MF 580SM GB

LOADER BACKHOE
580 SM
English version
Aprill 2002 Training Center
580SM Training manual 1.1
CONTENTS ......................................................................................................................... Page
580 SM INTRODUCTION.......................................................................................................................................1.2
580 SM CHASSIS DESIGN....................................................................................................................................1.3
STALL TESTS ........................................................................................................................................................1.4
MAINTENANCE TABLE .........................................................................................................................................1.5
RECOMMANDED SERVICING PRODUCTS.........................................................................................................1.6
Issued 04 - 2002Printed in France

1.2 580SM Training manual
580 SM INTRODUCTION
The "580 SM" is a CASE Backhoe-Loader. The main com-

ponents of the 580 SM are as follows :
- CHASSIS
This is the main structure. It is a welded, independent
chassis, specially designed for this use, with an integrated
mounting for the backhoe.
This gives the machine very high rigidity and maintains all
components in perfect alignment.
- ENGINE
It is a "CASE FAMILY" engine, type 4-T390 / 67-1.
This engine is the result of new technological develop-
ment.
It has a new cooling system with the fan mounted on a
viscous coupling to save engine power.
- TRANSMISSION
The four speed synchronised transmission is a new
design. It includes an electro-hydraulic forward and
reverse shuttle with modulation.
The reverse speeds are 20% higher than the forward
speeds.
The braking system is the multidisc oil-bath type plus a
parking brake operating on the same brake discs.
The rear axle has a mechanical locking differential and a
planetary reduction gears.
The front axle is mounted on a centre pivot.
- HYDRAULIC CIRCUIT
A tandem gear pump supplies a Q1 flow of 104 l/min
(large body end) to the steering, loader and rear backhoe
hydraulic circuits.
The steering is supplied from a priority valve. The rear
backhoe is supplied by the Q1 flow plus the extra Q2 flow
of 36 l/min (small body end).
An anti-rebond swing valve is used to absorb shocks at
the RH and LH backhoe swing stops.
- CAB
The cab has curved rear corner windows and an opening
rear window with a slide adjustable system, giving very
good visibility over the working area.
All controls and safety devices are located on the electro-
nic instrument panel.
Issued 04 - 2002 Printed in France

580 SM CHASSIS DESIGN
The chassis frame is a welded structure.

- The hydraulic tank is attached to the
right-hand side-member.
- The fuel tank is attached to the left-
hand side-member.
TWO TYPES ARE AVAILABLE :
- Chassis for axial backhoe version

This chassis is specially designed for this
version and cannot be modified.
At the front it carries the front loader atta-
chment and at the rear the swing base
assembly and the rear backhoe attach-
ment.
- Chassis for side shift backhoe ver-
sion Chssis pour version axiale
This chassis is specially designed for this
version and cannot be modified.
At the front it carries the front loader atta-
chment and at the rear the sliding
sideshift frame on which the swing base
assembly and rear backhoe attachment
is installed.
NOTE : A chassis for front loader only,
will be available on the 580 MXT version.
In its basic form, this chassis is designed
to carry only the front loader attachment.
With this specification there is only a
counterweight at the rear to balance the
machine.
A "3-point hitch" can be installed at the
rear as an option Side shift chassis

MACHINE CONDITION - STALL TESTS

The machine's condition can be quickly verified.
Before carrying out tests, check the following points :
- Engine temperature normal
- Hydraulic system oil temperature 50 C
- Transmission oil temperature Temperature warning lamp in middle of green area
- Engine speed :
- At idle (without load) 1000 1100 trpm
- At full speed (without load) 2285 2410 rpm
1. COMBINED STALL TEST
- Hydraulic and transmission system (combined)
a) Close the front bucket against the stop.
b) Immobilise the machine against a loading ramp and apply the parking brake.
c) Engage 4th speed forwards.
d) Operate the loader control lever to close the bucket and hold it in that position to force the main
hydraulic relief valve to open.
e) Check the engine speed :
- If engine speed is correct to the table below, the engine speed is correct and the torque converter
is operating correctly.
- If the result obtained is too high or too low, the transmission and the hydraulic stall tests must be
checked separately to find the problem.
2. TRANSMISSION STALL TEST

- Transmission only
Follow the procedure shown in (1a - 1b - 1c - 1e)
- If the engine speed is not correct, there is a fault in the torque converter or the forward and
reverse shuttle.
3. HYDRAULIC SYSTEM STALL TEST

- Hydraulic system only
Follow the procedure shown in (1a - 1d - 1e)
- If the result is not correct, there is a problem in the hydraulic system (pressure or flow).
4. STALL TEST SPEEDS (rpm)

Stall test MINI (SM) MAXI (SM) MINI (M) MAXI (M)
COMBINED 1410 1790 1040 1500

TRANSMISSION 2150 2280 2140 2300
HYDRAULICS 2225 2320 2235 2305
NOTE : - If the results of the transmission and hydraulic system stall tests are correct but the combined result
is incorrect, the engine lacks power.

MAINTENANCE TABLE
MAINTENANCE OPERATIONS MAINTENANCE INTERVALS IN WORKING HOURS

10 50 100 250 500 1000 2000 as req.
Grease the steering linkage points .............................. X
Check engine oil level.................................................. X
Check the expansion bowl level ................................. X
Check fan-belt condition .............................................. X
Check for leaks............................................................ X
Grease the rear backhoe linkage points ...................... X
Grease the loader linkage points ................................. X
Check the hydraulic oil level ........................................ X

Check the coolant solution level .................................. X
Check the engine air filter bowl ................................... X
Drain water from fuel filter ........................................... X
Grease the front axle linkage points ............................ X
Grease the 4-in-1 bucket linkage points ...................... X
Grease the Extendahoe pedal linkages....................... X

Check the tyres (pressure-cuts-stones)....................... X
Change the engine oil.................................................. X
Change the engine oil filter.......................................... X
Check the axle oil levels .............................................. X
Check the transmission oil level .................................. X
Check the A.C. drive belt tension ................................ X
Check the A.C. system ................................................ X
Clean the front (4WD) and rear axle breathers ........... X
Drain water from fuel tank ........................................... X
Check the tighteners and hoses of the cooling system X
Change the fuel filter ................................................... X

Grease the differential pedal bearing .......................... X
Check the cab mountings and cab condition............... X
Check the starter and generator .................................. X
Clean and check the backhoe ..................................... X
Adjust the valve rockers .............................................. X
Change the hydraulic oil .............................................. X
Clean the battery and check the levels ....................... X
Clean the cab air filters................................................ X
Clean the transmission inlet gauze filter ...................... X
Clean the transmission breather.................................. X
Change the transmission oil ........................................ X
Change the front (4WD) and rear axle oil .................... X
Change the transmission oil filter ................................ X
Change the hydraulic filter ........................................... X
Clean the cooling system and change the coolant ...... X
Change both engine air filters...................................... X
Clean the engine air filter............................................. X
Replace the hydraulic filter (warning light on).............. X
Retorque the wheels (nuts : 27 and 36) ...................... X
Check the stabilizers clearance .................................. X
RECOMMENDED SERVICING PRODCTS
SERVICING PRODCT CAPACITY

ENGINE 15W40 or CASE N1 11 litres
HYDRAULIC and BRAKE ISO VG 46 or MS 1210 125 litres (Tank = 54l)
TRANSMISSION HYTRAN ULTRA or MS 1209 2 R.M. 18,5 litres
(Power Shuttle) 4 R.M. 21 litres
TRANSMISSION ATF or DEXRON 3 Total 21 l
(Power Shift) Refill 14 l
AXLES and REDUCTION HYTRAN ULTRA or MS 1209 Rear Differential 14,2 litres
GEARS Final drive (x2) 2 x 2 litres
Front Differential 6,5 litres
Final drive (x2) 2 x 1 litre
ENGINE COOLANT
50% water and 50% glycol 15,8 to 16,5 l
AIR CONDITIONING FLUID R134a 1,82 Kg
PINS and BUSHES GREASE with MoS2

CONTENTS........................................................................................................................................................ Page
PRESENTATION OF CASE 4T-390 ENGINE ........................................................................................................2.2
GENERAL SPECIFICATIONS OF CASE 4T-390 ENGINE ....................................................................................2.5
AIR FILTER ............................................................................................................................................................2.6
FAN WITH VISCOUS COUPLING .........................................................................................................................2.7

PRSENTATION DU MOTEUR TURBO "CASE 4T-390"
4 Description :
14 4
EQUIPMENT
10 20 1. Engine identification plate
2. Fan belt
4. Turbocharger
G2. Alternator
M1. Starter motor
FUEL SYSTEM
5. Pre-filter
6. Fuel lift pump
7. Fuel filter
18 8. Injection pump
10. Injectors
R1. Pre-heater element
Y1. Engine stop solenoid
LUBRICATION SYSTEM
G2 2 12. Engine oil filler cap
M1 14 15 G2 2 18 13. Engine oil level dipstick
14 15 14. Oil filter
M1 15. Oil cooler
B2. Oil pressure switch
17
COOLING SYSTEM
17. Radiator
18. Fan
19. Coolant solution reservoir
20. Radiator plug
22. Thermostat
1 Y1
1 23 Water pump
B6. Water temperature sender
B7. Water temperature switch
6
19 8 7 5
8 B2 R1 12 Y1 13

CASE 4T-390 TURBO ENGINE PRESENTATION

The 580 SM is fitted with a CASE FAMILY 1 turbo-
charged engine, Type 4T-390 / 67-1 or 4T390 / 66-2.
For more information, refer to : G2

TRAINING MANUAL
"NEW CASE FAMILY 1 - ENGINE"
The main specifications :

- 4 cylinders in line
- Direct injection system
- Water + anti-freeze cooling system
Cooling system :
The fan (18), the alternator (G2) and the water pump
(23) are driven by a single "Poly-V" type drive belt.
The belt is tensioned by an automatic tensioner .
The water pump (23) is incorporated in the cylinder
block. It is independent of the cooling fan.
An O-ring provides sealing between the pump and
the block.
The engine coolant solution which passes through 23
the cylinder block also cools the engine oil cooler.
The engine temperature is controlled by a two stage
thermostat (22) which enables working temperature
to be attained quickly.
- Temperature under 83C : the thermostat allows
22
coolant to circulate around the engine but pre-
vents the coolant passing through the radiator.
- From 83C to 95C ; the thermostat allows the
coolant to pass through the radiator.
A temperature sender (B6) continuously transmits
temperature variations in the cooling system to the
temperature gauge on the instrument panel.
A switch (B7) for maximum water temperature activa-
tes the audible warning alarm if the engine overheats.
B6 B7

CASE 4T-390 TURBO ENGINE PRESENTATION

Fuel system :
The fuel is supplied by the fuel lift pump (6) which

is operateted by the camshaft. The fuel lift pump
has a manual priming lever.
Filtration is provided by a pre-filter (5) located
before the fuel lift pump and a filter (7) located after
the fuel lift pump. The filter is the screw-on type.
8
The injection pump (8) (Bosch) has an engine stop
solenoid (Y1), an adjustable idle stop and a shaft
locking screw (to enable the pump to be reinstalled
correctly after being removed). 8 B2 6 5 7
The 4 injectors (10) spray the fuel into the cylin- 5
ders.
A pre-heater element (R1) (optional) is an engine
starting aid for cold weather.
Lubricating system :
The engine oil sump design allows the engine to R1

operate safely at an angle of 44.
Provision is made in the sump for installing a sump
oil heater.
Use CASE N1 oil or an equivalent 15W-40 multi-
grade oil.
A gerotor type oil pump draws oil via the gauze fil-
ter and directs it via an oil cooler (14) and a filter
(15) to the main oil gallery. R1
The flow of oil lubricates the turbocharger, the
crankshaft bearings, connecting rod bearings,
camshaft and the rocker arm assembly.
An oil pressure switch (B2) senses low lubrication
system pressure and illuminates the warning lamp 14
on the instrument panel.
15

GENERAL SPECIFICATIONS OF THE "CASE 4T-390 / 67-1" ENGINE
Make of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CASE 4T-390 / 67-1

Order of injectors (Cylinder No. 1 at valve gear end) . . . . . . . . . . . . . . . . . . - 1-3-4-2
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm (4,02 inches)
Piston stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4,72 inches)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3922 cc (239 Cu In)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 : 1
Engine horsepower at 2200 rpm - SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 kW - 92 hp
Engine horsepower at 2200 rpm - DIN (ECER 24). . . . . . . . . . . . . . . . . . . . 67 kW - 91hp
Max DIN torque at 1500 rpm (ECER 24) . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Nm
Engine speeds in rpm

- Full speed without load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2325 to 2425
- Full speed with load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200
- Idle speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 to 975
Stall test speeds in rpm

- Combined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 to 1800
- Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 to 2300
- Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2220 to 2350
Engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 to 3.7 bar

........................................................... (42 to 52 psi)
Thermostat opening
- Starts to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83C
- Fully open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95C
Valve clearance cold

- Inlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 mm (0.010 inches)
- Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.508 mm (0.020 inches)
Engine oil capacity

- With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 litres
- Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 litres
Coolant solution capacity (without heater). . . . . . . . . . 15.8 litres

(with heater) . . . . . . . . . . . . 16.5 litres
NOTE : Use a mixture of 50% ethylene glycol and 50% water
for ambient temperatures below -37C.
Fuel tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 litres

NOTE : Use fuel DIESEL No. 2
Alternator at 6000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Amps
Starter motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 kW

GENERAL SPECIFICATIONS OF THE "CASE 4T-390 / 66-2" ENGINE
Make of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CASE 4T-390 / 66-2

Order of injectors (Cylinder No. 1 at valve gear end) . . . . . . . . . . . . . . . . . - 1-3-4-2
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm (4,02 inches)
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm (4,72 inches)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3922 cc (239 Cu In)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 : 1
Engine horsepower at 2200 rpm - SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 kW - 92 hp
Engine horsepower at 2200 rpm - DIN (ECER 24) . . . . . . . . . . . . . . . . . . . 66 kW - 91hp
Max DIN torque at 1500 rpm (ECER 24) . . . . . . . . . . . . . . . . . . . . . . . . . . . 360Nm
Engine speeds in rpm

- Full speed without load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2285 to 2410
- Full speed with load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200
- Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 to 1100
Stall test speeds in rpm

- Combined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1410 to 17900
- Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2150 to 2280
- Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2225 to 2320
Engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 to 3.7 bar

........................................................... (42 to 52 psi)
Thermostat opening
- Starts to open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83C
- Fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95C
Valve clearance cold

- Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 mm (0.010 inches)
- Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.508 mm (0.020 inches)
Engine oil capacity

- With filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 litres
- Without filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 litres
Coolant solution capacity (without heater) . . . . . . . . . 15.8 litres

(with heater). . . . . . . . . . . . 16.5 litres
NOTE : Use a mixture of 50% ethylene glycol and 50% water
for ambient temperatures below -37C.
Fuel tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 litres

NOTE : Use fuel DIESEL No. 2
Alternator at 6000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Amps
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 kW

FILTRE AIR
Description :
24e
24a. Filter body
24b. Secondary element
24c. Primary element
24d. Retaining clamp 24f
24e. Covers
24f. Dust bowl 24g
24g. Screw
24d
24h. Bowl support
24h
MAINTENANCE : 24c
Change the primary element (24c) after the third
cleaning or after one years use.
Use CASE No. A40910 cleaner to clean the ele-
ment.
24b
Do not clean the secondary element (24b). It must
be changed :
- After the third cleaning of the primary element
- If a visual inspection shows damage to the
secondary element 24a
- If the air filter warning lamp illuminates after
cleaning or replacing the primary element.
24f
24e
24c 24b

FAN WITH VISCOUS COUPLING

Description :
18a. Fan
18b. Viscous fluid
18c. Transfer orifice
18d. Driving disc
18e. Pulley
18f. Drive shaft
18g. Driven hub
18h. Coupling chamber
18i. Supply chamber
18j. Control valve
18k. Bi-metal strip
Operation :
In order to reduce the amount of energy absorbed in
driving the cooling fan, some engines are fitted with
fans with a clutch system, such as the viscous cou-
pler. It is located between the drive pulley and the 18j 18i
fan itself.
It includes a driving disc (18d) that can rotate inside 18k 18h
a coupling chamber (18h) which is inside the driven
walls of the fan hub (18g) plus a thermostatic valve. 18g
The viscous coupling contains a very viscous sili-
cone-based liquid which acts as the coupling agent
between the disc (18d) and the hub (18g).
When the engine is running at full power, the very
hot air flow coming from the radiator causes a bi-
metal strip (18k) to bend, which in turn opens a
valve (18j). The viscous liquid contained in the sup-
ply chamber (18i) can then move into the coupling
chamber (18h) and flow between the walls of the
disc and those of the hub, causing them to rotate,
with a very slight slippage.
18f
As the engine cools down, the air flow coming from
the radiator is cooler and the bi-metal strip slowly
closes the valve. The liquid thus leaves the coupling
chamber and moves into the supply chamber under 18e
the effect of centrifugal force, moving via the transfer
orifices (18c) located on the circumference of the
coupling chamber.
18d
This increase the slippage of the viscous coupling
18c
which now drives the fan only at reduced speed, to
prevent waste of energy. 18b
Control procedure :
Once the engine is hot, the fan is driven and it 18a
should rotate 1.3 times higher than the engine rpm.

4001
Section
4001
ELECTRICAL SCHEMATIC
Copyright 2002 Case France

Imprim en France
Cre 9-43270FR Mars 2002
4-2 580SM training manual
ELECTRICAL CIRCUIT
TABLE OF CONTENTS
SPECIAL TOOLS ..................................................................................................................................................... 3
SCHEMATIC LEGENDS .......................................................................................................................................... 3
FUSE AND RELAY BOX .......................................................................................................................................... 4
INSTRUMENT PANEL ............................................................................................................................................. 5
INSTRUMENT PANEL CLUSTER PRINTED CIRCUIT WIRING............................................................................. 6
580M-SUPER M OPERATORS COMPARTMENT ................................................................................................. 7
580SUPER M - 590SUPER M OPERATORS COMPARTMENT ............................................................................ 7
ELECTRICAL SCHEMATIC (PLATE 1) ................................................................................................................... 8
ELECTRICAL SCHEMATIC (PLATE 2) ................................................................................................................. 10
POWERSHIFT ELECTRICAL SCHEMATIC (PLATE 8) ........................................................................................ 22
POWERSHIFT ELECTRICAL HARNESS WIRING................................................................................................ 25
CHASSIS WIRING ................................................................................................................................................. 27
SIDE CONSOLE AND FRONT CONSOLE WIRING.............................................................................................. 29
CAB WIRING.......................................................................................................................................................... 33
REAR AND FRONT LIGHTING CABLE................................................................................................................. 35
RIDE CONTROL WIRING ...................................................................................................................................... 36
AUXILIARY HYDRAULIC WIRING......................................................................................................................... 37
BACKHOE QUICK COUPLER WIRING................................................................................................................. 38
LOADER ARM SAFETY VALVES WIRING ........................................................................................................... 39
OVERLOAD INDICATOR WIRING ........................................................................................................................ 40
REVERSING AUDIBLE WARNING DEVICE CUT-OUT WIRING (GERMANY) .................................................... 41
Edition 03-02
580SM training manual 4-3
SPECIAL TOOLS
SCHEMATIC LEGENDS
A (n) Radio/C.B.
B (n) Indicator/pressure contact switches/loud-speakers/pressure switches/detector/thermal sender/gauge
E (n) Lighting components
F (n) Fuses
G (n) Electrical supply generators
H (n) Warning devices (lighted)
K (n) Relays
M (n) Motor
P (n) Instruments
R (n) Elements/heater plugs
S (n) Switches/rotating switches/main circuit breaker
CS969K066 CS96K068 V (n) Diodes
Electrical system diagnostic box CAS-2110A Digital multimeter CAS-1559 X (n) Supply line connections
Y (n) Solenoid valves, solenoid shut-off valves, solenoids
Used with multi-meter CAS-1559 Used with electrical system diagnostic box CAS-2110A
NOTA: The (n) shows the number of components.
Earth connection terminal
Undercarriage earth
N Cable number
Intersection of two cables with connecting point
Intersection of two cables without connecting point
A Transfer to another plate with the same letter
Bulbs
Bulb test
Diodes
Harness connectors
X Shows a connection to another schematic
X Shows the location where the connection should take place (the circuit is in fact completed)
Cre 9-43270FR Edition 03-02

FUSE AND RELAY BOX Relay

K1 Power relay N1 K15 Direction of travel reverser locking time-delay
K18 K16 K2 Power relay N2 relay
K3 Power relay N3 K16 Transmission neutral point relay (by the stabi-
K4 Starting safety relay lizer function)
K5 Transmission cut-out relay K18 Stabilizer safety audible warning device relay
K7 Starter relay K19 Differential locking relay
K15 K14 K9 K19 K7 K9 Transmission forward travel relay K20 Horn relay
K10 Air conditioning relay (option) K21 Fuel solenoid valve relay
K12 Relay for neutralising 4th gear reverse (specific K22 Flasher unit
K13 K12 K20 K5 K4 to certain countries)
H1 Audible warning device
K13 Direction of travel reverser locking relay
K14 Transmission reverse travel relay
K21 K10 K3 K2 K1
K22
Fuses
H1 F1 10A Rotary light (optional)
F22 F23 F24 F25 F26 F27 F28 F2 10A Cab interior light
F15 F16 F17 F18 F19 F20 F21 F3 20A Horn and hazard warning lights
F8 F9 F10 F11 F12 F13 F14 F4 - Not used
F1 F2 F3 F4 F5 F6 F7 F5 15A Side lights
F6 - Not used
F7 30A Power socket
F8 20A Preheater
F9 10A Optional (+ battery)
F10 - Not used
CS02B586
F11 25A Heating, air conditioning and ventilation
F12 10A Front working, lights
F13 10A Radio and C.B. (option)
F14 30A Power socket
F15 10A Relay for forward travel, reverse travel 4-
wheel drive device
F16 10A Instrument panel and audible warning
device
F17 - Option (not used)
F18 10A Electronic control box
F19 Front LH side light and rear RH side light
F20 Rear LH side light, front RH side light, reg-
istration plate and fog light
F21 - Not used
F22 20A Rear working lights
F23 20A Front and rear windshield wiper and wind-
shield washer
F24 15A Charge warning lamp for alternator, flash-
ing indicators, brake lights and differential
locking
F25 10A Sideshift and return to dig carriage
F26 15A Auxiliary hydraulics, Radio, C.B., Ride
Control and tool quick coupler
F27 10A Electronic control box
F28 - Not used

