580 SM Service 3 PDF

SECTION INDEX
GENERAL
Section Title Section Number

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001
Fluid and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002
Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Copyright © 2008 CNH America LLC.

CNH America LLC. All rights reserved.
700 State Street Printed in U.S.A.
Racine, WI 53404 U.S.A. Bur 5-11910 Issued March, 2008
1001
Section
1001
GENERAL TORQUE SPECIFICATIONS

CASE, LLC. All rights reserved.
Racine, WI 53404 U.S.A. Bur 8-71603 Issued April, 2003 Revised July, 2005
1001-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bur 8-71603 Revised 7-05 Printed in U.S.A.

1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques
are not given. These torques apply to fasteners with Grade 8 Bolts, Nuts, and Studs
both UNC and UNF threads as received from
suppliers dry, or when lubricated with engine oil. Not
applicable if special graphities, Molydisulfide
greases, or other extreme pressure lubricants are
Pound- Newton
used.
Size Inches metres
1/4 inch 144 to 180 16 to 20
Grade 5 Bolts, Nuts, and Studs
5/16 inch 288 to 348 33 to 39
3/8 inch 540 to 648 61 to 73
Pound- Newton Pound- Newton

Size Inches metres Size Feet metres
1/4 inch 108 to 132 12 to 15 7/16 inch 70 to 84 95 to 114
5/8 inch 220 to 264 298 to 358
Pound- Newton 3/4 inch 380 to 456 515 to 618
Size Feet metres
7/8 inch 600 to 720 814 to 976
7/16 inch 54 to 64 73 to 87
1.0 inch 900 to 1080 1220 to 1465
1/2 inch 80 to 96 109 to 130
1-1/8 inch 1280 to 1440 1736 to 1953
9/16 inch 110 to 132 149 to 179
1-1/4 inch 1820 to 2000 2468 to 2712
5/8 inch 150 to 180 203 to 244
1-3/8 inch 2380 to 2720 3227 to 3688
3/4 inch 270 to 324 366 to 439
1-1/2 inch 3160 to 3560 4285 to 4827
7/8 inch 400 to 480 542 to 651
NOTE: Use thick nuts with Grade 8 bolts.
1.0 inch 580 to 696 787 to 944
1-1/8 inch 800 to 880 1085 to 1193
1-1/4 inch 1120 to 1240 1519 to 1681
1-3/8 inch 1460 to 1680 1980 to 2278
1-1/2 inch 1940 to 2200 2631 to 2983

1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not
given. Grade 10.9 Bolts, Nuts, and Studs
These values apply to fasteners with coarse threads
as received from supplier, plated or unplated, or 10.9
when lubricated with engine oil. These values do not
apply if graphite or Molydisulfide grease or oil is Pound- Newton
used. Size Inches metres
M4 36 to 48 4 to 5
Grade 8.8 Bolts, Nuts, and Studs M5 84 to 96 9 to 11
M6 132 to 156 15 to 18
8.8
M8 324 to 384 37 to 43
Pound- Newton
Size Inches metres Pound- Newton
M4 24 to 36 3 to 4 Size Feet metres
M5 60 to 72 7 to 8 M10 54 to 64 73 to 87
M6 96 to 108 11 to 12 M12 93 to 112 125 to 150
M8 228 to 276 26 to 31 M14 149 to 179 200 to 245
M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

M20 450 to 540 610 to 730
Pound- Newton M24 780 to 940 1050 to 1275

Size Feet metres M30 1470 to 1770 2000 to 2400
M12 66 to 79 90 to 107 M36 2580 to 3090 3500 to 4200
M14 106 to 127 144 to 172
Grade 12.9 Bolts, Nuts, and Studs
M16 160 to 200 217 to 271
M20 320 to 380 434 to 515
12.9
M24 500 to 600 675 to 815
M30 920 to 1100 1250 to 1500
Usually the torque values specified for grade 10.9
M36 1600 to 1950 2175 to 2600 fasteners can be used satisfactorily on grade 12.9
fasteners.

1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting Straight Threads with O-ring

Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton
Hose ID Size Inches metres Hose ID Size Inches metres
1/4 inch 7/16-20 72 to 144 8 to 16 1/4 inch 7/16-20 144 to 228 16 to 26
6.4 mm 6.4 mm
7.9 mm 7.9 mm
9.5 mm 9.5 mm
12.7 mm 12.7 mm
5/8 inch 7/8-14 300 to 696 34 to 79
15.9 mm Tube OD Thread Pound- Newton
Hose ID Size Feet metres
Tube OD Thread Pound- Newton 5/8 inch 7/8-14 58 to 92 79 to 124
Hose ID Size Feet metres 15.9 mm
3/4 inch 1-1/16-12 40 to 80 54 to 108 3/4 inch 1-1/16-12 80 to 128 108 to 174
19.0 mm 19.0 mm
7/8 inch 1-3/16-12 60 to 100 81 to 135 7/8 inch 1-3/16-12 100 to 160 136 to 216
22.2 mm 22.2 mm
1.0 inch 1-5/16-12 75 to 117 102 to 158 1.0 inch 1-5/16-12 117 to 187 159 to 253
25.4 mm 25.4 mm
1-1/4 inch 1-5/8-12 125 to 165 169 to 223 1-1/4 inch 1-5/8-12 165 to 264 224 to 357
31.8 mm 31.8 mm
1-1/2 inch 1-7/8-12 210 to 250 285 to 338 1-1/2 inch 1-7/8-12 250 to 400 339 to 542
38.1 mm 38.1 mm
Split Flange Mounting Bolts

Pound- Newton
Size Inches metres
5/16-18 180 to 240 20 to 27
3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61
Pound- Newton
Size Feet metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203

1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
O-ring Boss End

O-ring Face Seal End Fitting or Lock Nut
Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube OD Size Inches metres Size Inches metres
-4 1/4 inch 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27
6.4 mm
-6 3/8 inch 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
9.5 mm
-8 1/2 inch 13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
12.7 mm
Thread Pound- Newton

Size Feet metres
-10 5/8 inch 1-14 552 to 672 62 to 76 7/8-14 60 to 65 81 to 88
15.9 mm
Nom. 1-1/16-12 85 to 90 115 to 122

SAE
Dash Thread Pound- Newton 1-3/16-12 95 to 100 129 to 136
Size Tube OD Size Feet metres
-12 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-5/16-12 115 to 125 156 to 169
19.0 mm
-14 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-5/8-12 150 to 160 203 to 217
22.2 mm
-16 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-7/8-12 190 to 200 258 to 271
25.4 mm
-20 1-1/4 inch 1-11/16-12 125 to 140 170 to 190
31.8 mm
-24 1-1/2 inch 2-12 150 to 180 200 to 254
38.1 mm

1002
Section
1002
FLUIDS AND LUBRICANTS

1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications for Acceptable No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DYE AND BLACK LIGHT PROCEDURE FOR DETECTING OIL LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bur 5-11920 Issued 3-08 Printed in U.S.A.

1002-3
CAPACITIES AND LUBRICANTS

Engine Crankcase
All Machines ............................................................................................................... 13.6 liters (14.4 U.S. quarts)
Specifications .......................................................................................... Case AKCELA No. 1 15W-40 API CH-4
Fuel Tank
Capacity, usable (580M and 580SM) .........................................................................119 liters (31.4 U.S. gallons)
Capacity, usable (580SM+, 590SM and 590SM+) ........................................................159 liters (42 U.S. gallons)
Optional tank (580M and 580SM only).............................................................. 151 liters (40 U.S. gallons) usable
Specifications ...................................................................................................................................... See page 6
Cooling System
Capacity with heater (580M) ..................................................................................... 16.8 liters (17.8 U.S. quarts)
Capacity without heater (580M) ................................................................................... 16.1 liters (17 U.S. quarts)
Capacity with heater (580SM, 580SM+, 590SM and 590SM+)....................................... 18 liters (19 U.S. quarts)
Capacity without heater (580SM, 580SM+, 590SM and 590SM+)............................ 17.3 liters (18.3 U.S. quarts)
Specifications ............................................................................................... 50% water and 50% ethylene glycol
Hydraulic System
Total System
580M ................................................. 98.2 liters (25.95 U.S. gallons) add 5.7 liters (6 U.S. qts) for extendahoe
580SM and 580SM+ ....................... 111.5 liters (29.45 U.S. gallons) add 5.7 liters (6 U.S. qts) for extendahoe
590SM and 590SM+ .......................... 122 liters (32.20 U.S. gallons) add 5.7 liters (6 U.S. qts) for extendahoe
Capacity with filter change .....................................................................................47.1 liters (12.45 U.S. gallons)
Capacity without filter change ................................................................................45.2 liters (11.95 U.S. gallons)
Specifications ........................................................................................................ Case AKCELA Hy-Tran® Ultra
Transmission
Standard Transmission
2 Wheel Drive
Total system capacity ............................................................................................... 17 liters (18 U.S. quarts)
Refill capacity with or without filter change ......................................................... 10.5 liters (11.1 U.S. quarts)
Type of Fluid .................................................................................................... Case AKCELA Hy-Tran® Ultra
4 Wheel Drive
Total system capacity .......................................................................................... 19.4 liters (20.5 U.S. quarts)
Refill capacity with or without filter change ............................................................. 13 liters (13.7 U.S. quarts)
Powershift Transmission
4 Wheel Drive
Total system capacity ............................................................................................. 17.9 liters (19 U.S. quarts)
Refill capacity with or without filter change ............................................................. 11.3 liters (12 U.S. quarts)
Type of Fluid ................................................................................................... Case AKCELA Hy-Tran® Ultra
Front Drive Axle - 4 Wheel Drive
580M and 580SM
Capacity - center bowl .............................................................................................. 5.5 liters (5.8 U.S. quarts)
Capacity - each wheel end .................................................................................... 0.71 liters (0.75 U.S. quarts)
Type of Fluid.........................................................Wet Brake/Transmission Lubricant - SAE 80W140 MAT3510
580SM+
590SM and 590SM+
Capacity - each wheel end ......................................................................................0.65 liter (0.69 U.S. quarts)

1002-4
Rear Axle
580M and 580SM
Capacity ................................................................................................................. 13.6 liters (14.4 U.S. quarts)
580SM+, 590SM and 590SM+
Capacity - center bowl .......................................................................................... 18.6 liters (19.7 U.S. quarts)
Brake Master Cylinder .................................................................................... (Brake fluid supplied by transmission.)
ENGINE OIL RECOMMENDATIONS

Case AKCELA No.1 Engine Oil is recommended for
use in your Case Engine. Case AKCELA No.1
Engine Oil will lubricate your engine correctly under
all operating conditions. If Case AKCELA No. 1
Multi-Viscosity Engine Oil is not available, Case
AKCELA No. 1 Single Grade Engine Oil can be used.
I f C a s e A K C E L A N o. 1
Multi-Viscosity or Single Grade
Engine Oil is not available, use
only oil meeting API engine oil
service category CH-4.
See the chart for recommended
viscosity at ambient air
RH99K130 temperature ranges.
BD03A102
NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase. The oil intervals
given in the operators manual and service chart are according to tests with Case AKCELA lubricants.

1002-5
BC07N452

1002-6
DIESEL FUEL
Use No. 2 diesel fuel in the engine of this machine. Fuel Storage
The use of other fuels can cause the loss of engine
power and high fuel consumption. If you keep fuel in storage for a period of time, you
can get foreign material or water in the fuel storage
In very cold temperatures, a mixture of No. 1 and No. tank. Many engine problems are caused by water in
2 diesel fuels is temporarily permitted. See the the fuel.
following Note.
Keep the fuel storage tank outside and keep the fuel
NOTE: See your fuel dealer for winter fuel as cool as possible. Remove water from the storage
requirements in your area. If the temperature of the container at regular periods of time.
fuel is below the cloud point (wax appearance point),
wax crystals in the fuel will cause the engine to lose
power or not start.
The diesel fuel used in this machine must meet the
specifications in the chart below or Specification
D975-81 of the American Society for Testing and
Materials.
Specifications for Acceptable No. 2 Diesel Fuel

API gravity, minimum ............................................................................................................................................. 34
Flash Point, Minimum ......................................................................................................................... 60° C (140° F)
Cloud point (wax appearance point), maximum .........................................................-20° C (-5° F) See Note above
Pour point, maximum ............................................................................................... -26° C (-15° F) See Note above
Viscosity, at 100° F (88° C)
Centistokes ................................................................................................................................................. 2.0 to 4.3
Saybolt Seconds Universal ........................................................................................................................... 32 to 40

1002-7
DYE AND BLACK LIGHT PROCEDURE FOR DETECTING OIL LEAKS

Oils and grease have natural phosphors and will illuminate differently under the black light.
Oil, bluish-white, grease, brilliant-white, anti-freeze, greenish-yellow, sealing compounds, red to orange.
Kit part number 380040182 consisting of:
Part Number Description U/M Comments Usage

380002254 Black Light 12 Volt Ultra Violet Light
380002357 Dye-uniglow F2HF 10 ML Glows Green in Black Light Engine Oil/Crankcase
380002358 Dye-uniglow F4HF 65 ML Glows Yellow in Black Light Hydraulic Oil
380002359 Dye-uniglow 1750 10 ML Glows Purple in Black Light Trnasmission Oil
NOTE: Each dye is formulated to work in conjunction with a specific fluid, therefore the dyes are not
interchangeable and should only be used as described.
4. Use the entire contents of the bottle of dye in the
system/systems of the suspected leak.
5. Run the unit for 5 to 10 minutes and cycle
through suspect system functions to ensure that
the dye is available to all possible leak points.
NOTE: The hydraulic oil should be heated to
160° F (71° C), engine at normal operating
temperature, and transmission should be in the
normal operating range on the gauge.
6. Use a clean cloth and wipe the dipstick or the
inside surface of the filler tube on each of the 3
BC05C168 sumps.
1. Prior to adding dye, connect the black light to the
machines battery and investigate suspected 7. View traces of dyed fluid on the cloth under the
areas. black light to ensure good samples.
2. Once suspected leak areas are found, attempt to 8. Use these 3 samples as your baseline when
trace the leak completely to the origin. inspecting the unit with the black light.
NOTE: At the origin, the leak should be the NOTE: High hour engine oil can reduce the
brightest in color. effectiveness of the dye. In this event change the
oil.
3. After confirmation of the suspected leak,
thoroughly clean the area of the leak to remove 9. Avoid common errors.
any existing fluids. Recheck the area with the A. Fan airflow blowing leaking fluid.
black light to assure the area is clean.
B. Gravity pulling leak paths down.
NOTE: Good cleaning is important for the
following reasons. C. When paint at a joint is not broken, the joint is
not leaking.
A. Fluids captured by threaded joints or other
cavities will continue to show signs of leakage NOTE: It is not necessary to change oils after
unless completely clean. this check.
B. Casting surfaces can hold residual oil.

1002-8
NOTES

Section
1003
1003
METRIC CONVERSION CHART
Copyright © 2003 Case, LLC. All rights reserved.

CASE, LLC. Case is a registered trademark of Case, LLC.
Racine, WI 53404 U.S.A. Bur 7-52590 Issued April, 2003
1003-2
TABLE OF CONTENTS
CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1003-3
CONVERSION FACTORS
Metric to U.S.
MULTIPLY BY TO OBTAIN
Area: sq. meter 10.763 91 square foot

hectare 2.471 05 acre
Force: newton 3.596 942 ounce force

newton 0.224 809 pound force
Length: millimeter 0.039 370 inch

meter 3.280 840 foot
kilometer 0.621 371 mile
Mass: kilogram 2.204 622 pound
Mass/Area: kilogram/hectare 0.000 466 ton/acre
Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.
Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.
Power: kilowatt 1.341 02 horsepower
Pressure: kilopascal 0.145 038 lb/sq. inch

bar 14.50385 lb/sq. inch
Temperature: degree C 1.8 x C +32 degree F
Torque: newton meter 8.850 748 lb/inch

newton meter 0.737 562 lb/foot
Velocity: kilometer/hr. 0.621 371 miles/hr.
Volume: cubic centimeter 0.061 024 cubic inch

cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
litre 1.056 814 quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

litre/min. 0.219 969 gallon/min. (Imperial)

1003-4
U.S. to Metric
MULTIPLY BY TO OBTAIN
Area: square foot 0.092 903 square meter

acre 0.404 686 hectare
Force: ounce force 0.278 014 newton

pound force 4.448 222 newton
Length: inch 25.4 * millimeter

foot 0.304 8 * meter
mile 1.609 344 * kilometer
Mass: pound 0.453 592 kilogram

ounce 28.35 gram
Mass/Area: ton/acre 2241 702 kilogram/hectare
Mass/Energy: lb/hp/hr 608.277 4 gr/kW/hr
Mass/Volume: lb/cubic yd. 0.593 276 kg/cubic meter
Power: horsepower 0.745 700 kilowatt
Pressure: lbs/sq. in. 6.894 757 kilopascal

lbs/sq. in. 0.069 bar
lbs/sq. in. 0.070 303 kg/sq. cm
Temperature: degree F 1.8 F - 32 degree C
Torque: pound/inch 0.112 985 newton meter

pound/foot 1.355 818 newton meter
Velocity: miles/hr. 1.609 344 * kilometer/hr.
Volume: cubic inch 16.387 06 cubic centimeter

cubic foot 0.028 317 cubic meter
cubic yard 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallons (Imperial) 4.546 092 litre
Volume/Time: gallon/min. 3.785 412 litre/min.
* = exact

SECTION INDEX
ENGINE

Engine and Radiator Removal and Installation 580M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000
Engine and Radiator Removal and Installation 580SM, 580SM+. 590SM and 590SM+. . . . . . . . . . . . . . . . . . .2000
Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002
In Vehicle Injector Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2445
Counter Balance Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2447
For Engine Repair, See Engine Service Manual 87630273

Section
2000
ENGINE AND RADIATOR REMOVAL

AND INSTALLATION 580M SEREIS 3
2000

2000-2 580M ONLY
TABLE OF CONTENTS
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Illustration Of Radiator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Illustration Of Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MUFFLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HOOD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

580M ONLY 2000-3
RADIATOR
Put identification tags on all disconnected hoses and STEP 3
wires. Close disconnected hoses and fittings with
caps and plugs. 1
NOTE: The photos in this procedure may be
different from your machine and are for reference
only.
STEP 1
1
BD01B367
Open the hood. Connect acceptable lifting equipment

to the hood (1).
STEP 4
BD00G073 2
Park the machine on a level surface. Raise the loader
and lock the support strut (1) to hold the loader. Stop
the engine and apply the parking brake.
STEP 2
1
1
1
2
2 BD03K037
Do the following procedure to remove the hood.

A. Remove the retainers from the hood struts (1)
and disconnect the hood struts from the stud.
3
B. Disconnect the hood cable (2) from the
radiator shroud.
C. Carefully lower the hood back to the closed
BD08A490
position.
Remove the caps screws (1), bumpers (2), and the
grille (3) from the front of the machine. STEP 5
Remove the bolts, washers, and nuts from the pivot
point on the hood.

2000-4 580M ONLY
STEP 6 STEP 8
BD01B311 BS03K007
Drive the pivot tubes out of the hood pivot point. Loosen the clamp and disconnect the upper radiator
Remove the hood from the machine. hose.
STEP 7 STEP 9
BD08A489
Slowly remove the radiator cap. Install a hose on the BP9502290
drain valve and drain the radiator into a clean Loosen the clamp and disconnect the lower radiator
container that holds approximately 17 liters (18 U.S. hose.
quarts).
NOTE: During installation, fill the radiator and
STEP 10
deairiation reservoir to the full line. See Section 1002
for coolant specifications. Start and run the engine
until the coolant is at operating temperature. Stop the
engine and check for leakage. When the coolant is
cold, check the coolant level. Add coolant as
required.
BD08B466
If equipped with air conditioning discharge air

conditioning system, see section 9004. Disconnect
high pressure switch, disconnect hoses from
condenser and receiver drier. Remove the receiver
drier and horn from the machine.

580M ONLY 2000-5
STEP 11 STEP 13
BD03K040 BD08B470
Disconnect all four oil cooler hoses, two on each side Attach suitable lifting equipment to the radiator. Raise
of the machine, from the oil cooler. the cooling pack just enough to move it forward and
clear the fan.
STEP 12 NOTE: During installation, adjust fan shroud to
obtain 5mm (0.8 in) clearance with the fan.
STEP 14
BD08B470
Remove the radiator wrapper mounting bolts, remove

the radiator wrapper from the machine.
BD03K044
Make sure that you have cleared the fan from the
shroud, raise the cooling pack from the machine.
NOTE: Installation of the radiator is the reverse of
removal.

2000-6 580M ONLY
5
6
BS08B326
1. DEAIRIATION TANK 4. MOUNTING BOLTS

2. RADIATOR HOSES 5. OIL COOLER CONNECTORS
3. CLAMP 6. CONDENSER PIVOT BOLT
ILLUSTRATION OF RADIATOR MOUNTING

580M ONLY 2000-7
1. Place cooling pack on a bench, if equipped 8. Install the oil coolers and tighten the mounting
remove the condenser bracket mounting bolts, bolts.
three per side.
9. Install the clamps (3) and torque to 3.1 to 3.4 Nm
2. Remove the cooler line mounting clamps (3), (27 to 30 pound inches).
remove the oil cooler mounting bolts.
10. Install the mounting brackets and tighten the
3. Remove the fan shroud mounting bolts, mounting bolts.
deairiation tank (1), and radiator hoses (2) from
11. If equipped, Mount the condenser into the
the radiator.
bracket using the pivot bolt (6).
4. Install fan shroud and torque bolts to 13 to 25 Nm
12. Tighten the condenser pivot bolt (6) tight enough
(10 to 18 pound feet).
to remove the gaps between the mounting
5. Install deairiation tank (1). brackets but not tight enough to prevent the
condenser from swinging out for cleaning.
6. Install radiator hoses and clamps (2), torque
clamps to 4.5 to 5.5 Nm (40 to 50 pound inches). 13. Swing the condenser into position, install and
tighten retaining bolts.
7. If fittings were removed from the oil cooler, install
fittings and torque to 77 to 85 Nm (57 to 63
pound feet).
IMPORTANT: Use two wrenches to minimize the
torque transmitted into the elbow brazed to the oil
cooler.

2000-8 580M ONLY
ENGINE
wires. Close disconnected hoses and fittings with If the machine is equipped with air conditioning. See
caps and plugs. Section 9004 and discharge the air conditioning
NOTE: The photos in this procedure may be system.
different from your machine and are for reference NOTE: During installation see Section 9004 and
only. recharge the air conditioning system.
STEP 1 STEP 5
Remove the radiator wrapper, fan shroud, radiator, oil
coolers and if equipped with air conditioning the
condenser as an assembly, see radiator removal this
section.
STEP 6
1
BD00G073

and lock the support strut to hold the loader.
2
STEP 2
Remove the battery cover from the right step. If the
machine has only one batter y, disconnect the BS03K12
negative battery cable from the battery. If the machine is equipped with air conditioning,
disconnect the electrical connector (1). Remove the
STEP 3 tie strap (2 ). Disconnect th e hoses fr om the
compressor.
1
3 STEP 7
2
BD08A453
If the machine has two batteries, remove the terminal

nut (1). Remove the negative battery cable (2) from
the terminal and move the negative battery cable BD01B324
away from the battery. Make sure the jumper cable Remove the tie strap. Disconnect the electrical
(3) is installed on the terminal and start the terminal connectors for the air restriction indicator.
nut (2) onto the terminal.

580M ONLY 2000-9
STEP 8 STEP 12
BS03K003
BD01B323
Loosen the clamp on the air cleaner hose at the If equipped, disconnect grid heater positive cable and
turbocharger. Disconnect the air cleaner hose from sensor wires.
the turbocharger.
STEP 13
STEP 9
2
1
BS03K009
BD08A481
Disconnect the electrical connector for the fuel
Disconnect crank case ventilation hose and the
injection pump(1) and oil pressure sender (2).
aspiration hose.
STEP 10 STEP 14
BS03K001
BD01B307
Disconnect the throttle cable from the mounting
Remove the cap screws and flat washers that fasten
bracket.
the fixed hood to the uprights. Remove the fixed hood
and air cleaner as an assembly.
STEP 11
Remove muffler and brackets from engine.

2000-10 580M ONLY
STEP 15 STEP 18
2
1
BS03K002 BS03K004
D i s c on n e c t t h e th r o tt l e r o d ( 1 ). I f e q u i p p e d , Disconnect the wires from the alternator.

disconnect the heater hose (2).
STEP 19
STEP 16
2
BS03K014
BS03K010 Disconnect the heater hose, if equipped.

Disconnect the fuel return line (1) and the fuel input
line (2). STEP 20
STEP 17 1
2 2
2
BS03K005
Disconnect the ground strap (1). Disconnect the

BS03K006 wires (2) from the starter.
Disconnect the coolant temperature sender (1) and
coolant temperature switch (2).

580M ONLY 2000-11
STEP 21 STEP 24
Connect lifting equipment to the lifting eyes on the
engine to hold the engine in place.
STEP 25
BD03K031
Remove the starter from the engine. Remove the

access cover from the bell housing.
STEP 22 BD03K034
Remove the bolts, flat washers, and nuts from the

front engine mount.
NOTE: During installation, tighten the self-locking
nuts to 90 to 100 Nm (67 to 73 lb-ft).
STEP 26
Loosen and remove the 12 cap screws and flat
washers that fasten the transmission to the engine.
Move the heater hose and clamps out of the way.
NOTE: During installation tighten the transmission
cap screws to 52 to 57 Nm (38 to 42 lb-ft).
BC04A195
Install the engine turning tool, 380000988, to turn the STEP 27

flywheel for access to the cap screws. Move the engine forward and raise the engine.
Remove the engine from the machine.
STEP 23 IMPORTANT: Make sure that the flex plate/converter
assembly stays in place on the transmission. If the
engine will be separated from the transmission for an
extended period of time fasten the flex
plate/converter assembly in place on the
transmission.
NOTE: Installation of the engine is the reverse of
removal.
STEP 28
Fill the engine and cooling system, see section 1002
for specifications.
BD03K033
For machines equipped with either a standard or

powershift transmission, loosen and remove four cap
screws that fasten the flywheel to the flex plate.
NOTE: During installation tighten the cap screws to
52 to 57 Nm (38 to 42 lb-ft) for the standard
transmission or the powershift transmission.

2000-12 580M ONLY
1
2
1
2
5
3
2
6 2
6
BS08B234
1. MOUNT BOLT 4. MOUNTING BRACKET

2. WASHER FLAT 5. RUBBER ENGINE MOUNT
3. BOLTS 6. LOCK NUT
ILLUSTRATION OF ENGINE MOUNTING

580M ONLY 2000-13
MUFFLER INSTALLATION
8 1
4
5 9
6 2
7 3
BS08B233
1. MUFFLER 4. BOLTS (2) NUTS (2) AND WASHERS (4) 7. BOLT (1) SPACER (1) AND WASHER (1)
2. BOLTS (2) WASHERS (2) 5. BOLTS (2) NUTS (2) AND WASHERS (4) 8. BOLT (1) NUT (1) AND WASHERS (2)
3. CLAMP “T” BOLT 6. BOLT (1) NUT (1) AND WASHERS (2) 9. ASPIRATION HOSE
IMPORTANT: To prevent damage to the exhaust 5. Tighten front bracket to engine lifting bracket
system do the following procedures in sequence. mounting nuts (4) to a torque of 64 to 75 Nm
1. Assemble muffler (1) to engine with bolts finger
tight. 6. Tighten mounting bolts (5) to engine to a torque
of 64 to 75 Nm (47 to 55 pound feet).
NOTE: All gaps between mounting surfaces should
be eliminated before torque sequence is started. 7. Tighten brace mounting bolt (7) to gear housing
to a torque of 44 to 54 Nm (32 to 40 pound feet).
2. Align muffler flange with turbo and tighten “T” bolt
clamp (3) to 6.5 to 7.5 Nm (57.5 to 66.5 lb-in). 8. Tighten rear brace left hand bolt (8) to muffler to
a torque of 64 to 75 Nm (47 to 55 pound feet).
3. Tighten lower bolts (2) on rear bracket to engine
block to a torque of 64 to 75 Nm (47 to 55 pound 9. When mounting aspiration hose, torque hose
feet). clamps to 3.1 to 3.4 Nm (27 to 30 pound inches).
4. Tighten right hand bolt (6) to muffler to a torque


2000-14 580M ONLY
HOOD INSTALLATION
4
1
10
9
3
2
6
8 7
6 5
10
4
BC03K128
1. TILT HOOD 6. FLAT WASHER

2. RADIATOR WRAPPER 7. PIVOT TUBE
3. FIXED HOOD 8. NUT
4. PIVOT PLATE 9. COUNTER BALANCE SPRING
5. BOLT 10. HOOD RETAINER CABLE
NOTE: Hood is shown disassembled for clarity only. 4. Push tilt hood to the rear to minimize the gap
between side panels and chassis uprights.
1. Mount left and right pivot plates (4) onto frame
finger tight. 5. Tighten left and right pivot plates (4).
2. Place tilt hood (1) onto radiator wrapper (2) and 6. Raise tilt hood (1) just enough to attach the left
fixed hood (3). and right counter balance springs (9) to ball
studs, secure springs with retainer clips.
3. Install pivot tube (7), bolt (5), washers (6), and
nut (8), tighten nut. 7. Attach hood retainer cable (10) to radiator
wrapper.

Section
2000
ENGINE AND RADIATOR REMOVAL

AND INSTALLATION 580SM, 580SM+,
590SM, AND 590SM+ SERIES 3
2000

2000-2 580SM, 580SM+, 590SM, AND 590SM+ ONLY
TABLE OF CONTENTS
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Illustration Of Radiator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Illustration Of Engine Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MUFFLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HOOD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

580SM, 580SM+, 590SM, AND 590SM+ ONLY 2000-3
RADIATOR
wires. Close disconnected hoses and fittings with
caps and plugs. 1
NOTE: The photos in this procedure may be
different from your machine and are for reference
only.
STEP 1
1
BD01B367
Open the hood. Connect acceptable lifting equipment

to the hood (1).
STEP 4
BD00G073 2
Park the machine on a level surface. Raise the
loader and lock the support strut (1) to hold the
loader. Stop the engine and apply the parking brake.
STEP 2
1
1
1
2
2 BD03K037
Do the following procedure to remove the hood.

A. Remove the retainers from the hood struts (1)
and disconnect the hood struts from the stud.
3
B. Disconnect the hood cable (2) from the
radiator shroud.
C. Carefully lower the hood back to the closed
BD08A490
position.
Remove the six caps screws (1), two bumpers (2),
and the grille (3) from the front of the machine. STEP 5
Remove the bolts, washers, and nuts from the pivot
point on the hood.

STEP 6 STEP 8
BD01B311 BS03K007
Drive the pivot tubes out of the hood pivot point. Loosen the clamp and disconnect the upper radiator
Remove the hood from the machine. hose and purge hose from the engine.
NOTE: During installation torque the hose clamp to
STEP 7 4.5 to 5.5 Nm (40 to 50 pound inches).
STEP 9
BD08A489
Slowly remove the radiator cap. Install a hose on the

drain valve and drain the radiator into a clean
container that holds approximately 17 liters (18 U.S.
BS03K007
quarts). Loosen the clamps, disconnect and remove charge
NOTE: During installation, fill the radiator and air cooler hoses and pipes.
deairiation reservoir to the full line. See Section 1002 NOTE: During installation torque the charge air
for coolant specifications. Start and run the engine cooler hose clamps to 11 to 12 Nm (8 to 9 pound
until the coolant is at operating temperature. Stop the feet).
engine and check for leakage. When the coolant is
cold, check the coolant level. Add coolant as
required.

STEP 10 STEP 12
BD08B467
BD08A461
Loosen the clamp and disconnect the lower radiator Disconnect upper hose to the condenser, disconnect
hose. and plug hoses from the fuel cooler.
NOTE: During installation torque the hose clamp to
4.5 to 5.5 Nm (40 to 50 pound inches).
STEP 13
STEP 11
BD03K040
Disconnect all four oil cooler hoses, two on each side

of the machine, from the oil cooler.
BD08B466
If equipped with air conditioning discharge air

conditioning system, see section 9004. Disconnect
STEP 14
high pressure switch, disconnect hoses from
condenser and receiver drier. Remove the receiver
drier and horn from the machine.
BD08B470
Remove the radiator wrapper mounting bolts,

remove the radiator wrapper from the machine.

STEP 15 STEP 16
BD08B470 BD03K044
Attach suitable lifting equipment to the radiator. Make sure that you have cleared the fan from the
Raise the cooling pack just enough to move it shroud, raise the cooling pack from the machine.
forward and clear the fan.
NOTE: Installation of the radiator is the reverse of
NOTE: During installation, adjust fan shroud to removal.
obtain 5mm (0.8 in) clearance with the fan.

6
2
3
4
13
8 9
14
10
11
12
BS08B251

1. RADIATOR 8. TRANSMISSION COOLER LINES

2. HYDRAULIC OIL COOLER 9. CONDENSER AND FUEL COOLER PIVOT BOLT
3. CHARGE AIR COOLER 10. OIL COOLER LINES
4. AIR CONDITIONING CONDENSER 11. FAN SHROUD MOUNTING BOLTS
5. FUEL COOLER 12. CLAMP
6. TRANSMISSION OIL COOLER 13. DEAIRIATION TANK
7. CHARGE AIR SUPPORT BRACKET 14. RADIATOR HOSES AND CLAMPS
ILLUSTRATION OF RADIATOR MOUNTING
1. Place cooling pack on a bench, remove the 8. Install the oil coolers and tighten the mounting
charge air support bracket mounting bolts (7), bolts.
three per side.
9. Install the clamps (12) and torque to 3.1 to 3.4
2. Remove the cooler line mounting clamps (12), Nm (27 to 30 pound inches).
remove the oil cooler mounting bolts.
10. Install the charge air cooler brackets and tighten
3. Remove the fan shroud mounting bolts (11), the mounting bolts.
deairiation tank (13), and radiator hoses (14)
11. If equipped with fuel cooler and condenser,
from the radiator.
mount the charge air cooler and the mounting
4. Install fan shroud and torque bolts to 13 to 25 Nm brackets for the condenser and fuel cooler,
(10 to 18 pound feet). tighten the mounting bolts.
5. Install deairiation tank (13). 12. Mount the condenser and fuel cooler into the
bracket using the pivot bolt (9).
6. Install radiator hoses and clamps (14), torque
clamps to 4.5 to 5.5 Nm (40 to 50 pound inches). 13. Tighten the condenser and fuel cooler pivot bolt
(9) tight enough to remove the gaps between the
7. If fittings were removed from the oil cooler, install
mounting brackets but not tight enough to
fittings and torque to 77 to 85 Nm (57 to 63
prevent the components from swinging out for
pound feet).
cleaning.
IMPORTANT: Use two wrenches to minimize the
14. Swing the condenser and fuel cooler into
torque transmitted into the elbow brazed to the oil
position, install and tighten retaining bolts.
cooler.

ENGINE
wires. Close disconnected hoses and fittings with If the machine is equipped with air conditioning. See
caps and plugs. Section 9004 and discharge the air conditioning
NOTE: The photos in this procedure may be system.
different from your machine and are for reference NOTE: During installation see Section 9004 and
only. recharge the air conditioning system.
STEP 1 STEP 5
Remove the radiator wrapper, fan shroud, radiator, oil
coolers, CAC, and if equipped with air conditioning
the condenser as an assembly, see radiator removal
this section.
STEP 6
BD00G073

STEP 2
machine has only one batter y, disconnect the
BD08B469
negative battery cable from the battery.
If the machine is equipped with air conditioning,
disconnect the electrical connector. Disconnect the
STEP 3
hoses from the compressor.
1 STEP 7
3 2
BD08A453

nut (1). Remove the negative battery cable (2) from BD01B324
the terminal and move the negative battery cable Remove the tie strap. Disconnect the electrical
away from the battery. Make sure the jumper cable connectors for the air restriction indicator.
(3) is installed on the terminal and start the terminal

STEP 8 STEP 11
Remove muffler and brackets from engine.
STEP 12
BD01B323
Loosen the clamp on the air cleaner hose at the

turbocharger. Disconnect the air cleaner hose from
the turbocharger. BD08A309
If equipped, disconnect grid heater positive cable.

STEP 9
STEP 13
BD08A481
Disconnect crank case ventilation hose and the

aspiration hose. BD08A525
Disconnect the electrical connector engine controller.

STEP 10
STEP 14
2 3
1
BD01B307
Remove the cap screws and flat washers that fasten

BD08A309
the fixed hood to the uprights. Remove the fixed hood
Disconnect the fuel return line (1), fuel input line (3),
and the water in fuel sensor (2).
NOTE: If equipped with fuel cooler, attach the lines
to the engine during removal.

STEP 15 STEP 18
BD03K031
BS03K004 Remove the starter from the engine. Remove the
Disconnect the wires from the alternator. access cover from the bell housing.
STEP 16 STEP 19
BS03K014 BC04A195
Disconnect the heater hose, if equipped. Install the engine turning tool, 380000988, to turn the
flywheel for access to the cap screws.
STEP 17
STEP 20
1
2 2
BS03K005 BD03K033
Disconnect the ground strap (1). Disconnect the For machines equipped with either a standard or
wires (2) from the starter. powershift transmission, loosen and remove four cap
screws that fasten the flywheel to the flex plate.
NOTE: During installation tighten the cap screws to
52 to 57 Nm (38 to 42 pound feet) for the standard
transmission or the powershift transmission.

STEP 21 STEP 23
Connect lifting equipment to the lifting eyes on the Loosen and remove the 12 cap screws and flat
engine to hold the engine in place. washers that fasten the transmission to the engine.
Move the heater hose and clamps out of the way.
STEP 22 NOTE: During installation tighten the the
transmission cap screws to 52 to 57 Nm (38 to 42
pound feet).
STEP 24
Move the engine forward and raise the engine.
Remove the engine from the machine.
IMPORTANT: Make sure that the flex plate/converter
assembly stays in place on the transmission. If the
engine will be separated from the transmission for an
extended period of time fasten the flex
plate/converter assembly in place on the
BD03K034 transmission.
Remove the bolts, flat washers, and nuts from the
front engine mount. NOTE: Installation of the engine is the reverse of
removal.
NOTE: During installation, tighten the self-locking
nuts to 90 to 100 Nm (67 to 73 pound feet). STEP 25
Fill the engine and cooling system, see section 1002
for specifications.

1
2
1
2
5
3
2
6 2
6
BS08B234
1. MOUNT BOLT 4. MOUNTING BRACKET

2. WASHER FLAT 5. RUBBER ENGINE MOUNT
3. BOLTS 6. LOCK NUT
ILLUSTRATION OF ENGINE MOUNTING

MUFFLER INSTALLATION
1
1
8
5 4
2
7
6 2
3
BS08B235
1. MUFFLER 4. BOLTS (2) NUTS (2) AND WASHERS (4) 7. BOLT (1) SPACER (1) AND WASHER (1)
2. BOLTS (2) WASHERS (2) 5. BOLTS (2) NUTS (2) AND WASHERS (4) 8. BOLT (1) NUT (1) AND WASHERS (2)
3. CLAMP “T” BOLT 6. BOLT (1) NUT (1) AND WASHERS (2)
IMPORTANT: To prevent damage to the exhaust 4. Tighten right hand bolt (6) to muffler to a torque
system do the following procedures in sequence. of 64 to 75 Nm (47 to 55 pound feet).
1. Assemble muffler (1) to engine with bolts finger 5. Tighten front bracket to engine lifting bracket
tight. mounting nuts (4) to a torque of 64 to 75 Nm
NOTE: All gaps between mounting surfaces should
be eliminated before torque sequence is started. 6. Tighten mounting bolts (5) to engine to a torque
2. Align muffler flange with turbo and tighten “T” bolt
clamp (3) to 6.5 to 7.5 Nm (57.5 to 66.5 lb-in). 7. Tighten brace mounting bolt (7) to gear housing
to a torque of 44 to 54 Nm (32 to 40 pound feet).
3. Tighten lower bolts (2) on rear bracket to engine
block to a torque of 64 to 75 Nm (47 to 55 pound 8. Tighten rear brace left hand bolt (8) to muffler to
feet). a torque of 64 to 75 Nm (47 to 55 pound feet).

HOOD INSTALLATION
4
1
10
9
3
2
6
8 7
6 5
10
4
BC03K128
1. TILT HOOD 6. FLAT WASHER

2. RADIATOR WRAPPER 7. PIVOT TUBE
3. FIXED HOOD 8. NUT
4. PIVOT PLATE 9. COUNTER BALANCE SPRING
5. BOLT 10. HOOD RETAINER CABLE
NOTE: Hood is shown disassembled for clarity only. 4. Push tilt hood to the rear to minimize the gap
between side panels and chassis uprights.
1. Mount left and right pivot plates (4) onto frame
finger tight. 5. Tighten left and right pivot plates (4).
2. Place tilt hood (1) onto radiator wrapper (2) and 6. Raise tilt hood (1) just enough to attach the left
fixed hood (3). and right counter balance springs (9) to ball
studs, secure springs with retainer clips.
3. Install pivot tube (7), bolt (5), washers (6), and
nut (8), tighten nut. 7. Attach hood retainer cable (10) to radiator
wrapper.

NOTES

2002
Section
2002
STALL TEST

2002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PREPARING THE MACHINE FOR THE STALL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Machines with Standard Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Machines with Powershift Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PROCEDURE TO HEAT TORQUE CONVERTER AND HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STALL TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHECK SHEET 580M SERIES 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHECK SHEET 580SM SERIES 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHECK SHEET 580SM+ SERIES 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECK SHEET 590SM SERIES 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHECK SHEET 590SM+ SERIES 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2002-3
SPECIFICATIONS
NOTE: The following specifications are for an engine with more than 50 hours of operation.
580M Series 3
Full throttle - no load ................................................................................................................. 2320 to 2450 rpm
Idle speed .................................................................................................................................... 850 to 1025 rpm
Loader hydraulic stall ................................................................................................................ 2230 to 2330 rpm
Backhoe hydraulic stall................................................................................................................2230 to 2330 rpm
Torque converter stall ................................................................................................................ 2180 to 2310 rpm
Combined stall .......................................................................................................................... 1610 to 1890 rpm
580SM Series 3
Idle speed .................................................................................................................................... 900 to 1000 rpm
580SM+ Series 3
Idle speed .................................................................................................................................... 900 to 1000 rpm
NOTE: During stall tests if you get the following readings during the specified tests, the variable volume pump is at
maximum stroke. See section 6002 and troubleshoot the pump.
590SM Series 3
Full throttle - no load .................................................................................................................. 2320 to 2430 rpm
Idle speed..................................................................................................................................... 900 to 1000 rpm
Loader hydraulic stall ................................................................................................................. 2240 to 2335 rpm
Torque converter stall ................................................................................................................. 2125 to 2290 rpm
Combined stall ........................................................................................................................... 1838 to 2010 rpm
590SM+ Series 3
Idle speed .................................................................................................................................... 900 to 1000 rpm
NOTE: During stall tests if you get the following readings during the specified tests, the variable volume pump is at
maximum stroke. See section 6002 and troubleshoot the pump.
2002-4
GENERAL INFORMATION
Do the stall test to find the cause of poor Comparing the engine speeds from the stall test with
performance. the check sheets starting on page 6 will help to find
the cause of the problem. It can be necessary to
NOTE: The main relief valve must be set within
check a separate system to find the exact cause of
specifications to achieve accurate readings when
the problem.
performing the following stall tests.
Use a photo tachometer or other tachometer of equal
The engine is run at full throttle and the transmission
accuracy to get accurate results from the stall test.
and hydraulic systems are engaged separately, and
then together. The engine, transmission and hydraulic system must
be at operating temperature before doing the stall
test. Heat the oil according to instructions in this
section.
PREPARING THE MACHINE FOR THE STALL TEST
Machines with Standard Machines with Powershift

Transmission Transmission
NOTE: For 580M machines only, see section 9001 1. Apply the parking brake.
and check the throttle linkage adjustments.
2. Place the automatic/manual switch in the manual
1. Apply the parking brake. position.
2. Move the transmission gear selector into fourth 3. Select 4th gear on the range selector.
gear.
4. Lock the brake pedals together. Put your foot on
3. Lock the brake pedals together. Put your foot on the service brakes and hold the machine with
the service brakes and hold the machine with service brakes.
service brakes.
5. Release the parking brake.
4. Release the parking brake.
6. With the engine running at low idle, move the
5. With the engine running at low idle, move the direction control lever to FORWARD.
direction control lever to FORWARD.
7. Slowly increase the engine speed to full throttle.
6. Slowly increase the engine speed to full throttle.
8. If the machine begins to move at any time,
7. If the machine begins to move at any time, decrease the engine speed to low idle and stop
decrease the engine speed to low idle and stop the engine. See section 6004 and repair the
the engine. See section 6004 and repair the service brakes.
service brakes.

2002-5
PROCEDURE TO HEAT TORQUE CONVERTER AND HYDRAULIC OIL

1. Apply the parking brake. 7. Repeat steps 3 and 4 or 5 and 6 until the
temperature of the oil is 125°F (52°C). The side
2. Start and run the engine at low idle.
of the reser voir will be ver y war m at this
3. 580M, 580SM, and 590SM, run the engine at full temperature.
t h r o t t l e, h o l d t h e l o a d e r c o n t r o l l eve r i n
8. With the engine running at low idle, move the
ROLLBACK for 15 seconds.
transmission control to four th gear and the
4. Return the loader control lever to NEUTRAL for direction control lever to FORWARD.
15 seconds.
9. Run the engine at full throttle for 15 seconds.
5. 580SM+ and 590SM+, run the engine at full
10. Decrease the engine speed to low idle and move
throttle, with the boom in the travel lock position,
the direction control lever to NEUTRAL for 15
hold the boom control lever in the LOWER
seconds.
position (lever pushed away from seat) for 15
seconds. 11. Repeat steps 6 through 8 until the pointer in the
gauge for transmission oil temperature is in the
6. Return the boom control lever to NEUTRAL for
center of the green zone of the gauge for
15 seconds.
transmission oil temperature.
STALL TEST PROCEDURE

1. Prepare the machine for the stall test according 8. Lock the brake pedals together. Put your foot on
to instructions in this section. the service brakes and hold the machine with
service brakes.
2. Heat the oil according to instructions in this
section. 9. Release the parking brake.
3. Apply the parking brake and start the engine. 10. Move the direction control lever to forward.
4. With the engine running at full throttle, hold the 11. Slowly increase the engine speed to full throttle
loader control lever in the lift position and read and read the tachometer. Record the reading on
the tachometer. Record the reading on line 1 on line 3 on the check sheet.
the check sheet.
12. With the transmission control lever in fourth gear,
5. With the engine running at full throttle and boom the direction control lever in FORWARD, and the
in travel lock, hold the dipper lever in the in engine running at full throttle, hold the loader
position and read the tachometer. Record the control lever in the lift position and read the
reading on line 2 on the check sheet. tachometer. Record the reading on line 4 on the
check sheet.
6. Decrease the engine speed to low idle.
13. Decrease the engine speed to low idle, move the
7. Move the transmission control lever to fourth
directional control lever to neutral.
gear.
14. Run the engine at low idle for two minutes and
NOTE: For machines with power shift transmissions,
then stop the engine.
place the automatic/manual switch in the manual
position. 15. See the check sheet to understand the results of
the stall test.

2002-6
CHECK SHEET 580M SERIES 3
1. ________________ (2230 to 2330 specified) rpm (r/min) loader hydraulic stall speed
2. ________________ (2230 to 2330 specified) rpm (r/min) backhoe hydraulic stall speed
3. ________________ (2180 to 2310 specified) rpm (r/min) torque converter stall speed
4. ________________ (1610 to 1890 specified) rpm (r/min) loader hydraulic and torque converter stall speed
rpm (r/min) RESULTS
1. 2230 to 2330
2. 2230 to 2330
3. 2180 to 2310 All systems are good.
4. 1610 to 1890
1. Above 2330
2. 2230 to 2330 Engine problem. Check engine speeds. See specifications in Section 9001. See
3. Above 2310 engine service manual for your machine.
4. Above 1890
1. Below 2230
2. 2230 to 2330 Engine problem. Check engine speeds according to instructions in Section 9001.
3. Below 2180 Replace the fuel and air filters. See engine service manual for your machine.
4. Below 1610
1. Below 2230
2. 2230 to 2330 Hydraulic system problem(s). See section 8002. Check the setting of the main relief
3. 2180 to 2310 valve. Check the output of the hydraulic pump.
4. Below 1610
1. Above 2330
3. 2180 to 2310 valve. Check the output of the hydraulic pump. Check for leakage in the loader control
4. Above 1890 valve.
1. 2230 to 2330
2. Below 2230 Hydraulic system problem(s). See section 8002. Check the setting of the main relief
4. 1610 to 1890
1. 2230 to 2330
2. Above 2330 Hydraulic system problem(s). See section 8002. Check the setting of the main relief
3. 2180 to 2310 valve. Check the output of the hydraulic pump. Check for leakage in the backhoe
4. 1610 to 1890 control valve.
1. 2230 to 2330
2. 2230 to 2330 Torque converter or transmission problems. See Section 6002 and check the
3. Above 2310 transmission and torque converter.
4. Above 1890
1. 2230 to 2330
3. Below 2180 transmission and torque converter.
4. Below 1610

2002-7
CHECK SHEET 580SM SERIES 3
rpm (r/min) RESULTS
1. 2240 to 2335
2. 2160 to 2300
4. 1695 to 1930
1. Above 2335
4. Above 1930
1. Below 2240
4. Below 1695
1. Below 2240
4. Below 1695
1. Above 2335
1. 2240 to 2335
4. 1695 to 1930
1. 2240 to 2335
1. 2240 to 2335
4. Above 1930
1. 2240 to 2335
4. Below 1695

2002-8
CHECK SHEET 580SM+ SERIES 3
rpm (r/min) RESULTS
1. 2350 to 2420
2. 2350 to 2420
4. 2090 to 2270
1. Above 2420
4. Above 2270
1. Below 2350
4. Below 2090
1. Below 2350
4. Below 2090
1. Above 2420
1. 2350 to 2420
4. 2090 to 2270
1. 2350 to 2420
1. 2350 to 2420
4. Above 2270
1. 2350 to 2420
4. Below 2090

2002-9
CHECK SHEET 590SM SERIES 3
rpm (r/min) RESULTS
1. 2240 to 2335
2. 2190 to 2300
4. 1830 to 2010
1. Above 2335
4. Above 2010
1. Below 2240
4. Below 1830
1. Below 2240
4. Below 1830
1. Above 2335
1. 2240 to 2335
4. 1830 to 2010
1. 2240 to 2335
1. 2240 to 2335
4. Above 2010
1. 2240 to 2335
4. Below 1830

2002-10
CHECK SHEET 590SM+ SERIES 3
rpm (r/min) RESULTS
1. 2350 to 2425
2. 2350 to 2425
4. 2190 to 2305
1. Above 2425
4. Above 2305
1. Below 2350
4. Below 2190
1. Below 2350
4. Below 2190
1. Above 2425
1. 2350 to 2425
4. 2190 to 2305
1. 2350 to 2425
1. 2350 to 2425
4. Above 2305
1. 2350 to 2425
4. Below 2190

2447
Section
2447
ENGINE BALANCER

Racine, WI 53404 U.S.A. Bur 6-74700 Issued January, 2004
2447-2
TABLE OF CONTENTS
ENGINE BALANCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2447-3
ENGINE BALANCER
Removal STEP 8
Lower the drive shaft guard (9) and remove it from
NOTE: If your machine is two wheel drive go to step
under the machine.
11, if your machine is four wheel drive see page 5 for
guard and drive shaft removal an installation.
STEP 9
STEP 1 Remove the bolt (7) and washer (8) that fasten the
bracket (10) to the machine.
If your machine has a 117 liters (31 U.S. gallon) fuel
tank go to step 2, if it has a 151 liters (40 U.S. gallon)
or a 159 liters (42 U.S. gallon) fuel tank go to step 5. STEP 10
Loosen and remove the bolts (11) and retainers (12)
STEP 2 that fasten the drive shaft (13) to the flange on the
transmission. Remove the drive shaft (13).
Put a floor jack under the drive shaft guard (3) to hold
the drive shaft guard in position.
STEP 11
STEP 3 Drain oil from engine.
Loosen and remove the bolts (1) and flat washers (2)
that fasten the drive shaft guard (3) to the frame. STEP 12
Put a floor jack under the engine oil pan, loosen and
STEP 4 remove engine oil pan.
under the machine. Go to step 10. STEP 13
Loosen and remove the oil sump from the engine.
STEP 5
Put a floor jack under the drive shaft guard (9) to hold STEP 14
the drive shaft guard in position.
STEP 6
Loosen and remove the nut (4), bolt (5), and washer
(6) from the bracket (10).
STEP 7
Loosen and remove the bolts (7) and flat washers (8)
that fasten the drive shaft guard (9) to the frame. Do
not remove the bolt (7) and washer (8) from the
bracket (10) at this time.
BC04A234
Turn the engine while pressing in on the timing lock

pin until pin locks engine on number one TDC.
STEP 15
Loosen and remove the balancer from the engine.

