.076 mm
(0.0031 ÷ 0.0029 in) in depth.
Examine bearing block faces for scoring and flat-
ness, paying particular attention to the face which
abuts the gears.
Examine bearing block bushes for scoring.
Examine pump gears for scored or worn side faces,
journals and damaged teeth.
If pump block, gears or bearing blocks are worn and
require replacement the pump assembly must be
replaced.
Re-assemble using the disassembly procedure in
reverse order and observe the following warnings:
- ensure that all parts are perfectly clean and lubri-
cate bushes and gears with clean hydraulic fluid;
- replace all seals and O-rings;
- install the bearing blocks into the same positions
from which they were removed, using the identifi-
cation letters written during disassembly;
- ensure plastic back-up seals are correctly posi-
tioned in the rubber seal.
Front pump disassembly

To remove the pump assy (26) from the flange (29)
it is necessary to remove the snap ring (33).
Remove and replace the seal rings (30) and (31).
Identify and note the position of each bearing block

to ensure correct reassembly.
Disassemble the gears (28) and (34), the seals
(33), the elastic retainers and the bearings (23).
Wash all components in approved degreaser.
Inspect the wear track cut by the gears in the inlet

side of the pump body. The body can be reused if
the track is bright and polished and does not
exceed 0.15 mm (0.006 in) in depth.
Examine bearing block faces for scoring.
Inspect teflon coated bearings in body or flange for
wear. If bearings are worn the bronze backing will
be revealed.
Examine pump gears for scored or worn side faces,
journals and damaged teeth.
Examine flange seal contact area on driveshaft. If
pump block, gears, bearing blocks or drive shaft are
worn the pump assembly must be replaced.
Re-assemble using the disassembly procedure in
reverse order and observe the following warnings:
- ensure that all parts are perfectly clean and lubri-
cate bushes and gears with clean hydraulic oil;
- replace all seals and O-rings;
- install bearing blocks into the same positions from
which they were removed;
- make sure the safety retainers are correctly posi-
tioned in the rubber seal rings.
Assemble the inner seal, (30), with the spring and

the lip facing the pump.
Install the outer seal ring (31), with the spring and
the lip facing outwards and refit the snap ring (32).
Coat the rings with high melting point grease.
NOTE: ensure seal rings are fitted back to back.
NOTE: if the seal ring recess has been scored dur-
ing seal removal, coat the outside diameter of the
seal ring with flexible gasket sealant to prevent
leakage.
HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP

As an alternative to the fixed-flow-rate gear pump,
the machine can be provided with a variable-flow-
rate pump.
Pump 72 kW - 97 HP (580ST)
Displacement ............................................................................................................... 71 cm3/rev (4.33 in3/rev)
Pump 82 kW - 110 HP (590ST - 695ST)
Displacement ............................................................................................................... 75 cm3/rev (4.57 in3/rev)
COMPONENTS
6
62
7
48
61
47
60 46
59
58
57 56 45 8
44
55 43 9
54 10 1
2
12 11 3
4
15
5
16
25
13
14
24 20 17
28 27 18 31
19 32
21 33
34
22 35
23 36
29 26 37
30 38
39
TBR00110
1. Snap ring 28. O-ring

2. Seal ring 29. Load-sensing control valve
3. Pump body 30. Screw
4. O-ring 31. Piston
5. Plug 32. Piston disc
6. Plug 33. Articulation
7. O-ring 34. Pin
8. Bearing 35. Cylinder
9. Shaft 36. Washer
10. Cradle bearing 37. Spring
11. Pin 38. Washer
12. Snap ring 39. Ring
13. Pin 43. Plug
14. Swash plate 44. O-ring
15. Spring 45. Spool
16. Piston 46. Valve body
17. Cylinder assy 47. O-ring
18. O-ring 48. Plug
19. Bearing 54. Plug
20. Pin 55. O-ring
21. Valve plate 56. Spring guide
22. Check valve 57. Spring
23. Spring 58. Spring
24. O-ring 59. Back-up ring
25. Plug 60. O-ring
26. Cover 61. Adjusting screw
27. Screw 62. Screw

Disassembly
Remove the load-sensing control valve (29) by
removing the 4 screws (30).
Remove and discard the 4 O-rings (28).

Carefully remove the end cap (26).
Prevent the valve plate (21) from falling off.
Place the end cap and valve plate in a clean area,
protecting them from contamination.
Remove the bearing (19) and the O-ring (18).
Tilt the pump body to allow oil to drain.

Remove the cylinder assy (17).
Set the cylinder assy on a clean and dry surface.
Rotate the pump body (3) to a position so that the

shaft is pointing down.
Pull the shaft (9) out of the pump body (3).
Compress the spring (15) and rotate the piston (16)
towards the swash plate (14).
Lift the swash plate/piston assy until it is tilted and
remove it from the pump body (3).
Remove the piston (16) and the spring (15) from the
swash plate (17) by removing the pin (13) and the
snap ring (12).

Examine the cradle bearings (10) to determine if
they need replacement.
Removing the pins (11) will likely damage the cradle
bearings, so make sure you have replacement
bearings before you remove them.
If cradle bearings (10) need replacing, remove the 2
pins (11).
Note the location and orientation of the bearings for
re-installation.
Orient the pump body (3) with the flange upwards.

1
Carefully pry out the seal ring (2).
In case it is not possible to extract the seal ring (2),
try to push the seal out by going through the inside 2
of the pump body (3).
TBR00111
Disassembly of the load-sensing control valve

(29)
Remove the three plugs (43), (48), (46) and their O-
rings (44), (47).
43
Remove the spool (45). Note which bore each spool 44
came out of.
45
Also note the orientation of each spool for reinser-
tion.
47
There may be differences in reinserting into the
same bore. 48 46
Remove the adjusting screw (61), the O-ring (60)
62 47
and the back-up ring (59).
56 29
Remove the springs (57), (58) and the spring guide
(56). 57
NOTE: the disassembly will require resetting after 58
the pump is reinstalled on the machine.
59
60
61
TBR00112
Disassembly of cylinder assy (17)

Pull to extract the piston disc (32) with the pistons
(31) from the cylinder (35).
Number the pistons and bores for reassembly if
they are to be reused.
Remove the articulation (33).
Remove the 3 pins (34).
NOTE: perform this procedure only if you suspect
problems with the spring.
Turn the cylinder (35) over. Using a press, apply
pressure on the washer (38) to compress the spring
(37). Compress the spring enough to safely remove
the ring (39).
Carefully release the pressure and remove the
washer (38), the spring (37) and the washer (36)
from the cylinder (35).
S WARNING S
Compressing the spring (37) requires about
350 ÷ 400 N (79 ÷ 90 lbf).
Use a press sufficient to maintain this force.
Ensure that the spring is secure before attempting
to remove the ring (39).
Release the pressure slowly after the ring (39) has
been removed.
Inspection
After disassembly, wash all parts (including the end
cap and the pump body) thoroughly with clean sol-
vent and allow to air dry.
Clean the oil ducts in the pump body and the end
cover with compressed air.
Conduct inspection in a clean area and keep all
parts free from contamination.
Inspect the pistons (31) for damage and discolora-
tion. Discoloured pistons may indicate excessive
heat; do not reuse.
Inspect the running surface of the pistons (A).
Replace all pistons with scored or excessively
rounded edges. Measure the piston foot thickness
(B). Replace all excessively worn pistons.
Check the axial end-play (C).
Replace all pistons with excessive end-play.
Foot thickness (B) 3.23 mm (0.13 in)

Piston axial end-play (C) 0.05 mm (0.002 in)
The articulation (33) should be free of nicks and
scratches, and should not be excessively scored.
Examine for discoloration that may indicate exces-
sive heat or lack of lubrication.
The piston disc (32) must be flat. The pistons must
insert with a minimum side play.
Place the pins (34) on a flat surface and roll them to
make sure they are straight.
Discard and replace any damaged parts.
If the cylinder assy was fully dissembled, visual

inspection of the cylinder block, spring (37) and
washers (36), (38) should indicate minimal wear.
Replace if cracks or other damage is present.
Examine the running face of the cylinder (35). The

surface should be smooth and free of nicks and
burrs.
Ensure that no scratches or grooves exist; these
may drastically reduce output flow.
Minimum height (D) 62.25 mm (2.45 in)

Maximum bore diameter (E) 19.8 mm (0.78 in)
Inspection of the load-sensing control valve (29).

Carefully examine the plugs (43), (48), (46) for
signs of wear.
43
Inspect all springs to make sure they are intact. 44
Check the inside and outside surfaces of the 45
springs for wear.
Check the spool (45) outside diameter for scratches 47
and/or burrs.
Clean and coat all spools, bores and seals with a 48 46
light coating of oil.
62 47
56 29
57
58
59
60
61
TBR00112
Make sure that the shaft (9) and its splines are
straight and free of damage or heavy wear.
Inspect the shaft surface where it meets the seal
ring.
Replace the shaft if a groove exists at the sealing
land surface that may let dirt into or hydraulic oil out
of the unit.
Clean the sealing area with non-abrasive material.
Lubricate the shaft with a light coat of oil.
Carefully inspect each surface of the swash plate

(14) for wear. All swash plate surfaces should be
smooth.
Inspect the swash plate’s running surface for dam-
age and brass transfer.
Excessive transfer may indicate that the pistons
should be replaced.
Finally, check the swash plate pin for scratches.
Inspect the cradle bearings (10) for damage or

excessive wear.
The polymer wear layer must be smooth and intact.
Replace if scratched or excessively worn.
Inspect the valve plate (21) for scratches or
grooves.
Check the plate for evidence of any cavitation along
the running face.
If pitting from cavitation exists, replace the valve
plate.
Check for excess wear on the running face. If any
discoloration or burn marks are observed, replace.
Run a fingernail or a pencil tip across the diameter
of the sealing land surface. No deep or outstanding
grooves should be felt, as these may decrease
pump flow. Lap or replace if grooves or nicks are
present.
Inspect the mating surfaces of the end cap and
valve plate for any possible contamination.
Measure the thickness of the valve plate (21).
Ensure that valve plate parallelism is equal to or
less than 0.025 mm (0.0010 in).
Appearance should be flat and smooth on both the
running face and the bottom surface.
The valve plate should be flat to 0.005 mm (0.0002 in)
convex.
Carry out a magnetic particle inspection to detect
possible cracks.
The plate (21) must be replaced in case of cracks.
Check the cover (26).

Remove the check valve (22) to expose the spring
(23).
Check and record orientation of the pin (20). The
split in the pin should be facing into or out of the slot
in the valve plate.
Inspect the check valve (22) for wear on its sealing
face.
Make sure the spring (23) is undamaged.
Replace any components if excess wear is present.
Check that the piston assy (16) for any obvious

wear or damage.
Check the corresponding end cap bore for galling or
excessive wear.
Inspect the pump body (3) to ensure that it is clean

and free of foreign material.
Inspect the surfaces of the cradle bearings and the
mating surfaces of the end cover.
The bearings (8) consist of a race (B) and a cone

(A).
Make sure the cup (B) and cone (A) are free of
excessive wear or contamination.
Rotate the bearing to check for smoothness.
If a contaminated bearing is suspected, clean with
solvent and lubricate with hydraulic oil.
Inspect for uneven wear.
Assembly
Coat the cradle bearings (10) with oil and install
them into the pump body (3).
Insert the pins (11) a minimum of 0.5 mm (0.02 in)
below the bearing surface.
If the bearings (10) are reused, reinstall them in
their original position.
Install the bearing (8).
Before replacing the spring (15), coat the contact
surface of the swash plate (14) with oil.
Assemble the swash plate (14), and the piston (16)
and the spring (15) into the pump body (3).
Rotate the piston (16) perpendicularly to the swash
plate (14) and, at the same time, compress the spring
(15) to fit it into the pump body (3).
Liberally lubricate all sides of the piston (16) and its
relevant bore and also the flat face of the swash
plate to prevent premature wear during start-up.
Insert the shaft (9) through the bearing in the body.
Push on the piston to rotate the swash plate in order
to put the shaft in properly.
Lubricate components before assembly.

Install the inner washer (36), the spring (37) and the
outer washer (38) into the cylinder (35). Compress
the spring enough to insert the ring (39).
S WARNING S
Compressing the spring (37) requires about
350 ÷ 400 N (79 ÷ 90 lbf).
Use a press sufficient to maintain this force.
Ensure that the spring is secure before attempting
to assemble the ring (39).
Release the pressure slowly after the ring (39) has
been installed.
Turn the cylinder over and assemble the pins (34)

and the ball guide (33) into the cylinder (35).
Assemble the pistons (31) on the piston disc (32).
Install the piston/disc assy into the cylinder (35).
Ensure the concave surface of the disc seats cor-
rectly in the ball guide. If reusing the pistons, install
them to the original cylinder bores.
Lubricate the pistons (31), the piston disc (32) and
the ball guide (33) before assembly.
IMPORTANT: make sure to install the piston disc
(32) so that it mates correctly with the articulation
(33), the concave side of the disc against the con-
vex side of the ball guide.
Secure the end of the shaft with one hand and keep
it horizontal. Insert the cylinder assy (17) onto the
shaft (9).
While holding the shaft still, slightly rotate the cylin-
der assy (17) to help position the shaft splines over
the ball guide and align them with the cylinder
splines.
When the cylinder slides completely over the shaft
splines, reposition the body with the flange facing
downward.
Clean the valve plate (21) and the end cap.

Assemble the pin (20) in the end cap (26) and verify
that it is properly oriented with the split facing into or
out of the slot in the valve plate (21).
The pin should be installed to 3.61 ± 0.25 mm
(0.1421 ± 0.0098 in) above the valve plate (21) sur-
face.
Apply a liberal amount of grease to the backside of
the valve plate (21) surface to hold it in position.
Assemble the valve plate (21) over the pin (20).
Assemble the spring (23) and the check valve (22).
To ensure proper pump operation, it is extremely
important to guarantee that there is no contamina-
tion between the end cap (26) and the valve plate
(21).
Assemble the bearing cup (19).
Assemble the bearing race (19) onto the shaft (9).
Apply some grease to keep the O-ring (18) in place.
Assemble the cover (26) to the body (3).
Lubricate the seal ring (2) with oil.

Place a protective sleeve over the shaft end (9) to
prevent damage to the seal ring during installation. 1
Holding the seal ring (2) perpendicular to the shaft
(9), press it into the body just far enough to clear the 2
ring groove.
Assemble with the concave side towards the shaft
bearing. 9
TBR00113
CONTROL VALVES
The hydraulic circuit is a load-sensing flow sharing LOADER CONTROL VALVE
system working together with a hydraulic pump.
The loader control valve is mounted on the right
This system has the advantage that at any time the side of the machine adjacent to the pump.
distribution of flow to the services being operated is The control valve assembly consists of a maximum
in proportion to the openings of the control valve of three sections and provides oil to the loader
spools. attachment, to the bucket and to the 4x1 bucket, if
The flow distribution to the backhoe and loader installed.
control valves is independent of the load and it is
therefore possible to operate two or more spools at BACKHOE ATTACHMENT CONTROL VALVE
the same time. The backhoe attachment control valve is located in
Important components of the system are the pres- the rear part of the machine.
sure compensator valves in each control valve sec- The control valve consists of a maximum of 7 or 8
tion, together with the load-sensing line which sections and provides the oil flow for operating the
connects all spools of the loader and backhoe lifting, the digging, the bucket, the stabilizers, the
attachment control valves. swing, the (optional) telescopic arm and the auxil-
With the fixed-flow-rate hydraulic pump, the load- iary services, if installed.
sensing line only connects the loader and backhoe
attachment control valves and does not have any
connection to the hydraulic pump.
The hydraulic pump draws oil from the tank and
flow from the front pump is directed to the centre
galleries of the loader and backhoe control valves
assemblies.
The flow coming from the rear section of the pump
passes through the flow divider valve and sends
the priority flow to the steering system, while the
remaining flow adds to the flow from the front
pump, directed to the loader and backhoe attach-
ment systems.
The centre gallery of both the loader and backhoe
control valves are blocked by the end plate.
Pressure in the supply system is controlled by the
pump flow balancer valve in accordance with the
pressure in the load-sensing line.
Consequently, the higher the load sensing pressure
is, the less flow is returned to the tank, with a corre-
sponding increase in flow/pressure to the hydraulic
systems.
Maximum system pressure is limited by the load
sense pressure relief valve which relieves pressure in
the load sense line when it reaches 210 bar (304 psi).
Since the flow balancer valve is influenced by the
load-sensing pressure, the valve diverts a sufficient
quantity of oil to the tank to maintain the maximum
system pressure of 210 bar (304 psi).
SYSTEM DIAGRAM (BACKHOE ATTACHMENT MECHANICAL CONTROLS)
10
12 13
1
3
4
5
11 7
TBR00114
Hydraulic system oil Suction oil

Steering system oil Return to oil tank
Load-sensing line oil
1. Hydraulic tank 8. Backhoe hammer control valve

2. Hydraulic pump 9. Backhoe hammer
3. Power steering 10. Oil cooler
4. Hand hammer control valve 11. Return line manifold
5. Hand hammer 12. Filter
6. Backhoe attachment control valve 13. Oil cooler by-pass valve
SYSTEM DIAGRAM (BACKHOE ATTACHMENT PILOT CONTROLS)
10
12 13
3
4
5
2
15
7
11
6 8
9
14
16
TBR00115
Hydraulic system oil Suction oil

Steering system oil Return to oil tank
Load-sensing line oil Control circuit oil
1. Hydraulic tank 10. Oil cooler

2. Pump 11. Return line manifold
3. Power steering 12. Filter
4. Hand hammer control valve 13. Oil cooler by-pass valve
5. Hand hammer 14. Solenoid valve for piloting backhoe control
6. Backhoe attachment control valve valve
7. Loader attachment control valve 15. Hydraulic control lever
8. Backhoe hammer control valve 16. Accumulator
9. Backhoe hammer
OIL FLOW OPERATION

All loader/backhoe attachment systems are in
neutral position
Each control valve section within the backhoe or
loader control valve assemblies contains a spool,
two check valves and a load-sensing pressure com-
pensator.
A load-sensing gallery connects the compensators
in each control valve section.
When all control valves are in neutral position, the
spools stop the oil flow in each system and the pres-
sure of the load-sensing line can bleed to the tank
through the relevant return-to-tank port.
Because there is no load sense pressure being
applied to the rear face of the flow balancer valve,
the valve will move against the spring and off its
seat when pump pressure reaches 15 bar. The
pump flow is now diverted back to the tank and the
balancer valve maintains a stand-by pressure of 15
bar while the systems are in neutral position.
Flow balancer valve operation - All spools in neutral

Pump stand-by pressure 15 bar Return to oil tank
1. Load sense bleed orifice 1 l/min 4. Load sense line

2. Load-sensing limiter 5. Pump flow balancer (unload) valve
(system pressure relief valve) 6. Pump flow IN
3. Return to oil tank 7. To backhoe control valves
Load sensing flow sharing - All spools in neutral

Pump pressure Return to oil tank
Trapped oil
1. Load non-return check valve 3. Pressure compensator

2. Load sense line 4. Spool
One hydraulic circuit operating

When a single hydraulic circuit is operated the When pump pressure overcomes the pressure
spool in the control valve section is moved allowing behind the load check valve, the valve opens allow-
oil to flow past the lands of the spool and apply ing oil to flow into the cylinder port.
pressure to the metering element of the pressure Exhaust oil from the cylinder returns to tank through
compensating valve. the other port in the control valve section.
The metering element moves upwards to allow oil
If pressure in a load-sensing system reaches 195 bar
to flow to the load check valve and at the same time
(2828 psi), the relief valve is activated.
uncovers the drilling in the spool portion of the
pressure compensator valve enabling operating Pump pressure is now limited to 210 bar (304 psi).
pressure to be sensed in the load sense gallery. This is the pressure required to overcome the pres-
sure of the flow balancing valve spring [15 bar
As pressure increases to open the check valve, the (217 psi)] plus the load sensing pressure controlled
load-sensing pressure is applied to the spring side at 195 bar (2828 psi).
of the flow balancer valve.
A higher pressure is now required to operate the
flow balancer valve and pump pressure increase
accordingly.
Flow balancer valve operation - Hydraulic systems operating

Pump pressure
Load-sensing pressure
Return to oil tank
1. Load sense bleed orifice 1 l/min 4. Load sense line
2. Load-sensing limiter 5. Pump flow balancer (unload) valve
(system pressure relief valve) 6. Pump flow IN
2
3
1
TBR00116
Load sensing flow sharing - One spool operating

Pump pressure
Trapped oil
Return to oil tank
Two or more hydraulic systems operating

When two or more hydraulic systems operate, each Pump pressure will rise until it exceeds the pressure
system operates at a different pressure. of the check valve of the system operating at the
heaviest load and the pressure in the load sensing
If pump flow to a specific system is not controlled, the
line has a value similar to that of the high pressure.
system requiring a lower operating pressure will work
faster than the system requiring a higher pressure, The pressure required to operate the system with a
because the flow will have to overcome less resist- lower load is now too high and, if not limited, it will
ance. result in this system operating instead of and faster
than the system with a higher load.
To prevent this situation, the pressure compensating
valve regulates the oil flow directed to the system To compensate for this condition, the load sensing
operating at a lower load. pressure moves the metering element of the pressure
compensating valve in the system with a lower load
When two spools are operated simultaneously pump
downwards and restricts the flow to the system.
pressure is applied to the metering element of the
pressure compensating valve in both valve sections. This balancing of flow and pressure according to the
load ensures that both systems operate simultane-
Both metering elements therefore move upwards
ously and at a balanced flow rate.
allowing oil to flow to the load check valves. At the
same time, the port in the spool section of the pres-
sure compensating valve is uncovered to allow oper-
ating pressure to be sensed in the load-sensing
gallery.
Load sense relief valve operating

Pump pressure at 210 bar (304 psi) Return to oil tank
Load sense pressure at 195 bar (2828 psi)
1. Load sense bleed orifice 1 l/min (0.22 gal/min) 5. Pump flow balancer (unload) valve
2. Load sense limiter (system relief valve) 6. Pump flow IN
4. Load sense line
2
3
1
4 4
TBR00117
Load sensing flow sharing - Two spools operating

1st spool operating pressure (higher) Trapped oil
2nd spool operating pressure (lower) Return to oil tank

LOADER CONTROL VALVE

The loader control valve is mounted on the right side
of the machine adjacent to the pump.
This control valve may be of 2 types, similar to each
other, according to the hydraulic pump assembled to
the machine:
- gear pump (with fixed flow rate);
- piston pump (with variable flow rate).
The control valve consists of 2 or 3 sections, an end
cover and an inlet section.
The 3 control valve sections are:
- loader attachment lifting;
- loader bucket;
- 4x1 loader bucket.
The loader attachment control valve has three sec-
tions when the 4x1 bucket is installed on the
machine.
LOADER ATTACHMENT CONTROL VALVE WITH GEAR PUMP (WITH FIXED FLOW RATE)
TBROO118
A. 4x1 loader bucket section

B. Bucket section
C. Loader attachment lifting section
1. End cover
2. Bucket relief valve (rod side) - 240 bar (3481 psi)
3. Bucket relief valve (piston side) - 165 bar (2393 psi)
4. Hydraulic unloader relief valve - 165 bar (2393 psi)
5. 4x1 bucket relief valve - 240 bar (3481 psi)
6. Hydraulic unloader solenoid
7. Inlet section
LOADER ATTACHMENT CONTROL VALVE WITH PISTON PUMP (WITH VARIABLE FLOW RATE)
A. 4x1 loader bucket section

B. Bucket section
C. Loader attachment lifting section
1. End cover
2. Bucket relief valve (rod side) - 240 bar (3481 psi)
3. Bucket relief valve (piston side) - 165 bar (2393 psi)
4. 4x1 bucket relief valve - 240 bar (3481 psi)
5. Inlet section
CONTROL VALVE REMOVAL FROM MACHINE

shored cavity.
brake.
Lower the stabilizers to the ground.
On hydraulically controlled machines, turn the key
to ON and release the pressure by moving the
hydraulic control levers in all directions.
Drain oil from the hydraulic system.
Disconnect the battery.
Clean the area around the control valve.
Identify and disconnect the articulations, cables and
hoses and plug the hose ends.
A drip tray will be required to catch oil draining from
inside the hoses.
Loosen and remove the fastening screws.
Remove the control valve assembly from the
machine.
For installation, follow the removal procedure in
reverse order.
DISASSEMBLY
Loosen and remove the 3 nuts (1).
[Tightening torque = 27 ± 2 Nm (19.91 ± 1.47 lbf·ft)]
Extract the 3 tie rods (2).
Remove the end cover (7).

Disassemble the sections of the control valve (4),
(5) and (6) and the inlet section (3).
Check and, if necessary, replace the O-rings (8)
located between the different sections of the control
valve.
BACKHOE ATTACHMENT CONTROL VALVE

The backhoe attachment control valve is located in
the rear part of the machine.
The backhoe attachment control valve may be of 2
types, similar to each other, according to the
hydraulic pump installed on the machine:
- gear pump (with fixed flow rate);
- piston pump (with variable flow rate);
Furthermore, the backhoe attachment control valves
are divided into:
- control valves for backhoe attachment mechanical
controls;
- control valves for backhoe attachment pilot con-
trols.
The backhoe attachment control valve may consist
of 6 or 7 or 8 sections, an end cover and an inlet
section.
The possible 8 sections are:
- right-hand stabilizer;
- left-hand stabilizer;
- boom;
- digging;
- swing;
- bucket;
- telescopic dipper (optional);
- auxiliary attachment (only optional on control
valves for backhoe attachment pilot controls).
BACKHOE ATTACHMENT CONTROL VALVE - BACKHOE ATTACHMENT MECHANICAL CONTROLS

The backhoe attachment control valves for
machines with backhoe attachment mechanical
controls may have 6 or 7 sections (and not 8 sec-
tions).
With gear pump (with fixed flow rate)
A. Right stabilizer section 1. End cover

B. Left stabilizer section 2. Inlet section
C. Dipper section 3. Dipper relief valves - 240 bar (3481 psi)
D. Bucket section 4. Bucket relief valve (piston side) - 260 bar (3771 psi)
E. Swing section 5. Bucket relief valve (rod side) - 220 bar (3191 psi)
F. Boom section 6. Swing relief valve - 205 bar (2973 psi)
G. Telescopic dipper section 7. Boom relief valve (piston side) - 240 bar (3481 psi)
8. Boom relief valve (rod side) - 310 bar (4496 psi)
9. Telescopic dipper relief valve - 124 bar (1798 psi)
10. Pump flow rate balancer valve - 10 bar (145 psi)
With piston pump (with variable flow rate)
A. Right stabilizer section 1. End cover

B. Left stabilizer section 2. Inlet section
C. Dipper section 3. Dipper relief valves - 240 bar (3481 psi)
D. Bucket section 4. Bucket relief valve (piston side) - 260 bar (3771 psi)
E. Swing section 5. Bucket relief valve (rod side) - 220 bar (3191 psi)
F. Boom section 6. Swing relief valve - 205 bar (2973 psi)
G. Telescopic dipper section 7. Boom relief valve (piston side) - 240 bar (3481 psi)

shored cavity.
Lower the loader attachment and the backhoe
attachment to the ground.
brake.
Identify the position of all hoses to be disconnected
and tag them.
Disconnect the hoses and plug their ends.
Disconnect the manual control levers.
machine.
reverse order.

[Tightening torque = 27.2 Nm (20.06 lbf·ft)]

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

Remove the flow balancer valve (13).
[Tightening torque = 100 Nm (73.76 lbf·ft)]
Remove the load-sensing reliefe valve (14).
Remove the load sensing bleed valve (15).
Unscrew and remove the plugs (16) and (17).
[Tightening torque = 20 Nm (15 lbf·ft)]
Disassembly of the end cover

Remove the check valve (19).
Remove the valve (20).
Disassemble the control valve sections
NOTE: The figure shows the stabilizer section, the - loosen and remove the pin (25);
valves may be different in the other sections. [Tightening torque = 10 Nm (7.4 lbf·ft)]
Remove the check valves (21). - extract the spring (27) with the relevant spring
[Tightening torque = 30 Nm (22 lbf·ft)] guides (26);
Remove the flow balancer valve (22). - keep the seal (29).
[Tightening torque = 60 Nm (44 lbf·ft)] - loosen and remove the yoke (30) with the protec-
tion (31);
Remove the pressure relief valves (37).
- loosen and remove the screws (32);
Remove the spool: - remove the flange (33) with the relevant seal
- loosen and remove the screws (23); (34);
[Tightening torque = 10 Nm (7.4 lbf·ft)] - keep the seal (35);
- remove the cover (24) and the seal (28); - extract the spool (36).
Assembly of spool seals

Position the metal part of the seal (29) on the out-
side of the spool (36).
The seal must be fitted on the end of the spool so
that its grooves (S) are not damaged and its tight-
ness is not jeopardized.
Let the seal slide perpendicularly onto the spool.
BACKHOE ATTACHMENT CONTROL VALVE - BACKHOE ATTACHMENT PILOT CONTROLS

The backhoe attachment control valves for
machines with backhoe attachment pilot controls
may have 6 or 7 or 8 sections.
With gear pump (with fixed flow rate)
A. Right stabilizer section 4. Backhoe bucket relief valve (piston side) - 260
B. Left stabilizer section bar (3771 psi)
C. Dipper section 5. Backhoe bucket relief valve (rod side) - 220
bar (3191 psi)
D. Bucket section
6. Swing relief valve - 205 bar (2973 psi)
E. Swing section
7. Boom relief valve (piston side) - 124 bar (1798 psi)
F. Boom section
G. Telescopic dipper section
H. Auxiliary section
10. Auxiliary section relief valves - 220 bar (3191 psi)
1. End cover
2. Inlet section
12. Load-sensing relief valve - 205 bar (2973 psi)
3. Dipper relief valves - 220 bar (3191 psi)
With piston pump (with variable flow rate)
A. Right stabilizer section 3. Dipper relief valves - 220 bar (3191 psi)
B. Left stabilizer section 4. Backhoe bucket relief valve (piston side) - 260
C. Dipper section bar (3771 psi)
D. Bucket section 5. Backhoe bucket relief valve (rod side) - 220
bar (3191 psi)
E. Swing section
6. Swing relief valve - 205 bar (2973 psi)
F. Boom section
7. Boom relief valve (piston side) - 124 bar (1798 psi)
G. Telescopic dipper section
H. Auxiliary section
1. End cover
10. Auxiliary section relief valves - 220 bar (3191 psi)
2. Inlet section

shored cavity.
Lower the loader attachment and the backhoe
attachment to the ground.
brake.
Identify the position of all hoses to be disconnected
and tag them.
Disconnect the hoses and plug their ends.
Disconnect the manual control levers.
machine.
reverse order.

[Tightening torque = 27.2 Nm (20.06 lbf·ft)]

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

Remove the flow balancer valve (19).
Remove the load-sensing reliefe valve (14).
Remove the load sensing bleed valve (15).
Unscrew and remove the plugs (16) and (17).
Disassembly of the cover

Remove the check valve (21).
Remove the valve (20).
Disassemble the control valve sections
NOTE: the figure shows the swing section, the - if necessary, replace the O-ring (28);
valves may be different in the other sections. - remove the spring (29) and the relevant spring
Remove the check valves (22). guide (30);
[Tightening torque = 30 Nm (22 lbf·ft)] - loosen and remove the screws (31);
Remove the flow balancer valve (24). [Tightening torque = 10 Nm (7.4 lbf·ft)]
[Tightening torque = 60 Nm (44 lbf·ft)] - remove the cover (32);
Remove the pressure relief valve (23). - if necessary, replace the O-ring (33);
[Tightening torque = 70 Nm (52 lbf·ft)] - remove the spring (34) and the relevant spring
guide (35);
- extract the spool (25).
Remove the spool:
- remove the cover (27);
RELIEF VALVES
There are different relief valves installed on the
loader and backhoe attachment control valves.
The relief valves may be operated with anti-cavita-
tion feature (1) or direct acting (2) and protect the
single systems from excessive pressure.
OPERATION
Relief valve inoperative
When the system is not subject to overload condi-
tions pressure in the system is insufficient to over-
come pilot valve spring pressure and move the
valve of its seat.
System pressure sensed on the larger rear face of
the poppet valve maintains the poppet and sleeve
firmly on their seats.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
Exhaust oil
5. Piston High pressure oil
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery
Pilot valve operation

When the cylinder is subjected to shock forces, the
pressure increase in the cylinder supply gallery
exceeds the pilot valve spring pressure: this valve
lifts off its seat.
System pressure on the rear face of the poppet
valve escapes to tank between the sleeve poppet
and valve body causing a pressure differential
between the front and rear face of the poppet valve.
The higher pressure in the cylinder supply gallery
unseats the poppet valve and moves the piston to
seat against the pilot valve.
1. Sleeve Exhaust oil
2. Poppet valve High pressure oil
Reduced pressure oil
3. Pilot valve
4. Pilot valve body
5. Piston
Pilot and poppet valve operation

The excessive system pressure in the cylinder sup-
ply gallery now flows past the poppet valve to the
cylinder exhaust gallery and back to tank.
NOTE: during this operation the sleeve poppet is
held in the fully seated position by pressure oil.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
6. Control valve (cylinder) exhaust gallery High pressure oil
7. Cylinder supply gallery Exhaust oil
Reduced pressure oil
Anti-cavitation operation
Relief valves with an anti-cavitation feature are fitted
in systems where a rapid extension of the cylinder
could create a void condition and permit the transfer
of oil from the high pressure side of a cylinder to the
low pressure (void) side.
When for example the boom is rapidly lowered and
the cylinder rod end circuit relief valve operates, oil
has been removed from the rod end of the cylinder
and a void created in the piston end. This oil is 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
supply gallery and back pressure in the control
valve exhaust gallery acts on the outer face of the
sleeve poppet moving it to the right.
Exhaust oil is then directed into the cylinder supply
gallery to stop cavitation.
High pressure oil Relief valve exhaust oil

Anti-cavitation oil supply to cylinder
1. Anti-cavitation system pressure relief valve 4. Control valve exhaust gallery

2. Cylinder rod 5. Spool
3. System pressure relief valve
Pilot-operated pressure relief valve with anti-cavita-

tion feature subjected to overload and fully relieving
high-pressure oil
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
Anti-cavitation cylinder resupply oil

Exhaust oil
Direct-acting pressure relief valve operation

High-pressure oil in the system is sensed in the cyl-
inder supply gallery and acts on the surface of the
pressure relief valve poppet.
When pressure in the system exceeds the pressure
relief valve setting, the oil pressure lifts the poppet,
allowing excess pressure in the overloaded cylinder
to escape to the drain gallery.
A. Direct acting circuit relief valve

Valve not subjected to overload conditions
B. Direct acting circuit relief valve
Valve subjected to overload conditions
1. Relief valve seat
2. Relief valve poppet
3. Valve pressure adjusting screw
4. Spring
5. Control valve exhaust gallery
6. Cylinder supply oil
Exhaust oil
High-pressure system oil
OVERHAUL
Before removing the relief valves from the machine,
lower the loader and backhoe attachment to the
ground, stop the engine and relieve pressure in all
systems by moving the backhoe attachment, loader
attachment and telescopic dipper controls through
all operating positions. If the pressure relief valves
are suspected of contamination, they may be disas-
sembled and inspected for wear. During assembly,
restore the correct pressure.
During disassembly examine the poppet and seat in
the plunger assembly for a complete seating sur-
face.
Pilot operated relief valve
1. Body 9. O-ring
2. Shutter 10. Nut
3. Spring 11. O-ring
4. Spring 12. Adjusting screw
5. O-ring 13. Spring
6. O-ring 14. Pilot valve
7. Valve 15. Poppet
8. Cover 16. Piston
Direct acting circuit relief valve
1. Body 6. Cover
2. Poppet 7. O-ring
3. Spring 8. Nut
4. Spring 9. O-ring
5. Shim 10. Adjusting screw
Loader bucket relief valve
1. Relief valve assembly

2. Spring 7. Piston
3. Nut 8. Poppet
4. Body 9. Valve
5. Adjusting screw 10. Inner body
6. Spring 11. Spring seat
ADJUSTMENTS
System pressure relief valve adjustment
After overhaul, the pressure relief valves of the sys-
tem must be tested and adjusted using a suitable
hand pump (1), a 275 bar (3988 psi) pressure
gauge and a V. L. Churchill test kit (2).
The hand pump must be attached to inlet port Ι and

the drain hose to the outlet port T of test block using
suitable 1/2” BSP (British Standard Pipe) adaptors.
The pressure gauge may be connected to either the
hand pump or to the 3/8 UNF threaded port G in the
test block.
Remove the plug and insert the valve to be tested
into the appropriate port in the test block:
A. Stabilizer and backhoe relief valves
B. Loader bucket relief valves
C. Unload valve
NOTE: a special removable insert, which is part of

the test block, is installed in the bottom part of the
port used for testing the loader attachment valve. If
difficulty is experienced in screwing the loader valve
into the test block, check that the insert is fully
seated and correctly installed. When correctly
installed the O-ring (3) on the face of the insert
should be visible.
Operate hand pump and record maximum pressure

reading on gauge. Compare pressure values with
previous specifications.
IMPORTANT: before removing the valve from the
test block, release the pressure in the system using
the vent valve on the hand pump.
To adjust all relief valves with the exception of the

loader bucket relief valve remove the valve cap,
loosen locknut and turn adjuster to obtain correct
pressure.
IMPORTANT: relief valves must not be set outside
off the specified range.
Loader bucket relief valve adjustment

If the loader bucket circuit relief valve requires
adjustment, use the special adjusting tool supplied
with the test kit.
Hold relief valve in vice and using wrench supplied
with tool, unscrew the internal valve assembly from
the valve body.
Screw the internal valve assembly (2) into the body
of the adjusting tool (1).
Install valve into test block and operate hand pump

until valve is pressurized to 170 bar (2466 psi).
Using the special wrench supplied, loosen the lock-
nut on the end of the valve and adjust pressure set-
ting.
Operate hand pump and recheck pressure.
When pressure setting is correct tighten locknut and
release pressure in circuit using the vent valve on
the hand pump.
Remove the valve and, using a 3/8” 16 UNC screw,
remove the insert.
Reassemble the valve and install it on the test block.