INSTRUMENT CLUSTER & CONTROL PANEL 1 Heater control

B12 Air conditioning temperature adjustment control
E2 Air filter restriction indicator lamp
S25 E3 Engine oil pressure warning lamp
S29
E4 Alternator charge warning lamp
E5 Parking brake indicator lamp
E27 E6 Rear axle oil temperature warning lamp
S27 E7 Hydraulic filter restriction warning lamp
E27 Air conditioning warning lamp
S26 E29 Air conditioning pressure warning light
B12 E30 Secondary alarm lamp
E31 Steering pressure warning lamp
1 E32 Loader bucket floating indicator light
CD01NO67
CM00C011
E33 Fuel minimum level warning lamp
E34 Headlight indicator lamp
H6 S13 S19 H10
H5 Road light switch lighting
H6 Fog light switch lighting (optional)
H11 S20 S22 H13
H10 Rotary light switch lighting
H11 Front working light switch lighting
H12 Rear working light switch lighting
S24 H14
H5 S12 H13 Lighting for 4 wheel drive switch
H14 Sideshift carriage locking/unlocking switch lighting
H15 Hand auxiliary switch lighting (not shown)
S3 S21 H12 H20 Ride control switch lighting
H26 Lighting for backhoe quick coupler switch
H27 Lighting for overload indicator switch
S2 H28 Reversing audible warning device switch lighting
S18
H29 Overload indicator warning lamp
H30 Lighting for loader arm safety valve switch
P1 Transmission oil temperature indicator
P2 Battery charge indicator
P3 Engine coolant solution temperature indicator
H20 S51 H28 S58 H30 S61 S56 H26 S57 H27 H29 P4 Fuel level indicator
CD02C146 P5 Engine tachometer and hourmeter
P5A Road speed in 4th with 16.5/85/x28 tyres
E3 E6 E4 E7
E5 E2 S2 Starter key switch
E31 S3 Cold start push button
E30 E32
S12 Road light switch
E29 P2 S13 Fog light switch (optional)
S18 Horn switch
P1 S19 Rotary light switch (optional)
S20 Front working light switch
E34 E33
S21 Rear working light switch
S22 4 wheel drive switch
S24 Sideshift carriage locking/unlocking switch
S25 Front/rear windshield washer switch
S26 Front windshield wiper switch
S27 Rear windshield wiper switch
S29 Heater ventilation control
S34 Hand auxiliary switch (not shown)
S51 Ride Control switch
S56 Backhoe quick coupler switch
S57 Overload indicator switch
S58 Reversing audible warning device switch
S61 Loader arm safety valve switch
P3 P5A P5 P4
CS01N967

INSTRUMENT CLUSTER PRINTED CIRCUIT WIRING

Instrument cluster connector (A
X9 Connector Path Going to
N 1 +12 volt supply to following points:
- Air filter restriction warning lamp (E2)
1 2 3 4 5 6 7 8 9 - Engine oil pressure warning lamp (E3)
10 11 12 13 14 15 16 17 18 - Alternator charge warning lamp (E4)
- Parking brake indicator lamp (E5)
19 20 21 22 23 24 25 26 27 - Rear axle oil temperature warning lamp (E6)
- Hydraulic filter restriction warning lamp (E7)
28 29 30 31 32 33 34 35 36
- Transmission oil temperature indicator (P1)
- Battery charge indicator (P2)
- Engine coolant solution temperature indicator (P3)
CS02C511
- Fuel level indicator (P4)
N 2 - Engine oil pressure warning lamp (E3)
N 3 Air filter restriction warning lamp (E2)
A-Instrument cluster connector N 4 Hydraulic filter restriction warning lamp (E7)
A N 5 Alternator charge warning lamp (E4)
N 6 Rear axle oil temperature warning lamp (E6)
N 7 Parking brake indicator lamp (E5)
N 8 Audible warning control
N 9 Not used
N 10 Air conditioning warning lamp
N 11 Not used
N 12 Not used
N 13 Not used
N 14 Not used
N 15 Not used
N 16 Not used
N 17 Not used
N 18 Not used
N 19 Engine tachometer and hourmeter (P5)
N 20 Fuel level indicator (P4)
N 21 Transmission oil temperature indicator (P1)
N 22 Engine coolant solution temperature indicator (P3)
N 23 Not used
N 24 Headlight indicator lamp (E9)
N 25 Not used
CI02C505 N 26 Not used
N 27 Not used
Connector (X9) N 28 Not used
N 29 Not used
Path Going to Path Going to N 30 Not used
N 1 Fuse, F16 (4C) - Audible warning N 19 Alternator N 31 Not used
N 32 Not used
N 2 Engine oil pressure switch N 20 Fuel level indicator
N 33 Not used
N 3 Air filter restriction pressure switch N 21 Transmission oil temperature sender N 34 Not used
N 4 Oil filter restriction pressure switch N 22 Coolant solution temperature sender N 35 Audible warning control
N 5 Alternator N 23 Not used N 36 Indicator earth:
N 6 Rear axle oil temperature sensor N 24 Fuse, F19 (10C) - Transmission oil temperature indicator (P1)
N 7 Parking brake switches N 25 Not used - Battery charge indicator (P2)
N 8 Stabilizer raising safety switch N 26 Not used - Engine coolant solution temperature indicator (P3)
N 9 Not used N 27 Not used - Fuel level indicator (P4)
- Headlight indicator lamp (E9)
N 10 Air conditioning pressure switch N 28 Not used
- Air conditioning warning lamp (E27)
N 11 Not used N 29 Not used
N 17 Not used N 35 Audible warning device
N 18 Not used N 36 Earth

580 M - SUPER M OPERATORS COMPARTMENT
S30 S59
S16 H8
S15 S17 S10
S11
S6
H7
CS02B576
H7 Indicator lamp for direction indicator S11 Transmission cut-out switch
H8 Lighting hazard warning light switch S15 Direction indicator switch
S6 Transmission control: forward and reverse S16 Hazard warning light switch
travel S17 Horn switch
S10 Transmission cut-out switch S30 Cab lighting switch
S59 Differential locking switch
580 SUPER M - 590 SUPER M OPERATORS COMPARTMENT
S59
S30
S16 H8
S15 S17 A4
S11
S53
H7
CS02B577
A4 Powershift controller S17 Horn switch
H7 Indicator lamp for direction indicator S30 Cab lighting switch
H8 Lighting hazard warning light switch S53 Gear lever, direction of travel reverser and kick
S11 Transmission cut-out switch down
S15 Direction indicator switch S59 Differential locking switch
S16 Hazard warning light switch
ELECTRICAL SCHEMATIC (PLATE 1)

INSTRUMENT PANEL CHASSIS
F8 Fuse, 20A, preheating G1 Battery
K1 Power relay N1
K2 Power relay N2
K3 Power relay N3
K4 Starter motor relay
K7 Starter relay
R1 Y1 S3 Preheater push button
X1 Chassis harness/side console harness connec-
tor
X26 Earth connector, connected to the main earth-
ing screw
X27 Earth connector, connected to the starter motor
G2
earth braid
X3 Supply connector + battery
S2 Starter key switch
ENGINE
G2 Alternator
M1 Starter motor
R1 Pre-heater plug
Y1 Fuel injection pump solenoid valve (see plate
8 for Bosch in line pump)
WIRING CONNECTION BETWEEN SCHEMATICS
C See schematic plate 3 page 13
M1 D See schematic plate 3 page 13
F See schematic plate 2 page 11
M See schematic plate 2 page 11
F8-K1-K2-K3 N See schematic plate 2 page 11

K4-K7-X3
G See schematic plate 2 page 11 and 6 page 18
P See schematic plate 2 page 11
S3-S2-X1 G1
X26-X27
CS02B578

BATTERY ALTERNATOR POWER RELAY ENGINE KEY SWITCH STARTER RELAY COLD START ASSISTANCE
STOP
1D B+
3 IGN +
M
3
N
34 K1 12B Acc + 1
12A Acc + 2
85 86 #1
1 12A 12C 12C Acc + 3
31S 87a
12B
K7 S3
30 87 Y1
1D 86 85
1 K4
G2 85 86 #2 F8
87a
86 85 20A
+ 87a
X1 22 21C D
K2 87a
87 30
G1 30
S2
87 IGN
- 10 BATT 87 30
85 86
1D
87a
START 1F
4 30 87 #3 ACC
10 10 21A R1
K3 X1
F 4
28
1E
X3
1A 1B 1C 1C 19K
0 21B
X1 21A 21A C 19K
1J 1F
M1 1H 1J 1J G
10 10
1H 1H P
30 30
X26 X27
CI02B524
Wire Wire section Wire Wire Wire section Wire

number mm2 colour number mm2 colour
0 ST None 12A 3,32 Red
1 ? Red 12B 3,32 Red
1A 8,5 Red 12C 3,32 Red
1B 10 Red 19K 1,32 Red
1C 3,32 Red 21A 1,32 Light blue
1D 3,32 Red 21B 3,32 White
1E 3,32 Red 21C 1,32 White
1F 3,32 Red 22 1,32 White
1H 3.32 Red 28 2,07 Light blue
1J 3,32 Red 30 1,32 White
3 3,32 White 31S 1,32 Yellow
4 1,32 Grey 34 1,32 Light green
10 1,32 Black
Connector X1
N fil N fil
3 A3 28 N4
21B A4

SCHEMA ELECTRIQUE (PLANCHE 2)

INSTRUMENT PANEL ENGINE
E2 Air filter restriction indicator lamp
B2 Engine oil pressure switch
E3 Engine oil pressure warning lamp
B4 Air filter restriction pressure switch
E4 Alternator charge warning lamp
P6 B4 B2 B6 G2 X27 B6 Coolant solution temperature sender
E5 Parking brake indicator lamp
G2 Alternator
E6 Rear axle oil temperature warning lamp
E7 Hydraulic filter restriction warning lamp CHASSIS
E9 Headlight indicator lamp
B1 Oil filter restriction pressure switch
E27 Air conditioning warning lamp
B3 Rear axle temp. sender
F7 Fuse 30A, Power socket
B5 Transmission oil temperature sender
F14 Fuse 30A, Power socket
P6 Fuel level indicator
F16 Fuse 10A, instrument panel and audible warning
S4 Parking brake switch
device
S5 Parking brake switch
H1 Audible warning device
K18 Stabiliser safety audible warning device relay
tor
P1 Transmission oil temperature indicator
P2 Battery charge indicator
ing screw
P3 Engine coolant solution temperature indicator
P4 Fuel level indicator
earth braid
P5 Engine tachometer and hourmeter
X9 Instrument panel connector (36 pin)
X10 12V power socket.
F See schematic plate 1 page 9
G See schematic plate 1 page 9

B5
H1 See schematic plate 3 page 13
M See schematic plate 1 page 9
S4
F7-F14-F16-H1 N See schematic plate 1 page 9
B3 K18-X26
S5
Q See schematic plate 6 page 19

B1
E2-E3-E4-E5-E6-E7
E9-E27-P1-P2-P3-P4-P5 R See schematic plate 4 page 15
X1-X9-X10
S See schematic plate 3 page 13
T See schematic plate 4 page 15
U See schematic plate 4 page 15
V See schematic plate 3 page 13
CS02B579

INSTRUMENT CLUSTER Rear Air filter re- Torque

Coolant WARNING ALARM
Pressure solution
Oil filter re- Fuel level axle striction convert-
switch for temperat
striction indicator temp. pressure er temp.
engine ure send
sender switch sender
oil pres- er
sure Parking brake Warning alarm
B+ B+
IGN + 3 IGN +
ACC + 1 ACC + 1
ACC + 2 ACC + 2
ACC + 3 ACC + 3
P G
X1
X9 31T
F7 F14
P2 P5 P4 P3 P1 E27 E9 30A 30A 32T H1
36F X1
F16
E3 E2 E7 E6 E5 E4
10A
X1 X1
83 84
23F 37
2 3 4 6 7 1 5 36 19 20 22 21 10 24 35 8 36H
B1 P6 B2 B3 B4 B5 B6
P
60A 37 X10 P V T T
T K18
41C 52 S4 S5
85 86
H1 24
M Q 87a
33T 30
N 23F 37
R S 30 87
31S
G2 34
10
X1 30 30
X1 X1 X1
V
36P
1A
20B 31P
20A 20C 33T
F T 40A 40B U 38
23F 23F
10 10 10 10
30 30 30 30
X26 X27
CI02B526
Wire Wire sec- Wire colou Wire Wire sec- Wire colou X1 Connector
number tion mm2 number tion mm2
Wire no Wire no
1A 8,5 Red 34 1,32 Light green
3 3,32 White 36F 1,32 Yellow 31P B3 36P M2
10 1,32 Black 36H 1,32 Yellow 31T E5 37 B4
20A 1,32 Black 36P 1,32 Yellow 32T C2 38 D3
20B - - 37 1,32 Yellow 33T M3
20C - - 38 1,32 Yellow
36F B6
23F 1,32 Red 40A 3,32 Black
36H D5
24 1,32 Grey 40B 3,32 Black
30 1,32 Black 41C 1,32 Red
31P 1,32 Yellow 52 1,32 Grey
31S 1,32 Yellow 60A 1,32 Grey
31T 1,32 Yellow 83 3,32 Red
32T 1,32 Yellow 84 3,32 Red
33T 1,32 Yellow


E5 Parking brake indicator lamp E14 Reversing light
F15 Fuse 10A, forward and reverse travel relay and H4 Reverse audible warning device
four-wheel drive device M1 Starter motor
F16 Fuse 10A, instrument panel, audible warning S4 Parking brake switch
S6 X4 device S5 Parking brake switch
H1 Audible warning device S9 Stabilizer raising safety switch
H13 Lighting for 4 wheel drive switch S32 4th gear cut-out switch (optional)
K4 Starter motor relay V8 Forward travel transmission solenoid valve
K5 Transmission cut-out relay diode
K7 Starter relay V9 Reverse travel transmission solenoid valve
Y6 K9 Transmission forward travel relay diode
K12 4th gear reverse cut-out relay (optional) X1 Chassis harness/side console harness connec-
M1 K13 Direction of travel reverser locking relay tor
Y7 K14 Transmission reverse travel relay X4 Chassis harness/front console harness connec-
K15 Direction of travel reverser locking relay tor
K16 Transmission neutral point relay (by stabilizer X26 Earth connector, connected to the main earth-
function) ing screw
K18 Stabiliser safety audible warning device relay X27 Earth connector, connected to the starter motor
S22 4-wheel drive contact switch earth braid
V4 Stabilizer raising safety diode X31 Transmission forward travel and reverse travel
V5 Stabilizer raising safety diode connector
X3 Supply connector + battery X32 Transmission forward and reverse travel sole-
noid valve connector
OPERATOR'S COMPARTMENT
X33 4-wheel drive solenoid valve connector
S6 Transmission control: forward and reverse Y6 Forward travel transmission solenoid valve
S10 travel Y7 Reverse travel transmission solenoid valve
S10 Transmission cut-out switch (gear lever) Y8 4 wheel drive solenoid valve
S11 Transmission cut-out switch (loader lever)
X27
S4
C See schematic plate 1 page 9
S9
F15-F16-H1-K4-K5-K7-
S5 K9-K12-K13-K14-K15 D See schematic plate 1 page 9
E14 K16-K18-X3-X26
X26-V4-V5-V8-V9 B1 See schematic plate 4 page 15
H4 E5-H13 S32 Y8 S11
S22-X1
H1 See schematic plate 2 page 11
S See schematic plate 2 page 11
V See schematic plate 2 page 11
CS02B580

FOUR WHEEL DRIVE TRANSMISSION CONTROLS, FORWARD DIRECTION, NEUTRAL POSITION, REVERSE DIRECTION
B+ B+
IGN +
Acc + 1 Acc + 1
Acc + 2 Acc + 2
Acc + 3 Acc + 3
3
F16
10A H1 H1
F15 S10 S11
X1
10A 25
K18
23F 37 85 86
19E
K5 23F 24
S32 87a 25
85 86 X18(A) X18(D)
37
87a 30
21 87
X1 V
30 87 S6
S22 H13 X31 X4 X1 E5
K12 S4 S5
X4 R A 27A
D B 85 86
N
X31 F C 87a X1(G3)
25B NC
25C X4 30 10
87
K15 25B NO
86 X1 S9 X2(H)
24A X2
X1 1D 25A 24
K13 V4
85 86
36P
X4 K9
87a 10
85 86
X33 (A) X1 V5 25A
M1 87a X32 (A) X32 (B)
Y8 30 87 Y6
26
K16 30 87
X1
52 85 86
21C 10
87a V8 10
X33 (B) 52A
21B K4
30 87 K14 30
86 85
21C 85 86
10 27B
87a D 52 87a
86 85 21A Y7
22 24 19M
87a 87 30 27
30 87
X1 X32 (C) X32 (D)
87 30
1B X1 K7 V9
C S E14
30 1C B1 27
X3 10 P
10 10
H4
27 30
10
30
X26 X27
CI02B528
Wire Wire Wire colour Wire Wire Wire colour Wire Wire Wire colour
Connecteurs X1 Connectors X1
number section number section number section
mm2 mm2 mm22 N fil N fil
1B 10 Red 21C 1,32 White 27 1,32 Light blue 21 E4 27 J3
1C 3 Red 22 1,32 White 27A 1,32 Grey 21B A4 36P M2
1D 3 Red 23F 1,32 Red 27B 1,32 Grey
21C J4
3 3 white 24 1,32 Grey 30 1,32 Black Connectors X4
25 H3
10 1,32 Black 24A 1,32 White 36P 1,32 Yellow
25A C3 N fil
19E 1,32 Red 25 1,32 Red 37 1,32 Yellow
25B D6 21 A1
19M 1,32 Grey 25A 1,32 Light blue 52 1,32 Grey
21 1,32 Red 25B 1,32 Light blue 52A 1,32 Red 25C D2 21C B2
21A 1,32 Light blue 25C 1,32 Red 26 E6 25A H2
21B 3,32 White 26 1,32 Light blue 25B J4


F3 Fuse 20A, horn and hazard warning lights E11 LH brake light
F5 Fuse 15A, side lights E12 Rear LH side light
F19 Fuse 10A, LH front and RH rear sidelight E13 Registration plate light
F20 Fuse 10A, LH rear sidelight, RH front sidelight, E14 Reversing light
registration plate and fog light E15 RH brake light
F24 Fuse 15A, alternator charge warning lamp, E16 Rear RH side light
flasher and LH and RH rear brake lights E17 Fog light
E19-E22 E8-E9 S15 S17 X4 E9-E10 H5 Road light switch lighting E20 Rear LH direction indicator
H6 Fog light switch lighting (optional) E21 Rear RH direction indicator
S16-H8
K20 Horn relay H9 Horn
K22 Flasherunit S14 Brake light switch
S12 Road light switch X1 Chassis harness/side console harness connec-
E18-E23 S13 Fog light switch (optional) tor
S18 Horn switch (instrument panel) X2 Chassis harness/side console harness connec-
V10 Hazard warning light diode tor
X6 V11 Hazard warning light diode X4 Chassis harness/front console harness connec-
tor
X5 Chassis harness cab front RH light harness
E13
H7 Hazard warning light indicator lamp X6 Chassis harness/cab front LH light harness
H8 Hazard warning light switch lighting X7 Chassis harness/rear chassis light harness
E17 S15 Direction indicator switch connector
S16 Hazard warning light switch X26 Earth connector, connected to the main earth-
S17 Horn switch (steering wheel) ing screw
CAB
earth braid
E8 Front LH side light
H9 E9 Headlights
E10 Front RH side light
E18 RH side direction indicator
X27 E19 LH side direction indicator
X5 E22 Front LH direction indicator
E23 Front RH direction indicator
S14
B1 See schematic plate 3 page 13

E20 H7 E14 K20-K22-F3-F5-F19
E11-E12 F20-F24-X26
R See schematic plate 2 page 11
E21 S12-S13-S18-H5-H6-
V10-V11-X1-X2-X4-X7 T See schematic plate 2 page 11
E15-E16
X7
U See schematic plate 2 page 11
CS02B581

HEADLIGHTS AND REAR LIGHTS FLASHER UNIT - DIRECTION INDICATORS, HORN

HAZARD WARNING LIGHTS - BRAKE CONTROL
B+ B+
ACC 1 ACC 1
ACC 2 ACC 2
ACC 3 ACC 3
E8 E9 E9 E10 E20 E21
L R
H7
X6(B) E22 E23 S15 S17 S18
L R
X6(C) X7(F)
X1 X5(C) X5(B)
X5(A) R F3 F24 H9
41D 45R
15A 15A
E18 X7(E)
41D X1 40A
40B
45L 45L 40B
45L
41A 41D
40B 40B
X4 43 X4
L 40B 40A
41E 41E
F20 E19 45R
F19 F5 X1 X4
10A 15A 10A 40B K22 30
S12 27 X7(C) H8 S16 K20 X1
H5 X4 85 86
30 64A
X7(A) X7(D) 43 87a
44 30 64B
S14 40B
45L 45R 87
X1
19B 19B
44 30 10
46
E13 E14 10 X4 19L 19B
E11 E15 30 45
R X4
1D E12 E16
41C 10 X2
S13 H6 X4 X4
40B
X2 46
X1
40A
41 40A V10 X4
27
T 43 19L
30
40B 45R V11
41C X2
X2 45L
B1 41E X7(B) U 19L
47 30 40B 40B
10
40A 40A
E17
10 10 10
30 30 30
X26 X27 X26 X26
CI02B530
Connectors X1 Connectors X4 Wire Wire Wire colour Wire Wire Wire colour
number section number section
N fil N fil mm2 mm2
19B A2 19B A1 1D 3.32 Red 41D 1.32 Red
19L K6 19L B1 10 1.32 Black 41E 1.32 Red
41A C4 30 J3 19B 3.32 Red 43 1.32 Tan

19L 1.32 Red 45 1.32 Tan
41D E2 43 A3
27 1.32 Light blue 44 2.07 Tan
41E J2 44 K3
30 1.32 Black 45L 1.32 Tan
43 L4 45L K1 40A 3.32 Black 45R 1.32 Tan
46 J6 45R K2 40B 3.32 Black 46 1.32 Tan
47 K5 46 J2 41 2.07 Grey 47 1.32 Grey
64A J5 64A B4 41A 1.32 Red 64A 1.32 Red

41C 1.32 Red 64B 1.32 Grey
64B D4


INSTRUMENT PANEL OPERATOR'S COMPARTMENT
F1 Fuse 10A, rotary light (optional) S30 Cab lighting switch
F2 Fuse 10A, cab interior light
CHASSIS
F12 Fuse 10A, front working lights
F22 Fuse 20A, rear working light M4 Front windshield washer motor
F23 Fuse 20A, front and rear windshield wipers and M5 Rear windshield washer motor
washer S23 Bucket automatic return detector
F25 Fuse 10A, Side shift carriage and return to dig Y9 Bucket automatic return solenoid valve
H10 Rotary light switch lighting Y10 Sideshift carriage locking/unlocking solenoid
M3 S28 E24 E25 M2 E25 E28 M5 M4 H11 Front working light switch lighting valve
H12 Rear working light switch lighting X1 Chassis harness/side console harness connec-
H14 Sideshift carriage locking switch lighting tor
S19 Rotary light switch (optional) X2 Chassis harness/side console harness connec-
S20 Front working light switch tor
S21 Rear working light switch X4 Chassis harness/front console harness connec-
S24 Sideshift carriage locking/unlocking switch tor
S25 Front/rear windshield washer switch X8 Side console harness/cab harness connector
S26 Front windshield wiper switch X26 Earth connector, connected to the main earth-
E26 S27 Rear windshield wiper switch ing screw
CAB
earth braid
S30 E24 Rotary light
E25 Front working lights
E26 Rear working lights
E28 Cab interior lighting
M2 Front windshield wiper motor
M3 Rear windshield wiper motor
S28 Rear windshield wiper stop switch
S23 X27
F1-F2-F12-F22
Y10 F23-F25-X26
S19-S20-S21-S24-S25-S26-
Y9 S27-H10-H11-H12-H14-X1-
X2-X4-X8
CS02B582