2447-4
Installation STEP 22
Start and run engine, check for excessive vibration
STEP 16 and oil leaks.
NOTE: If your machine is four wheel drive continue
1 with the following steps, if your machine is two wheel
drive task is complete.
STEP 23
Install the drive shaft (13). Install the bolts (11) and
1 1 retainers (12) that fasten the drive shaft (13) to the
flange on the transmission.
STEP 24
Tighten the bolts (11) to 33 to 39 Nm (24 to 29 lb-ft).
2
STEP 25
BC04A235
Align the timing marks (1) on the balancer, install the If your machine has a 117 liters (31 U.S. gallon) fuel
retaining bolt (2) to keep the balancer in time. tank go to step 26, if it has a 151 liter (40 U.S. gallon)
or 159 liter (42 U.S. gallon) fuel tank go to step 29.
STEP 17
STEP 26
Raise the drive shaft guard (3) in position.
STEP 27
Install the bolts (1) and flat washers (2) that fasten
the drive shaft guard (3) to the frame.
STEP 28
Steps 47 through 50 are for machines with 151liter
(40 U.S. gallon) or 159 liter (42 U.S. gallon) fuel tank.
STEP 29
BC04A233 Raise the drive shaft guard (9) into position.
Raise the balancer into the engine, install and tighten
the mounting bolts. STEP 30
Install the bolts (7) and flat washers (8) that fasten
STEP 18 the drive shaft guard (9) to the frame.
Install and tighten the oil sump.
STEP 31
STEP 19 Put the bracket (10) into place and install the washer
Remove the retaining bolt from the balancer. (6), bolt (5), and nut (4).
STEP 20 STEP 32
Install the oil pan on the engine, fill the engine with Install the washer (8) and bolt (7) that fasten the
oil. bracket (10) to the machine.
STEP 21
Pull the timing lock pin from the cam gear.

2447-5
I
17
19
22
21
18
15
16 14
13 20
11
12 3
2
10
1
7
5 9
6
4
BC01B093
1. BOLT 6. WASHER 11. BOLT 17. LUBRICATION HOSE
2. WASHER 7. BOLT 12. RETAINER 18. PIVOT PIN
3. DRIVE SHAFT GUARD 8. WASHER 13. DRIVE SHAFT 19. AXLE
(UNITS WITH 117L (31 9. DRIVE SHAFT GUARD (UNITS 14. WHEEL NUT 20. WASHER
GALLON) FUEL TANK) WITH 151L (40 GALLON) FUEL
4. NUT TANK 15. WASHER 21. WASHER
5. BOLT 10. BRACKET 16. SNAP RING 22. SNAP RING

2447-6
NOTES

SECTION INDEX
FUEL SYSTEM

In Vehicle Injector Pump Removal and Installation 580M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3416
For Fuel System Repair, See the Engine Service Manual 87630273

Section
3416
580M IN VEHICLE INJECTOR PUMP REMOVAL,

INSTALLATION AND STATIC TIMING
3416

3416-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STATIC TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Establishing TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Checking Static Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Static Timing Reset Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3416-3
SPECIAL TOOLS
BC04A194 BC04A195
CAS 1691A GEAR PULLER 380000988 ENGINE TURNING TOOL
BC05F040
380001435 VALVE GAUGE TOOL

3416-4
REMOVAL
STEP 1 STEP 4
Secure loader in raised position, stop engine.
STEP 2
BD04A032
Remove grill from side of frame.
BD01B353
STEP 5
machine has only one batter y, disconnect the
negative battery cable from the battery.
STEP 3
1
3 BD04A033
Loosen hose clamp and remove air cleaner inlet

hose.
STEP 6
BD01B352

nut (1). Remove the negative battery cable (2) from
the terminal and move the negative battery cable
away from the battery. Make sure the jumper cable
(3) is installed on the terminal and start the terminal
BD04A029
Loosen jam nut for throttle cable.

3416-5
STEP 7 STEP 10
BS03K002 BD04A014
Remove the two throttle arm mounting bolts, move Remove the front rocker arm cover and injector line
the throttle cable out of the mounting bracket. retaining bracket mounting bolt. Using engine turning
tool turn engine in direction of running rotation until
push rods can be turned freely.
STEP 8 STEP 11
1
2 2
BS03K005 BD04A015
Disconnect the ground strap (1). Disconnect the Have an assistant continue to turn the engine with
wires (2) from the starter. turning tool while pressing in on lock pin located just
below injector pump.
STEP 9
Remove the star ter from the engine and install STEP 12
380000988 engine turning tool. Once the lock pin has engaged continue to turn with
light pressure on tur ning tool until engine has
completely stopped rotating.

3416-6
STEP 13 STEP 15
BD04A016 BD03K068
Loosen injector pump locking bolt and remove the Remove fuel filter and mounting bracket from engine.
slotted plate, tighten the locking bolt to 20 to 24 lb-ft
(27 to 33 Nm). STEP 16
STEP 14
BS03K009
Disconnect the power lead to the injector pump.

BD04A017
STEP 17
BD04A019
Remove the injector line retaining bracket mounting BS03K010

bolts. Disconnect the fuel inlet line from the fuel pump and
fuel return line from the injector pump. Cover line and
fitting to keep foreign material from entering the fuel
system.

3416-7
STEP 18 STEP 21
Remove the mechanical fuel pump and engine oil
filler tube from the engine.
NOTE: In the following photos the engine is shown
removed from the machine, this is for clarity only, it is
not required to remove the engine.
STEP 19
2 BD04A022
Disconnect temperature sensor.
STEP 22
1
BD04A020
Loosen fuel injector lines (1), disconnect fuel return

line (2), and boost line (3) at the pump. Cover lines
and fittings to keep foreign material from entering the
fuel system.
STEP 20
BD04A023
Reaching through the inlet hole in the frame, remove

the three plate retaining bolts, remove the plate.
STEP 23
BD04A021
Disconnect fuel feed line from injector pump. Cover

line and fitting to keep foreign material from entering
the fuel system.
BD04A024
Loosen and remove nut and washer.

WARNING: Use caution when removing nut and
washer they can be dropped inside of the engine,
engine will have to be disassembled to remove the
nut or washer.

3416-8
STEP 24
BD04A025
Install gear puller and tighten bolts until gear is loose.
STEP 25
BD04A018
Remove the three mounting nuts from the studs, two

are located at arrows, one is located at the bottom of
the pump. Remove the pump from the engine.

3416-9
INSTALLATION
STEP 26 STEP 29
Use solvent to remove oil from the injection pump
drive shaft and drive gear tapers.
IMPORTANT: Tapers should be dried completely.
STEP 27
BD04A024
Install lock washer and nut, torque nut to 66 to 70

lb-ft (90 to 95 Nm).
WARNING: Use caution when installing nut and
washer they can be dropped inside of the engine.
BD04A026
Replace gasket on pump mounting flange. STEP 30
STEP 28
BD04A023
Apply Loctite 5205 to the surface of the cover plate,

BD04A018
install cover plate and mounting bolts, tighten bolts.
Install pump and tighten the three mounting nuts.
STEP 31
BD04A022
Connect wire to temperature sensor.

3416-10
STEP 32 STEP 35
BD04A021 BD04A017
Connect the fuel feed line to the injector pump.
STEP 33
1 BD04A019
Install the injector line retaining bracket mounting

bolts.
BD04A020
Remove covers from lines and fittings. Connect fuel STEP 36

injector lines (1), connect fuel return line (2), and
boost line (3) to the pump.
STEP 34
1
2
BD04A016
Loosen injector pump locking bolt and install the

3 slotted plate, tighten the locking bolt to 9 to 10 lb-ft
(12 to 14 Nm).
BD04A030
Install oil filler tube (3), mechanical fuel pump (2),

and fuel filter (1) on the engine.

3416-11
STEP 37 STEP 40
1
3
BD04A015 BD01B352
Make sure locking pin is disengaged from gear. Install grounding cable (2) onto the terminal. Install
the jumper cable (3) on the terminal and start the
STEP 38 terminal nut (1) onto the terminal. Tighten the
Remove the engine turning tool and install the terminal nut.
starter.
STEP 41
STEP 39
BD04A014
BD01B353
Install the front rocker arm cover and injector line
If the machine has only one battery, connect the retaining bracket mounting bolt.
negative battery cable to the battery. Install the
battery cover. STEP 42
BD04A029
Install the throttle cable into the bracket and tighten

the jam nut.

3416-12
STEP 43 STEP 45
BS03K002 BD04A033
Install and thighten the two throttle arm mounting Install air cleaner inlet hose and tighten the hose
bolts. clamp.
STEP 44 STEP 46
BS03K009 BD04A032
Connect the power lead to the injector pump. Install grill on side of frame.
STEP 47
Actuate the lever on the mechanical fuel pump to
prime the fuel system.
STEP 48
Start the machine and check for fuel leaks, check
and adjust throttle linkage as needed.

3416-13
STATIC TIMING
Establishing TDC STEP 54
STEP 49
1
DD05A002
1. BRACKET
DD04K015
1. TONEWHEEL
Using Engine Turning Tool 380000988, manually turn
the engine over, rotating the tonewheel (1) until the
unslotted section is at the top. This will position the
No. 1 piston near TDC. 3
STEP 50
Remove the valve cover.
STEP 51 2
DD04K019
2. METAL REFERENCE ROD
3. PULLEY MARK
1 Attach a metal rod (2) to the bracket near the AC belt

pulley (1).
STEP 55
Use the metal rod as a reference point and mark the
pulley (3).
STEP 56
Remove tool 380001435 closing the intake valve.
DD04K017
1. VALVE GAUGE TOOL - 380001435
Install Valve Gauge Tool (1) on engine. STEP 57
Continue to turn the engine in a clockwise direction
STEP 52 for approximately 20 degrees, until the piston is on its
Use Valve Gauge Tool (1) to open the No. 1 cylinder down cycle.
intake valve.
STEP 58
STEP 53 Install tool 380001435 to open the No. 1 cylinder
intake valve.
Turn the engine over in a clockwise direction (as
viewed from the front) until the No. 1 piston makes
contact with the intake valve.
IMPORTANT: DO NOT use excessive force with the
tuning tool, this will damage the intake valve.
3416-14
STEP 59 Checking Static Timing
Turn the engine in a counterclockwise direction until
the piston makes contact with the valve. STEP 62
IMPORTANT: DO NOT use excessive force with the Remove tool 380001435 closing the intake valve.
tuning tool, this will damage the intake valve.
STEP 63
STEP 60 Locate the timing plug at the center of the four
injection lines and remove it with a 12 mm socket.
STEP 64
1 2
DD04K020
1. PULLEY MARK 1
Mark the AC belt pulley (1) using the rod as a
reference. DD04K022
1. ADAPTER
2. 5MM DIAL INDICATOR GAUGE
STEP 61
Install adapter (1) CAS 2458 and insert indicator
gauge (2) CAS 1745-1 into the pump.
STEP 65
Preload the gauge approximately 2.5 mm.
1 STEP 66
Turn the engine counterclockwise until the gauge
needle stops moving.
DD04K021
1. MIDPOINT MARK - TDC INDICATOR
Measure between the marks and make a third mark
at the midpoint (1). When aligned with the reference
rod, this mark indicates TDC. Use it to time the pump
with the engine.

3416-15
STEP 67 Static Timing Reset Instructions
Zero out the gauge.
STEP 71
STEP 68
2
DD04K025
DD04K023
1. TDC MARK
2. METAL REFERENCE ROD
Turn the engine clockwise until the TDC Mark (1)
lines up with the reference rod (2).
STEP 69
DD04K026
With engine at TDC and dial indicator installed,
loosen the three nuts that secure the pump to the
gear housing.
NOTE: Use a 38 cm (15 in.) socket extension (min.)
to loosen the back bolt so that the gauge reading will
DD04K022
not be altered.
Note the timing prelift shown on the gauge. The
specifications are as follows: STEP 72
Use the slots in the injection pump mount to rotate
● Natural Aspirated - 1.10-1.25 mm
(fine-tune) the pump into the correct position. For
● Turbo - 0.95-1.10 mm example: If the gauge reading is 0.90 mm, advance
the timing by rotating the pump CCW (upward) until
STEP 70 the specification is reached.
If timing prelift is out of specification, do the following
procedures. STEP 73
Tighten the pump mounting nuts.
NOTE: If the prelift specification cannot be reached
by rotating the pump, do the following procedures:
STEP 74
Make sure the gear housing nuts are tight.

3416-16
STEP 75 STEP 78
Turn the engine over until the pre-lift is: Turn engine back to TDC.
● Natural Aspirated - 1.20-1.25 mm
STEP 79
● Turbo - 1.00-1.10 mm
Tighten the pump gear, refer to step 29 and 30 this
section.
STEP 76
Lock the pump.
STEP 80
Verify that the pump prelift is within specifications:
STEP 77
Using Injection Pump Drive Gear Puller CAS 1691A, ● Natural Aspirated - 1.10-1.25 mm
loosen the pump gear, refer to step 22 through 24 ● Turbo - 0.95-1.10 mm
this section.

SECTION INDEX
ELECTRICAL SYSTEM

Removal and Installation of Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4000
Electrical Specifications and Troubleshooting 580M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4001
Electrical Specifications and Troubleshooting 580SM, 580SM+, 590SM and 590SM+. . . . . . . . . . . . . . . . . . . .4001
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4004
Instrument Cluster and Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005

Section
4000
REMOVAL OF ELECTRICAL COMPONENTS
4000

4000-2
TABLE OF CONTENTS
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4000-3
STARTER
Removal STEP 8
NOTE: The starter is located on the engine flywheel
housing.
STEP 1 3
Park the machine on a level surface and apply the
parking brake. 1
STEP 2 2
1
Remove the pin that fastens the support strut to the
loader frame.
STEP 3 BD01B352
Raise the loader frame until the support strut is 1. TERMINAL NUTS 2. JUMPER CABLE 3. GROUND STRAP
against the end of the lift cylinder.
If the machine has two batteries:
STEP 4 A. Remove the terminal nuts and jumper cable

from the battery.
Stop the engine and install the pin in the support
strut. B. Remove the negative ground strap from the
battery and move the negative ground strap
STEP 5 away from the battery.
Remove the bolts and washers that fasten the battery
cover to the right side of the machine by the step. STEP 9
Open the hood.
STEP 6
Remove the battery cover. STEP 10
STEP 7
2
1
BD03G008
Tag and disconnect the wires and cables from the

BD01B353 terminals on the starter.
1. BATTERY 2. GROUND STRAP NOTE: Starter wire is coated with RTV silicone
If the machine has only one battery, disconnect the sealant.
negative ground strap from the battery.

4000-4
STEP 11 Installation
STEP 12
Put the starter in place on the flywheel housing.
1 STEP 13
1
1
BD01B354
1. BOLTS
Remove the two bolts that fasten the starter to the 1

flywheel housing. Remove the starter.
2
BD01B354
1. BOLTS 2. GROUND CABLE

Install the bolts that fasten the starter to the flywheel
housing. Make sure the ground cable is installed
under the upper bolt. Torque bolts to 40 to 47 Nm
(30 to 35 lb-ft).
STEP 14
BD03G008
Connect the wires and cables to the terminals on the

starter.
STEP 15
Cover the starter wire terminal with 737 RTV silicone
sealant.
IMPORTANT: Use only 737 RTV silicone sealant.
Other sealants can corrode the terminal.
STEP 16
Close the hood.

4000-5
STEP 17 STEP 19
Install the battery cover.
STEP 20
1 Install the washers and bolts that fasten the battery
cover to the machine.
BD01B353
1. GROUND STRAP
If the machine has only one battery, connect the

negative ground strap to the battery.
STEP 18
1
2
1
BD01B352
1. TERMINAL NUTS 2. JUMPER CABLE 3. GROUND STRAP

A. Install the negative ground strap on the
battery.
B. Install the jumper cable and terminal nuts on
the battery.

4000-6
BS01C005
1. BATTERY 2. NEGATIVE GROUND STRAP
NEGATIVE GROUND STRAP REMOVAL AND INSTALLATION FOR A SINGLE BATTERY
3
2
GS99A404
1. BATTERY 2. NEGATIVE GROUND STRAP 3. TERMINAL NUT 4. JUMPER CABLE
NEGATIVE GROUND STRAP REMOVAL AND INSTALLATION FOR A DOUBLE BATTERY

4000-7
ALTERNATOR
Removal STEP 8
NOTE: The alternator is located behind the fan on
the engine housing.
STEP 1 3
parking brake.
1
STEP 2 2
1
Remove the pin that fastens the support strut to the
loader frame.
STEP 3 BD01B352
Raise the loader frame until the support strut is 1. TERMINAL NUTS 2. JUMPER CABLE 3. GROUND STRAP
against the end of the lift cylinder.
STEP 4 A. Remove the terminal nuts and jumper cable

from the battery.
Stop the engine and install the pin in the support
strut. B. Remove the negative ground strap from the
battery and move the negative ground strap
STEP 5 away from the battery.
Remove the bolts and washers that fasten the battery
cover to the right side of the machine by the step. STEP 9
Open the hood.
STEP 6
Remove the battery cover. STEP 10
Install a breaker bar in the bracket for the tension
STEP 7 pulley.
1 STEP 11
Use the breaker bar to move the tension pulley just
far enough to release tension on the drive belt and
remove the drive belt from the alternator.
BD01B353
1. GROUND STRAP
If the machine has only one battery, disconnect the

negative ground strap from the battery.

4000-8
STEP 12 STEP 16
Remove the breaker bar.
3
1 STEP 17
Close the hood.
STEP 18
1
2
BD03G001
1. WIRES 3. BOLT
2. BOLT 4. SPACER
Tag and disconnect all wires and cables from the
a l te r na t or. R e m ove t h e b o l t th a t fas te n s t he
alternator to the brace. Hold the alternator and
remove the bolt from the top of the alternator.
BD01B353
1. GROUND STRAP
STEP 13
If the machine has only one battery, connect the
Remove the alternator from the mounting bracket. negative ground strap to the battery.
STEP 14
3 3
1
1
2
1
BD01B352
2
1. TERMINAL NUTS 2. JUMPER CABLE 3. GROUND STRAP
BD03G001 If the machine has two batteries:
1. WIRES 3. BOLT
2. BOLT 4. SPACER A. Install the negative ground strap on the
battery.
Hold the alternator in alignment with the mounting
bracket and install the bolt at the top of the alternator. B. Install the jumper cable and terminal nut on
Do not tighten the bolt. Install the bolt that fastens the the battery.
alternator to the brace. Tighten both of the bolts.
Install the wires and cables on the alternator. STEP 20
STEP 15
Use the breaker bar to move the tension pulley just STEP 21
far enough to install the drive belt. Install the drive Install the washers and bolts that fasten the battery
belt on the alternator. cover to the machine.

4001
Section
4001
ELECTRICAL SPECIFICATIONS
AND TROUBLESHOOTING 580M SERIES 3

4001-2 580M ONLY
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL WIRE CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

580M ONLY 4001-3
SPECIFICATIONS
Electrical system, standard................................................................................ One 12 volt battery, negative ground
Electrical system, optional .............................................Two 12 volt batteries connected in parallel, negative ground
System voltage ....................................................................................................................... Approximately 12 volts
Batteries
Standard...............................................................................................................................87403835 or B4960W
Option................................................................................................................................ D128393 or BMF28SW
Replacement ......................................................................................................................... D127414 or BMF28S
Alternator ....................................................................................................................................... 12 volt, 90 ampere
Starter...................................................................................................................................................2.7 Kw, 12 volt
Component specification
Fuel level sending unit.................................................................................................................. Full 28 - 33 Ohm
Empty 240 - 245 Ohm
Return-To-Dig solenoid ............................................................................................................ 18 Ohm to 22 Ohm
Blower switch resistance ..................................................................................................................HIGH - 0 Ohm
MED - 0.4 Ohm
LOW - 0.8 Ohm
Grid heater temperature sender (wire disconnected)........................................... 5° C (41° F) - 4310 - 5420 Ohm
Injection pump solenoid ................................................Coil resistance at 12 volts, at 20° C (68° F) 3.5 - 4.0 Ohm
Mini relay coil..................................................................................................................................... 67 to 81 Ohm
Engine temperature gauge sender (wire disconnected)....................................93.3° C (200° F) - 193 to 236 Ohm
15.5° C (60° F) - 3825 to 4675 Ohm
Transmission temperature gauge sender (wire disconnected).........................110° C (230° F) - 72.1 to 81.1 Ohm
54.4° C (130° F) - 560 to 716 Ohm
Engine coolant cold start advance (KSB) thermostat switch
Close at 53 ± 3° C (127.5 ± 37.5° F) on decreasing temperature
Open at 63 ± 3°C (145.5 ± 37.5°F) on increasing temperature
Solenoid cold start advance (KSB) injector timing ....... Coil resistance at 12 volts, at 20° C (68° F) 4.8 ± 0.2 Ohm
Engine oil pressure switch............ Switch to close on falling pressure at 75 ± 15 kPa, 0.75 ± 0.15 bar (11 ± 2 psi)
Hydraulic filter switch .........................................Close 310 kPa, 3.1 bar (45 psi), Reset 241 kPa, 2.4 bar (35 psi)
Transmission forward and reverse solenoid coil ................................................................................... 4 to 6 Ohm
Four wheel drive solenoid .................................................................................................................... 6 to 8 Ohm
Differential lock solenoid ....................................................................................................................... 5 to 6 Ohm
Air conditioning pressure switches
Low pressure switch............................................................ Opens at 137.9 ± 21 kPa, 1.40 ± 0.21 bar (20 ± 3 psi)
Closes at 27.6 ± 14 kPa, 0.28 ± 0.14 bar (4 ± 2 psi)
High pressure switch ........................................................... Close at 2758 ± 69 kPa, 27.5 ± 0.6 bar (400 ± 10 psi)
Opens at 2068 ± 69 kPa, 20.6 ± 0.6 bar (300 ± 10 psi)
Air conditioning thermostat set point .......................................... Cold cut in 6.7° C (44° F), Cut out 1.7° C (35° F)

4001-4 580M ONLY
ELECTRICAL WIRE CIRCUITS
NO. GA. COLOR FROM TO

0 ST (None) Battery Ground
1 0 Red Battery Starter Battery Terminal
1A 4 Red Starter Battery Terminal Alternator
1B 4 Red Starter Battery Terminal Power Junction Post
1C 12 Red Power Junction Post Starter Relay T30
Ignition Switch (Batt) Fuse Block 2B, 4B, 6B, 8B,
1D 12 Red Power Junction Post
10B, 12B
1E 12 Red Power Junction Post Power Relay #1 T30
1G 12 Red Power Junction Post Power Relay #4 T30
1H 10 Red Power Junction Post Fuse Block 10C
1J 10 Red Power Junction Post Fuse Block 12C
1K 12 Red Power Junction Post Power Relay #2 T30
1L 12 Red Power Junction Post Power Relay #3 T30
1M 2 Red Starter Battery Terminal Cold Start Fuse T1
2A ST none Cold Start Fuse T2 Cold Start Relay T5
2B 2 Red Cold Start Relay T3 Grid Heater
3 12 White Ignition Switch (Ignition) Diode, Fuse Block 2D, 4D, and 6D
3C 16 Black RH Speaker T2 Ground at Radio
4 16 Gray Ignition Switch (ACC.) Power Relays 1, 2, 3, 4 T85
4D 16 Gray Radio (Right Output) RH Speaker T1
5E 16 Black LH Speaker T2 Ground at Radio
6F 16 Gray Radio (Left Output) LH Speaker T1
Loader Lever Differential Lock Engage Switch
7 16 Gray Loader Lever Differential Lock Enable Relay T86
Std. Transmission
10 16 Black Accessories - Front Console Ground
12A 12 Red Power Relay 1, T87 Fuse Block 2A, 4A, 6A, 8A, and 10A
12B 12 Red Power Relay 2, T87 Fuse Block 2C, 4C, 6C, and 8C
12C 12 Red Power Relay 3, T87 Fuse Block 8D, 10D, 12D, and 14D
12D 12 Red Power Relay 4, T87 Fuse Block 12A
13D 16 Gray Boom Lock Switch T3 Boom Lock Solenoid
15 16 White Fuse Block 5D Fuel Shutoff, Alt T2, Cold Start T6
19A 16 Red Fuse Block 7A Turn/Driving Lamp/Horn Switch T56
Hazard Switch T2, Turn/Driving Lamp/Horn
Switch T49a, Flasher Relay T2, Loader Lever
19B 12/16 Red Fuse Block 3C
Differential Lock Enable Relay T85 and T30,
Brake Switch (Com), SAHR Brake Relay T30
Rear Work Lamp Switch and Relay T2,
19C 12 Red Fuse Block 7D
SAHR Brake Switch T3, E.H. Clam Controller
19D 16 Red Fuse Block 5A Rotating Beacon Switch T2
Clutch Relay T85 and T30, Shuttle Interlock
19E 16 Red Fuse Block 1D
Timing Relay (B+)
19F 16 Red Fuse Block 9A Loader Valve RTD Solenoid
19K 14 Red Fuse Block 9D Front Work Lamp Switch T2
19M 16 Gray Shuttle Interlock Timing Relay “Load” Forward and Reverse Relay T30
19N 14 Red Fuse Block 9B Air Suspension Seat Adjustment Switch (B+)
20 16 Black Accessories - Side Console Ground
20A 16 Black Instrument cluster T36 Ground

580M ONLY 4001-5

20B 10 Black Power Plug Ground
20C 10 Black Power Plug Ground
20D 16 Black E.H. Clam Controller Ground
Forward/Neutral/Reverse Lever (+), Power Shift
21 16 Red Clutch Relay T87a
Lever T8, Power Shift Controller A1
21A 16 Lt. Blue Ignition Switch (Start) Neutral Relay T30
21B 12/16 White Starter Relay T87 Starter Solenoid, Cold Start T3
Forward/Neutral/Reverse Lever (Neu),
21C 16 White Neutral Relay T85, Shuttle Interlock Relay T85
Powershift lever T6
22 16 White Neutral Relay T87 Starter Relay T85
23F 16 Red Diode Instrument Cluster T1, Warning Alarm (+)
23G 16 Red Fuse block 3D Diode
24 16 White Shuttle Interlock Relay T30 Shuttle Interlock Timing Relay (Input)
25 16 Red Clutch Relay T86 Clutch Cutout Switches (Standard Transmission)
Std. Trans. Forward/Neutral/Reverse Lever
25A 16 Lt. Blue Forward Relay T85 & Diode
(Forward)
25B 16 Lt. Blue Reverse Relay T85 & Diode
(Reverse)
25C 16 Red Fuse Block 3A 4WD Engage Switch T2
25E 16 Gray 4WD Engage Switch T1 and T3 4WD Solenoid (Std. Trans.), Diode
25S 16 Gray Loader Lever Differential Lock Enable Relay T87 Differential Lock Solenoid
26 16 Lt. Blue Forward Relay T87 Forward Solenoid & Diode
27 16 Lt. Blue Reverse Relay T87 Reverse Solenoid, Backup Alarm (+), & Diode
10/14/
30 Black Accessories - Chassis Ground
16
31C 16 Yellow Cold Start T1 Instrument Cluster T16
31P 16 Yellow Instrument Cluster T2 Oil Pressure Switch
31S 16 Yellow Alternator T3 Instrument Cluster (Tach) T19
31T 16 Yellow Instrument Cluster T22 Coolant Temperature Sender
32T 16 Yellow Instrument Cluster T21 Transmission Temperature Sender
33T 16 Yellow Instrument Cluster T6 Rear Axle Temperature Sender
34 16 Lt. Green Alternator T1 Instrument Cluster T5, Cold Start T2
35 16 Lt. Blue Cold Start Temp Sender T2 Cold Start T5
36F 16 Yellow Instrument Cluster T20 Fuel Level Sender
36H 16 Yellow Instrument Cluster T4 Hydraulic Filter Restriction Switch
36R 16 Gray Seat Position Switch (NC) Instrument Cluster T9
37A 16 Yellow Instrument Cluster T35 Warning Alarm (-)
38 16 Yellow Instrument Cluster T3 Air Filter Restriction Switch
40A 14 Black Front Work Lamps, Front Wiper Ground
40B 12 Black Blower Motor, Rear Wiper, Dome Light Ground
40C 12 Black Rear Work Lights Ground
40D 14 Black Front Driving and Turn/Hazard Lights Ground
40E 14 Black Rear Stop, Tail, and Turn/Hazard Lights Ground
Front Driving and Tail Lamps, Instrument Cluster
41 16 Gray Turn Signal/Driving Lamp/Horn Switch T56a
T24
42C 12/16 Gray Rear Work Lamp Switch T1 Rear Work Lamps, Instrument Cluster T13
42F 14/16 Gray Front Work Lamp Switch T1 Front Work Lamps, Instrument Cluster T12
42G 12 Gray Rear Work Lamp Switch T1 Rear Work Lamps

4001-6 580M ONLY

44 16 Tan Brake Switch (N.O.) Brake Lamps
Turn/Horn/Driving Light Switch Term R, Left Turn
45L 16 Tan Flasher Relay T5
Signal Lamps
Turn/Horn/Driving Light Switch Term L, Right
45R 16 Tan Flasher Relay T7
Turn Signal Lamps
46 16 Tan Hazard Flasher Switch T1 Flasher Relay T1
47L 16 Tan Flasher relay T6 Left Turn Indicator
47R 16 Tan Flasher Relay T3 Right Turn Indicator
48 16 Gray Rotating Beacon Switch T1 Rotating Beacon
49 16 Red Fuse Block 5B Dome Lamp Door Switch, Dome Lamp
50 16 Black Options Harness Accessories Ground
Instrument Cluster T8, Shuttle Interlock Relay
52 16 Gray Diodes
T87a
53 16 Red Loader Valve RTD Solenoid RTD Limit Switch (NC)
56 16 Red Fuse Block 1B Optional Fused (B+), Optional Radio (B+)
Opt Radio (+), Loader Quick Coupler Switch T2,
57 16 Red Fuse Block 1C Backhoe Quick Coupler Switch “A” T2, Ride
Control Switch T2, Boom Lock Switch T2
Pilot Control/BH Aux T2, T5, Backhoe Auxiliary
58 14 Red Fuse Block 11A
Foot Switch T1
60 16 Red A/C Thermostat A/C Relay T30, A/C High Pressure Switch
A/C/ High Pressure Switch, Instrument Cluster
60A 16 Red A/C Relay T86 & T87
T10
60B 16 Gray A/C Relay T87a A/C Low Pressure Switch
60C 16 Gray A/C Low Pressure Switch A/C Compressor Clutch
61 12 Red Fuse Block 5C Blower Switch (+)
61B 16 Gray Dome Lamp Door Switch Dome Lamp
62 16 Gray Windshield Washer Switch T3 (Front) Front Windshield Washer Pump
Front Wiper Switch T2 and Motor, Rear Wiper
63 16 Red Fuse Block 1A Motor, Windshield Washer Switches T2, Rear
Wiper disconnect Switch
63A 16 Red Rear Wiper Disconnect Switch Rear Wiper Switch T2
Turn Signal/Drive Lamps/Horn Switch T31b,
64A 16 Red Fuse Block 3B Rear Horn Rocker Switch T2, Pilot Control Horn
SwitchT1
Turn Signal/Drive Lamps/Horn Switch T31, Rear
64B 16 Gray Horn
Horn Switch T3, Pilot Control Horn T2
65 16 Gray Windshield Washer Switch T3 (Rear) Rear Windshield Washer Pump
66 16 Gray Front Wiper Switch T1 (Low) Front Wiper Motor (Low)
67 16 Gray Front Wiper Switch T3 (High) Front Wiper Motor (High)
69 16 Gray Front Wiper Switch T4 (Brake) Front Wiper Motor (Brake)
Aux B’Hoe Hyd Foot Switch T2, Pilot Control Aux
75 16 Gray Aux B’Hoe Hydraulic Solenoid T1, Diode
Switch T2
81 16 Gray Rear Wiper Switch T1 (Low) Rear Wiper Motor (Low)
82 16 Gray Rear Wiper Switch T3 (High) Rear Wiper Motor (High)
83 10 Red Fuse Block 9C Power Plug (B+)
85 16 Gray Blower Switch A/C Thermostat
86 16 Gray Blower Switch (Low) Resistor Board (Low)
87 16 Gray Blower Switch (Medium) Resistor Board (Medium)

580M ONLY 4001-7

88 12 Gray Blower Switch (High) Resistor Board (High), Blower Motor
89 16 Gray Rear Wiper Switch T4 (Brake) Rear Wiper Motor (Brake)
90 16 Red Fuse Block 7C Comfort Steer Trans switch (1)
Power Shift LDR LVR Clutch Cutout Switch,
218 16 White Power Shift Controller “J3”
(Optional) Servo Clutch Cutout Connection.
400 16 Yellow SAHR brake Switch T2 SAHR Brake Relay T85, T87
401 16 Gray Ride Control Engage Switch T1 Ride Control Solenoids
402 16 Green SAHR Brake Pressure Switch Instrument Cluster T7
403 16 Gray SAHR Brake Switch T1 SAHR Brake Solenoid T1
Front Quick Coupler Switch T, Rear QC Switch
501 16 Gray Quick Coupler Load Sense Solenoid, Diodes
“A” T1
502 16 Gray Front Quick Coupler Switch T3 Front Quick Coupler Solenoid, Diodes
504 16 Gray Backhoe Quick Coupler Switch “B” T3 Backhoe Quick Coupler Solenoid And Diodes
504A 16 Gray Backhoe Quick Coupler Switch “A” T3 Backhoe Quick Coupler Switch “B” T2
601 14/16 White Pilot Control Switch T3 Pilot Control Relay T30, Pilot Control Module T1
Pilot Control Pressure Reducing Valve T1, Pilot
Control Relay T85, Pilot Control Pattern Change
602 16 Green Pilot Control Relay T87
Switch T2, Pilot Control Switch T6 and T8, LH
Joystick Aux Switch T1, Diode
603 16 Gray Pilot Control Module T3 LH Stab Up Solenoid T1
604 16 Gray Pilot Control Module T4 LH Stab Down Solenoid T1
605 16 Gray Pilot Control Module T5 RH Stab Up Solenoid T1
606 16 Gray Pilot Control Module T6 RH Stab Down Solenoid T1
607 16 Gray Pilot Control Module T7 E’Hoe Extend Solenoid T1
608 16 Gray Pilot Control Module T8 E’Hoe Retract Solenoid T1
609 16 Yellow LH Stab Joystick T2 Pilot Control Module T9
610 16 Yellow RH Stab Joystick T2 Pilot Control Module T10
611 16 Yellow RH Joystick T6 Pilot Control Module T11
613 16 Yellow LH Stab Pressure Switch T1 Pilot Control Module T13
614 16 Yellow RH Stab Pressure Switch T1 Pilot Control Module T14
615 16 Gray Pilot Control Module T15 Aux Forward Solenoid T1
LH Stab Joystick T1, RH Stab Joystick T1, LH
616 16 Red Pilot Control Module T16
Joystick T1 and T2, RH Joystick T1 and T2
617 16 Yellow LH Joystick T5 Pilot Control Module T17
623 16 Gray Pilot Control Module T23 Aux Reverse Solenoid T1
624 16 Lt. Blue Pilot Control Pattern Change Switch T3 Pilot Control Pattern Change Solenoid T1, Diode
700 16 Gray Comfort Steer Relay T85 Comfort Steer Switch ON/OFF (1,4)
701 16 Green Comfort Steer Trans. Switch (2) Comfort Steer Power Relay T30
Comfort Steer Switch ON/OFF (2,10), Comfort
702 16 Yellow Comfort Steer Relay T87
Steer Solenoid T1

4001-8 580M ONLY
UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Alternator 1
The alternator is located on the front, right side of the engine. 2
Check Points 3 Reading 4 Possible Cause of Bad Reading 5
Check the 15 ampere fuse at location
3 and 4C in the fuse block. (See fuse Good Bad fuse.
and relay location on page 4.)
Check wire 1A between the starter terminal (21) and the
Terminal for wire 1A to ground 12 volts
alternator (1).
NOTE: If the readings are good, see Section 4004 and check the starter.
6
7
1. This title is the number and component name on the Electrical Schematic.
2. Location of component on the machine.
3. This column shows the location of the check point.
4. This column shows the indication of the check.
5. This column shows the possible cause of a bad test indication.
6. The numbers in the parentheses show the number of the component on the Electrical Schematic.
7. This statement assumes that all other problems are solved at this point in the test.

580M ONLY 4001-9
TROUBLESHOOTING
Use a multi meter for the following tests.
1 – Battery
NOTE: The battery must be at full charge and all connections clean and tight before any testing of the electrical system.
2 – Alternator
The alternator is located on the front right-hand side of the engine.
Check Points Reading Possible Cause of Bad Reading
Check the 10 ampere fuse at location Good Bad fuse.

5 in the fuse block.
Terminal for wire 1A to ground 12 volts Check wire 1A between the starter terminal and the alternator.
NOTE: Turn the key switch to ON.

Approximately Check the wire between the alternator and the instrument cluster
Terminal for wire 34 to ground 10 volts (18). Check the instrument cluster (18).
NOTE: Make sure all electrical switches except the key switch are in the OFF position. Have another person start and run the
engine at low idle.
Check for voltage at terminal for wire Approximately Bad alternator. See Section 4007 of the Service Manual and
1A. 14 volts repair the alternator.
NOTE: Turn the work lamp switch to the ON position. (Continue to run the engine at low idle.)
Check for voltage at terminal for wire More than Bad alternator. See Section 4007 of the Service Manual and
3 – Chassis Ground
NOTE: Make sure the connection is good for the chassis ground.
4 – Starter and Starter Solenoid

The starter is located on the right rear side of the engine.
Battery terminal of starter solenoid to 12 volts Check the battery cable to the positive post of the battery.
ground
NOTE: Put the transmission control lever in Neutral. Have another person hold the key switch in the START position.
Check the starter relay (10), neutral start relay (11) and the key
Terminal for wire 21B to ground 12 volts
switch (8).
5 – Power Junction
Terminal for wire 1B to ground 12 volts Check the wire between the power junction and the battery.
NOTE: Make sure the connection is good for the power junction.

4001-10 580M ONLY
6 – Power Relays
See the electrical schematic foldout for fuse and relay locations.
Power Relay #1
Terminal for wire 1E to ground 12 volts Check the wire between power relay #1 and the battery (1).
Terminal for wire 10 to ground Continuity Bad ground circuit.

Power Relay #2
Terminal for wire 1K to ground 12 volts Check the wire between power relay #2 and the battery (1).

Power Relay #3
Terminal for wire 1L to ground 12 volts Check the wire between power relay #3 and the battery (1).

Power Relay #4
Terminal for wire 1G to ground 12 volts Check the wire between power relay #4 and the battery (1).
NOTE: Turn the key switch to the ON position.
Check the circuit between all power relays and the key switch (8).
Terminal for wire 4 to ground 12 volts
Check the key switch (8).
Terminal for wire 12A to ground 12 volts Bad power relay #1.
Terminal for wire 12B to ground 12 volts Bad power relay #2.
Terminal for wire 12C to ground 12 volts Bad power relay #3.
Terminal for wire 12D to ground 12 volts Bad power relay #4.
7 – Fuel Shutoff Solenoid

The fuel shutoff solenoid is located at the fuel injection pump on the left side of the machine.
Check the circuit between the fuel shutoff solenoid and the key
switch (8). Check the key switch (8)
NOTE: If the reading is good, replace the fuel shutoff solenoid.

580M ONLY 4001-11
8 – Key Switch
The key switch is located in console on right side of machine.
Terminal for wire 1D to ground 12 volts Bad circuit between the key switch and the battery (1).
NOTE: Disconnect the connector from the key switch. Turn the key switch to the ON position.
Check between the BAT terminal and Continuity Bad key switch.
the IGN terminal of the key switch
the ACC terminal of the key switch
NOTE: Have another person hold the key switch in the START position.
Between the START terminal and the Continuity Bad key switch.
BAT terminal of the key switch
9 – Front Console Ground

10 – Starter Relay
Terminal for wire 1C to ground 12 volts Check wire 1C between the starter relay and the battery (1).
NOTE: Put the transmission control lever in NEUTRAL. Have another person hold the key switch in the START position.
Bad circuit between the starter relay and the neutral start relay
(11). Also check the neutral start relay (11).
Terminal for wire 21B to ground 12 volts Bad starter relay.
11 – Neutral Start Relay

NOTE: Put the transmission control lever in NEUTRAL. Turn the key switch to ON.
Bad circuit between the neutral start relay and the FNR switch
Terminal for wire 21C to ground 12 volts
(13). Also check the FNR switch (13).
Bad circuit between the neutral start relay and the key switch (8).
Also check the key switch (8).
Terminal for wire 22 to ground 12 volts Bad neutral start relay.

4001-12 580M ONLY
12 – Clutch Cutout Relay

NOTE: Have another person push down and hold the loader handle clutch cutout switch.
Bad ground circuit through the loader handle clutch cutout switch
Terminal for wire 25 to ground Continuity
(44). Also check the loader handle clutch cutout switch (44).
NOTE: Have another person push down and hold the shift handle clutch cutout switch.
Bad ground circuit through the shift handle clutch cutout switch
(44). Also check the shift handle clutch cutout switch (44).
Bad circuit between the clutch cutout relay and the 10 ampere
Terminal for wire 19E to ground 12 volts fuse in the fuse block (16). Also check the 10 ampere fuse in the
fuse block (16).
Terminal for wire 21 to ground 12 volts Bad clutch cutout relay.
13 – FNR Switch
The FNR switch is located in the shuttle control valve.
Bad circuit between the FNR switch and the clutch cutout relay
(12). Also check the clutch cutout relay (12)
Terminal for wire 21C to ground 12 volts Bad FNR switch.
NOTE: Put the transmission control lever in FORWARD.
Terminal for wire 25A to ground 12 volts Bad FNR switch.
NOTE: Put the transmission control lever in REVERSE.
Terminal for wire 25B to ground 12 volts Bad FNR switch.
14 – Diode
NOTE: Disconnect the diode from the connector.

Continuity in
Between the terminals of the diode one direction Bad diode.
only.
15 – Diode

Continuity in
only.

580M ONLY 4001-13
16 – Fuse Block
See the electrical schematic foldout for fuse and relay locations
NOTE: Check all fuses in the fuse panel.
17 – Side Console Ground


4001-14 580M ONLY
18 – Instrument Cluster
The instrument cluster is located in the right console.
NOTE: When the key switch is first turned to the ON position, the air filter restriction lamp, hydraulic filter lamp, parking brake
lamp, and air conditioning system pressure lamp will illuminate for 3 seconds for a bulb self- test. If any of the lamps do not
turn on, see section 4005 and replace the lamp(s).
After the self-test, if the key is left in the ON position (without the engine running), alternator, and the low engine oil pressure
lamps are illuminated.
The five backlight bulbs are illuminated when the driving lamp, front work light, or rear work light switch is in the ON position.
NOTE: The instrument cluster controls the warning alarm (19). Wire 23F provides power to the warning alarm (19). The
ground wire (37A) is connected to the instrument cluster connector terminal T35. The warning alarm is activated under the
following conditions:
A. Low engine oil pressure, less than 75 kPa, 0.8 bar (11 psi).
B. High engine coolant temperature, more than 110°C (230°F).
C. Park brake engaged and in gear.
D. Seat turned from driving position and in gear.
NOTE: The hourmeter runs only when the engine is running. Every 6 seconds it will click (you can hear the click). If the
hourmeter is not counting, check the following:
A. Is the tachometer in the instrument cluster working? If not, check the rpm signal input at instrument cluster connector
terminal T19 (wire 31S).
B. Can you hear the hourmeter click every 6 seconds? If not, connect an ampmeter in the power circuit for the instrument
cluster connector at terminal T1 (wire 23F). Every 6 seconds the current draw should go up by approximately 80
milliamps. If not, replace the circuit board for the instrument cluster. If it does, the hourmeter is not working correctly
and must be replaced.
NOTE: Disconnect the connector from the instrument cluster. Turn the key switch and driving lamp switch to ON. Apply the
parking brake.
A. Terminal T1 in connector to Check the circuit between the connector and the key switch (8).
12 volts Also check the 10 ampere fuse in the fuse block (16) and the key
ground
switch (8).
Terminal T2 in connector (for Engine

Check the circuit between the connector and the engine oil
Oil Pressure Warning Lamp - Red Continuity
pressure switch (22). Also check the oil pressure switch (22).
lamp) to ground
Terminal T3 in connector (for Air Filter

Check the circuit between the connector and the air filter
Restriction Warning Lamp - Amber Continuity restriction switch (24). Also check the air filter restriction switch
lamp) to terminal for wire 38 at the air
(24).
filter restriction switch (24).
Terminal T4 in connector (for

Hydraulic Filter Warning Lamp - Check the circuit between the connector and the hydraulic filter
Amber lamp) to the terminal for wire Continuity restriction switch (20). Also check the hydraulic filter restriction
36H at the hydraulic filter restriction switch (20).
switch
Terminal T5 in connector (for

Alternator Warning Lamp - red lamp) Check the circuit between the connector and the alternator (2).
Continuity
to terminal for wire 34 at the alternator Also check the alternator (2).
(2)
Continued on next page.

580M ONLY 4001-15
18 – Instrument Cluster (Continued)

The instrument cluster is located in the right console.
Terminal T7 in connector (for Parking

Check the circuit between the connector and the parking brake
Brake Warning Lamp - red lamp) to Continuity
switches. Also check the parking brake switches.
ground
Check the circuit between the connector and the FNR lever switch
Terminal T8 in connector to ground 12 volts
(13). Also check the FNR lever switch (13).
NOTE: Make sure the operators seat is in the operating position.
Terminal T9 in connector to terminal

Check the circuit between the connector and the seat position
for wire 36R at the seat position Continuity
switch (29). Also check the seat position switch (29).
switch.
Check the circuit between the connector and the AC low pressure
Terminal T10 in connector to ground Continuity
switch (61). Also check the AC low pressure switch (61).
Check the circuit between the connector and the alternator (2).
Terminal T19 in connector to ground Continuity
Also check the alternator (2).
NOTE: The engine rpm signal comes from the alternator “P” terminal and is a 0 to 14 volt square wave signal. Frequency
changes with the engine rpm (307 Hz = 1000 rpm, 736 Hz = 2400 rpm).
Check the circuit between the connector and the fuel level sender
Terminal T20 in connector to ground Ohm
(21). Also check the fuel level sender (21).
Check the circuit between the connector and the transmission

Terminal T21 in connector to ground Ohm temperature sender (25). Also check the transmission
temperature sender (25).
Check the circuit between the connector and the engine

Terminal T22 in connector to ground Ohm temperature sender (26). Also check the engine temperature
sender (26).
Check the circuit between the connector and the turn

Terminal T24 in connector to ground 12 volts signal/driving lamp/horn switch (66). Also check the turn
signal/driving lamp/horn switch (66).
Check the circuit between the connector and the key switch (8).
Terminal T35 to ground 12 volts Also check the 10 ampere fuse in the fuse block (16) and the key
switch (8).
Terminal T36 to ground Continuity Bad ground circuit.
NOTE: If engine temperature is below 0°C (32°F).
Check the circuit between the connector and the grid heater
Terminal T16 to ground 12 volts
controller (118).
NOTE: Turn the front and rear work lamps ON.
Check the circuit between the connector and the front work lamp
switch (81).
Check the circuit between the connector and the rear work lamp
switch (83).

4001-16 580M ONLY
19 – Warning Alarm
The warning alarm is located in the front console.
NOTE: Turn the key switch to ON. If the warning buzzer does not sound, do the following checks.
Check the circuit between the warning alarm and the key switch
Terminal for wire 23F to ground 12 volts (8). Also check the 10 ampere fuse in the fuse block (16) and the
key switch (8).
Terminal for wire 37A to ground 12 volts Bad warning alarm.
20 – Hydraulic Filter Restriction Switch

The hydraulic filter switch is located in the hydraulic filter housing.
Check between the housing of the

hydraulic filter switch and the filter Continuity Bad ground connection.
housing
Check the circuit between the hydraulic filter and the instrument
Terminal for wire 36H to ground 12 volts
cluster (18). Also check the instrument cluster (18).
NOTE: If the readings are good, replace the hydraulic filter switch.
21 – Fuel Level Sender

The fuel level sender is located in the lower part of the fuel tank.
NOTE: Check the level of fuel in the fuel tank. Make sure the fuel tank is full of fuel.
Terminal for wire 30 to ground Continuity Bad ground connection.

Approximately
4 -8 volts Check the circuit between the fuel level sender and the instrument
Terminal for wire 36F to ground (empty) cluster (18) (including the connection on the instrument cluster).
2 - 3 volts Also check the instrument cluster (18).
(full)
Empty
Disconnect wire 36F from the fuel (Low fuel lamp
level sender. Check the reading of the Bad fuel level gauge.
should
fuel level gauge. illuminate)
Connect wire 36F to ground. Check Full Bad fuel level gauge.
the reading of the fuel level gauge.
NOTE: If the readings are good, use an ohmmeter and check the resistance of the fuel level sender. Disconnect the wires
from the fuel level sender. When the fuel tank is full, the resistance should be approximately 33 Ohm. If the fuel tank is empty,
the resistance should be 235 Ohm. If the ohmmeter readings are not correct, replace the fuel level sender.