Operate hand pump and recheck pressure.
If pressure is now lower than that recorded with the
insert installed it is an indication that the anti-cavita-
tion feature of the valve is leaking and the valve
requires overhaul or replacement.
The insert isolates the anti-cavitation feature of the
valve. When reassembling the insert into the test
block ensure it is installed correctly. When correctly
installed the O-ring (3) on the face of the insert
should be visible.
BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE
Solenoid valve is located under the cab floor and is

installed directly in the lower part of the chassis that
supports the operating levers. The solenoid valve is
installed on backhoe loaders with backhoe attach-
ment pilot controls and has the task to transform the
electric controls, received from the control levers,
into hydraulic controls, and to send them to the
backhoe attachment control valve. The module (A)
is installed only on the machines versions with tele-
scopic dipper. If the machine is not equipped with
telescopic dipper, the solenoid valve installed is of
type (B); while if the telescopic dipper is installed
the solenoid valve can be of type (A) + (B).
If the backhoe loader is equipped with a telescopic

dipper and if the rear control valve contains an aux-
iliary section, the solenoid valve consists of valve
(B) and module (C).
DISASSEMBLY
Unscrew and remove the accumulator (1) from the
solenoid valve assy (2).
Loosen and remove the three screws (3) and disas-

semble valve (4).
Check and replace the O-rings (5), if necessary.
If necessary, it is possible to disassemble the vari-

ous solenoid valves:
- disassemble the solenoid valves (7) by loosening
the screws (6);
- loosen and remove the valve (8);
- loosen and remove the solenoid valves (9) and
(10);
- check and replace the O-rings, if necessary.
ACCUMULATOR “AUTO GLIDE RIDE” PARKER
Capacity (gas)...........................................................................................................................2 litres (0.44 gal)
Capacity (oil) ........................................................................................................................1.84 litres (0.40 gal)
Precharge .................................................................................................................... 30 ± 1 bar (435 ± 14 psi)
MAINTENANCE SAFETY
Regularly check the gas pre-charge pressure dur- Charging must be carried out by qualified person-
ing the first few weeks of operation. nel.
Then check at suitable intervals based on this initial Before taking any readings or pressurizing with
experience. nitrogen, the accumulator must be isolated from the
hydraulic system and the fluid side discharged in
Carry out a visual examination of the accumulator
order to depressurize it.
periodically in order to detect any early signs of
deterioration such as corrosion, deformation etc. Use only nitrogen (N2) to pressurize the accumula-
tor.
Comply with the regulatory provisions concerning
the monitoring of operational equipment. Danger of Explosion - Never Charge with Oxygen
Before removal, make sure that there is no residual The types of nitrogen permitted are:
pressure in the accumulator. - type S (99.8% pure);
Before carrying out any maintenance operation,
- type R (99.99% pure);
discharge the gas of the accumulator using a
Parker UCA charging and measuring device. - type U (99.993% pure).
If the pressure of the gas contained in the nitrogen
bottle is greater than the maximum permissible
operating pressure of the accumulator, a pressure
regulator must be fitted to the nitrogen bottle.
The precharge should be checked during the first
week following commissioning of the system.
Thereafter, it should be checked every three
months, or at intervals determined by the Manufac-
turer.
Effect of temperature on precharge pressure
In order to compensate for the difference in pres-
sure at ambient and operating temperature, the
precharge pressure po should be adjusted accord-
ing to the operating temperature of the system.
Stabilization
The process of charging or discharging an accumu-
lator with nitrogen causes a temperature change
which is transmitted to the surrounding air as the
temperature of the accumulator stabilizes.
To allow for the effects of temperature transfer, the
accumulator should be allowed to stand for a mini-
mum of 15 minutes before a final reading of the
precharge pressure is taken.
CHECKING AND ADJUSTING THE PRECHARGE PRESSURE

To check the precharge pressure of the accumula-
tor, it is necessary to have the universal charging
and measuring kit UCA 380002714.
The kit must be screwed onto the accumulator’s
gas valve, allowing the precharge pressure to be
checked and reduced.
If the precharge pressure is to be increased, the
UCA can be connected to the nitrogen source with
the hose supplied.
The kit includes two pressure gauges for readings
of 0 ÷ 25 bar (0 ÷ 363 psi) and 0 ÷ 250 bar
(0 ÷ 3626 psi)
If a different pressure interval becomes necessary,
use a pressure gauge available in commerce.
Kit UCA 380002714
A. Inflation valve
B. Bleed valve
1. UCA
2. Adapter (long)
3. Adapter (short)
4. Adapter (insert)
5. Pressure gauge
6. Protective cap - gauge port
7. Collar - gas port
8. Protective cap - filling port
9. Hose (1/4) with O-ring
10. Valve
Remove the protective cover and cap (11) from the

accumulator, to gain access to the gas valve (12).
Select the appropriate pressure gauge (5) for the
pressure to be checked, remove the protective cap
(6) and connect the port to the UCA (1).
Make sure that the bleed valve (B) is fully closed
and that the inflation valve (A) is fully raised by turn-
ing the handwheel in a counterclockwise direction.
Assemble the short adapter and adapter insert (3)
and (4), screw onto the gas valve (12) and hand
tighten.
Screw the UCA onto the adapter.
Position the assembly to permit easy reading of the
gauge, then hand tighten the collar (7).
Open the inflation valve (A) by screwing the hand-
wheel clockwise until the inflation pressure registers
on the gauge.
READINGS AND RESULTS

3 conditions may become true. Screw the handwheel (A) counterclockwise to close
the accumulator gas valve.
Nitrogen po pressure is correct
Screw the handwheel (A) counterclockwise to close Slacken the bleed valve (B) to release pressure in
the accumulator gas valve. the UCA.
Slacken the bleed valve (B) to release pressure in Remove the hose carefully, to release internal pres-
the UCA. sure.
Unscrew the UCA from the adapter. Refit the cap (8) on the valve (10).
Unscrew the adapters from the accumulator gas Unscrew the UCA from the adapter(s).
valve. Unscrew the adapters from the accumulator gas
Nitrogen po pressure is too high valve.
Slacken the bleed valve (B) to vent nitrogen from After removing the UCA and adapter(s), make sure
the accumulator until, after stabilization, the desired that the accumulator gas valve (12) is sealing effec-
pressure po is registered. Nitrogen vents into the tively.
air. Refit the gas valve dust cover (12) and replace the
protective cover (11).
Tighten the bleed valve (B) once the desired filling
pressure is reached.
Screw the handwheel (A) counterclockwise to close
the accumulator gas valve.
Slacken the bleed valve (B) to release pressure in
the UCA.
Unscrew the UCA from the adapter.
Unscrew the adapters from the accumulator gas
valve.
Nitrogen po pressure is too low
Close the inflation valve (A) by screwing the hand-
wheel counterclockwise.
Remove the cap (8).
Connect the end of the hose (9) to the valve (10).
Connect the other end of the hose to the nitrogen
source.
Progressively open the valve on the nitrogen
source.
Turn the handwheel (A) clockwise to let pressurized
gas in.
Use special care if the accumulator has small
capacity.
When pressure po is reached, close the valve on
the nitrogen source.
To allow for the effects of temperature transfer, the
accumulator should be allowed to stand for a mini-
mum of 15 minutes to allow the temperature to sta-
bilize before a final reading of the precharge
pressure is taken.
HYDRAULIC SWING SYSTEM
OPERATION
The hydraulic swing system has two versions:
- Sideshift:
it can shift laterally with the backhoe attachment
because it is installed directly on the sideshift car-
riage performing the shifting;
- Center pivot:
it is fixed because it is installed directly on the
chassis.
The backhoe attachment may slew by 180° around
the main frame.
This movement is obtained by means of two
hydraulic cylinders (1) installed between the main
chassis and the backhoe attachment support.
The cylinders act directly on the backhoe attach-
ment support, with no need for connections or bell
cranks.
Each cylinder is free to rotate, around two pivots
(3), while the stem comes out or retracts inside of
the cylinder body (2).
As each cylinder extends or retracts, the swing post
and the cylinders turn, pivoting on the headstocks
within the carriage.
Each cylinder is double-acting and, as hydraulic oil
is fed to a cylinder to turn the post, one cylinder
pushes and the other cylinder pulls.
HYDRAULIC OIL FLOW

Hydraulic feed to the swing cylinders is controlled By allowing oil to flow unrestricted to the power side
by the swing section of the backhoe attachment of the cylinder and be restricted on the exhaust side
control valve, which contains pilot-operated pres- a smooth controlled swing of the backhoe at opti-
sure relief valves with anti-cavitation feature to pro- mum speed is achieved.
tect the system and the cylinders, should an When the swing system reaches the last 20° - 25°
overload condition occur. of travel, the sliding restrictor on the end of the pis-
The diagram illustrates the operation of the swing ton rod touches the outlet port of the cylinder barrel.
circuit when retracting the right-hand cylinder (4) This further restricts the flow of oil drained from the
and extending the left-hand cylinder (5) in order to cylinder. As the piston moves towards the end of its
swing the backhoe attachment to the right. stroke, the sliding restrictor is gently pushed down
towards the centre of the cylinder rod, allowing a
When swinging the backhoe to the left the oil flows
progressive and controlled stop of the swing cycle.
are reversed and exactly the same principle of
operation applies. If the swing control valve is suddenly returned to
neutral mid-way through a full power swing the sup-
The various operating stages for right swing are
ply and exhaust ports in the main control valve are
described below as an example.
totally blocked.
When the swing control is operated the control
The momentum of the swinging backhoe assembly
valve directs oil flow to the rod end of the right hand
if not controlled will make the machine extremely
cylinder.
unstable.
The oil flow at pump pressure lifts the one-way
To prevent this from occurring, the system pressure
restrictor (2) from its seat, thus allowing the flow to
relief valves operate and drain the oil until an
continue unrestricted to the inlet port of the piston
excess pressure is detected.
end of the left-hand cylinder.
When the relief valve operates the cylinder rod will
System pressure increases causing the right hand
move and a void will be created in the low pressure
cylinder to retract and the left hand cylinder to
side of the cylinder.
extend.
The anti-cavitation feature in the relief valves pre-
As the cylinders move, displaced oil on the piston
vents the void from creating by transferring the
side of the left hand cylinder flows towards the one
drain oil from the side of the system where an
way restrictor (7) in the inlet port on the rod end of
excess pressure occurred to the low pressure side.
the right hand cylinder.
The oil flow moves the restrictor to the restrict posi-
tion which limits the flow of oil and creates a back
pressure (1st stage restricted return oil) in the right
hand cylinder.
The restricted flow of oil passes through restrictor
(7) into the rod end of the left hand cylinder before
returning to the control valve and back to tank.
The spool in the swing control valve (1) is designed
so that, during operation, oil can flow freely through
the port directing oil flow to the swing cylinders, but
is restricted when going back to the tank.
This restriction is achieved using metering lands
machined into the lands of the spool and creates a
secondary back pressure (2nd stage restricted
return oil) in the rod end of the cylinder.
Pump pressure oil

1st stage restricted return oil
2nd stage restricted return oil
Return to oil tank
1. Control valve swing section 5. Left hand cylinder

2. Limiter 6. Compressor rod
3. Cushioning rod 7. Limiter
4. Right hand cylinder
HYDRAULIC CYLINDERS
6
5
6
4
5 2
11
1
10
3
6
7
5
6
4
2
3
1
9
8
TBR00121
1. Loader attachment boom cylinder 7. Telescopic cylinder

2. Loader bucket cylinder 8. Swing backhoe cylinder
3. 4x1 loader bucket cylinder 9. Stabilizer cylinder (center pivot models)
4. Backhoe boom cylinder 10. Stabilizer cylinder (sideshift models)
5. Backhoe dipper cylinder 11. Backhoe sideshift locking cylinder (sideshift
6. Backhoe bucket cylinder models)
LOADER ATTACHMENT BOOM CYLINDER

2WS
1. Stroke
2. Completely retracted
2WS-TC
1. Stroke
LOADER ATTACHMENT BOOM CYLINDER REMOVAL

Sufficiently raise the loader attachment to allow the
boom cylinder pivot pin to be removed and securely
support the front and rear part of the bucket with
stands to prevent the loader attachment arms from
lowering when the cylinder is disconnected.
If the bucket cannot be safely supported, remove it
and support the loader attachment arms using a
suitable stand or hoist.
S WARNING S
Always ensure that the loader is fully supported. Do
not work under or near an unsupported loader
attachment, to prevent the danger of personal
injury.
Relieve the residual pressure in the system by mov-

ing the loader control lever through all operating
positions.
Stop the engine.
Support the cylinder using sling and suitable hoist.
Disconnect the hoses.
Cap or plug all exposed openings.
Remove the snap ring (1) and the spacer (2).

Remove the ring (3) and the pin (4).

Use a hammer to extract the rod pin (5).
Remove the loader attachment boom cylinder.

LOADER ATTACHMENT BOOM CYLINDER DISASSEMBLY
1. Cylinder rod 9. Back-up ring

2. Bushing 10. O-ring
3. Wiper ring 11. Piston
4. Seal ring 12. Piston gasket
5. Seal ring 13. Piston guide rings
6. Guide bush 14. Screw
7. Cylinder gland 15. Cylinder tube
8. Safety screw 16. Bushing
The disassembly procedure described below may

start on the premise that the hydraulic lines have
already been disconnected.
S WARNING S
Cylinder weight (2WS): 32.5 kg (71.65 lb).
Cylinder weight (4WS): 41.3 kg (91.05 lb).
Lift and securely place the cylinder on a workbench.

Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
Support the cylinder rod (1).

Unscrew and remove the safety screw (8).
Use wrench 380000725 to loosen the cylinder gland
(7).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.
Remove the cylinder gland (7) from the cylinder bar-

rel (15) using a plastic hammer.
Remove the cylinder rod (1) and the cylinder gland
(7).
IMPORTANT: be sure to pull the cylinder rod (1)
straight so as not to damage the sliding surfaces.

Extract the piston (11) and the cylinder gland (7)
from the cylinder rod (1).
Only if necessary:
- remove the wiper ring (3), the seal ring (4), the
ring (5), the guide bush (6) and the back-up ring
(9) with the O-ring (10) from the cylinder gland (7);
- remove the piston seal (12) and the piston guide
rings (13) from the piston (11).
LOADER BUCKET CYLINDER

2WS
1. Stroke
4WS
1. Stroke
LOADER BUCKET CYLINDER REMOVAL

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

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

Hammer to slide out the pin (6).
Remove the loader bucket cylinder.

LOADER BUCKET CYLINDER DISASSEMBLY
2. Cylinder rod 10. Piston
3. Wiper ring 11. Piston gasket
4. Seal ring 12. Piston guide
5. Seal ring 13. Screw
7. Snap ring 15. Bushing
8. Back-up ring
The disassembly procedure described below is

based on the premise that the hydraulic hoses have
S WARNING S
Cylinder weight: 32.5 kg (71.65 lb).

Support the cylinder rod (2) and use the wrench

380000722 to loosen the cylinder gland (6).

Extract the cylinder gland (6) from the cylinder bar-
rel (14) by tapping it with a plastic hammer.
(6).

Only if necessary:
ring (5), the back-up ring (8) with the O-ring (9)
from the cylinder gland (6);
ring (12) from the piston (10).
4X1 LOADER BUCKET CYLINDER
1. Cylinder rod pin

2. Dowel
3. Bucket
4. Cylinder
5. Dowel
6. Nut
7. Cylinder bottom pin
LOADER 4x1 BUCKET CYLINDER REMOVAL

positions.

Unscrew and remove the clamping screws of the

cover (C).
Remove the cover (C).
Remove the pin (2).

Slide out the rod pin (1) with an hammer.
Unscrew and remove the nut (6) and the dowel (5).
Slide out the lower pin (7) with an hammer.
Remove the 4x1 bucket cylinder.

LOADER 4x1 BUCKET CYLINDER DISASSEMBLY
1. Cylinder tube 7. Cylinder gland

2. Piston 8. Gasket
3. Pin 9. Wiper ring
4. O-ring 10. Cylinder rod
5. Piston guide 11. Bushing
6. O-ring
BACKHOE BOOM CYLINDER
1. Stroke ) 590ST - 695ST

2 580ST
BACKHOE ATTACHMENT BOOM CYLINDER

REMOVAL
Support the backhoe attachment elements for cylin-
der removal using a suitable support.
S WARNING S
Always support the structural members so that they
will be stable and safe to work around.
Stop the engine and move the backhoe attachment

control levers through all operating positions to
relieve any residual pressures in the system.
Position a sling or other suitable lifting equipment
around the cylinder.
Disconnect the hoses (T).

Remove the snap ring (1) and the spacers (2).
Extract the pin (3) with a hammer.
Disconnect the yoke of the lock cylinder (4) for

transport from the hook (5).
Extract the pin (6).

Remove the hook (5) and the hook (8).
Now it is possible to remove the rod pin (7) by tap-
ping with a hammer on one side and extracting the
pin from the other.
Remove the backhoe attachment boom cylinder.
BACKHOE ATTACHMENT BOOM CYLINDER DISASSEMBLY
14
15
12
16 13
12
17 2
8
9
10 3
17 11 4
5
6
7
TBR00119
2. Bushing 10. Back-up ring

3. Cylinder rod 11. O-ring
6. Ring 14. Piston
8. Screw 16. Cylinder tube
9. Cylinder gland 17. Bushing

S WARNING S
Cylinder weight (580ST): 92.7 kg (204.36 lb).
Cylinder weight (590ST - 695ST): 106 kg (233.69 lb).


Use wrench 380000724 to loosen the cylinder
gland (9).

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

Only if necessary:
- remove the wiper ring (4), the seal ring (5), the ring
(6), the guide bush (7) and the back-up ring (10)
with the O-ring (11) from the cylinder gland (9);
- remove the piston guide ring (13) and the piston
seal (12) from the piston (14).
BACKHOE ATTACHMENT DIPPER CYLINDER
1. Stroke ) 590ST - 695ST

2 580ST
BACKHOE ATTACHMENT DIPPER CYLINDER

REMOVAL
der removal using a suitable support.
S WARNING S

Check that the dipper (A) and the boom (B) are in a
safe position to prevent involuntary movements
after the removal of the dipper cylinder (1).
Remove the snap rings (2) and the spacers (3).

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

Slide out the rod pin (7) with an hammer.
Remove the backhoe dipper cylinder.
BACKHOE ATTACHMENT DIPPER CYLINDER DISASSEMBLY
14
15
16
8
9
17 10
11 3
4
5
6
7
TBR00120

6. Ring 14. Piston
8. Safety screw 16. Cylinder tube

S WARNING S
Cylinder weight (590T - 695ST): 74.6 kg (164.46 lb).


Loosen the cylinder gland (9).

(9).

Only if necessary:
(10) with the O-ring (11) from the cylinder gland
(9);
BACKHOE BUCKET CYLINDER
1. Stroke 2 580ST
) 590ST - 695ST
BACKHOE BUCKET CYLINDER REMOVAL

S WARNING S


Extract the pin (3) with a hammer and pay attention
to bucket levers.
If necessary use hydraulic power to very slowly
retract the cylinder.
Disconnect the hoses (T).

Remove the backhoe bucket.

BACKHOE BUCKET CYLINDER DISASSEMBLY
14
15
16
12
13
2
8
17 9
10 3
11 4
5
17 6
7
TBR00122

6. Ring 14. Piston

S WARNING S
Cylinder weight (590ST - 695ST): 67 kg (147.71 lb).



(9).
Loosen and remove the screw (15). Extract the pis-

ton (14) and the cylinder gland (9) from the cylinder
rod (3).
Only if necessary:
(10) with the O-ring from the cylinder gland (9);
TELESCOPIC CYLINDER
1. Stroke 2 580ST
) 590ST - 695ST
TELESCOPIC CYLINDER DISASSEMBLY

3. Wiper ring 11. Piston
4. Ring 12. Piston gasket
8. Safety screw 16. Bushing

S WARNING S
Cylinder weight (590ST - 695ST): 41.9 kg (92.37 lb).



(7).

Only if necessary:
ring (4), the guide bush (5) and the O-ring (9) with
the back-up ring (8) from the cylinder gland (7);
STABILIZER CYLINDER - CENTER PIVOT (695ST)
(1) Stroke
(2) Completely retracted
STABILIZER CYLINDER REMOVAL - CENTER PIVOT

Make sure that the backhoe loader is locked in the
transfer position or parked in a safety work position.
Support the cylinder safely with suitable belt and

hoist.
Remove the snap ring (1) and the shim (2).
Extract the pin (3) with a hammer. Using the
hydraulic power, retract the cylinder very slowly.
Stop the engine.

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

STABILIZER CYLINDER DISASSEMBLY - CENTER PIVOT

2. Wiper ring 9. O-ring
3. Ring 10. Piston gasket
5. Guide bush 12. Piston
6. Safety screw 13. Screw

S WARNING S

Replace the cylinder rod (1).

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

(7).

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


Relieve possible residual pressures in the system
by moving the loader attachment control lever
through all operating positions.
Loosen and remove the screw (1) and the nut (2).
Extract the pin (3) to release the cylinder rod.
Disconnect the hydraulic tubes at the top of the sta-

bilizer leg.
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 cylinder.

STABILIZER CYLINDER DISASSEMBLY - SIDESHIFT

3. Seal ring 10. Piston
4. Ring 11. Piston guide
5. Guide bush 12. Piston gasket
6. Cylinder gland 13. Screw

S WARNING S
Lift and place the cylinder on a workbench and

secure it to a vice.

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

(7).

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

der removal using a suitable stand and a hoist.
S WARNING S

Loosen and remove the nut (1).

Slide out the screw (2) from the opposite side.
Now the pin (3) can come out and release the rod
cylinder.
If necessary hammer to help the pin (3) to come
out.
Disconnect the feed and return hose to the cylin-

ders and cap all exposed openings.
Loosen and remove the nuts (4) and the screws (5)
(from both sides).
Now it is possible to remove the support (6).
Carefully lift and remove the swing cylinder.

SWING CYLINDER DISASSEMBLY
1. Bushing 10. King pin

6. Ring 15. Piston
7. Guide bush 16. Lock retaining piston
8. Bushing 17. Cylinder tube
9. Seal ring

S WARNING S
Cylinder weight: 31 kg (68.34 lb).
Lift and place the cylinder on a workbench and

secure it to a vice.
Use the wrench 380000725 to loosen the king pin

(10).
Remove the rod assy with the king pin and the pis-
ton assy.
Unscrew and remove the piston lock (16).

Disassemble the cylinder rod (3) and piston assy
(15) and the king pin (10) complete with gaskets.
Check the bushings (8) status.
Only if necessary:
(12) with the O-ring (11) from the king pin (10).
ring (14) from the piston (15).
BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT

4 sideshift locking cylinders are installed on the
backhoe loader.
Their function is to lock the carriage once the back-
hoe attachment is in digging position.
The cylinder consists of:
1. Body
2. Cylinder
3. Gasket
BACKHOE ATTACHMENT LOCK CYLINDER

REMOVAL
Park the machine on a flat surface and position the
bucket on the ground.
Position the backhoe support in the centre of the
machine and lower the backhoe on the ground.
ing the control levers through all operating posi-
tions.
Disconnect the line (1).

Loosen and remove the two screws (2).
Now it is possible to remove the whole cylinder (3).
SPECIAL TOOLS
PN CNH DESCRIPTION APPLICATION

Telescopic dipper cylinder head
380000721 Wrench
Stabilizer cylinder head (sideshift)
380000722 Wrench Loader bucket cylinder head
Backhoe boom cylinder head
380000724 Wrench
Backhoe dipper cylinder head
Backhoe bucket cylinder head
380000725 Wrench Swing cylinder head
Loader cylinder head
380000726 Wrench Stabilizer cylinder head (center pivot)
HYDRAULIC CONTROL LEVERS
Weight 5.1 ÷ 5.3 kg (11.24 ÷ 11.68 lb)
Spool stroke 7.55 mm (0.29 in)
SPECIAL TORQUE SETTINGS
Maximum permissible on the hydraulic control lever 80 Nm (59 lbf·ft)
Control block retaining screw 30 Nm (22 lbf·ft)
Control block cardan joint 50 Nm (37 lbf·ft)
Control block nut 40 Nm (30 lbf·ft)
Lower body screw 50 Nm (37 lbf·ft)

CONTROLS AND OPERATION
1. CONTROL ENABLE SWITCH: when set to ON 6. TELESCOPIC DIPPER CONTROLS: (propor-

(control lamp on), this switch allows enabling all tional controls): press the right-hand button to
hydraulic controls of the backhoe attachment. extend the telescopic dipper.
2. LEFT HAND HYDRAULIC CONTROL LEVER: Press the left-hand button to retract the tele-
the left-hand hydraulic control lever controls scopic dipper.
attachment swing and the boom or the dipper 7. WRIST RESTS: the wrist rests may be adjusted
(depending on the control pattern adopted). to the required height.
3. RIGHT HAND HYDRAULIC CONTROL 8. HYDRAULIC CONTROL LEVER SUPPORT
LEVER: the right-hand hydraulic control lever ANGLE ADJUSTMENT: these controls are
controls the bucket and the boom or the dipper used for the fore/aft and left/right adjustment of
(depending on the control pattern adopted). the arm.
NOTE: the operating speed depends on the angle 9. HORN BUTTON: (momentary action control).
of movement of the control levers. In intermediate 10. CONTROLS OF AUXILIARY BIDIRECTIONAL
position, two movements may be obtained simulta- ATTACHMENT (If fitted): proportional buttons
neously. for the activation of the additional attachment.
4. STABILIZER CONTROLS: the right-hand con- 11. DECELERATOR BUTTON: by pressing this
trol is for the right-hand stabilizer and the left- button, the engine rpm sets to low idle. During
hand control is for the left-hand stabilizer. this phase, the accelerator knob and pedal are
disabled.
5. CONTROL PATTERN CHANGE SWITCH: this
By pressing the button again, the engine rpm is
switch is used for changing the standard control
restored and the accelerator knob and pedal
pattern to the ISO pattern.
are functional again.
COMPONENTS
RIGHT HAND HYDRAULIC CONTROL LEVER
1. Valve 10. Half handle

2. Plate 11. Cover
3. Screw 12. Switches
4. Nut 13. Washer
5. Boot 14. Spacer
6. Connector 15. Clip
7. Wedge 16. Clip
8. Half handle 17. Plugs [if the switches (12) are not fitted]
9. Screw
LEFT HAND CONTROL LEVER
1. Valve 11. Cover

2. Plate 12. Switch push button (horn)
3. Screw 13. Washer
4. Nut 14. Spacer
5. Boot 15. Clip
6. Connector 16. Clip
7. Wedge 17. Plugs [if the switches (18) are not fitted]
8. Half handle 18. Push-buttons (auxiliary bidirectional)
9. Screw 19. Connector
10. Half handle 20. Wedge

Disassembly
Release the pressure from the hydraulic systems by
carrying out the operations described below.
Turn the starter switch key to ON but do not start
the engine.
Turn pilot control enable switch to the ON position.
Move the hydraulic control levers through all posi-
tions.
Turn the starter switch key to OFF. Disconnect the
negative battery cables.
Mark the position of the lever parts (see the
exploded view on previous pages).
Remove the knob (P) and the support (S).
Remove the bracket (O) with the relevant screws
(with left hydraulic control lever).
Remove the decal (D), the mounting plate (D1) and

the detach the connectors (Q) (with left hydraulic
control lever).
Pull out both switches (I) and the detach relevant

connectors (Q1) (with right control lever).
Remove the knob (P1) in the rear section of control

lever.
Remove the screws (V) and the plate (N).
Lift the rubber boot (RL) for left control lever and the
rubber boot (RR) for right control lever.
Tag all hydraulic hoses before disconnecting them.

Disconnect all hoses (H).
Disconnect all connectors (Q2).
- Remove the screws (V1) and take out control

lever from the column.

Remove the half handles (8) and (10).
Remove the cap (11).
Remove the wedge (7) from the connector (6).
Remove the wedge (20) from the connector (19).
Remove the discs (6) and (19).
Remove the grommet (13), the clips (15) and the tie
hose (16).
Extract the switches (12) and (18).
Remove the spacers (14). Remove the boots (5).
Loosen the nut (4) and remove the screw (3).
Assembly
Proceed in reverse order.
Follow the marks made during disassembly and tighten
the nut (4) to a torque of 36 ÷ 44 Nm (26 ÷ 32 lbf·ft).
CONTROL LEVER VALVE

P. Supply
T. Return to tank
Right valve (dipper/bucket)

1. Retracting the dipper
2. Opening the backhoe bucket
3. Extending the dipper
4. Closing the backhoe bucket
Left valve (backhoe attachment/swing)

1. Boom
2. Right swinging
3. Lowering
4. Left swinging
1. cardan joint cam

2. Plate
3. Shim
4. Upper body
5. Rod guide
6. Seal ring
7. Seal ring
8. Rod
9. Spring guide
10. Spring
11. Shim
12. Cover
13. Safety ring
14. Spring
15. Spool
16. Shims
17. Valve
18. O-ring
19. Lower body
20. O-ring
21. O-ring
HYDRAULIC CONTROL LEVER VALVE OVERHAUL
Disassembly
Mark the direction of installation of all disassembled
parts.
Remove the U/J cam (1) using a key.
Remove the shim (3) from the upper body (4).
Extract the rod guide (5) and replace the seal rings
(6) and (7).
Drift the rod (8) out.
Remove the spring guide (9), the spring (10) and
the shims (11).
Extract the spool assembly.
Hold the cover (12) and remove the safety ring
(13).
Remove the spring (14) and the spool (15).
Remove and note the thickness of the shims (16).
Proceed in the same manner for the other rods.
Secure the upper body (4) in a vice.
Loosen and remove the screw (17) using a key and
replace the O-ring (18).
Separate the upper (4) and lower (19) bodies and
replace the seal rings (20) and (21).
Assembly
To reassemble, proceed in the reverse order to that
of removal.
In the case of reassembly without changing the U/J
cam (1), put the same value of shims (3) as those
in place.
After changing the U/J cam (1) adjust the pressure
of the cam on the rods.
Install a 2 mm (0.079 in) shim (3), check that the
recessing of the push-rods is less than 0.2 mm
(0.009 in), modify the shimming to more or less if
required.
Assemble the new seal rings (6), (7) and O-rings
(18), (20) and (21).
Lubricate the moving parts.
Apply brake thread fluid on the threads of the U/J
cam (1) and the screw (17).
Tighten the cam (1) and the screw (17) to a tighten-
TROUBLESHOOTING
PRELIMINARY CHECKS
When troubleshooting, the pressure and flow rate The above-described preliminary checks assume
test must be carried out in a systematic manner that the failure is not linked to the engine perform-
and the results analyzed. ance.
In this way, the trouble may be identified immedi- Having performed these checks and failed to locate
ately and accurately. the cause of the malfunction, the following proce-
dures should be adopted:
If short-cuts, assumptions and guesses are made,
unnecessary component disassembly or replace- - if possible, operate the backhoe attachment and
ment could result. make notes of its operating characteristics. Move
each cylinder control lever so that the cylinders
Follow the step-by-step procedures outlined below.
move from the fully extended to the fully retracted
As a first step in the fault finding procedure, several position;
preliminary checks should be made. - compare the operating characteristics in the pre-
These checks are important because, once they ceding stage with the malfunctions listed hereun-
have been performed, they need no longer be con- der.
sidered as a possible cause of the immediate or
reported malfunction.
Check that the hydraulic oil is at the correct level
and of the correct specification.
Check the loader, backhoe or any additional acces-
sory such as hydraulic bucket, hammers etc., for
correct assembly or installation and additionally for
signs of external damage that might cause gross
misalignment of structural members.
Check in more detail for other mechanical damage
such as kinked, twisted, worn or decayed hoses,
damaged cylinders and bent elements.
Do not forget to check underneath the unit for dam-
aged steel tubes, particularly if the unit has been
known to have operated in arduous conditions,
been grounded, or bogged down.
Ensure optimum operating temperature of the
hydraulic oil is achieved.
Perform the system pressure and rear pump relief
valve pressure tests.
TROUBLESHOOTING (WITH “REXROTH” CONTROL VALVES)

GENERAL
TROUBLE CAUSE ACTION

All systems fail to operate. Pump drive inoperative. Check and repair as necessary.
Low oil level. Check and top up.
Restricted pump suction line. Inspect the suction line and the tank
and repair as necessary.
Slow operation or loss of Worn pump Perform pump performance test and
power in all systems. replace/reseal as necessary.
Restricted pump suction line. Inspect the suction line and the tank
and repair as necessary.
Load sensing pressure relief valve Make a system pressure test.
incorrectly adjusted.
Hydraulic speed solenoid valve Make a system pressure test.
inoperative.
LOADER ATTACHMENT

The lifting system fails to Valve spool leaking. Examine lift section of loader control
operate, is slow or loses valve assembly for wear or scoring.
power. Piston seals leaking or cylinder barrel Examine/reseal piston and gland.
damaged.
The bucket fails to operate, The relief valves are stuck open, set to Check the bucket system relief valve.
is slow or loses power. a too low value or there is a leak in the
seat.
Valve spool leaking. Examine bucket section of loader
control valve assembly for wear or
scoring.
Piston seals leaking or cylinder barrel Examine/reseal piston and gland.
damage.
Cylinder leak (spools in Damaged piston barrel. Examine/reseal piston and gland.
neutral). Internal valve leak. Examine appropriate valve section of
loader control valve assembly for wear
or scoring.
Hesitation in the raising Load check valve between control Disassemble and inspect.
movement of the loader valve sections damaged.
attachment or of the
bucket cylinders when the
control is initially actuated.
BACKHOE
Refer to the following backhoe fault finding chart after first considering the preceding charts. This chart should
only be referred to if the supply system is operating normally, thereby confirming that the hydraulic supply sys-
tems and the pump are correctly operating. See also “Fault finding hydraulic pump”.