ROTATING BEACON, WORKING LIGHT DOME LIGHT BUCKET AUTOMATIC SIDESHIFT SLIDING WIPERS - WASHERS
RETURN TO DIG FRAME LOCKING
B+ B+
ACC 1 ACC 1
ACC 2 ACC 2
ACC 3 S28
F12 F1 12B 12C
F22
20A 10A 10A M2 M3
E24
F2 F25 F23
S19 H10 10A 10A 15A 80
X8 42F
H H
19D L L
10 E25
63 63
48
S30
67 66 69 81 82
S20 H11 90 E28 S23
40A 40B
19A E26 X4 NC
48 S24 H14
42F
X8 X8 X8 C NO
63
49 S26 S27
10 X1
S21 H12 30 63
40A 61B 53
S25 M4
Y9 72
19C 42C
53 19F 19F 10 63
30 M M
40B X1 X1 X8 30
Y10 X2 M5
65
30
X8 X8 62
X8 X2
90 X8
40B 40B 40B
40A
40A 40A 40A
10 10 10 10 10
30 30 30 30
X26 X26 X26 X27

CI02B532
Connectors X1 Connectors X4 Wire Wire Wire colour Wire Wire Wire colour
number section number section
Wire Wire mm2 mm2
no. no.
10 1,32 Black 53 1,32 Red
19F E3 61B B3 12B 3,32 Red 61B 1,32 Red
61B C5 12C 3,32 Red 62 1,32 Grey
62 L5 Connectors X8 19A 2,07 Red 63 2,07 Red
19C 3,32 Red 65 1,32 Grey
65 L6 Wire
no. 19D 1,32 Red 66 1,32 Grey
72 B5 40B H 19H 1,32 Grey 67 1,32 Grey

30 1,32 Black 69 1,32 Grey
42C K
40A 3,32 Black 72 1,32 Grey
42F F
40B 3,32 Black 80 2,07 Black
48 D 42C 3,32 Grey 81 1,32 Grey
49 N 42F 1,32 Grey 82 1,32 Grey
61B M 48 1,32 Grey 90 1,32 Black
49 1,32 Red
63 E
62 A
65 B


INSTRUMENT PANEL CAB
B12 Air conditioning temperature adjustment control A1 Radio (optional)
E27 Air conditioning warning lamp B10 LH loud-speaker
F11 Fuse, 10A, heater, air conditioning and ventila- B11 RH loud-speaker
tion. B14 Air conditioning low pressure switch
F13 Fuse, 10A, radio H15 Lighting for rear auxiliary hydraulics switch
R3-M6 F26 Fuse 15A, Auxiliary hydraulics, radio and C.B. H20 Lighting for Ride Control switch
B10 B11 B14 B15 B13
K10 Air conditioning relay M6 Heater blower motor
S29 Heater ventilation control R3 Heater blower motor supply resistor
S33 Auxiliary hydraulics control pedal
ENGINE
S34 Auxiliary hydraulics switch
B15 Air conditioning compressor electromagnetic S51 Ride Control switch
clutch
CHASSIS
B13 Air conditioning high pressure switch
tor
X8 Side console harness/cab harness connector
H15 ing screw
S34 X27 Earth connector, connected to the starter motor
earth braid
Y11 Rear auxiliary hydraulic solenoid valve
Y25 Ride control solenoid valve (accumulator)
Y26 Ride Control solenoid valve (return to reservoir)
G See schematic plate 1 page 9
X27
Q See schematic plate 2 page 11
Y11 F11-F13-F26-K10-X26
S33
H20-S51
B12-S29-E27
X2-X8
Y25-Y26
A1
CS02B583

RIDE CONTROL REAR AUXILIARY HYDRAULICS RADIO AIR CONDITIONING - HEATING
G
ACC 1
ACC 2
12B 1J 12A
88 M
M6 40A
F26 F13 F11
15A 10A 25A B15
X2 P 60B
R3 B14
57
X8
X2
61
57 P X8
B13
19P 60A
S51 H20 S34 H15 A1
88 87 86
E27
B+ GRD
ACC+ 3C
4D
5E
6F X8
70
X2
6F S29 H M L
B10 85 86
5E 40B 40A
87a
401 400 4D
B11 10
3C OFF B12 30 87
59
K10 60
B C
Y11 T
85 X8
71 70
10
S33 Q
Y25 Y26
40B 40B
40A 40A
400
10 10
X27 X26 X26 X26

CI02B534
Connectors X1 Wire Wire Wire Wire Wire Wire

number section colour number section colour
Wire no mm2 mm2
60 K2 1J 1,32 Red 60B 1,32 Grey
60A K3 10 1,32 Black 61 2,07 Red
60B K4 12A 3,32 Red 70 1,32 Black
12B 3,32 Red 71 1,32 Grey
Connectors X8
19P 1,32 Red 85 2,07 Grey
Wire no
40A 3,32 Black 86 2,07 Grey
40A G
40B 3,32 Black 87 2,07 Grey
60 P
57 1,32 Red 88 2,07 Grey
60A R
59 1,32 Red 400 1,32 Black
61 C
60 1,32 Red 401 1,32 Grey
60A 1,32 Red


INSTRUMENT PANEL CAB
F24 Fuse 15A, alternator charge warning lamp, H29 Overload indicator warning lamp
flashers, brake lights and differential locking H26 Lighting for backhoe quick coupler switch
F26 Fuse 15A, auxiliary hydraulics, radio, ride con- H27 Lighting for overload indicator switch
trol and quick coupler H28 Lighting for reversing audible warning cut-off
K19 Differential locking relay switch
CHASSIS
Y35-V50 Y37 H4 Reverse audible warning device S56 Backhoe quick coupler switch
Y35 Differential locking solenoid valve S57 Overload indicator switch
Y36 Backhoe quick coupler solenoid valve S58 Reversing audible warning device cut-off switch
V50 Backhoe quick coupler solenoid valve diode S59 Differential locking switch
Y38 X26 Earth connector S61 Loader arm safety valve switch
X27 Earth connector
BACKHOE ATTACHMENT
B50 Overload indicator pressure switch
LOADER ATTACHMENT
Y37 Loader arm safety valve
S59
F24-F26
K19
H4
S58-S57-S56-S2-S61
H27-H26-H28-H29-H30
CS02B584

DIFFERENTIAL LOCKING BACKHOE QUICK COUPLER LOADER ARM OVERLOAD INDICATOR REVERSING AUDIBLE WARNING DEVICE CUT-OUT (GERMANY)
(ONLY POWER SHUTTLE UNIT) SAFETY VALVE
Acc + 1 3 312
IGN
S58 H28
S59 F26 S57 H27
F24
15A 15A
S2 310
K19 311
19L
X18(C) 57
85 86 S56 H26 P
7 7
87a 57 S61 H30 H29 H4
30 87 10 313
25S Y35 27 502 500 27
401 P B50 30
10 501
X18(D) 10
V50
502
Y36 Y37 Y38 310
30
10
10
30
X26 X27
CI02B536
Wire Wire Wire Wire Wire Wire

number section colour number section colour
mm2 mm2
7 1,32 Grey 310 1,32 Brown
10 1,32 Black 311 1,32 Blue
19L 1,32 Red 312 1,32 Red
25S 1,32 Grey 313 1,32 Blue
27 1,32 Light blue 401 1,32 Grey
30 1,32 Black 500 1,32 Black
57 1,32 Red 501 1,32 Light blue
502 1,32 Light blue

POWERSHIFT ELECTRICAL SCHEMATIC (PLATE 8)

E5 Parking brake indicator lamp B16 Brake system pressure switch
F15 Fuse 10A, forward and reverse travel relay and B17 Brake system pressure switch
four-wheel drive device E14 Reversing light
F16 Fuse 10A, instrument panel, audible warning H4 Reverse audible warning device
X35 X32 2 S53 X34 Y35 X31B A4 Y27 device S4 Parking brake switch
H1 Audible warning device S5 Parking brake switch
K5 Transmission cut-out relay S9 Stabilizer raising safety switch
X4 K9 Transmission forward travel relay X1 Chassis harness/side console harness connec-
K12 Relay for neutralising 4th gear reverse travel tor
K13 Direction of travel reverser locking relay X4 Chassis harness/front console harness connec-
K14 Transmission reverse travel relay tor
S9 J4 K15 Direction of travel reverser locking time-delay X18BTransmission cut-out/differential locking con-
relay nector
K16 Transmission neutral point relay (by stabilizer X24 Powershift harness connector
function) X26 Earth connector, connected to the main earth-
K18 Stabilizer safety audible warning device relay ing screw
K21 Fuel solenoid valve relay X27 Earth connector, connected to the main earth-
S4 S2 Starter key switch ing braid
V4 Stabilizer raising safety diode X31BFront console harness/Powershift harness con-
V5 Stabilizer raising safety diode nector
V13 Audible warning device diode X32 Main chassis harness/Powershift harness con-
V15 Audible warning device relay diode nector
X33 Main chassis harness/Powershift harness con-
nector
X27 A4 Powershift controller X34 Gear lever, direction of travel reverser and kick
H13 Lighting for 4 wheel drive switch down connector
S11-S59 J4 Powershift controller connector X35 Gearbox connector
S11 Transmission cut-out switch X36 Brake pressure switch connector
F15-F16-H1 S22 4-wheel drive contact switch X37 Brake pressure switch connector
K5-K9-K12- S53 Gear lever, direction of travel reverser and kick Y27 Injection pump solenoid valve (Bosch in line
K13-K14-K15-
down pump)
K16-K18-K21- S59 Differential locking switch Y35 Differential locking solenoid valve
V4-V5-V13
V15-X26 1 Servopower harness
2 Powershift harness
X33 3 Main chassis harness
3
E5-S2-X1
S22-H13
B17 X37 S5 B16 X36 E14 H4 1 X18B X24
CS02B585

K21 KD A4
S53 J4
K3 H3 F3 D3 B3 K2 H2 F2 D2 B2 K1 H1 F1 D1 B1
4 S2 85 86 F N R F N R J3 G3 E3 C3 A3 J2 G2 E2 C2 A2 J1 G1 E1 C1 A1
ACC 10 1 4 1 4
START 21A
87a Y27 2 3 2 3 218 311 321 312 308 306 305 303 301 21
BATT 314 316 324 25C 315 307 317 309 304 302 30
X35
B+ 2 30
30 H
30 87 301
G
302 Y32
IGN
1G X34 7 8 5 6 2 3 4 303 D Y31
304
B Y29
322 21 323 21C 312 311 321 C
X1(A3) 305
F
Y30
306 Y34
E
307 B19
3 309
J
K T
314
F16 H1 316
L
F15 A
10A K18 317
M
B18 Y33 Y28
10A
21C
322
25S
X31B
323
K5 Y35 85 86
21
23F 37 24
23F 87a S11
85 86 D B C A E
X4(A2)
87a 30
21 25S 87
30 87 X1(E4) X4(J1) E5 X18B

X4(J4) 21 D
21
S5 A 218
25B S4
B
X1(F2) C 21
19E
X4(H2) NC
X1(C3)
X1(D6) 25S
NO
S22 H13 S9 24
X4(B2) X24
X1(M2)
V4 S59
25A 218
K9 36P B17
X1(C3) 324
X1(D2) 85 86 324
V5 X37 P
10 87a
25A X32 A
25C X1(J4) A 308 B 325
26
30 87 B
K16 X1(E6) C 315 325
K13 X36 B16
85 86 D A 325
85 86 B
21C 25B 87a 10 P
87a
24A 52 30
K14 30 30
30 87 25C
30 87 19M 85 86
27B
87a
K12 27
K15 X1(L2) 30 87
85 86 X1(J3) E14 X33 A B
Timer 87a 27
52A 30 87 10
H4
27
25C
X26 10
X27 30
CI02B540

S53
X34 A4
X31
J4
1
3
X24
X18
2
X35
X36
X32
B16
X33
X37
B17
BC00M064

POWERSHIFT ELECTRICAL HARNESS WIRING Wire Wire sec- Wire

1 Powershift harness number tion mm2 colour
2 Main chassis harness 21 1,32 Red
3 Gearbox 21C 1,32 White

25C 1,32 Red
A4 Powershift controller 25S 1,32 Grey
B16 Brake system pressure switch 30 1,32 Black
B17 Brake system pressure switch 218 1,32 Light blue
J4 Powershift controller connector 301 1,32 Light blue
S53 Gear lever, direction of travel reverser and kick 302 1,32 Light blue
down 303 1,32 Light blue
X18 Transmission cut-out and differential lock con- 304 1,32 Light blue
nector, connects to loader control lever harness 305 1,32 Light blue
if Servopower option is not installed on machine 306 1,32 Light blue
X24 Powershift harness connector, connects to Ser- 307 1,32 Black
vopower harness 308 1,32 Light blue
X31 Transmission connector, connects to front con- 309 1,32 Light blue
sole harness 311 1,32 Light blue
X32 Powershift harness connector, connects to 312 1,32 Light blue
chassis main harness 314 1,32 Grey
X33 Powershift harness connector, connects to 305 1,32 Light blue
chassis main harness 316 1,32 Grey
X34 Gear lever, direction of travel reverser and kick 317 1,32 Light blue
down connector 321 1,32 Light blue
X35 Gearbox connector 322 1,32 Light blue
X36 Brake pressure switch connector 323 1,32 Light blue
X37 Brake pressure switch connector 324 1,32 Grey
325 1,32 Grey

X30 62 30 30 65
50 60B
3 45 25 30 12 X4 60A
11 30 15 16 60
31T
13 14 17 19 49
44 45L C B 38
D A 41A
28 64B
X6 53 30
30
20
31P 10
41D 40A 30
A 9
54 8 A
30 25S 7
1J
X1 53 36F
6
3 2 30
52
33T 30 21B
4 30
25S
51
21
36H
2 32T 22
3 34
36P 30 1 24
1A
25
23
26 31S
X33
27
28 30 25C
C B
29 D A X32
30 X5 D
C B
A
48 34 33 31
45R 41E 40A 41A
35
43 30 27 30 26
19F 53
36
X7
42 37 46 47
44 45L
38
41 27A 25B 26 30
D E
41D C A F 45R
40 B G 30 36P
27 47 30 30 27
52
39 27 41E
72 30 24 30
CI02C501

CHASSIS WIRING 25 1,32 Red Clutch relay T87a FWD - N -REV lever (+), 3 & 4 slow speed relay T30. slow speed
control switch and PTO
1 Parking brake connector 27 Transmission forward, reverse connector 25A 1,32 White Starter motor relay T87 Starter motor solenoid
2 Rear axle oil temperature connector 28 X5 connector, chassis harness/cab harness, road 25B 1,32 White fwd - N - rev lever (neu.) Neutral relay T85
3 Hydraulic filter lights, sidelights and flasher lamp, see front and 25C 1,32 Grey Stab. lever switch Neutral 1 locking relay, T85. T87. neutral 2 locking relay, T85.
T87. audible warning locking relay T85
4 Hydraulic filter restriction switch rear lighting wiring
25S 1,32 Red Clutch relay T86 4th gear clutch locking switches
6 X1 connector, chassis harness/side console har- 29 Diodes REV (4th) clutch locking relay T30
ness, see side console wiring 30 4th gear reverse lock-out (option) 26 1,32 Light blue FWD - N - REV (FWD) lever front relay T85. diode
To cables 25G & 25J
7 Fuel level indicator harness 31 Negative battery cable
27 1,32 Light blue FWD - N - REV (REV) lever REV relay T85. diode, opt., 4th gear REV micro-switch
8 X6 connector, chassis harness/cab harness, road 33 Bucket automatic return connector
27A 1,32 Red 4WD cont. switch 4WD solenoid
lights, side lights and flasher lamp, see front and 34 Main chassis harness
28 2,07 Grey Differential locking relay T87 - Power- Differential locking solenoid valve, diode
rear lighting wiring 35 Parking brake connector shift option harness
9 Transmission temperature sender 36 X7 connector, chassis harness/brake lights har- 30 3,32/1,32 Light blue Neutral 1 locking relay, T87 front solenoid and diode
10 Transmission cut-out connector ness, fog light, flasher lamps, rear sidelights and 31P 1,32 Light blue Neutral 2 locking relay, T87 Wire 51A sol. forward travel & diode
11 Cold start cable registration plate light, see front and rear lighting 31S 1,32 Grey REV 4th gear micro-switch Relay T85. 4th gear reverse clutch locking
12 Air filter harness wiring 31T 1,32 Light blue Cold start switch Cold start pre-heat plug
13 Windshield washer pump connector 37 Reversing light connector 32T 1,32 Black Accessories Earth
14 Windshield washer pump connector 38 Reverse audible warning device connector 33T 1,32 Yellow Instrument cluster T2 Oil pressure switch & diode
15 X4 connector, chassis harness/front console har- 39 Reverse audible warning device 34 1,32 Yellow Tach. Alt. output Instrument cluster harness
ness, see front console wiring 40 X13 connector, stabilizer raising safety 36F 1,32 Yellow Instrument cluster T22 Oil cooler temp. sender
16 Starter motor earth strap 41 Sideshift carriage locking/unlocking connector 36H 1,32 Yellow Instrument cluster T21 Transmission temp. sender
17 Starter motor 42 Sideshift carriage locking/unlocking solenoid valve 36P 1,32 Yellow Instrument cluster T6 Rear axle temp. switch
19 Coolant solution temperature sender 43 Stabilizer raising safety switch 37 1,32 Light green Alternator Instrument cluster T5
20 Horn 44 Engine oil pressure cable 38 1,32 Yellow Instrument cluster T20 Fuel level sender
21 Alternator 45 Injection pump solenoid valve cable 41A 1,32 Yellow Instrument panel T4 Switch for hydraulic filter clogging
22 Cable, starter motor solenoid 46 Diode (V8), forward travel transmission solenoid 41D 1,32 Yellow Instrument panel T7 Parking brake switch
23 Starter motor/alternator positive cable valve 41E 1,32 Yellow Audible warning device (-) Instrument cluster T35
24 Battery positive cable 47 Diode (V9), reverse travel transmission solenoid 43 1,32 Yellow Instrument cluster T3 Air filter restriction switch
25 Bucket automatic return harness valve 44 2,07 Red Fuse block 10A Front road lighting
26 4 wheel drive connector 48 Starter motor/fuse block positive cable 45L 1,32 Red Fuse block 9C Forward LH position lights and rear lights. DR.
49 Air conditioning high pressure switch connector 45R 1,32 Red Fuse block 11C Fog light switch, front RH and rear brake lights G
50 Air conditioning compressor connector 46 1,32 Tan Flasher unit relay T49A Direction indicator & hazard warning light switches
51 Diode (V50), differential locking solenoid valve 47 1,32 Tan Brake switch Brake lights
52 Differential locking solenoid valve connector 52 1,32 Tan Direction indicator switch Diodes, direction ind. lamps, Frt & rear direction indicator, LH side
53 Supply wire to fuse F13 light
54 Fuel injection pump solenoid valve connector (low 53 1,32 Tan Direction indicator switch Diodes, flasher ind. lamp, frt. & rear flashers, RH side mounted
light
emissions engine) Tan Hazard warning lights switch Flasher unit relay T49
60 1,32
Wire Wire Wire 60A 1,32 Grey Fog light switch Fog light
number section mm2 colour Coming from Going to 60B 1,32 Grey Diodes T85a reverser, reverser locking relay, T8 instrument cluster, stabi-
lizers
1G 3,32 Red Battery Fuel solenoid valve relay T30 (low emission engine)
61B 1,32 Red Loader return to dig solenoid valve Return to dig limit switch (NC)
1J 3,32 Red Supply connectors X3 Fuse box 12B and 14B
62 1,32 Red Aircon. thermostat Air conditioning relay T30 and air conditioning control
2 3,32 White Fuel solenoid valve relay T87 Fuel injection pump solenoid valve
(low emission engine) 64A 1,32 Red Air conditioning relay T86. T87 High and low pressure air conditioning pressure switches, air
conditioning warning lamp, T10 instrument cluster
3 3,32 White Starter switch (cont.) Sol. Solenoid for fuel shut-off, cold start switch
Fuse block 2C, 4C, 6C & 8C 64B 1,32 Grey Aircon. relay T87a Aircon. compressor clutch
3C 1,32 Black RH cab loud-speaker Radio earth 65 1,32 Red Cab interior light Cab interior light switch
19B 3,32 Red Fuse block 5A Hazard warning light switch, horn relay T85. T30 72 1,32 Grey Washer switch (frt.) Frt. windshield washer pump
19F 1,32 Red Fuse block 7D Solenoid for loader return to dig, sideshift, locking switch
19L 1,32 Red Fuse block 5D Hazard warning switch, brake light switch, Differential lock
Wire Wire Wire

number section mm2 colour Coming from Going to
21 1,32 Red Cut off relay (K5) T87a (+) FNR switch S6
21B 3,32 White Starter motor relay (K7) T87 Starter motor solenoid
21C 1,32 White FNR switch (S6) (neutral ) (K13) lock out relay T85
24 1,32 Grey Safety stablizer switch (S9) . (K16) Relay T85 & T87 -(K18) Relay T85

CI02C504

SIDE CONSOLE AND FRONT CONSOLE WIRING

1 Cab lighting connector 43 Connector X18 transmission cut-out harness (loader lever)
2 Horn and direction indicator lamp connector 45 Earth wire
3 Horn and direction indicator control 46 Connector X1 chassis harness/side console harness, see
4 Cab lighting switch chassis wiring
5 Hazard warning light switch 49 Brake light switch harness
6 Hazard warning light connector 50 Hazard warning light diodes (V10. V11)
8 Relay 51 Connector, X4 front console harness/chassis harness, see
9 Audible warning device chassis wiring
10 Direction indicator lamp connector 52 Front console harness
11 Direction indicator lamp 53 Connector, X31 transmission control, connects to the for-
12 Transmission cut-out switch ward and reverse travel transmission control when Power-
13 Road light switch connector shift option is not installed
14 Road light switch 54 Connector - not used
15 Front working light switch 58 Connector, X19 connecting main harness/Servopower seat
16 4 wheel drive switch harness
17 Front working light connector 60 X31B connector transmission control connects to Power-
18 4 wheel drive connector shift harness
19 Rotary light switch 61 Connector, cab loud-speaker harness
20 Rotary light connector 62 Differential locking switch (loader control lever)
22 Rear working light switch 63 Connector, radio harness
23 Fog light switch 64 12 V Power socket. (X10)
24 Rear working light connector 65 12 V Power socket. (X10)
25 Fog light connector
26 Tachometer and hourmeter connector
27 Starter key switch
28 Starter switch connector
30 Cable X3. supply voltage
31 Relay
33 Cold start connector
34 Cold start push button
35 Sideshift carriage locking switch
36 Connector, X9. instrument panel
37 Sideshift carriage locking connector
38 Diodes
V5 stabilizer raising safety
V4 stabilizer raising safety
39 Cab harness connector X8
40 Rear horn connector
41 Rear horn switch
42 Main harness