580M ONLY 4001-17
22 – Engine Oil Pressure Switch

The engine oil pressure switch is located below the fuel injection pump on the left side of the engine.
Check between the housing of the oil Bad ground connection between the engine oil pressure switch
Continuity
pressure switch and the engine block and the engine block.
NOTE: Turn the key switch to ON. Disconnect the wire from the engine oil pressure switch.
Check the circuit between the engine oil pressure switch and the
Terminal for wire 31P to ground 12 volts
instrument cluster (18). Also check the instrument cluster (18).
NOTE: If the readings are good, replace the engine oil pressure switch. The engine oil pressure switch is closed when there
is no pressure (engine off) and open when the pressure is above 83 kPa, 0.84 bar (12 psi).
23 – Not Used
24 – Air Filter Restriction Switch

The air filter restriction switch is located in the hose between the air filter and the engine.
Bad circuit between the air filter restriction switch and the
25 – Transmission Temperature Sender

The transmission temperature sender is located in the top, right, rear cover of the transmission case.

transmission temperature sender and Continuity Bad ground connection.
the transmission housing
Check the circuit between the transmission temperature sender

Approximately
Terminal for wire 32T to ground and the instrument cluster (18). Also check the instrument cluster
12 volts
(18).
NOTE: If the readings are good, disconnect the wires from the transmission temperature sender. Use an ohmmeter and
check the resistance of the transmission temperature sender. The output of the transmission temperature sender must be
above 1000 Ohm with the transmission at ambient temperature. If the ohmmeter reading is not correct replace the
transmission temperature sender.

4001-18 580M ONLY
26 – Engine Temperature Sender

The engine temperature sender is located at the front top of the engine.

engine temperature sender and the Continuity Bad ground connection.
engine.
Check the circuit between the engine temperature sender and the
Terminal for wire 31T to ground 12 volts
NOTE: If the readings are good, disconnect the wires from the engine temperature sender. Use an ohmmeter and check the
resistance of the engine temperature sender. The output of the engine temperature sender must be above 1000 Ohm with the
engine at ambient temperature. If the ohmmeter reading is not correct replace the engine temperature sender.
27 – SAHR Parking Brake Pressure Switch

NOTE: The SAHR pressure switch is located on the rear of the transmission on the parking brake housing.
NOTE: With the park brake set and the machine not running.
Between the terminal of the switch Open Bad switch
NOTE: Block the tires of the machine to keep it from moving, with the engine running, release the parking brake.
Between the terminal of the switch Continuity Bad switch
NOTE: See section 7002 and troubleshoot the SAHR hydraulics.
28 – SAHR Parking Brake ON/OFF Switch

NOTE: No engineering information available at this time of printing.
NOTE:
NOTE:
29 – Seat Position Switch

The seat position switch is located in the seat column.
Check the circuit between the seat position switch and the
Terminal for wire 36R to ground 12 volts
NOTE: If the readings are good, replace the seat position switch

580M ONLY 4001-19
30 – SAHR Parking Brake Solenoid

NOTE: The SAHR solenoid is located on the rear of the transmission on the rear housing.
9.8 Ohm at
Between the terminals of the solenoid Replace solenoid
20° C (68° F)
31 – SAHR Parking Brake Relay

NOTE: The SAHR relay is located in the front console.
Terminal for wire 10 to ground Continuity Bad ground circuit
NOTE: Turn the ignition switch to the ON position.
Terminal for wire 19B to ground 12 volts Bad fuse, bad ignition switch
32 – Shuttle Interlock Relay

NOTE: Put the transmission control lever and FNR switch in NEUTRAL. Turn the key switch to ON. Make sure the clutch
cutout switches are in the disengaged position.
Check the circuit between the shuttle interlock relay and the FNR
switch (13). Also check the FNR switch (13).
NOTE: Make sure the transmission control lever is in NEUTRAL. Turn the key switch to ON. Make sure the clutch cutout
switches are in the disengaged position. Move the shift lever to the FORWARD position.
Terminal for wire 24 to ground 12 volts Bad Interlock Relay.
switches are in the disengaged position. Move the shift lever to the REVERSE position.
33 – Shuttle Interlock Timing Relay

Check the circuit between the shuttle interlock timing relay and the
Terminal for wire 24 to ground 12 volts shuttle interlock relay (32). Also check the shuttle interlock relay
(32).
Terminal for wire 19E to ground 12 volts
key switch (8). Also check the key switch (8).
Terminal for wire 19M to ground 12 volts Bad shuttle interlock timing relay.

4001-20 580M ONLY
34 – Diode

Continuity in
only.
35 – Diode

Continuity in
only.
36 – Forward Relay
Check the circuit between the forward relay and the FNR switch
Terminal for wire 25A to ground 12 volts (13). Check the diode (34) in the circuit. Also check the FNR
switch (13).
Check the circuit between the forward relay and the shuttle
Terminal for wire 19M to ground 12 volts interlock timing relay (33). Also check the shuttle interlock timing
relay (33).
Terminal for wire 26 to ground 12 volts Bad forward relay.
37 – Reverse Relay
NOTE: Turn the key switch to ON. Move the shift lever to the reverse position.
Check the circuit between the reverse relay and the shuttle
Terminal for wire 25B to ground 12 volts interlock timing relay (33). Check the diode (34) in the circuit. Also
check the FNR switch (13).
relay (33).
Terminal for wire 27 to ground 12 volts Bad reverse relay.

580M ONLY 4001-21
38 – Diode

Continuity in
only.
39 – Diode

Continuity in
only.
40 – Forward Solenoid
The forward solenoid is located in the transmission control valve.
NOTE: Turn the key switch to ON. Move the shift lever to the forward position.
Check the circuit between the forward solenoid and the forward
Terminal for wire 26 to ground 12 volts relay (36). Check the forward relay (36). Also check the diode (34)
in the circuit.
NOTE: If the readings are good, replace the forward solenoid.
41 – Reverse Solenoid
The reverse solenoid is located in the transmission control valve.
Check the circuit between the reverse solenoid and the reverse
Terminal for wire 27 to ground 12 volts relay (37). Check the reverse relay (37). Also check the diode (34)
in the circuit.
NOTE: If the readings are good, replace the reverse solenoid.

4001-22 580M ONLY
42 – Backup Alarm
The backup alarm is located in the rear of the machine.
Negative terminal to ground Continuity Bad ground connection.
Check the circuit between the backup alarm and the reverse relay
(37). Also check the reverse relay (37).
NOTE: If the readings are good, replace the backup alarm.
43 – Clutch Cutout Switch - Shift Handle

The clutch cutout switch is located in the switch handle.
Check the circuit between the clutch cutout switch and the clutch
cutout relay (12). Also check the clutch cutout relay (12).
NOTE: Push down and hold the clutch cutout switch.
Terminal for wire 25 to ground Continuity Bad clutch cutout switch.
44 – Clutch Cutout Switch - Loader Handle

The clutch cutout switch is located in the loader handle.
45 – Return-To-Dig Limit Switch

The return-to-dig limit switch is located on the right loader arm.
Check the circuit between the return-to-dig limit switch and the
Terminal for wire 53 to ground 12 volts loader valve solenoid (46). Also check the loader valve solenoid
(46).
NOTE: If the readings are good, replace the return-to-dig limit switch.

580M ONLY 4001-23
46 – Loader Valve Solenoid

The loader valve solenoid is located in the loader control valve.
Check the circuit between the loader valve solenoid and power
Terminal for wire 19F to ground 12 volts relay #1 (6). Also check the 10 ampere fuse in the fuse block (16)
and power relay #1 (6).
Terminal for wire 53 to ground 12 volts Bad loader valve solenoid.
47 – Front Wiper Switch (Cab)

The front wiper switch is located in the cab.

Check the circuit between the front wiper switch and power relay
Terminal for wire 63 to ground 12 volts #1 (6). Also check the 15ampere fuse in the fuse block (16) and
power relay #1 (6).
Terminal for wire 69 to ground 12 volts Bad front wiper switch.
NOTE: Turn the front wiper switch to LOW.
NOTE: Turn the front wiper switch to HIGH.
48 – Rear Wiper Switch (Cab)

NOTE: Turn the key switch to ON, close the cab rear glass.
Check rear wiper cut off switch (53). Check the circuit between the
Terminal for wire 63A to ground 12 volts rear wiper switch and power relay #1 (6). Also check the 15
ampere fuse in the fuse block (16) and power relay #1 (6).
Terminal for wire 89 to ground 12 volts Bad rear wiper switch.
NOTE: Turn the rear wiper switch to LOW.
NOTE: Turn the rear wiper switch to HIGH.

4001-24 580M ONLY
49 – Front Windshield Washer Switch (Cab/ROPS with Windscreen Only)

Check the circuit between the windshield washer switch and

Terminal for wire 63 to ground 12 volts power relay #1 (6). Also check the 15 ampere fuse in the fuse
block (16) and power relay #1 (6).
NOTE: Turn the front windshield washer switch to on.
Terminal for wire 62 to ground 12 volts Bad windshield washer switch.
50 – Rear Windshield Washer Switch (Cab/ROPS with Windscreen Only)


NOTE: Turn the rear windshield washer switch to on.
Terminal for wire 65

12 volts Bad windshield washer switch.
to ground
51 – Front Wiper Motor (Cab)

The front wiper motor is located at the front wiper.
Terminal for wire 40A to ground Continuity Bad ground circuit.
Check the circuit between the front wiper motor and power relay
Terminal for wire 63 to ground 12 volts #1 (6). Also check the 15 ampere fuse in the fuse block (16) and
power relay #1 (6).
Check the circuit between the front wiper and the front wiper
switch (47). Also check the front wiper switch (47).

580M ONLY 4001-25
52 – Rear Wiper Motor (Cab)

NOTE: Close rear cab glass.
Terminal for wire 40B to ground Continuity Bad ground circuit.
Check the circuit between the rear wiper motor and power relay
Terminal for wire 63 to ground 12 volts #1 (6). Also check the 15ampere fuse in the circuit and power
relay #1 (6).
Check the circuit between the rear wiper motor and the rear wiper
switch (48). Also check the rear wiper switch (48).
53 – Rear Wiper Cut Off Switch

NOTE: Disconnect the wires from the rear wiper cut off switch. Make sure the rear cab glass is open.
Between the terminals of the rear

Open Bad rear wiper cut off switch.
wiper cut off switch
NOTE: Close rear cab glass, make sure switch is being pushed to closed position.

Continuity Bad rear wiper cut off switch.
wiper cut off switch.
54 – Windshield Washer Motor

The windshield washer pump is located just above and in front of the radiator.
NOTE: Turn the key switch to ON. Have another person hold the front windshield washer switch in the on position.
Check the circuit between the windshield washer motor and the
Terminal for wire 62 to ground 12 volts windshield washer switch (49). Also check the windshield washer
switch (49).
NOTE: Make sure the key switch is in the ON position. Have another person hold the rear windshield washer switch in the on
position.
Terminal for wire 65 to ground 12 volts rear windshield washer switch (50). Also check the rear
windshield washer switch (50).

4001-26 580M ONLY
55 – Blower Switch
The blower switch is located in the console.
Bad circuit between the blower switch and power relay #2 (6). Also
Terminal for wire 61 to ground 12 volts check the 25 ampere fuse in the fuse block (16) and power relay
#2 (6).
NOTE: Turn the blower switch to LOW.
Terminal for wire 86 to ground 12 volts Bad blower switch.
NOTE: Turn the blower switch to MEDIUM.

NOTE: Turn the blower switch to HIGH.
56 – Air Conditioning Pressure Relay

NOTE: Turn the key switch to ON. Turn the blower switch to HIGH and the air conditioning temperature switch to COLD.
Check the circuit between the air conditioner relay and the air
Terminal for wire 60 to ground 12 volts conditioning temperature switch (60). Also check the air
conditioning temperature switch (60).
Bad low pressure switch (61) or high pressure switch (62) or

Terminal for wire 60A to ground Open
incorrect charge.
Terminal for wire 60B to ground 12 volts Bad compressor clutch relay or a bad high or low pressure switch.

580M ONLY 4001-27
57 – Blower Motor Resistor Board and Thermal Fuse

The blower resistor board and thermal fuse are located with the blower motor in the headliner.
NOTE: Turn the key switch to ON. Turn the blower switch to LOW.
NOTE: Disconnect the connector from the resistor board.
Between terminals 1 and 3 of the

3.8 Ohm Bad resistor board.
resistor board
58 – Blower Motor
The blower motor is located in the headliner.
NOTE: Turn the key switch to ON. Turn the blower switch to HIGH.
Bad circuit between the blower motor and the blower switch (55).
Also check the blower switch (55).
59 – Air Conditioning Compressor Clutch

The air conditioning compressor clutch is located on the left side of the engine.
Ground wire of the air conditioning

Continuity Bad ground wire.
clutch to ground
NOTE: Turn the key switch to ON. Turn the cab blower switch to HIGH and the air conditioning temperature switch to COLD.
Check the circuit between the air conditioning compressor clutch

Terminal for wire 60B to ground 12 volts and the compressor clutch relay (59). Also check the compressor
clutch relay (59).
NOTE: If the readings are correct, replace the air conditioning compressor clutch.
60 – Air Conditioning Temperature Switch

The air conditioning temperature switch is located in the console.
Bad circuit between the air conditioning temperature switch and

the blower switch (55). Also check the blower switch (55).
NOTE: Turn the air conditioning temperature switch all the way to COLD.
Terminal for wire 60 to ground 12 volts Bad air conditioning temperature switch.

4001-28 580M ONLY
61 – Air Conditioning Low Pressure Switch

The air conditioning low pressure switch is located above the headliner at the top of the right side of the cab.
Bad ground circuit between the air conditioning low pressure

Terminal for wire 60A to ground. Continuity
switch and ground.
Bad circuit between the low pressure switch and the air
NOTE: Disconnect the wires from the low pressure switch.

Between the terminals of the low Low charge in the air conditioning system. See Section 9002. Bad
Open
pressure switch. low pressure switch.
62 – Air Conditioning High Pressure Switch

The air conditioning high pressure switch is located in front of the radiator behind the grille.
Bad ground circuit between the air conditioning high pressure

switch and ground.
Bad circuit between the high pressure switch and the air
NOTE: Disconnect the wires from the high pressure switch.
Between the terminals of the high High charge in the air conditioning system. See Section 9002. Bad
Open
pressure switch. high pressure switch.
63 – Dome Lamp Door Switch

The dome lamp switch is located in the door frame at the hinge side of the cab door.
Check the circuit between the dome lamp door switch and the
battery (1). Also check the 10 ampere fuse in the fuse block (18).
NOTE: Put the dome lamp switch in the AUTO ON position (depress rear of switch). Open the cab door.
Bad ground circuit. Check the circuit between the dome lamp door
Terminal for wire 61B to ground 12 volts switch and the dome lamp switch (64). Also check the dome lamp
switch (64).

580M ONLY 4001-29
64 – Dome Lamp Switch

The dome lamp with switch is located in the headliner.
Bulb Good Bad bulb.
Check the circuit between the dome lamp and the battery (1). Also
check the 10 ampere fuse in the fuse block (16).
Check the circuit between the dome lamp switch and the dome
Terminal for wire 61B to ground 12 volts lamp door switch (63). Also check the dome lamp door switch
(63).
NOTE: If the readings are good replace the dome lamp switch
65 – Rear Horn Button

The rear horn button is located in the right console.
Terminal for wire 64B to ground Continuity Bad ground circuit through the horn (69). Also check the horn (69).
Check the circuit between the rear horn button and the battery (1).
Also check the 10 ampere fuse in the fuse block (16).
NOTE: Have another person push down and hold the horn button.
Terminal for wire 64B to ground 12 volts Bad horn button.

4001-30 580M ONLY
66 – Turn Signal/Driving Lamp/Horn Switch

Turn Signal Switch: The turn signal switch is located on the lever in the steering column.
Check the circuit between the turn signal switch and power relay
Terminal for wire 19B to ground 12 volts #2 (6). Also check the 15 ampere fuse in the fuse block (16) and
power relay #2 (6).
NOTE: Turn the key switch to ON. Move the turn signal/driving lamp/horn switch for a left turn.
Check the circuit between the turn signal switch and flasher relay
(72). Also check the flasher relay (72).
Intermittent 12
Terminal for wire 45L to ground Bad turn signal/driving lamp/horn switch.
volts
NOTE: Turn the key switch to ON. Move the turn signal/driving lamp/horn switch for a right turn.
Terminal for wire 45L to ground 12 volts
Intermittent 12
Terminal for wire 45R to ground Bad turn signal/driving lamp/horn switch.
volts
Driving Lamp Switch: The driving lamp switch is located on the lever in the steering column.
Check the circuit between the driving lamp switch and power relay
Terminal for wire 19A to ground 12 volts #1 (6). Also check the 15 ampere fuse in the ampere fuse in the
fuse block (16) and power relay #1 (6).
NOTE: Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad driving lamp switch.
Horn Switch:The horn switch is located on the lever in the steering column.
Check the circuit between the horn button and the battery (1). Also
Terminal for wire 64A to ground 12 volts check the 10 ampere fuse in the fuse block (16) and the battery
(1).
NOTE: Have another person push in and hold the horn button.
Terminal for wire 64B to ground 12 volts Bad horn switch.
67 – Driving Lamps
The driving lamps are located between the turn lamps and the front work lamps.
Terminal 40D to ground Continuity Bad ground connection.
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Bad circuit between the driving lamps and the turn signal/driving
Terminal for wire 41 to ground 12 volts lamp/horn switch (66). Also check the turn signal/driving
lamp/horn switch (66).

580M ONLY 4001-31
68 – Rear Stop and Tail Lamps

The rear tail lamps are located between the rear turn lamps and the rear work lamps.
Terminal 40E to ground Continuity Bad ground circuit.
Bulb Good Bad bulb.
Bad circuit between the rear tail lamps and the turn signal/driving
NOTE: Have another person push down and hold the brake pedal.
Bad circuit between the rear tail lamps and the brake lamp switch
(71). Also check the brake lamp switch (71).
69 – Horn
The horn is located on the left side of the engine.
NOTE: Turn the key switch to the ON position. Have another person hold down the horn button.
Check the circuit between the horn and the turn signal/driving
Terminal for wire 64B to ground 12 volts lamp/horn switch (66). Also check the turn signal/driving
NOTE: If the readings are correct and the horn does not work, replace the horn.
70 – Hazard Flasher Switch

The flasher switch is located in the front console.

Check the circuit between the hazard flasher switch and power
Terminal for wire 19B to ground 12 volts relay #2 (6). Also check the 15 ampere fuse in the fuse block (16)
NOTE: Put the flasher switch in the ON position.
Terminal for wire 46 to ground 12 volts Bad hazard flasher switch.
NOTE: If the readings are correct and the indicator lamp on the hazard flasher switch does not illuminate, do the following
check.
Terminal for wire 10 to ground Continuity Bad ground circuit for hazard flasher switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the flasher switch does not illuminate, replace the hazard flasher
switch.

4001-32 580M ONLY
71 – Brake Lamp Switch

The brake lamp switch is located on the fire wall below the brake pedals.

Check the circuit between the brake lamp switch and power relay
power relay #2 (6).
Terminal for wire 44 to ground 12 volts Bad brake lamp switch.
72 – Flasher Relay (Bottom of Socket)

Terminal for wire 10 (T4) to ground Continuity Bad ground circuit.
Check the circuit between the flasher relay and power relay #2 (6).
Terminal for wire 19B (T2) to ground 12 volts Also check the 15 ampere fuse in the fuse block (16) and power
relay #2 (6).
NOTE: Make sure the turn signal is in the OFF position. Turn the flasher switch ON.
Check the circuit between the flasher relay and the flasher switch
Terminal for wire 46 (T1) to ground 12 volts
(70). Also check the flasher switch (70).
Intermittent 12
Terminal for wire 45L (T5) to ground Bad flasher relay.
volts
Intermittent 12
Terminal for wire 45R (T7) to ground Bad flasher relay.
volts
NOTE: Make sure the hazard flasher switch is in the OFF position. Move the turn signal/driving lamp/horn switch to the left
turn position.
Check the circuit between the flasher relay and the turn
Terminal for wire 45R (T7) to ground 12 volts signal/driving lamp/horn switch (66). Also check the turn
Intermittent 12
volts
Intermittent 12
volts
NOTE: Make sure the hazard flasher switch is in the OFF position. Move the turn signal/driving lamp/horn switch to the right
turn position.
Terminal for wire 45L (T5) to ground 12 volts signal/driving lamp/horn switch (66). Also check the turn
Intermittent 12
volts
Intermittent 12
volts

580M ONLY 4001-33
73 – Front Turn Lamp

Left Front Turn Lamp: The left front turn lamp is located at the top of the ROPS cab or canopy on the left side of the front of
the machine.
Bulb Good Bad bulb.
Terminal for 40D to ground Continuity Bad ground circuit.
NOTE: Turn the key switch to ON. Move the turn signal switch for a left turn.
Intermittent 12 Check the circuit between the left front turn lamp and the turn
Terminal for wire 45L to ground volts signal switch (66). Also check the turn signal switch (66).
NOTE: Turn the key switch to ON. Move the turn signal switch for a right turn.
Check the circuit between the right front turn lamp and the turn
signal switch (66). Also check the turn signal switch (66).
Right Front Turn Lamp: The right front turn lamp is located at the top of the ROPS cab or canopy on the right side of the
front of the machine.
Bulb Good Bad bulb.
Intermittent 12 Check the circuit between the right front turn lamp and the turn
Terminal for wire 45R to ground volts signal switch (66). Also check the turn signal switch (66).
Check the circuit between the left front turn lamp and the turn

4001-34 580M ONLY
74 – Rear Turn Lamp

Left Rear Turn Lamp: The left rear turn lamp is located at the top of the ROPS cab or canopy on the left side of the rear of
the machine.
Bulb Good Bad bulb.
Terminal for 40E to ground Continuity Bad ground circuit.
Intermittent 12 Check the circuit between the left rear turn lamp and the turn
Check the circuit between the right rear turn lamp and the turn
Right Rear Turn Lamp: The right rear turn lamp is located at the top of the ROPS cab or canopy on the right side of the front
of the machine.
Bulb Good Bad bulb.
75 – Turn Signal Indicator Lamps

The turn signal indicator lamps are located in the front console.

Intermittent 12 Check the circuit between the right rear turn lamp and the turn
76 – Power Plug #1
The power plug is located to the rear of the right hand console.
Check the circuit between power plug #1 and the battery (1). Also
Terminal for wire 83 to ground 12 volts check the 30 ampere fuse in the fuse block (16), the power
junction (5) and the battery (1).

580M ONLY 4001-35
The power plug is located to the rear of the right hand console.a
Terminal for wire 20C to ground Continuity Bad ground circuit.
78 – Air Suspension Seat - Air Compressor Switch and Motor

Located in the base of the air suspension seat.
Check the circuit between the air compressor and the battery (1).
Terminal for wire 19N to ground 12 volts Also check the 20 ampere fuse in the fuse block (16) the power
79 – Rotating Beacon Switch

The rotating beacon switch is located in the front console.
Check the circuit between the rotating beacon switch and power
Terminal for wire 19D to ground 12 volts relay #1 (6). Also check the 10 ampere fuse in the fuse block (16)
NOTE: Put the rotating beacon switch in the ON position.
Terminal for wire 48 to ground 12 volts Bad rotating beacon switch.
NOTE: If the readings are correct and the indicator lamp on the rotating beacon switch does not illuminate, do the following
check.
Terminal for wire 10 to ground Continuity Bad ground circuit for rotating beacon switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the rotating beacon switch does not illuminate, replace the
rotating beacon switch.
80 – Rotating Beacon (Opt)

The rotating beacon is located on top of the ROPS cap or canopy.
Terminal for wire 40E to ground Continuity Bad ground circuit.
NOTE: Turn the key switch to ON. Turn the rotating beacon switch to ON.
Bulb Good Bad bulb.
Check the circuit between the rotating beacon and the rotating
beacon switch (79). Also check the rotating beacon switch (79).
NOTE: If the readings are good, replace the rotating beacon.

4001-36 580M ONLY
81 – Front Work Lamp Switch

The front work lamp switch is located in the console.
Check the circuit between the front work lamp switch and power
Terminal for wire 19K to ground 12 volts relay #3 (6). Also check the 10 ampere fuse in the fuse block (16)
NOTE: Put the front work lamp switch in the ON position.
Terminal for wire 42F to ground 12 volts Bad front work lamp switch.
NOTE: If the readings are correct and the indicator lamp on the front work lamp switch does not illuminate, do the following
check.
Terminal for wire 10 to ground Continuity Bad ground circuit for front work lamp switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the front work lamp switch does not illuminate, replace the front
work lamp switch.
82 – Front Work Lamps

The front work lamps are located between the front road lamps at the front of the machine.
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Turn the front work lamp switch to ON.
Check the circuit between the front work lamp and the front work
Terminal for wire 42F to ground 12 volts
lamp switch (81). Also check the front work lamp switch (81).
83 – Rear Work Lamp Switch

The rear work lamp switch is located in the console.
Check the circuit between the rear work lamp switch and power
Terminal for wire 19C to ground 12 volts relay #3 (6). Also check the 20 ampere fuse in the fuse block (16)
NOTE: Put the rear work lamp switch in the ON position.
Terminal for wire 42C to ground 12 volts Bad rear work lamp switch.
NOTE: If the readings are correct and the indicator lamp on the rear work lamp switch does not illuminate, do the following
check.
Terminal for wire 20 to ground Continuity Bad ground circuit for rear work lamp switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the rear work lamp switch does not illuminate, replace the rear
work lamp switch.

580M ONLY 4001-37
84 – Rear Work Lamps

The rear work lamps are located between the rear road lamps at the rear of the machine.
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Turn the rear work lamp switch to ON.
Check the circuit between the rear work lamps and the rear work
lamp switch (83). Also check the rear work lamp switch (83).
85 – 4WD Engage Switch (If Equipped)

The 4wd engage switch is located in the console.
NOTE: Turn the key switch to ON. Put the 4WD engage switch in the ON position.
Check the circuit between the 4WD engage switch and power
Terminal for wire 25E to ground 0 volts Bad 4WD engage switch.
NOTE: Put the 4WD engage switch in the OFF position.
NOTE: If the readings are correct and the indicator lamp on the 4WD engage switch does not illuminate, do the following
check.
Terminal for wire 10 to ground Continuity Bad ground circuit for 4WD engage switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the 4WD engage switch does not illuminate, replace the 4WD
engage switch.
86 – Diode

Continuity in
only.

4001-38 580M ONLY
87 – 4WD Solenoid (Disengages 4WD When Energized)

The 4wd solenoid is located in the on top of the transmission.
Check the circuit between the 4WD solenoid and the 4WD engage
switch (85). Also check the 4WD engage switch (85).
NOTE: If the readings are correct, replace the 4WD solenoid.
88 – Thumb Operated Rear Auxiliary Hydraulics Switch (Pilot Controls) Uni-directional

NOTE: Disconnect switch, push and hold the switch.
Between the terminals of the switch Continuity Bad switch
NOTE: Release the switch.
Between the terminals of the switch Open Bad switch
89 – Foot Operated Rear Auxiliary Hydraulic Switch

NOTE: Put the key switch in the ON position.
Terminal for wire 75 to ground 0 volts Bad foot operated rear auxiliary hydraulic switch.
NOTE: Have another person push down and hold the rear auxiliary hydraulic switch.
90 – Diode

Continuity in
only.

580M ONLY 4001-39
91 – Auxiliary Hydraulic Solenoid Uni-directional

NOTE: Put the hand operated auxiliary hydraulics engage switch in the ON position
Check the circuit between the auxiliary hydraulic solenoid and the
Terminal for wire 75 to ground 12 volts auxiliary hydraulics engage switch (88 or 89). Also check the
auxiliary hydraulics engage switch (88 or 89).
NOTE: If the readings are correct, replace the hand operated auxiliary hydraulics solenoid.
92 – Radio (Optional)
Check the circuit between the radio and the battery (1). Also check
the 10 ampere fuse in the fuse block (16) and the battery (1).
Check the circuit between the radio and power relay #2 (6). Also
#2 (6).
93 – Left Speaker
94 – Right Speaker
95 – Ride Control Engage Switch

Check the circuit between the ride control engage switch and
NOTE: Put the ride control engage switch in the ON position.
Terminal for wire 401 to ground 12 volts Bad ride control engage switch.
NOTE: If the readings are correct and the indicator lamp on the ride control engage switch does not illuminate, do the
following check.
Terminal for wire 10 to ground Continuity Bad ground circuit for ride control engage switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the ride control engage switch does not illuminate, replace the
ride control engage switch.

4001-40 580M ONLY
96 – Ride Control Solenoid (Accumulator)

NOTE: Turn the key switch to ON. Put the ride control engage switch in the ON position.
Check the circuit between the right ride control solenoid and the
Terminal for wire 401 to ground 12 volts ride control engage switch (95). Also check the ride control
engage switch (95).
NOTE: If the readings are correct, see Section 8002 and check the system for the right ride control solenoid.
97 – Ride Control Solenoid (Tank)

engage switch (95).
NOTE: If the readings are correct, see Section 8002 and check the system for the left ride control solenoid.
98 – Boom Lock Switch

Check the circuit between the boom lock switch and power relay
power relay #2 (6).
NOTE: Put the boom lock switch in the ON position.
Terminal for wire 13D to ground 12 volts Bad boom lock switch.
99 – Boom Lock Solenoid

NOTE: Turn the key switch to ON. Put the boom lock switch in the ON position.
Check the circuit between the boom lock solenoid and the boom
Terminal for wire 13D to ground 12 volts
lock switch (98). Also check the boom lock switch (98).
NOTE: If the readings are correct, replace the boom lock solenoid.

580M ONLY 4001-41
100 – Loader Quick Coupler Disengage Switch

The loader quick coupler disengage switch.
Check the circuit between the loader quick coupler disengage

Terminal for wire 57 to ground 12 volts switch and power relay #2 (6). Also check the 15 ampere fuse in
the fuse block (16) and power relay #2 (6).
NOTE: Put the front quick coupler disengage switch in the CONNECT position.
Terminal for wire 501 to ground 12 volt Bad loader quick coupler disengage switch
NOTE: Put the front quick coupler disengage switch in the DISCONNECT position.
101 – Loader Quick Coupler Solenoid

NOTE: Turn the key switch to ON. Put the front quick coupler disengage switch in the ON position.
Terminal for wire 502 to ground 12 volts loader quick coupler switch (100). Also check the loader quick
coupler switch (100).
102 – Loader Load Sensing Solenoid

103 – Diode

Continuity in
only.

4001-42 580M ONLY
104 – Backhoe Quick Coupler Switch A

Check the circuit between backhoe quick coupler switch #1 and

NOTE: Hold the backhoe quick coupler switch in the DISCONNECT position.
Terminal for wire 504A to ground 12 volt Bad backhoe quick coupler switch #1.
NOTE: Hold the backhoe quick coupler switch in the CONNECT position.
Terminal for wire 501 to ground 12 volt Bad backhoe quick coupler switch #1.
105 – Backhoe Quick Coupler Switch B

NOTE: Turn the key switch to ON. Put the backhoe quick coupler switch #1 in the DISCONNECT position.

Terminal for wire 504A to ground 12 volt backhoe quick coupler switch #1 (104). Also check the backhoe
quick coupler switch #1 (104).
NOTE: Hold the backhoe quick coupler switch #1 and #2 in the DISCONNECT position.
106 – Backhoe Quick Coupler Solenoid

NOTE: Turn the key switch to ON. Hold the backhoe quick coupler switch #1 and #2 in the DISCONNECT position.
Check the circuit between backhoe quick coupler solenoid (upper)

Terminal for wire 504 to ground 12 volts and backhoe quick coupler switch #2 (105). Also check the
backhoe quick coupler switch #2 (105).
107 – Loader Lever Differential Lock Engage Switch

Located on the loader lever.
NOTE: Disconnect the wires from the loader lever differential lock engage switch. Make sure the loader lever differential lock
engage switch is in the DISENGAGED position.
Between the terminals of the loader Open Bad loader lever differential lock engage switch.
lever differential lock engage switch
NOTE: Have another person hold the loader lever differential lock engage switch in the ENGAGED position
Between the terminals of the loader Continuity Bad loader lever differential lock engage switch.
lever differential lock engage switch.

580M ONLY 4001-43
108 – Loader Lever Differential Lock Enable Relay

NOTE: Have another person hold the loader lever differential lock engage switch in the ENGAGED position.
Bad ground circuit through the loader lever differential lock

Terminal for wire 7 to ground Continuity engage switch (107). Also check the loader lever differential lock
engage switch (107).
Check the circuit between the loader lever differential lock enable
Terminal for wire 19B to ground 12 volts relay and power relay #2 (6). Also check the 15 ampere fuse in the
NOTE: With the key switch in the ON position. Have another person hold the loader lever differential lock engage switch in the
ENGAGED position.
Terminal for wire 25S to ground 12 volts Bad loader lever differential lock enable relay
109 – Differential Lock Solenoid

NOTE: Turn the key switch to ON. Hold differential lock engage switch in the ENGAGED position.
Check the circuit between the differential lock solenoid and the
Terminal for wire 25S to ground 12 volts loader lever differential lock engage switch (107). Check the
loader lever differential lock engage switch (107).
NOTE: With the key switch in the ON position. Hold loader lever differential lock engage switch in the ENGAGED position.
Terminal for wire 25S to ground 12 volts loader lever differential lock enable relay (108). Check the loader
lever differential lock enable relay (108).
110 – KKSB Cutout Female Connector

NOTE:
111 – KKSB Cutout Male Connector

NOTE:

4001-44 580M ONLY
112 – KKSB Relay

NOTE:
113 – Grid Heater Relay

The grid heater relay is located on the left side of the frame behind the air filter.
Terminal for wire B to ground Continuity Bad ground circuit.
Terminal for wire 2A to ground 12 volts Bad 300 Amp fuse, bad wire from starter to fuse.
NOTE: Have an assistant put the transmission in neutral and the ignition switch in the ON position. Make sure the engine
temperature is below -1°C (29°F).
Terminal for wire Y to ground 12 volts Bad grid heater controller, bad circuit Y.
Terminal for wire 2B to ground 12 volts Bad grid heater relay.
114 – Diode

Continuity in
only.
115 – Grid Heater Unit

The grid heater is located on the engine air intake.
NOTE: Disconnect the positive wire from the grid heater.
Positive terminal of grid heater to

Resistance If an open or short circuit is obtained, replace the grid heater.
ground
116 – Cold Start Relay

NOTE:

580M ONLY 4001-45
117 – Grid Heater Fuse

The grid heater fuse is located on the left side of the frame behind the air filter.
Between terminals of fuse Continuity Bad Fuse
118 – Grid Heater Controller

The grid heater controller is located on the left side of the frame behind the air filter.
NOTE: Disconnect the connector from the grid heater controller. Put the ignition switch in the on position.
Terminal for wire B to ground Continuity Bad ground circuit.
Terminal for wire LB to ground 12 volts Bad fuse 5D.
NOTE: Have an assistant put the transmission in neutral and the ignition switch in the START position. Make sure the engine
temperature is below -1°C (29°F).
Terminal for wire WB to ground 12 volts Bad starter relay, bad wire 21B from starter solenoid.
NOTE: If the reading is good, replace the grid heater controller.
119 – Not Used
120 – Grid Heater Thermo Sending Unit

The grid heater thermo sending unit is located at the front top of the engine.
5680 to 7230
Between terminals for thermo switch Ohm Bad thermo sender
at -1° F (29° C)
121 – Extend-a-hoe Extend Push Button (Pilot Controls)

The push button is located on the right pilot control handle.
NOTE: Check for fault code at controller, see section 8002 pilot controls.
122 – Extend-a-hoe Retract Push Button (Pilot Controls)


4001-46 580M ONLY
123 – Horn Switch (Pilot Controls)

The push button is located on the left pilot control handle.
NOTE: Disconnect the connector and press the button
Between the terminals of the button Continuity Bad push button switch
NOTE: Release the button
Between the terminals of the button Open Bad push button switch
124 – Left Hand Stabilizer Switch (Pilot Controls)

The push button is located on the left pilot control tower.
125 – Right Hand Stabilizer Switch (Pilot Controls)

126 – Left Hand Stabilizer Pressure Switch (Pilot Controls)

The pressure switch is located inside of the left rear frame mounted to the stabilizer locking valve.
NOTE: Stabilizers in raised position, engine off.
Between terminals of switch Continuity Bad pressure switch.
127 – Right Hand Stabilizer Pressure Switch (Pilot Controls)

The pressure switch is located inside of the right rear frame mounted to the stabilizer locking valve.
128 – Electrical Pilot Controller (Pilot Controls)

The controller is located under the machine on the left front side of the mounted bracket for the pilot valve.
NOTE: Disconnect connector from controller, turn the ignition switch on and the pilot control switch on.
Terminal for wire 601 12 volts Bad pilot on/off switch (137), bad pilot relay (138), bad fuse.
Fault light on with no blink Bad control unit

580M ONLY 4001-47
129 – Right Hand Stabilizer Down Solenoid (Pilot Controls)

The solenoid is located under the machine on the pilot control hydraulic manifold.
NOTE: Disconnect the connector for the solenoid.
Between terminals of solenoid Ohm 5.5 Ohm at 68° F (20° C), replace as needed
NOTE: Make sure not to loose gasket on connector.
130 – Right Hand Stabilizer Up Solenoid (Pilot Controls)

131 – Left Hand Stabilizer Down Solenoid (Pilot Controls)

132 – Left Hand Stabilizer Up Solenoid (Pilot Controls)

133 – Auxiliary Reverse Solenoid Bi-directional (Pilot Controls)


4001-48 580M ONLY
134 – Auxiliary Forward Solenoid Bi-directional (Pilot Controls)

135 – Extend-a-hoe Retract Solenoid (Pilot Controls)

136 – Extend-a-hoe Extend Solenoid (Pilot Controls)

137 – Pilot On/Off Switch (Pilot Controls)

The pilot on/off switch is located on the right tower boot.
NOTE: Disconnect the connector and place the switch in position three (off)
Between pins 2 and 3, 5 and 6 Open Bad switch
NOTE: Place the switch in position two (momentary position)
Between pins 2 and 3 Continuity Bad switch
Between pins 5 and 6 Open Bad switch
NOTE: Place the switch in position one
Between pins 2 and 3, 5 and 6 Continuity Bad switch

580M ONLY 4001-49
138 – Pilot Control Relay (Pilot Controls)

The control relay is located under the machine on the left front side of the mounted bracket for the pilot valve.
NOTE: Place the pilot on/off switch in position two and the ignition switch in the on position
Terminal for wire 601 to ground 12 volts Bad pilot on/off switch (137).
Terminal for wire 601 and 602 to 12 volts Bad pilot on/off switch (137).
ground
139 – Auxiliary Forward Push Button Bi-directional (Pilot Controls)

Left hand pilot control handle.
140 – Auxiliary Reverse Push Button Bi-directional (Pilot Controls)

141 – Pattern Change Switch (Pilot Controls)

The pattern change switch is located right hand pilot control tower.
NOTE: Turn the ignition switch to the ON position and the pilot control on/off switch to position ONE.
Chick circuit between on/off switch (137) and pattern change

switch. Also check pilot control relay (138).
NOTE: Turn pattern change switch to position 2

Terminal for wire 624 to ground 12 volts Bad pattern change switch
NOTE: If readings are correct and the indicator lamp on the pattern change switch does not illuminate, do the following check.
Terminal for wire 30 to ground Continuity Bad ground circuit for pattern change switch indicator lamp
142 – Pressure Reducing Valve Solenoid (Pilot Controls)


4001-50 580M ONLY
143 – Diode (Pilot Controls)


Continuity in
only.
144 – Pattern Change Solenoids (Pilot Controls)



Continuity in
only.
146 – Comfort Steering Transmission Switch

NOTE:
NOTE:
NOTE:
147 – Comfort Steering Power Relay

NOTE:

580M ONLY 4001-51
148 – Comfort Steering ON/OFF Switch

NOTE:
149 – Comfort Steering Solenoid

NOTE:
150 – Electro Hydraulic Clam Control

NOTE:
NOTE:
151 – Electro Hydraulic Clam Control EVI Solenoid

NOTE: Disconnect wire from solenoid.
Between terminals x ohm Bad solenoid
152 – Electro Hydraulic Clam Control EVK Solenoid


4001-52 580M ONLY
CONNECTORS
CONNECTOR - FRONT WASHER PUMP MOTOR CONNECTOR - LOADER VALVE RTD
3227856R1 291718A1
CAV WIRE IDENT CIRCUIT CAV WIRE IDENT CIRCUIT

1 62 Gray 16 Front Washer Pump 1 53 Red 16 Loader Valve RTD
2 50 Black 16 Front Washer Ground 2 19F Red 16 Fuse Block 9A
CONNECTOR - REAR WASHER PUMP MOTOR CONNECTOR - COLD START
3227856R1 225350C1
1 65 Gray 16 Rear Washer Pump 1 31C Yellow 16 Instrument Cluster T16
2 50 Black 16 Rear Washer Ground 2 34 Lt. Green 16 Alternator

3 21B White 16 Starter Relay T87
4 30 Black 16 Ground
CONNECTOR - SEAT POSITION SWITCH
5 35 Lt. Blue 16 Coolant Temp Sender T2
6 15 White 16 Fuse Block 5D
245482C1
CAV WIRE IDENT CIRCUIT

A 36R Gray 16 Instrument Cluster T9
B 30 Black 16 Ground

580M ONLY 4001-53
CONNECTOR - PILOT CONTROL/BH AUXILLIARY CONNECTOR - GEAR SHIFT LEVER DE-CLUTCH
245482C1
182069A1 CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT A 25 Red 16 Clutch Relay T86
A 58 Red 14 Fuse Block 11A B 30 Black 16 Ground
CONNECTOR - POWER RELAY NO. 1

CONNECTOR - SIDE HARNESS A/C
CONNECTION
245731C1
245485C1
30 1E Red 12 Power Junction Post
A 57 Red 16 Fuse Block 1C
85 4 Gray 16 Ignition Switch (ACC)
B 60A Red 16 A/C Relay T86 & T87
C 85 Gray 16 Blower Switch
Fuse Block 2A, 4A, 6A, 8A, and
87 12A Red 12
10A
CONNECTOR - PILOT CONTROL HORN 87A None
245482C1

A 64A Red 16 Fuse Block 3B
B 64B Gray 16 Horn

4001-54 580M ONLY
245731C1
CAV WIRE IDENT CIRCUIT 245731C1
30 1K Red 12 Power Junction Post CAV WIRE IDENT CIRCUIT

85 4 Gray 16 Ignition Switch (ACC) 30 1G Red 12 Power Junction Post
86 10 Black 16 Ground 85 4 Gray 16 Ignition Switch (ACC)
87 12B Red 12 Fuse Block 2C, 4C, 6C, and 8C 86 10 Black 16 Ground
87A None 87 12D Red 12 Fuse Block 12A
87A None

CONNECTOR - LOADER LEVER DIFFERENTIAL
LOCK ENABLE RELAY
245731C1

245731C1
30 1L Red 12 Power Junction Post
30 19B Red 16 Fuse Block 3C
Fuse Block 8D, 10D, 12D, and
87 12C Red 12
14D Loader Lever Differential Lock
86 7 Gray 16 Engage Switch Standard
87A None
Transmission
87 25S Gray 16 Differential Lock Solenoid
87A None

580M ONLY 4001-55
CONNECTOR - CLUTCH RELAY CONNECTOR - FORWARD RELAY
245731C1 245731C1

30 19E Red 16 Fuse Block 1D Shuttle Interlock Timing Relay
30 19M Gray 16
“Load”
85 19E Red 16 Fuse Block 1D
85 25A Lt. Blue 16 FNR Lever (Forward)
86 25 Red 16 Clutch Cutout Switches
87 None
87 26 Lt. Blue 16 Forward Solenoid and Diode
Forward/Neutral/Reverse Lever
87A 21 Red 16
(+) 87A None
CONNECTOR - REVERSE RELAY CONNECTOR - NEUTRAL RELAY
245731C1 245731C1

Shuttle Interlock Timing Relay 30 21A Lt. Blue 16 Ignition Switch (Start)
30 19M Gray 16
“Load”
85 21C White 16 FNR Lever (Neutral)
85 25B Lt. Blue 16 FNR Lever (Reverse)
87 22 White 16 Starter Relay T85
Reverse Solenoid, Backup
87 27 Lt. Blue 16 87A None
Alarm (+), and Diode
87A None

4001-56 580M ONLY
CONNECTOR - STARTER RELAY CONNECTOR - SHUTTLE INTERLOCK TIMING
RELAY
245731C1
87122
30 1C Red 12 Power Junction Terminal CAV WIRE IDENT CIRCUIT
85 22 White 16 Neutral Relay T87 B+ 19E Red 16 Fuse Block 1D
86 10 Black 16 Ground G 10 Black 16 Ground
87 21B White 12 Starter Solenoid, Cold Start T3 I 24 White 16 Shuttle Interlock Relay T30
87A None L 19M Gray 16 Forward and Reverse Relay T30
CONNECTOR - SHUTTLE INTERLOCK RELAY
245731C1

Shuttle Interlock Timing Relay
30 24 White 16
(Input)
87 None
87A 52 Gray 16 Diodes

580M ONLY 4001-57
CONNECTOR - A/C RELAY CONNECTOR - FUEL SHUT OFF
245480C1
245731C1
30 60 Red 16 A/C Thermostat
A/C Low/High Pressure CONNECTOR - COMBINATION SWITCH 56
86 60A Red 16 Switches, Instrument Cluster
T10
A/C Low/High Pressure
T10
87A 60B Gray 16 A/C Compressor Clutch
CONNECTOR - FLASHER RELAY

1964527C1

1 19A Red 16 Fuse Block 7A
CONNECTOR - COMBINATION SWITCH 56A
352600

1 46 Tan 16 Hazard Flasher Switch T1
3 47R Tan 16 Right Turn Indicator
1964527C1
5 45L Tan 16 Left Turn Signal Lamps
6 47L Tan 16 Left Turn Indicator
Front Driving and Tail Lamps,
7 45R Tan 16 Right Turn Signal Lamps 1 41 Gray 16
Instrument Cluster T24

4001-58 580M ONLY
CONNECTOR - COMBINATION SWITCH 31 CONNECTOR - COMBINATION SWITCH R
1964527C1 1964527C1

1 64B Gray 16 Horn 1 45L Tan 16 Flasher Relay T5
CONNECTOR - COMBINATION SWITCH 31B

CONNECTOR - COMBINATION SWITCH L
1964527C1
1 64A Red 16 Fuse Block 3B CAV WIRE IDENT CIRCUIT

1 45R Tan 16 Flasher Relay T7

CONNECTOR - IGNITION SWITCH
1964527C1

1 19B Red 16 Fuse Block 3C 225253C1

1 1D Red 12 Power Junction Post
2 21A Lt. Blue 16 Neutral Relay T30
3 4 Gray 16 Power Relays 1, 2, 3, 4 T85
4 3 White 12 Diode, Fuse Block 2D, 4D, & 6D
5 None
6 None

580M ONLY 4001-59
CONNECTOR - RH AND LH PARK BRAKE CONNECTOR - A/C COMPRESSOR
SWITCH
245483C1 245480C1

A 36P Yellow 16 Instrument Cluster T7 A 60B Gray 16 A/C Relay T87a
CONNECTOR - OIL PRESSURE SWITCH

CONNECTOR - AIR SUSPENSION SEAT
245483C1 245480C1

A 19N Red 14 Fuse Block 9B 1 31P Yellow 16 Instrument Cluster T2
CONNECTOR - DIFF LOCK SOLENOID

CONNECTOR - FOUR WHEEL DRIVE SOLENOID
245483C1 225316C1

A 25E Gray 16 4 WD Engage Switch T1 and T3 Loader Lever Differential Lock
1 25S Gray 16
Enable Relay T87

4001-60 580M ONLY
CONNECTOR - A/C LOW PRESSURE SWITCH CONNECTOR - POWER OUTLET
245482C1
CAV WIRE IDENT CIRCUIT 314908A1
A 60A Red 16 A/C Relay T86 & T87 CAV WIRE IDENT CIRCUIT
B 60 Red 16 A/C Thermostat A 20C Black 10 Ground
B 84 Red 10 Fuse Block 11C
CONNECTOR - A/C HIGH PRESSURE SWITCH

CONNECTOR - POWER OUTLET
245482C1

A 60 Red 16 A/C Thermostat 314908A1
B 60A Red 16 A/C Relay T86 & T87 CAV WIRE IDENT CIRCUIT
A 20B Black 10 Ground
CONNECTOR - BACKUP ALARM
CONNECTOR - RIDE CONTROL SOLENOIDS
245482C1

A 27 Lt. Blue 16 Reverse Relay T87
256340A1

A 401 Gray 16 Ride Control Engage Switch T1

580M ONLY 4001-61
CONNECTOR - AIR FILTER RESTRICTION CONNECTOR - REAR WIPER SWITCH
SWITCH
245781C1
256340A1
A 30 Black 16 Ground 1 81 Gray 16 Rear Wiper Motor Low
B 38 Yellow 16 Instrument Cluster T3 2 63A Red 16 Rear Wiper Disconnect Switch

3 82 Gray 16 Rear Wiper Motor High
4 89 Gray 16 Rear Wiper Motor Brake
CONNECTOR - FRONT CONSOLE (OPT)
5
6
CONNECTOR - REAR HORN SWITCH
256340A1

B 63 Red 16 Fuse Block 1A
245781C1

1
2 64A Red 16 Fuse Block 3B
3 64B Gray 16 Horn
4
5
6

4001-62 580M ONLY
CONNECTOR - REAR WORK LIGHT CONNECTOR - FRONT WIPER SWITCH
SWITCH
245781C1
245781C1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT 1 66 Gray 16 Front Wiper Motor Low
Rear Work Lamps, Instrument 2 63 Red 16 Fuse Block 1A
1 42C Gray 12
Cluster T13
3 67 Gray 16 Front Wiper Motor High
2 19C Red 12 Fuse Block 7D
4 69 Gray 16 Front Wiper Motor Brake
3
5
4
6
5
CONNECTOR - FRONT WORK LIGHTS
SWITCH
CONNECTOR - FOUR WHEEL DRIVE
SWITCH
245781C1

245781C1
Front Work Lamps, Instrument
1 42F Gray 14
CAV WIRE IDENT CIRCUIT Cluster T12
1 25E Gray 16 4 WD Solenoid 2 19K Red 14 Fuse Block 9D
2 25C Red 16 Fuse Block 3A 3
3 25E Gray 16 4 WD Solenoid 4
4 5
5 6 10 Black 16 Ground

580M ONLY 4001-63
CONNECTOR - HAZARD SWITCH CONNECTOR - RIDE CONTROL SWITCH
245781C1 245781C1

1 46 Tan 16 Flasher Relay T1 1 401 Gray 16 Ride Control Solenoids
2 19B Red 16 Fuse Block 3C 2 57 Red 16 Fuse Block 1C
3 3
4 4
5 5
6 10 Black 16 Ground 6 50 Black 16 Ground
CONNECTOR - ROTATING BEACON CONNECTOR - REAR WIPER WASHER

SWITCH SWITCH
245781C1 245781C1

1 48 Gray 16 Rotating Beacon 1
2 19D Red 16 Fuse Block 5A 2 63 Red 16 Fuse Block 1A
3 3 65 Gray 16 Rear Windshield Washer Pump
4 4
5 5
6 10 Black 16 Ground 6