The lifting system is Lifting system relief valve stuck open, Test the pressure of the lifting system
inoperative, is too slow, set too low or seat leaking. relief valve.
loses power or does not Valve spool leaking. Examine lift section of backhoe control
hold. valve assembly for wear and scoring.
damaged.
The digging control fails to Digging system relief valve (piston Test the pressure of the digging
operate, is slow or loses end) stuck open, set too low or seat system relief valve.
power. leaking.
Valve spool leaking. Examine digging section of backhoe
control valve assembly for wear and
scoring.
damaged.
The digging control fails to The bucket relief valve (rod end) is Test the pressure of the bucket relief
operate, is slow or loses stuck open, set to a too low value or valve.
power. there is a leak in the seat.
Valve spool leaking. Examine bucket section of backhoe
control valve assembly for wear and
scoring.
damaged.
The telescopic dipper fails The telescopic dipper system relief Test the pressure of the telescopic
to operate, is slow or loses valve (piston end) is stuck open, set to dipper relief valve.
power. a too low value or there is a leak in the
seat.
Valve spool leaking. Examine telescopic dipper section of
backhoe control valve assembly for
wear and scoring.
damaged.
Stabilizer pads leaking. Stabilizer lock valve leaking. Inspect/overhaul the stabilizer lock
valve.
damaged.
SWING

Right or left swing is Swing system relief valves not Test the swing system relief valve.
inoperative, is too slow or seating, set too low or seat leaking.
loses power. Valve spool leaking. Examine swing section of backhoe
scoring.
damaged.
The swing fails to slow Built-in sliding limiter damaged. Disassemble and inspect.
down (bearing stop) at Piston seals leaking or cylinder barrel Examine/reseal piston and gland.
stroke end. damage.
The swing does not stop The system relief valve (return side) is Test the swing system relief valve.
when the control lever stuck open, set to a too low value or
returns to neutral (one there is a leak in the seat.
direction only). Valve spool leaking. Examine swing section of backhoe
scoring.
Cylinder leak (spools in Internal valve leak. Examine appropriate valve section of
neutral). backhoe control valve assembly for
wear or scoring.
damaged.
A system temporarily Load check valve between control Disassemble and inspect.
lowers when given the valve sections damaged.
control to lift.
HYDRAULIC PUMP

Noisy system. Worn or damaged pump gears or Make a hydraulic pump performance
pressure plates. test.
Aeration: air entering the systems at: Make a hydraulic pump performance
suction tube, pump shaft, fittings or test.
cylinder ring nuts.
Cavitation: system restrictions in the Make a visual check and/or a
suction line or in the tank filter. hydraulic pump performance test.
Water in the system. Visual check.
The system relief valve vibrates. Check system relief valve, adjust/
overhaul as necessary.
Vibrations in the lines. Visual check.
Cold hydraulic oil. Check the hydraulic oil operating
temperature.
Wrong oil type. Investigate/drain and top up.
Hydraulic oil drain through Tank overfilled. Check the hydraulic oil level.
tank breather. Aeration: air entering the system at: Make a hydraulic pump performance
suction tube, pump shaft, fittings or test.
cylinder ring nuts.
Cavitation: Restriction of the suction Make a visual check and/or a
filter in the tank. hydraulic pump performance test.
Oil heating. Low oil quantity. Fill the tank.
Contaminated oil. Drain the tank and refill with clean oil.
Too high/low setting of the relief valve. Drain the tank and refill with clean oil.
Test relief valves.
Oil in system too light. Drain the tank and refill with oil with
the correct viscosity.
Oil cooler fins obstructed. Clean the oil cooler.
Oil leaks through the shaft Worn shaft seal. Replace shaft seal and inspect pump.
seal.
Foamy oil. Low oil level. Fill the tank.
Air in the suction system. Check/tighten suction line.
Wrong oil type. Drain and refill with correct oil.
580ST
590ST
695ST
SECTION 39 - CHASSIS
DESCRIPTION ................................................................................................................................................. 3
REMOVAL AND INSTALLATION OF COMPONENTS .................................................................................... 5

COMPONENTS WITHIN THE CHASSIS .................................................................................................... 5
COMPONENTS OF THE LOWER PART OF THE CHASSIS ..................................................................... 6
COMPONENTS ATTACHED OUTSIDE THE CHASSIS........................................................................... 10
COMPONENTS OF THE UPPER PART ................................................................................................... 11
2 SECTION 39 - CHASSIS
SECTION 39 - CHASSIS 3
DESCRIPTION
The chassis of the Backhoe Loader is manufactured
as a one-piece unit, on which the main assemblies
are attached, or which supports the main assem-
blies.
TYPES
Some kinds of chassis are available, which differ
from each other according to some main character-
istics of the Backhoe Loader.
Backhoe attachment:
- Center pivot (fixed central rotation) (only 695ST):
the backhoe attachment is directly connected to
the chassis and cannot shift laterally;
- Sideshift: the backhoe attachment is installed on a
sideshift support and can shift laterally on the
chassis guides.
Steering:
- 2 wheel steering (2WS);
- 4 wheel steering (4WS).
2WS SIDESHIFT CHASSIS
4WS SIDESHIFT CHASSIS
4WS CENTER PIVOT CHASSIS

REMOVAL AND INSTALLATION OF COMPONENTS
COMPONENTS WITHIN THE CHASSIS
ENGINE
Supported by 2 rubber silent blocks and held in Remove:
position by 2 support brackets.
- the air filter;
The brackets are welded to the frame on either side - the engine guard;
of the engine.
- the radiator and the relevant hoses (or pivot it for-
wards if possible);
S WARNING S - the front support grid (if necessary).
Since they are fastened to each other, the engine
and the transmission operate as a one-piece unit. If Disconnect:
separated in the machine they are not self support- - the cable for supply pump throttle and electric
ing and will collapse causing injury or damage to shut-off;
the machine.
- the engine wiring harness;
TRANSMISSION - the fuel tank connection and the recovery/return
Attached to the rear side of the engine and sup- hoses;
ported by means of brackets provided with rubber - the relevant hoses (plug all ports as required) of
silent blocks. the hydraulic pump;
To make repairs that require disassembly of the - the transmission lever;
transmission or engine it will be necessary to - the transmission wiring harness connectors.
remove the engine/transmission as a complete unit
from the chassis.
To remove the engine/transmission from the
machine, it will be necessary to carry out some
operations.
COMPONENTS OF THE LOWER PART OF THE CHASSIS
FRONT AXLE
The front axle is attached to the underside of the
chassis by 6 through screws (2WS) or 4 through
screws (4WS).
To remove front axle from the machine see
“REMOVAL FROM MACHINE” in SECTION 25 -
FRONT AXLE.
REAR AXLE
The rear axle is attached to the frame at the rear of
the machine by 4 through screws.
To remove rear axle from the machine see
“REMOVAL FROM MACHINE” in SECTION 27 -
REAR AXLE.
CARDAN SHAFTS
2WS
1. Front axle
2. Front cardan shaft
3. Screw [tightening torque 33 ÷ 39 Nm (24 ÷ 29 lbf·ft)]
4. Bracket
5. Bracket
7. Rear cardan shaft
8. Rear axle
4WS
1. Front axle
2. Bracket
4. Front cardan shaft
5. Bracket
7. Rear cardan shaft
8. Rear axle
COUNTERWEIGHT
It is installed under the chassis in the front section of

the machine.
There are different types of counterweights:
2WS (A):
1. Standard counterweight .............159 kg (350 lb)
2. Medium counterweight...............330 kg (727 lb)
4WS (B):
3. Standard counterweight .............160 kg (352 lb)
COMPONENTS ATTACHED OUTSIDE THE CHASSIS
TANKS
The hydraulic oil tank (1) and the fuel tank (2) are
attached to the chassis under the cab, respectively
to the right-hand and left-hand side of the machine.
When drained of their contents, both tanks can be
removed from the machine, disconnecting the rele-
vant hoses and removing the fastening screws
[tightening torque of 85 Nm (63 lbf·ft)].
IMPORTANT: make sure that all inlets and pipes are
plugged or blanked off to prevent the dirt from enter-
ing them.
COMPONENTS OF THE UPPER PART

CAB
A. Front coupler 6. Nut

B. Rear coupler 7. Retaining screw
C. Cab skirts 8. Washer
1. Main frame 9. Cab floor
2. Anti-vibration 10. Cab support (rear)
3. Dampener 11. Support
4. Washer 12. Bushing
5. Washer 13. Cab support (front)
The cab frame is a one-piece unit, mounted on top

of the chassis.
To remove the cab it is necessary to carry out differ-
ent operations, listed below.
Remove the cab skirts (S) all around the cab.
Disconnect the two electric connectors from the
main harness and engine harness.
Remove the two front fixing screws (7) between the
cab floor and the cab support (13) (detail A).
Remove the two rear fixing screws (7) between the
cab floor and the rear supports (10) on the main
frame (1) (detail B).
Disconnect the two steering cylinder hoses (left
side).
Disconnect the pump - power steering valve hose.
Disconnect the power steering valve - oil tank hose.
Disconnect the load sensing valve hose.
Disconnect the stabilizer cables (mechanical ver-
sion).
Disconnect the parking brake cable.
Disconnect the water - heater hoses (after water dis-
charge).
Disconnect the air conditioning hoses (after coolant
drain).
Disconnect the transport lock cable (mechanical
version).
Disconnect the telescopic dipper control pedal
(mechanical version).
Turn the knobs and the boots of the various levers
(front and rear)
Lift the cab with the crane after its anchorage to lift-
ing hook.
IMPORTANT: when lifting the cab ensure the
hydraulic brake tanks are not caught and damaged
on the loader support frame.
580ST
590ST
695ST
SECTION 41 - STEERING SYSTEM
DESCRIPTION ................................................................................................................................................. 3
POWER STEERING ....................................................................................................................................... 11

COMPONENTS ......................................................................................................................................... 13
DISASSEMBLY.......................................................................................................................................... 15
ASSEMBLY................................................................................................................................................ 18
2 SECTION 41 - STEERING SYSTEM
SECTION 41 - STEERING SYSTEM 3
DESCRIPTION
The steering system has the following features:
- double-acting steering cylinder;
- oil tank in common with the main hydraulic sys-
tem;
- a hydraulic pump located on the rear part of the
transmission;
- steering (or power steering) control valve located
on the steering wheel’s column.
The oil is taken from the tank and reaches the
pump.
The front pump flow is directed to the loader and
backhoe attachment control valves.
Thanks to the presence of a flow divider, the rear
pump delivery guarantees priority oil delivery to the
steering system.
The flow divider includes a load-sensing valve and a
steering system pressure relief valve.
According to the machine model, the steering sys-
tem can be of 2 types:
- 2WS steering system;
- 4WS steering system.
2WS STEERING SYSTEM
1. Flow divider 5. Oil filter

2. Power steering 6. By-pass valve
3. Hydraulic tank 7. Radiator
4. Return manifold 8. Front axle
OPERATION
Power steering - Neutral position
Pump pressure Trapped oil

Stand-by pressure Return to oil tank
When the steering wheel is held still, the leaf springs

return and hold the power steering spool in neutral
position.
This ensures that no more oil is supplied to the
steering cylinder.
The spool also traps the oil in the steering cylinder
and allows the oil in the sensing lines to return to the
tank, thus allowing the priority flow divider to move
to the left.
Power steering - Turning right
Pump pressure Trapped oil

Metered pressure Return to oil tank
When the steering wheel is turned, the movement As the metering unit is turned by the drive shaft, it
of the power steering spool forms a series of pas- directs a measured quantity of oil along another set
sages. of passages in the spool then from these to the
steering cylinder.
During right turn, oil flows through the spool along a
groove and into a passage in the housing which Return oil from the other side of the cylinder is
leads to the metering unit. A gallery is also lined up directed through the spool to a return passage in
to allow pressure oil to flow down the sensing line the housing.
to the priority flow divider.
4WS STEERING SYSTEM
1. Flow divider 6. By-pass valve

2. Power steering 7. Radiator
3. Hydraulic tank 8. Front axle
4. Return manifold 9. 4WS steering control valve
5. Oil filter 10. Rear axle
4WS STEERING CONTROL VALVE

The valve is located on the rear axle.
Remove the four hoses and the two fastening
screws.
Remove the valve.
Draw a diagonal line across the complete valve
block this will assist in the correct reassembly later.
The valve consists of a central manifold block which
all input and output pipes are attached to.
On each side of this block is a solenoid valve.
The solenoid valves have two positions: both of
these positions are working positions and there is
no neutral point.
Each spool is detented and therefore the solenoids
are only energized momentarily to move the spool.
On the end of each solenoid is an emergency hand
operating pin which moves the control spool without
energizing the solenoid.
The switching of the steering valve is normally con-
trolled by a microprocessor located underneath the
right hand side console.
Components
1. Solenoid knob
2. Solenoid
3. Control spool
4. Block
5. Central block
6. Fixing screws
7. Piston
8. O-ring
9. O-ring
OPERATION
In the position shown both spools have been

moved by solenoids (2b) and (3b).
The detents on the (a) side of the solenoid hold the
spool in this position until another solenoid is
pulsed.
The spool in valve (3) was last moved by solenoid

(3b): oil flowing in from P3 flows through the internal
galleries of the spool and exits at port A3.
From here, oil enters valve (2), whose spool was
last moved by solenoid (2b).
Oil flows through port P2 and exits through port T2,
cutting off flow to the rear steering cylinder.
Now the oil returns in valve (3), entering through
port B3 and flowing out through port T3. From here,
oil enters the front steering cylinder.
The three modes of steering are as follows:
Front wheel only steering
Front and rear wheel steer
Front and rear wheel crab
The solenoids energized are shown in the table

below.
These are also the pins which need to be pressed
when changing steering mode manually in an emer-
gency.
X = Energized
O = Not Energized
3a 3b 2a 2b
2WS O X O X
2WS X O O X
4WS O X X O
CRAB X O X O
POWER STEERING
The power steering consists of a metering and
emergency pump that includes:
- a gearwheel with fixed stator with inner teeth and
a rotor with outer teeth;
- a 4-way rotary control valve consisting of an outer
sleeve and an inner selection rotor;
- a rotor connected to the steering wheel by means
of the steering column, which can be of two types,
fixed or adjustable;
- a cardan shaft which is mechanically tied to the
gearwheel and to the outer sleeve, and allows the
transmission’s movement;
- a set of centering springs between the outer
sleeve and the inner rotor.
L. Left control port (steering cylinder)
R. Right control port (steering cylinder)
P. Inlet to steering pump
T. Outlet to oil tank
LS. Outlet to steering pump
2WS (with variable-flow-rate pump)

Model ........................................................................................................................ EATON P/N 403 -8754-04
2WS (with gear pump)
Model ........................................................................................................................ EATON P/N 403 -8754-08
Load-sensing pressure relief valve adjustment...............................................................................................No
4WS
Model ........................................................................................................................ EATON P/N 403 -7754-04
COMPONENTS
A. Anticavitation valve 19. Seal ring

B. Manual check valve 20. Gasket
C. Inlet check valve 21. O-ring
D. Cylinder relief valve 22. Seal
E. Load-sensing relief valve 23. Bearing cup
F. Inlet relief valve 24. Bearing
1. Screw 25. Bearing cup
2. Cover 26. Spring
3. O-ring 27. Spacer
4. Spring 28. Sleeve
5. Plug 29. Plug
6. Ball 30. O-ring
7. Rotor/stator gear 31. Spring
8. Plate 32. Poppet
9. Shaft 33. O-ring
10. Power steering unit 34. O-ring
11. Valve seat 35. Ball
12. Ball 36. Pin
13. Ball holder 37. Spacer
14. O-ring 38. Valve seat
15. Spring 39. Poppet
16. Plug 40. Spring
17. Cross pin 41. O-ring
18. Spool 42. Plug
DISASSEMBLY
Cleanliness is extremely important when repairing
the power steering.
Work in a clean area.
Before disconnecting the lines, thoroughly clean the
area.
Use a wire brush to remove foreign material and
debris.
Use protective material on vice jaws.
Power steering unit distortion can result if jaws are
over-tightened.
M = mark

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

Remove the shaft (9).

Remove the O-ring (33) from the power steering
unit (10).
Carefully remove the anti-cavitation valve (A) and

the manual check valve (B) from the holes of the
screws by tipping.
Carefully remove the spool-sleeve (18) assembly

from the power steering unit (10), keeping it vertical.
Extract the pin (17) from the spool (18) and sleeve
(28) assembly.
S CAUTION S
Do not lift the spool-sleeve assembly inside the
power steering unit (10).
Slowly rotate the spool-sleeve assembly to remove
it from the power steering unit.
Remove the bearing race (25), the bearing (24) and

the bearing race (23) from the power steering unit
(10).
Partially push the spool (18) on the end of the

sleeve, then carefully remove the centering springs
(26) from the spool (18).
The power steering with low input torque uses four
centering springs (26) and two spacers (27).
The standard input torque power steering uses six
centering springs.
M = mark
S1 = low torque springs
S2 = standard springs
NOTE: do not remove any valves other than the
manual check valve and the anti-cavitation valves.
All other valves are factory preset and are non-serv-
iceable.
ASSEMBLY
Check all mating surfaces.
If any parts have scratches or burrs, the power
steering must be replaced.
The use of parts with scratches or burrs can cause
leakage and is therefore not recommended.
Clean all metal parts in clean solvent.
Blow dry with air.
Do not wipe dry with cloth or paper towel because
lint or other matter can get into the hydraulic system
and cause damage.
Do not use grit paper or file or grind these parts.
Lubricate all seals, replace all old seals with new
seals and do not use an excessive quantity of lubri-
cant on the seals of the rotor / stator gear.
Carefully assemble the spool (18) and the sleeve
(28) so that spring slots line up correctly. Rotate
spool while sliding parts together.
M = marks
Test for free rotation.
The spool should rotate smoothly in the sleeve with
finger tip force applied to its end.
Align the spool and the sleeve making reference to
the relevant marks (M).
The centering springs (26) for power steering with

low input torque (S1) have four arched springs with
two flat spacers (27) in the center.
The centering springs (26) for power steering with
standard input torque (S2) have six arched springs.
Position centering springs so that the notches line
up, and arched center sections are nested together.
Next, with spring notches facing sleeve, insert one
end of entire spring set into spring installation tool.
Compress the extended end of the spring set and

push it into the spool (18) - sleeve (28) assembly.
Keep pressure on spring ends while withdrawing
installation tool and pushing forward on springs at
same time.
Central springs set in spring slots. Seat springs
down evenly and flush with upper surface of spool
(28) and sleeve (18).
Insert the pin (17) through the spool (18) - sleeve

(28) assembly until the pin is within the outside
diameter of the sleeve.

Install the bearing races (23), (25) and the bearing
(24).
Position the spool (18) - sleeve (28) assembly so

that the splined end of the spool enters the power
steering body first.
S CAUTION S
While inserting the spool-sleeve assembly, make
sure that the parts do not tilt out of position. Gently
push the assembly into place with a slight rotation,
holding the pin so that it does not come out and
gets stuck in the internal groove.
Completely insert the spool-sleeve assembly into

the body.
With aligned spool-sleeve assembly, check for free
rotation by turning the assembly with fingertip force
applied to the end.
Position the power steering unit (10) in a vice.
Lightly clamp on the edges of the mounting area; do
not over-tighten the jaws.
NOTE: make sure that the spool and the sleeve are
flush or slightly below the unit’s surface.
Clean the upper surface of the unit.
Install the O-ring (33).

Install the anti-cavitation valves (A) and the manual
check valve (B).
Install the plate (8). Align the holes in the plate (8)
with the threaded holes in the unit (10).
Rotate the spool and sleeve assembly until the pin

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

Pretighten the screws to a tightening torque of 17 Nm
(12 lbf·ft).
Then tighten the screws to a tightening torque of
35 ÷ 45 Nm (26 ÷ 33 lbf·ft) in the sequence shown
in the figure.
Check for proper timing by turning the spool clock-

wise and feeling pressure in the “R” port.
NOTES:
580ST
590ST
695ST
SECTION 50 - CAB HEATING AND AIR

CONDITIONING
GENERAL.................................................................................................................................................... 3
CAB HEATING.................................................................................................................................................. 5
CONTROLS ................................................................................................................................................. 5
OPERATION................................................................................................................................................ 6
AIR FLOW DIFFUSERS .............................................................................................................................. 7
OVERHAUL ................................................................................................................................................. 9
AIR CONDITIONING ...................................................................................................................................... 12

PRINCIPLES OF AIR CONDITIONING ..................................................................................................... 12
CONTROLS ............................................................................................................................................... 17
OPERATION.............................................................................................................................................. 18
TROUBLESHOOTING AND TESTING...................................................................................................... 25
FLUSHING THE SYSTEM......................................................................................................................... 43
DRAINING THE SYSTEM ......................................................................................................................... 45
CHARGING THE SYSTEM........................................................................................................................ 46
OVERHAUL ............................................................................................................................................... 47
COMPRESSOR .............................................................................................................................................. 52
REMOVAL AND INSTALLATION .............................................................................................................. 53
2 SECTION 50 - CAB HEATING AND AIR CONDITIONING
SECTION 50 - CAB HEATING AND AIR CONDITIONING 3
GENERAL
ENGINE RADIATOR COOLANT
Anti-freeze - Akcela Premium .................................................................................................12 litres (2.64 gal)
Water ......................................................................................................................................12 litres (2.64 gal)
System type ........................................................... Pressurized FULL FLOW by-pass with expansion chamber
FAN BELT DEFLECTION

Natural suction ........................................................................................................ 13 ÷ 19 mm (0.51 ÷ 0.75 in)
Turbocharged.......................................................................................................... 10 ÷ 16 mm (0.39 ÷ 0.63 in)
THERMOSTAT
Opening starts at.......................................................................................................................... 82 °C (179 °F)
Fully open at ................................................................................................................................ 95 °C (203 °F)
Radiator cap.............................................................................................................................. 0.90 bar (13 psi)
MOUNTING SCREW TORQUE

Coolant/hot water hose connections...........................................................................................5 Nm (3.7 lbf·ft)
Air hose connections...................................................................................................................5 Nm (3.7 lbf·ft)
Heater housing to floor fastening screws.................................................................................6.2 Nm (4.6 lbf·ft)
REFRIGERANT
Type .................................................................................................................................................... HFC 134a
Refrigerant quantity....................................................................................................................... 1.2 kg (2.6 lb)
COMPRESSOR OIL
Type ......................................................................................................... SP15 (PAG type, viscosity index 100)
Oil change amount................................................................................................................. 135 cm3 (8.24 in3)
CHECK CONDITIONS
Air inlet temperature.................................................................................................................. 37.8 °C (100 °F)
Rated air inlet humidity ................................................................................................................................ 40%
Evaporation temperature ................................................................................................................. 0 °C (32 °F)
Overheating ..................................................................................................................................... 5 °C (41 °F)
Inlet air speed ...............................................................................................1.0 - 2.0 - 3.0 m/s (3.3-6.6-9.9 ft/s)
Condensation temperature .............................................................................. 58 °C (136 °F) (16 absolute bar)
Undercooling.................................................................................................................................... 2 °C (35 °F)
PERFORMANCE
Performance calculated at 1 m/s (3.28 ft) [191.72 m3/h (6769.31 ft3)]
Exchanged heat ................................................................................................. 5.48 kW 4718.28 kcal/h
Air outlet temperature......................................................................... 5.64 °C (42.15 °F)
Air side load loss ............................................................................................. 2.97 daPa 0.30 mmH20
....................................................................................................................(0.00431 psi) (0.012 inH20)
Coolant side load loss ....................................................................................... 13.1 kPa 0.13 bar (1.9 psi)
Performance calculated at 2.0 m/s (6.56 ft) [383.4 m3/h (13537.22 ft3)]
Exchanged heat ................................................................................................. 9.29 kW 7,998.69 kcal/h
Air outlet temperature....................................................................... 10.30 °C (50.54 °F)
Air side load loss ............................................................................................. 9.34 daPa 0.95 mmH20
..................................................................................................................... (0.0135 psi) (0.037 inH20)
Coolant side load loss ....................................................................................... 32.7 kPa 0.33 bar (4.8 psi)
3 3
Performance calculated at 3.0 m/s (9.84 ft) [575.1 m /h (20305.83 ft )]
Exchanged heat ............................................................................................... 12.00 kW 10332.00 kcal/h
Air outlet temperature....................................................................... 13.70 °C (56.66 °F)
Air side load loss ........................................................................................... 18.30 daPa 1.87 mmH20
...................................................................................................................... (0.0265psi) (0.074 inH20)
Coolant side load loss ..................................................................................... 51.20 kPa 0.51 bar (7.4 psi)
CAB HEATING
The cab is heated by a radiator mounted below the
cab seat, which is supplied hot water from the
engine coolant system.
A blower motor mounted behind the cab radiator is
used to transfer the heat into the cab.
CONTROLS
Heater blower control
The three-speed blower is controlled by means of a
knob (1) on the instrument console, to the right of
the operator’s seat.
Turn clockwise to the first position for slow speed.
A further clockwise rotation selects medium and
fast speeds.
The blower draws outside air from beneath the cab
floor and blows it into the cab through a filter.
Temperature control
The temperature of the air coming from the radiator
is adjusted by rotating the control knob (2), which
opens or closes the radiator valve, thus increasing
or decreasing the water flow as required.
Turn clockwise to increase the temperature of the
air coming from the heater.
By rotating counterclockwise, the temperature is
decreased.
OPERATION
CAB AIR FILTER
Before servicing the air filter situated under the
operator’s seat, switch off the blower and close all
windows and one door.
Forcibly close the other door.
The resulting back pressure will dislodge loose dirt
from the underside of the filters.
To remove the filter (1), release the retaining straps
(2) and remove the filter element.
Ensure the element, and sealing faces are not dam-
aged on removal.
IMPORTANT: in humid conditions, such as occur
on most early mornings, do not switch on the blower
prior to servicing the filters. Damp particles drawn
into the filter may solidify and prove difficult to
remove without washing.
The filter element is made of specially treated paper
with a sealing strip bonded to the outer face.
Clean this element by blowing with compressed air
from the clean side through to the dirty side. The
compressed air should not exceed 2 bar (29 psi)
and the air line nozzle should be at least 300 mm
(11.8 in) from the element.
HEATER RADIATOR
The heater radiator (1) is fitted in a housing under
the cab seat to guarantee a uniform distribution of
warm or cold air flow.
IMPORTANT: to ensure a good flow of air through
the heater radiator the filter should be cleaned more
frequently when operating in extremely dusty condi-
tions.
AIR FLOW DIFFUSERS

Air flow diffusers are connected to the heating sys-
tem and receive air from the blower, to direct warm
or cold air onto the windshield and side windows or
into the cab, as required.
Each diffuser may be swivelled and adjusted to con-
trol the flow of air.
To open a diffuser, press one side of the disc and
turn it, as required, to direct the air flow.
The diffusers are located as follows:
- two on the top of the front control panels (A);
- two to the rear of the seat (C);
- two under the seat, one in front, the other on the
rear (D);
- two on the cab posts, right and left (B);
- two on the ceiling, in front and back of operator’s
head (E).
NOTE: the diffusers (B) and (E) are mounted only
when air conditioning (optional) is fitted.
1
ELECTRIC HEATER VALVE

The electric valve is equipped with a software that,
each time the supply of the cock is delayed (there-
fore also at backhoe loader start), carries out the
momentary positioning of the cock to “completely
closed” and returns to the position set by the tem-
perature regulation handle located on the control
dashboard.
This enables the software to carry out a self-control
on the cock drive so as to always obtain an optimal
regulation of the ball for the water flow.
This is part of the cock normal operation and is not
to be considered as a fault.
Valve release
IMPORTANT: the release of the valve has to be per-
formed if this valve remains idle for long periods.
Carry out this operation observing the following pro-
cedure:
- disconnect the electric connectors (1);
- loosen the screws (2) and extract the electric
valve (3) from the evaporator;
- separate the driving unit (5) from the cock (6);

- by means of a wrench, turn the pin (A) of the cock
to unlock it.
S WARNING S
Once this operation is complete, reset pin (A) in the
correct start position.
Reinstall the heater valve, repeating the previously

carried out operations in reverse order.
OVERHAUL
IMPORTANT: when overhauling the heating system
remember that, with the engine running or shortly
after it is turned off, the system will be at engine
temperature and therefore the water will be hot and
under pressure.
To carry out the different checks and operations, it
is necessary to drain the system.
To drain the cooling system, disconnect either hose
at the union tee (1) found behind the engine oil filter,
mounted to the left-hand side of the engine.
RADIATOR CHECK
With the system drained, remove the heater radia-
tor hose connections, the attaching screws and
remove the radiator from the vehicle.
Inspect the radiator (2).
Check that the water flows freely through the heater
line (otherwise, clear any obstruction).
Fins must be free from debris and not damaged:
clean and/or repair.
Clean the heater radiator using compressed air not
exceeding 7 bar (102 psi) taking care not to dam-
age the radiator fins.
Make sure that the radiator is not leaking under
pressure.
Clean the chamber with a damp, cloth and re-
assemble the housing filter element with the seal
facing the inside of the cover.
BLOWER MOTOR CHECKS

The blower motor (3) can be removed by removing
the attaching screws and disconnecting the electric
connector.
Check that the fan operates correctly.
Otherwise, check the fuse and the continuity of the
fan motor. If defective, replace the blower unit as an
assembly.
HEATING VALVE
To service the control valve (4), disconnect the
hoses and the control tie rod and remove it.
Check its operation and replace it, if worn.
CONTROL PANEL
Check for the correct operation of the control knobs
(5) and (6).
TROUBLESHOOTING
Items that may cause trouble are listed in the table
below. Anyway, as a general rule, we recommend
carrying out some preliminary checks.
Ensure water flow to the heater radiator is steady
and all air has been removed from the system.
Hoses are unrestricted and not leaking.
Check the electric connections are good and the
blower motor is operational.
The operating cable to the heater valve and valve is
operational.

Dust enters the cab. Improper seal around filter element. Check the seal condition.
Restricted filter. Clean or replace the filter.
Defective filter. Replace the filter.
Excessive air leak(s) around doors Repair and seal air leak(s).
and windows.
Low blower motor air flow. Blocked filter or air recirculation filter. Clean or replace the filter(s).
Heater radiator core blocked. Clean radiator core thoroughly.
Blower motor not working. Blown fuse. Replace fuse.
Cab does not heat up. Engine not reaching operating Replace the temperature switch.
temperature. Thermostat stuck open.
Heater hose from engine to cab Ensure water flow to heater radiator
radiator kinked or blocked. is adequate and not restricted.
Cab does not cool down. Heater control turned on. Turn the temperature control knob
fully counterclockwise for maximum
cooling.
Heater control valve stuck in open Free up valve or change as required.
position.
Temperature not stable. Low engine coolant level. Top up coolant recovery tank.
AIR CONDITIONING
PRINCIPLES OF AIR CONDITIONING

The function of the air conditioning system is to
improve the operator’s comfort by cooling down the
air temperature inside the cab and reducing the
humidity level.
In order to achieve this heat transfer the following
principals of heat generation and transfer are
applied within the air conditioning system.
When two bodies with a different temperature come
together, heat is transferred from one to the other.
On air conditioning systems, an evaporator is used
to maintain the low temperature of the coolant,
which absorbs the heat from the air within the cab.
When a gas is pressurized the temperature of the

gas will rise.
In air conditioning systems the increase in pressure
is achieved using a compressor.
When a gas is cooled it will condense into a liquid.

In the air conditioning system a condenser is used
to cool the gas and the resulting liquid is stored in a
receiver dryer.
When a liquid is atomized through an orifice, the

temperature of the resultant vapour will lower.
The low temperature of the atomized liquid will then
absorb heat from its surrounding.
On air conditioning systems, coolant is atomized
using an expansion valve.
C ˚
OPERATING DIAGRAM
1. Expansion valve-atomizes liquid coolant before 3. Compressor-compresses and raises tempera-

passing to evaporator ture of coolant gas
2. Evaporator-absorbs heat from air in cab 4. Condenser and receiver dryer-converts coolant
from gas to a liquid
LOW PRESSURE SIDE HIGH PRESSURE SIDE
EXPANSION
VALVE
LOW
TEMPERATURE
LIQUID ATOMIZED HIGH PRESSURE
AT A LOWER LIQUID FILTERED
TEMPERATURE AND MOISTURE
REMOVED
RECEIVER DRYER
LOWER
TEMPERATURE
EVAPORATOR
HIGH PRESSURE
LIQUID
CONDENSER
WARM LOW
PRESSURE
VAPOUR
HIGH
TEMPERATURE
HIGH PRESSURE
VAPOUR
COMPRESSOR
HEAT FROM INSIDE HEAT MOVES TO

CAB MOVES TO OUTSIDE AIR FROM
COOLANT COOLANT
Air conditioning flow diagram
It can now be seen that the principal components of Coolant is drawn into the compressor as a cool, low
an air conditioning system are: pressure vapour which is compressed and then
pumped out as a hot, high pressure vapour to the
- Coolant
condenser.
- Compressor
As the hot, high pressure vapour passes through
- Condenser
the condenser core it gives off heat to the cooler
- Receiver dryer outside air, being drawn past the fins by the engine
- Expansion valve cooling fan.
- Evaporator
By giving off heat to the outside air, the vapour is

condensed to a liquid which moves under high pres-
sure to the receiver dryer where it is stored until
released to the evaporator by the temperature sens-
ing expansion valve.
As liquid coolant passes through the metered orifice
in the expansion valve the coolant changes from a
high pressure liquid to a low pressure atomized liq-
uid with a lower temperature.
This low pressure, low temperature, atomized liquid
enters the evaporator coils and absorbs heat from
the cab warm air blown across the coils and fins by
the cab blower motor.
The coolant now changes from a cold low pressure
atomized liquid to a warm low pressure vapour and
leaves the evaporator outlet, moving to the suction
(low pressure) side of the compressor to repeat the
cycle.
As this heat loss is taking place, moisture (humidity)
in the cab air will condense on the outside of the
evaporator and drain off as water through the drain
hoses attached to the evaporator drain pan, thereby
reducing the humidity level of the cab.
CONTROLS
CONTROLS
(580ST - 590ST - 695ST)
The air conditioning control can be adjusted to
obtain the desired temperature in the cab.
To activate air conditioning, turn the selector (2).
Upon activation, the lamp (4) on the side instrument
cluster turns on. The selector (1) allows choosing
the ideal temperature according to your require-
ments.
Positioning selector (1) to “0” and turning selector
(2) you will obtain more or less cold according to the
selector (2) position.
By positioning selector (1) to any other position dif-
ferent from “0”, you will obtain instead a mixture of
warm and cold air and the desired climate inside the
cab.
NOTE: the air conditioning can be operated only if

the ventilation selector (3) is not set to the stop posi-
tion.
Turn the selector (3) for air capacity according to
your requirements.
OPERATION
COOLANT
To achieve the absorption and the release of heat
which is, in essence, the function of an air condi- S WARNING S
tioning system, requires the use of a suitable “cool- HFC 134a can be dangerous if improperly handled.
ant” a liquid that has a relatively low temperature Therefore it is important the following warning and
boiling point, plus certain desirable safety and sta- directions are adhered to.
bility features. Never expose any part of the air-conditioner system
to flame or excessive heat because of risk of fire or
The coolant used in the air conditioning system is
explosion, and the production of phosgene gas.
coolant HFC 134a.
Never disconnect or disassemble any part of the air-
NOTE: to help protect the environment legislation conditioning system as escaping coolant can cause
has been introduced in most territories banning the frostbite.
release into the atmosphere of coolants, including
HFC 134a. All service procedures contained in this
manual can be carried out without the need to
S WARNING S
If coolant should contact the skin use the same
release coolant into the atmosphere.
treatment as for frostbite.
In order to prevent the incorrect type of coolant Warm the area with your hand or lukewarm water
being charged to the system the service valves fit- 32 °C (89.6 °F), cover the area loosely with a band-
ted to the Backhoe Loader and necessary to con- age to protect affected area against infection and
nect up coolant recovery, evacuation and recycling/ consult a doctor immediately.
re-charging equipment will be of two different sizes If coolant should contact the eyes wash immedi-
as recognized and specified by the air conditioning ately in cold clean water for at least 5 minutes and
industry. consult a doctor immediately.
S WARNING S
Coolant HFC 134a is not compatible with coolant
R-12. Do not try to replace coolant HFC 134a with
coolant R-12 or to test the system using instru-
ments or tools previously used with R12, as the
system could get damaged.
HFC 134a coolant is stable at all operating temper-

atures and able to absorb great quantities of heat.
The boiling point of HFC 134a is -22 °C (-7.6 °F) at
atmospheric pressure.
If the pressure is increased, HFC 134a will read-
ily vaporize to absorb heat at temperatures
between -11.7 °C (10.94 °F) at 1.9 bar (28 psi)
and 0 °C (32 °F) at 2.9 bar (42 psi) in the evapo-
rator.
At higher pressures, HFC 134a will condense and
give off heat at temperatures between 48 °C
(118.4 °F) at 12.4 bar (180 psi) and 58 °C
(136.4 °F) at 15.85 bar (230 psi) in the condenser.
COMPRESSOR
The compressor is mounted on the left-hand side of
the engine and is belt driven by the crankshaft pul-
ley.
The compressor separates the low and high pres-
sure sides of the system and has two functions:
- raising the coolant temperature by compressing
to a higher degree of temperature than the ambi-
ent (outside air) temperature;
- circulating the required volume of coolant through
the system.
The compressor is a 7-cylinder wobble plate unit,
housed in a die-cast aluminium housing.
TBR00090
The drive to the wobble plate comes from the pul-
ley, through the clutch to the main driveshaft.
Attached to the driveshaft, there is a cam rotor
which oscillates the wobble plate.
The wobble plate is prevented from rotating by a
static gear engaging with teeth formed in the face of
the plate.
The seven pistons are connected to the wobble
plate by rods located in ball sockets.
Coolant is drawn in on the downward stroke of a pis-
ton through the reed valves located either end of the
cylinder assembly.
Coolant enters the cylinder assembly through a gal-
lery in the outer circumference of the cylinder
assembly.
During the upward stroke, the piston compresses
the coolant and expels it through another reed valve
into an inner gallery in the cylinder and, from here,
out into the coolant system.
The compressor is lubricated with a Polyalklene
Glycol (PAG) oil Type SP15. This oil can be mixed
with coolant and is carried around in the coolant
system itself.
During the operation of the air conditioning system,
the compressor is activated by a clutch which
engages or disengages it as required.
TEMPERATURE SENSOR
The air conditioner temperature adjusting sensor is
mounted on the blower motor.
It is a device which turns the compressor clutch on
and off to maintain a constant average evaporator
temperature and senses the evaporator tempera-
ture using a thermistor (1).
The sensor compares the voltage of the thermistor,
which depends on the temperature of the evapora-
tor, with the voltage across the potentiometer of the
“in-cab” temperature control 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-OUT SENSOR