CI02C504

Side console and front console wiring (cont) 31P 1.32 Yellow Instrument cluster T2 Oil pressure switch
31S 1.32 Yellow Tach. Alt. output Instrument cluster T19
Wire
Wire Cable
Cable sec- Wire
sec- Numbe Coming from Going to
Numbe Wire colour Coming from Going to tion colour
tion r
r mm2
mm2
31T 1.32 Yellow Instrument cluster T22 Oil cooler temp. sender
1C 3.32 Red Supply terminal Starting relay T30
32T 1.32 Yellow Instrument cluster T21 Transmission temp. sender
1D 3.32 Red Supply terminal Key switch (batt.), 2A, 4A, 6A, 8A fuse block and road lighting switch
33T 1.32 Yellow Instrument cluster T6 Rear axle temp. switch
1E 3.32 Red Supply terminal Supply relay 1. 2. 3. T30
34 1.32 Light green Alternator Instrument cluster T5
1F 3.32 Red Supply terminal Fuse block 2B, 4B, & 6B
36F 1.32 Yellow Instrument cluster T20 Fuel level sender
1G 3.32 Red Supply terminal Fuel injection pump solenoid valve relay T30
36H 1.32 Yellow Instrument panel T4 Switch for hydraulic filter clogging
1H 3.32 Red Supply terminal Fuse box 13A
36P 1.32 Yellow Instrument panel T7 Parking brake switch
1J 3.32 Red Supply terminal Fuse box 12B and 14B
37 1.32 Yellow Audible warning device (-) Instrument cluster T35
2 3.32 White Fuel solenoid valve relay T87 Fuel solenoid valve (low emission engine)
38 1.32 Yellow Instrument cluster T3 Air filter restriction switch
3 3.32 White Starter switch (cont.) Sol. Solenoid for fuel shut-off, cold start switch Fuse block 2C, 4C, 6C & 8C
40A 3.32 Black Road lighting, working lights, front Earth
3C 1.32 Black RH cab loud-speaker Radio earth direction indicators, front windshield
4 1.32 Grey Starter switch (acc.) Supply relay 1. 2. 3. T85 wiper, blower
4D 1.32 Grey RH cab loud-speaker RH loud-speaker radio outlet 40B 3.32 Black Working lights, side lights, rear flash- Earth
5E 1.32 Black LH cab loud-speaker Radio earth ers, rear fog light, rear windshield
wiper switch, aircon. ind. lamp, reg.
6F 1.32 Grey LH cab loud-speaker LH loud-speaker radio output plate light
7 1.32 Grey Differential locking switch Differential locking relay T86) 41 2.07 Grey Front road lighting switch Fuse block 9A
(loader control lever)
41A 1.32 Red Fuse block 10A Front road lighting
10 1.32 Black Accessories Earth
41C 1.32 Red Road lighting switch Fuse block 10C & 12C, Instrument cluster T24
12A 3.32 Red Supply relay 1. T87 Fuse block 8B & 10B
41D 1.32 Red Fuse block 9C Forward LH position lights and rear lights. DR.
12B 3.32 Red Supply relay 2. T87 Fuse block 6D, 8D, 10D, 12D
41E 1.32 Red Fuse block 11C Fog light switch, frt RH and rear LH side lights G
12C 3.32 Red Supply relay 3. T87 Fuse block 2D & 4D
42C 3.32 Grey Rear working light switch. Rear working lights
19A 2.07 Red Fuse block 9B Front working light switch
42F 1.32 Grey Front working light switch Front working lights
19B 3.32 Red Fuse block 5A Hazard warning light switch, horn relay T85. T30
43 1.32 Tan Flasher unit relay T49A Direction indicator & hazard warning light switches
19C 3.32 Red Fuse block 1D Rear working light switch
44 2.07 Tan Brake switch Brake lights
19D 1.32 Red Fuse block 1A Rotary light switch
45 2.07 Tan Hazard warning lights switch Diodes
19E 1.32 Red Fuse block 1C T85 & T30 clutch relay, 4WD control switch
45L 1.32 Tan Direction indicator switch Diodes, direction ind. lamps, Frt & rear direction indicator, LH side light
19F 1.32 Red Fuse block 7D Sol. loader return to dig, sideshift. Locking switch
45R 1.32 Tan Direction indicator switch Diodes, flasher ind. lamp, frt. & rear flashers, RH side mounted light
19K 1.32 Red Fuse block 1B Cold start push button
46 1.32 Tan Hazard warning lights switch Flasher unit relay T49
19L 1.32 Red Fuse block 5D Hazard warning light switch, brake light switch.
47 1.32 Grey Fog light switch Fog light
19M 1.32 Grey Direction of travel reverser l Relay T30 for forward travel and relay T30 for reverse travel
ocking time-delay relay 48 1.32 Grey Rotary light switch Rotary light
19P 1.32 Red Fuse box 11B Radio option (battery +) 49 1.32 Red Fuse block 3A Cab interior light
20A 1.32 Black Instrument cluster T36 Earth 52 1.32 Grey Diodes T87a travel reverser, travel reverser locking relay, T8 instrument cluster, stabi-
lizers
20B - - Earth Power socket (-) instrument cluster
56 1.32 Red Fuse block 3B Radio option (BATT.)
20C - - Earth Power socket (-) instrument cluster
57 1.32 Red Fuse block 9D Radio (+) and/or rear aux. hyd.
21 1.32 Red Clutch relay T87a (+) fwd N rev lever / Slow gears relay 3 & 4 T30 /
Slow gears and PTO control switches 58 1.32 Red Fuse block 5B Free
21A 1.32 Light blue Starter switch (Start) T30 neutral position relay, Fuel solenoid valve 60 1.32 Red Aircon. thermostat Aircon. relay T30. high/low pressure switches
21B 3.32 White Starter motor relay T87 Starter motor solenoid 60A 1.32 Red Aircon. relay T86 & T87 High/low aircon pressure switches, aircon ind. lamp
21C 1.32 White fwd - N - rev lever (neu.) Neutral relay T85 60B 1.32 Grey Aircon. relay T87a Aircon. compressor clutch
22 1.32 White Neutral relay T87 Starter motor relay T85 61 2.07 Red Fuse block 7B Blower switch (+)
23F 1.32 Red Fuse box 3C Instrument cluster T1 61B 1.32 Red Cab interior light Cab interior light switch
24 1.32 Grey Stab. lever switch Neutral locking relay, T85, T87 62 1.32 Grey Washer switch (frt.) Frt. windshield washer pump
Horn locking relay T85 63 2.07 Red Fuse block 3D Frt/rear windshield wiper switches, motors, washer switch
24A 1.32 White Direction of travel reverser Direction of travel reverser locking time-delay relay (input) 64A 1.32 Red Horn relay T86 Frt & rear horn switches
ocking relay T30 64B 1.32 Grey Horn relay T87 Horn
25 1.32 Red Clutch relay T86 4th gear clutch locking switches 65 1.32 Grey Windshield washer Rear windshield washer pump
REV (4th) clutch locking relay T30 switch (rear)
25A 1.32 Light blue FWD - N - REV (FWD) lever front relay T85. diode 72 1.32 Grey Sideshift locking switch Sideshift locking solenoid valve
25B 1.32 Light blue FWD - N - REV (REV) lever REV relay T85. diodes/opt., 4th gear REV micro-switch 83 3.32 Red Fuse block 14A Power socket (+) instrument cluster
25C 1.32 Red 4WD cont. switch 4WD solenoid Wire
25S 1.32 Grey Differential locking relay T87 - Differential locking solenoid valve, diode Cable
sec-
Powershift option harness Numbe Wire colour Coming from Going to
tion
26 1.32 Light blue Transmission forward travel Forward travel solenoid & diode r
relay, T87 mm2
27 1.32 Light blue Transmission reverse travel Reverse solenoid and diode
relay, T87
27A 1.32 Grey REV 4th gear micro-switch Relay T85. 4th gear reverse clutch locking
27B 1.32 Grey Relay, 4th gear reverse Relay, T85 reverse travel transmission
neutralisation
28 2.07 Light blue Cold start switch Cold start pre-heat plug

CI02C503

CAB WIRING
Wire Wire sec- Wire
1 Front right-hand working light number tion mm2 colour Coming from Going to
2 Front left-hand working light
3C 1.32 Black RH cab loud-speaker Radio earth
3 Front right-hand working light harness
4D 1.32 Grey RH cab loud-speaker RH loud-speaker radio outlet
4 Front left-hand working light harness
5 Rotary light harness 5E 1.32 Black LH cab loud-speaker Radio earth
6 Front windshield wiper motor 6F 1.32 Grey LH cab loud-speaker LH loud-speaker radio output
7 Rear windshield wiper connector 40A 3.32 Black Road lighting, working lights, front direction Earth
indicators, front windshield wiper, blower
8 Windshield wiper harness
9 Cab interior lighting 40B 3.32 Black Working lights, side lights, rear flashers, rear Earth
fog light, rear windshield wiper switch, aircon.
10 Cab interior lighting harness ind. lamp, reg. plate light
11 Front windshield wiper connector 41E 1.32 Red Fuse block 11C fog light switch, LH brake light Rear LH side
12 Front windshield wiper connector light, registration plate lamp
13 Rear rotary light (optional) 42C 3.32 Grey rear working lights switch Rear working lights
14 Rear windshield wiper stop switch harness 42F 1.32 Grey Front working light switch Front working lights
15 Rear rotary light harness (optional) 48 1.32 Grey Rotary light switch Rotary light
16 Rear windshield wiper stop switch 49 1.32 Red Fuse block 3A Cab interior light
17 Rear right-hand working light
60 1.32 Red Aircon. thermostat Aircon. relay T30. high/low pressure switches
18 Front windshield wiper connector
60A 1.32 Red Aircon. relay T86 & T87 High/low aircon pressure switches, aircon ind.
19 Heater blower connector lamp
20 Rear right-hand working light 61 2.07 Red Fuse block 7B Blower switch (+)
21 Rear right-hand working light harness
61B 1.32 Red Cab interior light Cab interior light switch
22 Rear windshield wiper motor
62 1.32 Grey Washer switch (frt.) Frt. windshield washer pump
23 Rear left-hand working light
24 Rear windshield wiper connector 63 2.07 Red Fuse block 3D Frt/rear windshield wiper switches, motors,
washer switch
25 Heater blower connector
65 1.32 Grey Windshield washer switch (rear) Rear windshield washer pump
26 Cab harness
66 1.32 Grey Frt. windshield wiper switch (slow) Front windshield wiper - slow
27 Connector X8. cab harness/side console harness,
see side console and front console wiring 67 1.32 Grey Frt. windshield wiper switch (fast) Front windshield wiper - fast
28 Rear windshield wiper switch 69 1.32 Grey Frt. windshield wiper switch (brake) Front windshield wiper - brake
29 Front windshield wiper switch 80 2.07 Black Windshield wiper (earth) Rear windshield wiper motor stop switch
30 Front/rear windshield washer switch 81 1.32 Grey Rear windshield wiper switch (slow) Windshield wiper - slow
31 Front/rear windshield washer connector 82 1.32 Grey Rear windshield wiper switch (fast) Windshield wiper - fast
32 Rear left-hand working light
85 2.07 Grey Blower switch Aircon. thermostat
33 Rear left-hand working light harness
86 2.07 Grey Blower switch (slow) Resistance panel - slow
34 Heater blower connector
35 Heater blower 87 2.07 Grey Blower switch (medium) Resistance panel - medium
36 Rotary light 88 2.07 Grey Blower switch (fast) Resistance panel - fast/blower
37 Air conditioning temperature control harness 90 1.32 Black Rotary light Earth
38 Air conditioning warning lamp harness
39 Cab harness loud-speaker connector
40 Loud-speaker harness connector
41 Air conditioning low pressure switch connector

27
A B C D
30 A
B
C
47 D
41A 30
41E
1
30 47 41E
41E X7 45L
47 30
41E 41D
16
2 3
B G
30 41D C A F 45R
47 D E
4
45L
30 44 45L
41A 30
41E
45R
30
44 41E
45L
5 27
17 7
41E 6
44
30 18
45R
30 X6
41D
27 13
8
A B C D
X5
12 30 15
30 45R / 45L
14
C B 11
D A 44
30
27
30
41E 47 30 27
10
45R A B C D
9
41D
41A 41D / 41E
44
CI02C502

REAR AND FRONT LIGHTING CABLE

1 Registration plate lighting 11 Reversing light connector
2 Connector, registration plate and fog light 12 Reversing light connector
3 Connector, registration plate and fog light 13 Headlight, direction indicator and front right-hand
4 Fog light side light
5 Brake light, side light and left-hand rear direction 14 Connector X5. headlights, direction indicator
indicator flasher and RH front sidelight/chassis hear, see
6 Brake light, side light and left-hand rear direction chassis wiring
indicator connector 15 Connector X6. headlights, direction indicator
7 ConnectorX7,rear lighting harness, see chassis flasher and RH front sidelight/chassis hear, see
wiring chassis wiring
8 Reversing light 16 Headlight, direction indicator and front left-hand
9 Brake light, side light and right-hand rear direction side light
indicator 17 Rear lighting harness
10 Brake light, side light and left-hand rear direction 18 Reversing light connector
indicator connector
Wire
Wire Wire
section
number colour Coming from Going to
mm2
27 1.32 Light blue Transmission reverse travel relay Reversing light & reversing audible warning
device
41A 1.32 Red Fuse box Front road lights
41D 1.32 Red Fuse box Frt LH position lights and Rear RH light
41E 1.32 Red Fuse box Fog light switch, front RH sidelight and rear LH
sidelight, registration plate lighting
44 2.07 Tan Brake contact switch Brake lights
45L 1.32 Tan Direction indicator switch Diodes, flashing indicator lamp, LH front, rear
and side direction indicator flashing lights,
45R 1.32 Tan Direction indicator switch Diodes, flashing indicator lamp, RH front, rear
and side direction indicator flashing lights
47 1.32 Grey Fog light switch Fog light

RIDE CONTROL WIRING

1 Ride Control switch
2 Ride Control switch connector
3 Ride Control solenoid valve coil connector (accu-
mulator)
4 Ride Control solenoid valve coil connector (return
to reservoir)
5 Ride Control solenoid valve (accumulator)
6 Ride Control solenoid valve (return to reservoir)
7 Ride Control harness
8 Wire not used
X27 Main earth connector
Wire
Cable
section Wire colour Coming from Going to
Number
mm2
57 1.32 Red Fuse box Radio (+), auxiliary hydraulics, Ride Control and
quick tool coupler
400 1.32 Black Ride Control switch and solenoid valves Earth
401 1.32 Grey Ride Control switch Ride Control solenoid valve
CM00C027

REAR AUXILIARY HYDRAULIC WIRING

1 Auxiliary hydraulic harness
2 Auxiliary hydraulic switch connector Wire
Cable
section Wire colour
3 Connector - not used Number
mm2
4 Chassis earth 57 1.32 Red
H15 Auxiliary hydraulic switch lighting 59 1.32 Red
S33 Auxiliary hydraulics control pedal 70 1.32 Black
S34 Switch 71 1.32 Grey
Y11 Solenoid valve
57
3 1
S33
4
70
H15
S34
2
70
71 - 59
71 - 70
59
57
Y11
CI00C516

BACKHOE QUICK COUPLER WIRING

1 Backhoe quick coupler harness
2 Backhoe quick coupler switch connector
3 Wire not used
H26 Lighting for backhoe quick coupler switch
S56 Backhoe quick coupler switch
X27 Main earth connector
S56 H26 Y36 Backhoe quick coupler solenoid valve
Wire section
Cable Number Wire colour
mm2
10 1.32 Black
57 1.32 Red
502 1.32 Grey
2
10
3
502
57
57
1
10 - 502
X27
10
Y36
CI00C513

LOADER ARM SAFETY VALVES WIRING

1 Loader arm safety valves harness
2 Loader arm safety valves switch connector
3 Main earth connector
S61 Loader arm safety valve switch
Wire section
mm2
57 1.32 Red
10 1.32 Black
401 1.32 Grey
CM00C045

OVERLOAD INDICATOR WIRING

H29 1 Overload indicator harness
5 2 Overload switch connector
313 3 Overload indicator pressure switch harness
311
4 Cab earth
S57 H27 5 Starter switch connector
3 B50 Overload indicator pressure switch
H27 Lighting for overload indicator switch
S2 312
H29 Overload indicator warning lamp
310 S57 Overload indicator switch
2 Wire section
311 Cable Number
mm2
Wire colour
310 1.32 Brown

311 1.32 Blue
312 1.32 Red
313 1.32 Blue
312
310
1 4
313 - 310
B50
CI00C514

REVERSING AUDIBLE WARNING DEVICE CUT-OUT WIRING (GERMANY)

1 Reversing audible warning device cut-out switch
connector
2 Reversing audible warning device cut-out harness
3 Main chassis harness
4 Reversing audible warning device harness
500
S58 Reversing audible warning device cut-off switch
H28 Lighting for reversing audible warning cut-off
switch
H4 Reverse audible warning device
502
Wire section
501 mm2
500 1.32 Black
S58 H28
1 501 1.32 Light blue
502 1.32 Light blue
3
2
H4
CI00C515


580 SM Training manual
CONTENTS ...................................................................................................................... Page
FRONT AXLE - 4 WHEEL DRIVE VERSION..................................................................................................... 5.3
SIMPLIFIED STEERING CIRCUIT ON THE 580 SM.........................................................................................5.4
STEERING CONTROL VALVE...........................................................................................................................5.5
STEERING CYLINDER ...................................................................................................................................... 5.6
STEERING PRESSURE SETTING .................................................................................................................... 5.8
Issued 04-2002 Printed in France

5.2 580 SM Training manual
Issued 04-2002Printed in France

FRONT AXLE - 4 WHEEL DRIVE VERSION
Operation :
The front axle is engaged mechanically and disenga-
ged hydraulically.
With the 4WD control valve switch (30) OFF, the
4WD solenoid valve is energised and oil under pres-
sure pushes the clutch springs back. The transmis-
sion (5) is then disconnected from the transmission
shaft (12) and the machine is in 2WD.
With the 4WD control valve switch (30) ON, the sole-
noid valve is de-energised and the oil supply is stop-
ped. The springs engage the clutch connecting the
transmission (5) to the transmission shaft (12) and
the machine is in 4WD.
(NOTE : For clearer understanding, please refer to
pages 6.6, 6.7 and 6.15)

SIMPLIFIED STEERING CIRCUIT
Legend : directed to the reservoir via the filter.
1. Hydraulic tank The maximum steering pressure is controlled by a

2. Tandem hydraulic pump relief valve which is adjustable and located in the
3a. Inlet plate / Priority valve steering control valve.
3b. Bucket section NOTE : For further information refer to pages 8.12
3n. Priority valve and 8.13.
6. Hydraulic system pressure test port
8. Steering control valve
8a. Steering safety valve
8b. Orifice
14. Steering cylinder
21. Hydraulic filter
T 8a
Operating principle : B
The (Q1) pump (104 l/min) draws oil from the tank 8b
(1).
The pump output is directed to port (P) of the front LS
loader valve inlet plate (3a).
The oil is directed to the priority valve (3n), which via
(S1), supplies as first priority the steering control
valve (8), according to the demand.
The remaining pump flow is directed to the loader P A
control valves.
The return oil flow from the steering control valve is

STEERING UNIT
36 35 49 47 42 39
34 51
38
43
41
37
46
40
53 39
48
56 44 45
Legend : 1st tightening = 11 to 17 Nm 2nd tightening = 24 to 36 Nm

Max. play between stator & rotor =0.13 mm
34. Valve body
35. Outer spool Operating principle :
36. Inner spool
37. Leaf springs The steering control valve consists of two control spools and a metering pump.
38. Cross pin The metering pump also acts as an emergency pump in the event of main pump
39. Screw failure. It consists of a stator (42) and a rotor (41).
40. Cover plate The steering wheel shaft is connected to the inner spool. The cross pin loosely con-
41. Rotor nects the inner spool (36) to the drive shaft which transmits rotational movement to
42. Stator the rotor (41).
43. Drive shaft The inner spool (36) and outer spool (35) control the direction of the oil supply.
44. Intermediate plate
The inner sleeve is connected to the steering wheel shaft.
45. O-rings The outer spool (35) is connected to the inner spool by leaf springs (37).
46. Spacer The leaf springs (37) return the outer spool (35) to the neutral position in relation to
47. O-ring the inner spool (36).
48. Washers Initial rotation of the steering wheel overcomes the leaf springs and allows the inner
49. Ball stop pin spool to rotate a small amount before the outer spool begins to rotate.
51. Check valve ball
This initial movement changes the oil flow through the spools and the oil is now
53. Seal directed to the steering cylinder via the metering pump.
56. Needle bearing The direction of oil flow depends on the direction of rotation of the steering wheel.
The amount of flow is controlled by the metering pump according to the number of
Tightening torque steering wheel revolutions
settings : A ball (51) (check valve) is located between the supply port and the return port to
the tank. For manual steering ( without main pump supply) this check valve allows
Follow the order shown in the supply to the metering pump via the hydraulic tank return line.
service manual when tighte- A special tool (No. CAS-1239) is used to facilitate installation of the leaf springs.
ning the screws (39).
STEERING CYLINDERS
Description :
1. Cylinder assembly
2. Cylinder
3. Nut
4. Eye bolt
5. Nuts
6. Threaded rods
7. Cylinder cap
8. Dust seal
9. Seal
10. O-ring
11. Back-up ring
12. Cylinder rod
13. Piston
14. Wear ring
15. Back-up ring
16. Sealing ring
17. Nut
18. Eye bolt
20. Tie rod end
21. Coupling end
22. Cylinder retaining flange
23. Screw
2WD Steering cylinder
20
21
3
5
1
21
20
23 17
8 22
10
11 14
9 16
15 5
14
12
13
9
11
8
4WD Steering cylinder

STEERING CYLINDER
Legend :
11 10 7. Cylinder cap
7 8. Dust seal
9. Seal
10. O-ring
11. Back-up ring
8 12. Rod
13. Piston
9 14. Wear ring
15. Back-up ring
16. Sealing ring
Operating principle :
The steering cylinder is a single rod (12), double
acting cylinder, with a central piston (13).
The cylinder caps (7) are retained on the cylinder by
four threaded rods (6) on the 2WD version.
Before reinstalling a cylinder ensure that the rod and
the inside of the cylinder are in perfect condition ie,
no wear or scratches.
Wheel alignment is adjusted with the eye bolts (4)
16 and (18) (for 2WD) or the tie rod ends (20) (for 4WD)
15 14 13 12
The measurement at the rear of the wheels (X) must
be 0 to 5 mm greater than thmeasurement at the front
(Y) of the wheels.
The torque applied to the locking nuts must be from
20.3 to 27.1 mdaN.
2 WHEEL DRIVE 4 WHEEL DRIVE

(X - Y) between 0 and +5 mm (X - Y) between 0 and +5 mm
Y Y
X X

STEERING PRESSURE SETTINGS
7
6
21
Legend : Procedure :
2. Tandem hydraulic pump - The maximum pressure is controlled by the stee-
3. Front loader control valve ring relief valve (8a) located in the steering control
4. Rear backhoe control valve valve (8).
6. Hydraulic system pressure test point
- Install a pressure gauge (250 bar-3000 psi) on the
7. Hydraulic oil cooler
pressure test port (6) located on the front left-
21. Hydraulic return filter
hand side of the machine. (Use female quick cou-
pler E47894)
- Increase the oil temperature (54C) by holding the
bucket control in the closed position for 30
seconds and releasing for 15 seconds.
- With the engine at full speed, turn the steering
fully to the left or the right and read the pressure
on the pressure gauge.
- The pressure should be 155 and 160 bar.
- The steering is screw adjustable after removing
the cover plug.