4001-64 580M ONLY
CONNECTOR - BACKHOE QUICK CONNECTOR - FRONT WIPER WASHER
COUPLER SWITCH “A” SWITCH
245781C1 245781C1

1 501 Gray 16 Quick Coupler Solenoid, Diodes 1
2 57 Red 16 Fuse Block 1C 2 63 Red 16 Fuse Block 1A
Backhoe Quick Coupler Switch 3 62 Gray 16 Front Windshield Washer Pump
3 504A Gray 16
“B” T2
4
4
5
5
6
6
CONNECTOR - LOADER QUICK

CONNECTOR - BACKHOE QUICK COUPLER SWITCH
COUPLER SWITCH “B”
245781C1
245781C1
Front Quick Coupler Solenoid,
1 501 Gray 16
1 Diodes
Backhoe Quick Coupler Switch 2 57 Red 16 Fuse Block 1C
2 504A Gray 16
“A” T3
Rear Quick Coupler Solenoid,
3 502 Gray 16
3 504 Gray 16 Quick Coupler Solenoid, Diodes Diodes
4 4
5 5
6 6

580M ONLY 4001-65
CONNECTOR - COMBINATION SWITCH
CONNECTOR - MAIN CHASSIS OPTIONS
HARNESS
389487A1

256352A1
L 45R Tan 16 Flasher Relay T7
49a 19B Red 16 Fuse Block 3C
A Not Used
R 45L Tan 16 Flasher Relay T5
B 60 Red 16 A/C Thermostat
31b 64A Red 16 Fuse Block 3B
C 60A Red 16 A/C Relay T86 & T87
31 64B Gray 16 Horn
D 60B Gray 16 A/C Relay T87a
56B Not Used
Windshield Washer Switch T3
56D Not Used E 62 Gray 16
(Front)
Front Driving and Tail Lamps, F Not Used
56A 41 Gray 16
G 501 Gray 16 Ride Control Solenoids
H 502 Gray 16
Diodes
J Not Used
K 63 Red 16 Fuse Block 1A
CONNECTOR - TURN SIGNAL INDICATOR
16182559

3 47L Tan 16 Flasher Relay T6

4001-66 580M ONLY
CONNECTOR - SIDE CONSOLE OPTIONS
HARNESS CONNECTOR - FUSE BLOCK
256352A1 12177145
A Not Used Front Wiper Switch T2 and Motor,

A-1 63 Red 16 Rear Wiper Motor, Windshield
B 60 Red 16 A/C Thermostat Washer Switches T2
C 60A Red 16 A/C Relay T86 & T87 A-2 12A Red 12 Power Relay 1, T87
D 65 Gray 16 Windshield Washer Switch T3 A-3 25C Red 16 4WD Engage Switch T2
E Not Used A-4 12A Red 12 Power Relay 1, T87
F 401 Gray 16 Ride Control Engage Switch T1 A-5 19D Red 16 Rotating Beacon Switch T2
Backhoe Quick Coupler Switch A-6 12A Red 12 Power Relay 1, T87
G 501 Gray 16
“A” T1
Turn/Driving Lamp/horn Switch
Backhoe Quick Coupler Switch A-7 19A Red 16
H 504 Gray 16 T56
“B” T3
A-8 12A Red 12 Power Relay 1, T87
J Not Used
A-9 19F Red 16 loader Valve RTD Solenoid
A-11 58 Red 14 Pilot Control/BH Aux T1
A-12 12D Red 12 Power Relay 4, T87
A-13 Not Used
A-14 Not Used
Optional Fused (B+), Optional
B-1 56 Red 16
Radio (B+)
B-2 1D Red 12 Power Junction Post
B-3 64A Red 16 Rear Wiper Switch T2
Dome Lamp Door Switch, Dome
B-5 49 Red 16
Lamp
B-7 Not Used
Air Suspension Seat Adjustment
B-9 19N Red 14
Switch
B-11 Not Used
B-13 Not Used
B-14 Not Used

580M ONLY 4001-67
CAV WIRE IDENT CIRCUIT CONNECTOR - FRONT CONSOLE OPTIONS

HARNESS
Opt Radio (+), Loader Quick
Coupler Switch T2, Backhoe Quick
Coupler Switch “A” T2, Ride
C-1 57 Red 16
Control Switch T2, Hand Held Aux
Hyd’s Switch T2, (Remote) 3-Amp
Boom Lock
C-2 12B Red 12 Power Relay 2 T87
Hazard Switch T2, Turn/Driving
Lamp/Horn Switch T49a, Flasher
C-3 19B Red 16 Relay T2, Loader Lever
Differential Lock Enable Relay T85
and T30, Brake Switch (Com)
C-5 61 Red 12 Blower Switch (+) 256354A1
C-7 Not Used
A Not Used
C-9 83 Red 10 Power Plug B+
C-10 1H Red 10 Power Junction Post
E 62 Gray 16
C-12 1J Red 10 Power Junction Post (Front)
C-13 Not Used F Not Used
C-14 Not Used G 501 Gray 16 Ride Control Solenoids
Clutch Relay T85 and T30, shuttle Rear Quick Coupler Solenoid,
D-1 19E Red 16 H 502 Gray 16
Interlock Timing Relay (B+) Diodes
D-2 3 White 12 Ignition Switch (Ignition) J Not Used
D-3 23G Red 16 Diode K 63 Red 16 Fuse Block 1A
D-4 3 White 12 Ignition Switch (Ignition)

D-5 15 White 16 Fuel Shutoff, Alt T2, Cold Start T6
CONNECTOR - BACKHOE QUICK COUPLER
D-6 3 White 12 Ignition Switch (Ignition) SOLENOID
Rear Work Lamp Switch and Relay
D-7 19C Red 12
T2
D-8 12C Red 12 Power Relay 3, T87
D-9 19K Red 14 Front Work Lamp Switch T2
D-11 Not Used
D-13 Not Used
256340A1

A 504 Gray 16 Backhoe Quick Coupler Solenoid

4001-68 580M ONLY
CONNECTOR - LOADER QUICK COUPLER CONNECTOR - FRONT CAB/ROPS LIGHTS
SOLENOID HARNESS
256340A1 15326660

A 502 Gray 16 Front Quick Coupler Solenoid Front Work Lamps, Instrument
A 42F Gray 14
Cluster T12
Front Driving and Rail Lamps,
B 41 Gray 16
CONNECTOR - REAR CAB/ROPS LIGHTS C 63 Red 16 Fuse Block 1A

HARNESS D 45R Tan 16 Flasher Relay T7
E 45L Tan 16 Flasher Relay T5
F 66 Gray 16 Front Wiper Switch T1 (Low)
G Not Used
H Not Used
J 67 Gray 16 Front Wiper Switch T3 (High)
K 69 Gray 16 Front Wiper Switch T4 (Brake)
CONNECTOR - TRANSMISSION CONTROL

SOLENOIDS
15326660

Rear Work Lamps, Instrument
A 42C Gray 12
Cluster T13
B 41 Gray 16
C 44 Tan 16 Brake Lamps
D 45R Tan 16 Flasher Relay T7
F 48 Gray 16 Rotating Beacon
G Not Used 182077A1
H Not Used CAV WIRE IDENT CIRCUIT

Rear Work Lamps, Instrument A 26 Lt. Blue 16 Forward Solenoid & Diode
J 42C Gray 12
Cluster T13
K Not Used
C 27 Lt. Blue 16
Alarm (+), & Diode
D 30 Black 16 Ground

580M ONLY 4001-69
CONNECTOR - COOLANT TEMPERATURE CONNECTOR - INSTRUMENT CLUSTER
SENDER
371832C1
198456A1
1 23F Red 16 Diode
A Not Used
2 31P Yellow 16 Oil Pressure Switch
B 35 Lt. Blue 16 Cold Start T5
3 38 Yellow 16 Air Filter Restriction Switch
C 30 Black 16 Ground
Hydraulic Filter Restriction
4 36H Yellow 16
Switch
CONNECTOR - ALTERNATOR 5 34 Lt. Green 16 Alternator

6 33T Yellow 16 Rear Axle Temperature Sender
7 36P Yellow 16 Park Brake Switches
8 52 Gray 16 Diode
9 36R Gray 16 Seat Position Switch
10 60A Red 16 A/C Relay T86 & T87
11 Not Used
12 42F Gray 14 Front Work Lamp Switch T1
13 42C Gray 12/16 Rear Work Lamp Switch T1
14 Not Used
15 Not Used
382203A1
16 31C Yellow 16 Cold Start T1
CAV WIRE IDENT CIRCUIT 17 Not Used
1 34 Lt. Green 16 Instrument Cluster T5 18 Not Used
2 15 White 16 Fuse Block 5D 19 31S Yellow 16 Alternator Tach Output
3 31S Yellow 16 Instrument Cluster (Tach) T19 20 36F Yellow 16 Fuel Level Sender
Transmission Temperature
21 32T Yellow 16
Sender
22 31T Yellow 16 Coolant Temperature Sender
23 Not Used
24 41 Gray 16 Combination Switch T56a
25 Not Used
26 Not Used
27 Not Used
28 Not Used
29 Not Used
30 Not Used
31 Not Used

4001-70 580M ONLY
CAV WIRE IDENT CIRCUIT CONNECTOR - BLOWER SWITCH

32 Not Used
33 Not Used
34 Not Used
35 37A Yellow 16 Warning Alarm (-)
36 20A Black 16 Ground
CONNECTOR - SIDE OPTIONS HARNESS
754C-3

87 87 Gray 16 Resistor Board (Medium)
86 86 Gray 16 Resistor Board (Low)
61 61 Red 12 Fuse Block 5C
Resistor Board (High), Blower
88 88 Gray 12
Motor
85 85 Gray 16 A/C Thermostat
256344A1

CONNECTOR - CAB HARNESS
CONNECTOR - LOADER LEVER HARNESS FOR

STANDARD SHUTTLE SHIFT TRANSMISSION
282918A1

A-1 56 Red 16 Fuse Block 1B
A-2 57 Red 16 Fuse Block 1C
A-3 86 Gray 16 Blower Switch (Low)
A-4 87 Gray 16 Blower Switch (Medium)
256346A1
A-5 88 Gray 12 Blower Switch (High)
B-1 Not Used
A 25 Red 16 Clutch Relay T86
B-2 Not Used
B Not Used
B-3 49 Red 16 Fuse Block 5B
Loader Lever Differential Lock
C 7 Gray 16 B-4 Not Used
Enable Relay T86
B-5 Not Used
C-1 63 Red 16 Fuse Block 1A
C-2 81 Gray 16 Rear Wiper Switch T1 (Low)

580M ONLY 4001-71

CONNECTOR - MAIN CHASSIS OPITION
C-3 82 Gray 16 Rear Wiper Switch T3 (High)
C-4 89 Gray 16 Rear Wiper Switch T4 (Brake)
C-5 63A Red 16 Rear Wiper Switch T2
256354A1

A Not Used
Rear Windshield Washer Switch
D 65 Gray 16
T3
E Not Used
F 401 Gray 16 Ride Control Engage Switch T1
Backhoe Quick coupler Switch
G 501 Gray 16
“A” T1
H 504 Gray 16
“B” T3
J Not Used
CONNECTOR - A/C SIDE HARNESS
256345A1

C 85 Gray 16 A/C Thermostat

4001-72 580M ONLY
CONNECTOR - FNR STANDARD SHUTTLE SHIFT
LEVER
15300029

Reverse Relay T85 & Diode or
A 25B Lt. Blue 16 Optional (Powershift)
Transmission Harness Wire 323
Neutral Relay T85, Shuttle
B 21C White 16
Interlock Relay T85
Forward Relay T85 & Diode or
C 25A Lt. Blue 16 Optional (Powershift)
D 21 Red 16 Clutch Relay T87a

580M ONLY 4001-73
CONNECTOR - SIDE CONSOLE HARNESS
12129206
1-A 1D Red 12 Ignition Switch (Batt) 2-K Not Used
Instrument Cluster Connector 2-L 31P Yellow 16 Instrument Cluster Connector 2

1-B 32T Yellow 16
21 2-M 56 Red 16 Cab Harness Connector A1
1-C 63 Red 16 Cab Harness Connector C1 2-N Not Used
1-D 33T Yellow 16 Instrument Cluster Connector 6 3-A 19C Red 12 Rear Work Lamp Switch
1-E Not Used Instrument Cluster Connector
3-B 36F Yellow 16
20
1-F Not Used
3-C Not Used
1-G 83 Red 10 Power Plug (B+)
3-D 34 Lt. Green 16 Instrument Cluster Connector 5
Instrument Cluster Connector
1-H 31T Yellow 16
22 3-E Not Used
1-J Not Used 3-F Not Used
1-K Not Used 3-G Not Used
1-L 38 Yellow 16 Instrument Cluster Connector 3 3-H Not Used
1-M Not Used 3-J Not Used
1-N Not Used Horn Rocker Switch Connector
3-K 64B Gray 16
3
2-A Not Used
3-L 36P Yellow 16 Instrument Cluster Connector 7
4WD Engage Switch Connector
2-B 25C Red 16
Rear Horn Rocker Switch 3-N Not Used
2-C 64A Red 16
Connector 2
2-D 41 Gray 16
24
2-E Not Used
2-F Not Used
2-H Not Used
2-J Not Used

4001-74 580M ONLY
12129200
4-A 3 White 12 Ignition Switch Connector 4 Loader Lever Harness

5-K 25 Red 16
Connector A
Instrument Cluster Connector 8,
5-L Not Used
4-B 52 Gray 16 Shuttle Interlock Relay
Connector 87a 5-M Not Used
Instrument Cluster Connector 5-N Not Used
4-C 31S Yellow 16
19
Rear Work Lamps Switch
4-D Not Used 6-A 42C Gray 12 Connector 1, Instrument Cluster
4-E Not Used Connector 13
4-F 36R Gray 16 Instrument Cluster Connector 9 6-B Not Used
4-G Not Used 6-C Not Used
4-H Not Used 6-D Not Used
4-J Not Used 4WD Engage Switch Connector

6-E 25E Gray 16
1 and 3
4-K Not Used
6-F Not Used
4-L 23F Red 16 Instrument Cluster Connector 1
6-G Not Used
4-M Not Used
6-H Not Used
4-N Not Used
6-J Not Used
Loader Lever Harness
5-A 42C Gray 12 Connector 1, Instrument Cluster 6-K 7 Gray 16
Connector C
Connector 13
Cab Harness Connector
5-B Not Used 6-L 49 Red 16
Connector B-3
5-C Not Used
6-M 4 Gray 16 Ignition Switch Connector 3
5-D Not Used
6-N 61 Red 12 Blower Switch (+) Connector 61
5-E Not Used
5-F Not Used
5-G Not Used
5-H Not Used
5-J Not Used

580M ONLY 4001-75
12129200

7-A Not Used
7-B 31C Yellow 16
16
7-C 42F Gray 14
12
7-D Not Used
7-E Not Used
7-F Not Used
7-G Not Used
7-H Not Used
7-J Not Used
7-K 36H Yellow 16 Instrument Cluster Connector 4
7-L Not Used
7-M 21A Lt. Blue 16 Ignition Switch Connector 2
7-N Not Used

4001-76 580M ONLY
CONNECTOR - SIDE CONSOLE TO MAIN CHASSIS HARNESS
12129206
1-A 1D Red 12 Front Console Connector 1-A 2-G 84 Red 10 Front Console Connector 2-G
Transmission Temperature 2-H Not Used

1-B 32T Yellow 16
Sender 2-J Not Used
Front Light Harness Connector 2-K Not Used
1-C 63 Red 16
C, Front Console Connector 1-C
2-L 31P Yellow 16 Engine Oil Pressure Switch
Rear Axle Temperature Switch
1-D 33T Yellow 16 2-M 56 Red 16 Front Console Connector 2-M
A
1-E Not Used 2-N Not Used
1-F Not Used 3-A 19C Red 12 Front Console Connector 3-A
1-G 83 Red 10 Front Console Connector 1-G 3-B 36F Yellow 16 Fuel Level Sender
Coolant Temperature Sender 3-C Not Used

1-H 31T Yellow 16
Connector A 3-D 34 Lt. Green 16 Alternator Connector 1
1-J Not Used 3-E Not Used
1-K Not Used 3-F Not Used
Air Flow Restriction Switch 3-G Not Used
1-L 38 Yellow 16
Connector B
3-H Not Used
1-M Not Used
3-J Not Used
1-N Not Used
Pilot Control Horn Switch
2-A Not Used 3-K 64B Gray 16 Connector 2, Horn, Front
Console Connector 3-K
2-B 25C Red 16 Front Console Connector 2-B
Left and Right Hand Brake
Front Console Connector 2-C, 3-L 36P Yellow 16
2-C 64A Red 16 Pilot Control Horn Switch Switch
Connector 1 3-M 57 Red 16 Front Console Connector 3-M
Front Light Harness Connector 3-N Not Used
B, Rear Light Harness
2-D 41 Gray 16
Connector B, Front Console
Connector 2-D
2-E Not Used
2-F Not Used

580M ONLY 4001-77
12129200
4-A 3 White 12 Front Console Connector 4-A 5-L Not Used
4-B 52 Gray 16 Front Console Connector 4-B 5-M Not Used
4-C 31S Yellow 16 Alternator Connector 3 5-N Not Used
4-D Not Used Rear Cab/ROPS Lights

6-A 42C Gray 12
Connector A
4-E Not Used
6-B Not Used
Seat Position Switch Connector
4-F 36R Gray 16 6-C Not Used
A
6-D Not Used
4-G Not Used
4WD Solenoid Connector A,
4-H Not Used 6-E 25E Gray 16
Diode
4-J Not Used
6-F Not Used
4-K Not Used
6-G Not Used
4-L 23F Red 16 Front Console Connector 4-L
6-H Not Used
4-M Not Used
6-J Not Used
4-N Not Used
6-K 7 Gray 16 Front Console Connector 6-K
Rear Cab/ROPS Lights
5-A 42C Gray 12 6-L 49 Red 16 Front Console Connector 6-L
Connector A
6-M 4 Gray 16 Front Console Connector 6-M
5-B Not Used
6-N 61 Red 12 Front Console Connector 6-N
5-C Not Used
5-D Not Used
5-E Not Used
5-F Not Used
5-G Not Used
5-H Not Used
5-J Not Used
Front Console Connector 5-K,
5-K 25 Red 16 Gear Shift Lever Declutch
Connector A

4001-78 580M ONLY
12129200

7-A Not Used
7-B 31C Yellow 16 Cold Start Connector 1
Front Cab/ROPS Lights
7-C 42F Gray 14
Harness Connector A
7-D Not Used
7-E Not Used
7-F Not Used
7-G Not Used
7-H Not Used
7-J Not Used
7-K 36H Yellow 16
Switch
7-L Not Used
7-M 21A Lt. Blue 16 Front Console Connector 7-M
7-N Not Used

580M ONLY 4001-79
CONNECTOR - FRONT CONSOLE HARNESS
358378A1
Fuse Block 2B, 4B, 6B, 8B, 10B, 2-K Not Used
1-A 1D Red 12
12B 2-L Not Used
1-B 15 White 16 Fuse Block 5D 2-M 56 Red 16 Fuse Block 1B
Front Wiper Switch Connector 2-N 19N Red 14 Fuse Block 9B
1-C 63 Red 16
2, Fuse Block 1A
3-A 19C Red 12 Fuse Block 7D
1-D 19F Red 16 Fuse Block 9A
3-B Not Used
1-E Not Used
Rotating Beacon Switch
3-C 48 Gray 16
1-F Not Used Connector 1
1-G 83 Red 10 Fuse Block 9C 3-D 27 Lt. Blue 16 Reverse Relay Connector 87
1-H Not Used 3-E Not Used
1-L Not Used 3-H Not Used
Loader Lever Differential 3-J Not Used
Lock Enable Relay Connector
1-M 25S Gray 16 Combination Switch Connector
87, Optional (Powershift)
Transmission Harness 31, Rear Horn Switch Connector
3-K 64B Gray 16
3, Pilot Control Horn Connector
Front Work Lamp Switch 2
1-N 42F Gray 14
Connector 1
3-L Not Used
2-A Not Used
3-M 57 Red 16 Fuse Block 1C
2-B 25C Red 16 Fuse Block 3A
3-N Not Used
2-C 64A Red 16 Fuse Block 3B
Combination Switch Connector
2-D 41 Gray 16
56a
2-E Not Used
2-F Not Used
2-G 84 Red 10 Fuse Block 11C
2-H Not Used
2-J Not Used

4001-80 580M ONLY
358378A1
4-A 3 White 12 Diode, Fuse Block 2D, 4D, 6D 6-A Not Used
Diodes, Shuttle Interlock Relay 6-B 69 Gray 16 Front Wiper Switch Connector 4
4-B 52 Gray 16
Connector 87a 6-C Not Used
4-C 45L Tan 16 Flasher Relay Connector 5 6-D Not Used
4-D 26 Lt. Blue 16 Forward Relay Connector 87 6-E Not Used
4-E Not Used 6-F Not Used
4-F Not Used 6-G Not Used
4-G Not Used 6-H Not Used
4-H Not Used 6-J Not Used
4-J Not Used Loader Lever Differential Lock
6-K 7 Gray 16
Enable Relay Connector 86
4-K Not Used
6-L 49 Red 16 Fuse Block 5B
4-L 23F Red 16 Diode
6-M 4 Gray 16 Power Relays 1, 2, 3, 4 T85
4-M Not Used
6-N 61 Red 12 Fuse Block 5C
4-N Not Used
5-A 21B White 12 Starter Relay Connector 87
5-B Not Used
5-C 45R Tan 16 Flasher Relay Connector 7
5-D Not Used
5-E Not Used
5-F Not Used
5-G Not Used
5-H Not Used
5-J Not Used
5-K 25 Red 16 Clutch Relay Connector 86
5-L Not Used
5-M Not Used
5-N 58 Red 14 Fuse Block 11A

580M ONLY 4001-81
358378A1

7-A Not Used
7-B 66 Gray 16 Front Wiper Switch Connector 1
7-C Not Used
7-D 44 Tan 16 Brake Light Switch
7-E 67 Gray 16 Front Wiper Switch Connector 3
7-F Not Used
7-G Not Used
7-H Not Used
7-J Not Used
7-K Not Used
7-L Not Used
7-M 21A Lt. Blue 16 Neutral Relay Connector 30
7-N Not Used

4001-82 580M ONLY
CONNECTOR - FRONT CONSOLE TO MAIN CHASSIS HARNESS
358378A1
1-A 1D Red 12 Side Console Connector 1-A 2-J Not Used
Alternator Connector 2, Fuel 2-K Not Used

1-B 15 White 16
Shut Off, Cold Start Connector 6 2-L Not Used
Side Console Connector 1-C, 2-M 56 Red 16 Side Console Connector 2-M
1-C 63 Red 16 Front Cab/ROPS Lights
Harness Connector C Air Suspension Seat Connector
2-N 19N Red 14
A
1-D 19F Red 16 RTD Solenoid Connector 2
3-A 19C Red 12 Side Console Connector 3-A
1-E Not Used
3-B Not Used
1-F Not Used
1-G 83 Red 10 Side Console Connector 1-G 3-C 48 Gray 16
Connector F
1-H Not Used Transmission Control
1-J Not Used 3-D 27 Lt. Blue 16 Connector C, Diode, Backup
Alarm Connector A
1-K Not Used
3-E Not Used
1-L Not Used
3-F Not Used
Differential Lock Solenoid
1-M 25S Gray 16 3-G Not Used
Connector 1
Side Console Connector 1-N, 3-H Not Used
1-N 42F Gray 14 Front Cab/ROPS Lights 3-J Not Used
Harness Connector A
Side Console Connector 3-K,
2-A Not Used 3-K 64B Gray 16 Horn, Pilot Control Horn
Connector B
2-B 25C Red 16 Side Console Connector 2-B
3-L Not Used
Side Console Connector 2-C,
2-C 64A Red 16
Pilot Control Horn Connector A 3-M 57 Red 16 Side Console Connector 3-M
Side Console Connector 2-D, 3-N Not Used
2-D 41 Gray 16 Front and Rear Cab/Rops Lights
Harness Connector B
2-E Not Used
2-F Not Used
2-G 84 Red 10 Side Console Connector 2-G
2-H Not Used

580M ONLY 4001-83
358378A1
4-A 3 White 12 Side Console Connector 4-A 5-L Not Used
4-B 52 Gray 16 Side Console Connector 4-B 5-M Not Used
Front and Rear Cab/ROPS Pilot Control and Backhoe

5-N 58 Red 14
4-C 45L Tan 16 Auxiliary Connector A
Lights Harness Connector E
6-A Not Used
Transmission Solenoid
4-D 26 Lt. Blue 16
Connector A, Diode Front Cab/ROPS Lights
6-B 69 Gray 16
Harness Connector K
4-E Not Used
6-C Not Used
4-F Not Used
6-D Not Used
4-G Not Used
6-E Not Used
4-H Not Used
6-F Not Used
4-J Not Used
6-G Not Used
4-K Not Used
6-H Not Used
4-L 23F Red 16 Side Console Connector 4-L
6-J Not Used
4-M Not Used
6-K 7 Gray 16 Side Console Connector 6-K
4-N Not Used
6-L 49 Red 16 Side Console Connector 6-L
Starter Solenoid, Cold Start
5-A 21B White 12
Connector 3 6-M 4 Gray 16 Side Console Connector 6-M
5-B Not Used 6-N 61 Red 12 Side Console Connector 6-N
Front and Rear Cab/ROPS
5-C 45R Tan 16
Lights Harness Connector D
5-D Not Used
5-E Not Used
5-F Not Used
5-G Not Used
5-H Not Used
5-J Not Used
Gear Shift Lever Connector A,
5-K 25 Red 16
Side Console Connector 5-K

4001-84 580M ONLY
358378A1

7-A Not Used
7-B 66 Gray 16
Harness Connector F
7-C Not Used
Rear Cab/ROPS Lights Harness
7-D 44 Tan 16
Connector C
7-E 67 Gray 16
Harness Connector J
7-F Not Used
7-G Not Used
7-H Not Used
7-J Not Used
7-K Not Used
7-L Not Used
7-M 21A Lt. Blue 16 Side Console Connector 7-M
7-N Not Used

4001-85
INDEX
Symbols Grid Heater Thermo Sending Unit .....................45
4WD Grid Heater Unit ................................................44
Engage Switch ..................................................37 Relay .................................................................44
Solenoid ............................................................38 Comfort Steering
ON/OFF Switch .................................................51
A Power Relay ......................................................50
Air Compressor Switch and Motor .........................35 Solenoid ............................................................51
Air Conditioning Transmission Switch .........................................50
Compressor Clutch ...........................................27 Connector
High Pressure Switch ........................................28 A/C Compressor ................................................59
Low Pressure Switch .........................................28 A/C High Pressure Switch .................................60
Pressure Relay ..................................................26 A/C Low Pressure Switch ..................................60
Temperature Switch ..........................................27 A/C Relay ..........................................................57
Air Filter Restriction Switch ....................................17 A/C Side Harness ..............................................71
Air Suspension Seat ..............................................35 Air Filter Restriction Switch ...............................61
Alarm Air Suspension Seat ..........................................59
Backup ..............................................................22 Alternator ..........................................................69
Warning .............................................................16 Backhoe Quick Coupler Solenoid .....................67
Alternator .................................................................9 Backhoe Quick Coupler Switch "A" ...................64
Auxiliary Backhoe Hydraulics, Uni-directional, Lever Backhoe Quick Coupler Switch "B" ...................64
Position Switch (Unlatched Position) ........38 Backup Alarm ....................................................60
Blower Switch ....................................................70
B Bulk Head Front Console Harness ....................79
Backhoe Bulk Head Front Console Harness (Cont) ...80, 81
Quick Coupler Solenoid ....................................42 Bulk Head Front Console To Main Chassis Har-
Quick Coupler Switch A ....................................42 ness ...................................................82
Quick Coupler Switch B ....................................42 Bulk Head Front Console To Main Chassis Har-
Backup Alarm ........................................................22 ness (Cont) ..................................83, 84
Blower Bulk Head Side Console Harness .....................73
Motor .................................................................27 Bulk Head Side Console Harness (Cont) ....74, 75
Motor Resistor Board and Thermal Fuse ..........27 Bulk Head Side Console To Main Chassis Harness
Switch ................................................................26 ............................................................76
Boom Bulk Head Side Console To Main Chassis Harness
Lock Solenoid ....................................................40 (Cont) ...........................................77, 78
Lock Switch .......................................................40 Cab Harness .....................................................70
Brake Clutch Relay ......................................................55
Lamp Switch ......................................................32 Cold Start ..........................................................52
Combination Switch ..........................................65
C Combination Switch 31 .....................................58
Chassis Ground .......................................................9 Combination Switch 31B ...................................58
Circuits .....................................................................4 Combination Switch 49A ...................................58
Clam Combination Switch 56 .....................................57
Electro Control ..................................................51 Combination Switch 56A ...................................57
EVI Solenoid .....................................................51 Combination Switch L .......................................58
EVK Solenoid ....................................................51 Combination Switch R .......................................58
Clutch Coolant Temperature Sender ............................69
Cutout Relay .....................................................12 Differential Lock Solenoid .................................59
Cutout Switch - Loader Handle - Standard Trans- Flasher Relay ....................................................57
mission ...............................................22 FNR Lever For Standard Shuttle Shift ..............72
Cutout Switch - Shift Handle .............................22 Forward Relay ...................................................55
Relay .................................................................12 Four Wheel Drive Solenoid ...............................59
Cold Start Four Wheel Drive Switch ...................................62
Grid Heater Controller .......................................45 Front Cab/ROPS Lights Harness ......................68
Grid Heater Relay .............................................44 Front Console (Opt) ..........................................61
Front Console Options Harness ........................67
4001-86
Front Washer Pump Motor ................................52 Driving Lamps ....................................................... 30
Front Wiper Switch ............................................62
Front Wiper Washer Switch ..............................64 E
Front Work Lights Switch ..................................62 Electrical Wire Circuits ............................................ 4
Fuel Shut Off .....................................................57 Electro Hydraulic Clam Control ............................. 51
Fuse Block ........................................................66 EVI Solenoid ..................................................... 51
Gear Shift Lever De-Clutch ...............................53 EVK Solenoid ....................................................51
Hazard Switch ...................................................63 Engine
Ignition Switch ...................................................58 Oil Pressure Switch ........................................... 17
Instrument Cluster .............................................69 Temperature Sender ......................................... 18
Loader Lever Differential Lock Enable Relay ....54
Loader Lever Harness For Standard Shuttle Shift F
Transmission ......................................70 Flasher Relay ........................................................ 32
Loader Quick Coupler Solenoid ........................68 FNR
Loader Quick Coupler Switch ............................64 Switch - Standard Transmission .......................12
Loader Valve RTD .............................................52 Foot Operated Rear Auxiliary Hydraulic Switch .... 38
Main Chassis Option .........................................71 Forward
Main Chassis Options Harness .........................65 Relay .................................................................20
Neutral Relay ....................................................55 Solenoid ............................................................ 21
Oil Pressure Switch ...........................................59 Forward Relay ....................................................... 20
Park Brake Switch RH and LH ..........................59 Front
Pilot Control Horn ..............................................53 Console Ground ................................................ 11
Pilot Control/BH Auxiliary ..................................53 Turn Lamp ......................................................... 33
Power Outlet .....................................................60 Wiper Motor ...................................................... 24
Power Rely No. 1 ..............................................53 Wiper Switch (Cab) ........................................... 23
Power Rely No. 2 ..............................................53 Work Lamp Switch ............................................ 36
Power Rely No. 3 ..............................................54 Work Lamps ...................................................... 36
Power Rely No. 4 ..............................................54 Fuel
Rear Cab/ROPS Lights Harness .......................68 Level Sender ..................................................... 16
Rear Horn Switch ..............................................61 Shutoff Solenoid ................................................ 10
Rear Washer Pump Motor ................................52 Fuse Block ............................................................. 13
Rear Wiper Switch ............................................61
Rear Wiper Washer Switch ...............................63 G
Rear Work Light Switch .....................................62 Grid Heater
Reverse Relay ...................................................55 Controller .......................................................... 45
Ride Control Solenoids .....................................60 Heater Unit ........................................................ 44
Ride Control Switch ...........................................63 Relay .................................................................44
Rotating Beacon Switch ....................................63 Thermo Sending Unit ........................................ 45
Seat Position Switch .........................................52 Ground
Shuttle Interlock Relay ......................................56 Chassis ............................................................... 9
Shuttle Interlock Timing Relay ..........................56 Front Console ................................................... 11
Side Console Options Harness .........................66 Side Console ..................................................... 13
Side Harness A/C Connection ..........................53
Side Options Harness .......................................70 H
Stater Relay ......................................................56 Hand-Held Auxiliary Hydraulic Solenoid Uni-direction-
Transmission Control Solenoids .......................68 al ............................................................... 39
Turn Signal Indicator .........................................65 Hazard Flasher Switch .......................................... 31
Horn ....................................................................... 31
D Horn Button, Rear ................................................. 29
Differential Lock Hydraulic Filter Restriction Switch ......................... 16
Enable Relay, Loader Lever ..............................43
Engage Switch, Loader Lever ...........................42 I
Solenoid ............................................................43 Instrument Cluster ........................................... 14, 15
Diode .................................12, 20, 21, 37, 38, 41, 44
Dome Lamp K
Door Switch .......................................................28 Key ........................................................................ 11
Switch ................................................................29 KKSB
4001-87
Cutout Female Connector .................................43 #1 ......................................................................34
Cutout Male Connector .....................................43 #2 ......................................................................35
Relay .................................................................44 Power Relay ..........................................................10
Pressure Switch
L SAHR Parking Brake .........................................18
Lamp
Dome Switch .....................................................29 Q
Driving ...............................................................30 Quick Coupler
Front Turn .........................................................33 Disengage Switch, Loader ................................41
Front Work ........................................................36 Solenoid, Loader ...............................................41
Rear Stop and Tail ............................................31 Switch #1 ..........................................................42
Rear Turn ..........................................................34 Switch A ............................................................42
Rear Work .........................................................37 Switch B ............................................................42
Turn Signal Indicator .........................................34
Loader R
Lever Differential Lock Enable Relay ................43 Radio .....................................................................39
Lever Differential Lock Engage Switch .............42 Rear
Valve Solenoid ..................................................23 Auxiliary Hydraulic Switch, Foot Operated ........38
Horn Button .......................................................29
M Stop and Tail Lamps .........................................31
Motor Turn Lamp .........................................................34
Blower ...............................................................27 Wiper Motor .......................................................25
Blower Resistor Board and Thermal Fuse ........27 Wiper Park Switch .............................................25
Front Wiper .......................................................24 Wiper Stop Switch .............................................25
Rear Wiper ........................................................25 Wiper Switch (Cab) ...........................................23
Work Lamp Switch ............................................36
N Work Lamps ......................................................37
Neutral Relay
Start Relay ........................................................11 Clutch ................................................................12
Start Switch .......................................................12 Clutch Cutout ....................................................12
Cold Start ..........................................................44
O Comfort Steering ...............................................50
Oil Pressure, Engine ..............................................17 Flasher ..............................................................32
Forward .............................................................20
P KKSB ................................................................44
Pilot Loader Lever Differential Lock Enable ..............43
Auxiliary Forward Solenoid Bi-directional ..........48 Neutral Start ......................................................11
Auxiliary Reverse Solenoid Bi-directional ..........47 Pilot Control .......................................................49
Diode .................................................................50 Power ................................................................10
Electrical Controller ...........................................46 Reverse .............................................................20
Extend-a-hoe Extend Push Button ....................45 SAHR Park Brake .............................................19
Extend-a-hoe Extend Solenoid .........................48 Shuttle Interlock ................................................19
Extend-a-hoe Retract Push Button ...................45 Shuttle Interlock Timing .....................................19
Extend-a-hoe Retract Solenoid .........................48 Starter ...............................................................11
Horn Switch .......................................................46 Return-To-Dig Limit Switch ...................................22
Left Hand Stabilizer Down Solenoid ..................47 Reverse
Left Hand Stabilizer Pressure Switch ................46 Relay .................................................................20
Left Hand Stabilizer Switch ...............................46 Solenoid ............................................................21
Left Hand Stabilizer Up Solenoid ......................47 Reverse Relay .......................................................20
On/Off Switch ....................................................48 Ride Control
Pattern Change Solenoids ................................50 Engage Switch ..................................................39
Relay .................................................................49 Solenoid Accumulator .......................................40
Right Hand Stabilizer Down Solenoid ...............47 Solenoid Tank ...................................................40
Right Hand Stabilizer Pressure Switch .............46 Rotating Beacon (Opt) ...........................................35
Right Hand Stabilizer Switch .............................46 Rotating Beacon Switch ........................................35
Right Hand Stabilizer Up Solenoid ....................47
Power Plug
4001-88
S FNR - Standard Transmission .......................... 12
SAHR Parking Brake Foot Operated Rear Auxiliary Hydraulic ........... 38
ON/OFF Switch .................................................18 Front Wiper ....................................................... 23
Pressure Switch ................................................18 Front Work Lamp .............................................. 36
Relay .................................................................19 Hazard Flasher ................................................. 31
Solenoid ............................................................19 Hydraulic Filter .................................................. 16
Seat Position Switch ..............................................18 Key .................................................................... 11
Sender Loader Quick Coupler Disengage ..................... 41
Engine Oil Pressure ..........................................17 Pilot On/Off ....................................................... 48
Engine Temperature .........................................18 Rear Wiper (Cab) .............................................. 23
Fuel Level ..........................................................16 Rear Wiper Cut Off ........................................... 25
Fuel Level and Gauge .......................................16 Rear Work Lamp ............................................... 36
Transmission Temperature ...............................17 Return-To-Dig Limit ........................................... 22
Shuttle Interlock Ride Control Engage ......................................... 39
Relay .................................................................19 Rotating Beacon ............................................... 35
Timing Relay .....................................................19 SAHR Parking Brake ON/OFF .......................... 18
Side Console Ground ............................................13 Seat Position ..................................................... 18
Solenoid Turn Signal/Driving Lamp/Horn ......................... 30
4WD Standard Transmission ............................38 Windshield Washer, Front ................................. 24
Backhoe Quick Coupler ....................................42 Windshield Washer, Rear ................................. 24
Boom Lock ........................................................40
Differential Lock ................................................43 T
Forward .............................................................21 Transmission Temperature Sender .......................17
Fuel Shutoff .......................................................10 Troubleshooting ....................................................... 9
Hand Held Auxiliary Hydraulic Uni-directional ...39 Troubleshooting Tables, Understanding ................. 8
Left Ride Control ...............................................40 Turn Signal Indicator Lamps ................................. 34
Loader Quick Coupler .......................................41 Turn Signal/Driving Lamp/Horn Switch ................. 30
Loader Valve .....................................................23
Reverse .............................................................21 W
Right Ride Control .............................................40 Warning Alarm ....................................................... 16
SAHR Parking Brake .........................................19 Windshield
Starter .................................................................9 Washer Motor ................................................... 25
Speaker Left ..........................................................39 Washer Switch Front ......................................... 24
Speaker Right ........................................................39 Washer Switch Rear ......................................... 24
Specifications ..........................................................3 Wiper Motor Front ............................................. 24
Starter and Starter Solenoid ....................................9 Wiper Motor Rear .............................................. 25
Starter Relay ..........................................................11 Wire Circuits ............................................................ 4
Switch
4WD Engage - Standard Tansmission ..............37
Air Conditioning High Pressure .........................28
Air Conditioning Low Pressure ..........................28
Air Conditioning Temperature ...........................27
Air Filter Restriction ...........................................17
Auxiliary Backhoe Hydraulics Lever Position,
Uni-dirrectional ...................................38
Backhoe Quick Coupler #1 ...............................42
Backhoe Quick Coupler A .................................42
Backhoe Quick Coupler B .................................42
Blower ...............................................................26
Boom Lock ........................................................40
Brake Lamp .......................................................32
Clutch Cutout - Loader Handle - Standard Trans-
mission ...............................................22
Clutch Cutout - Shift Handle ..............................22
Differential Lock Engage, Loader Lever ............42
Dome Lamp .......................................................29
Dome Lamp Door ..............................................28

4001
Section
4001
ELECTRICAL SPECIFICATIONS
AND TROUBLESHOOTING
580SM, 580SM+, 590SM AND 590SM+ SERIES 3

4001-2 580SM, 580SM+, 590SM and 590SM+ ONLY
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL WIRE CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNDERSTANDING THE TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

580SM, 580SM+, 590SM and 590SM+ ONLY 4001-3
SPECIFICATIONS
Electrical system, standard................................................................................ One 12 volt battery, negative ground
Electrical system, optional .............................................Two 12 volt batteries connected in parallel, negative ground
System voltage ....................................................................................................................... Approximately 12 volts
Batteries
Standard...............................................................................................................................87403835 or B4960W
Option................................................................................................................................ D128393 or BMF28SW
Replacement ......................................................................................................................... D127414 or BMF28S
Alternator ....................................................................................................................................... 12 volt, 90 ampere
Starter...................................................................................................................................................2.7 Kw, 12 volt
Component specification
Fuel level sending unit.................................................................................................................. Full 28 - 33 Ohm
Empty 240 - 245 Ohm
Return-To-Dig solenoid ............................................................................................................ 18 Ohm to 22 Ohm
Blower switch resistance ..................................................................................................................HIGH - 0 Ohm
MED - 0.4 Ohm
LOW - 0.8 Ohm
Hydraulic filter switch .........................................Close 310 kPa, 3.1 bar (45 psi), Reset 241 kPa, 2.4 bar (35 psi)
Transmission forward and reverse solenoid coil ................................................................................... 4 to 6 Ohm
Four wheel drive solenoid .................................................................................................................... 6 to 8 Ohm
Differential lock solenoid ....................................................................................................................... 5 to 6 Ohm
Air conditioning pressure switches
Low pressure switch............................................................ Opens at 137.9 ± 21 kPa, 1.40 ± 0.21 bar (20 ± 3 psi)
Closes at 27.6 ± 14 kPa, 0.28 ± 0.14 bar (4 ± 2 psi)
High pressure switch ........................................................... Close at 2758 ± 69 kPa, 27.5 ± 0.6 bar (400 ± 10 psi)
Opens at 2068 ± 69 kPa, 20.6 ± 0.6 bar (300 ± 10 psi)
Air conditioning thermostat set point .......................................... Cold cut in 6.7° C (44° F), Cut out 1.7° C (35° F)

ELECTRICAL WIRE CIRCUITS

0 ST (None) Battery Ground
1 00 Red Battery Starter Battery Terminal
1A 4 Red Starter Battery Terminal Alternator (B+)
1B 4 Red Starter Battery Terminal Power Junction Post
1C 12 Red Power Junction Post Starter Relay
Ignition Switch (Batt) Fuse Block 2B, 4B, 6B, 8B,
1D 12 Red Power Junction Post
10B, 12B, Diagnostic Port (B)
1E 12 Red Power Junction Post Power Relay #1 T30
1G 12 Red Power Junction Post Power Relay #4 T30
1H 10 Red Power Junction Post Fuse Block 10C
1J 10 Red Power Junction Post Fuse Block 12C
1K 12 Red Power Junction Post Power Relay #2 T30
1L 12 Red Power Junction Post Power Relay #3 T30
1M 2 Red Starter Battery Terminal Cold Start Fuse T1
1P 16 Red Fuse Block 7B
1T 2 Red Power Junction Post Fuse Block 13B
2A ST none Cold Start Fuse T2 Cold Start Relay T5
2B 2 Red Cold Start Relay T3 Grid Heater
Diode, Fuse Block 2D, 4D, and 6D, Instrument
3 12/16 White Ignition Switch (Ignition)
Cluster (C1-2)
3C 16 Black RH Speaker T2 Ground at Radio
4 16 Gray Ignition Switch (ACC.) Power Relays 1, 2, 3, 4 T85
4D 16 Gray Radio (Right Output) RH Speaker T1
5E 16 Black LH Speaker T2 Ground at Radio
6F 16 Gray Radio (Left Output) LH Speaker T1
Loader Lever Differential Lock Engage Switch
7 16 Gray Loader Lever Differential Lock Enable Relay T86
(Std. Transmission)
10 16 Black Accessories - Front Console Ground
12A 12 Red Power Relay 1, T87 Fuse Block 2A, 4A, 6A, 8A, and 10A
12B 12 Red Power Relay 2, T87 Fuse Block 2C, 4C, 6C, and 8C
12C 12 Red Power Relay 3, T87 Fuse Block 8D, 10D, 12D, and 14D
12D 12 Red Power Relay 4, T87 Fuse Block 12A
13D 16 Gray Boom Lock Switch T3 Boom Lock Solenoid
Fuel Shutoff, Alt T2, Cold Start T6, Engine
15 16 White Fuse Block 5D
Control Unit T140, Water in fuel sensor
19A 16 Red Fuse Block 7A Turn/Driving Lamp/Horn Switch T56
Hazard Switch T2, Turn/Driving Lamp/Horn
Switch T49a, Flasher Relay T2, Loader Lever
19B 12/16 Red Fuse Block 3C
Differential Lock Enable Relay T85 and T30,
Brake Switch (Com), SAHR Brake Relay
Rear Work Lamp Switch T2,
19C 12 Red Fuse Block 7D
SAHR ON/OFF Switch
19D 16 Red Fuse Block 5A Rotating Beacon Switch T2
Clutch Relay T85 and T30, Shuttle Interlock
19E 16 Red Fuse Block 1D
Timing Relay (B+)
19F 16 Red Fuse Block 9A Loader Valve RTD Solenoid
19K 14 Red Fuse Block 9D Front Work Lamp Switch T2


10/14/
19M Gray Shuttle Interlock Timing Relay “Load” Forward and Reverse Relay T30
16
19N 14 Red Fuse Block 9B Air Suspension Seat Adjustment Switch (B+)
20 16 Black Accessories - Side Console Ground
20A 16 Black Instrument cluster (C2-26) Ground
20B 10 Black Power Plug Ground
20C 10 Black Power Plug Ground
20D 16 Black Warning Alarm Ground
Forward/Neutral/Reverse Lever (+), Power shift
Lever T8, Power shift Trax Controller (5,8 and
34), Loader Lever Kick down Switches, Loader
21 16/18 Red Clutch Relay T87a
Handle CC Switch, Auto/Manual Switch, RPM
Sensor, RH Brake Pressure Switch,
Carraro Sub-Harness 12-pin (8)
21A 16 Lt. Blue Ignition Switch (Start) Neutral Relay T30, Instrument Cluster (C1-15)
21B 12/16 White Starter Relay T87 Starter Solenoid
Neutral Relay T85, Shuttle Interlock Relay T85
Forward/Neutral/Reverse Lever (Neu), Power
21C 16 White Power shift Trax Controller T16,
shift lever T6
Instrument Cluster (C1-3)
22 16 White Neutral Relay T87 Starter Relay T85
24 16 White Shuttle Interlock Relay T30 Shuttle Interlock Timing Relay (Input)
25 16 Red Clutch Relay T86 Clutch Cutout Switches (Standard Transmission)
(Forward),
25A 16 Lt. Blue Forward Relay T85 & Diode
Powershift Forward/Neutral/Reverse Lever
Connector (C)
(Reverse)
25B 16 Lt. Blue Reverse Relay T85 & Diode
Powershift Forward/Neutral/Reverse Lever
Connector (A)
4WD Engage Switch T2,
25C 16 Red Fuse Block 3A
Power shift Trax Controller T22
4WD Engage Switch (Standard Trans) 4WD Solenoid (Std. Trans.)
25E 16 Gray
4WD Engage Switch (Powershift Trans) Powershift Controller T22
Loader Lever Differential Lock Enable Relay T87 Differential Lock Solenoid
25S 16 Gray Loader Lever Differential Lock Switch (Power Loader Lever Harness (C), Power shift Trax
shift) Controller T51
25T 16 Yellow Powershift Controller T50 LH Brake Pressure Switch
25X 16 Yellow Powershift Controller T39 Carraro Sub-Harness 12-pin (5)
26 16 Lt. Blue Forward Relay T87 Forward Solenoid
27 16 Lt. Blue Reverse Relay T87 Reverse Solenoid, Backup Alarm (+)
10/14/
30 Black Accessories - Chassis Ground
16
31S 16 Yellow Alternator T3 Power shift Trax Controller T53
32T 16 Yellow Instrument Cluster (C2-14) Transmission Temperature Sender
33T 16 Yellow Instrument Cluster (C2-15) Rear Axle Temperature Sender
34 16 Lt. Green Alternator T1 Instrument Cluster (C2-24)
36F 16 Yellow Instrument Cluster (C2-13) Fuel Level Sender
36H 16 Yellow Instrument Cluster (C1-17) Hydraulic Filter Restriction Switch
36R 16 Gray Seat Position Switch (NC) Instrument Cluster (C1-19)
38 16 Yellow Instrument Cluster (C1-16) Air Filter Restriction Switch


40A 14 Black Front Work Lamps, Front Wiper Ground
40B 12 Black Blower Motor, Rear Wiper, Dome Light, Radio Ground
40C 12 Black Rear Work Lights Ground
40D 14 Black Front Driving and Turn/Hazard Lights Ground
40E 14 Black Rear Stop, Tail, and Turn/Hazard Lights Ground
Front Driving and Tail Lamps, Instrument Cluster
41 16 Gray Turn Signal/Driving Lamp/Horn Switch T56a
(C1-4)
42C 12/16 Gray Rear Work Lamp Switch T1 Rear Work Lamps, Instrument Cluster (C1-6)
42F 14/16 Gray Front Work Lamp Switch T1 Front Work Lamps, Instrument Cluster (C1-5)
44 16 Tan Brake Switch (N.O.) Brake Lamps, Instrument Cluster (C1-7)
Turn/Horn/Driving Light Switch Term R, Left Turn
45L 16 Tan Flasher Relay T5
Signal Lamps
Turn/Horn/Driving Light Switch Term L, Right
45R 16 Tan Flasher Relay T7
Turn Signal Lamps
46 16 Tan Hazard Flasher Switch T1 Flasher Relay T1
47L 16 Tan Flasher relay T6 Left Turn Indicator
47R 16 Tan Flasher Relay T3 Right Turn Indicator
48 16 Gray Rotating Beacon Switch T1 Rotating Beacon
49 16 Red Fuse Block 5B Dome Lamp Door Switch, Dome Lamp
50 16 Black Options Harness Accessories Ground
Instrument Cluster (C1-3), Shuttle Interlock Relay
52 16 Gray Diodes
T87a, Power shift Trax Controller T2
53 16 Red Loader Valve RTD Solenoid RTD Limit Switch (NC)
56 16 Red Fuse Block 1B Optional Fused (B+), Optional Radio (B+)
Opt Radio (+), Loader Quick Coupler Switch T2,
Backhoe Quick Coupler Switch “A”, Backhoe
57 16 Red Fuse Block 1C
Quick Coupler Switch “B” T2, Ride Control Switch
T2, Boom Lock Switch T2
Pilot Control Switch T2, T5, Backhoe Auxiliary
58 14 Red Fuse Block 11A
Foot Switch T1
A/C Relay T30, A/C High Pressure Switch,
60 16 Red A/C Thermostat
A/C Pressure Relay
A/C/ High Pressure Switch,
60A 16/18 Red A/C Relay T86 & T87
Instrument Cluster (C1-10)
60B 16 Gray A/C Relay T87a A/C Low Pressure Switch
60C 16 Gray A/C Low Pressure Switch A/C Compressor Clutch
61 12 Red Fuse Block 5C Blower Switch (+)
61B 16 Gray Dome Lamp Door Switch Dome Lamp
62 16 Gray Windshield Washer Switch T3 (Front) Front Windshield Washer Pump
Front Wiper Switch T2 and Motor, Rear Wiper
63 16 Red Fuse Block 1A Motor, Windshield Washer Switches T2, Rear
Wiper disconnect Switch
63A 16 Red Rear Wiper Disconnect Switch Rear Wiper Switch T2
Turn Signal/Drive Lamps/Horn Switch T31b,
64A 16 Red Fuse Block 3B Rear Horn Rocker Switch T2, Pilot Control Horn
Switch T1, Power shift Trax Controller T1
Turn Signal/Drive Lamps/Horn Switch T31, Rear
64B 16 Gray Horn
Horn Switch T3, Pilot Control Horn T2
65 16 Gray Windshield Washer Switch T3 (Rear) Rear Windshield Washer Pump
66 16 Gray Front Wiper Switch T1 (Low) Front Wiper Motor (Low)