The low-pressure sensor (1) is on the upper part of
the filter, situated in front of the radiator.
The purpose of the sensor is to shut off the com-
pressor in case of low pressure in the cooling sys-
tem. 1
Low coolant pressure may occur due to a faulty
expansion valve, icing up of the expansion valve
orifice or coolant loss.
Low coolant pressure may result in damage to the
compressor pump.
The low-pressure sensor is set by the Manufacturer.
TBR00081
CONDENSER
The condenser (1), located at the front of the
machine in front of the engine radiator consists of a
number of turns of continuous coil mounted in a
series of thin cooling fins to provide a maximum of
heat transfer in a minimum amount of space.
The condenser receives the hot, high pressure
coolant vapour from the compressor.
The hot vapour passes through the condenser coils
and outside air is drawn through the condenser by
the engine cooling fan.
Heat moves from the hot coolant vapour into the
cooler outside air flowing across the condenser
coils and fins.
When the coolant vapour reaches the pressure and
temperature that will induce a change of state, a
large quantity of heat is transferred to the outside
air and the coolant changes to a high pressure
warm liquid.
The warm liquid coolant continues onto the
1
receiver/drier where it is filtered and desiccated, to
remove any moisture, before passing through an
TBR00082
outlet line to the thermostatic expansion valve.
RECEIVER DRYER
The receiver/dryer (1) stores the liquid coolant to
make sure that a steady flow to the expansion valve
is maintained also under extremely different operat-
ing conditions.
The drier contains a desiccant (molecular sieve)
which absorbs any moisture within the system, and
a filter which prevents the entry of foreign particles.
NOTE: any moisture in the air conditioning system
is extremely harmful. Moisture not absorbed by the 1
dehydrator will circulate with the coolant and drop-
lets may collect and freeze in the thermostatic
expansion valve orifice. This action will block the
coolant flow and stop the cooling action. Moisture TBR00083
will also react with coolant HFC 134a and the lubri-
cant to form a corrosive acid.
The desiccant can only absorb a limited amount of
moisture before reaching saturation point. Because
of this, after any system component replacement or
repairs requiring entry into the system, the receiver/
dryer should be replaced.
EXPANSION VALVE
The expansion valve (1) is located underneath the
evaporator in the pressure line coming from the
receiver/dryer and performs the following functions:
- metering action
(a metering orifice changes the liquid coolant from
a high-pressure low-temperature liquid to a low-
pressure, lower-temperature atomized liquid);
- modulating action
(a thermostatically controlled valve within the
expansion valve body controls the volume of liq-
uid coolant passing through the orifice and makes
sure that the coolant is fully vaporized within the
evaporator; the liquid coolant could damage the
compressor reed valves or freeze the pistons);
- control action
(the valve responds to changes in the cooling
requirements; when an increased cooling is
required, the valve opens to increase the coolant
flow, and when less cooling is required, the valve
closes and decreases the coolant flow).
Operation
All of the needed temperature sensing and pressure
sensing functions are consolidated into this basic
unit and no external tubes are required for these
purposes.
The coolant from the condenser and receiver dryer
enters the thermostatic expansion valve as a high
pressure warm liquid.
Upon passing through the ball and spring controlled
metering orifice, the pressure and temperature of
the coolant is reduced and the coolant leaves the
thermostatic expansion valve as a low pressure,
lower temperature atomized liquid.
The atomized liquid now passes through the evapo-
rator where it absorbs heat before returning via the
expansion valve to the compressor as a warm low
pressure vapour.
There are two coolant passages in the valve.
One passage is in the coolant line from the con-
denser to the evaporator and contains the ball and
spring type orifice valve.
The other passage is in the coolant line from the

evaporator to the compressor and contains the
valve’s temperature sensing element.
Liquid coolant flow from the condenser and receiver
dryer is controlled by a push-rod forcing the orifice
valve ball off its seat and the spring exerting pres-
sure on the ball to keep it on its seat.
During stabilized (vehicle shutdown) conditions, the
pressure on the bottom of the expansion valve dia-
phragm rises above the pressure on the top of the
diaphragm allowing the valve spring to close the ori-
fice.
When the system is started, the pressure on the bot-
tom of the diaphragm lowers rapidly, allowing the
orifice to open and metre atomized liquid coolant to
the evaporator where it begins to vaporize.
Suction from the compressor draws the vaporized
coolant out of the evaporator and back through a
gallery in the top of the valve which asses the tem-
perature sensor.
The temperature sensor reacts to variations in cool-
ant gas pressure returning from the evaporator.
When heat from the passenger compartment is
absorbed by the coolant the pressure of the gas
increases causing a differential pressure above and
below the temperature sensor diaphragm.
The diaphragm reacts to this pressure differential
and a push rod forces the ball in the expansion
valve orifice further off its seat.
This reaction allows an increase in the atomized
coolant to flow through the valve, to the evaporator,
so that more heat can be absorbed by the air condi-
tioning system.
Similarly when the temperature of the gas returning
from the evaporator decreases the pressure of the
gas decreases.
This causes the diaphragm to react accordingly and
allow the ball in the orifice to move closer towards its
seat thus reducing the flow of coolant through the
valve to the evaporator.
EVAPORATOR
The evaporator is located beneath the cab seat and
consists of a number of turns of continuous coils
mounted in a series of thin cooling fins to provide a
maximum of heat transfer in a minimum amount of
space.
Low temperature coolant in the evaporator absorbs
heat from the hotter air in the operator’s compart-
ment, thereby cooling the air.
An intake grille is located on the left side of the seat

base.
A portion of the air flow will recirculate through the
evaporator.
AIR FILTER
The blower fan draws warm air from outside the cab
through the intake filter (2) below the cab floor and a
ready cooled dehumidified air through the recircula-
tion grille (1).
The air passes over the evaporator then into the
cab through the six louvered diffusers.
Two diffusers are located on the front instrument
panel to direct air onto the windshield.
Two are located at the base of the rear posts to
direct air onto the rear window.
Two additional vents are located at the front and
rear of the seat base to direct air at the operator’s
feet.
TROUBLESHOOTING AND TESTING

Overhaul of the air conditioning system should only PRELIMINARY CHECKS
be undertaken by a certified specialist refrigeration
Always conduct the preliminary fault finding checks
engineer using a comprehensive air conditioning
before performance testing the system.
test kit, including a gas leak detector, suitable for
HFC 134a coolant gas. Run the engine at 1000-1200 rpm for 10 minutes
with the air conditioner set to maximum cooling and
S WARNING S the blower at high speed.
Before dismantling an air conditioning system for Check that the heater temperature control is
repair the gas within the system must be dis- switched OFF.
charged and recovered using a certified recovery Check that the blower fan is operating at all
unit designed for the type of coolant gas used in the speeds.
system.
NEVER release coolant gas into the atmosphere. Check that the compressor clutch engages when
ALWAYS wear safety goggles and gloves when the temperature control switch is turned from OFF
servicing any part of the air conditioning system. to ON position. A clicking sound indicates the clutch
is engaging. If the clutch fails to operate it may indi-
To prevent the entry of any foreign material, it is cate an electric problem in the high low pressure
necessary to observe some precautions. cut out switches or malfunction of the electric drive
Ensure all tools, gauges, hoses and replacement clutch on the compressor.
parts are kept clean and dry and are suitable for the Check the engine cooling fan is drawing cool air
type of coolant gas used in the system. through the condenser.
Clean all hoses and fittings before disconnecting. Check the compressor drive belt tension.
Cap or plug all openings when disconnected. Check the condenser core and grid is clean and
When adding lubricating oil to the system always free of obstruction.
uncap and re-cap the oil container immediately Check the cab air filter is clean and free of obstruc-
before and after use. Always ensure the oil remains tion.
free of moisture.
Check the evaporator fins are not plugged or
excessively dirty.
1. Low side gauge 6. Test hose to low side service connector

2. High side gauge 7. Shut-off valve
3. Shut-off valve 8. Low pressure (suction) side service valve
4. Test hose to high side service connector 9. High pressure (discharge) side service valve
5. Centre hose (not used)
Performance testing the air conditioning sys- Operating precautions

tem
IMPORTANT: always ensure the shut-off valves
The manifold gauge set is the most important tool are closed (turn clockwise until seated) during all
used in testing and servicing the air conditioning test operations.
system. In the closed position, coolant circulates around the
valve stems to the gauges. Therefore, when the
NOTE: for Dealers who posses the latest design
manifold gauge set is connected into a system,
level of coolant recovery, recycling and recharging
pressure is registered on both gauges.
station, these gauges are an integral part of the
machine. - NEVER open the HIGH SIDE shut off valve when
the system is operating.
The following instructions for performance testing
the air conditioning system is based on the use of - ALWAYS open the LOW SIDE shut off valve
the gauge set shown. The principal of operation is when adding coolant.
however similar when testing the system using a
recovery and recharging station with integral
gauges.
When using this type of equipment always consult
the manufacturers operating instructions.
Attaching the gauge set to the backhoe loader

Re-check that both the high and low side shut off
S WARNING S valves on the manifold gauge set are fully closed.
To avoid personal injury, stop the backhoe loader
Run the engine at 1000 ÷ 1200 rpm.
engine during connection of the manifold gauge set.
Turn the heater temperature control OFF.
Check that the gauge set shut off valves are closed
(turned fully clockwise). Operate the system at maximum cooling, with the
blower fan at high speed for 10 minutes to stabilize
Connect the high side gauge hose (normally red) to all components.
the high pressure (discharge) side service valve
and the low side gauge hose (normally blue) to the Check the manifold low pressure gauge reading
low pressure (suction) side service valve on the is within the specified range of approximately
backhoe loader. Ensure the hose connections are 0.28 ÷ 2.48 bar (4.06 ÷ 35.97 psi).
fully tightened. Check the manifold high pressure gauge reading
and compare the reading to the pressure indicated
IMPORTANT: prior to connection of the manifold
on the pressure temperature chart below.
gauge set, identify the suction (low pressure) and
discharge (high pressure) service gauge ports. The Measure and compare the temperature of conditioned
high pressure service valve is always in the line air entering the cab through the louvered air diffusers
from the compressor to the condenser. with the ambient air at the air intake filters on the out-
The high and low pressure service valves on the side of the cab.
backhoe loader are spring-loaded valves and will be If the system is operating correctly, the conditioned air
automatically opened when the test hose is con- entering the cab should be 6 - 9 °C (42.8 - 48.2 °F)
nected. cooler than the ambient temperature of the outside
air.
NOTE: the test hose must incorporate a valve
depressor to actuate this type of valve. If it is confirmed that the system is not operating
correctly refer to the fault diagnostic charts and per-
The service valves have a protective cap. This cap
formance test gauge reading examples on the fol-
must be removed for test gauge connections and
lowing pages for possible corrective action.
replaced when service operations are completed.
Test procedure S WARNING S
After the manifold gauge set has been connected A significant amount of coolant vapour may have
and before pressure tests can be made, the system condensed to a liquid at the service fitting at the high
must be stabilized as follows: side of the compressor. Use a cloth or other protec-
tive material when disconnecting the manifold hose
Apply the parking brake, check the gearshift levers
from this fitting to prevent personal injury to hands
are in neutral and close the cab windows and
and face.
doors.
APPROXIMATE HIGH PRESSURE GAUGE READINGS
Ambient air temperature High pressure gauge reading

°C (°F) bar (psi)
27 (80.6) 10.0 / 11.6 (145 / 168)
29 (84.2) 11.2 / 12.7 (162 / 184)
32 (89.6) 12.3 / 13.8 (178 / 200)
35 (95) 13.3 / 15.2 (193 / 220)
38 (100.4) 14.5 / 16.7 (210 / 242)
41 (105.8) 16.0 / 18.3 (232 / 265)
43 (109.4) 17.3 / 20.0 (251 / 290)
PERFORMANCE TEST DIAGNOSIS

Pressure gauge values: Low pressure - Low
High Pressure - Low

Evaporator air not cold. Low coolant charge. Perform leak tests and repair.
Drain the system.
Charge system, re-test system.
Evaporator air warm. Very low coolant charge. Perform leak tests and repair.
Drain the system.
Charge system, re-test system.
Evaporator air cool, but not Expansion valve not permitting Check expansion valve as follows:
sufficiently cold. sufficient flow. Set for maximum cooling.
Low pressure switch Stuck valve. Low pressure gauge should lower
cutting out. slowly.
Expansion valve to If expansion valve is defective:
evaporator tube shows
considerable condensation Discharge the system.
or frost. Replace the expansion valve.
Too cold to touch. Drain the system.
Charge the system.
Re-test.
PERFORMANCE TEST DIAGNOSIS CHART

Pressure gauge values: Low pressure - High
High Pressure - High

Evaporator air warm. Improper operation of condenser. Inspect for dirty condenser restricting
Liquid line hot (condenser air flow and cooling.
outlet to expansion valve Check operation of condenser cooling
tube). fans. Repair or replace as needed.
High pressure switch Overcharged with coolant. Check for overcharge as follows:
cutting out.
Air in the system. Stop the engine. Recover and recycle
the charge using correct recovery
equipment.
Recharge the system with the correct
quantity of coolant, replacing any lost
lubricant. Recheck performance of air
conditioning system.
Evaporator air not cold. Expansion valve allowing too much Check expansion valve as follows:
coolant to flow through the evaporator.
Set for maximum cooling.
Low pressure gauge should lower
slowly.
If expansion valve is defective:
Discharge the system.
Replace the expansion valve.
Drain the system.
Charge the system.
Re-test.

Pressure gauge values: Low pressure - Low
High Pressure - High

Insufficient cooling. Restriction in liquid line. Discharge the system.
Replace receiver/drier.
Inspect all lines and tubing from
compressor outlet to expansion valve.
Replace if needed.
Drain the system.
Charge the system.
Re-test.

High Pressure - Low

Evaporator air not cold. Internal leak in compressor (reed Discharge the system.
valves, gasket, worn or scored piston Replace the compressor.
rings or cylinder).
Drain the system.
Charge the system.
Re-test.

Pressure gauge values: Low pressure - Normal
High Pressure - Normal

Insufficient cooling. System low on charge. Air or Perform leak test.
Low pressure reading does moisture in system. Discharge the system.
not fluctuate with changes in Repair leaks.
temperature control switch
(pressure should lower until
compressor cycles). Check oil level.
Evaporator air not cold Drain the system.
Charge the system.
Re-test.

High Pressure - Normal

Compressor cycles ON and Defective temperature control Stop engine and shut off air
OFF too frequently. (thermostatic) switch. conditioning.
Replace temperature control switch.
Re-test system and check
compressor cycling.
EXAMPLES OF MANIFOLD GAUGE READINGS AND INTERPRETATIONS

The following examples show typical low and high pressure gauge readings obtained when performance test-
ing the air conditioning system with an ambient temperature of 35 °C (95 °F).
The recommended corrective action is based on a similar fault as identified in the performance test diagnosis
charts.
Performance Test Example 1
1. High side low 5. Low side hose connected to low side service
2. High side hand valve closed connector
3. High side hose connected to high side service 6. Low side hand valve closed
connector 7. Low side low
4. Not used
Problem Repair leaks. (Discharge and recover the coolant

from the system; replace lines or components).
Little or no cooling.
Check compressor oil to ensure no loss.
Cause
Drain the system.
Coolant slightly low.
Charge the system.
Conditions*
Performance test the system.
Too low pressure on low-pressure side.
Diagnostic
The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi).
System coolant is low. May be caused by a small
leak.
Too low pressure on high-pressure side.
NOTE: * test procedure based upon ambient tem-
The gauge should read 13.3 ÷ 14.8 bar ((193 ÷ 215 perature of 35 °C (95 °F).
psi)). For proper high side gauge reading for other ambi-
Evaporator air not cold. ent temperatures, refer to the pressure temperature
chart.
Corrective procedures
Leak test the system.
connector 7. Low side normal
4. Not used
Problem Corrective procedures

Insufficient cooling. Leak test the system.
Cause Discharge and recover the coolant from the sys-
tem.
Coolant excessively low.
Repair leaks.
Conditions*
Low side pressure very low.
Drain the system.
The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi).
Charge the system.
Too low pressure on high-pressure side.
The gauge should read 13.3 ÷ 14.8 bar ((193 ÷ 215
psi)). Diagnostic
Evaporator air warm. System coolant is extremely low. A serious leak is
indicated.
Low pressure switch cutting out.
perature of 35 °C (95 °F).
For proper high side gauge reading for other ambi-
ent temperatures, refer to the pressure temperature
chart.
1. High side normal 5. Low side hose connected to low side service
4. Not used

Insufficient cooling. Leak test the system. Give special attention to the
compressor seal area.
Cause
Discharge and recover the coolant from the sys-
Air in the system.
tem.
Conditions*
Repair leaks.
Low side pressure reading does not change when
compressor cycles ON and OFF.
High side pressure slightly high or slightly low. The
gauge should read 13.3 ÷ 14.8 bar ((193 ÷ 215 Drain the system.
psi)). Charge the system.
Evaporator air not cold. Performance test the system.
Diagnostic
Air or moisture in system. System not fully charged.
chart.
connector 7. Low side high
4. Not used

Insufficient cooling. Replace the compressor.
Cause Diagnostic
Compressor malfunction. Internal leak in compressor caused by worn or
scored pistons, rings, or cylinders.
Conditions*
Low side pressure too high. The gauge should read NOTE: * test procedure based upon ambient tem-
1 ÷ 2 bar (14.5 ÷ 29 psi). perature of 35 °C (95 °F).
Too low pressure on high-pressure side. The gauge ent temperatures, refer to the pressure temperature
should read 13.3 ÷ 14.8 bar ((193 ÷ 215 psi)). chart.
Evaporator air not cold.
1. High side high 5. Low side hose connected to low side service
4. Not used
Problem At this point, operate the system and check its per-
formance.
Little or no cooling. Engine overheats in some
cases. If still unsatisfactory, proceed as follows:
Cause - discharge and recover the coolant from the sys-
tem;
Condenser not functioning properly.
- remove the condenser, clean and flush it to
Conditions* ensure a free flow of coolant. Otherwise, if the
Low side pressure too high. The gauge should read condenser appears to be particularly dirty or
1 ÷ 2 bar (14.5 ÷ 29 psi). obstructed, replace it;
High side pressure too high. The gauge should - replace the receiver/drier;
read 13.3 ÷ 14.8 bar (193 ÷ 215 psi). - drain the system and recharge it with the correct
Liquid line hot. quantity of coolant;
- carry out the performance test of the system.
Evaporator air warm.
Diagnostic
High pressure switch cutting out.
Lack of cooling caused by pressure that is too high
Corrective procedures on the high side, resulting from improper operation
Check belt. Loose or worn drive belts could cause of condenser. (Coolant charge may be normal or
excessive pressures in the compressor head. excessive).
Look for clogged passages between the condenser NOTE: * test procedure based upon ambient tem-
fins and coil, or other obstructions that could reduce perature of 35 °C (95 °F).
condenser airflow. For proper high side gauge reading for other ambi-
If engine is overheating replace engine thermostat
chart.
and radiator pressure cap.
connector 7. Low side normal
4. Not used

Little or no cooling. Discharge and recover the coolant from the sys-
tem.
Cause
Large amount of air in system.
Drain the system.
Conditions*
Charge the system.
Low side pressure too high. The gauge should read
1 ÷ 2 bar (14.5 ÷ 29 psi). Performance test the system.
Too low pressure on high-pressure side. The gauge Diagnostic
should read 13.3 ÷ 14.8 bar (193 ÷ 215 psi). Air in the system. Air and humidity contained in it
Evaporator air not cold. contaminate the system: therefore, it will operate
incorrectly.
chart.
1. High side high 5. Low side hose connected to low side service
4. Not used
Problem If the test indicates that the expansion valve is

defective, proceed as follows:
Little or no cooling.
- discharge and recover the coolant from the sys-
Cause
tem;
Improper operation of thermostatic expansion valve - replace the expansion valve;
(stuck open).
- drain the system;
Conditions*
- charge the system;
Low side pressure too high. The gauge should read - carry out the performance test of the system.
1 ÷ 2 bar (14.5 ÷ 29 psi).
Diagnostic
High side pressure too high. The gauge should
Thermostatic expansion valve is allowing too much
read 13.3 ÷ 14.8 bar (193 ÷ 215 psi).
coolant to flow through the evaporator coils. Valve
Evaporator air warm. may be stuck open.
Evaporator and suction hose (to compressor) sur- NOTE: * test procedure based upon ambient tem-
faces show considerable moisture. perature of 35 °C (95 °F).
Corrective procedures For proper high side gauge reading for other ambi-
Check for sticking expansion valve as follows: chart.
- operate the system at maximum cooling;
- check the low-pressure side gauge. The pressure
should lower slowly.
4. Not used
Problem - operate the system at maximum cooling;

Insufficient cooling. - check the low-pressure side gauge. The pressure
Cause
If the previous procedure indicates that the expan-
Improper operation of thermostatic expansion valve sion valve is defective, proceed as follows:
(stuck open).
- discharge the system;
Conditions*
- replace the expansion valve;
Low side pressure too low (zero or vacuum). The - drain the system;
gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi).
- charge the system;
High side low. The gauge should read 13.3 ÷ 14.8 bar - carry out the performance test of the system.
((193 ÷ 215 psi)).
Diagnostic
Evaporator air cool, but not sufficiently cold.
Expansion valve is not permitting a sufficient flow of
Evaporator inlet pipe surface shows considerable coolant. May be caused by valve stuck in restricted
moisture or frost. or closed position.
Low pressure switch cutting out. NOTE: * test procedure based upon ambient tem-
Corrective procedures perature of 35 °C (95 °F).
Place finger on expansion valve to evaporator tube.
If too cold to touch, proceed as follows:
chart.
4. Not used
Problem
Little or no cooling. - check the low-pressure side gauge. The pressure
Cause
If the test indicates that the expansion valve is
Restriction in high side of system. defective, proceed as follows:
Conditions* - discharge and recover the coolant from the sys-
Too low pressure on low-pressure side. The gauge tem;
should read 1 ÷ 2 bar (14.5 ÷ 29 psi). - replace the expansion valve;
Too low pressure on high-pressure side. The gauge - drain the system;
should read 13.3 ÷ 14.8 bar ((193 ÷ 215 psi)). - charge the system;
NOTE: a normal or high reading of the high side - carry out the performance test of the system.
pressure gauge under these conditions indicates Diagnostic
the system is overcharged or the condenser or
receiver/dryer is too small. Thermostatic expansion valve is allowing too much
coolant to flow through the evaporator coils. Valve
Evaporator only slightly cool. may be stuck open.
Liquid line and receiver/dryer are cool to touch and
show frost or considerable moisture.
Corrective procedures For proper high side gauge reading for other ambi-
Check for sticking expansion valve as follows:
chart.
- operate the system at maximum cooling;
connector 7. Low side gauge
4. Not used Compressor cycles on at 2.3 bar (33.36 psi)
Compressor cycles off at 1.9 bar (27.56 psi)

Compressor cycles (cuts in and out) too rapidly. Stop engine and shut off air conditioning.
Cause Replace thermostatic switch with switch of same
type.
Thermostatic switch defective.
Make sure the switch’s temperature sensor is
Conditions*
installed in the same position and depth (in evapo-
Low-pressure side readings are too high during rator core) as previous.
both ON and OFF compressor cycles and between
cycles.
Diagnostic
Readings should be:
Defective thermostatic switch.
0.8 ÷ 1.0 bar (11.60 ÷ 14.50 psi) - OFF cycle
2.5 ÷ 2.7 bar (36.26 ÷ 39.16 psi) - ON cycle NOTE: * test procedure based upon ambient tem-
1.7 ÷ 1.9 bar (24.65 ÷ 27.56 psi) - between cycles For proper high side gauge reading for other ambi-
The pressure on the high-pressure side is normal. The ent temperatures, refer to the pressure temperature
gauge should read 13.3 ÷ 14.8 bar (193 ÷ 215 psi). chart.
LEAK TESTING, DISCHARGING AND CHARGING THE AIR CONDITIONING SYSTEM

Leak testing
To perform a leak test if coolant leakage is sus-
pected, use a leak detector following the manufac-
turer’s instructions.
Leak detectors use light or sound dependent upon
the type used to alert the operator of a leak. If the
leak detector’s sensitivity is adjustable, be sure you
calibrate the detector according to the manufac-
turer’s instructions before use.
When using a leak detector, keep in mind that a
very slight amount of leakage in the compressor
pulley area is normal and does not necessarily indi-
cate a repair is required.
When a leak is located, follow these steps.
- Discharge the system using a certified coolant
recovery system.
- Repair the leak.
- Drain the system.
- Partially charge the system with 400 g (0.88 lb) of
coolant.
- Check system for leaks.
- Fully charge the system.
Always check the system for leaks as a final test
after evacuating and before recharging. Refer to
“Evacuating the system”.
Discharging the system
Legislation has been introduced banning the
release of coolant into the atmosphere.
Whenever overhauling the air conditioning system
or performing other tasks which require the air con-
ditioning system to be dismantled it is necessary to
discharge the coolant gas before commencing
repair.
Before you can dismantle an air conditioning sys-
tem for repairs, you must discharge and recover the
coolant using a certified recovery unit in accord-
ance with the manufacturer’s instructions.
Shown is a combined coolant recovery, evacuation
and recycling/charging station. This equipment
removes HFC 134a coolant from the air condition-
ing system, recycles and recharges all in one hook
up.
The unit is designed to be used with the manifold
gauge set built into the control panel.
1. Built in manifold gauge set 3. Low side (suction) service valve (blue hose)
2. Recovery/recharging unit 4. High side (discharge) service valve (red hose)
Other recovery systems are available where the ting and the blue (low side) hose to the low side
manifold gauges are not an integral part of the (suction) fitting.
machine. When this type of equipment is used a
NOTE: if a unit requiring the manifold gauge set is
separate manifold gauge set must be used.
being used, the low and high sides of the manifold
The following is a summary of the steps for dis- set are connected to the low and high sides of the
charging the system using a recovery/recycling backhoe loader air conditioning system. The hose
unit. from the recovery unit is then connected to the
manifold centre port.
S WARNING S To recover coolant, open both high and low side
Never discharge coolant gas into the atmosphere. valves on the control panel or the valves on the
Always wear safety goggles and gloves when work- manifold gauge set if being used.
ing with coolant. Only use authorized coolant tanks.
Open the valves labelled “gas” and “liquid” on the
IMPORTANT: always follow the manufactures recovery unit coolant tank.
instructions when operating recovery equipment. Plug in the unit’s power cord.
Run the vehicle’s air conditioning system for a few
minutes. Operate the recovery system in accordance with
the manufacturers instructions.
Set up the recovery unit following manufacturer’s
instructions. Ensure that the units red (high side) The compressor will shut off automatically when the
hose is connected to the high side (discharge) fit- recovery is complete.
FLUSHING THE SYSTEM
1. High side gauge 5. Low side hose

2. High side shut-off valve 6. Low side shut-off valve
3. High side hose 7. Low side gauge
4. Centre service hose
Air conditioning systems may occasionally become

contaminated with solid particles. This contamina-
tion may be the result of allowing dirt to enter the
system while it was open, from aluminium corrosion
or sludge, or from disintegrated compressor reed
plates. Contamination of this nature can result in
plugged evaporators, condensers and expansion
valves.
Flush System with dry nitrogen.
Each individual component must be flushed after
disconnecting every hose fitting.
The compressor and expansion valve can not be
flushed, therefore, the compressor should be disas-
sembled and cleaned or replaced and the expan-
sion valve should be replaced. When flushing the
system always replace the receiver/drier.
NOTE: for flushing the air conditioning system,

never use any solvent other than the special flush-
ing solvent specifically produced for air conditioning
systems. Always follow the manufacturer’s recom-
mendations and directions for using the flushing
equipment and solvent.
Re-assemble and evacuate the system to remove
air and moisture as described in “Evacuating the
System”.
DRAINING THE SYSTEM

IMPORTANT: a system in which coolant has been If a combined recovery/evacuation unit is to be
recovered to facilitate repairs must be drained used attach the unit to the air conditioning system
before new coolant is filled in. in accordance with the manufacturers instructions.
Air and moisture are removed by evacuating the Be sure to read all installation and operating
system using a vacuum pump. instructions carefully before starting the unit.
The automatic recycling, recharge and evacuation After starting the evacuation cycle, note the low
stations or evacuating and charging stations availa- side gauge to be sure the system pulls down into a
ble throughout the air conditioning industry incorpo- vacuum.
rate a vacuum pump within the assembly. If this
Time the evacuation for a minimum of 30 minutes
type of equipment is not available a separate vac-
from the point when lowest vacuum is attained.
uum pump and manifold gauge set must be used.
Thirty minutes later when the low side gauge
As the system is evacuated the boiling point of any attains the lowest steady vacuum, stop the evacua-
moisture within the system is similarly lowered. As tion process.
the vacuum increases the boiling reduces to below
that of the ambient temperate and the moisture is NOTE: the vacuum pump achieves ultimate vac-
subsequently boiled away. uum with the vented exhaust valve closed. Do not
evacuate too quickly as oil may be drawn from the
The relationship of system vacuum to the boiling
system.
temperature at which the water vapour is removed
from the system is as follows: Check the system by closing the gauge shut-off
valves, turning the vacuum pump off and noting the
low side gauge reading. A loss of more than 5 cm
System System Temperature
(1.97 in) of vacuum in 5 minutes indicates either a
Vacuum Vacuum
leak or moisture in the system.
In mercury Cm (in) of °C (°F)
If the gauge needle remains stationary and the vac-
mercury
uum is maintained for 3-5 minutes, close both the
28.0 71.0 (28.9) 38 (100.4) high and low side manifold hand valves, turn off
and disconnect the centre hose from the pump. The
28.9 73.4 (29.0) 27 (80.6)
system is now ready for charging.
29.4 74.6 (29.4) 16 (60.8) If a leak is detected, charge the system with
29.7 75.4 (29.7) 5 (41) approximately 400 g (0.88 lb) of coolant, see charg-
ing the system and locate the leak using a leak
29.8 75.7 (29.8) -7 (19.4) detector.
29.9 75.9 (29.9) -18 (-0.4) Once the leak is located discharge and recover the
coolant in the system, repair the leak, then repeat
the evacuation procedure.
NOTE: for every 305 m (1000 ft) above sea level,
the vacuum gauge reading must be corrected by
adding 2.54 cm (1 in) of mercury to compensate for
the change in atmospheric pressure.
IMPORTANT: be sure the system is completely dis-
charged as coolant will damage the vacuum pump.
If the manifold gauge set is being used connect the
low and high sides of the manifold to the low and
high sides of the vehicle air conditioning system as
described for discharging the system.
Connect the manifold centre hose to the vacuum
pump suction port as per the manufacturers
instructions.
Fully open both the low and high side gauge shut
off valves.
CHARGING THE SYSTEM

IMPORTANT: make sure that there are no leaks in If the coolant charge will not completely transfer to
the system and that the system has been fully the air conditioning system, recover and recharge
drained. Observe all safety recommendations when the system.
handling coolant HFC 134a, see “Precautions when Close the high and low side valves on the unit con-
Handling coolant HFC 134a” in this Section. trol panel, or on the gauge assy if being used, and
Ensure the charging unit is correctly connected to test the air conditioning as described in the para-
the backhoe loader air conditioning system in graph relevant to the performance test of the air
accordance with the manufacturers instructions. conditioning system.
If a charging unit, in conjunction with the manifold
NOTE: after charging a system use the following
gauge set is used, open the high and low side hand
start up procedure to ensure the lubricating oil is
valves on the manifold.
properly dispersed around the system.
Charge the system with 1.35 kg (2.97 lb) of coolant
- Ensure air conditioning is switched OFF.
as per the manufacturers instructions.
- Start the engine and bring speed down to idle.
If the charging rate becomes very slow close the
- Turn the air conditioning ON and allow system to
high side valve carefully, start the backhoe loader
operate for at least one minute before increasing
and set engine speed to idle. Turn ON the air condi-
engine speed.
tioning so that the compressor can pull the remain-
der of the coolant into the system.
1. Built in manifold gauge set 3. Low side (suction) service valve (blue hose)
2. Recovery/recharging unit 4. High side (discharge) service valve (red hose)
OVERHAUL
S WARNING S
Before disconnecting components in the air condi-
tioning system the coolant gas must be discharged
and recovered using a certified recovery system.
Refer to Discharging the system. Do Not discharge
the gas into the atmosphere.
If an air conditioning component is to be replaced

during a system overhaul it is necessary to drain
any coolant oil that has collected in the component
being replaced into a clean calibrated container.
A volume of clean coolant oil equivalent to that
removed from the replaced component must then
be added to the new item before being installed onto
the backhoe loader.
Upon completion of the repair evacuate, recharge,
leak test and performance test the system to ensure
correct operation.
EXPANSION VALVE
The expansion valve is not a serviceable item and
must be replaced if defective.
Fully discharge the air conditioning system.
Remove the seat to gain access to the valve.
To gain access to the expansion valve partially lift
the evaporator core from its position in the cab floor.
Remove the screw securing the inlet and outlet con-
nections to the valve and pull valve from tubing.
Replace the O-ring seals and lubricate with coolant
oil prior to installing the valve using disassembly
procedure in reverse.
Evacuate, leak test and recharge the system.
EVAPORATOR
Discharge and recover coolant gas using certified
recovery systems.
Remove the seat and cover plate to reveal evapora-
tor assembly (1).
Remove temperature cycling control thermocouple.
Disconnect tubing to expansion valve.
Remove evaporator.
Check the evaporator assembly fins for damage.
Straighten fins if necessary.
Clean the evaporator core of all foreign material to
be sure it is free of obstructions.
Check the evaporator assembly for indications of
coolant leakage. If damage or leaks are evident,
replace the evaporator core.
If a new evaporator is to be installed drain the cool-
ant oil in the evaporator into a clean calibrated con-
tainer.
Measure the quantity of oil obtained and add the
same quantity of new coolant oil directly into the
replacement evaporator core.
Install evaporator using disassembly procedure in
reverse.
Evacuate, leak test and recharge the system.
ADJUSTING SENSOR OF AIR CONDITIONER

TEMPERATURE
Remove the seat mounting plate.
The temperature adjusting sensor (2) is mounted to
the side of the blower motor assembly.
Carefully pull and disconnect the switch wiring at the
connector.
Remove temperature control switch and replace as
required.
LOW-PRESSURE CUT-OUT SENSOR

With the engine OFF check continuity across the
switch contacts.
If the sensor (1) indicates an open circuit, replace it
as described below.
1
IMPORTANT: the sensor cannot be replaced with-
out discharging the system.
Remove the sensor by unscrewing it from the valve.
Replace with new switch and connect to harness.
TBR00081
BLOWER MOTOR ASSEMBLY
The blower motor (2) can if required be removed
without discharging the system as follows:
Remove the cab seat mounting plate.
NOTE: take care not to damage hoses during this
operation. If the cab heater hoses restrict move-
ment of the housing drain the heater assembly and
disconnect the hoses.
Disconnect the motor wiring connector block.
Remove the remaining motor securing screws and
withdraw motor.
Re-assembly follows the disassembly procedure in
reverse.
RECEIVER DRYER
The receiver/dryer (1) cannot be overhauled and
must be replaced as an assembly. The receiver/
dryer assembly should be replaced if it is suspected
that moisture is in the system.
The receiver dryer must also be replaced if the sys-
tem has been discharged and the air conditioning
joints disconnected.
Discharge and recover coolant gas using certified 1
recovery systems.
Disconnect the hoses and switch and remove the
dryer from the backhoe loader.
TBR00083
Drain the coolant oil from the receiver dryer into a
clean calibrated container. Measure the quantity of
oil obtained and add the same quantity of new cool-
ant oil directly into the new item.
Cap and plug all fittings to prevent any dirt entering
the system.
Install a new receiver dryer.
CONDENSER
Loosen and remove the fixing screws (2). 2
Remove the front grill (1).
TBR00123

Remove the horn (4).
Remove the fuel cooler (6).
Unscrew and remove the fixing upper nut (7) and

loosen the fixing lower nut.
Move the dryer filter (8) to the right side.
Unscrew and remove the nuts (9).