CONTENTS ...................................................................................................................... Page
580 SM TRANSMISSION DRIVE LINE.............................................................................................................. 6.2
TRANSMISSION ................................................................................................................................................ 6.3

Torque converter............................................................................................................................................ 6.4
Gear box ....................................................................................................................................................... 6.6
Input shaft and clutches................................................................................................................................. 6.8
Transmission hydraulic pump and pressure regulation ................................................................................. 6.9
Transmission hydraulic circuit...................................................................................................................... 6.10
Control and direction of travel inverter block ............................................................................................... 6.12
4 x 4 control solenoid valve .........................................................................................................................6.15
CHECKING THE TRANSMISSION PRESSURES ........................................................................................... 6.16
TRANSMISSION ELECTRICAL CIRCUIT .......................................................................................................6.18
REAR AXLE ASSEMBLY ................................................................................................................................. 6.22

Rear differential housing.............................................................................................................................. 6.22
Final reduction ............................................................................................................................................. 6.24

6.2 580SM training manual
580 SM TRANSMISSION DRIVE TRAIN
9 8 B5 5 6 4 30 3 2 1 7
10 11 12 13 14 15
Description : - Integrated disc brakes (8) which act as service bra-
kes and parking brake.
1. Engine (CASE 4T-390 /67-1) - A differential with dog-type mechanical locking sys-
2. Torque converter tem.
3. Transmission pump - 2 planetary reduction gears.
4. Transmission oil filter
5. Transmission with Forw. and Rev. control valve Drive shaft (12) connects the front axle (13) directly
6. Forward and Reverse control valve to the transmission.
7. Transmission oil cooler The transmission has its own hydraulic and lubrica-
8. Oil-bath disc brakes ting circuit with a hydraulic pump (3) and a separate
9 Rear axle oil cooler (7).
10. Gear lever
11. Drive shaft (transmission - rear axle) The hydraulic pump (3) located in the transmission
12. Drive shaft (transmission - front axle) housing is continuously driven by the torque conver-
13. Front axle (steering) ter (2).
14. Steering cylinder It supplies via the filter (4) :
15. Front axle oscillating pivot - The Forward and Reverse control valve (6)
30. 4 WD control valve - The 4 WD control valve (30) and clutch
B5. Temperature sender - The torque converter (2)
- Transmission lubrication and cooling
An oil cooler (7) maintains the correct oil tempera-

General information : ture.
The drive train consists of a torque converter (2) cou- A sender (B5) checks the transmission oil tempera-
pled to the engine flywheel and a transmission (5) fit- ture at the oil cooler outlet.
ted with :
(For further information see the hydraulic circuit on
- 4 synchronised ratios page : 6.10)
- 1 electro-hydraulic Forward and Reverse control valve
(6)
The transmission (5) is coupled to the engine (1) and
mounted on the chassis.
A drive shaft (11) connects the transmission to the rear
axle (9). The axle is fitted with :

TRANSMISSION COMPONENTS
30
6
4
27
Description : Introduction :
3. Transmission pump The transmission is driven by a torque converter to
4. Transmission oil filter which is coupled the transmission pump (3).
5. Transmission with Forw. and Rev. shuttle This pump supplies oil for the following functions :
6. Forward and Reverse control valve - The torque converter
27.Gauze inlet filter - The forward/reverse clutches
30.4 WD control valve - The front axle clutch (4 WD)
- The transmission lubrication system
The pump (3) takes oil from the housing via the
gauze filter (27) and passes it through the filter (4)
and then to the Forward and Reverse control valve
(6) or the 4 WD control valve.
In the Forward and Reverse control valve the flow is
divided between supply to the torque converter and
supply to the forward or reverse clutch control.
After use, the oil returns to the housing.
(See diagram page 6.10)

CONVERTISSEUR DE COUPLE
3
5
2a
2
2b
2c
2g
2d
2e
2f

TORQUE CONVERTER
Description : The stator directs the oil to the impeller, increasing
the speed and changing the direction of the oil, this
2. Torque converter increases its drive torque.
2a. Impeller
2b. Turbine This reaction continues to increase as long as there
2c. Stator is a requirement for a high torque (for example when
2d. Freewheel starting the machine or when thrusting on the loader
2e. Stator shaft (fixed) bucket) up to the torque converter stall ratio (STALL).
2f. Coupling plate At that point, the output shaft connected to the turbine
2g. Torque converter centring cup stops rotating.
3. Transmission pump In that situation, the oil temperature rises very quic-
5. Transmission kly.
A. Forward and reverse input shaft
P. Oil inlet from transmission pump (converter inlet) When the resistance is reduced, the torque require-
R. Return to housing (converter outlet) ment reduces and the rotating speeds between the
impeller (2a) and the turbine (2b) become almost the
Introduction : same.
The torque converter (2) replaces the mechanical If the machine drives the turbine faster than the
clutchIn that, it provides the connection between the speed of the impeller (when descending a slope) the
engine (1) and the transmission. stator (2c) would have a tendency to act as a brake,
reducing the speed of the machine and heating up
Drive is provided by the mechanical properties of the the oil. To prevent this, the stator is mounted on a
hydraulic oil, with the result that the engine-transmis- free wheel (2d), which enables the stator to turn with
sion connection is very flexible. the impeller.
The torque converter causes the transmitted engine NOTE
torque to be varied automatically and continuously,
within well defined limits, depending on the resisting When reassembling, the torque converter is centred
loads (stall ratio). in relation to the engine flywheel by means of the
centring device (2g).
Torque converter stall ratio = 2.63 / 1.
This is defined by the ratio of the output torque over
the torque at the converter input. In other words, it
multiplies the engine torque by 2.63. This gives the
machine an excellent thrust force, while still retaining
power which is used for the loader hydraulic circuit.
Operation :
The impeller (2a) is part of the external shell of the con-
verter and is connected to the engine flywheel by the
coupling disc (2f), it is therefore driven continuously.
When the impeller (2a) turns, its vanes project oil at
high speed to the turbine fins (2b) which drives the
turbine in a rotary direction. The turbine (2b) is con-
nected to the transmission input shaft (A).
The impeller represents the "pump" part of the torque
converter and can be compared to a centrifugal pump
which draws oil in at its centre and throws it out at its
circumference.
The oil leaves the turbine, following the fins towards
the centre and enters the stator (2c), (the stator is a
fixed component).

TRANSMISSION
5j 5a 5b 5p
D
3
5r
P
A G
5d
5c
5f
B 5e
2
G
C 11
12
H 5h
E
5g
A D
B 5i
C

TRANSMISSION
Description : Reverse travel :
A. Forward and reverse input shaft When reverse drive is selected the reverse clutch
B. Intermediate shaft (5a) is pressurized and the gear (5j) transmits the
C. "Synchronised speeds" output shaft
D. Reverse shaft drive to the reverse shaft (D).
E. Output shaft for front axle The 2 gears are fixed to the shaft (D), so the drive is
G. Shaft (A) lubricating passages transmitted via the right gear to gear (5r) on the inter-
G'. Shaft (C) lubricating passages mediate shaft (B).
H. 4 WD clutch supply passage The remainder of the drive train is unchanged, except
P. Supply passage to clutch
X. Gears locked on shaft that the shafts (B), (C), (E) are rotating in the opposite
2. Torque converter direction.
3. Transmission pump
5a. Reverse clutch Transmission cut-out :
5b. Forward clutch A transmission cut-out switch is located on the gear
5c. First gear
5d. Second gear lever (for use when changing gear).
5e. Third gear A second cut-out switch is located on the loader lever
5f. Fourth gear
5g. 4 WD idler gear (to transfer all power to the hydraulic system when fil-
5h. Synchros ling the bucket).
5i. 4 WD clutch springs
5j. Reverse gear These two switches control the forward and reverse
5p. Forward gear control valve (6) which cuts the supply to the clut-
5r. Input shaft idler gear ches, putting the transmission in neutral.
11. To rear axle drive shaft
12. To front axle drive shaft 4 wheel drive (4 WD) :
The gear (5g) fixed on the shaft (C) will transmit the
drive to the front axle shaft (E) when the 4 WD dog
Operation : clutch is engaged. The springs (5i) hold the 4 WD
This is a four-speed synchronised transmission fitted dog clutch (31) in the engaged position.
with : When the driver operates the 4 WD solenoid (2 WD
- A "powershift" type forward and reverse shuttle selected), oil arrives via the clutch supply passage
with forward and reverse clutches (5a and 5b), inte- (H) and pushes the piston back, compressing the
gral with the transmission springs (5i) and disengaging the drive.
- An electro/hydraulic forward and reverse control Lubrication of the transmission :
valve (6)
- An output shaft (C) on which the (first-second-third- Oil flow, from the oil cooler, enters passages (G) to
fourth) speed gears are fitted synchros (5h) lubricate the moving components of the input shaft
- An intermediate shaft (B) (A) and to lubricate and cool the clutch packs (5a)
- A front axle output shaft (E), for the "4-wheel drive" and (5b).
version. The oil also enters passage (G') and lubricates the
- A reverse shaft (D) to reverse the direction of rota- moving components of the output shaft (C).
tion of the 2 output shafts
Forward drive :
When forward drive has been selected, the clutch
(5b) provides the connection between the input shaft
(A) and the gear located on its right (5p). Drive is
transmitted to the gear (5r) on the intermediate shaft
(B). All the gears on shaft (B) rotate because they are
fixed to the shaft. It is now necessary to select one
speed with the gear lever for one of the synchros (5h)
to engage the gear for the required speed on the out-
put shaft (C).

INPUT SHAFT AND CLUTCHES
5j 5a 5o 5b 5k
P2 P1
A
5q 5k 5l 5m 5n 5p 5q
Description : Forward travel :
A. Forward and reverse input shaft When "forward" is selected, oil under pressure arri-
G. Clutch lubrication passage ves via passage (P1) and engages the clutch (5b).
P1. Pressure inlet passage for forward clutch This locks the input shaft (A) to gear (5p) :
P2. Pressure inlet passage for reverse clutch - The input shaft (A) drives the output shaft (C) via
5a. Reverse clutch the intermediate shaft at (B).
5b. Forward clutch - The input and output shafts rotate in the same
5j. Reverse gear direction.
5k. Reaction discs - Different speeds can be selected by the synchros
5l. Steel discs (5h) on the output shaft (C).
5m.Friction discs
5n. Piston return springs Reverse :
5o. Clutch pistons When "reverse" is selected, oil under pressure enga-
5p. Forward gear ges clutch (5a) via (P2).
5q. Sealing rings This locks the input shaft (A) to gear (5j) :
Operation : - The gear (5j) drives the reverse shaft (D) which
transmits the drive to the intermediate shaft (B) via
When "forward" or "reverse" is selected, power is gear (5p).
transmitted by the "powershift" type hydraulically con- - The input and output shafts rotate in different direc-
trolled clutches (5a) and (5b). tions.
In the neutral position : - Different speeds can be selected using the synch-
- Both clutch control pistons are held in the OFF ros (5h) on the output shaft (C).
position by the springs (5n).
- The input shaft (A) turns freely without driving the
transmission.

TRANSMISSION PUMP AND PRESSURE REGULATION
3 4
5
24
25
34
26
27
32
Description : Description :
3. Transmission pump 4. Filter (with by-pass valve, 15 micron)
25. Pump relief valve (cold oil, 20 bar) 5. Transmission housing
32. Torque converter relief valve (7.5 bar) 24. Pressure regulator (13 to 15 bar)
26. Spool
Operation : 27. Screen (250 micron)
34. Plug
The transmission pump (3) (with external gear teeth)
is located in the transmission behind the torque con-
verter and is continuously driven by the torque con-
verter (2) via the stator shaft (2e). You will see the operations of these components in
the next pages.
The pump is used to supply :
- The forward and reverse control valve and clutches
- The 4 WD control valve and clutch
- The transmission lubrication
- The torque converter.
Torque converter high pressure relief valve (32)
This valve protects the torque converter from pres-
sure peaks (over 7.5 bar) due to sudden changes in
oil flow when accelerating the engine or when the oil
cooler is clogged.
Pump relief valve (25)
This valve protects the pump from pressure peaks (in
excess of 20 bar) in the transmission circuit due to
cold oil or incorrect functioning of the pressure regu-
lating valve.

CIRCUIT HYDRAULIQUE DE TRANSMISSION
B5
2 2 M7 7 M6 M6
M7 7
32
32
B5
31 22
3 3
31
M5 22
1 17
1 0,6
21 4
16
17
3,5
16
24
M5 5
30
3,5 M4
23 4,5
24 M2 M3 18
30
21 M4
23 M2 4
M1
6 33 Y35 Y7 Y6
4
25
3 3
4 M1 6 Y6 18
1
3 34
Y7 19 20
25
3
1
19 20
27
Description : hydraulically)
32. Torque converter relief valve (7.5 bar)
1. Engine 33) Differential lock solenoid
2. Torque converter 34 Differential lock piston
3. Transmission pump (68 l/min at 2200 rpm) B5. Temperature sender
4. Filter (with by-pass valve, 15 micron) Y6. Forward control solenoid
6. Forward and reverse control valve Y7. Reverse control solenoid
7. Oil cooler Y35 differential lock solenoid coil
16. Forward and reverse spool M1. 4 WD clutch control pressure (13 to 15 bar)
17. Forward clutch M2. Control pressure (11 to 13 bar)
18. Reverse clutch M3. Forward clutch pressure (11 to 13 bar)
19. Bearing and clutch lubrication line M4. Reverse clutch pressure (11 to 13 bar)
20. Synchros and gears lubrication line M5. Torque converter inlet pressure (1.5 to 7.5 bar)
21. Modulator spool and piston M6. Lubrication pressure (0.5 to 3 bar)
22. Modulator valve
M7. Torque converter outlet pressure
23. Flow divider
24. Pressure regulator (13 to 15 bar)
25. Pump relief valve (cold oil, 22 to 26 bar)
27. Gauze filter (250 micron)
30. 4 WD control solenoid
31. 4 WD clutch (engaged by spring, disengaged

TRANSMISSION HYDRAULIC CIRCUIT
Y7
Y7
Y35 22
Y6
Y6
22
21a
21a
16
18 T
T 23
T
23
C
17 T C
P
P
Hydraulic circuit operation : speed is controlled by the modulation valve (22).
The oil enters the pump (3) from the transmission When the system returns to neutral, all the oil via the
housing via a screen (27). The oil flows via filter (4) 3.5 mm orifice returns to the housing and the check
then to the pressure regulator valve (24). This valve valve in the modulation valve (22) opens and empties
ensures that the 4 WD clutch disengagement pres- the valve (22).
sure is maintained. The relief valve (25) protects the If the reverse is selected, the forward and reverse
system (22 to 26 bar) when starting up or when spool (16) is moved in the other direction to supply
increasing speed from cold. the reverse clutch (18). The other functions operate
When the supply to the 4 WD clutch circuit is 13 to 15 as before.
bar, the regulator valve 1(24) opens and supplies the The torque converter relief valve (32) protects the tor-
forward and reverse control valve (6). que converter from excessive inlet pressure and will
The flow divider (23) maintains a supply to the open at 7.5 bar.
forward and reverse spool (16) via a 3.5 mm orifice A temperature sender (B5) is located in the oil cooler
and directs the remaining flow to the torque converter outlet to alert the operator of high oil temperatures.
(2), oil cooler (7) and lubrication circuit (19 and 20).
If the forward and reverse spool (16) is moved by the
forward control solenoid (Y6) the oil which returned to
the reservoir via the open centre of the spool (16) is
now directed to the forward clutch (17). Clutching

FORWARD AND REVERSE CONTROL VALVE
Figure 1
NEUTRAL
Y7 Y6
S2
Y35
22
21b
T
21a
18 23
C
T
S1
17
16 Sump Pressure Pump Pressure
Clutch Pressure TC Pressure
Description :
Operation of the valve (6):
16. Forward and reverse spool
17. Forward clutch In neutral (diagram 1)
18. Reverse clutch The oil enters the control valve (6) via passage P
21a.Modulation spool from the pump (3). The flow is controlled by the flow
21b.Modulation piston divider spool (23).
22. Modulation valve - Up to 18 l/min passes through the 3.5 mm orifice
23. Flow divider (S1) in the spool (23) and goes to the housing via the
Y6. Forward solenoid open centre of the forward and reverse spool (16).
Y7. Reverse solenoid
- The remainder (up to 50 l/min) is directed via pas-
S1. Orifice in flow divider piston (3.5 mm) sage C to the torque converter (2) and the lubrication
S2. Orifice in separator plate (1.0 mm)
circuit.
Introduction :
The forward and reverse valve (6) is fitted with a
modulation device to enable smooth take up of drive
and during forward and reverse shuttle operations.

Figure 2
VALVE AT START OF MODULATION
Y7 Y6
Y35 S2
22
21b
21a
T
18 23
T C
S1
17
16
Sump Pressure Pump Pressure
Description : Forward travel/start of modulation (Dia-

16. Forward and reverse spool gram 2)
17. Forward clutch When the forward solenoid (Y6) is energised the
18. Reverse clutch forward and reverse spool (16) is pushed DOWN.
21a.Modulation spool The oil is directed to the forward clutch (17) and the
21b.Modulation piston oil pressure is controlled by the modulation spool
22. Modulation valve (21a).
23. Flow divider
Y6. Forward solenoid NOTE : The flow divider (23) continues to control oil
Y7. Reverse solenoid flow to the converter via passage C.
S1. Orifice in flow divider piston (3.5 mm)

S2. Orifice in separator plate (1.0 mm)

Figure 3
VALVE AT END OF MODULATION Y7 Y6

S2
22
Y35
21b
T 21a
23
C
18 T
S1
17
Sump Pressure Pump Pressure

16
Forward travel/end of modulation (Dia- and reverse spool (16) returns to the neutral position.
gram 3) The forward clutch (17) and the area above the modulation
piston (21b) is then connected to the housing. To release
The clutch oil pressure is still controlled by the modu- the pressure above the modulation piston (21b) more quic-
lation spool (21a). At the same time, the modulation kly, the check valve ball lifts off its seat.
piston (21b) is moved by the clutch pressure, via the The entire valve therefore returns to the situation shown in
1.0 mm orifice (S2). Diagram 1 and is ready for a new command.
As the piston (21b) moves towards the modulation Reverse Travel

spool (21a) it compresses the springs between the When the operator selects reverse travel, the reverse sole-
two. In this way the clutch pressure increases until
noid (Y7) is energised and the spool (16) is pulled UP. The
the piston (21b) moves against its stop. At this point,
oil flow is directed to the reverse clutch (18).
modulation stops and the maximum clutch pressure The operation of the modulation spool is the same as for
has been reached. forward travelForward travel/end of modulation (Dia-
The speed of modulation is controlled by the flow gram 3)
through the 1.0 mm orifice (S2).
Return to neutral/valve emptying (22)
When the solenoid (Y6) de-energised, the forward

4 WD CONTROL (Y8)
Description of the solenoid valve
:
30a. Core attracted to the solenoide when
energised
30b. Connecting screw
Y8 30c. Spring
30d. Check valve
30e. Spool
30f. Sleeve
30a M1. Pressure test port
P. Inlet from pump
F. To 4 WD clutch
R. Return to housing
Y8. 2 WD solenoid
30b
4WD control valve operation :
30c The oil arrives at passage P from the filter (4),
pushes the check valve (30d) and is blocked by
30d the spool (30e).
M1 P The front axle output shaft (E) is engaged by the
4WD clutch springs (5i).
When the operator selects 2WD, the solenoid (Y8)
30e is energised which lifts the core (30a) and con-
R nects the spool (30e).
The oil available at passage (P) flows via passage
30f (F) to the 4WD clutch (31), and moves the 4WD
piston to disconnect the drive to the front axle
shaft (E).
F The return passage to the housing is therefore

closed.
If the operator selects 4WD again, the valve sole-
noid is de-energised and the spool (30e) is moved
down by the spring (30c)..

CHECKING THE TRANSMISSION PRESSURES
M1
30
M4
M3
M2
6
M5
Forward and reverse control valve
and 4 WD control solenoid
Pressure test
TEST BEING MADE, ENGINE RPM : 2200 rpm 900 rpm port location
Pump flow 68 l/min 32 l/min X
Pump relief valve (25) cold 26 bar 22 bar (M1)
Pressure regulator for 4 WD clutch (24)
- neutral 12 bar 10 bar M1
- clutch engaged 15 bar 13 bar M1
Control pressure
- neutral 0 bar 0 bar M2
- clutch engaged 13 bar 11 bar M2
Forward clutch pressure (21) 13 bar 11 bar M3
Reverse clutch pressure (21) 13 bar 11 bar M4
Torque converter relief valve (32) (4 WD) 7 bar 1.5 bar M5
Torque converter relief valve (32) (2 WD) 8 bar 1.5 bar M5
Lubrication pressure (shafts, clutches, gears) 3 bar 0.5 bar M6
Torque converter outlet pressure 4.5 bar 0.5 bar M7
NOTE :- The lubrication pressure test port (M6) is located behind the transmission.
- All values shown are given with the oil at working temperature.
- Pressure test port thread : 1/8 NPT
- On the 2 WD version, the transmission housing is fitted with a simple plug for pressure port (M1)between
the filtre and the control valve
CHECKING THE TRANSMISSION PRESSURES

Setting the transmission pressures :
The following procedure and the table may be used as a guide for checking transmission pressures :
1- Make sure that the transmission oil is at its correct level.
2- Install a 0 - 50 bar pressure gauge at pressure test port (M1).
3- Apply the parking brake, start the engine, warm up the transmission oil and check the pressures at the two
specified engine speeds. The pressures noted must be between 10 to 15 bar for the two engine speeds. If the
pressure is less, the transmission is not operating correctly.
4- If the pressure at step 3 is acceptable install a 0 - 50 bar pressure gauge at pressure test port (M2). At this test
port the forward clutch control pressure or the reverse clutch pressure may be read. With the transmission in
neutral, the pressure must be 0 bar. With the transmission engaged (forward or reverse), the pressure must
be between 11 to 13 bar.
Note : If the pressure remains at 0 bar when the transmission is engaged, the problem may in the control valve (6),
or an electrical circuit problem.
5- If the pressures noted at steps 3 and 4 are acceptable install a (0 - 15 bar) pressure gauge at test port (M5) to
check the torque converter circuit. The pressure should be 1.5 to 8 bar. This variation is because the pres-
sure in the torque converter is directly linked to the engine speed.
Forward System Torque Control Engine

and reverse pressure converter pressure speed
control valve (M1) pressure (M5) (M2)
Neutral idle
Forward idle
Reverse idle
Neutral full speed

Forward full speed
Reverse full speed
M7
M6

"POWER SHUTTLE" TRANSMISSION ELECTRICAL CIRCUIT

The electrical circuit of the transmission includes 3 safety devices::
1 The neutral start safety system controled by the shifter S6 and the relay K9.
2 The transmission cut off if the LH stabilizer is risen up . This is controled by the switch S9 and the relais K16 equip-
ped with a look out wire. As K16 is energized the relay K18 is energized too to connect the alarm H1 to the ground.
3 The transmission cutt off if a short circuit to the battery occures on the forward or reverse signal when the shifter S6
is shift back to neutral. If this occures the transmission is cut of 6 to 7 s later the short circuit . This safety is contro-
led by the relay K13 and the time delay relay K15.
The circuit also includes::
4 A 4 WD control activated by the switch S22 and the solenoid Y8. (4WD when Y8 is not energized).
5 A differential lock control operated with the switch S59, the relay K19 and the solenoid Y35.
6 A transmission cut off when the transmission is shifted in 4th reverse to comply an Italian regulation (option). This is
controled by the switch S32 onto the transmission and the relay K12.
Transmission in neutral and switches non activated