67 16 Gray Front Wiper Switch T3 (High) Front Wiper Motor (High)
69 16 Gray Front Wiper Switch T4 (Brake) Front Wiper Motor (Brake)
Aux B’Hoe Hyd Foot Switch T2, Pilot Control Aux
75 16 Gray Aux B’Hoe Hydraulic Solenoid T1, Diode
Switch T2
81 16 Gray Rear Wiper Switch T1 (Low) Rear Wiper Motor (Low)
82 16 Gray Rear Wiper Switch T3 (High) Rear Wiper Motor (High)
85 16 Gray Blower Switch A/C Thermostat
86 16 Gray Blower Switch (Low) Resistor Board (Low)
87 16 Gray Blower Switch (Medium) Resistor Board (Medium)
88 12 Gray Blower Switch (High) Resistor Board (High), Blower Motor
89 16 Gray Rear Wiper Switch T4 (Brake) Rear Wiper Motor (Brake)
90 16 Red Fast Steer Cutout Relay T30 Fuse Block 7C
94 16 Yellow Fast Steer Cutout Relay Powershift Lever
Fast Steer Control Switch, Fast Steer Power
95 16 Yellow Fast Steer Cutout Relay
Relay
96 16 Green Fast Steer Control Switch Fast Steer Power Relay
97 16 Red Fast Steer Control Switch Fast Steer Solenoid, Fast Steer Power Relay
101 12 Red Fuse Block Engine Controller T2, T3, T8, T9
Powershift LDR LVR Clutch Cutout Switch,
218 16 White Powershift Controller T21
(Optional) Servo Clutch Cutout Connection.
301 18 Lt. Blue Power shift Controller T9 Carraro Sub-Harn 12-pin (2)
307 18 Green Power shift Controller T12 Carraro Sub-Harn 8-pin (2)
311 18 Lt. Blue Power shift Controller T47 Fast Steer Cutout Relay
312 18 Green Power shift Controller T19 Power shift Lever T2
Power shift Lever T4, LDR. LVR. Loader Lever
321 16 Lt. Blue Power shift Controller T49
Kick down Switch
Power shift Lever T7, Power shift Front Console
322 16 Lt. Blue Power shift Controller T18
Connector (C)
Power shift Lever T5, Power shift Front Console
323 18 Gray Power shift Controller T46
Connector (A)
327 20 Green Power shift Trax Controller T55 Front Console CAN Connection T1
330 18 Yellow Power shift Trax Controller T25 Carraro Sub-Harn 12-pin (7)
343 18 Gray Power shift Trax Controller T43 Carraro Sub-Harn 12-pin (9)
344 16 Yellow Power shift Trax Controller T44 Carraro Sub-Harn 12-pin (11)
355 20 Yellow Power shift Trax Controller T27 Front Console CAN Connection T2
358 16 Green Power shift Trax Controller T23 Powershift Auto/Manual Switch T3, T8
360 16 White Power shift Trax Controller T41 Carraro Sub-Harn 8-pin (8)
400 16 White SAHR Control Switch SAHR Brake Relay


401 16 Gray Ride Control Engage Switch Ride Control Accumulator Solenoid
402 16 Green SAHR Brake Pressure Switch Instrument Cluster (C1-18)
SAHR Park Brake Solenoid, Ride Control Tank
403 16 Gray SAHR Control Switch
Solenoid
Loader Quick Coupler Switch T1, Back Hoe
501 16 Gray Quick Coupler Load Sense Solenoid, Diodes
Quick Coupler Switch “A” T1
502 16 Gray Loader Quick Coupler Switch T3 Loader Quick Coupler Solenoid, Diodes
504 16 Gray Backhoe Quick Coupler Switch “B” T3 Backhoe Quick Coupler Solenoid And Diodes
504A 16 Gray Backhoe Quick Coupler Switch “A” T3 Backhoe Quick Coupler Switch “B” T2
601 14/16 White Pilot Control Switch T3 Pilot Control Relay T30, Pilot Control Module T1
Pilot Control Pressure Reducing Valve T1, Pilot
Control Relay T85, Pilot Control Pattern Change
602 16 Green Pilot Control Relay T87 Switch T2, Pilot Control Switch T6 and T8, LH
Joystick Aux Switch T1, Diode, Pressure
Reducing Valve Solenoid
603 16 Gray Pilot Control Module T3 LH Stab Up Solenoid T1
604 16 Gray Pilot Control Module T4 LH Stab Down Solenoid T1
605 16 Gray Pilot Control Module T5 RH Stab Up Solenoid T1
606 16 Gray Pilot Control Module T6 RH Stab Down Solenoid T1
607 16 Gray Pilot Control Module T7 E’Hoe Extend Solenoid T1
608 16 Gray Pilot Control Module T8 E’Hoe Retract Solenoid T1
609 16 Yellow LH Stab Joystick T2 Pilot Control Module T9
610 16 Yellow RH Stab Joystick T2 Pilot Control Module T10
613 16 Yellow LH Stab Pressure Switch T1 Pilot Control Module T13
614 16 Yellow RH Stab Pressure Switch T1 Pilot Control Module T14
615 16 Gray Pilot Control Module T15 Aux Forward Solenoid T1
LH Stab Joystick T1, RH Stab Joystick T1
616 16 Red Pilot Control Module T16 E-Hoe Extend and Retract PB’s
Bi-Dir Aux Hyd Forward and Reverse PB’s
623 16 Gray Pilot Control Module T23 Aux Reverse Solenoid T1
624 16 Lt. Blue Pilot Control Pattern Change Switch T3 Pilot Control Pattern Change Solenoid T1, Diode
700 16 Gray Fast Steer Power Relay Fast Steer Control Switch
Fast Steer Power Relay, Fast Steer
701 16 Green Fast Steer Control Switch
Transmission Switch
702 16 Yellow Fast Steer Power Relay Fast Steer Control Switch, Fast Steer Solenoid
C26 16 Red Instrument Cluster (C2-6) Alarm
C111 18 Lt. Green Instrument Cluster (C1-11) Display Control Switch
C112 18 White Instrument Cluster (C1-12) Enter Control Switch
C113 18 Lt. Green Instrument Cluster (C1-13) Up Control Switch
C114 18 White Instrument Cluster (C1-14) Down Control Switch
C120 18 Gray Instrument Cluster (C1-20) Idle Validation Switch
C121 18 Green Instrument Cluster (C1-21) Pilot Control One Touch Decelerator Switch
C216 18 Green Instrument Cluster (C2-16) Foot Throttle
C217 18 Green Instrument Cluster (C2-11) Hand Throttle
C218 18 Red Instrument Cluster (C2-18) Foot Throttle


C219 18 Red Instrument Cluster (C2-19) Hand Throttle
C220 18 Gray Instrument Cluster (C2-20) Foot Throttle
C221 18 Gray Instrument Cluster (C2-21) Hand Throttle
Cold Start Relay (With Cold Start)
E12 18 Gray Engine Control Unit T112
1K Resistor (Without Cold Start)
E17 18 White Starter Relay T85 Engine Control Unit T117
E29 18 White Interlock Relay T30 Engine Control Unit T129
E32 18 White Interlock Relay T87 Engine Control Unit T132
E34 20 Green Engine Controller T34 CAN Low Diagnostic Port (C)
E35 20 Yellow Engine Controller T35 CAN High Diagnostic Port (D)
E37 18 White Starter Relay T86 Engine Control Unit T137
E42 16 Yellow Water in Fuel Sensor Engine Control Unit T142
Diagnostic Port (D), Front Console CAN
E44 16 Green Instrument Cluster (C2-3)
Connector
Diagnostic Port (C), Front Console CAN
E45 16 Yellow Instrument Cluster (C2-4)
Connector
Cold Start Relay (With Cold Start)
E75 16 White Engine Control Unit T117
1K Resistor (Without Cold Start)
E89 16 Blue Diagnostic Port (E) Engine Control Unit T189

UNDERSTANDING THE TROUBLESHOOTING TABLES
1 – Alternator 1
The alternator is located on the front, right side of the engine. 2
Check Points 3 Reading 4 Possible Cause of Bad Reading 5
Check the 15 ampere fuse at location
3 and 4C in the fuse block. (See fuse Good Bad fuse.
and relay location on page 4.)
Check wire 1A between the starter terminal (21) and the
alternator (1).
6
7
1. This title is the number and component name on the Electrical Schematic.
2. Location of component on the machine.
3. This column shows the location of the check point.
4. This column shows the indication of the check.
5. This column shows the possible cause of a bad test indication.
6. The numbers in the parentheses show the number of the component on the Electrical Schematic.
7. This statement assumes that all other problems are solved at this point in the test.

TROUBLESHOOTING
Use a multi meter for the following tests.
1 – Battery
NOTE: The battery must be at full charge and all connections clean and tight before any testing of the electrical system.
2 – Alternator
The alternator is located on the front right-hand side of the engine.
Check the 10 ampere fuse at location Good Bad fuse.

5 in the fuse block.
Terminal for wire 1A to ground 12 volts Check wire 1A between the starter terminal and the alternator.

Approximately Check the wire between the alternator and the instrument cluster
Terminal for wire 34 to ground 10 volts (17). Check the instrument cluster (17).
NOTE: Make sure all electrical switches except the key switch are in the OFF position. Have another person start and run the
engine at low idle.
Check for voltage at terminal for wire Approximately Bad alternator. See Section 4007 of the Service Manual and
NOTE: Turn the work lamp switch to the ON position. (Continue to run the engine at low idle.)
Check for voltage at terminal for wire More than Bad alternator. See Section 4007 of the Service Manual and
3 – Chassis Ground
4 – Starter and Starter Solenoid

The starter is located on the right rear side of the engine.
Battery terminal of starter solenoid to 12 volts Check the battery cable to the positive post of the battery.
ground
NOTE: Put the transmission control lever in Neutral. Have another person hold the key switch in the START position.
Check the starter relay (10), neutral start relay (11) and the key
Terminal for wire 21B to ground 12 volts
switch (7).
5 – Power Junction
Terminal for wire 1B to ground 12 volts Check the wire between the power junction and the battery.
NOTE: Make sure the connection is good for the power junction.

6 – Power Relays
Power Relay #1
Terminal for wire 1E to ground 12 volts Check the wire between power relay #1 and the battery (1).

Power Relay #2
Terminal for wire 1K to ground 12 volts Check the wire between power relay #2 and the battery (1).

Power Relay #3
Terminal for wire 1L to ground 12 volts Check the wire between power relay #3 and the battery (1).

Power Relay #4
Terminal for wire 1G to ground 12 volts Check the wire between power relay #4 and the battery (1).
NOTE: Turn the key switch to the ON position.
Check the circuit between all power relays and the key switch (7).
Check the key switch (7).
Terminal for wire 12A to ground 12 volts Bad power relay #1.
Terminal for wire 12B to ground 12 volts Bad power relay #2.
Terminal for wire 12C to ground 12 volts Bad power relay #3.
Terminal for wire 12D to ground 12 volts Bad power relay #4.
7 – Key Switch
The key switch is located in console on right side of machine.
Terminal for wire 1D to ground 12 volts Bad circuit between the key switch and the battery (1).
NOTE: Disconnect the connector from the key switch. Turn the key switch to the ON position.
the IGN terminal of the key switch
the ACC terminal of the key switch
Between the START terminal and the Continuity Bad key switch.
BAT terminal of the key switch
8 – Front Console Ground


9 – Clutch Cutout Relay

NOTE: Have another person push down and hold the loader handle clutch cutout switch.
Bad ground circuit through the loader handle clutch cutout switch
(37). Also check the loader handle clutch cutout switch (37).
NOTE: Have another person push down and hold the shift handle clutch cutout switch.
Bad ground circuit through the shift handle clutch cutout switch
(37). Also check the shift handle clutch cutout switch (37).
Bad circuit between the clutch cutout relay and the 10 ampere
Terminal for wire 19E to ground 12 volts fuse in the fuse block (15). Also check the 10 ampere fuse in the
fuse block (15).
Terminal for wire 21 to ground 12 volts Bad clutch cutout relay.
10 – Starter Relay
Terminal for wire 1C to ground 12 volts Check wire 1C between the starter relay and the battery (1).
NOTE: Put the transmission control lever in NEUTRAL. Have another person hold the key switch in the START position.
Bad circuit between the starter relay and the neutral start relay
(11). Also check the neutral start relay (11).
Terminal for wire 21B to ground 12 volts Bad starter relay.
11 – Neutral Start Relay

Bad circuit between the neutral start relay and the FNR switch
(13). Also check the FNR switch (13).
Bad circuit between the neutral start relay and the key switch (7).
Also check the key switch (7).
Terminal for wire 22 to ground 12 volts Bad neutral start relay.

12 – Interlock Relay
NOTE:
NOTE:
NOTE:
13 – FNR Switch
The FNR switch is located in the shuttle control valve.
Bad circuit between the FNR switch and the clutch cutout relay
(9). Also check the clutch cutout relay (9)
Terminal for wire 21C to ground 12 volts Bad FNR switch.
NOTE: Put the transmission control lever in FORWARD.
Terminal for wire 25A to ground 12 volts Bad FNR switch.

NOTE: Put the transmission control lever in REVERSE.
Terminal for wire 25B to ground 12 volts Bad FNR switch.
14 – Diode
Continuity in
only.
15 – Fuse Block
See the electrical schematic foldout for fuse and relay locations
NOTE: Check all fuses in the fuse panel.
16 – Side Console Ground


17 – Instrument Cluster Connector C1

NOTE:
18 – Instrument Cluster Connector C2

NOTE:
19 – UP/DOWN Switch
NOTE:
20 – Enter Escape Switch

NOTE:

21 – Hydraulic Filter Restriction Switch

The hydraulic filter switch is located in the hydraulic filter housing.

hydraulic filter switch and the filter Continuity Bad ground connection.
housing
Check the circuit between the hydraulic filter and the instrument
Terminal for wire 36H to ground 12 volts
cluster (17). Also check the instrument cluster (17).
NOTE: If the readings are good, replace the hydraulic filter switch.
22 – Air Filter Restriction Switch

The air filter restriction switch is located in the hose between the air filter and the engine.
Bad circuit between the air filter restriction switch and the
23 – Warning Alarm
The warning alarm is located in the front console.
NOTE: Turn the key switch to ON. If the warning buzzer does not sound, do the following checks.
Check the circuit between the warning alarm and the key switch
Terminal for wire 23F to ground 12 volts (7). Also check the 10 ampere fuse in the fuse block (15) and the
key switch (7).
Terminal for wire 37A to ground 12 volts Bad warning alarm.

24 – Fuel Level Sender

The fuel level sender is located in the lower part of the fuel tank.
NOTE: Check the level of fuel in the fuel tank. Make sure the fuel tank is full of fuel.

Approximately
4 -8 volts Check the circuit between the fuel level sender and the instrument
Terminal for wire 36F to ground (empty) cluster (17) (including the connection on the instrument cluster).
2 - 3 volts Also check the instrument cluster (17).
(full)
Empty
Disconnect wire 36F from the fuel (Low fuel lamp
level sender. Check the reading of the Bad fuel level gauge.
should
fuel level gauge. illuminate)
Connect wire 36F to ground. Check Full Bad fuel level gauge.
the reading of the fuel level gauge.
NOTE: If the readings are good, use an ohmmeter and check the resistance of the fuel level sender. Disconnect the wires
from the fuel level sender. When the fuel tank is full, the resistance should be approximately 33 Ohm. If the fuel tank is empty,
the resistance should be 235 Ohm. If the ohmmeter readings are not correct, replace the fuel level sender.
25 – Transmission Temperature Sender

The transmission temperature sender is located in the top, right, rear cover of the transmission case.

transmission temperature sender and Continuity Bad ground connection.
the transmission housing
Check the circuit between the transmission temperature sender

Approximately
Terminal for wire 32T to ground and the instrument cluster (17). Also check the instrument cluster
12 volts
(17).
NOTE: If the readings are good, disconnect the wires from the transmission temperature sender. Use an ohmmeter and
check the resistance of the transmission temperature sender. The output of the transmission temperature sender must be
above 1000 Ohm with the transmission at ambient temperature. If the ohmmeter reading is not correct replace the
transmission temperature sender.
26 – Hand Throttle Potentiometer

NOTE:
NOTE:

27 – Foot Throttle Potentiometer

NOTE:
NOTE:
28 – Idle Validation Switch

NOTE:
NOTE:
29 – SAHR Parking Brake Pressure Switch

NOTE: The SAHR pressure switch is located on the rear of the transmission on the parking brake housing.
NOTE: With the park brake set and the machine not running.
Between the terminal of the switch Open Bad switch
NOTE: Block the tires of the machine to keep it from moving, with the engine running, release the parking brake.
Between the terminal of the switch Continuity Bad switch
NOTE: See section 7002 and troubleshoot the SAHR hydraulics.
30 – SAHR Parking Brake ON/OFF Switch

NOTE:
NOTE:

31 – Seat Position Switch

The seat position switch is located in the seat column.
Check the circuit between the seat position switch and the
NOTE: If the readings are good, replace the seat position switch
32 – SAHR Parking Brake Solenoid

NOTE: The SAHR solenoid is located on the rear of the transmission on the rear housing.
9.8 Ohm at
Between the terminals of the solenoid Replace solenoid
20° C (68° F)
33 – SAHR Parking Brake Relay

NOTE: The SAHR relay is located in the front console.
NOTE: Turn the ignition switch to the ON position.
Terminal for wire 19B to ground 12 volts Bad fuse, bad ignition switch
34 – Shuttle Interlock Relay

NOTE: Put the transmission control lever and FNR switch in NEUTRAL. Turn the key switch to ON. Make sure the clutch
cutout switches are in the disengaged position.
switches are in the disengaged position. Move the shift lever to the REVERSE position.

35 – Shuttle Interlock Timing Relay

Terminal for wire 24 to ground 12 volts shuttle interlock relay (34). Also check the shuttle interlock relay
(34).
key switch (7). Also check the key switch (7).
Terminal for wire 19M to ground 12 volts Bad shuttle interlock timing relay.
36 – Clutch Cutout Switch - Shift Handle

The clutch cutout switch is located in the switch handle.
37 – Clutch Cutout Switch - Loader Handle (Standard Transmission)

The clutch cutout switch is located in the loader handle.
38 – Clutch Cutout Switch - Loader Handle (Power Shift Transmission)

NOTE:
NOTE:

39 – Forward Relay
Check the circuit between the forward relay and the FNR switch
Terminal for wire 25A to ground 12 volts (13). Check the diode in the circuit. Also check the FNR switch
(13).
Check the circuit between the forward relay and the shuttle
relay (35).
Terminal for wire 26 to ground 12 volts Bad forward relay.
40 – Reverse Relay
Terminal for wire 25B to ground 12 volts interlock timing relay (35). Check the diode in the circuit. Also
check the FNR switch (13).
relay (35).
Terminal for wire 27 to ground 12 volts Bad reverse relay.
41 – Forward Solenoid
The forward solenoid is located in the transmission control valve.
NOTE: Turn the key switch to ON. Move the shift lever to the forward position.
Check the circuit between the forward solenoid and the forward
Terminal for wire 26 to ground 12 volts relay (39). Check the forward relay (39). Also check the diode in
the circuit.
NOTE: If the readings are good, replace the forward solenoid.

42 – Reverse Solenoid
The reverse solenoid is located in the transmission control valve.
Check the circuit between the reverse solenoid and the reverse
Terminal for wire 27 to ground 12 volts relay (40). Check the reverse relay (40). Also check the diode in
the circuit.
NOTE: If the readings are good, replace the reverse solenoid.
43 – Diode

Continuity in
only.
44 – Backup Alarm
The backup alarm is located in the rear of the machine.
Negative terminal to ground Continuity Bad ground connection.
Check the circuit between the backup alarm and the reverse relay
(40). Also check the reverse relay (40).
NOTE: If the readings are good, replace the backup alarm.
45 – Return-To-Dig Limit Switch

The return-to-dig limit switch is located on the right loader arm.
Check the circuit between the return-to-dig limit switch and the
Terminal for wire 53 to ground 12 volts loader valve solenoid (46). Also check the loader valve solenoid
(46).
NOTE: If the readings are good, replace the return-to-dig limit switch.

46 – Loader Valve Solenoid

The loader valve solenoid is located in the loader control valve.
Check the circuit between the loader valve solenoid and power
Terminal for wire 19F to ground 12 volts relay #1 (6). Also check the 10 ampere fuse in the fuse block (15)
Terminal for wire 53 to ground 12 volts Bad loader valve solenoid.
47 – Front Wiper Switch (Cab)

The front wiper switch is located in the cab.

Check the circuit between the front wiper switch and power relay
Terminal for wire 63 to ground 12 volts #1 (6). Also check the 15ampere fuse in the fuse block (15) and
power relay #1 (6).
48 – Rear Wiper Switch (Cab)

NOTE: Turn the key switch to ON, close the cab rear glass.
Check rear wiper cut off switch (53). Check the circuit between the
Terminal for wire 63A to ground 12 volts rear wiper switch and power relay #1 (6). Also check the 15
ampere fuse in the fuse block (15) and power relay #1 (6).

49 – Front Windshield Washer Switch (Cab/ROPS with Windscreen Only)


NOTE: Turn the front windshield washer switch to on.
Terminal for wire 62 to ground 12 volts Bad windshield washer switch.
50 – Rear Windshield Washer Switch (Cab/ROPS with Windscreen Only)


NOTE: Turn the rear windshield washer switch to on.
Terminal for wire 65

12 volts Bad windshield washer switch.
to ground
51 – Front Wiper Motor (Cab)

The front wiper motor is located at the front wiper.
Check the circuit between the front wiper motor and power relay
power relay #1 (6).

52 – Rear Wiper Motor (Cab)

NOTE: Close rear cab glass.
Check the circuit between the rear wiper motor and power relay
Terminal for wire 63 to ground 12 volts #1 (6). Also check the 15ampere fuse in the circuit and power
relay #1 (6).
53 – Rear Wiper Cut Off Switch

NOTE: Disconnect the wires from the rear wiper cut off switch. Make sure the rear cab glass is open.

Open Bad rear wiper cut off switch.
wiper cut off switch
NOTE: Close rear cab glass, make sure switch is being pushed to closed position.

Continuity Bad rear wiper cut off switch.
wiper cut off switch.
54 – Windshield Washer Motor

The windshield washer pump is located just above and in front of the radiator.
NOTE: Turn the key switch to ON. Have another person hold the front windshield washer switch in the on position.
Terminal for wire 62 to ground 12 volts windshield washer switch (49). Also check the windshield washer
switch (49).
NOTE: Make sure the key switch is in the ON position. Have another person hold the rear windshield washer switch in the on
position.
Terminal for wire 65 to ground 12 volts rear windshield washer switch (50). Also check the rear
windshield washer switch (50).

55 – Blower Switch
The blower switch is located in the console.
Bad circuit between the blower switch and power relay #2 (6). Also
#2 (6).
NOTE: Turn the blower switch to LOW.

56 – Air Conditioning Pressure Relay

Check the circuit between the air conditioner relay and the air
Bad low pressure switch (61) or high pressure switch (62) or

Terminal for wire 60A to ground Open
incorrect charge.
Terminal for wire 60B to ground 12 volts Bad compressor clutch relay or a bad high or low pressure switch.

57 – Blower Motor Resistor Board and Thermal Fuse

The blower resistor board and thermal fuse are located with the blower motor in the headliner.
NOTE: Turn the key switch to ON. Turn the blower switch to LOW.
NOTE: Disconnect the connector from the resistor board.
Between terminals 1 and 3 of the

3.8 Ohm Bad resistor board.
resistor board
58 – Blower Motor
The blower motor is located in the headliner.
Bad circuit between the blower motor and the blower switch (55).
Also check the blower switch (55).
59 – Air Conditioning Compressor Clutch

The air conditioning compressor clutch is located on the left side of the engine.
Ground wire of the air conditioning

Continuity Bad ground wire.
clutch to ground
NOTE: Turn the key switch to ON. Turn the cab blower switch to HIGH and the air conditioning temperature switch to COLD.
Check the circuit between the air conditioning compressor clutch

Terminal for wire 60B to ground 12 volts and the compressor clutch relay (59). Also check the compressor
clutch relay (59).
NOTE: If the readings are correct, replace the air conditioning compressor clutch.
60 – Air Conditioning Temperature Switch

The air conditioning temperature switch is located in the console.
Bad circuit between the air conditioning temperature switch and

the blower switch (55). Also check the blower switch (55).
NOTE: Turn the air conditioning temperature switch all the way to COLD.
Terminal for wire 60 to ground 12 volts Bad air conditioning temperature switch.

61 – Air Conditioning Low Pressure Switch

The air conditioning low pressure switch is located above the headliner at the top of the right side of the cab.
Bad ground circuit between the air conditioning low pressure

switch and ground.
Bad circuit between the low pressure switch and the air
NOTE: Disconnect the wires from the low pressure switch.

Between the terminals of the low Low charge in the air conditioning system. See Section 9002. Bad
Open
pressure switch. low pressure switch.
62 – Air Conditioning High Pressure Switch

The air conditioning high pressure switch is located in front of the radiator behind the grille.
Bad ground circuit between the air conditioning high pressure

switch and ground.
Bad circuit between the high pressure switch and the air
NOTE: Disconnect the wires from the high pressure switch.
Between the terminals of the high High charge in the air conditioning system. See Section 9002. Bad
Open
pressure switch. high pressure switch.
63 – Dome Lamp Door Switch

The dome lamp switch is located in the door frame at the hinge side of the cab door.
Check the circuit between the dome lamp door switch and the
battery (1). Also check the 10 ampere fuse in the fuse block (18).
Bad ground circuit. Check the circuit between the dome lamp door
Terminal for wire 61B to ground 12 volts switch and the dome lamp switch (64). Also check the dome lamp
switch (64).

64 – Dome Lamp Switch

The dome lamp with switch is located in the headliner.
Bulb Good Bad bulb.
Check the circuit between the dome lamp and the battery (1). Also
check the 10 ampere fuse in the fuse block (15).
Check the circuit between the dome lamp switch and the dome
Terminal for wire 61B to ground 12 volts lamp door switch (63). Also check the dome lamp door switch
(63).
NOTE: If the readings are good replace the dome lamp switch
65 – Rear Horn Button

The rear horn button is located in the right console.
Terminal for wire 64B to ground Continuity Bad ground circuit through the horn (69). Also check the horn (69).
Check the circuit between the rear horn button and the battery (1).
Also check the 10 ampere fuse in the fuse block (15).
NOTE: Have another person push down and hold the horn button.
Terminal for wire 64B to ground 12 volts Bad horn button.

66 – Turn Signal/Driving Lamp/Horn Switch

Turn Signal Switch: The turn signal switch is located on the lever in the steering column.
Check the circuit between the turn signal switch and power relay
power relay #2 (6).
NOTE: Turn the key switch to ON. Move the turn signal/driving lamp/horn switch for a left turn.
Intermittent 12
Terminal for wire 45L to ground Bad turn signal/driving lamp/horn switch.
volts
NOTE: Turn the key switch to ON. Move the turn signal/driving lamp/horn switch for a right turn.
Intermittent 12
Terminal for wire 45R to ground Bad turn signal/driving lamp/horn switch.
volts
Driving Lamp Switch: The driving lamp switch is located on the lever in the steering column.
Check the circuit between the driving lamp switch and power relay
Terminal for wire 19A to ground 12 volts #1 (6). Also check the 15 ampere fuse in the ampere fuse in the
NOTE: Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad driving lamp switch.
Horn Switch:The horn switch is located on the lever in the steering column.
Check the circuit between the horn button and the battery (1). Also
Terminal for wire 64A to ground 12 volts check the 10 ampere fuse in the fuse block (15) and the battery
(1).
NOTE: Have another person push in and hold the horn button.
Terminal for wire 64B to ground 12 volts Bad horn switch.
67 – Driving Lamps
The driving lamps are located between the turn lamps and the front work lamps.
Terminal 40D to ground Continuity Bad ground connection.
Bulb Good Bad bulb.
Bad circuit between the driving lamps and the turn signal/driving

68 – Rear Stop and Tail Lamps

The rear tail lamps are located between the rear turn lamps and the rear work lamps.
Terminal 40E to ground Continuity Bad ground circuit.
Bulb Good Bad bulb.
Bad circuit between the rear tail lamps and the turn signal/driving
Bad circuit between the rear tail lamps and the brake lamp switch
(71). Also check the brake lamp switch (71).
69 – Horn
The horn is located on the left side of the engine.
NOTE: Turn the key switch to the ON position. Have another person hold down the horn button.
Check the circuit between the horn and the turn signal/driving
Terminal for wire 64B to ground 12 volts lamp/horn switch (66). Also check the turn signal/driving
NOTE: If the readings are correct and the horn does not work, replace the horn.
70 – Hazard Flasher Switch

The flasher switch is located in the front console.

Check the circuit between the hazard flasher switch and power
Terminal for wire 19B to ground 12 volts relay #2 (6). Also check the 15 ampere fuse in the fuse block (15)
NOTE: Put the flasher switch in the ON position.
Terminal for wire 46 to ground 12 volts Bad hazard flasher switch.
NOTE: If the readings are correct and the indicator lamp on the hazard flasher switch does not illuminate, do the following
check.
Terminal for wire 10 to ground Continuity Bad ground circuit for hazard flasher switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the flasher switch does not illuminate, replace the hazard flasher
switch.

71 – Brake Lamp Switch

The brake lamp switch is located on the fire wall below the brake pedals.

Check the circuit between the brake lamp switch and power relay
power relay #2 (6).
Terminal for wire 44 to ground 12 volts Bad brake lamp switch.
72 – Flasher Relay (Bottom of Socket)

Terminal for wire 10 (T4) to ground Continuity Bad ground circuit.
Check the circuit between the flasher relay and power relay #2 (6).
Terminal for wire 19B (T2) to ground 12 volts Also check the 15 ampere fuse in the fuse block (15) and power
relay #2 (6).
NOTE: Make sure the turn signal is in the OFF position. Turn the flasher switch ON.
Check the circuit between the flasher relay and the flasher switch
Terminal for wire 46 (T1) to ground 12 volts
(70). Also check the flasher switch (70).
Intermittent 12
volts
Intermittent 12
volts
NOTE: Make sure the hazard flasher switch is in the OFF position. Move the turn signal/driving lamp/horn switch to the left
turn position.
Terminal for wire 45R (T7) to ground 12 volts signal/driving lamp/horn switch (66). Also check the turn
Intermittent 12
volts
Intermittent 12
volts
NOTE: Make sure the hazard flasher switch is in the OFF position. Move the turn signal/driving lamp/horn switch to the right
turn position.
Terminal for wire 45L (T5) to ground 12 volts signal/driving lamp/horn switch (66). Also check the turn
Intermittent 12
volts
Intermittent 12
volts

73 – Front Turn Lamp

Left Front Turn Lamp: The left front turn lamp is located at the top of the ROPS cab or canopy on the left side of the front of
the machine.
Bulb Good Bad bulb.
Intermittent 12 Check the circuit between the left front turn lamp and the turn
Check the circuit between the right front turn lamp and the turn
Right Front Turn Lamp: The right front turn lamp is located at the top of the ROPS cab or canopy on the right side of the
front of the machine.
Bulb Good Bad bulb.

74 – Rear Turn Lamp

Left Rear Turn Lamp: The left rear turn lamp is located at the top of the ROPS cab or canopy on the left side of the rear of
the machine.
Bulb Good Bad bulb.
Check the circuit between the right rear turn lamp and the turn
Right Rear Turn Lamp: The right rear turn lamp is located at the top of the ROPS cab or canopy on the right side of the front
of the machine.
Bulb Good Bad bulb.
75 – Turn Signal Indicator Lamps

The turn signal indicator lamps are located in the front console.

Intermittent 12 Check the circuit between the right rear turn lamp and the turn
The power plug is located to the rear of the right hand console.

The power plug is located to the rear of the right hand console.a
78 – Air Suspension Seat - Air Compressor Switch and Motor

Located in the base of the air suspension seat.
Check the circuit between the air compressor and the battery (1).
Terminal for wire 19N to ground 12 volts Also check the 20 ampere fuse in the fuse block (15) the power
79 – Rotating Beacon Switch

The rotating beacon switch is located in the front console.
Check the circuit between the rotating beacon switch and power
Terminal for wire 19D to ground 12 volts relay #1 (6). Also check the 10 ampere fuse in the fuse block (15)
NOTE: Put the rotating beacon switch in the ON position.
Terminal for wire 48 to ground 12 volts Bad rotating beacon switch.
NOTE: If the readings are correct and the indicator lamp on the rotating beacon switch does not illuminate, do the following
check.
Terminal for wire 10 to ground Continuity Bad ground circuit for rotating beacon switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the rotating beacon switch does not illuminate, replace the
rotating beacon switch.
80 – Rotating Beacon (Opt)

The rotating beacon is located on top of the ROPS cap or canopy.
Terminal for wire 40E to ground Continuity Bad ground circuit.
NOTE: Turn the key switch to ON. Turn the rotating beacon switch to ON.
Bulb Good Bad bulb.
Check the circuit between the rotating beacon and the rotating
beacon switch (79). Also check the rotating beacon switch (79).
NOTE: If the readings are good, replace the rotating beacon.

81 – Front Work Lamp Switch

The front work lamp switch is located in the console.
Check the circuit between the front work lamp switch and power
Terminal for wire 19K to ground 12 volts relay #3 (6). Also check the 10 ampere fuse in the fuse block (15)
NOTE: Put the front work lamp switch in the ON position.
Terminal for wire 42F to ground 12 volts Bad front work lamp switch.
NOTE: If the readings are correct and the indicator lamp on the front work lamp switch does not illuminate, do the following
check.
Terminal for wire 10 to ground Continuity Bad ground circuit for front work lamp switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the front work lamp switch does not illuminate, replace the front
work lamp switch.
82 – Front Work Lamps

The front work lamps are located between the front road lamps at the front of the machine.
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Turn the front work lamp switch to ON.
Check the circuit between the front work lamp and the front work
Terminal for wire 42F to ground 12 volts
lamp switch (81). Also check the front work lamp switch (81).
83 – Rear Work Lamp Switch

The rear work lamp switch is located in the console.
Check the circuit between the rear work lamp switch and power
NOTE: Put the rear work lamp switch in the ON position.
Terminal for wire 42C to ground 12 volts Bad rear work lamp switch.
NOTE: If the readings are correct and the indicator lamp on the rear work lamp switch does not illuminate, do the following
check.
Terminal for wire 20 to ground Continuity Bad ground circuit for rear work lamp switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the rear work lamp switch does not illuminate, replace the rear
work lamp switch.

84 – Rear Work Lamps

The rear work lamps are located between the rear road lamps at the rear of the machine.
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Turn the rear work lamp switch to ON.
Check the circuit between the rear work lamps and the rear work
lamp switch (83). Also check the rear work lamp switch (83).
85 – 4WD Engage Switch (If Equipped)

The 4wd engage switch is located in the console.
Check the circuit between the 4WD engage switch and power
NOTE: If the readings are correct and the indicator lamp on the 4WD engage switch does not illuminate, do the following
check.
Terminal for wire 10 to ground Continuity Bad ground circuit for 4WD engage switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the 4WD engage switch does not illuminate, replace the 4WD
engage switch.
86 – Not Used
87 – 4WD Solenoid (Disengages 4WD When Energized)

The 4wd solenoid is located in the on top of the transmission.
NOTE: If the readings are correct, replace the 4WD solenoid.

88 – Thumb Operated Rear Auxiliary Hydraulics Switch (Pilot Controls) Uni-directional

NOTE: Disconnect switch, push and hold the switch.
Between the terminals of the switch Continuity Bad switch
NOTE: Release the switch.
Between the terminals of the switch Open Bad switch
89 – Foot Operated Rear Auxiliary Hydraulic Switch

NOTE: Put the key switch in the ON position.
NOTE: Have another person push down and hold the rear auxiliary hydraulic switch.
90 – Diode

Continuity in
only.
91 – Auxiliary Hydraulic Solenoid Uni-directional

NOTE: Put the hand operated auxiliary hydraulics engage switch in the ON position
Check the circuit between the auxiliary hydraulic solenoid and the
Terminal for wire 75 to ground 12 volts auxiliary hydraulics engage switch (88 or 89). Also check the
auxiliary hydraulics engage switch (88 or 89).
NOTE: If the readings are correct, replace the hand operated auxiliary hydraulics solenoid.
92 – Radio (Optional)

Check the circuit between the radio and the battery (1). Also check
the 10 ampere fuse in the fuse block (15) and the battery (1).
Check the circuit between the radio and power relay #2 (6). Also
#2 (6).

93 – Left Speaker
94 – Right Speaker
95 – Ride Control Engage Switch

Check the circuit between the ride control engage switch and
NOTE: Put the ride control engage switch in the ON position.
Terminal for wire 401 to ground 12 volts Bad ride control engage switch.
NOTE: If the readings are correct and the indicator lamp on the ride control engage switch does not illuminate, do the
following check.
Terminal for wire 10 to ground Continuity Bad ground circuit for ride control engage switch indicator lamp.
NOTE: If the reading was correct and the indicator lamp on the ride control engage switch does not illuminate, replace the
ride control engage switch.
96 – Ride Control Solenoid (Accumulator)

engage switch (95).
NOTE: If the readings are correct, see Section 8002 and check the system for the right ride control solenoid.
97 – Ride Control Solenoid (Tank)

engage switch (95).

98 – Boom Lock Switch

Check the circuit between the boom lock switch and power relay
power relay #2 (6).
NOTE: Put the boom lock switch in the ON position.
Terminal for wire 13D to ground 12 volts Bad boom lock switch.
99 – Boom Lock Solenoid

NOTE: Turn the key switch to ON. Put the boom lock switch in the ON position.
Check the circuit between the boom lock solenoid and the boom
Terminal for wire 13D to ground 12 volts
lock switch (98). Also check the boom lock switch (98).
NOTE: If the readings are correct, replace the boom lock solenoid.
100 – Loader Quick Coupler Disengage Switch

The loader quick coupler disengage switch.
Check the circuit between the loader quick coupler disengage

Terminal for wire 57 to ground 12 volts switch and power relay #2 (6). Also check the 15 ampere fuse in
the fuse block (15) and power relay #2 (6).
NOTE: Put the front quick coupler disengage switch in the CONNECT position.
NOTE: Put the front quick coupler disengage switch in the DISCONNECT position.
101 – Loader Quick Coupler Solenoid


102 – Loader Load Sensing Solenoid

103 – Diode

Continuity in
only.
104 – Backhoe Quick Coupler Switch A


NOTE: Hold the backhoe quick coupler switch in the DISCONNECT position.
Terminal for wire 504A to ground 12 volt Bad backhoe quick coupler switch #1.
NOTE: Hold the backhoe quick coupler switch in the CONNECT position.
105 – Backhoe Quick Coupler Switch B

NOTE: Turn the key switch to ON. Put the backhoe quick coupler switch #1 in the DISCONNECT position.

Terminal for wire 504A to ground 12 volt backhoe quick coupler switch #1 (104). Also check the backhoe
quick coupler switch #1 (104).
NOTE: Hold the backhoe quick coupler switch #1 and #2 in the DISCONNECT position.

106 – Backhoe Quick Coupler Solenoid

NOTE: Turn the key switch to ON. Hold the backhoe quick coupler switch #1 and #2 in the DISCONNECT position.
Check the circuit between backhoe quick coupler solenoid (upper)

Terminal for wire 504 to ground 12 volts and backhoe quick coupler switch #2 (105). Also check the
backhoe quick coupler switch #2 (105).
107 – Loader Lever Differential Lock Engage Switch (Standard Transmission)

Located on the loader lever.
NOTE: Disconnect the wires from the loader lever differential lock engage switch. Make sure the loader lever differential lock
engage switch is in the DISENGAGED position.
Between the terminals of the loader Open Bad loader lever differential lock engage switch.
lever differential lock engage switch
NOTE: Have another person hold the loader lever differential lock engage switch in the ENGAGED position
Between the terminals of the loader Continuity Bad loader lever differential lock engage switch.
lever differential lock engage switch.
108 – Loader Lever Differential Lock Engage Switch (Power Shift Transmission)
NOTE:
NOTE:
NOTE:

109 – Loader Lever Differential Lock Enable Relay

NOTE: Have another person hold the loader lever differential lock engage switch in the ENGAGED position.
Bad ground circuit through the loader lever differential lock

Terminal for wire 7 to ground Continuity engage switch (107). Also check the loader lever differential lock
engage switch (107).
Check the circuit between the loader lever differential lock enable
Terminal for wire 19B to ground 12 volts relay and power relay #2 (6). Also check the 15 ampere fuse in the
NOTE: With the key switch in the ON position. Have another person hold the loader lever differential lock engage switch in the
ENGAGED position.
Terminal for wire 25S to ground 12 volts Bad loader lever differential lock enable relay
110 – Differential Lock Solenoid

NOTE: Turn the key switch to ON. Hold differential lock engage switch in the ENGAGED position.
Terminal for wire 25S to ground 12 volts loader lever differential lock engage switch (107). Check the
loader lever differential lock engage switch (107).
NOTE: With the key switch in the ON position. Hold loader lever differential lock engage switch in the ENGAGED position.
Terminal for wire 25S to ground 12 volts loader lever differential lock enable relay (109). Check the loader
lever differential lock enable relay (109).
111 – Resistor (Machine Without Grid Heater)

NOTE:
112 – Grid Heater Unit

The grid heater is located on the engine air intake.
NOTE: Disconnect the positive wire from the grid heater.
Positive terminal of grid heater to

Resistance If an open or short circuit is obtained, replace the grid heater.
ground
113 – Not Used

114 – Not Used
115 – Not Used
116 – Not Used
117 – Grid Heater Fuse

The grid heater fuse is located on the left side of the frame behind the air filter.
Between terminals of fuse Continuity Bad Fuse
118 – Not Used
119 – Not Used
120 – Not Used
121 – Extend-a-hoe Extend Push Button (Pilot Controls)

122 – Extend-a-hoe Retract Push Button (Pilot Controls)

123 – Horn Switch (Pilot Controls)

The push button is located on the left pilot control handle.
NOTE: Disconnect the connector and press the button
Between the terminals of the button Continuity Bad push button switch

124 – Left Hand Stabilizer Switch (Pilot Controls)

125 – Right Hand Stabilizer Switch (Pilot Controls)

126 – Left Hand Stabilizer Pressure Switch (Pilot Controls)

The pressure switch is located inside of the left rear frame mounted to the stabilizer locking valve.
127 – Right Hand Stabilizer Pressure Switch (Pilot Controls)

The pressure switch is located inside of the right rear frame mounted to the stabilizer locking valve.
128 – Electrical Pilot Controller (Pilot Controls)

The controller is located under the machine on the left front side of the mounted bracket for the pilot valve.
NOTE: Disconnect connector from controller, turn the ignition switch on and the pilot control switch on.
Terminal for wire 601 12 volts Bad pilot on/off switch (137), bad pilot relay (138), bad fuse.
Fault light on with no blink Bad control unit
129 – Right Hand Stabilizer Down Solenoid (Pilot Controls)


130 – Right Hand Stabilizer Up Solenoid (Pilot Controls)

131 – Left Hand Stabilizer Down Solenoid (Pilot Controls)

132 – Left Hand Stabilizer Up Solenoid (Pilot Controls)

133 – Auxiliary Reverse Solenoid Bi-directional (Pilot Controls)

134 – Auxiliary Forward Solenoid Bi-directional (Pilot Controls)


135 – Extend-a-hoe Retract Solenoid (Pilot Controls)

136 – Extend-a-hoe Extend Solenoid (Pilot Controls)

137 – Pilot On/Off Switch (Pilot Controls)

The pilot on/off switch is located on the right tower boot.
NOTE: Disconnect the connector and place the switch in position three (off)
Between pins 2 and 3, 5 and 6 Open Bad switch
NOTE: Place the switch in position two (momentary position)
Between pins 2 and 3 Continuity Bad switch
Between pins 5 and 6 Open Bad switch
Between pins 2 and 3, 5 and 6 Continuity Bad switch
138 – Pilot Control Relay (Pilot Controls)

The control relay is located under the machine on the left front side of the mounted bracket for the pilot valve.
NOTE: Place the pilot on/off switch in position two and the ignition switch in the on position
Terminal for wire 601 to ground 12 volts Bad pilot on/off switch (137).
Terminal for wire 601 and 602 to 12 volts Bad pilot on/off switch (137).
ground
139 – Auxiliary Forward Push Button Bi-directional (Pilot Controls)


140 – Auxiliary Reverse Push Button Bi-directional (Pilot Controls)

141 – Pattern Change Switch (Pilot Controls)

The pattern change switch is located right hand pilot control tower.
NOTE: Turn the ignition switch to the ON position and the pilot control on/off switch to position ONE.
Chick circuit between on/off switch (137) and pattern change

switch. Also check pilot control relay (138).
NOTE: Turn pattern change switch to position 2
Terminal for wire 624 to ground 12 volts Bad pattern change switch
NOTE: If readings are correct and the indicator lamp on the pattern change switch does not illuminate, do the following check.
Terminal for wire 30 to ground Continuity Bad ground circuit for pattern change switch indicator lamp
142 – Pressure Reducing Valve Solenoid (Pilot Controls)



Continuity in
only.
144 – Pattern Change Solenoids (Pilot Controls)




Continuity in
only.
146 – Fast Steering Transmission Switch (Standard Transmission)

NOTE:
NOTE:
NOTE:
147 – Fast Steering Power Relay (Standard Transmission)

NOTE:
148 – Fast Steering ON/OFF Switch (Standard Transmission)

NOTE:
149 – Fast Steering Solenoid (Standard Transmission)

NOTE:

150 – Fast Steering Cutout Relay (Power Shift Transmission)

NOTE:
NOTE:
NOTE:
151 – Fast Steering Power Relay (Power Shift Transmission)

NOTE:
152 – Fast Steering ON/OFF Switch (Power Shift Transmission)

NOTE:
153 – Fast Steering Solenoid (Power Shift Transmission)

NOTE:
154 – Electro Hydraulic Clam Control

NOTE:
NOTE:

155 – Electro Hydraulic Clam Control EVI Solenoid

156 – Electro Hydraulic Clam Control EVK Solenoid

157 – Engine Control Unit

NOTE:
NOTE:
158 – Diagnostic Connector

NOTE:
NOTE:
159 – Water In Fuel Sensor

NOTE:
NOTE:

160 – Power Shift Transmission Controller

NOTE:
NOTE:
161 – Power Shift Transmission Shifter

NOTE:
NOTE:
162 – Loader Lever Kick Down Power Shift Transmission

NOTE:
NOTE:
163 – Auto/Manual Switch Power Shift Transmission

NOTE:
NOTE:

164 – Brake Pressure Switches Power Shift Transmission

NOTE:
NOTE:

CONNECTORS
CONNECTOR - FRONT WASHER PUMP MOTOR CONNECTOR - LOADER VALVE RTD
3227856R1 291718A1

1 62 Gray 16 Front Washer Pump 1 53 Red 16 Loader Valve RTD
2 50 Black 16 Front Washer Ground 2 19F Red 16 Fuse Block 9A
CONNECTOR - REAR WASHER PUMP MOTOR CONNECTOR - COLD START
3227856R1 225350C1
1 65 Gray 16 Rear Washer Pump 1 31C Yellow 16 Instrument Cluster T16
2 50 Black 16 Rear Washer Ground 2 34 Lt. Green 16 Alternator

3 21B White 16 Starter Relay T87
CONNECTOR - SEAT POSITION SWITCH
5 35 Lt. Blue 16 Coolant Temp Sender T2
245482C1

A 36R Gray 16 Instrument Cluster T9

CONNECTOR - PILOT CONTROL/BH AUXILLIARY CONNECTOR - GEAR SHIFT LEVER DE-CLUTCH
245482C1
182069A1 CAV WIRE IDENT CIRCUIT
CAV WIRE IDENT CIRCUIT A 25 Red 16 Clutch Relay T86
A 58 Red 14 Fuse Block 11A B 30 Black 16 Ground

CONNECTOR - SIDE HARNESS A/C
CONNECTION
245731C1
245485C1
30 1E Red 12 Power Junction Post
Fuse Block 2A, 4A, 6A, 8A, and
87 12A Red 12
10A
CONNECTOR - PILOT CONTROL HORN 87A None
245482C1

A 64A Red 16 Fuse Block 3B
B 64B Gray 16 Horn

CONNECTOR - POWER RELAY NO. 2 CONNECTOR - POWER RELAY NO. 4
245731C1 245731C1

30 1K Red 12 Power Junction Post 30 1G Red 12 Power Junction Post
85 4 Gray 16 Ignition Switch (ACC) 85 4 Gray 16 Ignition Switch (ACC)
87 12B Red 12 Fuse Block 2C, 4C, 6C, and 8C 87 12D Red 12 Fuse Block 12A
87A None 87A None
CONNECTOR - POWER RELAY NO. 3 CONNECTOR - LOADER LEVER DIFFERENTIAL

LOCK ENABLE RELAY
245731C1
245731C1
30 1L Red 12 Power Junction Post
Fuse Block 8D, 10D, 12D, and
87 12C Red 12 86 7 Gray 16 Engage Switch Standard
14D
Transmission
87A None
87 25S Gray 16 Differential Lock Solenoid
87A None

CONNECTOR - CLUTCH RELAY CONNECTOR - FORWARD RELAY
245731C1 245731C1

30 19E Red 16 Fuse Block 1D Shuttle Interlock Timing Relay
30 19M Gray 16
“Load”
85 19E Red 16 Fuse Block 1D
85 25A Lt. Blue 16 FNR Lever (Forward)
86 25 Red 16 Clutch Cutout Switches
87 None
87 26 Lt. Blue 16 Forward Solenoid and Diode
Forward/Neutral/Reverse Lever
87A 21 Red 16
(+) 87A None
CONNECTOR - REVERSE RELAY CONNECTOR - NEUTRAL RELAY
245731C1 245731C1