Move the condenser (10) forward.

Clean the condenser (10) by compressor air.
AIR FILTER
Before servicing the filter (1), switch off the blower
and close all windows and one door.
Slam the final door closed and the resulting back
pressure will dislodge most of the loose dirt from the
underside of the filter.
Remove the filter (1) and clean it by blowing with
compressed air not exceeding 2 bar (29 psi).
IMPORTANT: make sure you protect your face
before using compressed air.
Blow the dust from the upper surface through the
element to the lower surface. Hold the nozzle at
least 300 mm (11.8 in) from the element to prevent
damage to the paper pleats.
Clean both filter chambers with a damp, lint free
cloth.
Replace the filter element with the rubber seal
uppermost and re-install the covers.
COMPRESSOR
Basic compressor specifications
Displacement ......................................................................................................................... 155 cm3 (9.46 in3)
Weight ............................................................................................................................................ 9.9 kg (22 lb)
Oil type ....................................................................................................................................................... SP15
Rotation.............................................................................................................................. CW (Clockwise only)
Compressor clutch and pulley air gap............................................................... 0.9 ÷ 0.8 mm (0.035 ÷ 0.031 in)
Belt tension
Measure at the widest gap ...... 10 mm (0.40 in) deflection with 1 kg (2.2 lb) force applied midway between the pulleys
Speed rating
Constant............................................................................................................................................... 6000 rpm
Downshift ............................................................................................................................................. 8000 rpm
Tightening torque
M8 armature retaining nut .....................................................................................17.7 ± 2.9 Nm (13 ± 2.1 lbf·ft)
M6 cylinder head screws.......................................................................................13.7 ± 2.9 Nm (10 ± 2.1 lbf·ft)
M8 cylinder head screws....................................................................................34.3 ± 4.9 Nm (25.3 ± 3.6 lbf·ft)
Clutch dust cover screw ...............................................................................................9 ± 2 Nm (6.6 ± 1.5 lbf·ft)
Oil filler plug .......................................................................................................19.6 ± 4.9 Nm (14.5 ± 3.6 lbf·ft)
REMOVAL AND INSTALLATION
3
8 13
1
14
15
12 9
10
7
11
4
2
5
TBR00124
1. Bracket air conditioning mounting 9. M8x35 hex screw

2. Stud dowel ring [tightening torque 26÷31 Nm (19÷23 lbf·ft)]
3. Compressor air conditioning 10. M10x70 hex screw
4. Bracket idler support 11. Nut
5. Pulley idler 12. M8x50 hex screw
[tightening torque 37÷41 Nm (27÷30 lbf·ft)]
6. Belt
13. Stud dowel ring
7. Washer
14. Bracket air conditioning brace
8. M8x100 hex screw
[tightening torque 37÷41 Nm (27÷30 lbf·ft)] 15. M10x25 hex screw
REMOVAL
Discharge the air conditioning system. Disconnect
the wiring harness of the compressor (3) from the
wiring harness of the engine.
Disconnect tubing to compressor.
Remove the nut (11) and screw (10).
Remove the screws (9) of the support bracket (4)
belt tensioner (5).
Remove the belt (6).
Remove the screws (12), washers (7) and stud (2).
Remove the support (1) complete with compressor
(3).
Disassembly the compressor (3) from support (1)
removing the screws (8) and stud (13).
INSTALLATION
To install, follow the removal procedure in reverse

order.
Torque the fastening screws to 37 ÷ 43 Nm
(27 ÷ 31.7 lbf·ft).
NOTE: it is recommended that a new receiver/drier
assembly is installed after any system component
replacement or any repair that requires entry into
the system.
Drain the oil from the new compressor to be fitted
into a clean container, or if the old compressor is to
be refitted, obtain a new can of coolant oil.
Calculate the amount of oil to be installed and refill
the compressor.
Reconnect the hoses to the compressor and tighten
all screws and hoses.
BELT ADJUSTMENT
The compressor drive belt (1) can be tensioned by
rotating the bracket idler support (2).
Slacken the bracket idler support screw and adjust
the arm to a belt deflection of 16 mm (0.63 in).
Once adjusted re-torque the bracket idler support
screws to 37 ÷ 41 Nm (27 ÷ 30 lbf·ft).
TBR00089
OVERHAUL
Before any internal repair is done, drain the oil from
the compressor:
Remove the oil plug and drain as much oil as possi-
ble into a suitable container.
Remove the caps (if present) from suction and dis-
charge ports.
Drain oil from the section and discharge ports into
suitable container while turning the shaft clockwise
only with a socket wrench on the armature retaining
nut.
Measure and record the amount of oil discharged.

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

CLUTCH
1. Screw 6. Cover
2. Dust cover 7. Snap ring
3. Nut 8. Rotor
4. Plate 9. Snap ring
5. Shims 10. Coil
Disassembly
All clutch servicing should be done with the com-
pressor removed from the vehicle. Support the
compressor. If using a vice, do not hold on to the
housing.
If a dust cover (2) is present, remove the 3 or 6
screws (1) holding it in place and remove the cover.
If auxiliary sheet metal pulley is present, remove the
screws holding it in place.
Then remove pulley.
Attach the tool to the cover in front of the clutch disc
and remove the nut (3) using a wrench.
Using the front plate tool and a prybar, hold the

clutch plate stationary.
Place the screw into the tool and by tightening the
screw onto the end of the shaft the front plate will be
extracted from the shaft.
If shims (5) are above shaft key, remove them now.
If shims (5) are below shaft key, the key and bearing
dust cover (if present) must be removed before
shims can be removed.
Remove dust cover (6) (if present). Use caution to
prevent distorting cover when removing it.
Remove shaft key by tapping loose with a flat blade
screwdriver and hammer.
Remove shims (5).
Use a pointed tool and a small screwdriver to pre-
vent the shims from binding on the shaft.
Remove the snap ring (7), remove the shaft key and
lift the pulley assembly from the compressor.
Check the rotor assembly (8) for wear and replace

the assembly as necessary.
Remove the field coil wire retaining clip.
Remove the snap ring (9) of the coil.
Lift the coil (10) from the housing and replace as

required.
Assembly
Install the coil (10), making sure that the wire is
located behind the clip on the outside of the body
and that the snap ring (9) is located in the groove.
Position the rotor (8) on the housing hub and care-

fully slide the rotor (8) down the shaft.
Reposition the plate (4) and the retaining nut (3).

Tighten the nut to the prescribed torque of 18 Nm
(13 lbf·ft).
Check the clearance between the plate (4) and the

rotor (8). This should be consistent around the cir-
cumference and be between 0.4 ÷ 0.8 mm
(0.015 ÷ 0.031 in).
NOTE: if the air gap is not consistent, lightly pry up
on the counter weighted front plate at the low spots
or lightly tap down at the high spots.
If the clearance is not within specification, the shims

(5) under the front plate should be added or
removed, until the correct clearance is obtained.
NOTE: new shims are available in the following
sizes: 1.00, 0.50 and 0.13 mm (0.04, 0.02 and
0.005 in).
Reposition the dust cover (2), if present, and torque

the 3 or 6 screws (1).
COMPRESSOR
1. Shaft key 6. Gasket

2. Ring 7. Plate
3. Snap ring 8. Head gasket
4. Gasket 9. Cylinder head
5. Plug 10. Screw
Disassembly
Remove the armature plate, as detailed in the steps
of clutch disassembly.
Remove the shaft key (1) and the ring (2) to expose
the snap ring (3).
Insert the seal (A) remover/installer tool.

Turn the tool to engage the slots in the seal.
Pull up to remove and discard the seal (4).
Assembly
Thoroughly clean the seal cavity in the hub.
Use “lint free” cloth only.
Ensure the new shaft seal O-ring is installed onto
the seal assembly.
Dip the new seal assembly in clean coolant oil and
attach to the seal remover/installer tool.
Completely insert the new seal (4).

NOTE: if remover/installer tool (A) is not available,
position the seal squarely in the hub and tap gently
until fully seated.

If the snap ring has a bevelled edge, this should
face outwards.
Install the new ring (2) and push into position.

Position the shims over the shaft and refit the shaft
key.
Reinstall the plate as described in clutch reassem-
bly.
CYLINDER HEAD
Disassembly
Drain the coolant oil from the compressor into a
clean graduated container.
Measure and record the quantity of oil obtained.
This information is required during installation of the
new or overhauled unit.
Remove the six cylinder head screws (10) and
using a hide mallet, gently tap the cylinder head (9)
free.
The use of a gasket scraper may also be required
to free the cylinder head from the compressor body.
If the plate (7) and/or cylinder head are to be

reused, carefully remove the gasket (8) using a suit-
able scraper.
Gently pry the plate (7) free from the cylinder block
and remove the gasket (6).
Inspect the plate (7) for damage.
Assembly
Coat the top of the valve plate with clean coolant oil
and reassemble the cylinder head following the
removal procedure in reverse order.
When installing the gaskets and valve plate ensure
they are correctly positioned over the locating pins
in the cylinder block.
Install the cylinder head screws and tighten using
the sequence shown.
Torque initially to 20 Nm (15 lbf·ft).
When the overhaul is complete add to the compres-
sor a volume of oil equivalent to that drained prior to
disassembly, or as the reclaim measured fill.
TROUBLESHOOTING

Unusually high suction Valve plate test. Replace or repair:
pressure with unusually low Broken head or block gasket.
discharge pressure.
Broken or deformed reed valve.
Foreign substance under reed valve
or gasket.
Unusually low suction and Check for low coolant charge. Replace or repair:
discharge pressure. Shaft seal leak.
Compressor leak check. Cylinder head leak.
Gasket leak.
Leak check and diagnostic system. Oil filler plug leak.
Cracked cylinder block.
Front housing O-ring leak.
Intermittent or inoperative. Check belt tension. Replace.
Check clutch air gap. Adjust air gap.
Check voltage, amperage, coil lead Replace or repair:
wire of the clutch. Broken lead wire.
Internal clutch coil defect.
System ground (see system
manual).
Difficult start. Shaft turning smoothness test. Internal compressor failure.
Clutch engaged. Check compressor mounting Replace or repair.
components.
Check engine components. Replace or repair.
Check for intermittent or slipping Adjust air gap - defective coil.
clutch.
Check for proper coolant charge. Recharge and recheck.
Check clutch bearing. Replace rotor / armature assembly.
Oil level procedure. Fill to proper level.
Shaft turning smoothness test. Internal compressor failure.
Remove valve plate and inspect. Replace or repair:
Broken discharge valve reed or
retainer.
Broken suction valve reed.
Broken gasket.
“Chattering” disengaged Check air gap. Replace or repair:
clutch. Adjust air gap.
Defective clutch pulley or front plate.
NOTES:
580ST
590ST
695ST
SECTION 55 - ELECTRIC SYSTEM
ELECTRIC DIAGRAMS .................................................................................................................................... 3

ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580ST - 590ST electronic engine) ............................. 3
CONTROLS AND INSTRUMENTS ................................................................................................................ 59

FRONT CONTROL PANELS (580ST - 590ST) ......................................................................................... 59
FRONT CONTROL PANELS (695ST)....................................................................................................... 61
CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST electronic engine) ............. 63
SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST)....................................................................... 65
ANTI-START SYSTEM .............................................................................................................................. 67
DIAGNOSTIC DISPLAY (580ST - 590ST - 695ST)........................................................................................ 68

SYMBOLS.................................................................................................................................................. 70
SETUP MENU ........................................................................................................................................... 71
PROCEDURE ABOUT SELF TEST .......................................................................................................... 72
ON BOARD ERROR CODE RETRIEVAL ................................................................................................. 73
BACKLIGHTING AND DIMMING............................................................................................................... 74
WORK HOURS.......................................................................................................................................... 75
OPERATION.............................................................................................................................................. 76
WARNING SYSTEM.................................................................................................................................. 80
MAINTENANCE......................................................................................................................................... 81
WARNING MESSAGES ............................................................................................................................ 82
STARTING SYSTEM ...................................................................................................................................... 88

OPERATION.............................................................................................................................................. 88
STARTER MOTOR.................................................................................................................................... 91
2 SECTION 55 - ELECTRIC SYSTEM
ALTERNATOR ................................................................................................................................................ 98
OPERATION .............................................................................................................................................. 99
BATTERY...................................................................................................................................................... 101
OPERATION ............................................................................................................................................ 101
REPLACEMENT ...................................................................................................................................... 102
CHARGE AND ELECTROLYTE LEVEL CHECK .................................................................................... 103
CONNECTING A BOOSTER BATTERY ................................................................................................. 104
BATTERY MASTER SWITCH ................................................................................................................. 104
TROUBLESHOOTING .................................................................................................................................. 105

SECTION 55 - ELECTRIC SYSTEM 3
ELECTRIC DIAGRAMS
ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580ST - 590ST electronic engine)

FUSES AND RELAYS
K6 Outer front work light relay
Fuse
Rating Function
no. K7 Outer rear work light relay
F1A 15 A Rear windshield wiper and washer K8 Inner front work light relay
(+15) anti-theft device, (+15) ECU power K9 Inner rear work light relay
F1B 7.5 A
supply, fuel shut off, key switch
K10 Reverse travel relay
F1C 10 A Stop light switch
K11 Forward travel relay
Instrument power supply, pneumo-elec-
F2A 15 A K12 Direction indicator flashing
tric seat, speed sensor, start up
F2B 15 A Air conditioning
F2C 15 A Pilot control
Rear right/front left side light, instrument

F3A 3A
backlighting
Rear left/front right side lights, number

F3B 3A
plate light
F3C 10 A Work light switch, 4x1 bucket handgrip
Forward travel, reverse travel, reverse

F4A 5A
travel buzzer, speed switch
Backhoe hammer button, sensor + buck-

et level solenoid valve, transmission dis-
F4B 10 A
connect button and differential lock
button
Backhoe attachment lock, backhoe at-

F4C 10 A tachment travel lock, rear work light
switch
F5A 15 A Outer front work light relay
F5B 10 A Low beams
F5C 15 A Main beams
F6A 7.5 A Rotating beacon
F6B 7.5 A (+15) hazard warning light power supply

F6C 7.5 A Hand hammer, 4WD
(+30) power supply for hazard warning

F7A 10 A
lights, horn
F7B 10 A Electric socket, radio, roof lamp
F7C 6A Front windshield wiper
F8A 15 A Outer rear work lights
F8B 15 A Inner rear work lights
F8C 15 A Outer rear work lights
K1 Forward-reverse travel control relay
K3 Starting relay
TBR00079
K4 Bucket level solenoid valve relay
K5 Low and main beam relay

COMPONENTS
NAME DESCRIPTION
NAME DESCRIPTION
A14 Antitheft unit E51 Outer front work light
A53 Radio (optional) E55 Cigarette lighter

E406 Rotating beacon
A461 Engine control unit
A469 Glow control unit E407 Right side work light
B4 Air filter blocked switch E409 Left side work light

B5 Fuel level sensor
B25 Foot accelerator F1 Diagnostic socket +30 fuse
B26 Bucket sensor F1E Main fuse engine control unit
B30 Parking brake microswitch F2 Side work light relay fuse, 15 A

F2E Main fuse engine control unit
B66 Transmission oil temperature switch
B69 Air conditioning pressure switch F3 +30 switch and +30 instrument panel fuse
B411 Speed sensor F3E Lambda + engine fuse

F4 Quick coupler fuse
B463 Water in fuel sensor
B468 Lambda sensor F5 Ride control, front panel and lock valve
fuse, 7.5 A
B474 Air temperature sensor
F112 Air conditioning fuse
B475 Diff. pressure sensor
F466 Glow control unit fuse
B476 Gas temperature sensor 1
F500 General fuse
G1 Battery
B608 Hand accelerator
G67 Alternator
B805 Ride control pressure switch
H2 Horn
BS1 Left speaker (optional)
H7 Reverse buzzer
BS2 Right speaker (optional)
H26 Backhoe attachment lock warning light
E2 Front left light (optional)
E3 Front right light H606 Buzzer
E18 Roof lamp K103 Starting
E27 Number plate light K104 Starter motor relay
E28 Rear left light K105 Air conditioning compressor relay
E29 Rear right light K224 Differential lock relay
E38 Outer rear work light K226 4WD relay
E40 Inner rear work light K230 Hand hammer relay
E44 Outer front work light K232 Ride control relay
E45 Inner front work light K464 Main relay
E46 Inner rear work light K473 A/C clutch
E47 Outer rear work light K605 Side work light relay
E50 Inner front work light M1 Starter motor
NAME DESCRIPTION NAME DESCRIPTION

M39 Rear windshield wiper motor ST3 4x1 bucket control lever
M41 Blower motor (optional) X17 Seat (optional)
M49 Front windshield wiper motor X55 Auxiliary 12 V socket
M56 Front windshield wiper pump X72 Pilot control interface connector
M57 Rear windshield wiper pump X112 A/C fuse connector
P1 Side instrument cluster panel X201 Accelerator knob
P125 Speedometer (optional) X463 WIF connector
S2 4WD switch X448 Manifuse connector
S3 Hand hammer switch X461 Engine control unit connector
S5 Ride control switch X462 Engine control unit connector
S9 Lights switch X466 Glow control unit fuse connector
S15 Rotating beacon switch X468 Lambda sensor connector
S15.1 Starting panel X469 Glow control unit connector
S32 Stop light switch X470 Connect to engine harness
S33 Stop light switch X471 Electric valves connector
S34 Port left microswitch X473 A/C clutch connector
S35 Port right microswitch X474 Air temperature sensor connector
S36 Rear hammer button (optional) X475 Diff. pressure sensor connector
S41 Light-windshield wiper control lever X476 Gas temperature sensor 1 connector
S42 Warning switch X477 Gas temperature sensor 2 connector
S100 Quick coupler A switch (optional) X496 Front harness - engine harness interface
connector
S101 Quick coupler B switch (optional)
X600 General cable - engine cable 1 way
S132 Gearshift lever
connector
S135 Vertical backhoe attachment lock switch
X800 Front harness - engine harness interface
S136 Menu scroll switch connector
S137 Rear work light switch X801 Front harness - general harness interface
connector
S138 Windshield wiper + pump switch
X805 Ride control pressure switch connector
S139 Display enter switch
X810 Telematies connector
S140 Rear travel switch
Y6 Forward travel solenoid valve
S141 Front work light switch
Y8 4WD solenoid
S144 Rear horn button
Y12 Proportional solenoid valves
S210 Transmission disconnect button
S205a Clutch disconnect button
S205b Differential lock switch
S604 Side work light switch
SB1 Battery master switch

Y34 Ride control solenoid valve (optional) X29 4-way rear left light connector
Y35 Hand hammer control valve (optional) X31 General line fuse box connector
Y74 Differential lock solenoid valve X34 2-way ride control solenoid valve
connector
Y105 Quick coupler solenoid valve
X35 2-way hand hammer solenoid valve
Y106 Load sensor solenoid valve
connector
Y200 Reverse speed solenoid valve X36 2-way backhoe hammer button connector
Y202 Backhoe attachment travel solenoid valve X38 2-way rear right work light connector
Y203 Backhoe attachment lock solenoid valve
X39 4-way rear windshield wiper connector
(optional)
X40 2-way rear right work light connector
Y206 Bucket level solenoid valve
(optional)
Y207 Double delivery solenoid valve (optional) X41 2-way blower connector (optional)
Y209 Backhoe hammer control valve (optional) X43 6-way rotating beacon connector
X44 2-way front right work light connector
(optional)
CONNECTORS
X46 2-way rear left work light connector
NAME DESCRIPTION (optional)
X1 18-way general line - engine line connector X47 2-way rear left work light connector
X6 2-way forward travel connector X49 6-way front windshield wiper connector
X7 2-way reverse travel buzzer connector X50 2-way front left work light connector
(optional)
X8 2-way 4WD solenoid valve connector
X51 2-way front left work light connector
X10 31-way solenoid valve line - general line
connector X53 8-way radio connector (brown)
X12 9-way general line - upper cab line X54 8-way radio connector (black)
connector X55 2-way electric socket connector
X13 17-way general line - front instrument X56 2-way front windshield washer connector
panel connector
X57 2-way rear windshield washer connector
X14 11-way antitheft connector
X67 3-way alternator connector
X15.1 Starting panel connector
X69 2-way air conditioning pressure switch
X15.2 Starting panel connector connector
X17 4-way pneumo-electric seat connector X72 1-way pilot control line connector
X19 Gearshift lever connector X87 13-way general line - left side instrument
X22 5-way right work light connector cluster line connector
X24 Lock valve interface connector X88 9-way general line - right side instrument
cluster line connector
X25 Foot accelerator connector
X102 Diode connector
X26 3-way bucket sensor connector
X27 2-way number plate light connector
X28 4-way rear right light connector

X105 2-way quick coupler solenoid valve XC3 Control unit 21-way connector
connector
XC4 Control unit 21-way connector
X106 Load sensor solenoid valve connector
X110 2-way air conditioner connector
XX Diode connector
X125 Front instrument cluster connector
XST1 Side panel connector
XST2 Side panel connector
X200 2-way reverse travel connector
X201.s Accelerator knob connector
X201.p Accelerator knob connector
X202 2-way backhoe attachment travel lock
solenoid valve connector
X203 2-way backhoe attachment lock solenoid
valve connector
X204 2-way horn button on pilot control
connector
X205 4-way lever button connector
X206 2-way bucket levelling connector
X207 2-way delivery doubling solenoid valve
connector
X208 4x1 bucket control lever connector
X209 2-way backhoe hammer solenoid valve
connector
X210 2-way clutch disengage button connector
X220 Air conditioning connector
X406 2-way rotating beacon connector
X411 Speed sensor connector
X420 2-way reverse travel buzzer connector
X421 2-way engine stop diode connector
X603 Front instrument panel - quick coupler kit
connector
X603/1 Quick coupler kit connector
X606 Buzzer connector
X607 Diagnostic plug
X608 Manual accelerator connector
ENGINE LINE DIAGRAM

(table 1)
TBR00165
ENGINE LINE DIAGRAM

(table 2)
TBR00166
SOLENOID VALVE LINE DIAGRAM

(table 1)
TBR00167

(table 2)
TBR00168
LIGHT LINE DIAGRAM
TBR00169
REAR WORK LIGHT LINE DIAGRAM
TBR00178
WORK LIGHT LINE DIAGRAM
TBR00179
WINDSHIELD WIPER AND WASHER LINE DIAGRAM
TBR00180
CAB LINE DIAGRAM
TBR00181
AIR CONDITIONING LINE DIAGRAM
1
3
10 11
9
4
A S
X111 X110 S45

9 8 7 6 5 4 1 2 3 2 1 5 6 7 8 9 4 3 2 1 10 11
X111 X110 S45 X1

pos 11
+15 +30 +15
TBR00154
S Evaporator box S45 11-way connector

1 3rd speed relay 9 Potentiometer
2 Fuse 25 A 10 Speed switch
3 Blower motor 11 Temperature switch
4 1 and 2 speed resistor A 2-way waterproof connection
5 Electric cock B 5-way waterproof connection
X111 9-way connector
X110 2-way power connector
BACKHOE ATTACHMENT QUICK COUPLER LINE DIAGRAM
) See “Solenoid valve line”

2 Quick coupler (optional)
SIDE INSTRUMENT CLUSTER
INSTRUMENT INPUT READING TOLERANCE

320 Ohm Empty - minimum reading +0/-2 Ohm
Level fuel 185 Ohm Right - edge of red band ± 3 Ohm (Ref)
6.5 Ohm Full - maximum reading +4/-0 Ohm
193 Ohm ON ± 5 Ohm
Low fuel level (lamp)
185 Ohm OFF ± 5 Ohm
Speedometer Can message 0 - 3000 rpm ± 50 rpm
Can message Minimum reading 65 °C (149 °F) ± 3 °C (± 37.4 °F)
Coolant temperature Can message Left edge of red band 106 °C (223 °F) ± 2 °C (± 35.6 °F)
Can message Maximum reading 112 °C (234 °F) ± 3 °C (± 37.4 °F)
11 V Right edge of lower red band ± 3°
Battery charge
16 V Edge of upper red band ± 3°
385 Ohm Minimum reading 75 °C (167 °F) ± 3 °C (± 37.4 °F)
Transmission
149 Ohm Left edge of red band 105 °C (221 °F) ± 2 °C (± 35.6 °F)
temperature
112 Ohm Maximum reading 115 °C (239 °F) ± 3 °C (± 37.4 °F)
CN1 CN2
PIN FUNCTION NOTE PIN FUNCTION NOTE
1 Not used 1 Keep alive power Need to fuse at 1
2 Key on power Wake up ampere without
disconnect
3 In gear input Digital input
2 Not used
4 Driving lights Digital input
3 Can Bus line input
5 Front work lights Digital input
6 Rear work lights Digital input
5 Not used
7 Not used
6 Buzzer
8 Not used
7 Starter motor lock 40 Ohm relay = 300
9 Not used mA
10 Air conditioning Digital input 8 Not used
pressure
9 Not used
11 Display switch input Digital input
10 Not used
12 Menu confirmation Digital input
switch input 11 Not used
13 UP switch input Digital input 12 Not used
14 DOWN switch input Digital input 13 Fuel level gauge Resistance
15 Cranking Digital input 14 Transmission Thermistor

temperature
16 Clogged air filter Digital input
15 Not used
17 Not used
16 Foot accelerator 0.5 ÷ 4.5 V
18 Parking brake Digital input
17 Accelerator knob 0.5 ÷ 4.5 V
19 Not used
18 Foot accelerator Output monitored
20 Minimum Digital input for diagnostics
confirmation switch
19 Accelerator knob Output monitored
21 Decelerator button Digital input for diagnostics
22 Not used 20 Foot accelerator
23 Not used 21 Accelerator knob
24 Not used 22 Not used
25 Transmission oil Digital input 23 Not used
pressure
24 Alternator excitation
26 Not used
25 Not used
26 Ground Digital input
ELECTRIC DIAGRAMS - POWERSHIFT CAB (2WS)

FUSES AND RELAYS
Fuse K3 Starting relay

Rating Circuit
no.
F1A 15 A Rear windshield wiper and washer
Engine stop, (+15) anti-theft device, (+15)
F1B 7.5 A K6 Outer front work light relay
ECU power supply
Trax controller + 4WD, automatic/manual K7 Outer rear work light relay
F1C 10 A
switch for transmission disconnection K8 Inner front work light relay
Side instrument power supply, pneumo- K9 Inner rear work light relay
F2A 15 A
electric seat, start up
K10 Optional
K11 Direction indicator flashing relay

F3A 3A
backlighting

F3B 3A
plate light
Front work light switch, side work light

F3C 10 A
switch, 4x1 bucket handgrip
F4A 7.5 A Stop lights, Trax controller
Backhoe hammer button, bucket level so-

F4B 10 A
lenoid valve + sensor
switches
F5A 15 A Inner front work light relay
F5B 10 A Low beams
F5C 15 A Main beams
F6A 15 A Rotating beacon
F6B 7.5 A (+15) hazard warning light power supply
F6C 7.5 A (+15) steering column lights switch
F7A 10 A (+30) warning, horn, anti-theft device,
F8B 15 A Outer front work lights
F8C 15 A Inner rear work lights
TBR00182
COMPONENTS
NAME DESCRIPTION
NAME DESCRIPTION
A14 Antitheft unit E46 Inner rear work light
A53 Radio (optional) E47 Outer rear work light

E50 Inner front work light
A401 Transmission control unit
A461 Engine control unit E51 Outer front work light
A469 Glow control unit E55 Cigarette lighter

B4 Air filter blocked switch
B5 Fuel level sensor E407 Right side work light
B25 Foot accelerator E409 Left side work light
B26 Bucket sensor E412 Rotating beacon

F1 Diagnostic socket +30 fuse
B30 Parking brake microswitch
B66 Transmission oil temperature switch F1E Main fuse engine control unit
B69 Air conditioning pressure switch F2 Side work light relay fuse, 15 A
B108 Transmission temperature sensor
B109 Pressure switch F3 +30 switch and +30 instrument panel fuse

B468 Lambda sensor F5 Ride control, front instrument cluster and
lock valve fuse, 7.5 A
F500 General fuse
G1 Battery
B608 Hand accelerator
G67 Alternator
H2 Horn
BS1 Left speaker
H7 Reverse buzzer
BS2 Right speaker
H26 Backhoe attachment lock warning light
E2 Front left light (optional)
E3 Front right light H606 Buzzer
E18 Roof lamp K14 Transmission disconnect relay
E27 Number plate light K103 Starting
E28 Rear left light K104 Starter motor relay
E29 Rear right light K105 Air conditioning compressor relay
E38 Outer rear work light K227 4WD relay
E40 Inner rear work light K230 Hand hammer relay
E44 Outer front work light K232 Ride control relay
E45 Inner front work light K464 Main relay

K473 A/C clutch S400 Gearshift lever
K605 Side work light relay S604 Side work light switch
M1 Starter motor SB1 Battery master switch
M39 Rear windshield wiper motor ST1 Side instrument cluster panel
M41 Blower motor (optional) ST3 4x1 bucket control lever
M49 Front windshield wiper motor X17 Seat (optional)
M56 Front windshield wiper pump X55 Diagnostic socket
M57 Rear windshield wiper pump X72 Pilot control interface connector
P125 Speedometer (optional) X100 “Carraro” harness solenoid valve connector
S2 4WD switch X101 “Carraro” harness solenoid valve connector
S3 Hand hammer switch X102 “Carraro” harness solenoid valve connector
S5 Ride control switch X103 “Carraro” harness solenoid valve connector
S9 Lights switch X104 “Carraro” harness solenoid valve connector
S15 Rotating beacon switch X105 “Carraro” harness solenoid valve connector
S15.1 Start switch X108 “Carraro” harness transmission
temperature sensor
S29 Front horn switch
X109 “Carraro” harness pressure switch connector
S32 Stop light switch
X112 A/C fuse connector
S33 Stop light switch
X113 “Carraro” harness solenoid valve connector
S34 Port left microswitch
X114 “Carraro” harness solenoid valve connector
S35 Port right microswitch
X201 Accelerator knob
S36 Hand hammer button (optional)
X469 Glow control unit connector
S41 Light-windshield wiper control lever
X470 Connect to engine harness
S42 Warning switch
X471 Electric valves connector
S48 Manual-auto switch
X473 A/C clutch connector
S100 Quick coupler A switch (optional)
X474 Air temperature sensor connector
S101 Quick coupler B switch (optional)
X475 Diff. pressure sensor connector
S135 Vertical backhoe attachment lock switch
X476 Gas temperature sensor 1 connector
S136 Menu scroll switch
S137 Rear work light switch
S138 Windshield wiper + pump switch
connector
X607 Diagnostic
X607 Horn/left light 7 way connector
S141 Front work light switch
Y12 Proportional solenoid valves
S144 Rear horn button
S205a Clutch disconnect button
S205b Differential lock switch

Y34 Ride control solenoid valve (optional) X23 Front instrument panel line - general line
interface connector
Y35 Hand hammer solenoid valve
X24 Lock valve interface connector
Y100 Forward travel solenoid valve
Y101 Reverse speed solenoid valve
Y102 PWM 1/3 solenoid valve
Y103 PWM 1/3 - PWM 2/4 solenoid valve
Y104 S13 - PWM 1/3 solenoid valve
X29 4-way rear left light connector
Y105 Quick coupler solenoid valve
X31 General line fuse box connector
Y106 Load sensor solenoid valve
X34 2-way ride control solenoid valve
Y113 4WD solenoid
connector
Y114 Differential lock solenoid valve
X35 2-way hand hammer solenoid valve
Y202 Backhoe attachment travel solenoid valve connector
Y203 Backhoe attachment lock solenoid valve X36 2-way backhoe hammer button connector
(optional)
Y206 Bucket level solenoid valve
X39 4-way rear windshield wiper connector
Y207 Double delivery solenoid valve (optional)
Y209 Backhoe hammer control valve (optional) (optional)
X41 2-way blower connector (optional)
CONNECTORS
NAME DESCRIPTION X45 2-way front right work light connector
(optional)
X1 18-way general line - engine line connector
X7 2-way reverse travel buzzer connector
(optional)
connector
X49 6-way front windshield wiper connector
X12 9-way general line - upper cab line
connector X50 2-way front left work light connector
(optional)
X13 17-way general line - front instrument
panel connector X51 2-way front left work light connector
X14 11-way antitheft connector X53 8-way radio connector (brown)
X15.1 Starting panel connector X54 8-way radio connector (black)
X15.2 Starting panel connector X55 2-way electric socket connector
X17 4-way pneumo-electric seat connector X56 2-way front windshield washer connector
X21 7-way left light - horn connector X57 2-way rear windshield washer connector
X22 5-way right light connector X64 1-way air conditioning compressor
connector
X67 3-way alternator connector

X69 2-way air conditioning pressure switch X409 Transmission line - front instrument panel
connector line connector
X72 1-way pilot control line connector X412 2-way rotating beacon connector
X87 13-way general line - left side instrument X420 2-way reverse travel buzzer connector
X421 2-way engine stop diode connector
X88 9-way general line - right side instrument
X448 Minifuse connector
X461 Engine control unit connector
X463 WIF connector
X125 Front instrument cluster connector
X466 Glow control unit fuse connector
X201.s Accelerator knob connector
X468 Lambda sensor connector
X201.p Accelerator knob connector
X202 2-way backhoe attachment travel lock
solenoid valve connector X603 Front instrument panel - quick coupler kit
connector
valve connector X603/1 Quick coupler kit connector
X204 2-way horn button on pilot control X606 Buzzer connector
connector
X608 Manual accelerator connector
X206 2-way bucket levelling connector connector
X207 2-way delivery doubling solenoid valve X801 Front harness - general harness interface
connector connector
X208 4x1 bucket control lever connector X805 Ride control pressure switch connector
X209 2-way backhoe hammer solenoid valve X810 Telematies connector
connector
X262 Connector (optional)
X400 Gearshift lever connector
X401 Transmission control unit connector
X402 Transmission line - “Carraro” transmission
line connector XX Diode connector
X403 Transmission line - “Carraro” transmission XST1 36-way multifunctional side panel
line connector connector
X404 Transmission line - front instrument panel XST2 26-way multifunctional side panel
line connector connector
X406 Transmission line connector

X406 Rotating beacon connector
X408 General line - front instrument panel line
connector
ENGINE LINE DIAGRAM

(table 1)
TBR00183
ENGINE LINE DIAGRAM

(table 2)
TBR00184
TRANSMISSION CONTROL UNIT LINE DIAGRAM
TBR00185

(table 1)
TBR00186

(table 2)
TBR00187
LIGHT LINE DIAGRAM
TBR00188
TBR00189
TBR00190
TBR00191
CAB LINE DIAGRAM

v
TBR00192
AIR CONDITIONING LINE DIAGRAM
1
3
10 11
9
4
A S
X111 X110 S45

9 8 7 6 5 4 1 2 3 2 1 5 6 7 8 9 4 3 2 1 10 11
X111 X110 S45 X1

pos 11
+15 +30 +15
TBR00154
S Evaporator box S45 11-way connector

1 3rd speed relay 9 Potentiometer
2 Fuse 25 A 10 Speed switch
3 Blower motor 11 Temperature switch
4 1 and 2 speed resistor A 2-way waterproof connection
5 Electric cock B 5-way waterproof connection
X111 9-way connector
X110 2-way power connector


193 Ohm ON ± 5 Ohm
Battery charge
Transmission
temperature
CN1 CN2
disconnect
2 Not used
5 Not used
7 Not used
6 Buzzer
8 Not used
9 Not used mA
pressure
9 Not used
10 Not used

temperature
15 Not used
17 Not used
19 Not used
confirmation switch
pressure
26 Not used
25 Not used
ELECTRIC DIAGRAMS - POWERSHIFT CAB (4WS)

RELAY FUSES
Fuse K3 Starting relay

Rating Function
no.
F1A 15 A Rear windshield wiper and washer
Engine stop, (+15) anti-theft device, (+15)
F1B 7.5 A K6 Outer front work light relay
ECU power supply, starter switch key
Trax controller + 4WD, automatic/manual K7 Outer rear work light relay
F1C 10 A
switch, declutch transmission K8 Inner front work light relay
Side instrument power supply, pneumo- K9 Inner rear work light relay
F2A 15 A
electric seat, start up
K10 Optional relay
K12 Direction indicator flashing relay