FWD
FWD
+
Stabili-
zer

CIRCUIT ELECTRIQUE DE LA TRANSMISSION "POWER SHUTTLE"
FWD
+
NEU-
TRAL at
+ 12V
FWD
+
Neutral
at +12V
+
6 sec


590 SM REAR AXLE ASSEMBLY

Description :
9a 8. Oil-bath disc brake
8a. Brake piston
9a. Planetary reduction gear
9b
9b. Wheel hub
9c. Rear axle half housing
9c 9d. Coupling sleeve
9e. Half-shaft
9f. Mechanical differential lock
9g. Rear axle input shaft
9d
9h. Breather
9i. Differential housing
B3. Temperature sender
9e
Operation :
The drive from the drive shaft (trans-
mission - rear axle) (11) is transmit-
ted by the differential housing (9i) to
the two half-shafts (9e) which then
transmit the drive to the planetary
reduction gears (9a) to increase the
torque at the wheel hubs (9b).
The axle is fitted with a mechanical
8 differential lock (9f), located on the
right hand half-shaft (9e).
The braking system (8) is located in
9f the rear axle (for more details see
section 7).
9g
B3
9i
8a
9e
9h

590SM REAR DIFFERENTIAL
9r 9n 9m 9q 9l 9s
9f
9o
9g
9k
9l
9m
9n
9q
9p 9e
Description : Operation :
9e. Half-shaft The differential locking system is mechanical, control-
9f. Mechanical differential locking ring led by a fork which runs in the groove of ring (9f).
9g. Rear axle input shaft When the fork moves towards the half-shaft (9e), the
9k. Collapsible spacer ring (9f) pushes the 4 studs (9s) into the carrier (9q).
9l. Spider gears (x 4) The studs go into the grooves machined on the side
9m.Spider gear carrier shafts (x 2) gear (9n) and thus lock the side gears (9n) together.
9n. Side gears (x 2)
9o. Shims The two road wheels then rotate at the same speed.
9p. Differential crown wheel
9q. Differential carrier (half) (x 2)
9r. Thrust washer (x 4)
9s. Differential locking pins (x 4)

590SM FINAL REDUCTION GEAR
9t 9u 9v
9w
9x
9b
9y
9z
9c
9d
description :
9b. Wheel hub
9c. Rear axle half housing
9d. Coupling sleeve
9t. Planetary shaft
9u. Reduction gears (x 3)
9v. Reduction carrier cover
9w. Ring gear
9x. Snap rings (x 2)
9y. Ring gear hub
9z. Double lip seal

CONTENTS ...................................................................................................................... Page
BRAKE CIRCUIT................................................................................................................................................ 7.3
BRAKE MASTER CYLINDERS.......................................................................................................................... 7.4
OIL-BATH DISC BRAKES .................................................................................................................................. 7.6
PARK BRAKE ..................................................................................................................................................... 7.8


BRAKE SYSTEM
Legend :
5 1. Brake master-cylinder
2. LH brake pedal
3. RH brake pedal
17 4. Locking pin
5. Protective sleeve
17. Brake fluid reservoir
S14. Brake light switch
P1. Oil inlet to LH oil-bath disc brake
P2. Oil inlet to RH oil-bath disc brake
21
This machine is fitted with two self equalising
brake master-cylinders (1), controlled by two
1 pedals (2) and (3).
These two pedals can be connected together by
means of a locking pin (4).
- When the two brake pedals are not connec-
ted together, each master-cylinder can be
used independently. This enables the brake
to be used to make very tight steering turns.
- When the two brake pedals are connected
together the pressure equalising line
between the two master-cylinders ensures
the same pressure to both brake pistons.
P1
P2 Straight line braking is therefore achieved.
Two inboard oil-bath disc brakes are located in
the rear axle.
A brake light switch (S14) controls the brake
1 lights.
The two master-cylinders (1) are located behind
the black sound-proofing cover.
Brake reservoir :
The brake oil reservoir (17) is located above the
master cylinders. It is continuously filled from the
hydraulic system, by a connection at the filter hou-
sing (21). For further information refer to page 8.4
S14
2
3

BRAKE MASTER-CYLINDERS
Diagram 1
1c 1b 1a
1e 1d 1f
A 1o
1g 1m
1l 1i
from reservoir 1j
1n
1h
1k
1g
1f
1e
1d to reservoir 1a
under pressure
Description : The port (1k) supplies the LH disc brake.

1a. Master-cylinder piston The port (1l) supplies the RH disc brake.
1b. Return spring The pipe (1j) connects the two master-cylinders when
1c. Check valve rod both pedals are pressed.
1d. Check valve The use of both pedals (locked by the pin) provides
1e. Valve seat simultaneous braking, with identical pressure on both
1f. Circlip disc brakes.
1g. Seal The use of one pedal provides braking on one disc
1h. Body brake alone, which enables the turning circle of the
1i. Balls machine to be reduced.
1j. Equalising passage Diagram 1 : brakes released
1k. LH brake port
1l. RH brake port The two return springs (1b) push the master-cylinder
1m. RH master-cylinder pistons to the right against the circlips (1f).
1n. LH master-cylinder The rod (1c) and valve (1d) assembly is lifted off the
1o. Push rod valve (1e). The oil from the reservoir (17) flows via
these valves and fills the master-cylinders (1m and
Operating principle : 1n) and the pipes (1k and 1l).
The two master-cylinders (1m) and (1n) are conti-
nuously supplied by the reservoir (17).

BRAKE MASTER-CYLINDERS
Diagram 2 : RH brake applied
Diagram 2
1b The rod (1o) and the piston (1a) are
1d 1c 1a pushed into the master-cylinder (1m).
1f
The valve (1d) is closed at point "A",
separating the reservoir from the brake
A circuit.
1o
The movement of the piston moves the
ball and opens the check valve (1i). The
pressure created in the master cylinder
is also transmitted via this check valve
1l into the equalising pipe (1j) and to the
1i 1j 1g 1m second master-cylinder (1n). The pres-
1k B sure is blocked at point "B" by the other
1n check valve (1i).
1f The pressure, which is proportional to
the force applied to the pedal, can only
be applied to the RH brake, via port (1l).
When the pedal is released, the piston
1e
(1a) is pushed back by the spring (1b).
The oil in the circuit returns freely to the
1d au rservoir 1a reservoir via the check valve (1d) and
1c en pression the pressure returns to zero.
1h
Diagram 3 : Both pedals pressed

Diagram 3 down
1d 1b 1a
1c 1g If both pedals are pressed down, the two
rods (1o) and the two pistons (1a) are
1f
1e 1o pushed inwards.
The two check valves (1d) close the pas-
sages to the reservoir. In addition the
two check valves (1i) are opened by the
pistons (1a), connecting both master
cylinders together via the equalising pipe
(1j). This equalises the pressures and
1h ensures the same pressure is transmit-
du rservoir 1l 1i 1j ted to both brakes.
Therefore the same braking force is
1k 1g applied to each wheel.
1f
1d
au rservoir 1a
en pression

WET DISC BRAKES
8c 8d 8e 8f 9e 8g 8h
8i
P1
8b
8j
8a 8z 8t
8k
8r 8q 8p 8k 8n 8m 8l
Description : This machine has 2 oil-bath disc brakes, located at

each side of the differential.
8a. Brake piston
8b. Piston O-rings (x 2) Each brake assembly consists of :
8c. Friction discs (x 2) - One piston (8a) fitted with two O-rings (8b). This pis-
8d. Pressure plate ton is moved by brake circuit pressure via passage
8e. Reaction disc (P1).
8f. Pressure plate - Two flanges (8g and 8h), which are moved by the
8g. Inner flange piston (8a) or the park brake cam (8z) and clamp the
8h. Outer flange 1st pressure plate (8d).
8i. Locating pins (x 3) - Three locating studs (8i) which are used to prevent
8j. Brake housing rotation between the piston (8a) and the 1st pressure
8k. Spacers (x6) plate (8d).
8l. Flat washers (x 3) - 2 pressure plates (8d and 8f) with a reaction plate
8m. Screws (x 3) (8e) which cannot rotate.
8n. Wear take-up spacers - 2 friction discs (8c) connected to the half-shaft by
8p. Spring covers (x 3) splines.
8q. Screws (x 3) - 3 piston return units (8k to 8r) which return the brake
8r. Springs (x 3) pistons when the brakes are released.
8t. Park brake shaft - 3 automatic adjusters units (8k to 8n) which return
8z. Cam the piston the correct amount when the brakes are
9e. Half-shaft released and adjust to take up wear.
P1. Brake oil inlet

WET DISC BRAKES

When the brake pedal is pressed, the oil in the mas-
ter-cylinder is directed to the piston chamber (8a) via
port (P1).
Under pressure, the piston (8a) compresses the rota-
ting friction discs (8c) between the stationary pres-
sure plates (8d and 8f) and the stationary reaction
plate (8e).
The braking force is transmitted to the half-shaft (9e).
Taking up wear : 8s
When the brakes are applied the flange (8h) is
moved by the piston or park brake cam. Connected
to this flange is the piston return units (x3) and the
8j
automatic adjuster units (x3). These units move with
the flange.
The springs (8r) which press on the housing (8j) are
compressed when braking pressure is applied. They
pull back the flange (8h) and piston (8a) when the
brakes are released.
The spacers (8n) are tightly fitted in the housing (8j)
but will move during braking, as the flange (8h) and
piston (8a) move to take up wear clearance. When
the brakes are released these spacers cannot move
back and therefore limit the return travel of the piston P1
and flange.
Brake bleeding procedure :
The brakes must be bled if air is present in the sys-
tem or after reassembly. nue to run the engine until the reservoir is full.
- Start and run the engine at low speed to keep the
brake reservoir full.
Legend :
8j. Brake housing
- Unscrew the bleed screw (8s), located on top of the
8s. Bleed screw
brake housing (8j) (behind the parking brake).
P1. Brake oil inlet
- Press the pedal for the circuit to be bled half down
and hold in that position.
- Pump the other pedal SLOWLY until only oil comes
out of the bleed screw.
NOTE : If the pedal is pumped quickly air may be
drawn in past the master cylinder piston seals or via
the brake reservoir return pipe.
- Retighten the bleed screw and repeat for the other
circuit.
- With both circuits free of air apply maximum brake
pressure to both brakes to self-set the automatic
adjusters.
- Check the oil level in the brake reservoir, if low conti-

PARK BRAKE
Legend :
8j. Brake housing
8s. Bleed screw
8v 8v 8t. Shaft
8u. Spring
8u
8v. Lever
8u
8w. Cam
8x. Adjusting nut
8y. Balls (1 or 2)
S4. Park brake switch
8t
8t
S4 8s 8s The park brake uses the same friction
discs as the service brake.
8j
8j The cam (8w) and lever (8v) are fixed to
the shaft (8t) with splines.
Pulling the cable causes the lever (8v),
shaft (8t) and cam (8w) to rotate.
8w The cam presses on the inner flange (8g)
and the brake plate (8d), compressing
the friction discs (8c) and immobilising
the machine.
s4 8y 8w
A park brake switch is fitted in each
brake. It consists of two balls (8y) located
in a cavity in the shaft (8t).
When the parking brake is applied, the
shaft turns and pushes the balls out,
which in turn push the switch plunger
(S4).
The switch closes and the electrical cir-
cuit for the brake warning light illuminates
the light on the instrument panel.
Adjusting the parking brake :

The parking brake should be adjusted to
prevent the machine moving with the
engine at 1500 rpm and the transmission
in 3rd gear.
For park brake adjustment, see the ser-
vice manual.

580SM training manual 8.1
CONTENTS ...................................................................................................................... Page
580 SM HYDRAULIC COMPONENT LOCATIONS............................................................................................ 8.2
SIMPLIFIED HYDRAULIC CIRCUIT ..................................................................................................................8.3
580 SM HYDRAULIC CIRCUIT.......................................................................................................................... 8.4
580 M HYDRAULIC CIRCUIT ............................................................................................................................ 8.6
GENERAL TECHNICAL SPECIFICATIONS ...................................................................................................... 8.7
HYDRAULIC RESERVOIR................................................................................................................................. 8.8
HYDRAULIC PUMP ...........................................................................................................................................8.9
FILTRATION AND COOLING ........................................................................................................................... 8.10
"FRONT LOADER" CONTROL VALVES.......................................................................................................... 8.11

Inlet plate with priority valve ........................................................................................................................ 8.12
Bucket section ............................................................................................................................................. 8.14
Loader arm section...................................................................................................................................... 8.16
"4 in 1" bucket section ................................................................................................................................. 8.17
Outlet plate ..................................................................................................................................................8.18
"REAR BACKHOE" CONTROL VALVES .........................................................................................................8.20

Inlet plate ..................................................................................................................................................... 8.22
Swing section .............................................................................................................................................. 8.23
Swingdampening valve................................................................................................................................8.24
Swing sequence valve................................................................................................................................. 8.28
Boom section............................................................................................................................................... 8.35
Stabiliser section.......................................................................................................................................... 8.36
Dipper section.............................................................................................................................................. 8.37
Bucket section ............................................................................................................................................. 8.38
"Extendahoe" section ..................................................................................................................................8.39
Outlet plate ..................................................................................................................................................8.40
Regeneration function ................................................................................................................................. 8.41
STABILISER SAFETY CHECK VALVE ............................................................................................................ 8.42
CYLINDERS ..................................................................................................................................................... 8.45
SIDE SHIFT LOCKING VALVE.........................................................................................................................8.46
PRESSURE AND FLOWMETER TESTS.........................................................................................................8.47
ADJUSTMENT OF BUCKET AUTOMATIC SYSTEMS.................................................................................... 8.49
RIDE CONTROL .............................................................................................................................................. 8.50

LOCATION OF HYDRAULIC COMPONENTS ON THE 580 SM
16 21 17
9 6
20
10 14
5 8
13
7
12
11
4
2
19
1
15 18
3
Description :
1. Hydraulic reservoir
2. Tandem hydraulic pump
3. "Front loader" control valve
4. "Rear backhoe" control valve
5. Swing sequence valve
6. Hydraulic circuit pressure test port
9. Fuel tank
10. Side shift locking solenoid valve
11. Side shift locking cylinders
12. Swing cylinder
13. Swing cylinder
15. Right hand stabiliser cylinder
16. Left hand stabiliser cylinder
17. Brake circuit reservoir (supplied with hydraulic oil)
18. Hydraulic reservoir breather
19. Right hand stabiliser safety check valve
20. Left hand stabiliser safety check valve

SIMPLIFIED HYDRAULIC CIRCUIT
Operation :
The first pump Q1 of the tandem hydraulic pump (2) draws oil from the reservoir (1).
This oil is directed to the "front loader" control valve inlet plate (3).
A flow divider, located inside the inlet plate, gives flow priority to the STEERING function of the backhoe. The
remainder of the oil flow passes through the free passage in the "front loader" control valves.
If all the "front loader" control valves are in neutral position, the oil flows through the series passage to the out-
let plate then supplies the "rear backhoe" control valve via the inlet plate.
The flow from the second pump (Q2) enters the "rear backhoe" control valve swing section and joins with the
supply to supply the various valve sections in parallel.
The "front loader" valves and the "rear backhoe" valves can both be used therefore simultaneously.
If the "rear backhoe" valves are not being used, the flow of oil passes through each control valve via the series
passage and returns to the reservoir, via the hydraulic filter (21) and the oil cooler (7) (both protected by the
by-pass valves).


DESCRIPTION DU CIRCUIT HYDRAULIQUE 580 SM

1. Hydraulic reservoir 3n
2. Tandem hydraulic pump
Q1 flow = 104 l/min S1 P LS
3k
Q2 flow = 36 l/min 3h
)(
3. "Front loader" control valves
3
3a. Inlet plate 3i

3a
)(

3b. Bucket section

3c. Arm section
3d. 4 in 1 bucket section 3g A1

3b
3e. Outlet plate B1

3f. Main relief valve 3j

3g. Secondary relief valve B2

X 3c
3h. Check valve
)(

3m A2 X
3i. Detent solenoid (Y9)

3j. "Float" position detent B3

3k. Swing pilot relief valve

X

3d
A3 X
3l. Check valve 3p
T
3m. Forced feed valve
3n. Flow divider 3f

3p. Plug S2 3e
4. "Rear backhoe" control valves
4a. Inlet plate 3l

4b. Swing section
4c. Boom section
4d. Left hand stabiliser section 4j
4e. Right hand stabiliser section
4f. Dipper section 4a
4g. Bucket section 4q
4h. "Extendahoe" section
4i. Outlet plate 4b
4j. Main forced feed valve 4m
4k. Secondary relief valves 4r
4l. Load holding check valves
4m. Forced feed valves
4n. Piloted stabiliser valves 4c
4p. Flow regeneration valve
4q. Orifice (55 l/min)
4r. Check valve
5. Swing sequencing valve 4d
6. Hydraulic circuit pressure test port 4n
8a. Steering pilot relief valve 4e
8b. Orifice (signal drain)
10. Side shift locking solenoid valve 4l
11. Side shift locking cylinders
12. Swing cylinder
13. Swing cylinder 4f
15. Right hand stabiliser cylinder
16. Left hand stabiliser cylinder
17. Brake circuit reservoir (supplied with hydraulic oil) 4g 4k
18. Hydraulic reservoir breather
19. Right hand stabiliser safety check valve
20. Left hand stabiliser safety check valve
21. Hydraulic filter on return line 4h
22. Loader bucket cylinders
23. Loader arm cylinders
24. "4 in 1" bucket cylinders
25. Boom braking check valve / orifice dia = 7.9 mm 4i
26. Dipper braking check valve / orifice dia = 6.35 mm 4p
27. "Extendahoe" cylinder
28. Bucket cylinder
29. Dipper cylinder
30. Boom cylinder

CIRCUIT HYDRAULIQUE 580 M

580 SM GENERAL TECHNICAL SPECIFICATIONS

HYDRAULIC RESERVOIR
Reservoir capacity .................................................................................................... 54 litre
Total circuit capacity.................................................................................................. 125 litre
Reservoir pressure ................................................................................................... 0.6 bar
HYDRAULIC TANDEM PUMP

Q1 pump displacement ............................................................................................. 52.3 cm33/r
Q2 pump displacement ............................................................................................. 17.9 cm /r
Pump drive speed ..................................................................................................... 2200 rpm
Q1 pump flow at 2200 rpm / 210 bar ........................................................................ 104 ltr/min
Q2 pump flow at 2200 rpm / 210 bar ........................................................................ 36 ltr/min
PRESSURE RELIEF VALVES

Main relief valve pressure setting ............................................................................. 210 - 215 bar
Steering relief valve pressure setting ........................................................................ 155 - 160 bar
Swing relief valve pressure setting ........................................................................... 190 - 195 bar
SECONDARY SAFETY VALVES (check with manual pump)

Loader bucket secondary relief valves pressure setting .......................................... 220 bar
Rear backhoe secondary relief valves pressure setting :
- on left and right hand swing................................................................................... 190 bar
- on boom lowering .................................................................................................. 220 bar
- on boom raising ..................................................................................................... 330 bar
- on extending and retracting the dipper .................................................................. 235 bar
- on opening and closing the bucket ........................................................................ 235 bar
SWING SEQUENCING VALVE (check with manual pump)

Secondary relief valve pressure setting .................................................................... 300 bar
REAR BACKHOE BOOM CYLINDER

Pressure setting of valve in the piston (not adjustable) ............................................ 345 bar
FRONT LOADER CYLINDERS DIMENSIONS (PIST dia x ROD dia x STROKE)

Bucket cylinders........................................................................................................ 81.6 x 44.4 x 537 mm
Loader arm cylinders ................................................................................................ 89 x 44 x 766 mm
"4 in 1" bucket cylinders............................................................................................ 76 x 44 x 229 mm
REAR BACKHOE CYLINDER DIMENSIONS (PIST dia x ROD dia x STROKE)

Boom cylinder ........................................................................................................... 127 x 57 x 842 mm
Dipper cylinder .......................................................................................................... 127 x 63 x 583 mm
Bucket cylinder ......................................................................................................... 89 x 63 x 872 mm
Extendahoe cylinder ................................................................................................. 76 x 44 x 1068 mm
Side shift stabiliser cylinders..................................................................................... 76 x 51 x 688 mm
Side shift swing cylinders.......................................................................................... 114 x 51 x 190 mm
Axial stabiliser cylinders............................................................................................ 108 x 51 x 553 mm
Axial swing cylindersl ................................................................................................ 89 x 51 x 305 mm
STEERING CONTROL VALVE

Type ......................................................................................................................... Closed centre
Number of revolutions from lock to lock (2 WD / 4 WD) .......................................... 2.7 / 3 turn
Steering cylinder dimension (2 WD) ........................................................................ 70 x 38 x 170 mm
Steering cylinder dimension (4 WD) ........................................................................ 63 x 38 x 242 mm

HYDRAULIC RESERVOIR
1b
1b
18
1c
1a
1c
18
Description :
1a. Battery cable chanel
1b. Filler cap
1c. Oil level
18. Breather
Operation :
When the level lowers, air enters the reservoir via the
The hydraulic reservoir is installed on the right hand
breather.
side of the chassis. The level of hydraulic oil can be
When the level rises, the air is compressed until it
checked from ground level using the external sight
reaches the pressure setting of the valve (pressure
glass (1c) which is located on the front of the reser-
setting = 0.6 b).
voir.
Checking the oil level :
Battery :
- Park the machine on flat, horizontal ground.
- Position the rear backhoe in the transport position. The battery is located under the cover behind the
- Lower the loader bucket flat on the ground. reservoir. As an optional fitment for cold regions, two
12 volt batteries can be installed in parallel.
When the oil is at ambient temperature, the level
should be half way up the sight glass (1c). Top up if
necessary, removing the filler cap (1b) located next to
the sight glass.
CAUTION :
Before opening any component on the hydraulic
Breather : circuit, make sure the reservoir pressure is
This breather (18) is fitted on the end of a hose, released. This is done by slowly releasing the filler
above the reservoir. It controls variations of air pres- cap (1b).
sure within the reservoir caused by the changes of The drain plug is at the front of the reservoir.
temperature and oil level. There is no suction gauze screen.

HYDRAULIC TANDEM PUMP
2f
2b
2a
2e
2c
2c
2d
Description :
2a. Front pump (Q2 = 36 l/min) 2b
2b. Rear pump (Q1 =104 l/min)
2c. Pump outlet
2d. Pump inlet
2e. Drive shaft 2c
2f. Splined coupling shaft
Operation :
The 580 SLE hydraulic system is supplied by a tan-
dem type gear pump, with external teeth. The body of
the pump is in cast steel.
The larger of the two pumps (engine side) supplies :
2d 2a
- The "STEERING" function
- The "FRONT LOADER" functions
- The "REAR BACKHOE" functions
The smaller of the two pumps supplies :
- The "REAR BACKHOE" functions
The pressure in the hydraulic system is checked by
connecting a pressure gauge to the pressure test port
(6) (see also page 8.2)..