Shuttle Interlock Timing Relay 30 21A Lt. Blue 16 Ignition Switch (Start)
30 19M Gray 16
“Load”
85 25B Lt. Blue 16 FNR Lever (Reverse)
87 22 White 16 Starter Relay T85
87 27 Lt. Blue 16 87A None
Alarm (+), and Diode
87A None

CONNECTOR - STARTER RELAY CONNECTOR - SHUTTLE INTERLOCK TIMING
RELAY
245731C1
87122
30 1C Red 12 Power Junction Terminal CAV WIRE IDENT CIRCUIT
85 22 White 16 Neutral Relay T87 B+ 19E Red 16 Fuse Block 1D
86 10 Black 16 Ground G 10 Black 16 Ground
87 21B White 12 Starter Solenoid, Cold Start T3 I 24 White 16 Shuttle Interlock Relay T30
87A None L 19M Gray 16 Forward and Reverse Relay T30
CONNECTOR - SHUTTLE INTERLOCK RELAY
245731C1

Shuttle Interlock Timing Relay
30 24 White 16
(Input)
87 None
87A 52 Gray 16 Diodes

CONNECTOR - A/C RELAY CONNECTOR - FUEL SHUT OFF
245480C1
245731C1
30 60 Red 16 A/C Thermostat
A/C Low/High Pressure CONNECTOR - COMBINATION SWITCH 56
T10
A/C Low/High Pressure
T10
87A 60B Gray 16 A/C Compressor Clutch
CONNECTOR - FLASHER RELAY

1964527C1

352600

1 46 Tan 16 Hazard Flasher Switch T1
3 47R Tan 16 Right Turn Indicator
1964527C1
5 45L Tan 16 Left Turn Signal Lamps
6 47L Tan 16 Left Turn Indicator
Front Driving and Tail Lamps,
7 45R Tan 16 Right Turn Signal Lamps 1 41 Gray 16

CONNECTOR - COMBINATION SWITCH 31 CONNECTOR - COMBINATION SWITCH R
1964527C1 1964527C1

1 64B Gray 16 Horn 1 45L Tan 16 Flasher Relay T5
CONNECTOR - COMBINATION SWITCH 31B

CONNECTOR - COMBINATION SWITCH L
1964527C1
1 64A Red 16 Fuse Block 3B CAV WIRE IDENT CIRCUIT


CONNECTOR - IGNITION SWITCH
1964527C1

1 19B Red 16 Fuse Block 3C 225253C1

1 1D Red 12 Power Junction Post
2 21A Lt. Blue 16 Neutral Relay T30
3 4 Gray 16 Power Relays 1, 2, 3, 4 T85
4 3 White 12 Diode, Fuse Block 2D, 4D, & 6D
5 None
6 None

CONNECTOR - RH AND LH PARK BRAKE CONNECTOR - A/C COMPRESSOR
SWITCH
245483C1 245480C1

A 36P Yellow 16 Instrument Cluster T7 A 60B Gray 16 A/C Relay T87a
CONNECTOR - OIL PRESSURE SWITCH

CONNECTOR - AIR SUSPENSION SEAT
245483C1 245480C1

A 19N Red 14 Fuse Block 9B 1 31P Yellow 16 Instrument Cluster T2
CONNECTOR - DIFF LOCK SOLENOID

CONNECTOR - FOUR WHEEL DRIVE SOLENOID
245483C1 225316C1

A 25E Gray 16 4 WD Engage Switch T1 and T3 Loader Lever Differential Lock
1 25S Gray 16
Enable Relay T87

CONNECTOR - A/C LOW PRESSURE SWITCH CONNECTOR - POWER OUTLET
245482C1
CAV WIRE IDENT CIRCUIT 314908A1
A 60A Red 16 A/C Relay T86 & T87 CAV WIRE IDENT CIRCUIT
B 60 Red 16 A/C Thermostat A 20C Black 10 Ground
CONNECTOR - A/C HIGH PRESSURE SWITCH

CONNECTOR - POWER OUTLET
245482C1

A 60 Red 16 A/C Thermostat 314908A1
B 60A Red 16 A/C Relay T86 & T87 CAV WIRE IDENT CIRCUIT
A 20B Black 10 Ground
CONNECTOR - BACKUP ALARM
CONNECTOR - RIDE CONTROL SOLENOIDS
245482C1

A 27 Lt. Blue 16 Reverse Relay T87
256340A1

A 401 Gray 16 Ride Control Engage Switch T1

CONNECTOR - AIR FILTER RESTRICTION CONNECTOR - REAR WIPER SWITCH
SWITCH
245781C1
256340A1
A 30 Black 16 Ground 1 81 Gray 16 Rear Wiper Motor Low
B 38 Yellow 16 Instrument Cluster T3 2 63A Red 16 Rear Wiper Disconnect Switch

3 82 Gray 16 Rear Wiper Motor High
4 89 Gray 16 Rear Wiper Motor Brake
CONNECTOR - FRONT CONSOLE (OPT)
5
6
CONNECTOR - REAR HORN SWITCH
256340A1

B 63 Red 16 Fuse Block 1A
245781C1

1
2 64A Red 16 Fuse Block 3B
3 64B Gray 16 Horn
4
5
6

CONNECTOR - REAR WORK LIGHT CONNECTOR - FRONT WIPER SWITCH
SWITCH
245781C1
245781C1 CAV WIRE IDENT CIRCUIT

CAV WIRE IDENT CIRCUIT 1 66 Gray 16 Front Wiper Motor Low
Rear Work Lamps, Instrument 2 63 Red 16 Fuse Block 1A
1 42C Gray 12
Cluster T13
3 67 Gray 16 Front Wiper Motor High
2 19C Red 12 Fuse Block 7D
4 69 Gray 16 Front Wiper Motor Brake
3
5
4
6
5
CONNECTOR - FRONT WORK LIGHTS
SWITCH
CONNECTOR - FOUR WHEEL DRIVE
SWITCH
245781C1

245781C1
Front Work Lamps, Instrument
1 42F Gray 14
CAV WIRE IDENT CIRCUIT Cluster T12
1 25E Gray 16 4 WD Solenoid 2 19K Red 14 Fuse Block 9D
2 25C Red 16 Fuse Block 3A 3
3 25E Gray 16 4 WD Solenoid 4
4 5
5 6 10 Black 16 Ground

CONNECTOR - HAZARD SWITCH CONNECTOR - RIDE CONTROL SWITCH
245781C1 245781C1

1 46 Tan 16 Flasher Relay T1 1 401 Gray 16 Ride Control Solenoids
2 19B Red 16 Fuse Block 3C 2 57 Red 16 Fuse Block 1C
3 3
4 4
5 5
CONNECTOR - ROTATING BEACON CONNECTOR - REAR WIPER WASHER

SWITCH SWITCH
245781C1 245781C1

1 48 Gray 16 Rotating Beacon 1
2 19D Red 16 Fuse Block 5A 2 63 Red 16 Fuse Block 1A
3 3 65 Gray 16 Rear Windshield Washer Pump
4 4
5 5
6 10 Black 16 Ground 6

CONNECTOR - BACKHOE QUICK CONNECTOR - FRONT WIPER WASHER
COUPLER SWITCH “A” SWITCH
245781C1 245781C1

1 501 Gray 16 Quick Coupler Solenoid, Diodes 1
2 57 Red 16 Fuse Block 1C 2 63 Red 16 Fuse Block 1A
Backhoe Quick Coupler Switch 3 62 Gray 16 Front Windshield Washer Pump
3 504A Gray 16
“B” T2
4
4
5
5
6
6
CONNECTOR - LOADER QUICK

CONNECTOR - BACKHOE QUICK COUPLER SWITCH
COUPLER SWITCH “B”
245781C1
245781C1
Front Quick Coupler Solenoid,
1 501 Gray 16
1 Diodes
Backhoe Quick Coupler Switch 2 57 Red 16 Fuse Block 1C
2 504A Gray 16
“A” T3
3 502 Gray 16
3 504 Gray 16 Quick Coupler Solenoid, Diodes Diodes
4 4
5 5
6 6

CONNECTOR - COMBINATION SWITCH
CONNECTOR - MAIN CHASSIS OPTIONS
HARNESS
389487A1

256352A1
L 45R Tan 16 Flasher Relay T7
49a 19B Red 16 Fuse Block 3C
A Not Used
R 45L Tan 16 Flasher Relay T5
31b 64A Red 16 Fuse Block 3B
31 64B Gray 16 Horn
56B Not Used
56D Not Used E 62 Gray 16
(Front)
Front Driving and Tail Lamps, F Not Used
56A 41 Gray 16
G 501 Gray 16 Ride Control Solenoids
H 502 Gray 16
Diodes
J Not Used
CONNECTOR - TURN SIGNAL INDICATOR
16182559

3 47L Tan 16 Flasher Relay T6

CONNECTOR - SIDE CONSOLE OPTIONS
HARNESS CONNECTOR - FUSE BLOCK
256352A1 12177145
A Not Used Front Wiper Switch T2 and Motor,

A-1 63 Red 16 Rear Wiper Motor, Windshield
B 60 Red 16 A/C Thermostat Washer Switches T2
C 60A Red 16 A/C Relay T86 & T87 A-2 12A Red 12 Power Relay 1, T87
D 65 Gray 16 Windshield Washer Switch T3 A-3 25C Red 16 4WD Engage Switch T2
E Not Used A-4 12A Red 12 Power Relay 1, T87
F 401 Gray 16 Ride Control Engage Switch T1 A-5 19D Red 16 Rotating Beacon Switch T2
Backhoe Quick Coupler Switch A-6 12A Red 12 Power Relay 1, T87
G 501 Gray 16
“A” T1
Turn/Driving Lamp/horn Switch
Backhoe Quick Coupler Switch A-7 19A Red 16
H 504 Gray 16 T56
“B” T3
J Not Used
A-9 19F Red 16 loader Valve RTD Solenoid
A-11 58 Red 14 Pilot Control/BH Aux T1
A-12 12D Red 12 Power Relay 4, T87
A-13 Not Used
A-14 Not Used
Optional Fused (B+), Optional
B-1 56 Red 16
Radio (B+)
B-3 64A Red 16 Rear Wiper Switch T2
Dome Lamp Door Switch, Dome
B-5 49 Red 16
Lamp
B-7 Not Used
Air Suspension Seat Adjustment
B-9 19N Red 14
Switch
B-11 Not Used
B-13 Not Used
B-14 Not Used

CAV WIRE IDENT CIRCUIT CONNECTOR - FRONT CONSOLE OPTIONS

HARNESS
Opt Radio (+), Loader Quick
Coupler Switch T2, Backhoe Quick
Coupler Switch “A” T2, Ride
C-1 57 Red 16
Control Switch T2, Hand Held Aux
Hyd’s Switch T2, (Remote) 3-Amp
Boom Lock
Hazard Switch T2, Turn/Driving
Lamp/Horn Switch T49a, Flasher
C-3 19B Red 16 Relay T2, Loader Lever
Differential Lock Enable Relay T85
and T30, Brake Switch (Com)
C-5 61 Red 12 Blower Switch (+) 256354A1
C-7 Not Used
A Not Used
C-10 1H Red 10 Power Junction Post
E 62 Gray 16
C-12 1J Red 10 Power Junction Post (Front)
C-13 Not Used F Not Used
C-14 Not Used G 501 Gray 16 Ride Control Solenoids
Clutch Relay T85 and T30, shuttle Rear Quick Coupler Solenoid,
D-1 19E Red 16 H 502 Gray 16
Interlock Timing Relay (B+) Diodes
D-2 3 White 12 Ignition Switch (Ignition) J Not Used
D-3 23G Red 16 Diode K 63 Red 16 Fuse Block 1A
D-4 3 White 12 Ignition Switch (Ignition)

D-5 15 White 16 Fuel Shutoff, Alt T2, Cold Start T6
CONNECTOR - BACKHOE QUICK COUPLER
D-6 3 White 12 Ignition Switch (Ignition) SOLENOID
Rear Work Lamp Switch and Relay
D-7 19C Red 12
T2
D-9 19K Red 14 Front Work Lamp Switch T2
D-11 Not Used
D-13 Not Used
256340A1

A 504 Gray 16 Backhoe Quick Coupler Solenoid

CONNECTOR - LOADER QUICK COUPLER CONNECTOR - FRONT CAB/ROPS LIGHTS
SOLENOID HARNESS
256340A1 15326660

A 502 Gray 16 Front Quick Coupler Solenoid Front Work Lamps, Instrument
A 42F Gray 14
Cluster T12
B 41 Gray 16
CONNECTOR - REAR CAB/ROPS LIGHTS C 63 Red 16 Fuse Block 1A

HARNESS D 45R Tan 16 Flasher Relay T7
F 66 Gray 16 Front Wiper Switch T1 (Low)
G Not Used
H Not Used
J 67 Gray 16 Front Wiper Switch T3 (High)
K 69 Gray 16 Front Wiper Switch T4 (Brake)
CONNECTOR - TRANSMISSION CONTROL

SOLENOIDS
15326660

Rear Work Lamps, Instrument
A 42C Gray 12
Cluster T13
B 41 Gray 16
C 44 Tan 16 Brake Lamps
D 45R Tan 16 Flasher Relay T7
F 48 Gray 16 Rotating Beacon
G Not Used 182077A1
H Not Used CAV WIRE IDENT CIRCUIT

Rear Work Lamps, Instrument A 26 Lt. Blue 16 Forward Solenoid & Diode
J 42C Gray 12
Cluster T13
K Not Used
C 27 Lt. Blue 16
Alarm (+), & Diode

CONNECTOR - COOLANT TEMPERATURE CONNECTOR - INSTRUMENT CLUSTER
SENDER
371832C1
198456A1
1 23F Red 16 Diode
A Not Used
2 31P Yellow 16 Oil Pressure Switch
B 35 Lt. Blue 16 Cold Start T5
3 38 Yellow 16 Air Filter Restriction Switch
C 30 Black 16 Ground
4 36H Yellow 16
Switch
CONNECTOR - ALTERNATOR 5 34 Lt. Green 16 Alternator

6 33T Yellow 16 Rear Axle Temperature Sender
7 36P Yellow 16 Park Brake Switches
8 52 Gray 16 Diode
9 36R Gray 16 Seat Position Switch
10 60A Red 16 A/C Relay T86 & T87
11 Not Used
12 42F Gray 14 Front Work Lamp Switch T1
13 42C Gray 12/16 Rear Work Lamp Switch T1
14 Not Used
15 Not Used
382203A1
16 31C Yellow 16 Cold Start T1
CAV WIRE IDENT CIRCUIT 17 Not Used
1 34 Lt. Green 16 Instrument Cluster T5 18 Not Used
2 15 White 16 Fuse Block 5D 19 31S Yellow 16 Alternator Tach Output
3 31S Yellow 16 Instrument Cluster (Tach) T19 20 36F Yellow 16 Fuel Level Sender
Transmission Temperature
21 32T Yellow 16
Sender
22 31T Yellow 16 Coolant Temperature Sender
23 Not Used
24 41 Gray 16 Combination Switch T56a
25 Not Used
26 Not Used
27 Not Used
28 Not Used
29 Not Used
30 Not Used
31 Not Used

CAV WIRE IDENT CIRCUIT CONNECTOR - BLOWER SWITCH

32 Not Used
33 Not Used
34 Not Used
35 37A Yellow 16 Warning Alarm (-)
36 20A Black 16 Ground
CONNECTOR - SIDE OPTIONS HARNESS
754C-3

87 87 Gray 16 Resistor Board (Medium)
86 86 Gray 16 Resistor Board (Low)
61 61 Red 12 Fuse Block 5C
Resistor Board (High), Blower
88 88 Gray 12
Motor
85 85 Gray 16 A/C Thermostat
256344A1

CONNECTOR - CAB HARNESS
CONNECTOR - LOADER LEVER HARNESS FOR

STANDARD SHUTTLE SHIFT TRANSMISSION
282918A1

A-1 56 Red 16 Fuse Block 1B
A-2 57 Red 16 Fuse Block 1C
A-3 86 Gray 16 Blower Switch (Low)
A-4 87 Gray 16 Blower Switch (Medium)
256346A1
A-5 88 Gray 12 Blower Switch (High)
B-1 Not Used
A 25 Red 16 Clutch Relay T86
B-2 Not Used
B Not Used
B-3 49 Red 16 Fuse Block 5B
C 7 Gray 16 B-4 Not Used
Enable Relay T86
B-5 Not Used
C-1 63 Red 16 Fuse Block 1A
C-2 81 Gray 16 Rear Wiper Switch T1 (Low)


CONNECTOR - MAIN CHASSIS OPITION
C-3 82 Gray 16 Rear Wiper Switch T3 (High)
C-4 89 Gray 16 Rear Wiper Switch T4 (Brake)
C-5 63A Red 16 Rear Wiper Switch T2
256354A1

A Not Used
Rear Windshield Washer Switch
D 65 Gray 16
T3
E Not Used
F 401 Gray 16 Ride Control Engage Switch T1
G 501 Gray 16
“A” T1
H 504 Gray 16
“B” T3
J Not Used
CONNECTOR - A/C SIDE HARNESS
256345A1

C 85 Gray 16 A/C Thermostat

CONNECTOR - FNR STANDARD SHUTTLE SHIFT
LEVER
15300029

Reverse Relay T85 & Diode or
A 25B Lt. Blue 16 Optional (Powershift)
Neutral Relay T85, Shuttle
B 21C White 16
Interlock Relay T85
Forward Relay T85 & Diode or
C 25A Lt. Blue 16 Optional (Powershift)
D 21 Red 16 Clutch Relay T87a

12129206
1-A 1D Red 12 Ignition Switch (Batt) 2-K Not Used
Instrument Cluster Connector 2-L 31P Yellow 16 Instrument Cluster Connector 2

1-B 32T Yellow 16
1-C 63 Red 16 Cab Harness Connector C1 2-N Not Used
1-D 33T Yellow 16 Instrument Cluster Connector 6 3-A 19C Red 12 Rear Work Lamp Switch
1-E Not Used Instrument Cluster Connector
3-B 36F Yellow 16
20
1-F Not Used
3-C Not Used
3-D 34 Lt. Green 16 Instrument Cluster Connector 5
1-H 31T Yellow 16
22 3-E Not Used
1-L 38 Yellow 16 Instrument Cluster Connector 3 3-H Not Used
1-M Not Used 3-J Not Used
1-N Not Used Horn Rocker Switch Connector
3-K 64B Gray 16
3
2-A Not Used
3-L 36P Yellow 16 Instrument Cluster Connector 7
4WD Engage Switch Connector
2-B 25C Red 16
Rear Horn Rocker Switch 3-N Not Used
2-C 64A Red 16
Connector 2
2-D 41 Gray 16
24
2-E Not Used
2-F Not Used
2-H Not Used
2-J Not Used

12129200
4-A 3 White 12 Ignition Switch Connector 4 Loader Lever Harness

5-K 25 Red 16
Connector A
Instrument Cluster Connector 8,
5-L Not Used
4-B 52 Gray 16 Shuttle Interlock Relay
Connector 87a 5-M Not Used
Instrument Cluster Connector 5-N Not Used
4-C 31S Yellow 16
19
4-D Not Used 6-A 42C Gray 12 Connector 1, Instrument Cluster
4-E Not Used Connector 13
4-F 36R Gray 16 Instrument Cluster Connector 9 6-B Not Used
4-G Not Used 6-C Not Used
4-H Not Used 6-D Not Used
4-J Not Used 4WD Engage Switch Connector

6-E 25E Gray 16
1 and 3
4-K Not Used
6-F Not Used
4-L 23F Red 16 Instrument Cluster Connector 1
6-G Not Used
4-M Not Used
6-H Not Used
4-N Not Used
6-J Not Used
Loader Lever Harness
5-A 42C Gray 12 Connector 1, Instrument Cluster 6-K 7 Gray 16
Connector C
Connector 13
Cab Harness Connector
5-B Not Used 6-L 49 Red 16
Connector B-3
5-C Not Used
6-M 4 Gray 16 Ignition Switch Connector 3
5-D Not Used
6-N 61 Red 12 Blower Switch (+) Connector 61
5-E Not Used
5-F Not Used
5-G Not Used
5-H Not Used
5-J Not Used

12129200

7-A Not Used
7-B 31C Yellow 16
16
7-C 42F Gray 14
12
7-D Not Used
7-E Not Used
7-F Not Used
7-G Not Used
7-H Not Used
7-J Not Used
7-K 36H Yellow 16 Instrument Cluster Connector 4
7-L Not Used
7-M 21A Lt. Blue 16 Ignition Switch Connector 2
7-N Not Used

12129206
1-A 1D Red 12 Front Console Connector 1-A 2-G 84 Red 10 Front Console Connector 2-G
Transmission Temperature 2-H Not Used

1-B 32T Yellow 16
Sender 2-J Not Used
Front Light Harness Connector 2-K Not Used
1-C 63 Red 16
C, Front Console Connector 1-C
2-L 31P Yellow 16 Engine Oil Pressure Switch
Rear Axle Temperature Switch
1-D 33T Yellow 16 2-M 56 Red 16 Front Console Connector 2-M
A
1-E Not Used 2-N Not Used
1-F Not Used 3-A 19C Red 12 Front Console Connector 3-A
1-G 83 Red 10 Front Console Connector 1-G 3-B 36F Yellow 16 Fuel Level Sender
Coolant Temperature Sender 3-C Not Used

1-H 31T Yellow 16
Connector A 3-D 34 Lt. Green 16 Alternator Connector 1
1-J Not Used 3-E Not Used
1-K Not Used 3-F Not Used
Air Flow Restriction Switch 3-G Not Used
1-L 38 Yellow 16
Connector B
3-H Not Used
1-M Not Used
3-J Not Used
1-N Not Used
Pilot Control Horn Switch
2-A Not Used 3-K 64B Gray 16 Connector 2, Horn, Front
Console Connector 3-K
2-B 25C Red 16 Front Console Connector 2-B
Left and Right Hand Brake
Front Console Connector 2-C, 3-L 36P Yellow 16
2-C 64A Red 16 Pilot Control Horn Switch Switch
Connector 1 3-M 57 Red 16 Front Console Connector 3-M
Front Light Harness Connector 3-N Not Used
B, Rear Light Harness
2-D 41 Gray 16
Connector B, Front Console
Connector 2-D
2-E Not Used
2-F Not Used

12129200
4-A 3 White 12 Front Console Connector 4-A 5-L Not Used
4-B 52 Gray 16 Front Console Connector 4-B 5-M Not Used
4-C 31S Yellow 16 Alternator Connector 3 5-N Not Used
4-D Not Used Rear Cab/ROPS Lights

6-A 42C Gray 12
Connector A
4-E Not Used
6-B Not Used
Seat Position Switch Connector
4-F 36R Gray 16 6-C Not Used
A
6-D Not Used
4-G Not Used
4WD Solenoid Connector A,
4-H Not Used 6-E 25E Gray 16
Diode
4-J Not Used
6-F Not Used
4-K Not Used
6-G Not Used
4-L 23F Red 16 Front Console Connector 4-L
6-H Not Used
4-M Not Used
6-J Not Used
4-N Not Used
6-K 7 Gray 16 Front Console Connector 6-K
5-A 42C Gray 12 6-L 49 Red 16 Front Console Connector 6-L
Connector A
6-M 4 Gray 16 Front Console Connector 6-M
5-B Not Used
6-N 61 Red 12 Front Console Connector 6-N
5-C Not Used
5-D Not Used
5-E Not Used
5-F Not Used
5-G Not Used
5-H Not Used
5-J Not Used
Front Console Connector 5-K,
5-K 25 Red 16 Gear Shift Lever Declutch
Connector A

12129200

7-A Not Used
7-B 31C Yellow 16 Cold Start Connector 1
7-C 42F Gray 14
Harness Connector A
7-D Not Used
7-E Not Used
7-F Not Used
7-G Not Used
7-H Not Used
7-J Not Used
7-K 36H Yellow 16
Switch
7-L Not Used
7-M 21A Lt. Blue 16 Front Console Connector 7-M
7-N Not Used

358378A1
Fuse Block 2B, 4B, 6B, 8B, 10B, 2-K Not Used
1-A 1D Red 12
12B 2-L Not Used
1-B 15 White 16 Fuse Block 5D 2-M 56 Red 16 Fuse Block 1B
Front Wiper Switch Connector 2-N 19N Red 14 Fuse Block 9B
1-C 63 Red 16
2, Fuse Block 1A
3-A 19C Red 12 Fuse Block 7D
1-D 19F Red 16 Fuse Block 9A
3-B Not Used
1-E Not Used
Rotating Beacon Switch
3-C 48 Gray 16
1-F Not Used Connector 1
1-G 83 Red 10 Fuse Block 9C 3-D 27 Lt. Blue 16 Reverse Relay Connector 87
1-H Not Used 3-E Not Used
1-L Not Used 3-H Not Used
Loader Lever Differential 3-J Not Used
Lock Enable Relay Connector
1-M 25S Gray 16 Combination Switch Connector
87, Optional (Powershift)
Transmission Harness 31, Rear Horn Switch Connector
3-K 64B Gray 16
3, Pilot Control Horn Connector
Front Work Lamp Switch 2
1-N 42F Gray 14
Connector 1
3-L Not Used
2-A Not Used
3-M 57 Red 16 Fuse Block 1C
2-B 25C Red 16 Fuse Block 3A
3-N Not Used
2-C 64A Red 16 Fuse Block 3B
Combination Switch Connector
2-D 41 Gray 16
56a
2-E Not Used
2-F Not Used
2-G 84 Red 10 Fuse Block 11C
2-H Not Used
2-J Not Used

358378A1
4-A 3 White 12 Diode, Fuse Block 2D, 4D, 6D 6-A Not Used
Diodes, Shuttle Interlock Relay 6-B 69 Gray 16 Front Wiper Switch Connector 4
4-B 52 Gray 16
Connector 87a 6-C Not Used
4-C 45L Tan 16 Flasher Relay Connector 5 6-D Not Used
4-D 26 Lt. Blue 16 Forward Relay Connector 87 6-E Not Used
4-E Not Used 6-F Not Used
4-F Not Used 6-G Not Used
4-G Not Used 6-H Not Used
4-H Not Used 6-J Not Used
4-J Not Used Loader Lever Differential Lock
6-K 7 Gray 16
Enable Relay Connector 86
4-K Not Used
6-L 49 Red 16 Fuse Block 5B
4-L 23F Red 16 Diode
6-M 4 Gray 16 Power Relays 1, 2, 3, 4 T85
4-M Not Used
6-N 61 Red 12 Fuse Block 5C
4-N Not Used
5-A 21B White 12 Starter Relay Connector 87
5-B Not Used
5-C 45R Tan 16 Flasher Relay Connector 7
5-D Not Used
5-E Not Used
5-F Not Used
5-G Not Used
5-H Not Used
5-J Not Used
5-K 25 Red 16 Clutch Relay Connector 86
5-L Not Used
5-M Not Used
5-N 58 Red 14 Fuse Block 11A

358378A1

7-A Not Used
7-B 66 Gray 16 Front Wiper Switch Connector 1
7-C Not Used
7-D 44 Tan 16 Brake Light Switch
7-E 67 Gray 16 Front Wiper Switch Connector 3
7-F Not Used
7-G Not Used
7-H Not Used
7-J Not Used
7-K Not Used
7-L Not Used
7-M 21A Lt. Blue 16 Neutral Relay Connector 30
7-N Not Used

358378A1
1-A 1D Red 12 Side Console Connector 1-A 2-J Not Used
Alternator Connector 2, Fuel 2-K Not Used

1-B 15 White 16
Shut Off, Cold Start Connector 6 2-L Not Used
Side Console Connector 1-C, 2-M 56 Red 16 Side Console Connector 2-M
1-C 63 Red 16 Front Cab/ROPS Lights
Harness Connector C Air Suspension Seat Connector
2-N 19N Red 14
A
1-D 19F Red 16 RTD Solenoid Connector 2
3-A 19C Red 12 Side Console Connector 3-A
1-E Not Used
3-B Not Used
1-F Not Used
1-G 83 Red 10 Side Console Connector 1-G 3-C 48 Gray 16
Connector F
1-H Not Used Transmission Control
1-J Not Used 3-D 27 Lt. Blue 16 Connector C, Diode, Backup
Alarm Connector A
1-K Not Used
3-E Not Used
1-L Not Used
3-F Not Used
Differential Lock Solenoid
1-M 25S Gray 16 3-G Not Used
Connector 1
Side Console Connector 1-N, 3-H Not Used
1-N 42F Gray 14 Front Cab/ROPS Lights 3-J Not Used
Harness Connector A
Side Console Connector 3-K,
2-A Not Used 3-K 64B Gray 16 Horn, Pilot Control Horn
Connector B
2-B 25C Red 16 Side Console Connector 2-B
3-L Not Used
Side Console Connector 2-C,
2-C 64A Red 16
Pilot Control Horn Connector A 3-M 57 Red 16 Side Console Connector 3-M
Side Console Connector 2-D, 3-N Not Used
2-D 41 Gray 16 Front and Rear Cab/Rops Lights
Harness Connector B
2-E Not Used
2-F Not Used
2-G 84 Red 10 Side Console Connector 2-G
2-H Not Used

358378A1
4-A 3 White 12 Side Console Connector 4-A 5-L Not Used
4-B 52 Gray 16 Side Console Connector 4-B 5-M Not Used
Front and Rear Cab/ROPS Pilot Control and Backhoe

5-N 58 Red 14
4-C 45L Tan 16 Auxiliary Connector A
Lights Harness Connector E
6-A Not Used
Transmission Solenoid
4-D 26 Lt. Blue 16
Connector A, Diode Front Cab/ROPS Lights
6-B 69 Gray 16
Harness Connector K
4-E Not Used
6-C Not Used
4-F Not Used
6-D Not Used
4-G Not Used
6-E Not Used
4-H Not Used
6-F Not Used
4-J Not Used
6-G Not Used
4-K Not Used
6-H Not Used
4-L 23F Red 16 Side Console Connector 4-L
6-J Not Used
4-M Not Used
6-K 7 Gray 16 Side Console Connector 6-K
4-N Not Used
6-L 49 Red 16 Side Console Connector 6-L
Starter Solenoid, Cold Start
5-A 21B White 12
Connector 3 6-M 4 Gray 16 Side Console Connector 6-M
5-B Not Used 6-N 61 Red 12 Side Console Connector 6-N
Front and Rear Cab/ROPS
5-C 45R Tan 16
Lights Harness Connector D
5-D Not Used
5-E Not Used
5-F Not Used
5-G Not Used
5-H Not Used
5-J Not Used
Gear Shift Lever Connector A,
5-K 25 Red 16
Side Console Connector 5-K

358378A1

7-A Not Used
7-B 66 Gray 16
Harness Connector F
7-C Not Used
Rear Cab/ROPS Lights Harness
7-D 44 Tan 16
Connector C
7-E 67 Gray 16
Harness Connector J
7-F Not Used
7-G Not Used
7-H Not Used
7-J Not Used
7-K Not Used
7-L Not Used
7-M 21A Lt. Blue 16 Side Console Connector 7-M
7-N Not Used

4001-87
INDEX
Symbols A/C Low Pressure Switch ..................................62
4WD A/C Relay ..........................................................59
Engage Switch - Standard Tansmission ...........37 A/C Side Harness ..............................................73
Solenoid Standard Transmission ......................37 Air Filter Restriction Switch ...............................63
Air Suspension Seat ..........................................61
A Alternator ..........................................................71
Air Compressor Switch and Motor .........................35 Backhoe Quick Coupler Solenoid .....................69
Air Conditioning Backhoe Quick Coupler Switch "A" ...................66
Compressor Clutch ...........................................27 Backhoe Quick Coupler Switch "B" ...................66
High Pressure Switch ........................................28 Backup Alarm ....................................................62
Low Pressure Switch .........................................28 Blower Switch ....................................................72
Pressure Relay ..................................................26 Bulk Head Front Console Harness ....................81
Temperature Switch ..........................................27 Bulk Head Front Console Harness (Cont) ...82, 83
Air Filter Restriction Switch ....................................16 Bulk Head Front Console To Main Chassis Har-
Air Suspension Seat ..............................................35 ness ...................................................84
Alarm Bulk Head Front Console To Main Chassis Har-
Backup ..............................................................22 ness (Cont) ..................................85, 86
Warning .............................................................16 Bulk Head Side Console Harness .....................75
Alternator ...............................................................11 Bulk Head Side Console Harness (Cont) ....76, 77
Auxiliary Backhoe Hydraulics, Uni-directional, Lever Bulk Head Side Console To Main Chassis Harness
Position Switch (Unlatched Position) ........38 ............................................................78
Bulk Head Side Console To Main Chassis Harness
B (Cont) ...........................................79, 80
Backhoe Cab Harness .....................................................72
Quick Coupler Solenoid ....................................42 Clutch Relay ......................................................57
Quick Coupler Switch A ....................................41 Cold Start ..........................................................54
Quick Coupler Switch B ....................................41 Combination Switch ..........................................67
Backup Alarm ........................................................22 Combination Switch 31 .....................................60
Blower Combination Switch 31B ...................................60
Motor .................................................................27 Combination Switch 49A ...................................60
Motor Resistor Board and Thermal Fuse ..........27 Combination Switch 56 .....................................59
Switch ................................................................26 Combination Switch 56A ...................................59
Boom Combination Switch L .......................................60
Lock Solenoid ....................................................40 Combination Switch R .......................................60
Lock Switch .......................................................40 Coolant Temperature Sender ............................71
Brake Differential Lock Solenoid .................................61
Lamp Switch ......................................................32 Flasher Relay ....................................................59
FNR Lever For Standard Shuttle Shift ..............74
C Forward Relay ...................................................57
Chassis Ground .....................................................11 Four Wheel Drive Solenoid ...............................61
Circuits .....................................................................4 Four Wheel Drive Switch ...................................64
Clutch Front Cab/ROPS Lights Harness ......................70
Cutout Relay .....................................................13 Front Console (Opt) ..........................................63
Cutout Switch - Loader Handle - Power Shift Front Console Options Harness ........................69
Transmission ......................................20 Front Washer Pump Motor ................................54
Cutout Switch - Loader Handle - Standard Trans- Front Wiper Switch ............................................64
mission ...............................................20 Front Wiper Washer Switch ..............................66
Cutout Switch - Shift Handle .............................20 Front Work Lights Switch ..................................64
Relay .................................................................13 Fuel Shut Off .....................................................59
Cold Start Fuse Block ........................................................68
Grid Heater Unit ................................................43 Gear Shift Lever De-Clutch ...............................55
Connector Hazard Switch ...................................................65
A/C Compressor ................................................61 Ignition Switch ...................................................60
A/C High Pressure Switch .................................62 Instrument Cluster .............................................71
Loader Lever Differential Lock Enable Relay ....56
4001-88
Loader Lever Harness For Standard Shuttle Shift Engine Control Unit ............................................... 51
Transmission ......................................72 Enter Excape Switch ............................................. 15
Loader Quick Coupler Solenoid ........................70
Loader Quick Coupler Switch ............................66 F
Loader Valve RTD .............................................54 Fast Steering
Main Chassis Option .........................................73 Cutout Relay (Power Shift Transmission) ......... 50
Main Chassis Options Harness .........................67 ON/OFF Switch (Power Shift Transmission) ..... 50
Neutral Relay ....................................................57 ON/OFF Switch (Standard Transmission) ........ 49
Oil Pressure Switch ...........................................61 Power Relay (Power Shift Transmission) ......... 50
Park Brake Switch RH and LH ..........................61 Power Relay (Standard Transmission) ............. 49
Pilot Control Horn ..............................................55 Solenoid (Power Shift Transmission) ................ 50
Pilot Control/BH Auxiliary ..................................55 Solenoid (Standard Transmission) .................... 49
Power Outlet .....................................................62 Transmission Switch (Standard Transmission) . 49
Power Rely No. 1 ..............................................55 Flasher Relay ........................................................ 32
Power Rely No. 2 ..............................................56 FNR
Power Rely No. 3 ..............................................56 Switch - Standard Transmission .......................14
Power Rely No. 4 ..............................................56 Foot Operated Rear Auxiliary Hydraulic Switch .... 38
Rear Cab/ROPS Lights Harness .......................70 Foot Throttle Potentiometer ................................... 18
Rear Horn Switch ..............................................63 Forward
Rear Washer Pump Motor ................................54 Relay .................................................................21
Rear Wiper Switch ............................................63 Solenoid ............................................................ 21
Rear Wiper Washer Switch ...............................65 Forward Relay ....................................................... 21
Rear Work Light Switch .....................................64 Front
Reverse Relay ...................................................57 Console Ground ................................................ 12
Ride Control Solenoids .....................................62 Turn Lamp ......................................................... 33
Ride Control Switch ...........................................65 Wiper Motor ...................................................... 24
Rotating Beacon Switch ....................................65 Wiper Switch (Cab) ........................................... 23
Seat Position Switch .........................................54 Work Lamp Switch ............................................ 36
Shuttle Interlock Relay ......................................58 Work Lamps ...................................................... 36
Shuttle Interlock Timing Relay ..........................58 Fuel
Side Console Options Harness .........................68 Level Sender ..................................................... 17
Side Harness A/C Connection ..........................55 Fuse Block ............................................................. 14
Side Options Harness .......................................72
Stater Relay ......................................................58 G
Transmission Control Solenoids .......................70 Grid Heater
Turn Signal Indicator .........................................67 Heater Unit ........................................................ 43
Ground
D Chassis ............................................................. 11
Diagnostic Connector ............................................51 Front Console ................................................... 12
Differential Lock Side Console ..................................................... 14
Enable Relay, Loader Lever ..............................43
Engage Switch, Loader Lever (Powe Shift Trans- H
mission) ..............................................42 Hand Throttle Potentiometer ................................. 17
Engage Switch, Loader Lever (Standard Transmis- Hand-Held Auxiliary Hydraulic Solenoid Uni-direction-
sion) ...................................................42 al ............................................................... 38
Solenoid ............................................................43 Hazard Flasher Switch .......................................... 31
Diode ...................................................14, 22, 38, 41 Horn ....................................................................... 31
Dome Lamp Horn Button, Rear ................................................. 29
Door Switch .......................................................28 Hydraulic Filter Restriction Switch ......................... 16
Switch ................................................................29
Driving Lamps ........................................................30 I
Idle Validation Switch ............................................ 18
E Instrument Cluster Connector C1 .......................... 15
Electrical Wire Circuits .............................................4 Instrument Cluster Connector C2 .......................... 15
Electro Hydraulic Clam Control .............................50
EVI Solenoid .....................................................51
EVK Solenoid ....................................................51

4001-89
K #2 ......................................................................35
Key ........................................................................12 Power Relay ..........................................................12
L Power Shift Transmission

Lamp Auto/Manual Switch ..........................................52
Dome Switch .....................................................29 Brake Pressure Switches ..................................53
Driving ...............................................................30 Controller ...........................................................52
Front Turn .........................................................33 Loader Lever Kick Down ...................................52
Front Work ........................................................36 Shifter ................................................................52
Rear Stop and Tail ............................................31 Pressure Switch
Rear Turn ..........................................................34 SAHR Parking Brake .........................................18
Rear Work .........................................................37
Turn Signal Indicator .........................................34 Q
Loader Quick Coupler
Lever Differential Lock Enable Relay ................43 Disengage Switch, Loader ................................40
Lever Differential Lock Engage Switch (Powe Shift Solenoid, Loader ...............................................40
Transmission) .....................................42 Switch #1 ..........................................................41
Lever Differential Lock Engage Switch (Standard Switch A ............................................................41
Transmission) .....................................42 Switch B ............................................................41
Valve Solenoid ..................................................23
R
M Radio .....................................................................38
Motor Rear
Blower ...............................................................27 Auxiliary Hydraulic Switch, Foot Operated ........38
Blower Resistor Board and Thermal Fuse ........27 Horn Button .......................................................29
Front Wiper .......................................................24 Stop and Tail Lamps .........................................31
Rear Wiper ........................................................25 Turn Lamp .........................................................34
Wiper Motor .......................................................25
N Wiper Park Switch .............................................25
Neutral Wiper Stop Switch .............................................25
Start Relay ........................................................13 Wiper Switch (Cab) ...........................................23
Start Switch .......................................................14 Work Lamp Switch ............................................36
Work Lamps ......................................................37
P Relay
Pilot Clutch ................................................................13
Auxiliary Forward Solenoid Bi-directional ..........46 Clutch Cutout ..............................................13, 14
Auxiliary Reverse Solenoid Bi-directional ..........46 Fast Steering (Power Shift Transmission) .........50
Diode ...........................................................48, 49 Fast Steering (Standard Transmission) ............49
Electrical Controller ...........................................45 Fast Steering Cutout (Power Shift Transmission) .
Extend-a-hoe Extend Push Button ....................44 50
Extend-a-hoe Extend Solenoid .........................47 Flasher ..............................................................32
Extend-a-hoe Retract Push Button ...................44 Forward .............................................................21
Extend-a-hoe Retract Solenoid .........................47 Loader Lever Differential Lock Enable ..............43
Horn Switch .......................................................44 Neutral Start ......................................................13
Left Hand Stabilizer Down Solenoid ..................46 Pilot Control .......................................................47
Left Hand Stabilizer Pressure Switch ................45 Power ................................................................12
Left Hand Stabilizer Switch ...............................45 Reverse .............................................................21
Left Hand Stabilizer Up Solenoid ......................46 SAHR Park Brake .............................................19
On/Off Switch ....................................................47 Shuttle Interlock ................................................19
Pattern Change Solenoids ................................48 Shuttle Interlock Timing .....................................20
Relay .................................................................47 Starter ...............................................................13
Right Hand Stabilizer Down Solenoid ...............45 Resistor (Machine Without Grid Heater) ...............43
Right Hand Stabilizer Pressure Switch .............45 Return-To-Dig Limit Switch ...................................22
Right Hand Stabilizer Switch .............................45 Reverse
Right Hand Stabilizer Up Solenoid ....................46 Relay .................................................................21
Power Plug Solenoid ............................................................22
#1 ......................................................................34 Reverse Relay .......................................................21

4001-90
Ride Control Clutch Cutout - Shift Handle ............................. 20
Engage Switch ..................................................39 Differential Lock Engage, Loader Lever (Powe
Solenoid Accumulator .......................................39 Shift Transmission) ............................ 42
Solenoid Tank ...................................................39 Differential Lock Engage, Loader Lever (Standard
Rotating Beacon (Opt) ...........................................35 Transmission) .................................... 42
Rotating Beacon Switch ........................................35 Dome Lamp ...................................................... 29
Dome Lamp Door .............................................. 28
S FNR - Standard Transmission .......................... 14
SAHR Parking Brake Foot Operated Rear Auxiliary Hydraulic ........... 38
ON/OFF Switch .................................................18 Front Wiper ....................................................... 23
Pressure Switch ................................................18 Front Work Lamp .............................................. 36
Relay .................................................................19 Hazard Flasher ................................................. 31
Solenoid ............................................................19 Hydraulic Filter .................................................. 16
Seat Position Switch ..............................................19 Key .................................................................... 12
Sender Loader Quick Coupler Disengage ..................... 40
Fuel Level ..........................................................17 Pilot On/Off ....................................................... 47
Fuel Level and Gauge .......................................17 Rear Wiper (Cab) .............................................. 23
Transmission Temperature ...............................17 Rear Wiper Cut Off ........................................... 25
Shuttle Interlock Rear Work Lamp ............................................... 36
Relay .................................................................19 Return-To-Dig Limit ........................................... 22
Timing Relay .....................................................20 Ride Control Engage ......................................... 39
Side Console Ground ............................................14 Rotating Beacon ............................................... 35
Solenoid SAHR Parking Brake ON/OFF .......................... 18
4WD Standard Transmission ............................37 Seat Position ..................................................... 19
Backhoe Quick Coupler ....................................42 Turn Signal/Driving Lamp/Horn ......................... 30
Boom Lock ........................................................40 Windshield Washer, Front ................................. 24
Differential Lock ................................................43 Windshield Washer, Rear ................................. 24
Forward .............................................................21
Hand Held Auxiliary Hydraulic Uni-directional ...38 T
Left Ride Control ...............................................39 Transmission Temperature Sender .......................17
Loader Quick Coupler .................................40, 41 Troubleshooting ..................................................... 11
Loader Valve .....................................................23 Troubleshooting Tables, Understanding ............... 10
Reverse .............................................................22 Turn Signal Indicator Lamps ................................. 34
Right Ride Control .............................................39 Turn Signal/Driving Lamp/Horn Switch ................. 30
SAHR Parking Brake .........................................19
Starter ...............................................................11 U
Speaker Left ..........................................................39 UP/DOWN Switch ................................................. 15
Speaker Right ........................................................39
Specifications ..........................................................3 W
Starter and Starter Solenoid ..................................11 Warning Alarm ....................................................... 16
Starter Relay ..........................................................13 Water In Fule Sensor ............................................ 51
Switch Windshield
4WD Engage - Standard Tansmission ..............37 Washer Motor ................................................... 25
Air Conditioning High Pressure .........................28 Washer Switch Front ......................................... 24
Air Conditioning Low Pressure ..........................28 Washer Switch Rear ......................................... 24
Air Conditioning Temperature ...........................27 Wiper Motor Front ............................................. 24
Air Filter Restriction ...........................................16 Wiper Motor Rear .............................................. 25
Auxiliary Backhoe Hydraulics Lever Position, Wire Circuits ............................................................ 4
Uni-dirrectional ...................................38
Backhoe Quick Coupler #1 ...............................41
Backhoe Quick Coupler A .................................41
Backhoe Quick Coupler B .................................41
Blower ...............................................................26
Boom Lock ........................................................40
Brake Lamp .......................................................32
Clutch Cutout - Loader Handle - Standard Trans-
mission ...............................................20

Section
4003
4003
BATTERIES
Copyright © 2007 CNH Ameica LLC.

Racine, WI 53404 U.S.A. Bur 6-42331 Issued April, 2003 Revised February, 2007
4003-2
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4003-3
SAFETY RULES
WARNING: Never try to charge the battery if WARNING: Battery acid causes severe
the electrolyte in the battery is frozen. burns. Batteries contain sulfuric acid. Avoid
47-83A contact with skin, eyes, or clothing. Antidote:
EXTERNAL-Flush with water.
WARNING: Never cause sparks to occur or
INTERNAL-Drink large quantities of water or
smoke near batteries that are charging or
milk. Follow with milk of magnesia, beaten
have been recently charged.
egg, or vegetable oil. Call physician
13-8A
immediately. Eyes: Flush with water for 15
WARNING: Disconnect the ground cable minutes and get prompt medical attention.
first when the battery cables are Batteries produce explosive gases. Keep
disconnected from the battery. sparks, flame, and cigarettes away. Ventilate
Connect the ground cable last when the when charging or using in enclosed area.
battery cables are connected to the battery. Always shield eyes when working near
47-55A batteries.
WARNING: Some batteries have a Keep out of reach of children.

ventilation tube. If there is battery acid in the D-47-53A
ventilation tube, this battery acid can be

released when the battery is turned upside
down. If you turn the battery upside down,
make sure that the end of the ventilation tube
is away from you and away from any other
people in the area. Battery acid can cause
severe burns.
48-57B
SPECIAL TOOLS
B795328
The CAS10147 tester is used to do the Capacity

(Load) Test. This tool is first used on Page 6.

4003-4
MAINTENANCE
Electrolyte Level Inspecting and Cleaning a Battery

If the battery is a maintenance free battery, check the If damage causes an electrolyte leak, replace the
level of the electrolyte every 1000 hours of operation battery.
or six months, whichever occurs first. For all other
Inspect the battery at regular intervals for dir t,
batteries, check the level of the electrolyte every 250
corrosion, and damage. Electrolyte and dirt on the
hours of operation.
top of the battery can cause the battery to discharge
NOTE: A maintenance free battery will have the by making a passage for the current to flow.
words Maintenance Free on the decal on the top of
If the battery must be cleaned, remove the battery
the battery. If the center part of the decal has been
from the battery carrier and clean the battery, cable
removed for access to the battery caps, it is possible
terminals, and the battery carrier. When available,
that the words Maintenance Free have been removed
use Case Battery Saver and Cleaner according to
from the decal.
the instructions on the container. Case Battery Saver
Check the level of the electrolyte more often during and Cleaner also helps prevent corrosion. If Case
hot weather. The use of a large amount of water by Battery Saver and Cleaner is not available, use
the batter y can be caused by high batter y baking soda and water as a cleaner. DO NOT permit
temperature or a voltage regulator setting that is too any type of cleaner to enter the cells of the battery.
high. Keep the electrolyte level above the top of the
Install the battery in the machine and make sure the
plates in the battery at all times to prevent damage to
fasteners are tight. Apply Case Battery Saver and
the battery.
Cleaner or Urethane Seal Coat to the cable terminals
NOTE: On maintenance free batteries it is to prevent corrosion. See the Parts Counter Catalog.
necessary to remove the center part of the decal for DO NOT apply grease.
access to the battery caps. Do not discard the center
part of the decal. Install the center part of the decal
after the battery caps have been installed.
If the level of the electrolyte is low, add distilled water
or other clean water until the electrolyte is just below
the cell opening. Do not add more water than is
n e e d e d . To o m u c h w a t e r c a n c a u s e b a d
performance, a short service life, and corrosion
around the battery.
NOTE: Add water only. DO NOT add electrolyte.

4003-5
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the 1 2
battery.
Visual Checks
1. Make sure the cable connections are clean and
tight. Clean foreign material from the top of the
battery.
2. Inspect the battery case, battery posts, and
cables for damage.
3. Check the electrolyte level. See Page 4.
4. If you added water to the battery, the battery
must be charged for 15 minutes at 15 to 25
amperes to mix the water with the electrolyte.
Specific Gravity Check 1. TEMPERATURE IN F 2. TEMPERATURE IN C

B790863
A hydrometer is used to check the specific gravity SPECIFIC GRAVITY CHART

(weight) of the electrolyte. The specific gravity is an 4. Make a record of the corrected specific gravity
indication of the level of charge for each cell. reading for each cell.
Hydrometers are made to show the correct specific 5. If the difference between the high reading and
gravity when the temperature of the electrolyte is the low reading is 0.050 or more, charge the
26.7°C (80°F). battery and check the specific gravity again. If
When you check the specific gravity, you must know after charging, the difference is still 0.050 or
the temperature of the electrolyte. If your hydrometer more, install a new battery.
does not have a thermometer, get a thermometer to 6. The corrected specific gravity reading shows the
check the temperature of the electrolyte. The level of charge for the cell. The level of charge
thermometer must indicate a high temperature of at must be at least 75% in each of the cells. ln
least 52°C (120°F). maintenance free batteries the level of charge is
1. Remove enough electrolyte from a cell so that at least 75% if the corrected specific gravity
the float is free in the tube. reading is 1.240 or higher. In all other batteries
the level of charge is at least 75% if the corrected
NOTE: If the specific gravity cannot be checked specific gravity reading is 1.230 or higher.
without first adding water to the cell, the battery must
be charged for 15 minutes at 15 to 25 amperes to mix 7. If the difference between the high reading and
the water with the electrolyte. Then check the specific the low reading is less than 0.050, and the level
gravity. of charge is at least 75% in all of the cells, do the
Capacity (Load) Test.
2. Read the float.
8. If the difference between the high reading and
3. Read the thermometer. If the reading is above the low reading is less than 0.050, but the level of
26.7°C (80°F) add specific gravity points to the charge is less than 75% in any of the cells,
reading for specific gravity. If the reading is below charge the battery and check the specific gravity
26.5°C (80°F) subtract specific gravity points again. If after charging:
from the reading for specific gravity. See the
following illustration and add or subtract specific A. The level of charge is less than 75% in any of
gravity points as needed. the cells, discard the battery.
B. The level of charge is at least 75% in all of the
cells, do the Capacity (Load) Test.

