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580 SM
English version
Aprill 2002 Training Center
580SM Training manual 1.1
580 SM INTRODUCTION.......................................................................................................................................1.2
580 SM INTRODUCTION
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
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
CONTENTS........................................................................................................................................................ Page
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
B6 B7
Lubricating system :
15
Thermostat opening
- Starts to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83C
- Fully open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95C
Thermostat opening
- Starts to open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83C
- Fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95C
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
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.
ELECTRICAL SCHEMATIC
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
ELECTRICAL SCHEMATIC (PLATE 3) ................................................................................................................. 12
ELECTRICAL SCHEMATIC (PLATE 4) ................................................................................................................. 14
ELECTRICAL SCHEMATIC (PLATE 5) ................................................................................................................. 16
ELECTRICAL SCHEMATIC (PLATE 6) ................................................................................................................. 18
ELECTRICAL SCHEMATIC (PLATE 7) ................................................................................................................. 20
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.
Undercarriage earth
N Cable number
Bulbs
Bulb test
Diodes
Harness connectors
X Shows the location where the connection should take place (the circuit is in fact completed)
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
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
Cre 9-43270FR Edition 03-02
4-8 580SM training manual
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
Connector X1
N fil N fil
3 A3 28 N4
21B A4
S4
F7-F14-F16-H1 N See schematic plate 1 page 9
B3 K18-X26
P See schematic plate 1 page 9
S5
CS02B579
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
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
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
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
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
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
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
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
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
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
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
401 P B50 30
10 501
X18(D) 10
V50
502
Y36 Y37 Y38 310
30
10
10
30
X26 X27
CI02B536
E5-S2-X1
S22-H13
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
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
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
CI02C504
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
30 1.32 Black Accessories Earth
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
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
30 1.32 Black Accessories Earth
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
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
57
3 1
S33
4
70
H15
S34
2
70
71 - 59
71 - 70
59
57
Y11
CI00C516
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
Wire section
Cable Number Wire colour
mm2
57 1.32 Red
10 1.32 Black
401 1.32 Grey
CM00C045
310
1 4
313 - 310
B50
CI00C514
S58 H28
1 501 1.32 Light blue
502 1.32 Light blue
3
2
H4
CI00C515
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)
STEERING UNIT
36 35 49 47 42 39
34 51
38
43
41
37
46
40
53 39
48
56 44 45
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
20
21
3
5
1
21
20
23 17
8 22
10
11 14
9 16
15 5
14
12
13
9
11
8
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.
Y Y
X X
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.
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
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).
5j 5a 5o 5b 5k
P2 P1
A
5q 5k 5l 5m 5n 5p 5q
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.
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.
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
Y7
Y7
Y35 22
Y6
Y6
22
21a
21a
16
18 T
T 23
T
23
C
17 T C
P
P
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
Figure 1
NEUTRAL
Y7 Y6
S2
Y35
22
21b
T
21a
18 23
C
T
S1
17
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
Figure 3
21b
T 21a
23
C
18 T
S1
17
Sump Pressure Pump Pressure
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.
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).
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
Issued 04-2002 Printed in France
580SM Training manual 6.17
Neutral idle
Forward idle
Reverse idle
M7
M6
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.
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.
FWD
+
Stabili-
zer
FWD
+
NEU-
TRAL at
+ 12V
FWD
+
Neutral
at +12V
+
6 sec
9g
B3
9i
8a
9e
9h
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)
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
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
21. Hydraulic filter
S14. Brake light switch
P1. Oil inlet to LH oil-bath disc brake
P2. Oil inlet to RH oil-bath disc brake
21
Operating principle :
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
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
1f
1d
au rservoir 1a
en pression
8c 8d 8e 8f 9e 8g 8h
8i
P1
8b
8j
8a 8z 8t
8k
8r 8q 8p 8k 8n 8m 8l
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
Operating principle :
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.
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
7. Hydraulic oil cooler
8. Steering control valve
9. Fuel tank
10. Side shift locking solenoid valve
11. Side shift locking cylinders
12. Swing cylinder
13. Swing cylinder
14. Steering 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
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).
)(
)(
3m A2 X
3i. Detent solenoid (Y9)
3p. Plug S2 3e
4. "Rear backhoe" control valves
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.
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)..
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
3f
3h
3e
S2
Description : Operation :
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.
P S1
LS
3k
RB RA
P2
3n P1
Drawing A
Drawing B
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.
RB
P1 2
B1 A1
RA
ANB
3i
3g 3g
3h P2 3h
3m 3m
3j
1 P2
3p 3h 3h 3p
P1
(F) - Floating position A2
RB B2 RA FANB
3j
1
3p 3h P2 3h 3p
Description : Operation :
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
P1
RB A3 RA
B3
ANB
3h P2 3h
3p 1 3p
3m 3m
Description : Operation :
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.
3f
3e
S2
1
3l
P1
RA
RB
P2
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.).
4i 4h 4g 4f 4e 4d 4c 4b 4a
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
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
4p. Flow regeneration valve
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
U1
RA RB
U2
7 2 3 5
P1
4j
Description : Operation :
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
U2. Parallel passage
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)
9 8 7 6 B1 A1 5 3 2
10
RB RA
4k 4k
4m 4l 4q 4l 4m
Description : Operation :
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.
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.
C D B
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
T. Outlet to reservoir
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
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.
E 5d
5c 5c A
20 to 40 %
B
4b
5c E 5d 5c A
40 to 60%
B
4b
5c E 5d 5c A
5
60 to 80%
5c E 5d 5c A
80 to 100 %
B
4b
RB RA
U1
B2 A2 5
8 7 6
3
ANB
9
10
2
U2
4k 4k
1
4l 4l 4m
Description : Operation :
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).
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
Description : Operation :
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).
RB
U1 RA
B5 A5 5
8 7 6
9 3 ANB
10
2
4k 4k
1 4l U2 4l
4m 4m
Description : Operation :
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.
4k. Secondary relief valve
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)
RB
U1 RA
B6 A6 5
8 7 6
9 3 ANB
10
2
4k 4k
1 4l U2 4l
Description : Operation :
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.
4k. Secondary relief valve
4l. Load holding check valve Each outlet (A6) and (B6) has :
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)
RB
U1 A7 RA
B7 5
8 7 6
9 3 ANB
10
11 11
1 4l U2 4l
Description : Operation :
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
4l. Load holding check valve Each outlet (A7) and (B7) has :
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).
9 8 7 6 RB U1 RA 5 3 2
B8 A8
ANB
4k 1 4l U2 4l 4k
Description : Operation :
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
5 6 7
4p
8
1
U1
RB RA
4i
3
U2 2
T
Description : Operation :
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).
4p. Flow regeneration valve
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.
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.
- 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.
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.
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.
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.
RIDE CONTROL
+
-
33 RD
Y26
T
+
-
32 HD
34
Y25
ACC
+ +
- -
+ +
- -