FILTRATION AND COOLING

Description :
21a A 21c
1. From the reservoir
2. To the pump
7. Oil cooler
E T 21a.By-pass valve (3.5 bar)
21b.Oil filter element
21c.Oil cooler by-pass valve (1.5 bar)
B1. Filter clogging indicator
E. Inlet
T. Return to reservoir
F A. Outlet to oil cooler
F. Filtered oil
21b Operation :
Filtration
To ensure that the hydraulic system components
work efficiently, the hydraulic oil is filtered by a filter
element (21b).
In addition, a clogging pressure switch (B1) controls
the warning light on the instrument panel to show
when the filter element is starting to get clogged
(about = 2 bar).
7
Cooling
After supplying the entire hydraulic circuit, the two
flows from the tandem pump pass through the
hydraulic filter (21) and then through the oil cooler
(7).
The hydraulic oil cooler is located in front of the
2 engine water radiator. It is cooled by the same fan .
The oil cooler is protected from pressure variations
1 by a "by-pass" valve (21c), located in the top of the
hydraulic filter housing.
These pressure variations are due :
- To oil viscosity (when circuit is cold).
B1 - To variations of flow in the return circuit
CAUTION
If the filter is completely clogged, a "by-pass" valve
(21a) opens to avoid the risk of bursting the filter
E element. In this case the oil is no longer filtered.
It is essential to change the filter immediately.
A T
21

"FRONT LOADER" CONTROL VALVE - 3

3k LS Ports :
P
P. (Q1) flow inlet from hydraulic pump
RA P1. Series flow passage
S1 P2. Parallel flow passage
3b A1. Bucket cylinder large chamber supply (digging
end)
P1
B1. Bucket cylinder small chamber supply (dumping
end)
A2. Loader arm cylinder small chamber supply
3a (lowering)
3c 3m B2. Loader arm cylinder large chamber supply (rai-
sing)
RB A3. 4 in 1 cylinder small chamber supply (clamshell
3g
opening)
P2 B3. 4 in 1 cylinder large chamber supply (clamshell
3i
3h closing)
S1. Outlet to steering control valve + swing valve
S2. Outlet to backhoe control valves
3j
LS. Signal inlet from steering and swing control val-
ves
3l T. Return to reservoir
T 3m RA. Return passage from ports (A)
3d RB. Return passage from ports (B)
3f
3h
3e
S2
3a. Inlet plate This is a series, open centre type control valve which
3b. Bucket section controls the following functions :
3c. Loader arm section
1- Opening and closing the bucket
3d. "4 in 1" bucket section
3e. Outlet plate 2- Raising and lowering the loader arm
3- Opening the 4 in 1 bucket (or option)
3f. Main relief valve
3g. Secondary relief valve Bucket control features :
3h. Load check valve
The bucket control section (3b) is fitted with a "auto-
3i. Quick return detent coil (Y9)
matic return" device (3i) which enables the bucket to
3j. "Floating" arm position
3k. Swing relief valve be brought automatically back to the horizontal posi-
tion at ground level. This system is actuated by
3l. Check valve
means of a mechanical sensor operated by a cam on
3m. Forced feed check valve
3n. Steering and swing priority spool the arm linkage.
In addition, an anti-dumping system opens the bucket
3p.Plug when it is raised by the loader arms.
Loader arm control features :
The loader arm section is fitted with a "floating" arm
position ; this enables the bucket to follow all the con-
tours of the ground when smoothing slopes or when
picking up spoil from ground level.

"FRONT LOADER" CONTROL VALVE INLET PLATE (3A)
P S1
LS
3k
RB RA
P2
3n P1
Description : - With both valves in neutral only a small flow of oil

flows through the steering control valve and the remai-
3k. Swing relief valve ning flow causes an increase in supply pressure. This
3n. Steering and swing priority spool pressure is applied to the right hand end of the spool
8a. Steering relief valve (3n) via an orifice.
8b. Calibrated orifice - When the supply pressure is greater than the spring
P. Inlet from (Q1) pump (18) pressure, the spool moves to the left, directing the
S1. Outlet supply to steering + swing remaining supply into the series passage (P1) and
LS. Signal inlet from steering + swing control valves parallel passage (P2) of the loader control valve.
P1. Series passage through loader control valve - The parallel passage is connected through the control
P2. Parallel passage through loader control valve valves to the outlet plate where the main relief valve
RA. Return passage to reservoir (3f) is located, this valve limits the pressure in the
RB. Return passage to reservoir FRONT LOADER and BACKHOE functions.
Operation of the flow divider, with

steering being fed (drawing B) :
Operation : - When the steering is used, the operating pressure in
The inlet plate has : the steering control valve has access via the (LS) port
to the left end of the spool (3n).
- a priority spool (3n) which enables the "STEERING"
functions to have priority supply with the correct flow. - This operating pressure combined with the spring (18)
pressure is greater than the pressure which is acting on
- a relief valve (3k) which limits the pressure in the the right end of the spool.
"HAND HOLD AUXILIARY CIRCUIT" (the steering
- The spool moves towards the right directing a priority
system has its own relief valve(8a))..
flow to the STEERING function.
- Flow which is not required for the steering increases
Operation of the priority spool, with no pressure until higher than the combined spring and
feed to steering (drawing A) : operating pressure acting on the left end of the spool.
This higher pressure moves the spool to the left enough
- The oil supply from (Q1) pump enters the inlet plate via to allow the remaining supply to flow to passages (P1
port (P). It flows past spool (3n) and through port (S1) to and P2).
the steering control valve.

"FRONT LOADER" CONTROL VALVE INLET PLATE (3A)
Drawing A
Drawing B
Adjusting the steering pressure :

- When the steering operating pressure at (LS) is greater than the pressure setting of the steering relief valve (8a)
(150-160 bar), the valve opens and allows the oil to flow from port (LS) to the reservoir.
- As a result of this leak via the steering relief valve (8a) (155-160 bar), the orifice (4q) creates a pressure diffe-
rence between the steering control valve supply and the left end of the spool (3n).
- The pressure is now higher on the right end of the spool, so it moves towards the left. The flow to the steering
control valve at (S1) maintains pressure in the steering circuit, but most of the supply from (Q1) pump now flows
past the spool to passages (P1 and P2).
The steering relief valve is screw adjustable and set to 155-160 bar at valve (8a).

"FRONT LOADER" CONTROL VALVE BUCKET SECTION (3B)
(N) - With spool in neutral
RB
2
B1 P1 A1
RA
ANB
3i
3g 3g
1 3h P2 3h
3m 3m
Description :
1. Section body
2. Spool
3g. Secondary relief valve
3h. Check valve
3i. Quick return detent solenoid (Y9)
3m. Forced feed check valve B D
B. Microswitch holder ...........................................................................................................................................
C. Setting screw
D. Cam
E. Cable A
S23. Microswitch
Spool positions :
A. Supply to bucket cylinder large chambers via port (A1) S23
(bucket roll back)
N. Neutral position, series passage open to other functions
B. Supply to bucket cylinder small chambers via port (B1)
(emptying bucket)
Operation :
The first section of the loader valve controls the bucket operation. D E
In the bucket section, the spool has three mechanically controlled positions, one of these positions is also maintai-
ned by an electro-magnet (3i) for the automatic return to dig position of the bucket.
Each cylinder supply line includes :

- A load holding check valve (3h) A. Adjusting screw D.Crank
- A secondary relief valve (3g) B. Microswitch braket E. Cable
- A forced feed check valve (3m) S23. Microswitch
"FRONT LOADER" CONTROL VALVE BUCKET SECTION (3B)
(A) - Spool is pushed in
RB
P1 2
B1 A1
RA
ANB
3i
3g 3g
3h P2 3h
3m 3m
(N) - Spool in neutral position

When the bucket is in the correct position, the cam
When the spool is in the neutral position, the oil flows located on the right hand arm operates the
through the section via the series passage (P1) to the microswitch, which cuts off the supply to the solenoid.
next control valve section. The spring pushes the spool back to the neutral posi-
The cylinder supply ports (A1 and B1) are closed by tion.
the spool (2).
Load holding check valve - 3h
(A) - Spool is pushed in - Closing the bucket
Each cylinder supply line is fitted with a load holding
When the spool is pushed in, the series passage (P1) check valve.
is closed. This valve maintains the line under pressure at the
beginning of the supply (gradual opening) or when the
The flow from the pump via the parallel passage (P2)
pressure in the cylinders exceeds the pressure setting
opens the load holding check valve (3h), then passes
of the main relief valve (3f).
around the spool (2) and through port (A1) to supply
the bucket cylinder large chambers. Secondary safety valve - 3g
The returning oil from the bucket cylinder small cham-
These are direct action valves. This means that the oil
bers flows via port (B1) and passage (RB) to the reser-
pressure acts on the end of the valve and opens it
voir.
when it exceeds thepressure of the springs.
When the spool is pulled into position (B) the operation
They are intended to protect the cylinders, pipes and
is opposite to that of position (A).
hoses from shock loads when the spool is in the neu-
Bucket automatic return to horizontal position tral position.
The spool can be actuated manually, but can also be
Forced feed valves - 3m
maintained in the position (A) by means of a solenoid
(3i), activated by a microswitch (S23) (see photo on When the amount of flow being supplied to the bucket
preceding page). section is too low to prevent cavitation, additional flow
This enables the bucket cylinder large chambers to be can be supplied from the return circuit via these val-
supplied automatically during the lowering phase of the ves.
loader arm.

"FRONT LOADER" CONTROL VALVE ARM SECTION (3C)
(N) - Spool in neutral position P1

RB B2 A2 RA
FANB
3j
1 P2
3p 3h 3h 3p
P1
(F) - Floating position A2
RB B2 RA FANB
3j
1
3p 3h P2 3h 3p
1. Section body In the loader arm section, the spool has four mechani-
2. Spool cally controlled positions : F - A - N - B.
3h. Load holding check valve
In the floating position (F) :
3j. Floating position detent
3p. Plug The flow from the pump passes via the series pas-
A. Supply to loader arm cylinder small chambers at sage (P1) and supplies the other functions.
(A2) (loader arm lowering) The cylinder supply ports (A2) and (B2) are inter-con-
N. Neutral position, series passage open to other nected via thepassages (RA) and (RB) which also
functions connected to the reservoir .
B. Feed to arm cylinder large chambers at (B2) (rai-
This enables the bucket to follow the contours of the
sing loader arms)
ground when the machine is working on ground level-
F. "Floating arm" position maintained by ball type ling or when picking up spoil from a heap.
CAUTION :
The arm must only be placed in the "floating" position when the bucket is empty

"FRONT LOADER" CONTROL VALVE "4 IN 1" SECTION (3D))
P1
RB A3 RA
B3
ANB
3h P2 3h
3p 1 3p
3m 3m
1. Section body This section is generally used to supply the "4 in 1"
2. Spool bucket, but it can also be used to supply other optio-
3h. Load holding check valve nal equipment.
3m. Forced feed check valve
In the "4 in 1" section, the spool has three mechani-
3p. Plug
cally controlled positions : A - N - B.
A. Supply to "4 in 1" cylinder small chambers at (A3) Each supply line is fitted with :
(clamshell opening)
- A load holding check valve (3h)
N. Neutral position, series passage open to other func-
tions - A forced feed check valve (3m)
B. Supply to "4 in 1" cylinder large chambers at (B3) This section has no secondary relief valve. Two plugs
(clamshell closing) (3p) replace this function.

"FRONT LOADER" CONTROL VALVE OUTLET PLATE (3E)
3f
3e
S2
1
3l
P1
RA
RB
P2
Description : Whenever one of the functions (bucket, arm, "4 in 1")

is used, the series passage is closed.
1. Outlet plate body The pump operating pressure at (P1) is connected via
3e. Outlet plate assembly the parallel passage (P2) to the main relief valve (3f).
3f. Main relief valve (for loader and backhoe)
3l. Check valve The check valve (3f) prevents flow at passage (P2)
4. Main relief valve inner spool entering passage (P1) which supplies the backhoe
6. Screen function.
10. Pilot valve ball Nevertheless, when both functions, "front loader" and
16. Valve adjusting screw "rear backhoe", are used simultaneously, (to get the
E. Outlet passage machine out of bad ground), the series passage is
H. Orifice partially open, and the greater of the two pressures is
acting on the main valve (3f).
Operation : If the pressure increases to a level greater than the
When operating, the backhoe with the three loader con- pressure setting of the main valve, that valve opens
trol valve sections in neutral, the oil passes through the and the oil goes to the reservoir via port (T).
series passage (P1), to the outlet plate at (S2) and con-
tinues to the backhoe function. The pump operating
pressure at (P1) is also connected to the main relief
valve via check valve (3l).
"FRONT LOADER" CONTROL VALVE OUTLET PLATE (3E)
A B

16
H 10
4 6
Main valve - 3f
The pump operating pressure acts on the inner spool (4) at (A) and via the orifice (H) on the inner spool at (B). This
pressure also acts on the pilot valve ball (10).
When the pressure reaches the pilot valve opening pressure setting, the oil in cavity (B) escapes via passage (E) to
tank (T), this creates a pressure difference between (A) and (B).
Because the pressure at (A) is greater, the inner spool (4) opens and allows the flow to pass to tank (T).
The main relief valve is screw adjustable.).

"REAR BACKHOE" CONTROL VALVE (4)
4i 4h 4g 4f 4e 4d 4c 4b 4a
Control valve block turned 180
A1 37
A7 A6 A5 A2 A1 P1
B1
4r
LS
T B7 B6 B5 B2 B1
4n
A3
4k RA 4h 4i
A4
P1
4m
4j
4q
B3
B4
4k
U2 RB U1 T P2

"REAR BACKHOE" CONTROL VALVE (4)
Description :
4a. Inlet plate 4i 4g 4e 4c 4a
4b. Swing section
4c. Boom section
4d. Left hand stabiliser section
4e. Right hand stabiliser section
4f. Dipper section A7 A6 A5 A2 A1
4g. Bucket section
4h. "Extendahoe" section
4i. Outlet plate
LS
4j. Main forced feed valve
4k. Secondary relief valves B7 B6 B5 B2 B1
4l. Load holding check valves
4m. Forced feed check valves
4n. Stabiliser piloted check valves
4q. Orifice (55 l/min)
4r. Check valve
4b 4d 4f 4h
37 Swing dampening valve
Ports :
A3 A4
P1. (Q1) pump flow inlet
P1
P2. (Q2) pump flow inlet
U1. Free passage
U2. Parallel passage
A1. Left hand swing supply
B1. Right hand swing supply
B3 B4
A2. Boom lowering supply (large chamber)
B2. Boom raising supply (small chamber)
A3. Right hand stabiliser lowering supply T
(large chamber)
B3. Right hand stabiliser raising supply (small cham-
ber)
A4. Left hand stabiliser lowering supply (large cham-
ber)
B4. Left hand stabiliser raising supply (small cham-
ber)
37
A5. Dipper opening supply (small chamber)
B5. Dipper closing supply (large chamber)
A6. Bucket opening supply (small chamber)
B6. Bucket closing supply (large chamber)
A7. Extendahoe dipper extension supply (large
chamber)
B7. Extendahoe dipper retraction supply (small
chamber)
RA. Return passage for prt (A)
RB. Return passage for port (B)
LS. Outlet to (LS) line for priority flow divider (3n)
T. Outlet to reservoir
This control valve has 6 or 7 or 8 sections with open
center parallel type

"REAR BACKHOE" CONTROL VALVE INLET PLATE (4A)
U1
RA RB
U2
7 2 3 5
P1
4j
1. Inlet plate body (Q1) pump flow from the front loader control valve
2. Plug enters the inlet plate at (P1).
3. O-ring
4j. Main forced feed check valve This flow supplies the parallel passage at (U2).
5. Valve spool The main forced feed check valve (4j) separates the
7. Spring pump supply from the return to reservoir passages
P1. (Q1) pump flow inlet (RA) and (RB).
U1. Series passage Main forced feed check valve 4j
RA. Return passage for port (A) It provides a forced feed function for those sections
which do not have an integral forced feed check valve.
RB. Return passage for port (B
(See "regeneration" function, page 8.43)

"REAR BACKHOE" CONTROL VALVE SWING SECTION (4B))
9 8 7 6 B1 A1 5 3 2
10
RB RA
4k 4k
4m 4l 4q 4l 4m
1. Section body The swing section is a closed centre type, with a three
2. Spool position mechanically controlled spool.
3. Seal If there is no demand for flow, the pressure will
4k. Secondary relief valve increase, moving the priority flow divider spool (3n)
4m. Forced feed check valve and directing the flow from both pumps to the backhoe
4q. Q 2 Inlet port control valve (except for the swing).
5. O-ring When one of the priority functions (swing or steering) is
6. Stop washer activated, the pressure increases in the LS line, which
7. Stop cup enables more flow to pass to these two functions.
8. Spring
Secondary relief valve - 4k
9. Snap ring
10. Cap These are direct action valves, ie, the pressure acts
directly on the valve and causes it to open when the
A. Supply port to sequencing valve (left hand pressure is greater than the spring pressure.
swing)
Forced feed valve - 4m
N. Neutral position, open centre
When the supply to the boom lowering section is too
B. Supply port to sequencing valve (right hand low to prevent cavitation, extra flow can be supplied via
swing) the return flow from this valve.

SWING DAMPENING VALVE (37)
37
A1 C A2
37 D 37
B
C
A1 A2
1.8 mm
1.8 mm
0.75mm

The Anti-Rebound valve or swing dampening valve is designed to meter oil from one side of the swing cylinder cir-
cuit to the other as the control spool is returned to the neutral position. When the backhoe is swinging and the con-
trol spool is returned to the neutral position, returning oil flow from the cylinder to the control valve is forced over
the port relief. The inertia in the backhoe will cause the cylinders to continue to stroke, which creates high pressure
in the return circuit and a negative pressure in the supply side of the circuit. When the backhoe stops moving, there
is a pressure difference on each side of the swing cylinder pistons. This difference may cause the backhoe to move
in the opposite direction.
The Anti-Rebound system is activated when oil is returning to the control valve and the control spool is returned to
the neutral position. At that point, the return side of the circuit becomes the high-pressure side. The oil then goes
over the restrictor (D). The pressure differential across the restrictor shifts a two-position valve (B) that allows a
restricted "cross over" flow between the two swing cylinders. This restricted flow through (A1) and (A2) allows the
swing cylinders to de-accelerate to a smooth stop. When the pressure differential decreases, the cross over valve
closes.
If the temperature is not above approximately 18 degre Celcius (65 degrees F, a thermal compensating valve (C)
equalizes the two pilot pressures and the spool (B) will not open, due to the spring force (E) holding the spool
closed.
Anti rebund valve with temperature < 18C
C D B

Swing in operation status

Swing in stopped status

"REAR BACKHOE" CONTROL VALVE SEQUENCING VALVE (5)

12 11
10
14 2
5c 1 E 5b
5d
Description : General :
1. Valve body The swing system includes a sequencing valve, its
2. Spool purpose is to :the effect of which is to
3. Clevis pin
1) Maintain the swing torque throughout the entire
4. Clevis
swing travel. This prevents the swing torque being
5. Nut
reduced when the backhoe approaches 90 in
5b. Plugs
relation to the axis of the machine.
5c. 2 relief valves (one is
hidden) 2) Create a brake effect at the end of hydraulic
5d. Check valve with ori- stroke.
fice
The valve has five positions which are controlled by
6. Control rod
a cam which is fixed in line with the bachoe axis.
7. Ball joint
8. Cam roller Ports
9. Cam
A1. Swing section flow inlet
10. Seal
B1. Swing section flow inlet
11. O-ring
S1. Right hand cylinder large chamber inlet
12. Springs
S2. Right hand cylinder small chamber inlet
13. Stop cup
S3. Left hand cylinder large chamber inlet
14. Cap S4. Left hand cylinder small chamber inlet
Note
The sequencing valve does not affect the opera-
tion of the secondary valves or the swing section
forced feed valves (4b). They function normally to
protect the system against excess pressure and
cavitation.
The sequencing valve is only fitted on side shift
model

"REAR BACKHOE" SEQUENCING VALVE (5)
Phase 1 : From 0 % to 20 % swing

A
5c E
5d 5c
0 to 20 %
B
4b
When the backhoe swing begins to move from fully right to fully left (viewed with the operator sitting in the backhoe
working position)
- The swing movement begins
- The valve spool is in position (1) - see drawing above
- The two cylinders rods are to the right of the backhoe pivot pin
- The supply to the cylinders and the movement of the rods are shown below.
CYLINDER ROD LARGE SMALL

MOVEMENT CHAMBER CHAMBER
A Rod extends Supplied Supplied
B Rod extends Supplied Return to reservoir
- The thrust on cylinder (B) is the largest thrust

- The thrust of cylinder (A) is low because the pressure is acting on both chambers
- The flow to the cylinder large chambers passes via the check valve (5d)
- A small flow passes via the calibrated orifice (E)

Phase 2 : Swing between 20 % and 40 %
E 5d
5c 5c A
20 to 40 %
B
4b
The swing movement of the backhoe has passed the 20 % point.
- The sequencing valve spool is in position (2) - see drawing above

- The two cylinders rods have moved but are still right of the backhoe pivot pin
- The supply to the cylinders and the movement of the rods are shown below.

A Rod extends Supplied Supplied
- The thrust of cylinder (B) is still the greatest thrust

- The thrust of cylinder (A) is still low
- The flow to the cylinder large chambers no longer passes via the check valve (5d)

REAR BACKHOE" SEQUENCING VALVE (5)
5c E 5d 5c A
40 to 60%
B
4b
The backhoe swing movement has passed the 40 % point.
- The sequencing valve spool is in position (3) - see above drawing

- The heads of the two cylinders are in line with the backhoe pivot pin
- The supply to the cylinders and the movement of the rods are shown below

A Rod retracts Return to reservoir Supplied
- The two cylinders are working at the same time

- The flow to the cylinder large chambers passes via the spool

5c E 5d 5c A
5
60 to 80%
The backhoe swing the movement has passed the 60 % point.

- The two cylinders rods are left of the backhoe pivot pin

A Rod retracts Return to reservoir Supplied
B Rod retracts Return to reservoir Return to reservoir
- Only the small chamber of cylinder (A) is used

- The supply flows directly to cylinder (A)
- The small chamber of cylinder (B) is forced fed by the return from the large chambers

5c E 5d 5c A
80 to 100 %
B
4b
The swing movement of the backhoe has passed the 80 % point

- The backhoe swing is approaching the end of its stroke and its speed must be reduced to give better opera-
tor control

A Rod retracts Return to reservoir via orifice Supplied
B Rod retracts Return to reservoir via orifice Return to reservoir
- Only the small chamber of cylinder (A) is used

- The supply is direct to cylinder (A)
- The return flows from the cylinder large chambers (A) and (B) pass via orifice (E).
- If the supply pressure is too high because of restricted return flow, the relief valve (5c) opens, which auto-
matically reduces the swing speed

"Sideshift backhoe" control adjust-

ment
1. Swing the attachment to the right.
2. Unscrew the nuts (5).
NO
3. Adjust the length of screw (6) to 26 mm (at the
adjustment end).
4. Ensure that the end of the screw (6) is contac-
ting the connecting arm (7).
NO
5. Tighten the nuts (5).
6. Start the engine and run it at about half speed.
7. Swing the backhoe completely to the left and
then to the right. YES
See the illustration for correct adjustment of the
swing. Shorten or lengthen the control rod (6) if
required SWING ADJUSTMENT

"REAR BACKHOE" CONTROL VALVE BOOM SECTION (4C)
RB RA
U1
B2 A2 5
8 7 6
3
ANB
9
10
2
U2
4k 4k
1
4l 4l 4m
1. Section body The boom section is series / parallel open centre type
2. Spool with a mechanically controlled three position spool.
3. Seal
Each outlet (A2) and (B2) is fitted with :
4k. Secondary relief valve
4l. Load holding check valve - A secondary relief valve (4k)
4m. Forced feed check valve - A load holding check valve (4l)
5. O-ring - A forced feed valve (4m) (for A2 only)
6. Stop washer
7. Stop cup
Forced feed valve - 4m
8. Spring
When the supply to the boom lowering section is too
9. Snap ring
low to prevent cavitation, extra flow can be supplied via
10. Cap
the return flow from this valve.
A. Boom lowering supply via port (A2)
Secondary safety valve - 4k
N. Neutral position, open centre
These are valves of the direct action type. The pressure
B. Boom raising supply via port (B2) at (A) acts directly on the valve then causes it to open
when the pressure exceeds the setting of the springs.
Load holding check valve - 4l
It enables the load to be held, either at the beginning of
supply (gradual valve opening), or during full supply,
A
when the required operating pressure is higher than the
pressure setting of the main relief valve (3f).