F3A 3A
backlighting

F3B 3A
plate light
Front work light switch, side work light

F3C 10 A
switch, 4x1 bucket handgrip
F4A 7.5 A Stop lights, Trax controller
Backhoe hammer button, bucket level so-

F4B 10 A
lenoid valve + sensor
switch
F5A 15 A Inner front work light relay
F5B 10 A Low beams
F5C 15 A Main beams
F6A 15 A Rotating beacon
F6B 7.5 A (+15) hazard warning lights
F6C 7.5 A (+15) steering column lights switch
(+30) hazard warning lights, horn, anti-

F7A 10 A
theft device

F8B 15 A Outer front work lights
F8C 15 A Inner rear work lights
TBR00182
COMPONENTS
NAME DESCRIPTION
NAME DESCRIPTION
A14 Antitheft unit E40 Inner rear work light
A53 Radio (optional) E44 Outer front work light

A95 Steering unit
A401 Transmission control unit E46 Inner rear work light
A461 Engine control unit E47 Outer rear work light

A469 Glow control unit
B4 Air filter blocked switch E51 Outer front work light
B5 Fuel level sensor E55 Cigarette lighter lamp
B25 Foot accelerator E406 Rotating beacon

E407 Right side work light
B26 Bucket sensor
B30 Parking brake microswitch E409 Left side work light
B66 Transmission oil temperature switch E412 Rotating beacon

F1 Diagnostic socket +30 fuse
B69 Air conditioning pressure switch
B97 Front axle sensor F1E Main fuse engine control unit
B98 Rear axle sensor F2 Side work light relay fuse, 15 A

B108 Transmission temperature sensor
B109 Pressure switch F3 +30 switch and +30 instrument panel fuse

B468 Lambda sensor F5 Ride control, front instrument cluster and
lock valve fuse, 7.5 A
F500 General fuse
G1 Battery
B608 Accelerator knob
G67 Alternator
H2 Horn
BS1 Left speaker
H7 Reverse buzzer
BS2 Right speaker
H26 Backhoe attachment lock warning light (opt.)
E2 Front left light
H606 Buzzer
E3 Front right light
K14 Transmission cut-off relay
E18 Roof lamp
K103 Starting
E27 Number plate light
K104 Starter motor relay
E28 Rear left light
K105 Air conditioning compressor relay
E29 Rear right light
K227 4WD relay
E38 Outer rear work light

K230 Hand hammer relay S141 Front work light switch
K232 Ride control relay S144 Rear horn button
K464 Main relay S205a Clutch disconnect button
K605 Side work light relay S400 Gearshift lever
M1 Starter motor S604 Side work light switch
M39 Rear windshield wiper motor SB1 Battery master switch
M41 Blower motor (optional) ST1 Side instrument cluster panel
M49 Front windshield wiper motor ST3 4x1 bucket control lever
M56 Front windshield wiper pump X17 Seat (optional)
M57 Rear windshield wiper pump X55 Diagnostic socket
M473 A/C clutch X72 Pilot control interface connector
P125 Speedometer (optional) X201 Accelerator knob
S2 4WD switch X607 Diagnostic
S3 Hand hammer switch Y12 Proportional solenoid valves
S5 Ride control switch Y34 Ride control solenoid valve (optional)
S9 Lights switch Y35 Hand hammer solenoid valve
S15 Rotating beacon switch Y91 Crab steering solenoid valve
S15.1 Start switch Y92 Round steering solenoid valve
S29 Front horn switch Y93 4WS steering solenoid valve
S32 Stop light switch Y94 2WS steering solenoid valve
S33 Stop light switch Y100 Forward travel solenoid valve
S34 Port left microswitch Y101 Reverse speed solenoid valve
S35 Port right microswitch Y102 PWM 1/3 solenoid valve
S36 Hand hammer button (optional) Y103 PWM 1/3 - PWM 2/4 solenoid valve
S41 Light-windshield wiper control lever Y104 S13 - PWM 1/3 solenoid valve
S42 Warning switch Y105 Quick coupler solenoid valve
S47 Steering selector Y106 Load sensor solenoid valve
S48 Manual-auto switch Y113 4WD solenoid
S100 Quick coupler A switch (optional) Y114 Differential lock solenoid valve
S101 Quick coupler B switch (optional) Y202 Backhoe attachment travel solenoid valve
S135 Vertical backhoe attachment lock switch Y203 Backhoe attach. lock solenoid valve (opt.)
S136 Menu scroll switch Y206 Bucket level solenoid valve
S137 Rear work light switch Y207 Double delivery solenoid valve (optional)
S138 Windshield wiper + pump switch Y209 Backhoe hammer control valve (optional)
CONNECTORS
NAME DESCRIPTION
NAME DESCRIPTION
X1 18-way general line - engine line connector X47 2-way rear left work light connector
X7 2-way reverse travel buzzer connector X49 6-way front windshield wiper connector
X50 2-way front left work light connector (opt.)
connector X51 2-way front left work light connector
X12 9-way general line - upper cab line X53 8-way radio connector (brown)
connector
X54 8-way radio connector (black)
X13 17-way general line - front instrument
panel connector X55 2-way electric socket connector
X14 11-way antitheft connector X56 2-way front windshield washer connector
X15.1 Starting panel connector X57 2-way rear windshield washer connector
X15.2 Starting panel connector X67 3-way alternator connector
X17 4-way pneumo-electric seat connector X69 2-way air conditioning pressure switch conn.
X21 7-way left light - horn connector X72 1-way pilot control line connector
X22 5-way right light connector X87 13-way general line - left side instrument
X23 Front instrument panel line - general line
interface connector X88 9-way general line - right side instrument
X24 Lock valve interface connector
X91 Crab steering solenoid valve connector
X92 Round steering solenoid valve connector
X93 4WS steering solenoid valve connector
X94 2WS steering solenoid valve connector
X95 Steering control unit connector
X29 4-way rear left light connector
X96 Steering control unit connector
X31 General line fuse box connector
X97 Front axle connector
X34 2-way ride control solenoid valve
connector X98 Rear axle connector
X35 2-way hand hammer solenoid valve X100 “Carraro” harness solenoid valve connector
connector X101 “Carraro” harness solenoid valve connector
X36 2-way backhoe hammer button connector X102 “Carraro” harness solenoid valve connector
X38 2-way rear right work light connector X103 “Carraro” harness solenoid valve connector
X39 4-way rear windshield wiper connector X104 “Carraro” harness solenoid valve connector
X40 2-way rear right work light connector X105 “Carraro” harness solenoid valve connector
(optional)
X108 “Carraro” harness transmission
X41 2-way blower connector (optional) temperature sensor
X43 6-way rotating beacon connector X109 “Carraro” harness pressure switch connector
X44 2-way front right work light connector X110 Air conditioner connector
X45 2-way front right work light connector X111 Air conditioner connector
(optional)
X112 A/C fuse connector
X46 2-way rear left work light connector (opt.)

X113 “Carraro” harness solenoid valve connector X462 Engine control unit connector
X114 “Carraro” harness solenoid valve connector X463 WIF connector
X125 Front instrument cluster connector X466 Glow control unit fuse connector
X201.s Accelerator knob connector X468 Lambda sensor connector
X201.p Accelerator knob connector X469 Glow control unit connector
X202 2-way backhoe attachment travel lock X470 Connect to engine harness
solenoid valve connector
X471 Electric valves connector
X473 A/C clutch connector
valve connector
X474 Air temperature sensor connector
X204 2-way horn button on pilot control connector
X475 Diff. pressure sensor connector
X206 2-way bucket levelling connector
X207 2-way delivery doubling solenoid valve
connector X496 Front harness - engine harness interface
connector
X208 4x1 bucket control lever connector
X209 2-way backhoe hammer solenoid valve
connector X603 Front instrument panel - quick coupler kit
connector
X603/1 Quick coupler kit connector
X606 Buzzer connector
X262 Connector (optional)
X607 Horn/left light 7 way connector
X400 Gearshift lever connector
X608 Accelerator knob connector
X401 Transmission control unit connector
connector
line connector
X801 Front harness - general harness interface
connector
line connector
X805 Ride control pressure switch connector
X404 Transmission line - front instrument panel
line connector X810 Telematies connector
X406 Transmission line connector XC1 Control unit 11-way connector
X406 Rotating beacon connector XC2 Control unit 7-way connector
X408 General line - front instrument panel line XC3 Control unit 21-way connector
connector
X409 Transmission line - front instrument panel
line connector XC5 Control unit 17-way connector
X412 2-way rotating beacon connector XC6 Control unit 13-way connector
X420 2-way reverse travel buzzer connector XX Diode connector
X421 2-way engine stop diode connector XST1 36-way multifunctional side panel connector
X448 Minifuse connector XST2 26-way multifunctional side panel connector

ENGINE LINE DIAGRAM

(table 1)
TBR00193
ENGINE LINE DIAGRAM

(table 2)
TBR00194
TRANSMISSION CONTROL UNIT LINE DIAGRAM
TBR00195
4WS STEERING LINE DIAGRAM
TBR00196

(table 1)
TBR00197

(table 2)
TBR00198
LIGHT LINE DIAGRAM
TBR00199
TBR00200
TBR00201
TBR00202
CAB LINE DIAGRAM
TBR00203


193 Ohm ON ± 5 Ohm
Battery charge
Transmission
temperature
CN1 CN2
disconnect
2 Not used
5 Not used
7 Not used
6 Buzzer
8 Not used
9 Not used mA
pressure
9 Not used
10 Not used

temperature
15 Not used
17 Not used
19 Not used
confirmation switch
pressure
26 Not used
25 Not used
CONTROLS AND INSTRUMENTS
FRONT CONTROL PANELS (580ST - 590ST)
10
5
1
6
2
7
3
8
4
9
TBR00078
1. SWITCH 2. HAND-HELD AUXILIARY HYDRAULIC

This switch is used to engage or disengage the ATTACHMENT SWITCH (Optional)
4WD function. This switch has two positions:
This switch has two positions: - The first position is OFF.
- First position (powershuttle), by pushing but- - The second position is ON and enables the
ton on the left : auxiliary hydraulic attachments.
rear wheel drive and braking on rear wheels 3. LOADER ATTACHMENT SWITCH (Optional)
(for all gears) (lamp off).
4. LOADER ATTACHMENT LOCKING SWITCH
- First position (powershift), by pushing button (Optional)
on the left : When operated, this switch prevents any move-
rear wheel drive with braking only on rear ment of the loader attachment during travel.
wheels (only in first and second gear) (lamp
5. ROTATING BEACON SWITCH
off);
This switch is used to turn the rotating beacon
four wheel drive and braking (in third and
on or off.
fourth gear) (lamp on).
- Second position (by pushing button on the
right ):
4 wheel drive and braking on 4 wheels (lamp
on).
6. ROLL-OVER PROTECTION SWITCH 9. HORN BUTTON

(Optional) This button operates the warning horn.
This switch is used to engage or disengage the 10. HAZARD LIGHT SWITCH
roll-over protection device. When the operator Press the control down to locked position.
is about to start working with the backhoe The direction indicators and the control will
attachment in conditions which could cause the flash simultaneously.
machine to roll over, he/she must activate the Press the control down again to turn off the
roll-over protection device by pressing the direction indicators and the lamp.
switch (ON position and lamp turned on).
In this condition, the audible alarm will sound by
means of the buzzer when the pressure switch,
installed on the backhoe attachment boom cyl-
inder, detects a pressure exceeding the follow-
ing values:
2WS = 116 bar (17 psi)
4WS = 126.5 bar (18 psi)
7. “AUTO GLIDE RIDE” SWITCH (Optional)
The “auto glide ride” system control improves
the machine comfort during travel, regardless
of the type of terrain and with the loader bucket
full or empty.
It reduces forward and rearward pitching when
moving rearwards or forwards and when carry-
ing loads, at the same time increasing produc-
tivity and operator comfort.
It also reduces impact forces to the machine
during operation.
Do not use this system while operating the
loader attachment.
S WARNING S
Never operate the “auto glide ride” system control
when the loader arm and loader bucket are main-
taining the front of the machine raised off the
ground. The machine could fall and cause serious
or fatal injury.
8. MANUAL MODE SELECTION SWITCH

(Powershift transmission)
In situations where manual gearshifting (up or
downshift) is required, the automatic gearshift
of the powershift transmission can be overrid-
den by means of this switch.
NOTE: changing gears up or down must always be
done using the powershift transmission lever.
When the manual mode is no longer required,
place the switch back to the OFF position to return
to automatic gearshifting.
FRONT CONTROL PANELS (695ST)
10 b a
4 c
5
6 1
7
2
8
3
9
TBR00080
1. SWITCH 2. HAND-HELD AUXILIARY HYDRAULIC

This switch is used to engage or disengage the ATTACHMENT SWITCH (Optional)
4WD function. This switch has two positions:
This switch has two positions: - The first position is OFF.
- First position (powershuttle), by pushing but- - The second position is ON and enables the
ton on the left : auxiliary hydraulic attachments.
rear wheel drive and braking on rear wheels 3. LOADER ATTACHMENT LOCKING SWITCH
(for all gears) (lamp off). (Optional)
- First position (powershift), by pushing button When operated, this switch prevents any move-
on the left : ment of the loader attachment during travel.
rear wheel drive with braking only on rear 4. STEER MODE SWITCH
wheels (only in first and second gear) (lamp This switch has a locking cover and is used to
off); select “Road”, “4 wheel steer” or “Crab steer”.
four wheel drive and braking (in third and This switch has three positions:
fourth gear) (lamp on). - Position (a) = Road
- Second position (by pushing button on the - Position (b) = 4 wheel steer
right ): - Position (c) = Crab steer
4 wheel drive and braking on 4 wheels (lamp
on). IMPORTANT: before undertaking any road travel,
select “Road” mode and fold back the cover to lock
the switch in this position.
5. ROTATING BEACON SWITCH 8. MANUAL MODE SELECTION SWITCH

This switch is used to turn the rotating beacon (Powershift transmission)
on or off. In situations where manual gearshifting (up or
6. ROLL-OVER PROTECTION SWITCH downshift) is required, the automatic gearshift
(Optional) of the powershift transmission can be overrid-
This switch is used to engage or disengage the den by means of this switch.
roll-over protection device. When the operator NOTE: changing gears up or down must always be
is about to start working with the backhoe done using the powershift transmission lever.
attachment in conditions which could cause the
machine to roll over, he/she must activate the When the manual mode is no longer required,
roll-over protection device by pressing the place the switch back to the OFF position to return
switch (ON position and lamp turned on). to automatic gearshifting.
In this condition, the audible alarm will sound by 9. HORN BUTTON
means of the buzzer when the pressure switch, This button operates the warning horn.
installed on the backhoe attachment boom cyl- 10. HAZARD LIGHT SWITCH
inder, detects a pressure exceeding the follow- Press the control down to locked position.
ing values: The direction indicators and the control will
2WS = 116 bar (17 psi) flash simultaneously.
4WS = 126.5 bar (18 psi) Press the control down again to turn off the
7. “AUTO GLIDE RIDE” SWITCH (Optional) direction indicators and the lamp.
The “auto glide ride” system control improves
the machine comfort during travel, regardless
of the type of terrain and with the loader bucket
full or empty.
It reduces forward and rearward pitching when
moving rearwards or forwards and when carry-
ing loads, at the same time increasing produc-
tivity and operator comfort.
It also reduces impact forces to the machine
during operation.
Do not use this system while operating the
loader attachment.
S WARNING S
Never operate the “auto glide ride” system control
when the loader arm and loader bucket are main-
taining the front of the machine raised off the
ground. The machine could fall and cause serious
or fatal injury.
CONTROL PANEL AND SIDE INSTRUMENT CLUSTER

(580ST - 590ST - 695ST electronic engine)
1. FRONT WORK LIGHT SWITCH 3. SIDE WORK LIGHT SWITCH (Optional)

This switch has three positions: This switch has two positions:
- The first position is OFF (control lamp off). - The first position is OFF (control lamp off).
- Second position, by pressing the symbol side - Second position, by pressing the symbol
(first click), the outer front work lights are side, the side work lights turn on at the same
turned on (control lamp on). time (control lamp on).
- Third position, by pressing the symbol side 4. BACKHOE ATTACHMENT LOCKING SWITCH
again (second click), the inner front work The switch is used to lock or unlock the back-
lights are turned on too (control lamp on). hoe attachment safety hook in preparation for
2. LIGHT SWITCH road travel.
This switch has three positions: 5. REAR WORK LIGHT SWITCH
- The first position is OFF (control lamp off). This switch has three positions:
- Second position, by pressing the symbol side - The first position is OFF (control lamp off).
(first click) the instrument cluster panel is - Second position, by pressing the symbol side
powered, the side lights and the low beam (first click), the outer rear work lights are
indicator lamp are turned on (control lamp turned on (control lamp on).
on). - Third position, by pressing the symbol side
- Third position, by pressing the symbol side again (second click), the inner rear work
again (second click), the high beams are lights are turned on too (control lamp on).
enabled and the low beams and the high 6. SIDE INSTRUMENT CLUSTER
beam indicator lamp are turned on (control
lamp on).
7. MENU SCROLLING SWITCH 13. BACKHOE ATTACHMENT SIDESHIFT CAR-

By means of this control, it is possible to scroll RIAGE LOCKING SWITCH (Sideshift version)
through the menu or data options shown on the It allows locking (control lamp on) or unlocking
diagnostic display. (control lamp off) the sliding carriage the back-
8. MENU ENTER SWITCH hoe attachment is mounted on.
By means of this control it is possible to display
and confirm the menu options shown on the
display.
9. REAR WINDSHIELD WIPER AND WASHER
SWITCH
This switch has three positions:
- The first position is OFF (lamp off) and both
the windshield wiper and the windshield
washer are disabled.
- The second position allows to press the sym-
bol side of the switch to activate the rear
windshield wiper (lamp on).
- The third position, allows to press the symbol
side of the switch and hold to activate the
windshield washer (lamp on).
When releasing the switch, the windshield
washer stops and the windshield wiper starts
moving.
10. BACKHOE ATTACHMENT SIDESHIFT CAR-
RIAGE HYDRAULIC SHIFTING SWITCH
This button allows hydraulically moving the
backhoe attachment towards the track sides.
Press the button on the upper side of the sym-
bol to shift the backhoe attachment to the
right side of the track.
Press the button on the lower side of the sym-
bol to shift the backhoe attachment to the
left side of the track (track sides are referred to
the travel direction of the machine).
11. HORN BUTTON
(only models with mechanical backhoe con-
trols)
This button operates the warning horn.
12. BACKHOE ATTACHMENT QUICK COUPLER
SWITCH (Optional)
You have to press both switches to activate the
quick coupler of the backhoe attachment.
Press on the 2 switches to unlock (retract

pins) of quick coupler on backhoe attachment.
Press on the 2 switches to lock (extend

pins) of quick coupler on backhoe attachment.
SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST)
1. CAUTION MASTER LAMP 7. “CRAB” (4WS) STEER INDICATOR LAMP

This lamp signals a not critical caution. This lamp turns on when crab steer mode is
When this caution is active, it is necessary to selected and phased.
change the operating mode, plan a down time
NOTE: if the three lamps turn on at once, this
to carry out maintenance or, if the fault contin-
means there is a problem with the electric circuit.
ues, consult your dealer.
Consult your Dealer.
This warning lamp turns on at the same time of
lamps (8), (10), (12) and (14) that indicates a 8. ENGINE OIL PRESSURE WARNING LAMP
fault on the machine. This warning lamp turns on and the audible
warning device sounds when the engine oil
2. SIDE LIGHT AND LOW BEAM INDICATOR
pressure is too low.
LAMP
This indicator lamp turns on when the side 9. STOP MASTER LAMP
lights or the low beams are on. The stop master lamp signals a critical caution.
When this lamp turns on, stop the machine
3. MAIN BEAMS INDICATOR LAMP
immediately and shut off the engine.
This indicator lamp turns on when the main
If this is not the case, the machine can get dam-
beams are on.
aged or accidents may occur.
4. DIRECTION INDICATOR LAMP
10. BATTERY CHARGE WARNING LAMP
This lamp turns on when the direction indicators
This warning lamp turns on when the alternator/
are working.
fan belt is broken or when the alternator is not
5. “4 WHEEL STEER” (4WS) INDICATOR LAMP charging the battery.
This lamp turns on when 4 wheel steer mode is
11. PARKING BRAKE INDICATOR LAMP
selected and phased.
This indicator lamp turns on when the parking
6. “ROAD” (4WS) STEER INDICATOR LAMP brake lever is in the raised position (wheels
This lamp turns on when 2 wheel steer mode is braked).
selected and phased.
12. AIR FILTER RESTRICTION LAMP 20. TRANSMISSION OIL TEMPERATURE WARN-
This warning lamp turns on when the air filter ING LAMP
element needs to be cleaned or replaced. This indicator shows the transmission oil tem-
13. AIR CONDITIONER INDICATOR LAMP perature.
(Optional) When the temperature is normal, the needle is
This lamp turns on when the air conditioner is in the grey area.
working. If the needle is in the red area, change down to
a lower gear. If the needle still remains in the
14. “GRID HEATER” LAMP (Optional)
red area, stop the machine travel, place the
If the machine is equipped with a “grid heater”,
gearshift lever and the direction-of-travel con-
wait for the indicator lamp to turn off before
trol lever in the neutral position and leave the
starting the engine.
engine running at 1000/rpm.
15. LOW FUEL LEVEL WARNING LAMP If this operation does not enable the oil temper-
This warning lamp turns on when the fuel level ature to be reduced, check the gearbox oil level
is low. You have approximately an hour to fill and make sure that the radiator and oil cooler
the fuel tank. are perfectly clean.
NOTE: when the starter switch key is in the ON 21. ENGINE COOLANT TEMPERATURE GAUGE
position, all lamps turn on and the instrument This indicator shows the temperature of the
buzzer sounds for 5 seconds. After this period only engine coolant solution.
lamp (8) remains alight. The gauges (16) and (17) When the temperature is normal, the needle is
set to position. in the grey area.
16. FUEL LEVEL GAUGE If the needle is in the red area, the audible
This gauge shows the quantity of fuel in the fuel warning sounds.
tank.
17. BATTERY CHARGE INDICATOR
This indicator shows the state of charge of the
battery.
At normal charge the needle should be in the
grey area.
If the needle is in the left red area, this shows
that the battery charge is insufficient or that the
alternator is not charging the battery.
If the needle is in the right red area, this indi-
cates excessive battery charge which may
cause damage to the battery.
18. DIAGNOSTIC DISPLAY
By means of this display it is possible to visual-
ize the various data of diagnostics. The service
hours are also indicated.
19. TACHOMETER
The tachometer shows the engine speed in rev-
olutions per minute.
The figures indicated must be multiplied by 100.
Each intermediate mark shows a value of
100 rpm.
We recommend not to reach the red line.
ANTI-START SYSTEM
F28667
A. M38 Immobiliser E. Starter motor

B. Electronic key socket with LED F. + 15 key positive
C. 2 piece electronic key G. Electronic key
D. + 50 to ignition
WIRE FUNCTION CONNECTION

No.
1 (+15) Key positive Connected to the + 12 V full ignition supply
2 (+30) Permanent + 12 V power supply Connected to the wire from the battery positive
3 (-31) Negative power supply Connected to the vehicle negative at two independent
points
5-6 Immobilization relay No. 2 Connected in line with the wire controlling the starter
motor relay/solenoid - Minimum 500 mA maximum 10 A
capacity
7-8-9 Immobilization relay No. 1 Connected in line with the cable controlling the ignition
or the fuel system - minimum capacity 500 mA,
maximum capacity 10 A
DIAGNOSTIC DISPLAY (580ST - 590ST - 695ST)

The diagnostic display (1) is located in the middle of
the side instrument cluster (4).
The diagnostic switches are the following:
- MENU SCROLL SWITCH (2)

Use this UP/DOWN switch to scroll through the
menus.
NOTE: push the arrow at start up to display engine
rpm on the display.
- DISPLAY ENTER SWITCH (3)

Use this switch to select and confirm a service
menu.
The Diamond icon, or top portion of the switch, is
used to select displays.
The 90° arrow icon or bottom portion of the switch,
is used to enter selected choices.
Using the display switches, you will be able to scroll

through the following:
- battery voltage;
- backhoe loader hours;
- setup.
Features adjustable during setup:

- backlighting dimming and contrast control,
- maintenance/service interval customization;
- storage of error codes;
- “grid heater” presence:
it is possible to select or deselect the “grid heater”
option;
- low temperature idle speed setting:
when the engine coolant temperature is below
10 °C (50 °F), the unit will change from a normal
low idle to a low temperature idle which can be
adjusted between 975 and 1500 rpm. The
default setting is 1000 rpm;
- high idle speed setting (2500 rpm maximum).
SYMBOLS
Hydraulic oil filter blocked
Work hours
Transmission oil pressure too high

Maintenance
Battery charging failure

Maintenance heavy (hours)
HEAVY
1000
Contaminated fuel
Maintenance light (hours)
LIGHT
500
Malfunction
Stored error code
Back-light dimming
Grid heater
Battery voltage too high

Engine speed
n/min
Battery voltage too low
Engine area of fault
Engine intake air filter blocked
Charge air temperature too high
Engine coolant level too low
Engine coolant temperature too high
Engine oil pressure too low
Brake fluid level too low
Parking brake engaged
Put the shuttle lever into neutral

position
SETUP MENU
Dimmer
Increase O
Decrease P
Increase
Decrease
Service
interval
Increase
Decrease
Stored error
code
3-second scroll unless the switch is

pressed
“Grid heater”
presence Select / Deselect
Low and high Increase O

idle speed
Decrease P
HARDWARE
P/N Increase O
Hardware code
ID Decrease P
VER
SOFTWARE
P/N O Press Enter to make the value flash and then set up
Software code
ID P Press Enter to make the value stop flashing
VER
PROCEDURE ABOUT SELF TEST
Z Power up LCD and show

work hours for 10 seconds
Any of the above at with ignition low Maximum foot
accelerator: X.X.
Minimum foot accelerator: 113/111
X.X. field

Go to menu
Maximum accelerator
knob: X.X. 125/120
Minimum accelerator field
Normal “Key ON” Z
knob: X.X.

Z
Initiate Self test
Accelerator pedal %: XXX 113/122
Accelerator knob %: XXX field
Any of the keys above and with “Key ON”
Check:
100 mA < Current draw <
Step 1: Lamps switch on at full intensity. 1amp
Requested engine rpm: 98/88

Step 2: Lamps switch off after 2 seconds. XXX field
10 mA < Current draw < 1 mA

Step 3: Wait 2 seconds.
Check: Fuel level: XX.X 117/120

Step 4: Instrument backlighting turns on at full intensity. 100 mA < Current draw < 1 A Fuel tank: XX field

Step 5: Lamps switch off after 2 seconds.
10 mA < Current draw < 100
mA Voltage: XX.X
Transmission oil 116/124
Step 6: Wait 2 seconds. field
temperature: XX

Step 7: Sweep all 5 gauges to maximum angle.
Makes sure that needles can
move freely and have proper Brakes: XXX 102/92
position Engine rpm: XXXX field
Step 8: 2 seconds after maximum angle sweep to red border.
Step 9: 2 seconds after red-green border is reached move to Makes sure that needles are
properly calibrated to
second red border for voltage. applique
Radiator water 107/123
temperature XXX
Step 10: Park all gauges and start LCD test. Air temperature XXX field

Step 11: When LCD test is complete sound alarm for 2 seconds.
Engine oil temperature:

XXX 122/126
field
Fuel temperature: XXX
Step 12: The following is shown on the LCD display until the key is turned to OFF or the cycle
ends. All gauges and lamps should work as normal and engine will be able to be started.

ON BOARD ERROR CODE RETRIEVAL
↵
Z
Stored error code
Z Page 1/6
CODE 3059 3-second scroll unless
the up/down button is
↵ OCCURRENCE 3 pressed
TIME 1004.5
Page 2/6
CODE 3009
OCCURRENCE 2
TIME 1010.6
Page 3/6
CODE 1018
Occurrence counter will be incremented on transition from OCCURRENCE 1
inactive to active status. Status has to be stored in EEPROM
TIME 1024.5
and checked at key on. Only the hour count of the last
occurrence will be stored per SAE convention.
Page 4/6
CODE 3022
OCCURRENCE 1
HOUR 969 .4
Page 5/6
CODE 3113
OCCURRENCE 2
TIME 1050.6
Page 6/6
CODE 1003
OCCURRENCE 3
TIME 1076.4
BACKLIGHTING AND DIMMING

A proper and uniform backlighting for matrix, gauge DIMMING LAW
pointer and symbols shall be provided.
The dimming adjustment is done through the setup
Separate backlighting electronics shall be provided menu, it can be used in single.
for matrix and symbols-gauge pointers. The back- In single step mode, the luminance level go from
lighting will be achieved by LEDs and dimming shall min to max value in 10 steps.
be provided through the setup menu selections.
The luminance levels of display and gauges always
The backlighting shall go at its maximum level varies in parallel.
when the front, rear and driving lights are off.
The cluster switches between day and night lumi-
The gauges backlighting dimming is switched on
nance levels using the work and driving light status,
when the cluster sees a HIGH level on front work
and is able to manage the display and gauges inde-
lights, rear work lights or driving lights for more then
pendently using the same law and customer set-
100 ms.
ting.
The lamps intensity is decreased when side lights Only the night settings can be adjusted since the
are activated. The two different brightness levels day setting of the display is 100% intensity.
are defined as 100% during daytime use and 50%
when backlighting is active. During dimming setup the matrix shows the dim-
ming symbol together with the percentage of lumi-
The display intensity of luminance will be 6 cd/m2
nance: its value varies using a step of 10%.
(not dimmed).
The dimming symbol appears when the proper
The maximum available luminance spread will be menu is selected and stays on the matrix for at
30%. least 2 seconds.
To avoid dark zones the maximum difference of The dot matrix visualization will be as follows:
intensity of luminance between closed points is
15%.
Note that the matrix backlighting may go to 0 by
customer selection.
The lamps and the audible alarm will warn the cus- The default value is 80% and the may go to zero if
tomer of an alarm condition occurring. set by the customer.
WORK HOURS
In order to allow service or the customer to view - once in the adjustment mode the meaning of the
vehicle hours of operation, it will not be necessary arrow UP switch is “increase hourmeter value”,
to have the key. and the meaning of arrow DOWN switch is
“decrease hourmeter value”. A single pressure of
By pressing the menu enter/display scroll switch,
the switch will increase or decrease the value by
with the key turned to OFF, the instrument cluster
one unit (6 min). Continuous switch pressure will
panel will activate and display the service hours for
increase or decrease the value continuously (1
10 seconds.
every 300 milliseconds): when the value reaches
The hourmeter increments when the engine is run- a multiple of 10, the increment/decrement rate is
ning (rpm> 600). The hours are displayed starting 10 units every 300 ms; when the value reaches a
from 0.0 until 210,554,060.7 using an interval of 6 multiple of 100, the rate is 100 units every 300
minutes. ms; when the value reaches a multiple of 1000,
In case of battery disconnection, the cluster can the rate is 1000 units every 300 ms.
lose 0.1 hour or 6 minutes max.
During continuous setting the value stops flashing.
WORK HOURS SETTING
Once the operator has reached the desired value
In order to allow service to install a new Vehicle
press and hold down the arrow UP and display
Control Module (VCM) on an old vehicle, it is possi-
switches for 15 seconds to end setting procedure.
ble to increase (no decrease will be allowed) the
hour to the same setting as the original. It is not possible to set a value lower than the cur-
rent one, and the procedure can be repeated three
To modify the hourmeter value, execute the follow-
times in the cluster life.
ing procedure:
- select the hourmeter function on the display;
- press and hold depressed for 15 seconds “arrow
UP” and “display” until the value shown on dis-
play starts to blink (1 Hz, duty 50%);
Work hours
Power up LCD and show work hours

for 10 seconds
Any of the above at with ignition low
To save the new value

Hourmeter setting
0.1, 1, 10, 100 or 1000 hours

step depending on
With the key turned to ON, press for 15 continuous time pressed
seconds
Blinking to indicate ability to edit To exit without saving
values
Value may only increase for the hourmeter. While setting the value it can be decreased due to
operator overshoot, but the value can not be stored if it is below the current stored value. Pressing
DISPLAY will exit without saving. ENTER must be pressed to store the modified value in protected
memory.
OPERATION
Auto wake up at every 600 ms for sensing a With the key OFF, all indicators set to the parking
change in ENTER, DISPLAY, UP or DOWN switch position. The parking position is hard to obtain with
status will be provided. Upon sensing of one of the internal stops of the stepper motor. With the key
those inputs transition, the cluster has to wake up. ON, follow the procedure below.
As a general rule, at engine start-up, it is necessary
to deactivate all alarms and instrument gauges,
unless an error is detected on the starting line.
Needle collision
control at key-on
At key-on drive all
needles CCW for 1
second
Vibration, service,
TRUE
transport or If RTZ is observed
battery loss can on all 5 gauges
generate a FALSE
FALSE
Remove power from gauges:
- engine coolant
- fuel level
Drive gauges until they reach:

- tachometer
- transmission temp
- battery voltage
Drive gauges:
- engine coolant
- fuel level
Start all normal
display functions
TACHOMETER ENGINE COOLANT TEMPERATURE INDICATOR

The tachometer accuracy should be less than or A stepper motor will drive coolant temperature
equal ±50 rpm. gauge. The gauge accuracy should be less than or
equal 3%. Needle calibration has never to be lost
The above-specified tolerances must be respected
for any external condition.
in all operating ranges (temperature, voltage, etc.).
A stepper motor will drive the tachometer. INSTRUMENT TEMPERATURE
Needle calibration has never to be lost for any
Gauge indication range +65 ÷ +112 °C
external condition.
(+149 ÷ +234 °F)
The message to be used is EEC1.
Green field +65 ÷ +106 °C
(+149 ÷ 223 °F)
EEC1 MESSAGE INSTRUMENT
POSITION Red field +106 ÷ +112 °C
(+223 ÷ 234 °F)
0000 0 rpm
0001 => FFFD According to the value The message to be used is engine temperature.
Green field 0 ÷ 2500 rpm
ENGINE INSTRUMENT
Red field 2500 ÷ 3000 rpm TEMPERATURE POSITION
FFFF 0 rpm MESSAGE
00 => FD According to the logic
above
In case of faulty sensor, the instrument will go back
to parking position. FE Minimum value
Since this signal is a function of the engine control- FF Minimum value
ler the appropriate warning lamp and lamp will be
illuminated.
An audible alarm must sound when the engine tem-
During cranking, the needle movement shall be fro- perature exceeds 106 °C (223 °F).
zen in order to inhibit any spurious movement of it.
In case the sender is disconnected, the gauge has
to go to 65 °C (149 °F) position.
Reconnecting the sensor the gauge has to return to
the correct position.
Both the movements have to be uniform.
In case of faulty sensor, the instrument will go back
to parking position.
Since this signal is a function of the engine control-
ler the appropriate warning lamp and lamp will be
illuminated.
During cranking, the needle movement shall be fro-
VOLTMETER GAUGE TRANSMISSION OIL TEMPERATURE GAUGE

The voltmeter will indicate the voltage of the vehicle The oil temp gauge indicates transmission oil tem-
electric system. perature from 75 °C ÷ 115 °C (167 ÷ 239 °F).
This gauge is broken up into two ranges, green
This gauge will have three operating ranges: two
and red. The green field goes from 75 °C ÷ 106 °C
reds and one green.
(167 ÷ 223 °F).
One red range will indicate low voltage. The red zone is from 105 °C ÷ 115.5 °C (221 ÷ 240 °F).
The other red will indicate high voltage. This gauge will be connected to a sensor that will
provide a specific resistance to correlate to a spe-
The green range will indicate normal operating volt- cific oil temperature.
age.
Bottom of the scale will be 9 V. INSTRUMENT TEMPERATURE
Low voltage range is 11 V or less. Gauge indication range +75 ÷ +115 °C