4003-6
Capacity (Load) Test NOTE: Never apply a load for longer than 15
seconds. After each 15 seconds, turn the load control
This test can be done using a variable load tester knob to OFF for at least one minute.
s u c h a s t h e S u n E l e c t r i c VAT- 3 3 . O t h e r t e s t
equipment can be used. Connect the test equipment 4. Apply a 15 ampere load to the battery for 15
according to the instructions of the manufacturer of seconds. Wait at least three minutes before
the equipment. applying the load again.
1. The level of charge of the battery must be at 5. Check and make a record of the temperature of
least 75%. Do the Specific Gravity Check in this the electrolyte.
section. 6. Find the correct load for this test in Specifications
2. Prepare the tester (Sun Electric VAT-33 shown) in Section 4002.
for the test. NOTE: The correct load is half of the cold cranking
A. Select the voltmeter range that will measure 1 amperes at -17°C (0°F).
to 18 volts. 7. Turn the load control knob until the ammeter
B. Make sure the load control knob is in the OFF indicates the specified load. Keep the load for 15
position. seconds and read the voltmeter. Turn the load
control knob to OFF.
C. Select the ammeter range that will measure 0
to 1000 amperes. 8. Compare the test reading and the temperature of
the electrolyte to the chart below.
D. Move the volt lead switch to the NT. position. Temperature of . . . . . . . . . . . . . . . Minimum Voltage
3. Connect the tester to the battery as shown. electrolyte
21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6
16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
2
4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
-1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
-7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
-12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
1 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
A. If the test result is equal to or more than the
vo l t a g e s h o w n , t h e b a t t e r y i s i n g o o d
condition.
B. If the test result is less than the voltage
shown, discard the battery.
B790499
1. LOAD CONTROL KNOB 2. AMMETER CLAMP (TIP OF

ARROW AWAY FROM
BATTERY)

4003-7
CHARGING A BATTERY
The charging rate must be decreased if:
WARNING: Never try to charge the battery if
the electrolyte in the battery is frozen. 1. Too much gas causes the electrolyte to flow from
47-83
the cells.
Before you charge the battery, check the level of the 2. The temperature of the electrolyte rises above
electrolyte. 52°C (125°F).
It is difficult to give an exact charging rate because of NOTE: For the best charge, use the slow charging
the following variable conditions: (1) temperature of rates.
the electrolyte, (2) level of charge, and (3) condition
The battery is fully charged when, over a three hour
of the battery. Use the charging guide for the correct
period at a low charging rate, no cell is giving too
charging rate and time.
much gas, and the specific gravity does not change.
See Specifications in Section 4001 for the reserve
capacity of the battery in this machine.
Charging Guide For Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See

Reserve Capacity under Slow Charge Fast Charge
Specifications
10 Hours at 5 Amperes 2.5 Hours at 20 Amperes

80 Minutes or Less 5 Hours at 10 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1 .5 Hours at 50 Amperes
20 Hours at 5 Amperes 5 Hours at 20 Amperes

Above 125 to 170 Minutes 10 Hours at 10 Amperes 2 Hours at 50 Amperes

*lnitial rate for standard taper charger.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words
Maintenance Free will have been removed from the decal.
Continued on next page

4003-8
Charging Guide For Batteries Other Than Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See

Reserve Capacity under Slow Charge Fast Charge
Specifications

80 Minutes or Less 5 Hours at 10 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes 7.5 Hours at 10 Amperes 1 .5 Hours at 50 Amperes
20 Hours at 5 Amperes 5 Hours at 20 Amperes


6 Hours at 40 Amperes
Above 250 Minutes 24 Hours at 10 Amperes
4 Hours at 60 Amperes
*lnitial rate for standard taper charger.
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery. 5. Charge the battery at 30 amperes until the
spe cific gravity is 1 .25 0 or m ore a nd the
2. Fill each cell to the top of the separators with
temperature of the electrolyte is at least 15.5°C
electrolyte. This will per mit the volume of
(60°F).
electrolyte to increase when heated by charging
the battery. 6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of
3. Install the caps on the battery.
the cell opening.
4. Connect a battery charger to the battery.

Section
4004
4004
STARTER AND STARTER SOLENOID

4004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
NO-LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Understanding No Load Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Field Coil Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STARTER SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Starter Solenoid Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4004-3
SPECIFICATIONS
Manufacturer...........................................................................................................................................Nippondenso
No-Load Test at 20 C (68 F)
Volts.....................................................................................................................................................................11
Current draw...................................................................................................................... 200 amperes maximum
Starter drive speed........................................................................................................3000 rpm (r/min) minimum
LUBRICATION
Interval.......................................................................................................When the starter is disassembled or each
time the engine is removed for repairs
Lubricant
Molykote-GN ......................................................................................... Use on shaft at pinion end of starter drive
Case multipurpose grease ................................................................................................Use on bearings, gears,
idler gear shaft and spring.
NO-LOAD TEST
General Information Test Equipment
1. The No-Load Test is done with the starter The No-Load Test can be done using a Sun Electric
removed from the engine. VAT-33 Tester, an equivalent tester, or separate
pieces of test equipment.
2. Check to see if you can pull the gear on the
starter drive out of the starter drive housing. A hand held tachometer is needed to measure the
speed of the armature shaft.
3. Check to see if the starter drive can be turned.
Pull the gear on the starter drive out of the starter A remote starter button is needed to actuate the
drive housing. Turn the gear to turn the starter starter.
drive and the armature.
A fully charged 12 volt battery is needed to supply
4. If the starter drive cannot be turned, disassemble the electricity to turn the starter.
the starter and make repairs as needed. Then do
the No-Load Test.

4004-4
Test Procedure STEP 3

The illustrations in this procedure show the use of the
Sun Electric VAT-33 tester. Other test equipment can
be used. Connect the test equipment according to
this procedure and the manufacturer’s instructions.
STEP 1
1 3
2
B831430
1. POSITIVE BATTERY CABLE 3. NEGATIVE BATTERY

2. BATTERY TERMINAL CABLE
B795328 Connect the positive battery cable to the battery
If the VAT-33 tester is being used: terminal on the starter solenoid and the negative
battery cable to the mounting flange of the starter.
A. Select the 0 to 100 ampere range.
B. Select the 18 to 40 volt range. STEP 4
C. Move the volt lead switch to the EXT. position.
D. Turn the load control to the OFF position.
STEP 2 1
Fasten the starter in a vise or use another method to
prevent the starter from moving. This must be done 2
to prevent personal injury.
B831431
1. POSITIVE BATTERY CABLE

2. NEGATIVE LOAD CABLE
Connect the positive load cable to the positive post of
the battery. Connect the negative load cable to the
negative post.

4004-5
STEP 5 STEP 7
1
1
2
B831432
1. RED VOLTMETER LEAD

2. MOTOR TERMINAL
Connect the red voltmeter lead to the motor terminal B831434
on the starter solenoid.
1. AMMETER CLAMP
STEP 6 Fasten the ammeter clamp around the positive

battery cable so that the tip of the arrow is toward the
starter.
STEP 8
B831433
1. BLACK VOLTMETER LEAD

Connect the black voltmeter lead the mounting flange
on the starter. 1 2
3
B831435
1. REMOTE STARTER BUTTON 3. SWITCH TERMINAL

2. BATTERY TERMINAL
Connect the leads from the remote starter button to
the Battery and Switch terminals.

4004-6
IMPORTANT: Steps 9, 10, and 11 must be done STEP 10
rapidly. Do not load the battery for more than 15 Look at the ammeter and make a record of the
seconds at one time. After the battery has been ammeter indication.
loaded for 15 seconds, let the starter cool for 60
seconds.
STEP 11
Use the hand held tachometer and check the
STEP 9
armature shaft speed. Make a record of armature
shaft speed.
4 3
2 STEP 12
Release the remote starter button and turn the load
control to the OFF position.
B831436
1. REMOTE STARTER BUTTON 4. AMMETER

2. LOAD CONTROL 5. HAND HELD
3. VOLTMETER TACHOMETER
Actuate the remote starter button and turn the load

control until the voltmeter indicates 11 volts.

4004-7
Understanding No Load Test 4. If the armature does not rotate and the current
draw is zero, possible causes are:
Results
A. An open field circuit. Disassemble the starter
1. If the current draw and the armature shaft speed and inspect the field coil connections.
are within the ranges under Specifications, the
starter is good. B. An open armature coil. Disassemble the
starter and check for burned commutator bars.
2. Low armature shaft speed and high current draw Use an armature tester to test the armature.
are indications of too much friction. Possible U s e t h e i n s t r u c t i o n s i n c lu d e d w i t h t h e
causes of too much friction are: armature tester.
A. Tight, dirty, or worn bearings. C. Brushes not making good contact with the
B. A bent armature shaft. commutator bars. Check for high insulation
between the commutator bars, broken brush
C. Loose pole shoes (pole shoes make contact springs, or worn brushes.
with the armature).
5. Low armature shaft speed and low current draw
D. A short circuit in the armature coil. are indications of:
Disassemble the starter. Use an armature
tester to test the ar mature. Use the A. Dirt or corrosion on connections.
instructions included with the armature tester. B. Damaged wiring.
E. Damaged field coil. Do the test on page 13. C. Dirty commutator bars.
3. If the armature does not rotate and the current D. All causes in Step 4.
draw is high, possible causes are:
6. High armature shaft speed and high current draw
A. Field terminal making contact with the field are indications of a short circuit in the field coil. It
frame. Inspect the insulators for the field is difficult to find a short circuit in a field coil.
terminal. Install a new field coil. Do the No Load Test again
B. Damaged field coil. Do the tests on page 13. to check for improvement in the operation of the
starter.
C. Damaged bearings.

4004-8
Disassembly STEP 4
STEP 1
B330735
Remove the cover.

B330731
Pull back the boot on the motor terminal and loosen STEP 5
and remove the nut and lock washer.
STEP 2
B330736
Hold the spring away from one of the brushes

connected to the field coil and remove the brush from
B330732
the brush holder. Repeat this step for the other brush
Loosen and remove the screws that mount and hold connected to the field coil.
the brush holder to the cover.
STEP 6
STEP 3
B330737
B330733
Remove the brush holder.
Loosen and remove the bolts.

4004-9
STEP 7 STEP 10
B330738 B330741
Remove the field frame assembly. Remove the starter drive housing from the starter
solenoid.
STEP 8
STEP 11
B330739
Remove the armature. B330743
Push down the starter drive housing as shown to

STEP 9 loosen and remove the starter drive.
STEP 12
B330740
Fasten the starter solenoid in a vise and loosen and

remove the screws that hold the star ter dr ive B330744
housing. Remove the steel ball from the star ter drive. If
necessary, use a magnet.

4004-10
STEP 13 STEP 16
B330701 B330704
Remove the O-ring from the groove in the starter Remove the bearing cage.
drive housing.
STEP 17
STEP 14
B330705
B330702 Remove the thrust washer.

Remove the spring.
STEP 18
STEP 15
B330706
B330703 Loosen and remove the screws that hold the cover.
Remove the idler gear.

4004-11
STEP 19 STEP 21
B330707 B330709
If necessary, use a hammer to loosen the cover. Remove the plunger.
STEP 20 STEP 22
B330708 B330710
Remove the cover. If necessary, remove the gasket from the cover.

4004-12
Inspection
All parts except the starter drive must be cleaned
using mineral spirits and a brush or cloth. Use a
clean, dry cloth to clean the starter drive.
Brushes and Brush Springs

1. If the length of a brush that is attached to the
brush holder is less than 11 mm (7/16 inch), a
new brush holder assembly must be used when
the starter is assembled.
2. If the length of a brush that is attached to the
field coil is less than 11 mm (7/16 inch), a new B834918
field frame assembly must be used when the 2. Put the armature on vee-blocks as shown and
starter is assembled. check the runout of the armature with a dial
3. Use a spring scale to check the tension of the indicator. The runout must not be more than
brush springs. Pull the brush spring up until the 0.05 mm (.002 inch).
brush spring is just above the brush holder. The 3. If necessary, put the armature in a lathe and
scale indication must be between 1.8 and 4.1 kg remove enough material from the commutator to
(4 and 9 pounds). If a brush spring is not as make the runout less than 0.05 mm (.002 inch).
specified, use a new brush spring when the
starter is assembled.
Brush Holder
B313141
4. Measure the diameter of the commutator. If the

diameter is less than 35 mm (1.377 inch), install
B313142 a new armature.
1. Hold the leads of an ohmmeter against the frame 5. If the depth of the groove between the
and the brush holders that have insulation commutator bars is less than 0.2 mm (.008 inch),
between the brush holder and frame. cut the insulation between the commutator bars
2. The needle of the ohmmeter must not move, if to a depth of 0.4 to 0.8 mm (1/64 to 1/32 inch).
the needle moves replace the brush holder. Use sandpaper to remove the rough edges from
the commutator bars.
Armature 6. Check the bearings on the armature for free
1. Test the armature on an armature tester. Use the rotation, rough balls, and damage to the inner
equipment manufacturer’s instructions. race or outer race. If a bearing is to be replaced,
use a press and acceptable tools to remove and
install the bearings.

4004-13
Field Coil Test STEP 2
STEP 1
B610616
Hold one of the leads of the ohmmeter against the

end of the cable. Hold the other lead of the ohmmeter
B610614
against one of the brushes and look at the ohmmeter.
Hold one of the leads of an ohmmeter against the
Move the lead that is on the brush to the other brush
field frame. Hold the other lead of the ohmmeter
and look at the ohmmeter. The needle of the
against one of the brushes and look at the ohmmeter.
ohmmeter must move when the lead is in both
Move the lead that is on the brush to the other brush
positions. If the needle of the ohmmeter did not
and look at the ohmmeter. The needle of the
move, install a new field frame assembly.
ohmmeter must not move when the lead is in either
position. If the needle of the ohmmeter moved, install
a new field frame assembly.

4004-14
Assembly STEP 4
STEP 1
B330712
Install and tighten the screws.

B330709
Install the plunger in the starter solenoid. STEP 5
STEP 2
B330714
Install the bearings in the bearing cage.

B330711
If necessary, install a new gasket in the cover. STEP 6
STEP 3
B330715
Lubricate the bearings and teeth of the idler gear with

B330708
the grease specified on page 3.
Install the cover.

4004-15
STEP 7 STEP 10
B330834 B330837
Install the thrust washer. Install the spring.
STEP 8 STEP 11
B330835 B330838
Install the bearing cage as shown. Install a new O-ring in the groove in the starter drive
housing. Lubricate the O-ring with the grease
STEP 9 specified on page 3.
STEP 12
B330836
Install the idler gear.

B330841
Lubricate the open bearing on the starter drive with

the grease specified on page 3.

4004-16
STEP 13 STEP 16
B330802 B330741
Start the starter drive into the starter drive housing. Assemble the star ter drive housing and star ter
solenoid.
STEP 14
STEP 17
B330803
Push down the starter drive housing to push the B330805
starter drive all the way into the starter drive housing. Install a lock washer, flat washer, and O-ring on the
screws that hold the starter drive housing. Lubricate
STEP 15 the O-rings with the grease specified on page 3.
STEP 18
B330804
Put a small amount of grease in the hole in the

starter drive and install the steel ball in the hole. B330807
Install the screws in the starter drive housing.

4004-17
STEP 19 STEP 22
B330740 B330808
Fasten the starter solenoid in the vise and tighten the Use the springs to hold the brushes in the brush
screws that hold the starter drive housing. holder as shown.
STEP 20 STEP 23
B330739 B330809
Install the armature. Install the brush holder.
STEP 21 STEP 24
B330738 B330810
Install the field frame assembly. Put the springs on top of the brushes connected to
the brush holder.

4004-18
STEP 25 STEP 28
B330811 B330814
Install the brushes that are connected to the field coil. Install the cover and align the cover with the brush
holder.
STEP 26
STEP 29
B330812
Use a bolt to align the brush holder with the field B330815
frame assembly. Install and tighten the screws that hold the brush
holder.
STEP 27
STEP 30
B330813
Move the brush holder so that the brush holder is B330816
even with the end of the armature. Install a lock washer, flat washer, and O-ring on the
bolts. Lubricate the O-rings with the grease specified
on page 3.

4004-19
STEP 31 STEP 32
B330818 B330731
Install and tighten the bolts. Install the cable, lock washer, and nut on the motor
terminal, and tighten the nut.
STEP 33
Pull the boot over the motor terminal.
STARTER SOLENOID TEST

This test will check the condition of the pull-in winding 3. Connect a jumper wire to the battery terminal
and the hold-in winding in the starter solenoid. and the switch terminal in the starter solenoid
housing. The jumper wire must be made from
The jumper cable connected to the starter mounting
No. 10 or larger wire.
flange and the motor terminal must have a common
connection at the negative battery post. 4. Connect the jumper cable with the common
connection to the starter mounting flange and the
Starter Solenoid Test Procedure motor terminal in the starter solenoid housing.
1. Remove the rubber boot from the motor terminal. NOTE: Steps 5 and 7 must be done in a maximum of
Remove the nut and lock washer from the motor 5 seconds to prevent damage to the pull-in winding
terminal. Then remove the wire from the motor and the hold-in winding.
terminal. 5. Connect the jumper cable with the common
2. Connect a jumper cable to the positive battery connection to the negative battery post. The
post of a fully charged 12 volt battery. Connect pinion gear on the starter drive must come all the
the other end of the jumper cable to the battery way out rapidly and with force.
terminal on the starter solenoid housing. 6. If the pinion gear did not come out rapidly and
with force, the pull-in winding is damaged. The
2 complete starter solenoid housing assembly
must be replaced.
7. Disconnect the jumper cable from the motor
3 terminal in the starter solenoid housing. The
1 pinion gear on the starter drive must not move
toward the starter drive housing.
8. If the pinion gear started to move toward the
5 star ter drive housing, the hold-in winding is
damaged. The complete starter solenoid housing
4 assembly must be replaced.
BC02J086
1. 12 VOLT BATTERY 4. SWITCH TERMINAL

2. STARTER 5. MOTOR TERMINAL
3. BATTERY TERMINAL

4004-20
5
19 2
18 4
23
4
22
17 21
16 2 14 20
15
14
2
5 13
12
11
8 2
5 10
9
8 2
5
6 1
4
3
2
B831437
1. BOLT 7. BRUSH HOLDER 13. PLUNGER 19. BEARING CAGE

2. LOCK WASHER 8. BEARING 14. NUT 20. SPRING
3. FLAT WASHER 9. ARMATURE 15. STARTER SOLENOID ASSEMBLY 21. STEEL BALL
4. O-RING 10. FIELD FRAME 16. THRUST WASHER 22. STARTER DRIVE
5. SCREW 11. COVER 17. IDLER GEAR 23. STARTER DRIVE HOUSING
6. COVER 12. GASKET 18. ROLLER (5)

Section
4005
INSTRUMENT CLUSTER AND FAULT CODES
4005

4005-2
TABLE OF CONTENTS
580M INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacing a Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gauge and Tachometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Gauge and Tachometer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Circuit Board and Hourmeter
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING THE WARNING LAMPS AND INDICATOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Low Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Oil Filter Restriction and
Air Filter Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parking Brake Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Driving Lamps Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Conditioning System Pressure Indicator (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grid Heater Indicator (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CHECKING THE GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Coolant, Oil Temperature, or Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHECKING THE TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
580SM, 580SM+, 590SM, AND 590SM+ INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Retrieving Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Analog Gauge Movement Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Digital Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RETRIEVING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault Code Grouping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Erasing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VEHICLE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ENGINE FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRANSMISSION FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTRUMENT CLUSTER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4005-3
580M INSTRUMENT CLUSTER
Replacing a Bulb
1. Remove the instrument cluster from the console.
BD00H150
1. SOCKET ASSMEBLY
4. Turn the socket assembly (1) counterclockwise to

BD00H152 remove. The bulb and the socket assembly (1)
2. Remove the 2 screws that fasten the rear cover are ser viced together. Replace the socket
to the frame. assembly (1) as required.
BD00H151
1. REAR COVER
2. FRAME
3. O-RING
3. Remove the rear cover (1) from the frame (2).

NOTE: Make sure the O-ring (3) is in the correct
position on the rear cover (1) before the rear cover
(1) is installed onto the frame (2).

4005-4
Gauge and Tachometer Removal Gauge and Tachometer Installation

1. Remove the instrument cluster from the console. 1. Install the overlay, gauges, tachometer, and light
pipe as one unit and install into the frame.
2. Loosen and remove the 2 screws that fasten the
rear cover to the frame. 2. Install the lens and O-ring onto the frame. Install
the 8 screws which fasten the lens to the frame.
3. Remove the rear cover (1) from the frame.
Tighten the screws to a maximum torque of 10
4. Loosen and remove the 12 screws which fasten pound - inches. Do not over torque the screws.
the circuit board to the frame.
3. Install the front trim onto the instrument cluster
5. Loosen and remove the 15 nuts and 15 washers and tighten the 2 screws which fasten the front
from the 4 gauges and the tachometer. trim to the frame.
NOTE: To avoid damage to the circuit board be sure 4. Turn the instrument cluster over and install and
that you are properly grounded before removing the tighten the 5 screws which fasten the overlay,
circuit board from the frame. Handle the circuit board gauges, tachometer, and light pipe to the frame.
by the edges only.
NOTE: To avoid damage to the circuit board be sure
6. Remove the circuit board from the frame. that you are properly grounded before removing the
circuit board from the frame. Handle the circuit board
7. Loosen and remove the 5 screws which fasten
by the edges only.
the overlay, gauges, tachometer, and light pipe to
the frame. 5. Install the circuit board into the frame. Install the
15 washers and 15 nuts which fasten the 4
8. Loosen the 2 screws which fasten the front trim
gauges and the tachometer to the circuit board.
to the instrument cluster and remove the front
Tighten the nuts.
trim.
6. Install and tighten the 12 screws which fasten the
9. Loosen and remove the 8 screws which fasten
circuit board to the frame.
the lens to the frame and remove the lens from
the frame. 7. Install the rear cover and O-ring onto the frame.
Install and tighten the 2 screws which fasten the
10. Remove the overlay, gauges, tachometer, and
rear cover to the frame.
light pipe from the frame as one unit.
8. Install the instrument cluster into the console.
11. The gauges and tachometer are not serviced
individually. The gauges, tachometer, light pipe
and overlay must all be replaced as 1 unit. Circuit Board and Hourmeter
Replace as required. Removal and Installation
NOTE: The circuit board and the hourmeter are
serviced as one unit.
1. Follow Steps 1 through 6 for Removal of the
Gauge and Tachometer procedure to remove the
circuit board and hourmeter from the instrument
c l u s t e r. Fo l l ow S t e p s 5 t h r o u g h 8 o f t h e
Installation of the Gauge and Tachometer
procedure to install the circuit board and
hourmeter into the instrument cluster.
2. The circuit board does not normally cause any
problems. Use an ohmmeter to check the
continuity of the circuit board strips If there is no
continuity in any one of the strips the circuit
board must be replaced. Replace the circuit
board and hourmeter as required.

4005-5
CHECKING THE WARNING LAMPS AND INDICATOR LAMPS

NOTE: The backlighting for the instrument cluster is Hydraulic Oil Filter Restriction and
illuminated only when the driving lamp switch is in the
ON position.
Air Filter Restriction
NOTE: When the key switch is in the ON position 1. The warning lamp for the Hydraulic Oil Filter
and the engine is NOT running the Air Filter Restriction and the Air Filter Restriction should
Restriction, Hydraulic Oil Filter Restriction, be illuminated with the key switch is in the on
Alternator, and Low Engine Oil Pressure Warning position and the engine NOT running. If the one
Lamps are illuminated. or both of the warning lamps does not illuminate:
NOTE: When the key switch is first turned to the ON A. Check for a bad lamp.
position the Air Filter Restriction Warning Lamp, B. Check for corrosion or bad connections at the
Hydraulic Oil Filter Restriction Warning Lamp, socket in the instrument cluster and at the
Parking Brake Indicator Lamp and the Air Hydraulic Oil Filter Restriction and / or the Air
Conditioning System Pressure Indicator Lamp (if Filter Restriction switch.
equipped), will illuminate for 3 seconds for a bulb self
test. C. Check the wire between the Hydraulic Oil
Filter Restr iction and / or the Air Filter
Restriction switch and the instrument cluster.
Low Engine Oil Pressure
D. Check for a damaged wire between the
1. The warning lamp for low engine oil pressure instrument cluster and the IGN terminal of the
should be illuminated with the key switch is in the key switch.
ON position and the engine NOT running. If the
warning lamp does not illuminate: E. A bad key switch.
A. Check for a bad lamp. 2. The warning lamp for the Hydraulic Oil Filter
Restriction and the Air Filter Restriction should
B. Check for corrosion or bad connections at the NOT be illuminated while the engine is running. If
socket in the instrument cluster and at the the one or both of the warning lamps illuminate
switch for engine oil pressure. while the engine is running, the cause can be:
C. Check the wire between the oil pressure A. Dirty filter(s).
switch and the instrument cluster.
B. Bad switch for the warning lamp(s).
D. See Section 4001 in this Manual for complete
troubleshooting procedure for the instrument C. Short circuit in the wire between the switches)
cluster. and the warning lamp(s).
D. Cold hydraulic oil will also cause the switch to
Alternator activate.
1. The warning lamp for the alternator should be E. See Section 4001 in this Manual for complete
illuminated with the key switch is in the on troubleshooting procedure for the instrument
position and the engine NOT running. If the cluster.
warning lamp does not illuminate:
A. Check for a bad lamp.
B. Check for corrosion or bad connections at the
socket in the instrument cluster and at the
alternator.
C. Check the wire between the alternator and the
instrument cluster.
D. See Section 4001 in this Manual for complete
troubleshooting procedure for the instrument
cluster.

4005-6
Parking Brake Indicator Low Fuel Level

1. The Parking Brake Indicator Lamp will illuminate 1. The Low Fuel Level Warning Lamp illuminates
when the parking brake is applied. when the fuel level in the fuel tank is low.
2. See Section 4001 in this Manual for the 2. See Section 4001 in this Manual for the
procedure to check the Parking Brake Indicator procedure to check the Fuel Level Sender.
lamp.
Air Conditioning System Pressure
Driving Lamps Indicator Indicator (If Equipped)
1. The Driving Lamps Indicator Lamp will illuminate
1. The Air Conditioning System Pressure Indicator
when the driving lamp switch is in the ON
Lamp illuminates when the air conditioner has
position.
stopped due to refrigerant pressures that are too
2. See Section 4001 in this Manual for the high.
procedure to check the Driving Lamps Indicator
2. See Section 4001 in this Manual for the
Lamp.
procedure to check the Air Conditioning System
High and or Low Pressure switch.
Grid Heater Indicator (If equipped)

1. The Grid Heater Indicator lamp will illuminate
when the engine temperature is below 0° C
(32° F) and the grid heater is functioning.
2. See Section 4001 in this Manual for the
procedure to check the Grid Heater and the Grid
Heater Indicator Lamp.

4005-7
CHECKING THE GAUGES

NOTE: The Engine Coolant Temperature, The Oil 2. If the gauge only works part of the time, the
Temperature, Voltmeter, Fuel Level Gauges, and the cause can be:
Tachometer are all serviced as one unit. If one gauge
A. A bad connection at the sender.
or the tachometer is defective, they must all be
replaced as one unit in the instrument cluster. B. A bad connection at the instrument cluster.
C. A bad connection in the connectors in the
Engine Coolant, Oil Temperature, wiring harness.
or Fuel Level D. A short circuit or an open circuit in the wires
1. If the gauge does not work correctly: between the instr ument cluster and the
sender.
A. Disconnect the wire from the sender.
E. A bad sender.
B. Turn the key switch to the ON position.
F. A bad gauge.
C. Hold the wire against the frame or the engine
until you have a good ground connection. 3. See Section 4001 in this Manual for complete
troubleshooting procedure for the instrument
D. Have another person look at the gauge. If you cluster.
are checking the engine coolant or the oil
temperature gauge, the needle must move all
the way to the right (red zone). If you are
Voltmeter
checking the fuel level gauge, the needle must 1. Connect the positive lead of a test voltmeter to
move all the way to the left (empty position). the positive post of the batteries. Connect the
E. If the needle moved, the sender is bad and negative lead of the test voltmeter to the negative
must be replaced. If the needle did not move, post of the batteries. If the machine has two
the gauge is bad or there is an open circuit in batteries, make sure the leads are connected to
the wires between the sender and the gauge. the same battery.
F. Install the wire on the sender. 2. Start and run the engine at 1500 r/min (rpm).
G. Refer to page 4005-3 and remove the 3. Read the test voltmeter, reading should be 12+
instrument cluster from the console and volts.
disconnect the wir ing har ness from the 4. Check the voltage gauge on the machine, is the
instrument cluster. gauge in the green.
H. Refer to Section 4001 in this manual for the 5. Replace the gauge assembly as required.
location of the terminal in the connector on the
wiring har ness. Connect one lead of an 6. See Section 4001 in this Manual for complete
ohmmeter to the terminal in the connector. troubleshooting procedure for the instrument
Connect the other lead of the ohmmeter to a cluster.
good ground connection.
I. If the ohmmeter did not indicate continuity,
there is a short circuit in the wires between the
connector and the sender. Repair or replace
the wires. If the ohmmeter indicated continuity,
the wires are good and the gauge assembly
must be replaced.

4005-8
CHECKING THE TACHOMETER

1. The tachometer shows the engine speed in 4. If the alternator is working correctly, remove the
revolutions per minute (rpm). The engine rpm instrument cluster from the console. Disconnect
signal comes from the alternator “W” terminal. If the electrical connector form the console.
the tachometer is not working the cause could
A. Connect one lead of an ohmmeter to terminal
be:
T19 in the connector and connect the other
A. Check the operation of the alternator. lead of the ohmmeter to a good ground.
2. See Section 4001 in this Manual for the B. The ohmmeter should indicate continuity.
p r o c e d u r e t o c h e ck t h e o p e r a t i o n o f t h e
C. If the ohmmeter does not indicate continuity,
alternator.
check the wire between the connector and the
3. If the alternator is not working correctly see alternator. Repair or replace the wire.
Section 4007 in this Manual and repair or replace
5. If the tachometer still does not operate, check the
the alternator.
instrument cluster.
A. See Section 4001 in the Manual for the
procedure to check the instrument cluster.
Replace the gauge and tachometer assembly
as required.

4005-9
580SM, 580SM+, 590SM, AND 590SM+ INSTRUMENT CLUSTER
Power On
1. Turn the ignition (key) switch to the ON position. Digital Display Mode
2. All LED’s (Light Emitting Diodes) will illuminate NOTE: This can be used for accurate diagnostics.
for 2 - 3 seconds.
1. Press and hold the down arrow and the escape
3. The warning alarm will sound for 1 second. key at the same time.
4. If an active fault is found, the associated 2. Turn the ignition (key) switch to the ON position.
visualization will occur with the display, LEDs, 3. The instrument cluster will go into a digital
and alarm. display mode.
5. If not active fault is found, the display will be 4. To reset the instrument cluster, turn the ignition
green in color showing the current vehicle hour (key) switch off.
meter value.
5. Us the up/down arrows to select the value
desired.
Retrieving Software Version
6. Press the up arrow the first screen will be:
1. Press the enter key. Transmission oil temperature and Vehicle
2. Press the up arrow 3 times. Voltage.
3. The software version will be displayed. 7. Press the up arrow the second screen will be:
Fuel level% and Fuel Tank #.
Analog Gauge Movement Test 8. Press the up arrow the third screen will be:
Requested RPM.
1. Press and hold the down or up arrow and the
escape or enter key at the same time. 9. Press the up arrow the fourth screen will be: Foot
Throttle% and Hand Throttle%.
2. Turn the ignition (key) switch to the ON position.
10. Press the up arrow the fifth screen will be: Hand
3. The analog gauges will sweep and stop at the
Throttle Voltage Output and Hand Throttle Signal
minimum position, green/red boarder positions
Voltage Out.
(s), maximum position.
11. Press the up arrow the sixth screen will be: Foot
4. The instrument cluster will then go into a digital
Throttle Voltage Output and Foot Throttle Signal
display mode.
Voltage Out.
12. Press the up arrow the seventh screen will be:
Oil Temperature and Fuel Temperature.
13. Press the up arrow the eighth screen will be:
Coolant Temperature and Air Temperature.
14. Press the up arrow the ninth screen will be:
Brake Enable ON/OFF and RPM.
15. By pressing the down arrow the screen
sequence will be reversed.

4005-10
RETRIEVING FAULT CODES
Fault Code Display

A
B
C
A
C
E
D
B
BD08A318-01
A. Fault number
BD08A330-01
A. Escape key B. Number of faults
B. Enter key C. Fault code
C. Up arrow D. Number of occurrences of this fault
D. Down arrow E. The hour reading on the machine of the last

occurrence
1. Press the enter key once.
3. The screen will automatically scroll to the next
1. Press the down arrow until warning triangle is fault.
displayed.
4. Press the escape key to return.
BD08A317-01
2. Press ENTER to view the faults.

4005-11
Fault Code Grouping Erasing Faults

1. 1000 to 1999 vehicle errors. The EST must be used to remove faults from
memory.
2. 2000 to 2999 not used.
3. 3000 to 3999 engine errors.
4. 4000 to 4999 transmission errors.
5. 5000 to 5999 eltro-hydraulic system errors.
6. 6000 to 6999 reserved.
7. 7000 to 7999 reserved.
8. 8000 to 8999 optional equipment IE: GPS.
9. 9000 to 9999 internal AIC errors.

4005-12
VEHICLE FAULT CODES
CODE DEFINITION POSSIBLE STEPS FOR REPAIR
1001 Engine air filter blocked Check for obstruction, clean or change filter
1. Stop machine operations
2. Run engine at 1500 rpm
1002 Engine coolant temperature above normal 3. Check fan operation
4. Check radiator core for clogs
AC pressure too high, see section 9002 for
1003 Air conditioning not functioning
troubleshooting procedures.
Warm hydraulic system
1004 Hydraulic filter restricted Check the sensor
Check/replace the filter
1. Stop machine operations
2. Check cooling core for clogs
1009 Transmission oil temperature to high 3. See section 6002 for troubleshooting
procedures.
1010 Foot throttle sensor signal is out of range.
1011 Foot throttle sensor signal above range max.
1. Check wiring
1012 Foot throttle sensor signal below range 2. Check foot throttle
minimum. 3. Check instrument cluster
1013 Foot throttle sensor - no signal
1014 Battery voltage high Check charging system, refer to section 4001 for
1015 Battery voltage low troubleshooting procedures.
1018 Intake manifold temperature high - critical Check for defective or clogged after cooler
Engine coolant temperature entered red zone
1019
on gauge.
For historical diagnostic purposes only.
Transmission oil temperature entered red
1020
zone on gauge.
1021 Fuel temperature too high. Check fuel level.
1022 Water detected in fuel Drain water from fuel.
Foot throttle sensor supply voltage over 5.2 for Check wiring
1023
5 seconds Replace instrument cluster.
Foot throttle sensor voltage under 4.8 volts for
1024
5 sec.
Foot throttle sensor voltage over 5.3 volts for
1025
5 sec.
Foot throttle sensor voltage under 200 mV for 1. Check wiring
1026
5 sec. 2. Check foot throttle
3. Check instrument cluster.
Foot throttle sensor voltage over 5.3 volts for
1029
5 sec.
1030 Foot throttle sensor voltage under 200 mV for

5 sec.
4005-13
Hand throttle sensor voltage under 4.8 volts

1032
for 5 sec.
Hand throttle sensor voltage over 5.3 volts for
1033
5 sec.
Hand throttle sensor voltage under 200 mV for
1034
5 sec.
Hand throttle sensor signal above 95% of input
1035
for 5 sec. 1. Check wiring
2. Check foot throttle
1036 Hand throttle sensor signal below 5% of input 3. Check instrument cluster.
for 5 sec.
1037 Hand throttle sensor signal out of range
1038 Hand throttle sensor voltage over 5.3 volts for

5 sec.
1039 Hand throttle sensor voltage under 200 mV for

5 sec.
1040 Engine RPM signal above 2750 for 5 sec. For historical diagnostic purposes. The machine
1041 Engine RPM signal above 3000 for 5 sec. has exceeded recommended operation range.
1044 Fuel level sensor below 2.0 ohm for 5 sec. Open circuit in wiring or in sensor. Check wiring
1045 Fuel level sensor open circuit. or replace sensor.
1047 Transmission temperature sensor below 3.0 Open circuit in wiring or in sensor. Check wiring
ohm for 5 sec. or replace sensor.
See section 4001 and troubleshoot the charging
1050 Alternator unable to charge
system.
CAN malfunction, 5 sec. without message
1051
EEC1
1052 CAN malfunction, 5 sec. without message
1053 CAN malfunction, 25 sec. without message

CNFBAM
1054
engine temperature
1055 Check communication BUS wiring
inlet/exhaust
Check engine controller, instrument cluster.
1056
engine fluid
1057
vehicle electrical
1058
EDC2BC
1059
DM1

4005-14
ENGINE FAULT CODES
DESCRIPTION AND POSSIBLE

CODE DEFINITION
STEPS FOR REPAIR
Coolant temperature sensor signal out of See OTS (Oil Temperature Sensor) plausibility
3006
range. check (Fault 3033)
Sensor defective or short circuit to external
Coolant temperature sensor signal above
3007 source.
range max.
Check wiring or replace sensor.
Coolant temperature sensor signal below Sensor defective or short circuit to ground.
3008
range min. Check wiring or replace sensor.
No CAN plausibility check performed, restart
3009 Coolant temperature sensor null (via CAN) system, if problem reoccurs.
Air intake temperature sensor signal above
3010 source.
range max.
Air intake temperature sensor signal below Sensor defective or short circuit to ground.
3011
range min. Check wiring or replace sensor.
3012 Air intake temperature sensor null (via CAN) system, if problem reoccurs.
3015 Fuel temperature signal above range max. source.
3016 Sensor defective or short circuit to ground.

Fuel temperature signal below range min.
Boost pressure sensor signal above range
3019 source.
max.
3021 Boost pressure sensor null (via CAN) system, if problem reoccurs.
Difference of ambient and boost pressure is out
3022 Boost pressure sensor signal out of range of range.
3023 Atmospheric pressure sensor signal out of

range
Ambient pressure sensor inside ECU is defect.
Atmospheric pressure sensor signal above
3024 Replace ECU (not necessary if never running in
range max.
high altitude).
3025 Atmospheric pressure sensor signal below
range min.
Inaccurate oil pressure sensor or defect (e.g. too
low oil level, leakage...) in the oil system.
3028 Oil pressure sensor pressure too low
Check oil pressure sensor for accuracy and
check oil system.

4005-15

CODE DEFINITION
STEPS FOR REPAIR

3029 Oil pressure sensor short-circuit to battery source.
Sensor defective or short circuit to ground.
3030 Oil pressure sensor short-circuit to ground
3031 Oil pressure sensor ADC conversion error No information available at time of print.
Inaccurate oil pressure sensor or defect (e.g.
blocked piping) in the oil system.
3032 Oil pressure sensor pressure too high
Check oil pressure sensor for accuracy and
check oil system.
Inaccurate oil or coolant temperature sensors or
insufficient oil or coolant recirculation (low
coolant level etc.).
3033 Oil temperature sensor signal out of range
Check oil and coolant temperature sensor for
accuracy and check oil and coolant system for
proper functioning.
Oil temperature sensor signal above range
3034 source.
max.
Oil temperature sensor signal below range Sensor defective or short circuit to ground.
3035
min. Check wiring or replace sensor.
3036 Oil temperature sensor signal CAN
system, if problem reoccurs.
transmission disturbed
Sensor defective or short circuit to ground.
3037 Boost pressure sensor signal low
Defective coil of injector.
3083 Cylinder 4 short-circuit high side to ground
Check the wiring and replace injector
3047 Main relay 2 failure - short-circuit to battery Check wiring
3048 Main relay 2 failure - short-circuit to ground Replace engine controller.
Alternator voltage governor defect.

3051 Battery voltage to ECM too high
Replace alternator governor device or alternator.
Battery defect, alternator defect, wiring problems
(too high resistance) or ECU defect. Occurrence
3052 Battery voltage to ECM too low possible during cold start.
Replace battery or alternator. Check ECU and
wiring.
Historical information, power was disconnected
3059 ECM after run was interrupted
before ECM was shutdown.
Depending on the pattern, various reasons can
cause the defect, internal ECU problems also
3060 Cylinder 1 unclassified error in injector possible.
Check the wiring and the injection signals,
replace ECU

4005-16

CODE DEFINITION
STEPS FOR REPAIR
Cylinder 1 injector cable short-circuit low side Short circuit in wiring with external source.
3061
to battery Check the wiring or replace injector
replace ECU
3069
3070 Cylinder 3 signal low
replace ECU.
replace ECU
3077
replace ECU
3081 Cylinder 4 injector cable short-circuit low side Short circuit in wiring with external source.
Signal interrupted do to wiring problem, defective
or incorrectly installed crankshaft speed sensor.
3088 Crankshaft sensor lost synchronization Check wiring, sensor installation and proper
functioning of crankshaft sensor (evaluate raw
signals)
Check wiring, sensor installation and proper
3089 Crankshaft sensor defective functioning of crankshaft sensor (evaluate raw
signals).
or incorrectly installed camshaft phase sensor.
3090 Camshaft sensor lost phase Check wiring, sensor installation and proper
functioning of camshaft phase sensor (evaluate
raw signals)

4005-17

CODE DEFINITION
STEPS FOR REPAIR

Camshaft sensor phase synchronization
3091 functioning of camshaft phase sensor (evaluate
failure
raw signals).
or incorrectly installed camshaft or crankshaft
3093 Offset between camshaft and crankshaft sensor.
outside boundaries Check wiring, sensor installations and proper
functioning of camshaft and crankshaft sensors
(evaluate raw signals)
3095 Operating with camshaft sensor only functioning of crankshaft sensor (evaluated raw
signals).
Short circuit of wiring to ground or defective
Rail pressure sensor CP3 signal below range pressure sensor.
3102
min. Check wiring and proper functioning of rail
pressure sensor
Defective rail pressure sensor, defect in other
injection relevant component.
3104 Rail pressure relief valve open Check rail pressure sensor for plausible values,
ensure proper functioning of the injection
components
Pressure relief valve does not open once the
pressure limit is reached: Mechanical defect or
Rail pressure relief valve pressure shock wrong application parameter.
3105
requested Check application value of maximum rail
pressure, check functioning of the pressure relief
valve
Pressure relief valve does not open even after
pressure shock: Stuck Pressure relief valve or
Rail pressure relief valve did not open after wrong application parameter.
3106
pressure shock Check application value of maximum rail
pressure, check functioning of the pressure relief
valve
3107 Metering unit output short-circuit to battery Short circuit of wiring to external source or inside
relay.
3108 Metering unit output short-circuit to ground Check wiring or replace relay
Rail pressure sensor offset monitoring signal
3110 Rail pressure sensor inaccurate.
above range max.
Ensure correct wiring and proper functioning of
Rail pressure sensor offset monitoring signal rail pressure sensor, replace sensor
3111
below range min.
Short circuit of wiring to external source or
defective pressure sensor, rail pressure
Rail pressure sensor CP3 signal above range
3112 overshoot.
max.
Check wiring and proper functioning of rail
pressure sensor

4005-18

CODE DEFINITION
STEPS FOR REPAIR
Short circuit of main relay to external source or

Grid heater battery switch relay short-circuit to defective main relay.
3113
battery Check the wiring connecting the battery to the
ECU or replace main relay
Short circuit to ground of main relay or defective
Grid heater battery switch relay short-circuit to main relay.
3114
ground Check the wiring connecting the battery to the
ECU or replace main relay
3118 ECM 12V sensor supply voltage high Ambient pressure sensor inside ECU is defective.
Replace ECU (not necessary if never running in
3119 ECM 12V sensor supply voltage low high altitude).
Short circuit to ground of grid heater.
3131 Grid heater always switched on
Check grid heater switch and replace it
Broken or disconnected wiring or defective relay.
3137 Metering unit open load
Check of wiring or replace relay
Defective wiring, ECU, power stage or metering
unit.
3138 Metering unit temperature too high
Check wiring, ECU, power stage and metering
unit
High pressure system: Rail pressure sensor
inaccurate, high pressure pump defective.
3141 Set point of fuel volume flow through metering
Low pressure system: Metering unit reflux too
unit is lower than calculated limit
low.
Check for defects according to failure list.
3142 High pressure test - test active Historical information
3145 Terminal 15 - no signal Check wiring.
3147 Oil temperature sensor signal above normal Check oil temperature sensor for accuracy and
range check oil system.
Short circuit of wiring to external source or inside
3154 Grid heater relay short-circuit to battery relay.
Check wiring or replace relay
Short circuit of wiring to ground or inside relay.
3155 Grid heater relay short-circuit to ground
3156 Grid heater relay no load
High pressure side: Leakage in high pressure
section, injection nozzle stuck in open position,
worn high pressure pump, worn injector, leaking
3171 Fuel rail/system pressure - too low pressure relieve valve
Low pressure side: Pressure before gear pump
too low, gear pump output too low (fuel filter
clogged, leakage in low pressure side).

4005-19

CODE DEFINITION
STEPS FOR REPAIR
Metering unit stuck in open position,

zero-delivery throttle clogged, metering unit
without power due to electrical error.
3172 Fuel rail/system pressure - too high
Low pressure side: Pressure before gear pump
too high (e.g. by pressure relieve valve), pressure
after zero-delivery throttle too high.
3173 Fuel rail/system pressure - too low See fault 3171
3174 Fuel rail/system pressure - too high See fault 3172
Leakage in the high pressure section, injection
nozzle stuck in open position, worn high pressure
3175 Fuel system leak detected – large leak
pump, worn injector, leaking pressure relieve
valve, injector reflux too high.
High pressure system: Leakage in the high
pressure section, injection nozzle stuck in open
position, worn or defective high pressure pump,
3176 Fuel delivery exceeded threshold for pressure worn injector, leaking pressure relieve valve.
in overrun mode Low pressure system: 'Zero delivery' is not active
in metering unit (excessive leakage in metering
unit).
Check for defects according to failure list.
For historical diagnostic purposes. Machine has
3177 Engine over speed detected
exceeded recommended operation range.
3188 Cylinder 1 open load
3192 Cylinder 2 open load Broken wire or disconnection of wiring or inside
injector.
3196 Cylinder 3 open load Check the wiring or replace injector.
3200 Cylinder 4 open load
Short circuit of high-side to battery or ground.
3210 Bank 1 general short-circuit on injection cable
Check the wiring or replace injector.
Short circuit of low-side to ground in injector
Bank 1 injection cable short-circuit low side to
3211 cable.
ground
cause the defect, internal ECU problem.
3213 Bank 1 unclassified error
replace ECU
Short circuit of high-side to battery or ground.
3218 Bank 2 general short-circuit on injection cable
Short circuit of low-side to ground in injector
3219 Bank 2 injection cable short-circuit low side to
cable.
ground
cause the defect, internal ECU problem.
3221 Bank 2 unclassified error
replace ECU

4005-20

CODE DEFINITION
STEPS FOR REPAIR
Clock error or interruption of the power supply

voltage.
3227 Injection processor error - stop engine
Check the power supply or replace ECU if
problem reoccurs.
Defective ECU, reset ECU.
If no recovery, replace ECU.
Internal failure of ECU or 'TESTMODE' takes too
long.
Check 'TESTMODE' parameters or replace ECU
if problem reoccurs
Defective SPI-bus participant, timing problem
due to software bug.
Replace ECU if problem reoccurs (Send in ECU
for investigation)
3232 Injection processor error - stop engine Defective ECU.
3233 Injection processor error - stop engine Replace ECU if problem reoccurs

3238 Communication error of CJ940 processor
3239 ECM EEPROM - read operation failure Electric disturbances, internal defect of the ECU
leading to a SPI bus communication error.
3240 ECM EEPROM - write operation failure Replace ECU if failure remains present
3241 ECM EEPROM - default value used
3242 Recovery which is locked Electronic disturbances, various hardware
defects (ECU internal) or configuration problems.
3243 Recovery which is suppressed
Analyze what error triggered the recovery (Read
out label HWEMon_numRecovery and compare
the value with the according table). If error occurs
3244 Recovery which is visible
repeatedly, reprogram ECU. If error remains,
replace ECU.
Defective monitoring module or CPU (e.g.
impaired functioning of the CPU clock) of the
ECU. Disturbed SPI-Bus.
Communication supervision watchdog control If error exists only temporary (i.e. injection
3245
flag reoccurs) error can be ignored and error deleted
in the fault memory. In case of a permanent error
the injection remains blocked and the ECU has to
be replaced
Watch dog switch off path defect.
3246 Redundant shutoff paths during initial If failure remains after ECU initialization: replace
ECU
3247 Redundant shutoff paths during initial Electronic disturbances, internal ECU problem.
If failure remains after ECU initialization: replace
3248 Redundant shutoff paths during initial ECU

4005-21

CODE DEFINITION
STEPS FOR REPAIR
TPU monitoring - time deviation between TPU Check wiring

3249
and system out of range Replace ECU
3250 Dataset - variant defective Update ECU software
3251 Dataset - requested variant could not be set Replace ECU
Controller watchdog - SPI communication

3252 Replace ECU
failure
3253 ADC monitoring - reference voltage too low
3254 ADC monitoring - reference voltage too high Update ECU software
3255 ADC monitoring - test impulse error Replace ECU
3256 ADC monitoring - queue error

Short-circuit to battery at high side power
3258 relay.
stage
3259 Short-circuit to ground at high side power Short circuit of wiring to ground or inside relay.
stage Check of wiring or replace relay
3260 Open load at low side power stage
Short-circuit to battery or excessive
3261 relay.
temperature at low side power stage
Short circuit of wiring to ground or inside relay.
3262 Short-circuit to ground at low side power stage
3263 ECM bus off on CAN C Internal ECU condition.
Electronic disturbances, requested torque
increase via tester, wrong application of injection
3265 Energizing time exceeds limit of over run
relevant parameters, defective ECU.
monitoring
Check injection relevant application, if failure
persists replace ECU
Electronic disturbances, internal ECU problem.
3266 Plausibility error in engine speed check
If failure persists after reinstallation replace ECU
Excessive voltage supply of a CJ940 component:
High battery voltage, defective wiring, internal
defect of the EDC.
3278 Supply voltage CJ940 upper limit
Check the battery for correct voltage supply,
check wiring. If defect remains replace EDC
(internal defect)
Insufficient voltage supply of a CJ940
component: Low battery voltage, defective wiring,
internal defect of the EDC.
3279 Supply voltage CJ940 lower limit
Check the battery for sufficient voltage supply,
check wiring. If defect remains replace EDC
(internal defect)

4005-22

CODE DEFINITION
STEPS FOR REPAIR
Excessive battery voltage, defect in wiring

harness, electrical failure in connected sensors
or in the EDC.
3280 Sensor supply voltage 1 high
Check battery voltage, check wiring for correct
voltage supply of the sensor and the EDC,
replace EDC
Insufficient battery voltage, defect in wiring
harness, electrical failure connected sensors or
in the EDC.
3281 Sensor supply voltage 1 low
replace EDC
or in the EDC.
replace EDC
in the EDC.
replace EDC
or in the EDC.
replace EDC
in the EDC.
replace EDC
Minimum number of injections not reached - Check wiring
3316
stop engine Replace ECU
CAN malfunction - time-out of CAN message
3334 Instrument cluster off-line
TCS1 speed
Check wiring
CAN malfunction - time-out of CAN message See section 4001 for troubleshooting procedures.
3339
TCS1 torque
3350 Terminal 50 - always ON Check wiring.
Update ECU software
3361 ECM EEPROM - general error
Replace ECU
Atmospheric pressure sensor - processed via
3363 Replace ECU at high altitude conditions.
ADC, no CAN plausibility

4005-23

CODE DEFINITION
STEPS FOR REPAIR
Check wiring
3856 Coolant temperature signal test failure
Check sensor
3998 Unknown engine error code with amber lamp Reset system by turning ignition off and starting
machined again.
3999 Unknown engine error code with red lamp If fault is recorded again contact TSS.