"REAR BACKHOE" CONTROL VALVE STABILISER SECTION (4D/E)
U1 RA
7 6
RB 5
8
9 3 ANB
10
15 2
16
11 4n
U2 13 14
1 B3 / B4 12 A3 / A4
1. Section body Both stabiliser sections are the series / parallel type with
2. Spool open centre and mechanically controlled three position
3. Seal spool.
4n. Piloted return check valve This section has a piloted return check valve (4n), in the
5. O-ring stabiliser cylinder large chamber supply.
6. Stop washer The piloted check valves prevent the stabilisers raising
7. Stop cups when the spools are in the neutral position.
8. Spring In these sections there is no secondary valve, the pres-
9. Snap ring sure is limited by the main relief valve (3f) located in the
10. Cap outlet plate of the front loader control valve .
11. Plug N - Spool in neutral position
12. Pilot spool The supply flows through the section via the series pas-
13. Valve body sage at (U1) to the dipper section.
14. Pilot valve spool
15. Spring A - Spool is pushed in
16. Plug The series passage (U1) is closed, the supply flows via the
parallel passage (U2), opens the valve (14) then flows via
A - Supply for stabiliser lowering via port (A3 or A4) port (A3) to the cylinder large chamber (stabiliser lowe-
N - Neutral position, open centre ring).
B - Supply for stabiliser raising via port (B3 or B4). B - Spool is pulled out
The series passage (U1) is closed. The supply flows via
the parallel passage (U2) and port (B3) to the cylinder
small chamber.
The return flow from the cylinder large chamber is stopped
by the return check valve (14), this causes an increase in
pressure at port (B3).
This pressure moves the pilot spool (12) which opens the
return check valve (14).
The return circuit is now open and the flow can return to
the reservoir via the passage (RA).

"REAR BACKHOE" CONTROL VALVE DIPPER SECTION (4F)
RB
U1 RA
B5 A5 5
8 7 6
9 3 ANB
10
2
4k 4k
1 4l U2 4l
4m 4m
1. Section body This section is a series / parallel type, with an open
2. Spool centre and a three position mechanically controlled
3. Seal spool.
4l. Load holding check valve Each outlet (A5) and (B5) has :
4m. Forced feed check valve - A secondary safety valve (4k)
5. O-ring - A load holding valve (4l)
6. Stop washer - A forced feed valve (4m)
7. Stop cups
8. Spring Secondary safety valve - 4k
9. Snap ring (See operation pages : 8.23 & 8.35)
10. Cap
A - Dipper extending supply via port (A5)
N - Neutral position, open centre
B - Dipper retracting supply via port (B5)

"REAR BACKHOE" CONTROL VALVE BUCKET SECTION (4G)
RB
U1 RA
B6 A6 5
8 7 6
9 3 ANB
10
2
4k 4k
1 4l U2 4l
1. Section body This section is a series / parallel type, with an open
2. Spool centre and a three position mechanically controlled
3. Seal spool.
5. O-ring - A secondary relief valve (4k)
6. Stop washer - A load holding check valve (4l)
7. Stop cups
8. Spring This function does not have forced feed check valves.
9. Snap ring Secondary safety valve - 4k
10. Cap
A - Bucket opening supply via port (A6)
N - Neutral position, open centre
B - Bucket closing supply via port (B6)

"REAR BACKHOE" CONTROL VALVE EXTENDAHOE SECTION (4H)
RB
U1 A7 RA
B7 5
8 7 6
9 3 ANB
10
11 11
1 4l U2 4l
1. Section body This section is a series / parallel type, with an open cen-
2. Spool tre and a three position mechanically controlled spool.
3. Seal
5. O-ring - A load holding check valve (4l)
6. Stop washer
7. Stop cups There is no secondary safety valve in this section. The
8. Spring pressure is limited by the main relief valve located in
9. Snap ring the outlet plate of the front loader control valve .
10. Cap A plug (11) replaces each secondary safety valve.
11. Plug
Load holding check valve - 4l
A - Dipper extending supply via port (A7) It enables the load to be held, either at the beginning
N - Neutral position, open centre of supply (gradual valve opening), or during full sup-
B - Dipper retracting supply via port (B7) ply, when the required operating pressure is higher
than the pressure setting of the main relief valve (3f).

REAR AUXILIARY HYDRAULIC SECTION
9 8 7 6 RB U1 RA 5 3 2
B8 A8
ANB
4k 1 4l U2 4l 4k
1. Section body This section is a series / parallel type, with an open cen-
2. Spool tre and a three position mechanically controlled spool.
3. Seal
Each outlet (A8) and (B8) has :
4l. Load holding check valve
5. O-ring - A load holding check valve (4l)
6. Stop washer
There is no secondary safety valve in this section. The
7. Stop cups
pressure is limited by the main relief valve located in
8. Spring
the outlet plate of the front loader control valve .
9. Snap ring
10. Cap A plug (11) replaces each secondary safety valve.
11. Plug Load holding check valve - 4l
A -Dipper extending supply via port (A8) It enables the load to be held, either at the beginning of
N -Neutral position, open centre supply (gradual valve opening), or during full supply,
B -Dipper retracting supply via port (B8) when the required operating pressure is higher than the
pressure setting of the main relief valve (3f).

Free page

"REAR BACKHOE" CONTROL VALVE OUTLET PLATE (4L)
5 6 7
4p
8
1
U1
RB RA
4i
3
U2 2
T
1. Section body The outlet plate receives flow from the series passage
2. Pilot spool (U1) (if all the sections are in neutral) and the return
3. Regeneration spool flow from the sections via the passages (RA and RB)
4i. Outlet plate and directs them to the reservoir via port (T).
The outlet plate has a regeneration valve (4p) which is
5. Spring
6. O-ring piloted by the pressure existing in the parallel passage
(U2).
7. Plug
Regeneration valve - 4p
8 Regeneration check valve
This valve prevents the return flow from the operating
section via (RA) and (RB) returning to the reservoir
until the supply pressure in the parallel passage (U2)
moves the pilot spool (2) and opens the regeneration
spool (3).
This enables the oil in the return circuit to be used to
supply additional flow for the forced feed of the swing
(4b) and boom (4c) sections, and prevent cavitation
on the U2 passage.
For further information see the following page.

"REAR BACKHOE" CONTROL VALVE REGENERATION FUNCTION (4P)
RA/RB
Description :
U2 U1 4a. Inlet plate
4c. Boom section
4i. Outlet plate
4j. Main forced feed check valve
P1. Flow inlet (Q1)

P2. Flow inlet (Q2)
U1. Series passage
A2. Boom lowering feed (large chamber)
B2. Boom raising supply (small chamber)
RA.Return passage from ports (A)
RB.Return passage from ports (B)
Neutral position
- The supply from the pump (Q1) enters the control valve at
(P1) via the inlet plate (4a).
It flows through the control valves via the series passage (U1)
and returns to the reservoir via the outlet plate (4i) at (T).
- The flow from the pump (Q2) enters the block at (P2) via the
RA/RB outlet plate (4i), then passes through the parallel passage (U2),
joins flow (Q1) to pass through the series passage (U1) and
returns to the reservoir.
oom raising position

- The boom section spool (4c) is pulled out.
This closes the series passage (U1) and causes the pump (Q1) flow to pass through the parallel passage (U2)
- The flow from the pump (Q2) enters at (P2) into the parallel passage (U2).
- The supply pressure increases, opening the load holding check valve (4l), and allowing flow to the boom cylinder
small chamber via port (B2).
- The supply pressure also opens the regeneration valve pilot (4p), located in the outlet plate (4i).
- The return flow from the boom cylinder large chamber enters the control valve at (A2), passes via the return pas-
sage (RA) and returns to the reservoir via the regeneration valve (4p) held open by the boom supply pressure.
The boom lowering position
- The boom section spool (4c) is pushed in.
This closes the series passage (U1) and causes the pump flow to pass through the parallel passage (U2) to open
the load holding check valve (4l) and supply the boom cylinder large chamber via port (A2).
- The load in the bucket, plus the weight of the backhoe increases the speed of the lowering.
The flow from the pumps is not sufficient to fill the cylinder quick enough, so there is risk of cavitation.
- When the backhoe is being driven downwards, the supply pressure is reduced and the regeneration valve (4p) clo-
ses, this prevents the return flow from the boom cylinder small chamber going to the reservoir.
Instead this flow is directed into the boom cylinder large chamber via the forced feed check valve (4m).
- Forced feed continues as long as the supply pressure is lower than the pressure setting of the regeneration valve
spring (23 bar).
Remark
The check valve (4j), located in the inlet plate (4a), provides a force feed function to the sections whithout forced feed
check valves.

STABILIZER SAFETY CHECK VALVE (19 / 20)
4d Description :
2
2. Pilot spool
4d. Right Stabiliser control section
15. Right Stabiliser cylinder
19a. Check valve
19b. Pilot spool
19c. Section body
19d. Spring
Purpose :
B3 A3 These piloted check valves (19) and
19c 19b 19a 19d (20) are in the circuit between the
stabiliser control sections (4d) and
A (4e) and each cylinder (15) and
(16).
They prevent the stabilisers raising
B (because of internal or external lea-
kage) when the control spools are in
the neutral position.
15
Operation :
N - Stabiliser section spool in neutral position
There is no flow from the stabiliser section port (A3) to the safety check valve (19) port (A) or from the stabiliser sec-
tion port (B3) to the safety check valve (19) port (B). The check valve (19a) is closed by its spring (19d) and the oil in
the circuit from port (C) to the cylinder (15) is locked in.
A - Stabiliser section spool is pushed in
The oil flows from port (A3) to the safety check valve (19) port (A) and pushes open the check valve (19a). The oil
flows past the check valve to port (C) then to the cylinder (15) large chamber (stabiliser lowering).
B - Stabiliser section spool is pulled out
The oil flows from port (B3) to the cylinder (15) small chamber and also to the safety check valve pilot port (B).
The return flow from the cylinder large chamber is stopped by the check valve (19a). This causes an increase in
pressure at port (B3) and the safety check valve pilot port (B). This pressure moves the pilot spool (19b) which
opens the check valve (19a).
The return circuit is now open and the flow can return to the reservoir via the stabiliser section (4d).
NOTA : The function of the left stabiliser safety check valve (20 ) is the same as explained above.

CYLINDERS
Disassembly of all the
cylinders :
All the cylinders are of identical
design in regard to the piston and
the bearing, only the diameters of
the rods and pistons are different.
Reconditioning of the cylinders is
very simple but does require special
tooling for installing the gland seals.
Reference numbers for special

tools to be used
- CAS 1659 for rods diameter 25
mm
mm to 38 mm
mm
Installing the piston retaining

screw
- Make sure that the threads of the
screw and the rod are clean and
dry.
- Smear "loctite 242" on the first
thread of the screw.
Operation : - Tighten the screw to the torque
setting shown in the service
Boom piston end of stroke shock valve manual.
This valve is located in the boom cylinder piston and is between the small
and large chambers. Installing the gland
This valve enables the rod extending speed to be controlled when the pis- - Tighten the gland to a torque of
ton reaches the end of the stroke so reducing the shock of the piston on 13.5 to 54.2 mdaN (100 to 400 lb ft).
the bearing stop.
- All the cylinder glands on the
Checking the end of course valve pressure setting machine are tightened to the same
- Remove the two cylinder supply hoses. torque setting.
- Connect a manual pump, fitted with a 450 bar (6000 psi) pressure gauge - Drill another threaded hole of a
at the small chamber outlet port. depth of 11 mm to enable the gland
locking screw to be inserted.
- Do not plug the union.
- Pump to purge the air from the circuit and plug the union.
- Pump to check the pressure at which the valve opens.
- The pressure setting value should be about 345 bar (4900 psi).
- This valve is not adjustable and must be replaced if the pressure is incor-
rect.

SIDE SHIFT LOCKING SOLENOID VALVE (10))
y10
Description :
10a. Body
10b. Check valve
10c. Sleeve
10d. O-ring
10e. Pilot spool spring
10f. Sleeve spring
10g. Main spool
10f
10c 10h. Pilot spool
10b 10i. Orifice
Y10. Solenoid
10a
S2. Pressure inlet from "front
loader" control valve block
T. Return to reservoir
V. Supply to the 4 side shift
10g locking cylinders
10h
10d
V
E
10e
10i
S2 T
Operation :
This valve is supplied from the supply line (S2) at the loader control valve block outlet (3). The oil enters the sole-
noid valve (10a) at port (S2) flows through the orifice (10i) and opens the check valve (10b).
Locking
With the solenoid (Y10) NOT energised , the oil is directed to the side shift locking cylinders (11) which lock the
rear backhoe to the side shift.
The oil also has access around and inside the solenoid spool (10g) with equal pressures but the spring holds the
spool on its seat.
Unlocking
With the solenoid energised, the pilot spool (10h) is lifted from its seat. The pressure drop created above the orifice
(E) enables the main spool (10g) to lift the spool off its seat and allow the oil from the cylinders to return to the
reservoir (T).
The supply at port (S2) can also flow to the reservoir via the energised solenoid valve but the orifice (10i) limits this
flow.

CHECKING THE 580SM PRESSURE SETTINGS
Correct temperature
The hydraulic system oil must be at least 54 C before con-
ducting pressure tests.
This can be achieved by holding the bucket control in the
closed position for 15 seconds at a time.
This operation must be repeated until the correct operating
temperature is reached.
Adjusting the main valve - 3f
The main relief valve (3f), which is located in the outlet
plate of the "front loader" control valve, protects the "front
loader" circuits and those of the "rear backhoe".
6
- Connect the pressure gauge (250 bar) to the pressure
test point located on the inside of the left hand section of
the chassis at (6).
- Run the engine at 2200 rpm.
- The minimum pressure should be around 20 bar
- Hold the "front loader" bucket control lever in the closed
3k 3g
position.
- The pressure reading should be between 210 and 215
bar.
- If the reading is outside those limits, the main valves
must be adjusted.
Adjusting the steering valve - 8a
(See SECTION 5 : STEERING SYSTEM)
Adjusting the sequencing valve - 5
Two valves (5c) (see page : 8.24) are located on the cap
end of the sequencing valve.
To adjust these valves, they must be removed from the
sequencing valve and fitted on a test block (CAS - 1205), 3f
which is then connected to a manual pump.
Using the manual pump, check the pressure at which the
valves open, see the table of specifications (page 8.7) to
find the pressure setting values.
Adjusting the secondary valves
Two secondary relief valves (3g) are fitted in the "front loa-
der" control valve bucket section.
Eight secondary relief valves (4k) are fitted in the "rear
backhoe" control valve section for swing, boom, dipper and
bucket. 5c
All these valves are checked by means of a manual pump.
The values are shown in the table of specifications (page
8.7)..

TESTING THE 580SM USING THE FLOWMETER

Pump (Q1)
1 - Remove the cap with the pressure test port.
2 - Install the flowmeter inlet tube in its place.
3 - Disconnect and plug the supply tube to the "loader control valve".
4 -Install the flowmeter outlet tube directly into the hydraulic reservoir (make sure it is secure).
5 - Start the engine and run it at full speed.
6 - Use the flowmeter to increase the oil temperature in the hydraulic system to 54C.
7 - Run the engine at 2200 rpm.
8 - Open the flowmeter valve completely and read the flow reading. Make a note of it.
9 - Gradually close the flowmeter valve to the pressures in the table below and note the readings :
Q1 PUMP PRESSURE FLOW

RESULTS Bar Psi Litre/min. UK gal/min.
A 0 0
B 34.5 500
C 69.0 1000
D 103.5 1500
E 138.0 2000
Pump (Q2) identical except :

1 and 2 - Connect the tube coming from the pump to the flowmeter inlet.
3 - Disconnect and plug the "rear backhoe" control valve supply tube.
Q2 PUMP PRESSURE FLOW

RESULTS Bar Psi Litre/min. UK gal/min.
A 0 0
B 34.5 500
C 69.0 1000
D 103.5 1500
E 138.0 2000
If the results obtained for test (A) (without load) are lower than 103 litre/min for (Q1), or 35 litre/min for (Q2), check
for one of the following problems :
- The hydraulic pump inlet tube is blocked or is drawing air.
- The hydraulic pump is excessively worn.
To check the efficiency of the pump, Flow at (E)
the following calculations must be performed : Efficiency = X 100
If the output of the pump is greater than 70 %,
Flow at (A)
it is satisfactory.

ADJUSTING THE BUCKET AUTOMATIC DEVICES

Adjusting the anti-dumping system :
- Check that the cable (E) / clevis (F) assembly measures D S23 B
about 69 cm.
- Position the bucket pivot pins about 1.10 m from the
ground.
- Close the bucket and raise the loader arms to their
maximum extent.
- The bucket side blade should be approximately
horizontal.
- Adjust if necessary by screwing the clevis (F) in or out A
(lengthen the cable to increase the anti-dumping effect,
shorten it to reduce the anti-dumping effect).
Return to level operation : F E

The position of the bucket is determined by a micro-switch
(S23) which is controlled by a cam (D).
With the return to level switch ON, it provides an electrical
supply to the spool detent solenoid (3i) which will hold the
spool in position A when pushed to that position by the ope-
rator. When the cam contacts the micro-switch the circuit is
broken, denergising the solenoid and allowing the spool to
return to neutral. D
However if the bucket is already too open the micro-switch
cannot touch the cam so preventing an electrical supply to
the detent solenoid (3i).
Adjusting the bucket return to dig:

- Park the machine on a flat surface and apply the hand-
brake. Lower the bucket flat to the ground.
- Stop the engine.
- Loosen screw (A) and move the bracket (B) with micro-
switch (S23) until the roller touches the cam (D). Tighten
the screw (A).
Checking correct operation
- Start the engine. Raise the loader arms and open the
bucket. S23
- Run the engine at full speed.
B
- Engage the bucket Return to Dig. The arms should
lower and the bucket should close.
- Check the position of the bucket.
- If the bucket is not closed enough adjust the micro-
switch (S23) forward and vice-versa
- Check the operation and the correct position of the buc-
ket in a real cycle.

RIDE CONTROL OPTION

Description :
1
1. Hydraulic reservoir
3. "Front loader" control valve
32. Ride control solenoid valve (accumulator)
33. Ride control solenoid valve (return to reservoir)
34. Accumulator
Y25. Ride control solenoid valve coil (accumulator)
Y26. Ride control solenoid valve coil (return to reser-
voir)
Operation :
32
"Ride Control" is a device which improves operating
33 conditions for the backhoe-loader on all types of terrain,
with the bucket full or empty. It reduces front and rear
roll during driving.
This enables loading or transporting to be carried out at
3 a higher speed, giving increased productivity and more
comfortable driving conditions for the operator.
The ride control system is a shock absorber which sta-
bilises bucket loading.
34 The solenoid valve (32) provides a connection between

the pressure in the cylinder large chambers and the
nitrogen accumulator (34). If the weight of the bucket
Y25 has a tendency to cause the machine to tip over, the
excess pressure generated is absorbed by the accumu-
lator, the arms are lowered a little, thus preventing the
Y26 whole machine from rolling.
The second solenoid valve (33) connects the cylinder
small chambers with the reservoir return line to enable
the loader arms to be raised again when required.
Ride Control Switch :
A switch (S51) is located on the RH console. Placing
the switch in the ON position switches on the anti-roll
system and causes the indicator lamp (H20) to light up.
When the switch is placed in the OFF position the indi-
cator lamp (H20) goes out and immediately deactivates
the ride control.
When should the ride control be switched off?
The only time that the ride control should be switched

off is when the bucket and the loader arms are used in
delicate earthmoving operations or when using the bac-
khoe.
During such operations the operator has no control of
his position. Ride control must also be switched off
when a load in the bucket (or any other mechanism)
has to be accurately positioned.

RIDE CONTROL
+
-
33 RD
Y26
T
+
-
32 HD
34
Y25
ACC
+ +
- -
+ +
- -
RIDE CONTROL OFF RIDE CONTROL ON

Ride control accumulator pressure at 20 +Celcius : 25 +/- 1bar


Centre de Formation
RN 330 Penchard
77122 MONTHYON
Tl : 01.64.36.54.70 / 33.1.64.36.54.70
Fax : 01.64.36.54.89 / 33.1.64.36.54.89

MF 580SM GB

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LOADER BACKHOE

CONTENTS ......................................................................................................................... Page

580 SM CHASSIS DESIGN....................................................................................................................................1.3

STALL TESTS ........................................................................................................................................................1.4

MAINTENANCE TABLE .........................................................................................................................................1.5

RECOMMANDED SERVICING PRODUCTS.........................................................................................................1.6

Issued 04 - 2002Printed in France

The "580 SM" is a CASE Backhoe-Loader. The main com-

Issued 04 - 2002 Printed in France

The chassis frame is a welded structure.

TWO TYPES ARE AVAILABLE :

- Chassis for axial backhoe version

Issued 04 - 2002Printed in France

MACHINE CONDITION - STALL TESTS

2. TRANSMISSION STALL TEST

3. HYDRAULIC SYSTEM STALL TEST

4. STALL TEST SPEEDS (rpm)

COMBINED 1410 1790 1040 1500

Issued 04 - 2002Printed in France

MAINTENANCE OPERATIONS MAINTENANCE INTERVALS IN WORKING HOURS

Check the hydraulic oil level ........................................ X

Grease the Extendahoe pedal linkages....................... X

Change the fuel filter ................................................... X

RECOMMENDED SERVICING PRODCTS

SERVICING PRODCT CAPACITY

AIR CONDITIONING FLUID R134a 1,82 Kg

PINS and BUSHES GREASE with MoS2

Issued 04 - 2002 Printed in France

PRESENTATION OF CASE 4T-390 ENGINE ........................................................................................................2.2

GENERAL SPECIFICATIONS OF CASE 4T-390 ENGINE ....................................................................................2.5

AIR FILTER ............................................................................................................................................................2.6

FAN WITH VISCOUS COUPLING .........................................................................................................................2.7

Issued 04 - 2002 Printed in France

PRSENTATION DU MOTEUR TURBO "CASE 4T-390"

Issued 04 - 2002 Printed in France

CASE 4T-390 TURBO ENGINE PRESENTATION

For more information, refer to : G2

The main specifications :

Issued 04 - 2002 Printed in France

CASE 4T-390 TURBO ENGINE PRESENTATION

The fuel is supplied by the fuel lift pump (6) which

The engine oil sump design allows the engine to R1

Issued 04 - 2002 Printed in France

GENERAL SPECIFICATIONS OF THE "CASE 4T-390 / 67-1" ENGINE

Make of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CASE 4T-390 / 67-1

Engine speeds in rpm

Stall test speeds in rpm

Engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 to 3.7 bar

Valve clearance cold

Engine oil capacity

Coolant solution capacity (without heater). . . . . . . . . . 15.8 litres

Fuel tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 litres

Alternator at 6000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Amps

Starter motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 kW

Issued 04 - 2002 Printed in France

Make of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CASE 4T-390 / 66-2

Engine speeds in rpm

Stall test speeds in rpm

Engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 to 3.7 bar

Valve clearance cold

Engine oil capacity

Coolant solution capacity (without heater) . . . . . . . . . 15.8 litres

Fuel tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 litres

Alternator at 6000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Amps