(+167 to +239 °F)
The pointer will be at ±3° from the thick centerline
that indicates 11 V. Green field +75 ÷ +106 °C
(+167 ÷+ 223 °F)
The normal operating range will be 11 V to 16 V.
Red field +105 ÷ +115.5 °C
High voltage range is 16 V or higher.
(+221 ÷ +240 °F)
The pointer will be at ±3° from the thick centerline
that indicates 16 V.
- 5 V = 75 °C (167 °F).
Top of the scale will be 18 V. The centerline of the pointer will be at ±2 angular
A stepper motor will drive the voltmeter gauge. degrees from the centerline of the bold reference
mark that indicates this temperature.
The gauge accuracy should be less than or equal
3%. - 2.6 V = 93.3 °C (200 °F).
The centerline of the pointer will be at ±3 angular
Needle calibration has never to be lost for any degrees from the centerline of the bold reference
external condition. mark that indicates this temperature.
Loss of voltmeter sensor will be the loss of the - 2.05 V = 115.5 °C (240 °F).
internal VCM A/D converter. The centerline of the pointer will be at ±2 angular
During cranking, the needle movement shall be fro- degrees from the centerline of the bold reference
zen in order to inhibit any spurious movement of it. mark that indicates this temperature.
The same range of temperature is used for power-
A/D accuracy is specified as ±180 mV during self
shift and powershuttle transmissions.
test operation.
The gauge will move by 9 angular degrees at key-
on in the clockwise position, to replicate the current
instrument cluster behaviour.
This is necessary due to the cool temperatures
present when the unit is working in backhoe posi-
tion. In case the sender is disconnected, the gauge
has to go down to home position.
Reconnecting the sensor will make the error code
inactive and the gauge has to return to the correct
position.
A stepper motor will drive the transmission oil tem-
perature gauge. The gauge accuracy should be
less than or equal ±2%.
external condition. During cranking, the needle
movement shall be frozen in order to inhibit any
spurious movement of it.
FUEL LEVEL GAUGE

When a certain low fuel level is reached, the rele-
vant “low fuel” lamp will be lit according to the fol-
lowing logic.
The filtering of the data read is obtained with a hys-
teresis on the resistance value joined to a delay
time of 2 seconds.
Ohmic parameter threshold and delay time value
must be kept in NVM.
Lamp activation depends on values used for needle
movement; this means that at key-on the low fuel
level warning is active if the cluster sees a resist-
ance value greater the table below.
Resistance values
The fuel level gauge will indicate the fuel level of the
vehicle tank.
The gauge dial will be divided into two ranges: red
and green.
The red range will indicate a low fuel zone. The
green range will indicate a non-low fuel zone.
This gauge will be connected to a sensor that will
provide specific a resistance to correlate to a spe-
cific fuel tank level.
TANK SIZE EMPTY VALUE (X) RED-GREEN FULL VALUE (Z) INDICATED FUEL
BORDER (Y) LEVEL
133 litres 320 Ohm 186 Ohm 6.5 Ohm 30% with 18
(29.25 gal) angular degrees of
gauge motion
- X = empty. The centerline (CL) of the pointer will In case the sender is disconnected, the gauge has
be at +0° / -2° angular degrees from the center- to go down in empty position.
line of this empty mark. Reconnecting the sensor the gauge has to return to
- Y = red - green threshold. The centerline (CL) of the correct position.
the pointer will be at +/-3 angular degrees from
the centerline of this “half” mark.
- Z = full. The centerline (CL) of the pointer will be A stepper motor will drive fuel level gauge.
at +4/-0 angular degrees from the centerline of The gauge accuracy should be less than or equal
this “full” mark. ±2%.
external condition.
During cranking, the needle movement shall be fro-
WARNING SYSTEM
The diagnostic has to inform the operator regarding ALARM ACTIVATION
all the operating conditions of the loader backhoe
Non Critical
which are out of range.
A failure is present but the operator can continue
These conditions are different from each other: his work: the purpose is to warn the operator as
- warnings; regards the presence of the fault. A beep will sound
- error codes; every 30 seconds.
- faults in the system; Critical

- required action. A serious fault that can affect either the safety of
the operator or the damage of the loader backhoe
is present: the operator shall stop the loader back-
We can define warnings as all those situations that hoe. This will be a continuous alarm.
could be dangerous for the loader backhoe or for
Action Required
the operator.
The system is asking for a certain manoeuvre from
The diagnostic will move the display to the red the operator in order to return to the normal func-
range or will activate the buzzer. tionality. This will be a continuous alarm.
The display will show the symbol indicating the cur- Safety
rent problem.
The system purpose is to warn the operator regard-
There are conditions in which the diagnostic ing the presence of a dangerous situation for his
detects one of its sensors out of order: in this case safety. This will be a continuous alarm.
it will generate an error code.
General Sound
According to the severity of the failure, it will control
There are certain conditions in which it is necessary
the relevant warning lamp and the audible alarm:
to activate an audible alarm. It is a one-second
the display will display the appropriate Icon
beep to draw the operator’s attention to the instru-
together with the error code number.
ment cluster.
If it is necessary to inform the operator that he/she
has done an incorrect manoeuvre, or that he/she
must perform a special operation (required action), Whenever an audible alarm activation is related to
the diagnostics will display an icon again or will an icon visualization, this icon should remain dis-
activate the relevant buzzer. played at least for 4 seconds in order to give the
possibility to the operator to understand the cause
of the alarm activation.
When many warnings with different priority occur,
the audible alarm is related to the higher priority
warning.
When a warning activates with an audible alarm dif-
ferent from the current one, the corresponding icon
must be displayed simultaneously.
If a warning lamp dedicated to a function is associ-
ated to the activation cause of the audible alarm,
the warning lamp will activate together with the
audible alarm.
MAINTENANCE
Two different kinds of maintenance will be availa- HEAVY MAINTENANCE
ble:
From 10 hours before the set value, display on the
- light maintenance; display the “heavy maintenance symbol” at every
- heavy maintenance. key on and should last for 1 second after cranking.
After cranking after this, the last selected icon will
LIGHT MAINTENANCE be visualized on the display. The hours shown will
be the hours when light maintenance is required,
From 2 hours before the set value, display on the
not the standard hours displayed by the hourmeter.
display the “light maintenance symbol” at every key
on for 1 second after cranking; after this, the last
selected icon will be visualized on the display. The
HEAVY
hours shown will be the hours when light mainte-
1000
nance is required, not the standard hours displayed
by the hourmeter. Amber-coloured lighting
The interval can be set between 50 and 500 hours
in steps of 100 (0.0, 500, 600, 700, 800, 900,
LIGHT
1000). The 0.0 setting turns the heavy maintenance
500
feature off.
Amber-coloured lighting
The interval can be set between 50 and 500 hours
in steps of 50 (0.0, 50, 100, 150, 200, 250, 300,
350, 400, 450, 500). The 0.0 setting turns the light
maintenance feature off.
DISPLAY FUNCTION
When the hourmeter reaches the light service interval
3 seconds
LIGHT 3 seconds
500
GREEN AMBER
Audible alarm for 1 second when displaying either service interval for the first time
When the hourmeter reaches the heavy service interval
3 seconds
HEAVY
3 seconds
1000
GREEN AMBER
Audible alarm for 1 second when displaying either service interval for the first time
Since heavy maintenance contains light maintenance the following will be shown:
500 - Light
1000 - Heavy
1500 - Light
2000 - Heavy
The service indicator message will be cleared with a single key cycle
WARNING MESSAGES
Function Lamp Alarm Lamp Display Condition DTC SA Description Priority Colour
lamp
Engine Coolant above

Coolant
coolant 112 °C
STOP Continuous 1002 VCM temperature 1 Red
temperature (234 °F) for 5
signal - too high
too high seconds
Pressure
Engine oil <26 bar Oil pressure
pressure too STOP Continuous (377 psi) 3028 ECU sensor - 1 Red
low pressure too low
500> rpm
The engine must

Transmission Switch closed
be running with
oil pressure STOP Continuous to ground for 1008 VCM 1 Red
switch closed for
too low 25 seconds
25 seconds
5 seconds
Time-out of
Malfunction STOP Continuous without 1051 ECU 1 Red
message
message
25 seconds
Time-out of
Malfunction STOP Continuous without 1053 ECU 1 Red
message
message
5 seconds Time-out of
Malfunction STOP Continuous without 1054 VCM message engine 1 Red
message temperature
Malfunction STOP Continuous without 1055 VCM message inlet/ 1 Red
message exhaust
Malfunction STOP Continuous without 1056 VCM message engine 1 Red
message fluid
Malfunction STOP Continuous without 1057 VCM message 1 Red
message electric system
5 seconds
Time-out of
Malfunction STOP Continuous without 1059 VCM 1 Red
message display
message
Transmission
Transmission
oil above Transmission oil
oil
STOP Continuous 115 °C 1009 VCM temperature limit 1 Red
temperature
(239 °F) for 5 reached
too high
seconds
General Only display

DTC’s 3000 -
display STOP Continuous STOP with display 1 Red
3366
message request
lamp
One touch idle

AUTO N/A VCM 1 Red
active
n/min
Continuous, This prevents

Parking brake Switch closed
if vehicle is in N/A VCM damaging the 2 Red
engaged to ground
gear parking brake
Sender
Brake temperature Warns customer
temperature Continuous over 152 °C 1006 VCM before brake 2 Red
too high (306 °F) for 5 fade
seconds
Engine oil Pressure

pressure too STOP Continuous depends on 3032 ECU 2 Red
high speed
Battery charge
Battery voltage
voltage too Continuous 3051 ECU 2 Red
too high
high
Supply
Battery charge Supply battery
source above
voltage too Continuous 1014 VCM voltage above 2 Red
16 V for 5
high 16 V
seconds
Battery charge
Battery voltage
voltage too Continuous 3052 ECU 2 Red
too low
low
Supply
Battery charge Supply battery
source below
voltage too Continuous 1015 VCM voltage below 2 Red
11 V for 5
low 11 V
seconds
Alternator L+
Alternator
terminal Alternator
unable to Continuous 1050 VCM 2 Red
under 1.5 V unable to charge
charge
for 5 seconds
IVS not
Accelerator One second Foot accelerator
changing
pedal signal alarm every 1010 VCM sensor - not 2 Amber
state in 300
out of range 30 seconds plausible
ms
Accelerator One second Accelerator Foot accelerator

pedal signal alarm every above 4.75 V 1011 VCM sensor -signal 2 Amber
out of range 30 seconds for 5 seconds above range

pedal signal alarm every under 0.25 V 1012 VCM sensor -signal 2 Amber
out of range 30 seconds for 5 seconds below range
lamp
Accelerator One second Foot accelerator

pedal signal alarm every 1013 VCM sensor - no 2 Amber
out of range 30 seconds signal

pedal signal alarm every above 9 V for 1029 VCM sensor - shorted 2 Amber
out of range 30 seconds 5 seconds high to Vbat

pedal signal alarm every under 0.5 V 1030 VCM sensor - shorted 2 Amber
out of range 30 seconds for 5 seconds low to Vbat
5V
One second Accelerator Foot accelerator
accelerator
alarm every above 5.1 V 1023 VCM supply voltage 2 Amber
pedal power
30 seconds for 5 seconds too high
supply
5V
accelerator
alarm every under 4.9 V 1024 VCM supply voltage 2 Amber
pedal power
30 seconds for 5 seconds too low
supply
5V
accelerator
alarm every above 9 V for 1025 VCM supply shorted 2 Amber
pedal power
30 seconds 5 seconds high to Vbat
supply
5V Foot accelerator
One second Accelerator
accelerator supply voltage
alarm every under 0.5 V 1026 VCM 2 Amber
pedal power shorted low to
30 seconds for 5 seconds
supply ground
Accelerator
Accelerator One second Accelerator
knob sensor -
knob signal alarm every above 4.75 V 1035 VCM 2 Amber
signal above
out of range 30 seconds for 5 seconds
range
Accelerator
knob sensor -
knob signal alarm every under 0.25 V 1036 VCM 2 Amber
signal above
range

knob signal alarm every 1037 VCM knob sensor - no 2 Amber
out of range 30 seconds signal
lamp
Accelerator
knob sensor -
knob signal alarm every above 9 V for 1038 VCM 2 Amber
shorted high to
out of range 30 seconds 5 seconds
Vbat
Accelerator
knob sensor -
knob signal alarm every under 0.5 V 1039 VCM 2 Amber
shorted low to
ground
5V
One second Accelerator Accelerator
accelerator
alarm every above 5.1 V 1031 VCM knob supply 2 Amber
knob power
30 seconds for 5 seconds voltage too high
supply
5V
One second Accelerator Accelerator
accelerator
alarm every under 4.9 V 1032 VCM knob supply 2 Amber
knob power
30 seconds for 5 seconds voltage too low
supply
5V Accelerator
accelerator knob supply
alarm every above 9 V for 1033 VCM 2 Amber
knob power voltage shorted
30 seconds 5 seconds
supply high
5V Accelerator
accelerator knob supply
alarm every under 0.5 V 1034 VCM 2 Amber
knob power voltage shorted
supply low
Switch closed
This must have
Seat not in to ground
a debounce
driving Continuous with vehicle in N/A VCM 2 Amber
time of less then
position gear and no
500 ms
parking brake
Boost
temperature
Boost air One second over Engine over
temperature alarm every 1018 VCM operating boost 3 Amber
too high 30 seconds 88 °C air temperature
(1276 °F) for
5 seconds
Engine Coolant Engine over

One second
coolant above 106 °C operating
alarm every 1019 VCM Amber
temperature (223 °F) for 5 coolant
30 seconds
too high seconds temperature
Engine
One second Coolant
coolant
alarm every 3007 ECU temperature 3 Amber
temperature
30 seconds signal high
too high
lamp
Transmission Coolant above

One second Transmission
oil 105 °C
alarm every 1020 VCM over operating 3 Amber
temperature (221 °F) for 5
30 seconds temperature
above 105 °C seconds
Fuel over
Fuel One second Fuel over
temperature alarm every 82 °C 1021 VCM operating 3 Amber
too high 30 seconds (1189 °F) for temperature
5 seconds
Fuel
Fuel One second
temperature
temperature alarm every 3015 ECU 3 Amber
signal source
too high 30 seconds
high
Fuel One second Fuel

temperature alarm every 3016 ECU temperature 3 Amber
too high 30 seconds signal no signal
One second Switch closed

Clogged air Air filter
alarm every to ground for 1001 VCM 4 Red
filter threshold
Air One second Switch closed

Air conditioning
conditioning alarm every to Vbat for 5 1003 VCM 4 Amber
system pressure
not functional 30 seconds seconds
One second Switch closed

Hydraulic oil Hydraulic filter
alarm every to ground for 1004 VCM 4 Red
filter restriction threshold
Fuel One second

Display
contaminated alarm every 1022 VCM 4 Amber
message
with water 30 seconds
Fuel sender
One second Fuel sender
Fuel level shorted high -
alarm every above 9 V for 1043 VCM 4 Amber
sensor instrument in
stand-by
Fuel sender
One second Fuel sender
Fuel level shorted low -
alarm every below 0.5 V 1044 VCM 4 Amber
sensor instrument in
stand-by
Input is Fuel sender

One second
Fuel level switched open circuit -
alarm every 1045 VCM 4 Amber
sensor battery for 5 instrument in
30 seconds
seconds stand-by
lamp
Transmission
Transmission
Transmission One second temperature
temperature
temperature alarm every sender above 1046 VCM 4 Amber
sender shorted
sensor 30 seconds 9 V for 5
high
seconds
Transmission
Transmission
Transmission One second temperature
temperature
temperature alarm every sender below 1047 VCM 4 Amber
sender shorted
sensor 30 seconds 0.5 V for 5
low
seconds
Input is
Transmission One second Transmission
switched
temperature alarm every 1048 VCM temperature 4 Amber
battery for 5
sensor 30 seconds open circuit
seconds
Brake
Brake One second Sender over
temperature
temperature alarm every 1000 Ohm for 1049 VCM 4 Amber
sender out of
sensor 30 seconds 5 seconds
range
General Only display

One-second DTC’s 3000 -
display VCM with display 4 Amber
alarm 3366
message request
Low fuel - must

Low fuel One-second stay on for
VCM 5 Amber
warning alarm remaining key
cycle
STARTING SYSTEM
OPERATION CHECKING THE STARTER MOTOR SYSTEM

The system includes a key switch, a reinforced wir- To troubleshoot the starter motor system rapidly and
ing, a starter motor and a relay-solenoid valve easily, it is recommended that a battery-starter motor
assembly. testing device (quick discharge) be used, which
includes a 0 - 20 V voltmeter and a 0 - 500 A ammeter
The starter motor has a built-in solenoid valve and to detect problems in the starter motor system.
a positive engagement drive system.
Use a testing device in accordance with the manu-
When the key switch is operated with the forward facturer’s instructions.
and reverse travel lever in neutral position, the
solenoid coils are energized and cause the piston If a testing device of the type indicated is not availa-
to be magnetically drawn inside the solenoid. ble, use a standard 0 - 20 V voltmeter and a 0 - 500 A
ammeter to check the operation of the starter motor
This movement causes the drive pinion to mesh
on the vehicle.
with the ring gear on the engine flywheel.
Before testing:
When the pinion touches the ring gear, the piston of
the solenoid valve closes a series of contacts ena- - check that the battery is fully charged.
bling the battery to directly power all four field coils, - check that no wire of the starting system is cut or
thus providing full power to the starter motor. stripped and that the connections are not loose.
The starter motor contains a single set of contacts - check that the motor is not seized.
and a solenoid valve piston, which completely
closes the contacts, even if the teeth of the pinion
are not perfectly aligned with the teeth of the ring
gear.
In this case, a spring is compressed and forces the
complete engagement of the pinion as soon as the
starter motor starts rotating.
Once the ignition is turned off, the solenoid and the
starter motor are de-energized.
The solenoid’s recoil spring causes the drive pinion
to be uncoupled and the contacts of the solenoid to
reopen.
Current draw on the starter motor system

Disconnect the ground cable (negative) from the
battery (3).
Disconnect the positive cable from the battery on
the solenoid of the starter motor. Connect the posi-
tive cable of the ammeter (1) to the positive terminal
of the battery and the negative cable to the input
terminal of the solenoid.
Reconnect the ground cable (negative) of the bat-
tery to the negative terminal of the battery.
Connect the positive cable of the voltmeter (2) to
the positive terminal of the battery and the negative
cable of the voltmeter to the negative terminal of the
battery.
Disconnect the injection pump fuel inlet cut-off wire
from the solenoid.
Start the motor and observe the values indicated by
the voltmeter and ammeter. The voltage must
remain steady at around 12 V with a current draw of
250 - 300 A.
If the current draw is within the indicated range, the
starter motor (4) is operating correctly.
If the voltage drops during the test, refer to chapter
“Resistance on the system of the starter motor sys-
tem”.
If the current draw is higher than the specified
range, check the system as indicated below.
If tests of the starting system have proved satisfac-
tory, the starter motor is defective and must be
removed in order to identify the source of the prob-
lem.
If the current draw is less than the specified range,
the starter motor is defective and must be removed
in order to identify the source of the problem.
RESISTANCE ON THE SYSTEM OF THE STARTER MOTOR

(Voltage lowering)
If the current draw is excessive, it is necessary to
check the system according to the voltage drop
occurring between its single components.
IMPORTANT: disconnect the injection pump fuel
inlet cut-off wire from the solenoid.
Positive cable of the battery
the positive terminal of the battery (2).
Connect the negative cable of the voltmeter (1) to
the battery terminal of the starter motor solenoid
valve (3).
Start the starter motor and observe the reading on
the voltmeter. If the voltage drop exceeds 0.2 V,
check and retighten the cable connections. Check
the voltage again. If it is still excessive, replace the
cable.
Starter motor connections to ground

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

the motor block (2).
the negative terminal of the battery (3).
check and retighten the ground cable connections.
Check the voltage again. If it is still excessive,
replace the ground cable.
STARTER MOTOR
Manufacturer............................................................................................................................................. Denso
Voltage......................................................................................................................................................... 12 V
Rated power............................................................................................................................................. 2.7 kW
Starting system .......................................................................................................................................Positive
Operating time ..............................................................................................................................................30 s
Direction of rotation.................................................................................... Clockwise seen from the pinion side
Weight......................................................................................................................................... 8.4 kg (18.5 lb)
Maximum consumption without load at 11 V and 3000 rpm minimum...................................... 200 A maximum
Maximum consumption with a torque of 19.6 Nm (14.5 lbf·ft) at 8 V and 1130 rpm minimum .........600 A maximum
Maximum consumption when shimming at 3 V with a torque of 39.2 Nm (568 lbf·ft) minimum ......1400 A maximum
MAIN COMPONENTS
1. Motor
2. Induction coils
3. Armature
4. Commutator
5. Brush assembly
6. Pinion gear
7. Intermediate pinion
8. Solenoid
9. Clutch
10. Drive pinion
1. Shim
2. Bearing
3. Armature
4. Bearing
5. Coils housing
6. Protection
7. Brush spring
8. Brush assembly
9. Disc
10. Cover
11. Screw
12. Screw
13. Drain
14. Screw
15. Protection
16. Gasket
17. Washer
18. Nut
19. Rod
20. Connection assembly
21. Screw
22. Connection assembly
23. Nut
24. Ring
25. Roller
26. Cage
27. Pinion
28. Ball
29. Spring
30. Drain
31. Screw
32. Washer
33. O-ring
34. Flange
35. Pinion, rings and spring assembly
36. O-ring
37. Bearing
38. Bearing
39. Spring
40. Shaft
41. Body
42. Clutch assembly
REMOVAL AND INSTALLATION

Disconnect the ground cable (negative) from the
battery.
Remove the rear protection cover and disconnect all
cables connected to the starter motor.
Remove the three retaining screws of the starter
motor and remove the starter motor.
To install the starter motor again, proceed in the
reverse order to that of removal.
TEST BENCH CHECK

Check
NOTE: before carrying out the test, check that the
battery is fully charged then obtain a battery-starter
motor testing device (quick discharge) and a carbon
cell (variable load resistance).
Lock the starter motor in a vice with soft jaws.
Connect the negative cable (4) of the battery to the
mounting flange of the starter motor.
Connect a short cable (6) between the solenoid bat-
tery wire and the terminals of the solenoid switch.
the positive terminal of the battery and the negative
cable to the negative terminal of the battery, the
positive cable of the ammeter (1) to the positive ter-
minal of the battery and the negative terminal the
solenoid valve battery or to the starter motor clamp.
Install a tachometer (5) at the end of the armature
shaft. Activate the starter motor by adjusting the car-
bon cell (2) to obtain a voltage of 11 V.
When the armature is rotating at 3000 rpm, the max-
imum current draw must not exceed 200 A.
If the starter motor does not operate in these condi-
tions, check that the field coils are not grounded,
that the armature is not rubbing and that its shaft is
not deformed.
Armature
The surface of the commutator must be clean and
without traces of burns. If necessary, remove traces
of burns using fine sandpaper. Do not use emery
cloth. Then, clean the commutator with a cloth
soaked in gasoline.
After rectifying the commutator, polish it with fine
sandpaper, then wipe it with a cloth soaked in gaso-
line.
NOTE: make sure not to graze the metal of the com-
mutator during rectification of insulating notches.
The resistance of the armature insulation may be
checked by connecting an ohmmeter (1) between
the blades of the commutator (2) and the armature
shaft (3). The resistance must be infinite (no conti-
nuity).
To check that the armature is not short-circuited, a
special device for armatures must be used. The
other solution is to replace the armature.
If the circumference of the armature has come into
contact with the starter pole shoes, the bearings of
the armature are probably excessively worn out.
First check that the starter pole shoes have been
tightened and that the armature rotates without any
concentric defect. If necessary, replace the arma-
ture bearings.
Field coils
To check the resistance of the field coil insulation,
connect an ohmmeter (1) between the brushes of
each induction coil (2) and a clean unpainted area
of the body (3). The resistance must be infinite (no
continuity).
To check the continuity of the field coils, connect an
ohmmeter between the brushes of each induction
coil and the main supply terminal (the thickest
braided wire). The resistance must be equal to 1
MW.
If the field coils are defective, the entire assembly
consisting of the body and the field coils must be
replaced.
Drive pinion
The drive pinion must only rotate clockwise. If the
pinion is seized or turns in both directions or if its
teeth are damaged, change the complete drive
assembly.
NOTE: if the teeth of the drive pinion are damaged,
also check the teeth of the engine flywheel ring
gear.
TROUBLESHOOTING
STARTING SYSTEM
The motor does not start when the starter switch key is operated and the transmission is in the neutral position.
Is the battery properly charged?

NO Charge or replace the battery.
YES
Check the starter motor wiring. Are there bad

YES Repair or replace the cables.
connections, cut or stripped cables?
NO
Is the starter motor seized? YES Repair or replace the starter motor.
NO
Operate the starter switch key. Is there Does the solenoid
a voltage of +12 V on the (white) input Windings, brush or starter
YES make a “clicking” YES
wire of the starting solenoid valve motor mechanism possibly
sound?
(terminal 30)? defective.
NO
NO
Check the starter motor relay (K01). Can you hear Solenoid possibly
the relay operate after operating the starter switch defective. Remove the
key? starter motor and inspect.
NO
Remove the connector from the relay (K01). Is there a voltage of +12 V
at terminal 86 (white/black) after the starter switch key is operated? YES Replace the relay.
NO
Check the starter motor safety relay (K3). Can one hear the relay
operate after operating the reverse travel lever?
NO
Remove the connector from relay K3. Is there a voltage of +12 V at

YES Replace the relay.
terminal 86 (white/black) after the reverse travel lever is operated?
NO
Are the cable wires of the reverse travel lever properly
NO Reconnect the wires to the switch.
connected?
YES
Does the reverse travel lever switch operate correctly? NO Replace the switch.
YES
Check the main power supply
Are the indicators on the instrument panel correctly lighted between the battery and the
after operating the key switch? NO starter motor key. Pin 2 (red wire)
YES of the ignition key connector.
Are the cable wires of the key switch connected correctly?
YES NO
Replace the key switch. Reconnect the wires to the key switch.
STARTER MOTOR

The starter motor does not run Too low specific density and Inspect the battery.
(the magnetic switch makes no battery level.
operating noise).
Poor ignition switch system Replace the wiring harness and the
connection or contact. ignition switch.
Malfunction of the coil or of the Replace the magnetic switch.
magnetic switch pull-in piston.
The starter motor does not run Too low specific density and Inspect the battery.
(the magnetic switch makes an battery level.
operating noise).
Poor start-up system contact. Repair the wiring harness.
Poor magnetic switch contact. Replace the magnetic switch.
Motor malfunction (e.g. short Repair or replace the motor
circuit, brush wear). assembly.
The starter motor runs too slowly. Poor magnetic switch contact. Replace the magnetic switch.
Motor malfunction (e.g. short Repair or replace the motor
circuit, brush wear). assembly.
The starter motor running cannot The pinion gear does not engage Repair or replace the clutch and the
crank the engine. with the ring gear. control lever.
Sliding clutch. Replace the clutch.
Anomalous noise. Anomalous bushing wear. Replace the bushing.
Wear on pinion gear or ring gear Replace the clutch and the ring gear.
tooth tips.
Poor pinion gear sliding. Lubricate or replace the clutch.
The pinion gear springs. Poor ignition switch return. Replace the ignition switch.
Field coil loss. Pinion gear disengagement fault Replace the magnetic switch.
caused by a coil short circuit in
Magnetic switch coil burnt, etc.
the magnetic switch.
ALTERNATOR
Rated voltage ............................................................................................................................................14.5 V
Current ......................................................................................................................................................120 A
Swing speed......................................................................................................................... 12000 ÷ 13500 rpm
Operating temperature ......................................................................................-30 °C ÷ 90 °C (-435 ÷ 1305 °F)
Direction of rotation .................................................................................... Clockwise seen from the pulley side
Regulated voltage at 5000 rpm with 10 A at 25 °C (362 °F) .......................................................... 14.2 ÷ 14.8 V
Maximum load that can be applied at terminal L.........................................................................12 V, 3.4 W x 6
OPERATION
The alternator, installed on the motor, on the front
RH side of the vehicle, is driven by the crankshaft
pulley with the help of a belt.
The alternator contains built-in regulators.
Current draw on the starter motor system:
When the ignition key is turned, a current of low
intensity is sent by the battery to the field winding of
the rotor (terminal IG).
At this stage, the indicator lamp (terminal L) turns
on and the rotor is partially magnetized.
When the motor starts and the partially magnetized
rotor rotates inside the stator, a three-phase alter-
nating current is generated (terminal B+). 1. Terminal W
A constant portion of this current is transformed into 2. Terminal IG
a direct current by three excitation diodes installed 3. Terminal L
in the rectifier.
4. Terminal B
The direct current is sent as reinforcement through
the field winding of the rotor.
Using this method an increase in the magnetic field
of the rotor is obtained, as well as a rapid rise in the
voltage and current generated at the output.
The luminosity of the indicator lamp decreases
when the voltage generated at the output is increas-
ing (terminal L).
The indicator lamp goes out when the voltage at ter-
minal “L” is equal to that of the battery.
The voltage continues to increase up to the value
predefined by the regulator.
In case the alternator belt is broken, the voltage
does not accumulate in the alternator and the load
indicator lamp remains lighted to indicate the prob-
lem.
TROUBLESHOOTING

Not recharged. Recharging system interrupted Check the connections of the
(warning lamp, fuse, connector, recharging system, clean and
etc.). tighten the alternator and battery
terminals.
Voltage regulator inefficient. Replace the part.
Rotor winder interrupted. Replace the part.
Worn brushes. Replace the part.
Recharge insufficient. Slackened fan belt. Supply the correct voltage.
Voltage regulator faulty. Replace the part.
Excessive wear of rotor rings or Replace the part.
brushes.
Short-circuited diodes. Replace the part.
Short-circuited stator winders or Replace the part.
rotor winder.
Excessive recharge. Loose system connections. Check the connections of battery
terminals, starter motor terminals
and alternator.
Voltage regulator inefficient. Replace the part
Ground connection faulty. Check connections for leaks.
BATTERY
For the loader backhoe models two different kinds of installation are provided:
- with one battery;
- with two batteries (for cold climates).
Single battery
Voltage:........................................................................................................................................................ 12 V
Capacity (20 h):.......................................................................................................................................... 95 Ah
Discharge current:...................................................................................................................................... 900 A
Weight with electrolyte: ................................................................................................................... 25 kg (55 lb)
Double battery
Voltage:........................................................................................................................................................ 12 V
Capacity (20 h):.......................................................................................................................................... 60 Ah
Discharge current:...................................................................................................................................... 600 A
Weight with electrolyte: ................................................................................................................ 17 kg (37.5 lb)
OPERATION
All models feature one or two 12 V, negative The battery is constructed in such a manner that
ground, “maintenance free” lead calcium (Pb-Ca) each cell contains positive and negative plates
type battery. placed alternatively next to each other.
IMPORTANT: “Maintenance Free” means that Each positive plate is separated from a negative
under normal charging conditions the battery does plate by a non conducting porous envelope separa-
not lose water from the electrolyte. Conditions that tor.
may cause water loss include prolonged charging If any of the positive plates should make contact
above 14.4 V where gassing occurs as it with negative plates within a cell, the cell will short
approaches full charge. This can be caused by a circuit and suffer irreparable damage.
faulty charging system or boost/recovery charging
equipment. All of the positive plates are welded to a bus-bar,
The battery has four major functions: forming a positive terminal and all of the negative
plates are welded to a similar bus-bar forming a
- to provide a source of current for starting, lighting negative terminal.
and instrumentation;
Each positive plate is composed of a lead grid with
- to help control the voltage in the electric system;
lead peroxide pasted into the grid openings.
- to provide current when the electric consumption
exceeds the alternator output; The negative plates are composed of a lead grid
with spongy lead pasted into the grid openings.
- to support quiescent loads from radio and micro-
processor memory. The plates are submerged in a liquid electrolyte
solution of diluted sulphuric acid.
REPLACEMENT
position.
brake.
S WARNING S
Never reverse the battery terminals. Connect the
positive cable to the positive terminal (+) and the
negative cable to the negative terminal (-).
When disconnecting the battery cables, always dis-
connect the negative cable (-) first.
When reconnecting the battery cables, always con-
nect the negative (-) cable last.
Never short-circuit the battery terminals with metal
objects.
This could generate an electrolysis inside the
human body and damage the body’s vital organs.
Place the battery switch in the OFF position.

Remove the battery master switch support (6) with-
out disconnect the battery cables.
Remove the terminal covers and disconnect the
cables, first from the negative terminal (1) then the
positive terminal (2).
Remove the nuts and washers (3), the clamping bar
(4) and the brackets (5) and remove the old battery.
Install the new battery.
Install the brackets (5), the clamping bar (4) and the
washers and nuts (3).
Clean the cables and the connecting terminals and
coat them with grease.
Connect the cables, first to the positive terminal (2),
then the negative terminal (1) and install the termi-
nal covers.
Reassemble the battery master switch support (6).
CHARGE AND ELECTROLYTE LEVEL CHECK
S WARNING S S WARNING S
The battery electrolyte generates severe burns. Before carrying out any welding on the machine or
The battery contains sulphuric acid. Avoid any con- repair work on the electric circuit, disconnect the
tact with the skin, eyes or clothing. battery and disconnect the B+ and D+ wires on the
alternator. When reconnecting, check the wire
Antidote:
markings.
EXTERNAL: rinse well with water, removing any
soiled clothing. CHARGE CHECK
INTERNAL: avoid vomiting. Drink water to rinse Measure the density of the acid of the single cells
your mouth. Consult a doctor. with a commonly available measuring device.
EYES: rinse thoroughly with water for 15 minutes The measured values (see table below) indicate
and get prompt medical attention. the charge status of the battery.
When working with batteries, always wear gloves, When measuring, the temperature of the acid
protection goggles and suitable clothes. should be +20 °C (68 °F), if possible.
S WARNING S ELECTROLYTE CONCENTRATION

in kg/dm3 (lb/ft3) Charge
This could generate an electrolysis inside the
human body and damage the body’s vital organs. Normal Tropical
1.28 (80) 1.23 (77) good
S WARNING S 1.20 (75) 1.12 (70) reduced: charge
Batteries produce explosive gases. To prevent any
risk of explosion, observe the following instructions: 1.12 (70) 1.08 (67) low: immediately charge
- place the battery switch in the OFF position;
- when disconnecting the battery cables, always
ELECTROLYTE LEVEL CHECK
disconnect the negative cable (-) first;
Remove the vent plugs and check the level in each
- when reconnecting the battery cables, always
battery cell.
connect the negative (-) cable last;
The level should come up to 6 mm (0.24 in) above
- never short-circuit the battery terminals with
the separator plates.
metal objects;
Add distilled water if necessary.
- do not weld, grind or smoke near a battery.
Keep open flames away and do not smoke near
batteries. Always provide good ventilation when
charging a battery or using a battery in an enclosed
space.
CONNECTING A BOOSTER BATTERY
S WARNING S
When the electrolyte of a battery is frozen, it can
explode if you attempt to charge the battery or if
you try to start the engine using a booster battery.
Always keep the battery charged to prevent the
electrolyte freezing.
S WARNING S
Connecting jumper cables wrongly or short-
circuiting battery terminals can cause an accident.
Connect the jumper cables following the instruc-
tions in this manual.
IMPORTANT: make sure that the voltage of the

booster batteries is the same as that of the machine
system (12 V).
Open the battery box and then remove the tool box.
Remove the terminal covers.
Connect the positive (+) jumper cable to the positive
(+) terminal of the machine’s battery.
Connect the negative (-) jumper cable to one of the
fastening screws (1) of tank.
Start the engine
First disconnect the negative (-) jumper cable, then
disconnect the positive (+) jumper cable from the
booster battery.
Install the terminal covers.
Install the tool box and close the battery box.
BATTERY MASTER SWITCH
S WARNING S
The battery master switch must be switched off at
the end of each working day, for machine service or
for any operations on the electric system.
It acts as an anti-theft device when the cab doors
and windows are locked.
The battery master switch (1) is located in the bat-

tery compartment and is used to completely discon-
nect the battery from the electric system.
When the battery master switch has an inclination of
45°, the circuit is disconnected.
When the master switch is in vertical position, the 1
circuit is connected.
TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE ACTION
The electric system is Loose or oxidised battery Check that the battery voltage with
inoperative. connections. open circuit is at least 12.6 V.
Clean and tighten the connections. Check the electrolyte level and
Sulphated batteries. density.
Battery isolator switch off. Restore the battery isolator switch.
The main connection fuse of the Find the reason of the failure and
machine is blown. replace the connection fuse.
Starter motor speed too low, Loose or corroded connections. Clean and tighten loose
the engine cranks slowly. connections.
Low battery output voltage. Check that the battery voltage with
open circuit is at least 12.6 V.
Check the electrolyte level and
density.
Incorrect viscosity of the engine oil. Use an oil with correct viscosity for
the temperature conditions.
Starter motor inoperative. Transmission gearshift lever Move gearshift lever to neutral.
engaged.
Loose or corroded connections. Clean and tighten loose

connections.
Dead batteries. Charge or replace the batteries.
The charge indicator lamp Low engine idle speed. Increase idle speed.
stays on with the engine
running. Loose belt. Check belt tension.
Malfunctioning battery. Check that the battery voltage with

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

necessary.
TROUBLE POSSIBLE CAUSE ACTION
Batteries will not charge. Loose or corroded battery Clean and tighten the connections.
connections.
Sulphated batteries. Check that the battery voltage with

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

If necessary, replace the belt.
The charge indicator flashes, Malfunctioning alternator. Check the alternator and repair, if
indicating excessive charging necessary.
voltage.
580ST
590ST
695ST
SECTION 82 - LOADER ATTACHMENT
LOADER ATTACHMENT CONTROLS............................................................................................................. 3

LOADER ATTACHMENT OPERATION ...................................................................................................... 3
4x1 LOADER BUCKET CONTROL (Optional) ............................................................................................ 6
LOADER ATTACHMENT CONTROL LOCK (Specific to certain countries)................................................ 7
BUCKET SELF-LEVELLING............................................................................................................................. 8
LOADER ATTACHMENT SAFETY STRUT...................................................................................................... 9

LOADER ATTACHMENT SAFETY STRUT (2WS) ..................................................................................... 9
LOADER ATTACHMENT SAFETY STRUT (4WS) ................................................................................... 10
REMOVAL AND INSTALLATION OF LOADER BUCKET .............................................................................. 11

STANDARD LOADER BUCKET................................................................................................................ 11
LOADER BUCKET WITH FORKS (Optional) ............................................................................................ 12
BUCKET TEETH REPLACEMENT............................................................................................................ 13
LOADER REMOVAL....................................................................................................................................... 14
2 SECTION 82 - LOADER ATTACHMENT
SECTION 82 - LOADER ATTACHMENT 3
LOADER ATTACHMENT CONTROLS
S WARNING S
Before starting the engine, make sure you are fully
aware of the location and the function of each con-
trol. Operating the controls wrongly can cause seri-
ous physical injury.
S WARNING S
Before using the controls make sure that the opera-
tor’s seat is correctly adjusted in the loader attach-
ment position.
WITH STANDARD LOADER BUCKET

Located on the right of the steering wheel, this nine
position lever operates all the loader attachment
controls.
The speed of movement of each control depends on
the angle to which the lever is tilted. In the interme-
diate position, two movements can be obtained
simultaneously.
WITH 4x1 LOADER BUCKET

The function of the lever is identical to that of the
machine fitted with the standard loader bucket, with
the addition of the clam control.
LOADER ATTACHMENT OPERATION

NEUTRAL AND HOLD
With the lever in the neutral/hold position (0), the
attachment movement can be stopped.
As soon as the lever is released, it automatically
returns to the neutral position (0) and the attach-
ment remains in the position where it was when
movement stopped.
RAISING THE LOADER ATTACHMENT

With the lever in position (1), the attachment rises.
LOWERING THE LOADER ATTACHMENT

With the lever in position (2), the attachment lowers.
LOADER BUCKET FLOAT CONTROL

With the lever in position (3), the bucket follows the
contours of the ground without it being necessary to
operate the lever.
NOTE: in this position the lever does not automati-
cally return to neutral when it is released. It is nec-
essary to move it manually.
FILLING THE LOADER BUCKET

With the lever in position (4), the bucket rolls back
(fills).
DUMPING THE LOADER BUCKET

With the lever in position (5), the bucket rolls for-
ward (dumps).
AUTOMATIC RETURN TO LOADER BUCKET

FILLING
With the lever in position (6), the attachment lowers
and, simultaneously, the bucket places itself to the
digging position.
NOTE: it is possible to adjust the tilt angle for bucket
filling.
4x1 LOADER BUCKET CONTROL (Optional)

This control operates the opening and closing of the
4x1 bucket clam.
This control is proportional:
When releasing the roller (7), it automatically returns
to the initial position (neutral) and the bucket
remains in the position where it was when move-
ment stopped.
When shifting the roller (7) forward: the loader
bucket clam closes (A).
When shifting the roller (7) backward: the loader
bucket clam opens (B).
4x1 loader bucket control roller detent proce-
dure
The operator may install a detent position for the
4x1 bucket operation.
This position alters operation in order to allow the
operator to lock the switch in the open circuit posi-
tion, so that this position is held until the operator
unlocks the switch.
The standard position of the switch is with the open
U shape pointing upwards. In this configuration, the
switch will automatically spring back to the neutral
position when released, from any position.
To set the detent position to the bucket open posi-
tion, it is necessary to remove the top of the switch,
rotating it by 180°.
Remove the screw (2) of the roller (1) using a small
phillips screwdriver.
Lift and remove the top portion (3) of the roller

switch, rotate it by 180° and tighten the screw in the
top portion of the roller.
NOTE: the open U shape must point downwards.
Carefully restore the screw (2) into place and do not
overtighten.
Test the switch by lifting it up into detent position
before restoring the cap into place. The switch
should lock into position.
In this condition, the 4x1 loader bucket control roller
is locked. To unlock it, it is necessary to rotate the
top portion again and take it back to its initial posi-
tion.
LOADER ATTACHMENT CONTROL LOCK

(Specific to certain countries)
This pin (1), located next to the control lever, is used
to lock the attachment controls.
To lock the controls, extract the pin from its housing
and insert it into the specially provided hole of the
lever support.
S WARNING S
Before leaving the operator’s compartment, under-
taking any road travel or working with the backhoe
attachment, place the pin in locking position.
BUCKET SELF-LEVELLING
SELF-LEVELLING ADJUSTMENT
The “return to dig” device is an electrically activated
feature which enables the operator to automatically
return the bucket to a level digging position for a fur-
ther work cycle, with one simple movement of the
control lever (3).
Whenever the bucket is rolled forward to dump the
return to dig electric circuit is completed and the
solenoid on the bucket spool is energised.
When the loader bucket control lever (3) is moved
diagonally left to the return to dig position (2) the
electromagnet will hold the bucket spool in the roll
back position until the bucket is in the level digging
position at which time the indicator on the rod of the
bucket linkage will pass in front of the sensor which
de-energises the electromagnet on the bucket spool
enabling the spool to return to the neutral position.
RETURN TO DIG SENSOR - ADJUSTMENT

The return to dig device consists of an electromag-
net mounted on the loader bucket control valve
spool, a sensor (1) mounted on top of the loader
arm and a pointer attached to the tube of the bucket
self-levelling linkage.
Place the bucket on the ground in the preferred dig-
ging position.
Check the dimensions of 88.5 mm (3.5 in) and 7.5 mm
(0.3 in) are maintained as shown.
Make sure that the sensor (1) is 6 mm (0.24 in) from
the tie rod (2).
As a visual aid for the operator, while seated in the
cab, the pointer mounted on the loader arm can be
seen to align with the pointer on the return to dig
linkage, when the loader arms are lowered and the
bucket is in the level digging position.
LOADER ATTACHMENT SAFETY STRUT

Located on the left-hand side of the loader attach-
ment, this safety strut enables the loader attach-
ment to be locked in the raised position in case of
defects in the system.
LOADER ATTACHMENT SAFETY STRUT

(2WS)
LOCKED POSITION
Completely raise the loader attachment. Stop the
engine and remove the starter switch key.
Remove the split pin (3) to extract the pin (2).
Raise the loader attachment to the desired position.

Now the safety strut (1) is free and positions itself
onto the cylinder rod, thus locking it.
As a safety precaution, position the pin (2) into the
relevant hole (4) in the safety strut (1).
UNLOCKED POSITION
Extract the pin (2) from the hole (4) in the safety
strut (1).
Lower the loader attachment.
Place the safety strut (1) to storage position: align
the holes of the safety strut (1) and bracket (5) and
assemble the pin (2).
Fasten the pin (2) by installing the split pin (3).
LOADER ATTACHMENT SAFETY STRUT (4WS)

LOCKED POSITION
Completely raise the loader attachment. Stop the
engine and remove the starter key.
Remove the split pins (1) and the safety strut (2)
from the arm. Put the split pins back in place.
Place the strut (2) on the cylinder rod and fasten it
by means of the fastening flip (3).
S WARNING S
It is mandatory to install the safety strut when carry-
ing out any operation requiring the loader attach-
ment to be in the raised position.
UNLOCKED POSITION
Remove the flip (3) and the strut (2) from the cylin-
der rod.
2
Install the safety strut (2) on the loader arm by
means of the split pins (1).
Start the engine and lower the loader attachment.
3
REMOVAL AND INSTALLATION OF LOADER BUCKET
STANDARD LOADER BUCKET

REMOVAL
Lower the bucket to the ground in dump position
(tilted completely forward).
If the machine is fitted with a 4x1 bucket, release the
pressure from the bucket circuit: turn the key to ON
(with engine stopped) and operate the accelerator
knob.
Remove the retaining rings and pins, then drive out
the pins (1).
S WARNING S
Always wear eye protection when using a tool
which might project metal particles. Use a hammer
with a soft face, such as copper, for pins assembly/
disassembly.
(4x1 bucket) disconnect and plug the hydraulic sup-

ply lines.
Start the engine.
Operate the attachment controls so as to release
4
the bucket.
Reverse the machine from the bucket.
INSTALLATION
Make sure all bushings are completely clean.
Remove any dirt or foreign matter, if necessary.
Start the engine.
Use the attachment controls to engage the attach-
ment between the bucket lugs.
Reinstall the arm/bucket pins (1) and then install the
relevant retaining pins and rings.
Use the bucket controls to align the connecting rod
holes (3) with the bucket lugs.
(4x1 bucket) release the pressure from the bucket
circuit. 5
Install the rod/bucket pins (2) and then install the rel-
evant retaining pins and rings.
(4x1 bucket) remove the plugs and reconnect the
hydraulic lines.
LOADER BUCKET WITH FORKS (Optional)
S WARNING S
The forks are heavy, so use great care when swing-
ing them into their working and stowage position.
INSTALL FORKS IN WORKING POSITION

Move the bucket to a level and firm ground.
Raise the parking brake lever.
Remove the retained pin and the pin (1).
Lower the fork (2) manually and carefully until it is
laying in position against the bucket cutting edge.
IMPORTANT: the forks must be laying against the
cutting edge of the bucket, and never against bucket
teeth.
Install the pin (1) and the safety pin.

Repeat the same operations for the other fork.
Slide the forks until they are suitably spaced for the
intended job.
IMPORTANT: the two forks must be positioned at
the same distance from the centre of the bucket.
IMPORTANT: never use the forks to lift the
machine.
S WARNING S
When using the forks with a 4x1 bucket, never
attempt to use the bucket jaw opening function.
INSTALL THE FORKS IN REST POSITION

Rest the loader bucket on a level and firm ground.
Stop the engine and remove the starter key. Disen-
gage the parking brake lever.
Remove the retained pin and the pin (1).
Tilt the fork (2) manually and carefully until it is rear-
wards into transport position.
Reinstall the pin (1) and the safety pin into their
housing.
NOTE: if necessary, slide the fork to the side to
bring it into its housing.
Repeat the same operations for the other fork.
IMPORTANT: the forks must be securely retained in
their proper storage position using the pins and split
pins provided for this purpose. If forks are not cor-
rectly secured, they can cause serious injury.
BUCKET TEETH REPLACEMENT

Position the loader bucket so that the bucket teeth
can be replaced.
brake.
Loosen and remove the screws (2) with the nuts (3).
Extract the tooth (1).
Clean the area around the tooth.
Assemble the new tooth (1).
Screw in and tighten the screws (2) with the nuts (3).
LOADER REMOVAL
Remove the loader bucket (see procedure
described previously).
Fully retract bucket cylinders and raise arm until lift
cylinder pivots can be seen above engine guard.
Place a suitable stand under the end of the arm to
take the weight.
Switch off the engine and relieve hydraulic pressure.
Remove the snap rings (2) and the pins, then

extract the pins (1).
Lower the lift cylinders carefully onto the chassis.
Remove the snap rings (3) and drive out the pins
(4).
Lower the arms onto the lift cylinders.
Disconnect and cap the lift cylinder hoses (5) at the

top of the loader arm on each side of the machine
and disconnect the return to dig sensor cable (7) on
the right hand side.
If the 4x1 bucket is fitted disconnect and cap hose
(6) on each side of the loader.
Support loader using a suitable sling.
Remove the snap ring and the pin, then extract the
pin (8).
Remove the loader attachment from the machine.
INSTALLATION
reverse order.
NOTES:
580ST
590ST
695ST
SECTION 84 - BACKHOE ATTACHMENT
DESCRIPTION AND OPERATION................................................................................................................... 3
BACKHOE ATTACHMENT CONTROLS.......................................................................................................... 6

BACKHOE ATTACHMENT MECHANICAL CONTROLS ............................................................................ 7
BACKHOE ATTACHMENT HYDRAULIC CONTROLS ............................................................................. 18
BACKHOE ATTACHMENT SIDESHIFT (Sideshift version) ...................................................................... 24
BACKHOE ATTACHMENT DISASSEMBLY .................................................................................................. 26

580ST-590ST-695ST................................................................................................................................. 28
BACKHOE BUCKET REPLACEMENT...................................................................................................... 31
BACKHOE BUCKET.................................................................................................................................. 32
BACKHOE ATTACHMENT HYDRAULIC HANDLING ................................................................................... 33

CONTROLS ............................................................................................................................................... 33
HYDRAULIC DIAGRAM ............................................................................................................................ 34
2 SECTION 84 - BACKHOE ATTACHMENT
SECTION 84 - BACKHOE ATTACHMENT 3
DESCRIPTION AND OPERATION

Backhoe loaders are available with center pivot or
(only 695ST) sideshift backhoe attachment.
On sideshift machines the backhoe is attached to a
carriage hydraulically clamped to the machine
frame.
This allows the operator to reposition the carriage
on the frame and to adjust the position of the back-
hoe attachment to suit the operating conditions.
The machine is raised using two vertical stabilisers
attached to each side of the machine.
On center pivot machines, the backhoe attachment

pivots around a fixed central point on the rear side of
the machine.
Independently operated stabilizers are attached to
the base of the chassis and pivot about an arc to
raise or lower each side of the machine.
Each stabilizer is independently operated using:

- levers (1) and (2) on mechanical control backhoe
loaders;
- control levers (3) and (4) on “pilot” control back-

hoe loaders.
The backhoe attachment is locked in position during

transport using a hydraulically operated lock which
acts on the hook (5).
The lock is activated by the switch (7).
The backhoe on the mechanical control models is

controlled using two main control levers.
There are three configuration types for 2-lever con-
trol systems (7) and (8), as described in the follow-
ing pages.
A 4-lever system installed by the Dealer is also
available as optional accessory.
The backhoe attachment on the hydraulic control

models is controlled using two rear hydraulic control
levers (9) and (10).
Machines may be fitted with an optional telescopic

dipper which can be operated simultaneously with
other boom, dipper and bucket movements.
The telescopic dipper on the manually controlled

models is controlled by a pedal (11) located in the
rear part of the cab.
The telescopic dipper on pilot control modes is con-

trolled using the two buttons (12) and (13) on the left
hydraulic control lever.
BACKHOE ATTACHMENT CONTROLS

NOTE: the instruments represented may not exactly
correspond to the instruments on your machine.
IMPORTANT: before using the backhoe attachment,
make sure that the sideshift carriage locking switch
(1) is in the OFF position and that the lock hook has
been disengaged, either by means of the lever (3) or
the switch (2).
IMPORTANT: whenever the backhoe attachment is
used, the machine must be resting on the stabiliz-
ers.
S WARNING S
Check control functions before operating the
machine. Failure to check control pattern before
operating can cause unexpected machine move-
ment, death or serious injury.
S WARNING S
Any uncontrolled movement of the machine can
cause an accident. Before turning the operator’s
seat to the backhoe attachment working position, it
is essential to place the direction-of-travel control
lever and the powershuttle gearshift lever in the
neutral position and immobilize the machine by
means of the parking brake lever.
S WARNING S
Before using the backhoe controls, make sure that
the operator’s seat is correctly adjusted in the back-
hoe attachment position.
BACKHOE ATTACHMENT MECHANICAL

CONTROLS
STABILIZER MECHANICAL CONTROLS
ers.
Left-hand stabilizer left-hand control lever
This lever has three positions:
Position (0): neutral. This position stops the move-
ment of the left-hand stabilizer. As soon as the lever
is released, it automatically returns to the neutral
position (0) and the left-hand stabilizer stops raising
or lowering.
Position (1): the left-hand stabilizer lowers.
Position (2): the left-hand stabilizer rises.
Right-hand stabilizer right-hand control lever
ment of the right-hand stabilizer. As soon as the
lever is released, it automatically returns to the neu-
tral position (0) and the right-hand stabilizer stops
raising or lowering.
Position (1): the right-hand stabilizer lowers.
Position (2): the right-hand stabilizer rises.
NOTE: to raise or lower the two stabilizers at the
same time, operate the two levers simultaneously.
IMPORTANT: before machine travel or before using
the loader attachment, make sure the stabilizers are
completely raised.
During road travel, the stabilizers must be com-
pletely raised and immobilized by means of the pins
provided for that purpose.
Locking the stabilizer mechanical controls (spe-
cific to certain countries)
This pin (1), located in front of the stabilizer control
levers, is used to lock the stabilizer controls.
lever support.
S WARNING S
ATTACHMENT MECHANICAL CONTROLS

These control levers are used to operate the back-
hoe attachment. The speed of movement of each
control depends on the angle to which the lever is
tilted. In the intermediate position, two movements
can be obtained simultaneously.
Four backhoe attachment control configurations
exist, depending on the country concerned:
- standard configuration;
- ISO configuration;
- four lever pattern configuration;
- cross-pattern configuration.
The operating pattern of the control levers is differ-
ent. Check which configuration you have on your
machine.
Standard configuration
Backhoe boom and backhoe attachment swing left-
hand control lever
This lever has five positions:
Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as
the lever is released, it automatically returns to the
neutral position (0) and the attachment remains in
the position where it was when movement stopped.
Position (A): the boom lowers.
Position (B): the boom rises.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.
Backhoe dipper and backhoe bucket right-hand
control lever
Position (E): the backhoe dipper extends.
Position (F): the backhoe dipper retracts.
Position (G): the backhoe bucket closes.
Position (H): the backhoe bucket opens.
ISO configuration
Backhoe dipper and backhoe attachment swing left-
hand control lever
Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
left.
right.
Backhoe boom and backhoe bucket right-hand con-
trol lever
Position (E): the boom lowers.
Position (F): the boom rises.
Four-lever pattern configuration

Lever (1) for dipper
Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
Lever (2) for boom
Position (C): the boom rises.
Position (D): the boom lowers.
Lever (3) for backhoe bucket
Position (E): the backhoe bucket closes.
Position (F): the backhoe bucket opens.
Lever (4) for backhoe attachment swing
Position (G): the backhoe attachment swings to the
right.
Position (H): the backhoe attachment swings to the
left.
Cross-pattern configuration
hand control lever
left.
right.
control lever
TELESCOPIC DIPPER MECHANICAL CONTROL

PEDAL (If fitted)
This pedal (A) has three positions:
Position (0): neutral. This position enables the
movement of the telescopic dipper to be stopped.
This position is selected automatically, as soon as
the pedal is released.
Position (1): the telescopic dipper extends.
Position (2): the telescopic dipper retracts.
Before using this pedal make sure that the tele-
scopic dipper is mechanically unlocked.
NOTE: operating the backhoe attachment control
levers and this pedal simultaneously will enable
numerous possibilities of progressive functioning.
AUXILIARY ATTACHMENT CONTROL PEDAL

(Optional)
This pedal (1) is located to the right of the backhoe
attachment controls and is used for operating the
auxiliary attachment, such as a hydraulic hammer.
BACKHOE ATTACHMENT MECHANICAL

CONTROL LOCK
(Specific to certain countries)
This pin (1), located in front of the stabilizer control
levers, is used to lock the backhoe attachment con-
trols.

lever support.
S WARNING S
BACKHOE ATTACHMENT HYDRAULIC CONTROLS
1. CONTROL ENABLE SWITCH: when set to ON 6. TELESCOPIC DIPPER CONTROLS: (propor-

(control lamp on), this switch allows enabling all tional controls): press the right-hand button to
hydraulic controls of the backhoe attachment. extend the telescopic dipper.
2. LEFT-HAND HYDRAULIC CONTROL LEVER: Press the left-hand button to retract the tele-
the left-hand hydraulic control lever controls scopic dipper.
attachment swing and the boom or the dipper 7. WRIST RESTS: the wrist rests may be adjusted
(depending on the control pattern adopted). to the required height.
3. RIGHT-HAND HYDRAULIC CONTROL 8. HYDRAULIC CONTROL LEVER SUPPORT
LEVER: the right-hand hydraulic control lever ANGLE ADJUSTMENT: these controls are
controls the bucket and the boom or the dipper used for the fore/aft and left/right adjustment of
(depending on the control pattern adopted). the arm.
NOTE: the operating speed depends on the angle 9. HORN BUTTON (momentary action control).
of movement of the control levers. In intermediate 10. CONTROLS OF AUXILIARY BIDIRECTIONAL
position, two movements may be obtained simulta- ATTACHMENT (If fitted): proportional buttons
neously. for the activation of the additional attachment.
4. STABILIZER CONTROLS: the right-hand con- 11. DECELERATOR BUTTON: by pressing this
trol is for the right-hand stabilizer and the left- button, the engine rpm sets to low idle. During
hand control is for the left-hand stabilizer. this phase, the accelerator knob and pedal are
5. CONTROL PATTERN CHANGE SWITCH: this disabled.
switch is used for changing the standard control By pressing the button again, the engine rpm is
pattern to the ISO pattern. restored and the accelerator knob and pedal
are functional again.
CONTROL ENABLE SWITCH

This control is located on the right-hand control
lever.
This switch has three positions:
- position OFF: (lamp off) all controls will deactivate;
- position (1): by pressing the upper side (lamp off),
the stabilizers will activate;
- position (2): by pressing the upper side (lamp on)
again, all controls will activate.
S WARNING S
After using the attachment or before leaving the
machine, always tilt the switch to OFF by pressing
the lower side of the switch (lamp off). Never forget
this basic safety requirement.
NOTE: when starting the engine, the position OFF

for disabled controls is automatically selected.
CONTROL PATTERN CHANGE SWITCH (BOOM

OR DIPPER)
Located on the right-hand hydraulic control lever,
this switch is fitted with a locking device.
The switch is used to change from standard pattern
to ISO version, or vice versa.
To unlock the switch, push the locking device
upwards and at the same time press the top of the
switch (1). In this position, the switch turns on and
the controls are in ISO pattern.
The boom and dipper controls on the hydraulic con-
trol levers are now inverted.
Press the bottom of the switch (1) to lock and return
to standard pattern operation.
BACKHOE ATTACHMENT HYDRAULIC

CONTROLS
Standard configuration
hand hydraulic control lever
This hydraulic control lever has five positions:
the hydraulic control lever is released, it automati-
cally returns to the neutral position (0) and the
attachment remains in the position where it was
when movement stopped.
left.
right.

control lever
This hydraulic control lever has five positions:
the hydraulic control lever is released, it automati-
cally returns to the neutral position (0) and the
attachment remains in the position where it was
when movement stopped.
STABILIZER HYDRAULIC CONTROLS

These controls are located on the left-hand hydrau-
lic control lever and may be operated independently
or simultaneously. These controls are proportional,
and therefore, the stabilizer speed may vary.
ers.
Left-hand stabilizer left-hand control lever

This lever has four positions:
ment of the left-hand stabilizer. As soon as the lever
is released from positions (1) or (2), it automatically
returns to the neutral position (0) and the left-hand
stabilizer stops raising or lowering.
When held in position (1): the left-hand stabilizer
lowers.
When held in position (2): the left-hand stabilizer
rises.
Position (3): stabilizer auto-up feature.
Right-hand stabilizer right-hand control lever

This lever has four positions:
ment of the right-hand stabilizer. As soon as the
lever is released from positions (1) or (2), it automat-
ically returns to the neutral position (0) and the right-
hand stabilizer stops raising or lowering.
When held in position (1): the right-hand stabilizer
lowers.
When held in position (2): the right-hand stabilizer
rises.
Position (3): stabilizer auto-up feature.
Auto-up feature (Center pivot version) (Optional)

Position (3): when the levers are momentarily pulled
back to this position and then released, they return
to the neutral position and the stabilizers automati-
cally rise to road travel position, thereby leaving
your hand free for other duties. To stop the auto-
matic rise at any time, push or pull the levers; the
rise of the stabilizers stops.
NOTE: the machines not provided with the optional
auto-up feature still have the relevant detent posi-
tion, but this does not affect the stabilizer operation
in any way.
IMPORTANT: before machine travel or before using
the loader attachment, make sure the stabilizers are
completely raised.
IMPORTANT: during road travel, the stabilizers
must be completely raised and immobilized by
means of the pins provided for that purpose.
TELESCOPIC DIPPER CONTROLS (Optional)

Press and hold down the right-hand button (1) to
extend the telescopic dipper. As soon as the button
is released the dipper stops and remains in the posi-
tion it occupied when the button was released.
Press and hold down the left-hand button (2) to
retract the telescopic dipper. As soon as the button
is released the dipper stops and remains in the posi-
tion it occupied when the button was released.
By pressing button (3), it is possible to set the
engine rpm to idle run disabling accelerator handle
and accelerator pedal. By pressing again button (3)
the engine rpm are restored and the accelerator
handle and accelerator pedal as well.
Before using these controls, make sure the tele-
scopic dipper is mechanically unlocked.
NOTE: operating the backhoe attachment control
levers and these controls simultaneously will enable
numerous possibilities of progressive functioning.
AUXILIARY BI-DIRECTIONAL CONTROLS (Optional)

Press and hold the left-hand button (1) to let the oil
flow out of the left-hand side of the boom.
Press and hold the left-hand button (2) to let the oil
flow out of the right-hand side of the boom.
HYDRAULIC CONTROL LEVER SUPPORT

ADJUSTMENTS
Fore and aft
Press the two levers (1), then tilt the hydraulic con-
trol levers to the desired position.
Once the desired position is reached, release the
two levers (1).
Left and right

Loosen the two knobs (2) located in front of each
hydraulic control lever support, then tilt the supports
to the required position.
Once the adjustment has been carried out, tighten
the two knobs (2).
BACKHOE ATTACHMENT SIDESHIFT

(Sideshift version)
To dig alongside a building or fence, etc., it is possi-
ble to shift the backhoe attachment sideways to the
right or the left.
MECHANICAL HANDLING
Place the backhoe attachment to the left if you want
to shift the attachment to the right, or place it to the
right if you want to shift it to the left, then place the
attachment on the ground.
Press the backhoe attachment sideshift unlocking
switch (1). The switch lamp turns on (ON position).
(A) Version with mechanical engines
(B) Version with electric engines
Operate the backhoe attachment controls alter-

nately so as to slide the sideshift carriage sideways.
Once the attachment is in the side position required,
swing it round into alignment with the machine.
Work on the opposite side of the sideshift carriage
as much as possible. Otherwise, reduce the load in
the bucket for better stability.
Press the backhoe attachment sideshift locking
switch (1). The switch lamp turns off (OFF position).
IMPORTANT: except when the sideshift carriage is
being moved, the switch (1) must always be in the
OFF position. Never use the backhoe attachment
with the sideshift carriage unlocked.
HYDRAULIC HANDLING
For handling, press:

- the button (2) side with the symbol to move the
backhoe attachment to the left side of the track;
- the button (2) side without symbol to move the
backhoe attachment to the right side of the track.
NOTE: track sides are referred to the travel direc-
tion of the machine.
BACKHOE ATTACHMENT DISASSEMBLY

Park the machine on a flat surface and position the
backhoe on the ground.
S WARNING S
Lower stabilizers sufficiently and however ensure

that the rear tyres are in contact with the ground to
remove the weight from the rear wheels.
IMPORTANT: the rear wheels must remain in con-
tact with the ground.
Fully retract dipper cylinder and lower boom until

bucket is firmly resting on the ground.
Support the backhoe using suitable stand and hoist
capable of carrying 1500 Kg (3307 lb).
Turn off engine, then move backhoe control levers
through all operating positions to relieve pressure in
the system.
Re-check that backhoe elements are fully sup-
ported.
Disconnect all hoses that travel through the swing
bracket reach the backhoe.
Disconnect the yoke of the lock cylinder (1) for

transport from the hook (2).
Extract the pin (3).

Remove the hook (2) and the hook (4).
Now remove the pins (5) and (6) by tapping with a
hammer on one side and extracting the pins from
the other.
Thus the boom cylinder rod has been released.
Loosen and remove the screw (7) with the relevant

washer (8).
Remove the retaining plate (9).
Now it is possible to remove the backhoe attach-

ment from the machine.

580ST, 590ST-695ST
1. Remove the dipper extension according to the
instructions in this section.
2. Remove the bolts, the washers, the wear
plates, and the shims.
3. Remove the grease from the sides and the bot-
tom of the dipper and from the inside of the dip-
per extension.
4. Select shims for the side wear plates so that the
total distance from one wear surface to the
other is 146 - 147 mm (5.75 - 5.79 in). The wear
surface of each wear plate must be even with or
up to 0.08 mm (0.003 in) beyond the rails on
the dipper.
5. Install the shim(s), the side wear plates, the
stepped washers, and the bolts.
NOTE: On 695ST machines only, 9.5 mm (0.374
in) flat washers are used in addition to the stepped
washers. Use a 9.5 mm (0.374 in) flat washer only
when there is no more than one shim installed
under that side wear plate.
6. Tighten the bolts to a torque of 70.5 - 77.3 N·m
(52 - 57 lb ft).
7. Select shims for the top and bottom wear plates
so that the total distance from one wear surface
to the other is 234 - 235 mm (9.21 - 9.25 in).The
wear surface of each wear plate must be even
with or up to 0.8 mm (0.031 in) beyond the rails
on the dipper.
8. Install the shim(s), the side wear plates, the
stepped washers, and the bolts.
NOTE: On 695ST machines only, 9.5 mm (0.374
in) flat washers are used in addition to the stepped
washers. Use a 9.5 mm (0.374 in) flat washer only
when there are no more than three shims installed
under that top or bottom wear plate.
9. Tighten the cap screws to a torque of 70.5 -
77.3 N·m (52 - 57 lb ft).
10. Apply molydisulfide grease to the rails on the
dipper.
11. Install the dipper extension according to the
instructions in this section.
DIPPER EXTENSION - EXPLODED VIEW - EXTENDABLE DIPPER

INSTALLATION 580ST
TBR00105
DIPPER EXTENSION - EXPLODED VIEW - EXTENDABLE DIPPER

INSTALLATION 590ST-695ST
TBR00106
BACKHOE BUCKET REPLACEMENT

REMOVAL
Lower the stabilizers until they are resting on the
ground.
Place the bucket on the ground.
Remove the snap ring (1) and the ring (2).
Slide out the pin (3).
S WARNING S
Always wear eye protection when using a tool
which might project metal particles.
Restart the engine.

Operate the backhoe attachment controls so that
the hook (4) releases from the pin (5).
INSTALLATION
Start the engine.
Slowly approach the arm to the backhoe bucket
paying attention that hook (4) engages in the bucket
pin (5).
Move the arm so that the pin hole (3) aligns with the
holes of the bucket lugs.
Insert pin (3) and install the stop ring (1) and the ring
(2).
BACKHOE BUCKET
Position the backhoe bucket so that the bucket teeth
can be replaced.
brake.
S WARNING S
Nobody must be in the trajectory of the tooth holder
and of the tooth to be removed.
During tooth removal, both the tooth holder and the
tooth could be unexpectedly projected, thus hitting
persons standing in their trajectory or nearby.
Projected metal chips could hit persons and cause
injury.
Remove the tooth holder (2) using a hammer and a

chisel.
Remove the tooth (1) from the tooth holder (3).
Clean the inside of the tooth holder, removing any
dirt or rust.
Insert a new tooth (1) into the tooth holder (3).
Lock the new tooth by installing the tooth holder (2).
BACKHOE ATTACHMENT HYDRAULIC HANDLING

A unit enabling the hydraulic handling of the side-
shift carriage which supports the backhoe attach-
ment may be installed on the machine.
CONTROLS
For handling, press:

- the button (2) side with the symbol to move the
backhoe attachment to the left side of the track;
- the button (2) side without symbol to move the
backhoe attachment to the right side of the track.
NOTE: track sides are referred to the travel direc-
tion of the machine.
HYDRAULIC DIAGRAM
A. Backhoe attachment control valve

B. Union tee of main load-sensing line from back-
hoe attachment control valve
1. M14 x 210 hex screw 12. Washer

[Tightening torque = 85 ÷ 115 Nm 13. Spacer
(62.69 ÷ 84.82 lbf·ft)]
14. Spacer
2. Washer
15. Snap ring
3. Plate
16. Pin
4. Pin
17. Cylinder support
5. Snap ring
18. Handling cylinder
6. Nut M14
19. M8 x 14 hex screw
7. Support
20. Shim
8. Shoe
21. Washer
9. Shim
22. Shoe
10. Handling cylinder assy
23. Shim
11. M14 x 50 hex screw
24. Fitting
[Tightening torque = 135 ÷ 183 Nm
(99.57 ÷ 134.97 lbf·ft)] 25. M12 x 20 socket head screw
26. Shoe
HANDLING CYLINDER
1. Stroke

Servis Manual 590ST, 695ST

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Servis Manual 590ST, 695ST

Uploaded by

Copyright:

Available Formats

580ST

Print No. 84568047A

SERVICE MANUAL The Service Manuals for “Backhoe loader” and

VOLUME MACHINE TYPE PRINT NUMBER

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

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

CNH ITALIA S.p.A.

580ST 590ST 695ST

Center pivot stabilizers / / O

Engine Iveco 72 kW - 97 HP model

SECTION 00 - SAFETY RULES

SAFETY INSTRUCTIONS ................................................................................................................................ 6

PREVENTION OF FIRE OR EXPLOSIONS..................................................................................................... 8

PREVENTION OF BURNS ............................................................................................................................... 9

PRECAUTIONS FOR WASTE DISPOSAL..................................................................................................... 10

SECTION 02 - TECHNICAL SPECIFICATIONS

IDENTIFICATION OF MAIN COMPONENTS................................................................................................... 4

DIMENSIONS AND PERFORMANCE............................................................................................................ 18

MAXIMUM LIFTING LOADS........................................................................................................................... 27

SUPPLY SUMMARY TABLE .......................................................................................................................... 29

ENGINE ERROR CODES............................................................................................................................... 46

POWERSHIFT TRANSMISSION.................................................................................................................. 142

SECTION 25 - FRONT AXLE

4WD - 2WS FRONT AXLE ............................................................................................................................. 10

4WS FRONT AXLE......................................................................................................................................... 62

SECTION 27 - REAR AXLE

2WS REAR AXLE (590ST) ............................................................................................................................. 69

4WS REAR AXLE (695ST) ........................................................................................................................... 135

SECTION 33 - BRAKE SYSTEM

SERVICE BRAKE ........................................................................................................................................... 15

SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC PUMP ........................................................................................................................................ 19

BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE .................................................. 78

ACCUMULATOR “AUTO GLIDE RIDE” PARKER .......................................................................................... 81

HYDRAULIC SWING SYSTEM ...................................................................................................................... 84

BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT.................................................................. 127

HYDRAULIC CONTROL LEVERS ............................................................................................................... 129

REMOVAL AND INSTALLATION OF COMPONENTS .................................................................................... 5

SECTION 41 - STEERING SYSTEM

2WS STEERING SYSTEM ............................................................................................................................... 4

4WS STEERING SYSTEM ............................................................................................................................... 7

POWER STEERING ....................................................................................................................................... 11

SECTION 50 - CAB HEATING AND AIR CONDITIONING

SECTION 55 - ELECTRIC SYSTEM

CONTROLS AND INSTRUMENTS ................................................................................................................ 59

DIAGNOSTIC DISPLAY (580ST - 590ST - 695ST)........................................................................................ 68

STARTING SYSTEM ...................................................................................................................................... 88

BATTERY ..................................................................................................................................................... 101

SECTION 82 - LOADER ATTACHMENT

LOADER ATTACHMENT SAFETY STRUT...................................................................................................... 9

REMOVAL AND INSTALLATION OF LOADER BUCKET .............................................................................. 11

SECTION 84 - BACKHOE ATTACHMENT

BACKHOE ATTACHMENT CONTROLS .......................................................................................................... 6

BACKHOE ATTACHMENT DISASSEMBLY................................................................................................... 26

BACKHOE ATTACHMENT HYDRAULIC HANDLING.................................................................................... 33

SECTION 00 - SAFETY RULES

The non-compliance with the warnings preceded by

The manufacturer/supplier cannot be held responsi-

The current Operator’s Manual is the user’s guide

Carefully read this Operator’s Manual and store it in SPARE PARTS

Wear close fitting clothing and safety equipment

PREVENTION OF FIRE OR EXPLOSIONS