4005-24
TRANSMISSION FAULT CODES

NOTE: All pin references for 4xxx fault codes, unless other wise stated, refer to the transmission controller.
Power supply pin 2, FWD drive pin 3, or RVS

4000
drive pin 4 shorted to ground
Power supply pin 5, PWM 1 pin 6, PWM 2 pin
4001
7 shorted to ground
Power supply for digital outputs pin 8 does not
4002
have power
Battery voltage pin 34 below 10 volts got 2.5
4004
seconds with engine speed above 900 rpm
4006 FWD input pin 12 feedback circuit is reading

current without command
4007 FWD input pin 12 current is too low with

command present
FWD solenoid is drawing more current than
4008
commanded
4009 TWD solenoid is drawing less current than

commanded
4010 FWD signal erratic or incorrect
RVS input pin 40 feedback circuit is reading Check wiring
4011
current without command Refer to section 6002 for troubleshooting
procedures.
4012 RVS input pin 40 current is too low with
command present
RVS solenoid is drawing more current than
4013
commanded
RVS solenoid is drawing less current than
4014
commanded
4015 RVS solenoid erratic or incorrect
First and third shift modulation solenoid input
4016 pin 13 feedback circuit is reading current
without command
First and third shift modulation solenoid input
4017
pin 13 current is too low with command
First and third shift modulation solenoid is
4018
drawing more current than commanded
First and third shift modulation solenoid is
4019
drawing less current than commanded
First and third shift modulation solenoid erratic
4020
or incorrect

4005-25
Second and fourth shift modulation solenoid

4021 input pin 41 feedback circuit is reading current
without command
4022 Second and fourth shift modulation solenoid

input pin 41 current too low with command
Second and fourth shift modulation solenoid is
4023
drawing more current than commanded
Second and fourth shift modulation solenoid is
4024
drawing less current than commanded
Second and fourth shift modulation solenoid
4025
erratic or incorrect
4026 First / third shift solenoid shorted to ground
Second / fourth shift solenoid shorted to
4027
ground
4028 Differential lock or 4 wheel drive solenoid

shorted to ground
Shifter lever improperly connected, no power
4029
to pin 16, pin 18, or pin 46 for more than 3 sec.
4030 Shifter lever malfunction: transmission in

neutral receives forward and neutral together
Check wiring
Shifter lever malfunction: transmission in
4031 Refer to section 6002 for troubleshooting
neutral receives reverse and neutral together
procedures.
4032
forward receives forward and reverse together
4033 Shifter lever malfunction: transmission in

reverse receives forward and reverse together
4034
forward receives neutral and forward together
4035
reverse receives neutral and reverse together
During transition from second to third gear,
4036 gear command CMD-01 signal erratic or
incorrect
During transition from first to second gear,
4037 gear command CMD-02 signal erratic or
incorrect
During transition from third to fourth gear, gear
4038
command CMD-02 signal erratic or incorrect
4039 Crab input erratic or incorrect
4040 Circle input erratic or incorrect
4041 Transmission output shaft frequency above

3000 Hz detected

4005-26
4042 Temperature signal erratic or incorrect
4043 Temperature sensor input pin 43 is shorted to

ground
Temperature sensor input pin 43 is open
4044
circuit or shorted to a voltage above 5 volts Check wiring
Charge pressure is not detected when engine Refer to section 6002 for troubleshooting
4045 procedures.
speed is above 700 rpm for 10 sec.
Charge pressure is not detected when vehicle
4046
speed is over 10 kph
Charge pressure switch is closed with no
4047
frequency input to the TRAX controller
Check wiring
4100 Missing EEC 1 message on CAN
Check transmission controller.
4101 Internal TRAX failure, hardware measurement
4101 Internal TRAX failure, software timing
4101 Internal TRAX failure, software not running
4101 Internal TRAX failure, flash memory
Replace TRAX controller if reoccurring
Internal TRAX failure, redundant flash
4101
memory
4101 Internal TRAX failure, sensor supply high
4101 Internal TRAX failure, sensor supply low
Loss of messaging form an active transmission
controller.
4997 Loss of messaging from TRAX controller
Check wiring
Check transmission controller.
Unknown transmission error code with amber
4998 Reset system by turning ignition off and starting
lamp
machined again.
Unknown transmission error code with red If fault is recorded again contact TSS.
4999
lamp

4005-27
INSTRUMENT CLUSTER FAULT CODES

CODE DEFINITION
STEPS FOR REPAIR
9001 Hour meter plausibility

9002 Hour meter RAM checksum failure
9003 J1939 Receive buffer overflow
EEPROM checksum failure, hourmeter
9004
location 1
EEPROM checksum failure, hourmeter
9005
location 2
EEPROM checksum failure, hourmeter If error is permanent or repeats often, replace
9006 instrument cluster.
location 3
9007 Abnormal reset watchdog time-out
9008 A/D fault foot throttle
9009 A/D fault foot throttle power
9010 A/D fault hand throttle
9011 A/D fault foot throttle
9012 A/D

4005-28
NOTES

SECTION INDEX
STEERING - TRACK

Removal and Installation of Steering Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5000
Steering Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5001
Steering Control Valve Standard Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5002
Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5003
Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5005
Front Axle - Four Wheel Drive - 580M and 580SM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5006
Front Axle - Four Wheel Drive - 580SM+, 590SM and 590SM+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5006

Section
5000
REMOVAL AND INSTALLATION OF

STEERING COMPONENTS
5000

5000-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STEERING CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Steering Control Valve Hydraulic Installation 580M, 580SM and 590SM . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering Control Valve Hydraulic Installation 580SM+ and 590SM+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Comfort Steering Valve Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cab Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Canopy Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
STEERING CYLINDER, TWO WHEEL DRIVE MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STEERING CYLINDER, FOUR WHEEL DRIVE MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FRONT AXLE - TWO WHEEL DRIVE MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Two Wheel Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT AXLE - FOUR WHEEL DRIVE MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Four Wheel Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5000-3
SPECIFICATIONS
Special Torques
Nut for the steering wheel..................................................................................... 41 to 54 Nm (30 to 40 pound feet)
Steering cylinder two wheel drive axle ............................................................................... 335 Nm (247 pound feet)
Steering cylinder four wheel drive axle ................................................................................. 120 Nm (89 pound feet)
Front drive shaft.................................................................................................... 33 to 39 Nm (24 to 29 pound feet)
Front drive shaft guard........................................................................................ 50 to 90 Nm (36.5 to 66 pound feet)
Nut that fastens the tie rod end to the pivot arm
Four wheel drive axle (580M, 580SM, SM +).............................................................. 165 Nm (122 pound feet)
Four wheel drive axle (590SM) ................................................................................... 220 Nm (162 pound feet)
Two wheel drive axle all models.................................................................................. 165 Nm (122 pound feet)
Wheel nuts 4 WD axles .................................................................................... 122 +3 -10 Nm (90 +2 -7 pound feet)
Then turn nut an additional 90 degrees ± 5 degrees
Wheel bolts 2 WD axles ...................................................................................................... 251 Nm (185 pound feet)
SPECIAL TOOLS
The tool shown is needed to remove the steering
wheel. Make the tool in your shop.
1
2
3 3
6 7 GS99J514
4 CAS10486 Puller
This tool is used to remove the ball joint for the
GS99J500
steering cylinder from the axle.
Make from 6 MM. (1/4 inch) Cold Rolled Steel
1. 50.4 MM. (2 INCH) 5. 19 MM. (3/4 INCH)
2. 25.4 MM. (1 INCH) 6. TWO HOLES, 5.5 MM. (7/32 INCH)
3. 15.9 MM. (5/8 INCH) 7. USE NO. 4 DRILL FOR 1/4 - 24
4. 9.5 MM. (3/8 INCH) 8. THREADS METRIC THREAD
OPTIONAL TWO 10-32 X 1 INCH
SCREWS REQUIRED
B4097488M
380100091 for all two wheel drive and the 580M,
580SM four wheel drive front axle.
38010092 for the 580SM+ and 590SM and 590SM+
four wheel drive front axle.
This tool is used to remove and install the tie rod.

5000-4
STEERING CONTROL VALVE
Removal STEP 6
NOTE: Put identification tags on all disconnected
hoses. Close disconnected hoses and fittings with
caps and plugs.
STEP 1
parking brake.
STEP 2
Raise the loader and lock the support strut to hold
the loader.
BD01B307
Remove the bolts and flat washers that fasten the

STEP 3
fixed hood to the uprights. Use acceptable lifting
Open the hood. equipment and remove the fixed hood and air cleaner
as an assembly.
STEP 4
STEP 7
BD01B324
Tag and disconnect the wires for the air restriction BD01B329
switch. Cut the tie strap from the wires. Push the wires for the air restriction switch through
the hole in the curtain. Remove the bolts and the
STEP 5 engine curtain from the engine compartment.
BD01B323
Loosen the clamp on the air cleaner hose.

Disconnect the air cleaner hose from the turbo. Put a
shop cloth in the turbo opening or the intake opening.

5000-5
STEP 8 STEP 12
Remove the bolts (4), washers (5), and mount (6)
that fasten the steering control valve (7) to the cab.
STEP 13
Remove the steering control valve (7), mount (8), and
spacer (9) from the cab.
BD08B044-01
Tag and disconnect the hoses from the fittings in the

steering control valve.
NOTE: Refer to illustration this page for the following
steps. 9
STEP 9
If your machine has a cab go to step 12. If the
machine has a canopy go to step 10. 8
STEP 10 6
Have another person hold the steering control valve 5
in position. Remove the bolts (1) and washers (2)
that fasten the steering control valve (3) to the 4 7
steering column. 1
2
STEP 11 3
Remove the steering control valve from the canopy. BC01B088
1. BOLT 6. MOUNT
2. WASHER 7. CONTROL VALVE
3. CONTROL VALVE 8. MOUNT
4. BOLT 9. SPACER
5. WASHER

5000-6
Stop the engine and check for oil leaks, put a shop
STEP 14 cloth in the turbo opening.
Have another person hold the steering control valve
in position. STEP 24
Check the oil level in the hydraulic reservoir. Add oil
STEP 15 as required. See Section 1002.
If your machine is equipped with a cab go to step 16.
If it is equipped with a canopy go to step 18. STEP 25
NOTE: Refer to illustration page 5.
STEP 16
Put the spacer (9), mount (8), and steering control
valve (7) into position.
STEP 17
Install the mounts (6), washers (5), and bolts (4). Go
to step 20.
STEP 18
Put the steering control valve (3) into position.
BD01B329
Push the wires for the air restriction switch through

STEP 19 the hole in the engine curtain. Put the engine curtain
Install the washers (2) and bolts (1) that fasten the in position on the mounting bracket and install the
steering control valve (3) to the steering column. bolts that fasten the engine curtain to the mounting
bracket.
STEP 20
STEP 26
BD08B044-01
Connect hoses to the fittings on the steering control BD01B307

valve, remove the tags. Put the fixed hood and air cleaner assembly in
position on the uprights. Install the bolts and flat
STEP 21 washers that fasten the fixed hood to the uprights.
Remove the shop cloth from the turbo opening, start
and run the engine at low idle.
STEP 22
Turn the steering wheel all the way to the right and
left several times to remove any air from the steering
system.

5000-7
STEP 27 STEP 28
BD01B323 BD01B324
Remove the shop cloth from the turbo opening. Connect the electrical connector for the air restriction
Connect the air cleaner hose to the turbo. Tighten the switch. Install a new tie strap.
clamp on the air cleaner hose.
STEP 29
Close the hood.

5000-8
8 4 7
7
5
6 5
8
6
3
1 2
BC08B080
1. HYDRAULIC FILTER 4. RETURN HOSE 7. LEFT HOSE FOR
2. HYDRAULIC PUMP 5. PRESSURE HOSE STEERING CYLINDER
3. STEERING PUMP 6. RIGHT HOSE FOR STEERING CYLINDER 8. LOAD SENSE HOSE
STEERING CONTROL VALVE HYDRAULIC INSTALLATION 580M, 580SM AND 590SM

5000-9
8 4
7
7 5 5
8
6
6
5
1 8
2
BC08B082
1. HYDRAULIC FILTER 4. RETURN HOSE 7. LEFT HOSE FOR
2. LOADER VALVE 5. PRESSURE HOSE STEERING CYLINDER
3. STEERING PUMP 6. RIGHT HOSE FOR STEERING CYLINDER 8. LOAD SENSE HOSE
STEERING CONTROL VALVE HYDRAULIC INSTALLATION 580SM+ AND 590SM+

5000-10
1 5
3 4
6
7
BC08B083
1. PRESSURE HOSE TO SOLENOID 4. RETURN HOSE TO RESERVOIR 7. HYDRAULIC FILTER
2. STEERING PUMP 5. COMFORT STEER SOLENOID
3. PRESSURE HOSE FROM SOLENOID 6. SOLENOID TO TANK FITTING
COMFORT STEERING VALVE HYDRAULIC INSTALLATION

5000-11
STEERING COLUMN
Removal STEP 10
Disconnect the connectors from the rocker switches
STEP 1 (14) in the front console (15).
parking brake. STEP 11
Remove the bolts that fasten the instrument console
STEP 2 cover (15) to the cab.
Lower the bucket to the floor.
STEP 12
NOTE: Refer to illustration on page 13 for the
If equipped, remove the filler cap from the windshield
following steps.
washer reservoir. Remove the front console (15).
STEP 3 STEP 13
Remove the cover (1) from the steering wheel (4).
The cover is held by the fit of an O-ring (2).
If it is equipped with a canopy go to step 16.
STEP 4 NOTE: Refer to illustration on page 14 for steps 14
Loosen and remove the nut (3) that holds the and 15.
steering wheel (4) in place. Remove the steering
wheel (4). STEP 14
Remove the nuts (1) from the steering column (5).
STEP 5
Remove the screws (5) that fasten the upper and STEP 15
lower steering column cover (6 and 8) in place. Remove the nuts (2), washers (3), and U-bolt (4)
from the steering column (5). Go to step 18.
STEP 6 NOTE: Refer to illustration on page 15 for steps 16
Remove the upper steering column cover (6). and 17.
Disconnect the wiring connector from the turn signal
indicator (7). STEP 16
STEP 7 (3) in place and remove the bolts (1) and washers (2)
Remove the lower steer ing column cover (8). that fasten the steering column (8) to the canopy and
Disconnect the wiring connector from the turn the steering control valve (3).
signal/driving light switch (9).
STEP 17
STEP 8 Remove the nuts (4), washers (5), U-bolt (6), and
Disconnect the connector (10) from the transmission spacer (7) from the steering column (8).
shift lever (13).
STEP 18
STEP 9 Remove the steering column from the machine.
Loosen and remove the screws (12) that fasten the
transmission shift lever (13) to the steering column.
Remove the transmission shift lever (13).

5000-12
Install the bolts that fasten the front console cover
STEP 19 (15) to the cab.
If it is equipped with a canopy go to step 22. STEP 27
Connect the connectors to the rocker switches (14) in
NOTE: Refer to illustration on page 14 for steps 20
the front console (15).
and 21.
STEP 28
STEP 20
Put the transmission shift lever (13) in place. Install
Grease the splines of the steering column and
the screws (12) that fasten the transmission shift
control valve with high temperature grease. Put the
lever (13) to the steering column.
steering column (5) in place and install the nuts (1).
Tighten the nuts (1) to a torque of 46 to 50 Nm (34 to
37 pound feet). STEP 29
Connect the connector (10) to the transmission shift
STEP 21 lever.
Install the U-bolt (4), washers (3), and nuts (2). Go to
step 25. STEP 30
Connect the wir ing connector (9) to the tur n
NOTE: Refer to illustration on page 15 for steps 22 signal/driving light switch. Put the lower steering
through 24. column cover (8) in place.
STEP 22 STEP 31
Grease the splines of the steering column and control
valve with high temperature grease. Put the steering Connect the wiring connector to the turn signal
column in place on the machine. indicator (7). Install the upper steering column cover
(6).
STEP 23
STEP 32
(3) in place. Install the washers (2) and bolts (1) that Install the screws (5) that fasten the upper and lower
fasten the steering column (8) to the canopy and the steering column cover (6 and 8) in place.
steering control valve (3). Tighten the bolts (1) to a
torque of 46 to 50 Nm (34 to 37 pound feet). STEP 33
Put the steering wheel (4) in place. Install the nut (3)
STEP 24 that holds the steering wheel in place. Tighten the
Install the spacer (7), U-bolt (6), washers (5), and nut to a torque of 41 to 54 Nm (30 to 40 pound feet)
nuts (4).
STEP 34
NOTE: Refer to illustration on page 13 for the
Install the cover (1) on the steering wheel (4). The
following steps.
cover is held by the fit of an O-ring (2).
STEP 25 STEP 35
Put the front console cover (15) in position. If
With the engine off, turn the steering wheel about 5
equipped, install the cap on the windshield washer
degrees in either direction. Effort will be light when
reservoir.
w o r k i n g a g a i n s t t h e s p r i n g s, bu t s t i f f w h e n
approaching manual steer. Release the wheel when
approaching manual steer, and confirm the wheel
returns back to neutral freely. If not free, check the
bind.

5000-13
2
3
4
14
15
6 9
5
13
11 8
12 12
10
GS99J508
1. COVER 6. UPPER STEERING COLUMN COVER 11. POWER SHIFT CONTROLLER WIRE HARNESS
2. O-RING 7. TURN SIGNAL INDICATOR CONNECTOR 12. SCREW
3. NUT 8. LOWER STEERING WHEEL COLUMN COVER 13. TRANSMISSION SHIFT LEVER
4. STEERING WHEEL 9. TURN SIGNAL/DRIVING LIGHT SWITCH 14. ROCKER SWITCHES
5. BOLT 10. TRANSMISSION SHIFT LEVER CONNECTOR 15. FRONT CONSOLE COVER
FRONT CONSOLE

5000-14
2
1 3
1
4
BS01C010
1. NUT 5. COLUMN
2. NUT 6. U-BOLT MOUNTING HOLES FOR TILT COLUMNS
3. WASHER 7. U-BOLT MOUNTING HOLE FOR NON-TILT COLUMNS
4. U-BOLT
CAB MODELS

5000-15
8
7
6 1 3
2
BS01C009
1. BOLT 4. NUT 7. SPACER
2. WASHER 5. WASHER 8. STEERING COLUMN
3. STEERING CONTROL VALVE 6. U-BOLT 9. U-BOLT MOUNTING HOLES FOR NON-TILT COLUMNS
CANOPY MODELS

5000-16
STEERING CYLINDER, TWO WHEEL DRIVE MACHINES
Removal Installation
STEP 1 STEP 6
Clean the hose connection at the steering cylinder. Install the steering cylinder on the axle and install the
bolts.
STEP 2
Put and identification tag on one of the hoses. STEP 7
Torque the bolts to 335 Nm (247 pound feet).
STEP 3
Disconnect the hoses from the steering cylinder and STEP 8
cap the fittings and plug the hoses. Install the tie rod ends and torque to 165 Nm
(122 pound feet).
STEP 4
STEP 9
Connect the hoses to the steering cylinder.
STEP 10
Start and run the engine at low idle.
STEP 11
system.
BC03N152 STEP 12
Loosen and remove the tie rod end. Stop the engine and check for oil leaks.
STEP 5 STEP 13
Check the level of the oil in the reservoir and add oil
as required.
STEP 14
Grease the pins for the steering links.
STEP 15
Check and adjust the toe-in according to the
instructions in Section 5005.
BC03N151
Remove the mounting bolts for the cylinder, remove

the steering cylinder from the axle.

5000-17
STEERING CYLINDER, FOUR WHEEL DRIVE MACHINES
Removal STEP 6
NOTE: The following photographs show the steering
cylinder being removed from the axle with the axle
removed from the machine. It is not necessary to
remove the axle from the machine to remove the
steering cylinder.
STEP 1
Clean the hose connections and the steering
cylinder.
STEP 2
Fasten an identification tag to one of the hoses to the
GS99J518
steering cylinder.
Remove the nut and remove the ball joint from the
arm.
STEP 3
Disconnect the hoses from the steering cylinder. STEP 7
Install a plug is each hose and a cap on each fitting.
Repeat steps 4, 5, and 6 for the other end of the axle.
NOTE: Some of the photo may look different than
your machine. The procedure is the same. STEP 8
STEP 4
GS99J519
Install the 380100091 or 380100092 tool on the flats

GS99J516 of the piston rod and install a wrench on the tie rod.
Loosen the nut several turns. Do not remove the nut Prevent the piston rod from turning and loosen the tie
at this time. rod.
STEP 5 STEP 9
Install the CAS10486 puller and tighten the screw to Remove the tie rod and ball joint assembly from the
loosen the ball joint. piston rod.

5000-18
STEP 14
Install the steering cylinder in the axle.
STEP 15
bd08b041-01
Loosen and remove the bolts that fasten the steering

cylinder to the axle.
STEP 11
bd08b040-01
Install the bolts that fasten the steering cylinder to the

axle. Tighten the bolts to 120Nm (89 pound feet).
STEP 16
Start the ball joint assembly and tie rod onto the
piston rod.
STEP 17
BD08B042-01
A hose fitting will be installed in your steering

cylinder. Remove the hose fitting.
STEP 12
GS99J525
Install the 380100091 or 380100092 tool on the flats

of the piston rod and install a wrench on the tie rod.
Prevent the piston rod from turning the tie rod.
Tighten the tie rod to a torque of 300 Nm (222 pound
feet).
bd08b043-01
Hit the steering cylinder with a soft hammer to drive

the steering cylinder out of the axle.
STEP 13
Remove the steering cylinder from the axle.
5000-19
STEP 18 STEP 20
Repeat steps 18, 19, and 20 for the other end of the
axle.
STEP 21
Connect the hoses to the fittings in the steering
cylinder.
STEP 22
Start and run the engine at low idle.
STEP 23
GS99J518
Install the ball joint in the arm. system.
STEP 19 STEP 24
Stop the engine and check for oil leaks.
STEP 25
Check the level of the oil in the reservoir and add oil
as required.
GS99J526
Install the nut on the ball joint and tighten the nut to
165 Nm (122 pound feet) for the 580M, 580SM and
580SM +. Tighten to 220 Nm (162 pound feet) for the
590SM.

5000-20
FRONT AXLE - TWO WHEEL DRIVE MACHINES
NOTE: Refer to illustration on page 21.
STEP 11
STEP 1 Raise the axle into alignment with the machine.
Raise the front wheels above the floor and use
suitable stands to hold the machine in place. STEP 12
Install a spacer (5) between the front of the axle and
STEP 2 the frame.
Loosen and remove the wheel bolts and remove the
wheels. STEP 13
Start the pivot pin (4) into the frame, spacer(s) (5)
STEP 3 and axle.
Fasten an identification tag to one of the hoses for
the steering cylinder. STEP 14
Drive the pivot pin (4) into the rear pivot of the axle
STEP 4 but not through the rear pivot.
Disconnect the hoses from the fittings in the steering
cylinder. Install a plug in each hose and a cap on STEP 15
each fitting. Install the washer (2) between the rear of the axle
and the frame.
STEP 5 NOTE: Remove or install washer(s) (2) as required
Loosen and remove the lubrication hose (1) from the between the axle and the frame to remove any and
fitting. play.
STEP 6 STEP 16
Put a floor jack under the axle to hold the axle in Drive the pivot pin (4) through the rear pivot and the
position. frame.
STEP 7 STEP 17
Remove snap ring (3) from the pivot pin (4), remove Install the snap rings.
the thrust washer.
STEP 18
STEP 8 Connect the lubrication hose (1) to the fitting.
Drive the pivot pin (4) out of the frame.
STEP 19
STEP 9 Loosen and remove the plugs from the hoses and the
Spacers are used at the front and rear of the axle, caps from the fittings for the steering cylinder.
between the axle and the frame. Lower the axle and
remove the spacers (5). STEP 20
Connect the hoses to the steering cylinder.
STEP 10
Remove the axle from under the machine. STEP 21
Install the wheels and wheel bolts. DO NOT use an
impact wrench to tighten the wheel bolts.

5000-21
STEP 22 STEP 24
Tighten the bolts to 251 Nm (185 pound feet). Lubricate the pivot pin (4) for the axle.
STEP 23 STEP 25
Remove the stands and lower the wheels to the floor. Check and adjust the toe-in according to the
instructions in Section 5005.
4
1
BC03N150
1. REMOTE GREASE HOSE 3. SNAP RING 5. SPACER

2. WASHER THRUST 4. PIVOT PIN
TWO WHEEL DRIVE AXLE

5000-22
FRONT AXLE - FOUR WHEEL DRIVE MACHINES
Removal STEP 11
Raise the front wheels above the floor and use
suitable stands to hold the machine in place.
STEP 1 STEP 12
If your machine has a 117 liters (31 U.S. gallon) fuel
Install blocks between the axle (1) stops and the
tank go to step 2, if it has a 151 liters (40 U.S. gallon)
frame to prevent the axle from tilting.
or a 159 liters (42 U.S. gallon) fuel tank go to step 5.
STEP 13
STEP 2
Loosen and remove the wheel nuts (8) and hardened
Put a floor jack under the drive shaft guard (13) to
washers (7) and remove the wheels.
hold the drive shaft guard in position.
STEP 14
STEP 3
Fasten an identification tag to one of the hoses for
Loosen and remove the bolts (12) and flat washers
the steering cylinder.
(11) that fasten the drive shaft guard (13) to the
frame.
STEP 15
STEP 4 Disconnect the hoses from the fittings in the steering
cylinder. Install a plug in each hose and a cap on
each fitting.
under the machine. Go to step 10.
STEP 16
STEP 5
Disconnect the lubrication hose (2) from the axle (1).
Put a floor jack under the drive shaft guard (14) to
hold the drive shaft guard in position.
STEP 17
STEP 6 Put a floor jack under the axle (1) to hold the axle in
position.
Loosen and remove the nut (15), bolt (17), and
washer (16) from the bracket (20).
STEP 18
STEP 7 Remove the snap ring (28) from the rear of the pivot
pin (6).
Loosen and remove the bolts (21) and flat washers
(22) that fasten the drive shaft guard (14) to the
frame. Do not remove the bolt (18) and washer (19) STEP 19
from the bracket (20) at this time. Remove bolt (3) and install a slide hammer into the
pivot pin (6), pull the pivot pin (6) out of the frame.
STEP 8
Lower the drive shaft guard (14) and remove it from STEP 20
under the machine. Washers are used at the front and rear of the axle
(1), between the axle and the frame. Lower the axle
STEP 9 (1) and remove the washers (5).
Remove the bolt (18) and washer (19) that fasten the
bracket (20) to the machine, remove the bracket (20). STEP 21
Remove the axle (1) from under the machine.
STEP 10
Loosen and remove the bolts (27) and retainers (26)
that fasten the drive shaft (25) to the flange on the
transmission. Remove the drive shaft (25).

5000-23
Install the wheels, hardened washers (7), and nuts
STEP 22 (8).
Raise the axle (1) into alignment with the frame.
STEP 36
STEP 23 Tighten the wheel nuts (8) to 122 +3 -10 Nm (90 +2
Install the pivot pin (6) with the bolt hole end of the -7 pound feet). Then tur n nut an additional 90
pivot pin toward the front of the machine. degrees ± 5 degrees.
STEP 24 STEP 37
Install a washer (5) between the front of the axle (1) Remove the blocks from between the axle (1) stops
and the frame. Use washer(s) as required for and the frame.
minimum end play between the frame and the axle
(1). STEP 38
Remove the stands and lower the wheels to the floor.
STEP 25
Start the pivot pin (6) into the frame, washer (5), and STEP 39
axle (1). Lubricate the pivot pin (6) for the axle (1).
STEP 26 STEP 40
Drive the pivot pin (6) into the rear pivot of the axle Install the drive shaft (25). Install the bolts (27) and
(1) but not through the rear pivot. retainers (26) that fasten the drive shaft (25) to the
flange on the transmission.
STEP 27
Install a washer (5) between the rear of the axle (1) STEP 41
and the frame. Tighten the bolts (27) to 33 to 39 Nm (24 to 29
pound feet).
STEP 28
Drive the pivot pin (6) through the rear pivot and the STEP 42
frame. If your machine has a 117 liters (31 U.S. gallon) fuel
tank go to step 43, if it has a 151 liter (40 U.S. gallon)
STEP 29 or 159 liter (42 U.S. gallon) fuel tank go to step 46.
Install the snap ring (28) on the pivot pin (6).
STEP 43
STEP 30 Raise the drive shaft guard (13) in position.
Drive the pivot pin (6) toward the front of the machine NOTE: If your machine is equipped with a powershift
as far as possible. transmission, install O-ring (9) and spacer (10) on the
bolts, use the O-ring to hold the hardware in place.
STEP 31
Check the end play between the frame and the snap STEP 44
ring (4) on the pivot pin (6) at the front of the Install the bolts (12) and flat washers (11) that fasten
machine. Use washers (5) as required to remove any the drive shaft guard (13) to the frame.
end play.
STEP 45
STEP 32 Torque the bolts (12) to 50 to 90 Nm (36.5 to 66
Connect the lubrication hose (2) to the axle (1). pound feet).
STEP 33 STEP 46
Loosen and remove the plugs from the hoses and the Raise the drive shaft guard (14) into position.
caps from the fittings for the steering cylinder.
NOTE: If your machine is equipped with a powershift
STEP 34 transmission, install O-ring (23) and spacer (24) on
Connect the hoses to the steering cylinder. the bolts, use the O-ring to hold the hardware in
place.

5000-24
STEP 47 STEP 50
Install the bolts (21) and flat washers (22) that fasten Install the washer (19) and bolt (18) that fasten the
the drive shaft guard (14) to the frame. bracket (20) to the machine.
NOTE: f your machine is equipped with a powershift
STEP 48 transmission, install O-ring (23) and spacer (24) on
Torque the bolts (21) to 50 to 90 Nm (36.5 to 66 the bolt, use the O-ring to hold the hardware in place.
pound feet).
STEP 51
STEP 49 Torque the bolt (18) to 50 to 90 Nm (36.5 to 66 pound
Put the bracket (20) into place and install the washer feet).
(17), bolt (16), and nut (15).

5000-25
I
3
2
1
4
5
6
5
28
7
8
25
24
23
20 27
9
22 26
10
21
11
19
12
18 14
17 16 15 13
BC01B093
1. AXLE 8. NUT 15. NUT 22. WASHER

2. LUBRICATION HOSE 9. O-RING 16. WASHER 23. SPACER
3. BOLT 10. SPACER 17. BOLT 24. O-RING
4. SNAP RING 11. WASHER 18. BOLT 25. DRIVE SHAFT
5. SPACER 12. BOLT 19. WASHER 26. RETAINER
6. PIVOT PIN 13. DRIVE SHAFT GUARD 580M 20. BRACKET 27. BOLT
7. WASHER 14. DRIVE SHAFT GUARD ALL SM’S 21. BOLT 28. SNAP RING
FOUR WHEEL DRIVE AXLE

5000-26
NOTES

5001
Section
5001
STEERING SPECIFICATIONS,
PRESSURE CHECKS AND TROUBLESHOOTING

5001-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHECKING THE PRESSURE SETTING OF THE RELIEF VALVE 580M, 580SM, AND 590SM . . . . . . . . . . . . 5
CHECKING THE PRESSURE SETTING OF THE RELIEF VALVE 580SM+ AND 590SM+ . . . . . . . . . . . . . . . . 6
CHECKING PISTON PACKING FOR THE STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Optional Comfort Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5001-3
SPECIFICATIONS
Location of steering relief valve ........................................................................................... In steering control valve
Pressure setting..................................................................................................... 172 +0 -10 bar (2500 +0 -150 psi)
SPECIAL TOOL
B877558U
CAS1804 PRESSURE FITTING KIT

5001-4
TROUBLESHOOTING PROCEDURE
Check the machine for oil leaks and damaged or missing parts. Repair as required.
Is the oil in the hydraulic reservoir at the Fill reservoir to proper level, See Section
No
correct level? 1002.
Yes
With the oil at operating temperature, operate S e e S e c t i o n 8 0 0 2 fo r t r o u bl e s h o o t i n g

all systems. Is the problem in the steering No instructions.
system only?
Yes
See the hydraulic schematic in the rear pocket Connect the hoses according the hydraulic
and check the hose connections. Are the No schematic.
hoses connected correctly?
Yes
With the oil at operating temperature and the Does the steering control valve return to
engine running at low idle, is the steering No NEUTRAL when the steering wheel is not
wheel difficult to turn? being turned?
Yes No
Check the setting of the relief valve according

to the instructions in this section. Is the setting Replace or repair the steering control valve
No
correct? according to instructions in Section 5002.
Yes
580SM+ and 590SM+. Check to see that the

spool for the priority valve in the inlet of the
No Troubleshooting complete.
loader control valve moves freely. Repair or
replace as required. Is there still a problem?
Yes
580M, 580SM and 590SM. Check to see that

the spool for the priority valve in pump moves
freely. Repair or replace as required. Is there
still a problem?
Yes
Continued

5001-5
Check the piston packing for the steering

cylinder according to instructions in this Repair as required according to instructions in
No
section. Is the piston packing good? Section 5003.
Yes
Do the flowmeter test for the hydraulic pump R e p l a c e o r r e p a i r t h e hy d r a u l i c p u m p

according the instructions in Section 8002. Is No according to the instructions in Section 8004.
the hydraulic pump good?
Yes
Replace or repair the steering control valve

according to the instructions in Section 5002.
COMFORT STEER TROUBLESHOOTING
When Comfort Steer switch is activated does

No Is there power at the the solenoid?
steering get easier?
Yes Yes
Comfort Steer is operating correctly. Replace solenoid No
C h e c k f u s e a n d sw i t c h .
Replace fuse or switch as
needed.

5001-6
CHECKING THE PRESSURE SETTING OF THE RELIEF VALVE 580M, 580SM,
AND 590SM
1. Park the machine on a level surface. Put the 3. See the illustration below. Use a pressure gauge
backhoe in the transport position and lower the with a capacity of at least 4000 psi (276 bar).
loader bucket to the floor. Connect the pressure gauge to the quick
2. The oil must be at operating temperature. To disconnect fitting at the test port. The quick
heat the oil, do the following steps: disconnect fitting is located on the pump at the
rear of the transmission.
A. With the engine running at full throttle, hold
the loader control lever in the ROLLBACK 4. With the engine running at full throttle, turn and
position for 15 seconds. hold the steering wheel all the way to the right or
to the left and read the gauge. Make a record of
B. Put the loader control lever in the NEUTRAL the reading.
position for 15 seconds.
5. Decrease the engine speed to low idle for two
C. Repeat steps A and B until the temperature of minutes and stop the engine.
the oil is 125°F (51°C) or the side of the
reservoir is very warm. 6. Compare the reading with the specification on
page 3. If the reading is not correct, see Section
5002 and repair or replace the steering control
valve.
4 3
1 1
BC04A021
1. TO INLET OF LOADER CONTROL VALVE 3. HYDRAULIC PUMP 580M
2. TEST PORT 1 4. HYDRAULIC PUMP SM ALL

5001-7
CHECKING THE PRESSURE SETTING OF THE RELIEF VALVE 580SM+ AND

590SM+
1. Park the machine on a level surface. Put the 4. With the engine running at full throttle, turn and
backhoe in the transport position and lower the hold the steering wheel all the way to the right or
loader bucket to the floor. to the left and read the gauge. Make a record of
the reading.
2. The oil must be at operating temperature. To
heat the oil, do the following steps: 5. Decrease the engine speed to low idle for two
minutes and stop the engine.
A. Run the engine at full throttle, with the boom in
the travel lock position, hold the boom control 6. Compare the reading with the specification on
lever in the LOWER position (lever pushed page 3. If the reading is not correct, see Section
away from seat) for 15 seconds. 5002 and repair or replace the steering control
valve.
B. Put the boom control lever in the NEUTRAL
C. Repeat steps A and B until the temperature of
reservoir is very warm.
3. See illustration. Use a pressure gauge with a
capacity of at least 4000 psi (276 bar). Connect
the pressure gauge to the quick disconnect fitting
that was installed at “D” port.
BD08B039
NOTE: A Tee connection will have to be installed at

the “D” port on the loader valve for steering pressure
tests.

5001-8
CHECKING PISTON PACKING FOR THE STEERING CYLINDER
1. Apply the parking brake and lower the loader 5. Start the engine and run the engine at full
bucket to the floor. throttle.
2. Turn the steering wheel all the way to the right 6. Turn the steering wheel all the way to the right
and stop the engine. and continue to turn the steering wheel to the
3. Disconnect the hose at the left side of the right while another person checks for leakage at
steering cylinder. the open fitting.
4. Install a plug in the hose. 7. If there is constant leakage, the piston packing is
damaged and must be repaired. See Section
5003 for repair instructions.

5001-9
ILLUSTRATIONS
9 6
4 2 3 1
2 1
5 7
4
BC03C188/BC03C190
1. INLET 4. CHECK VALVE 7. GEROTOR

2. OUTLET 5. SPOOL AND SLEEVE ASSEMBLY 8. STEERING RELIEF VALVE
3. PILOT 6. DRIVE LINK 9. ANTI-CAVITATION RELIEF VALVE

5001-10
12
11 10 9
BC08B040
OPTIONAL COMFORT STEERING CONTROL VALVE
1. ANTI-CAVITATION CHECK VALVE 4. SPOOL 7. SPOOL AND SLEEVE ASSEMBLY 10. LOAD SENSE
2. GEROTOR 5. SOLENOID 8. CHECK VALVE 11. RETURN
3. GEROTOR 6. DRIVE LINK 9. INLET 12. STEERING RELIEF VALVE

5002
Section
5002

STANDARD STEERING

5002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5002-3
SPECIFICATIONS
Rotor and Stator clearance........................................................................................................0.13 mm (0.005 inch)
Special torques
Allen Head Plug ........................................................................................................... 11 Nm (100 pound-inches)
Ferry Head Screws................................................................................... 25 to 31 Nm (225 to 275 pound-inches)
SPECIAL TOOLS
B785606M BD04H050
CAS-1239 CENTERING SPRING TOOL 380002000 AND 380002001

5002-4
DISASSEMBLY
STEP 1 STEP 4
BD04H001
M a r k t h e p u m p fo r p r o p e r a l i g n m e n t d u r i n g BD04H004
assembly. Remove the O-ring from the stator of the metering

gear set.
STEP 2
STEP 5
BD04H002
Put the steering control valve in the vise so that the

end plate is up. BD04H005
Lift the spacer plate as from the body.

STEP 3
STEP 6
BD04H003
Remove the cap screws and end cap. BD04H006
Remove the metering gear from the pump.

5002-5
STEP 7 STEP 10
BD04H011
BD04H007 Find the manual steering check valve. Remove the

Remove the O-ring from the spacer plate, remove manual steering check valve ball and roll pin.
the spacer plate. Remove and discard the O-ring
NOTE: The manual steering check valve is located
from the body.
in the bolt hole with the thread instert.
STEP 8 STEP 11
1 1
BD04H009
BD04H012
Find the anticavitation valves (1) in the body. Put
Pull the sleeve and spool out of the body.
identification marks on the body for use during
assembly. NOTE: The photo show the steering control in a
horizontal position, disassemble steering control unit
STEP 9 in a vertical position, the pin that links the sleeve,
spool, and driver could possibly slip and lock the
parts in the housing.
BD04H010
Remove the 4 springs, the pins, and the balls from

the ports in the body.

5002-6
STEP 12 STEP 15
BD04H013 BD04H016
Use a punch to push the pin out of the sleeve and Remove the spring retainer.
spool.
NOTE: Hold the spring into the sleeve and spool
while removing the ring, they can come out
STEP 13 unexpectedly.
STEP 16
BD04H014
Remove the drive shaft from the sleeve and spool.

BD04H017
STEP 14 Remove the springs and centering spacers from the
sleeve and spool.
STEP 17
BD04H015
Remove the thrust washer, the thrust bearing, and

lower thrust washer.
BD04H019
Pull the spool straight out of the sleeve.

5002-7
STEP 18 STEP 20
BD04H020 BD04H022
There are four centering springs and three spacers. Remove the spool seal.
STEP 19
BD04H021
Remove the seal from the gland.

5002-8
INSPECTION
Use cleaning solvent to clean all parts. Put the parts STEP 22
on paper towels until the parts are dry. Do not use
cloths to wipe the parts dry. 2
Check all machined surfaces for wear or damage. If 1
there are rough places on the ends of the stator and
rotor or on the machined surfaces on the body, end
plate, or spacer plate, use 600 grit emery cloth to
make the surfaces smooth. Put the emery cloth on a
flat surface. If the emery cloth is new, move a piece
of steel across the emery cloth six times to remove
the sharp pieces of grit. Move the rotor, stator, body,
end plate, or spacer across the emery cloth six times. 1
Then check to see if the rough places have been
removed. Use this method until all rough places are
B1759A88J
gone. Make sure that you keep the part flat on the
emery cloth as you move the part across the emery Inspect the thrust washers (1) and the thrust bearing
cloth. Use cleaning solvent to remove any grit from (2) for damage or wear. Use new parts as required.
the parts.
STEP 23
STEP 21 Inspect the springs, the pins, and the balls of the
anticavitation valve for damage or wear. Use new
3 parts as required.
STEP 24
2 Inspect the roll pin and ball of the manual steering
valve for damage or wear. Use new par ts as
required.
1
STEP 25
B1757A88J
If the spool (1), the sleeve (2), or the bore in the body
(3) of the steering control valve is damaged or worn,
use a complete new steering control valve. The spool
(1), the sleeve (2), and the body (3) of the steering
control valve are not available separately.
BD04H049
Use a feeler gauge to measure the clearance

between the rotor and the stator. If the clearance is
more than 0.13 mm (0.005 inch), a new metering
gear set must be used.

5002-9
ASSEMBLY
STEP 26 STEP 29
BD04H024 BD04H027
Install the sleeve into the body. Press the seal cup into the “O” ring.
STEP 27 STEP 30
BD04H025 BD04H028
Put the “O” ring of the two piece seal on the recessed Lubricate the seal with hydraulic oil.
tip of the plunger.
STEP 31
STEP 28
BDO4H029
BD04H026 Install the plunger into the bore of the sleeve.

Place the seal cup onto the recessed tip of the
plunger.
NOTE: Flat portion of the seal should be facing you.

5002-10
STEP 32 STEP 35
Use clean hydraulic oil to lubricate the inside of the
sleeve.
STEP 36
Use clean hydraulic oil to lubricate the outside of the
spool.
STEP 37
BD03H030
Push the plunger into the sleeve until it bottoms out,

remove the special tools.
STEP 33
BD04H033
Install the spool in the sleeve. The spool must be

installed straight into the sleeve. Turn the spool in
both directions as the spool is pushed into the
sleeve.
STEP 38
BD04H031
Inspect the seal to make sure that it is seated

properly in the body.
NOTE: Seal and “O” ring must both be within shaft
seal counterbore of the housing.
STEP 34
BD04H020
There are four centering springs and three spacers.
B8461588M
Install the seal in the gland so that the lip is toward

the outside of the body. Drive the seal into the gland
until the seal stops moving.

5002-11
STEP 39 STEP 42
BD04H034 BD04H037
Insert the spring spacers and springs one at a time Install the inner thrust washer, the thrust bearing, and
into the spool and sleeve. the outer thrust washer on the spool.
STEP 40 STEP 43
BD04H035 BD04H039
Place the spring retainer onto the sleeve. Put the drive shaft into the spool.
STEP 41 STEP 44
BD04H036
Work the retaining ring into place over the springs. BD04H040
Align the holes for the sleeve, spool, and drive shaft.
Press the pin into the sleeve until it is flush with the
sleeve.

5002-12
STEP 45 STEP 47
BD04H041 BD04H043
Find the port with the screw insert, instal the ball and The pin can move out of the sleeve and the spool. If
roll pin for the manual steering check valve. the pin moves out of the sleeve and the spool, the pin
can keep the sleeve and the spool from being
STEP 46 pushed into the body. Assembly the steering control
unit in a vertical position.
NOTE: The photo show the steering control in a
horizontal position, assemble steering control unit in
a vertical position, the pin that links the sleeve, spool,
and driver could possibly slip and lock the parts in the
housing.
STEP 48
BD04H042
Install the anticavitation balls, pins, and springs into

the holes that were marked during disassembly.
BD04H044
Install a new O-ring in the groove in the body, place

the spacer on the body. Put a new O-ring in the
spacer.

5002-13
STEP 49 STEP 52
1 6
3 4
5 2
7
BD04H045 BC04H022
Align the timing mark on the drive shaft with a valley Torque the cap screws to a torque of 11 to 17 Nm
of the gerotor. (100 to 150 pound-inches) in the sequence shown.
Then final torque the cap screws to a final torque of
STEP 50 25 to 31 Nm (225 to 275 pound-inches) in the
sequence shown.
STEP 53
Assembled unit should rotate smoothly.
BD04H046
Align the marks made during disassembly, install the

gerotor spacer,
STEP 51
BD04H047
Install a new O-ring in the gerotor spacer. Install the

end plate on the metering gear set. Align the holes in
the end plate with the holes in the stator.

5002-14
17
18
19
20
21
22
23
24
10
16
11
12
13
1
14
15
2
3
4
5 6
7
8
9
BS04H021
1. CAP SCREWS 7. O-RING 13. SLEEVE 19. NEEDLE THRUST BEARING
2. END PLATE 8. GEROTOR 14. PIN 20. BREARING RACE
3. SPRING 9. O-RING 15. SRING RETAINER 21. O-RING
4. PIN 10. DRIVE SHAFT 16. CENTERING SPRING 22. SEAL HALF
5. SPRING 11. SPACER PLATE 17. O-RING 23. HOUSING
6. BALL 12. SPOOL 18. BREARING RACE 24. DUST SEAL

Section
5003
5003
STEERING CYLINDERS

5003-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TWO WHEEL DRIVE STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FOUR WHEEL DRIVE STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5003-3
SPECIFICATIONS
Four wheel drive steering cylinder mounting screws .......................................................................120 Nm (89 lb-ft)
Two wheel drive steering cylinder mounting screws .......................................................................335 Nm (247 lb-ft)

5003-4
TWO WHEEL DRIVE STEERING CYLINDER
Disassembly Assembly
1. Clean the outside of the steering cylinder. 13. Install a new seals and O-rings.
2. Fasten the steering cylinder in a vise or other 14. Fasten the tube (5) in the vise or other holding
holding equipment. Be careful to prevent equipment. Be careful to prevent damage to the
damage to the tube (5). tube (5).
3. Remove the right (7) and left (1) end caps. 15. Lubricated the bore of the tube (5) with clean oil.
4. Pull the piston rod (3) out of the tube (5). 16. Lubricate the O-rings (6) on both end caps (1
and 7) and the bore of both end caps (1 and 7)
5. Remove and discard all O-rings and seals.
with clean oil.
Inspection 17. Lubricate the piston (3) with clean oil.
6. Clean all parts in cleaning solvent. 18. Push the piston rod assembly (3) straight into the
tube (5).
7. Illuminate the inside of the tube (5). Inspect the
inside of the tube (5) for deep grooves and other 19. Carefully start the end caps (1 and 7) onto the
damage. If there is damage to the tube (5), a piston (3).
new steering cylinder must be used. 20. Make sure the ports in both glands (8) are
8. Check to be sure that the piston rod (3) is installed correctly and drive the end caps (1 and
straight. If the piston rod (3) is not straight, a new 7) into the tube (5).
steering cylinder must be used.
9. Inspect the piston (8) for damage and wear. If the
piston (8) is damaged, or worn, a new steering
cylinder must be used.
10. Remove the small scratches on the piston rod (3)
and inside the tube (5) with emery cloth of
medium grit. Use emery cloth with a rotar y
motion.
11. Inspect both ends of the tube (5) for sharp edges
that will cut the end cap O-rings (1 and 7) and
remove the sharp edges as necessary.
12. Inspect all components for rust. Clean and
remove rust as necessary.

5003-5
1 3 6
2
BC03N154
1. LEFT END CAP 3. PISTON SHAFT 5. TUBE 7. RIGHT END CAP

2. SEALS 4. O RINGS 6. O RINGS 8. PISTON
TWO WHEEL DRIVE STEERING CYLINDER - EXPLODED VIEW

5003-6
FOUR WHEEL DRIVE STEERING CYLINDER
Disassembly STEP 4
STEP 1
Remove the tie rod ball joint assembly.
STEP 2
BD08B192-01
Remove the gland from the piston rod assembly.
STEP 5
BD08B190-01
Fasten the tube in a vise or other holding equipment.
Do not damage the tube.
STEP 3
BD08B193-01
Use a soft faced hammer and drive the piston against

the gland, remove the gland from the tube.
STEP 6
BD08B191-01
Use a soft faced hammer and separate the gland
from the tube.
BD08B194-01
Pull the piston rod assembly straight out of the tube
to prevent damage to the tube.

5003-7
STEP 7 Inspection
1. Discard the parts that were removed from the
glands and piston rod assembly.
2. Clean all parts in cleaning solvent.
3. Inspect the gland, piston rod assembly, and the
tube for damage and wear. These parts are not
serviced separately, if these parts need to be
replaced, a new steering cylinder must be used.
Assembly
STEP 10
BD08B195-01
Remove the gland from the piston rod.
STEP 8
BD08B200-01
Install a new seals in the grooves of the piston rod

assembly.
STEP 11
Remove the wiper and the seal from the gland.
Remove the seal reing from the gland. Repeat the
procedure for the other gland.
STEP 9
BD08B197-01
Install a new seal in the gland. The lip of the seal
must be toward the inside of the gland.
Remove the seals from the piston rod assembly.

5003-8
STEP 12 STEP 16
Push the piston rod assembly all the way into the
tube, use a soft faced hammer and drive the gland
into the tube.
STEP 17
Lubricate the wiper, seal, and seal ring on the gland
with clean oil.
STEP 18
BD08B199-01
Install a new wiper in the gland. the lip of the wiper
must be toward the outside of the gland.
STEP 13
Install a new seal ring in the groove on the gland.
STEP 14
Lubricate the piston seals with clean oil.
BD08B192-01
STEP 15 Install the gland on the piston rod assembly and push
the gland against the tube, use a soft faced hammer
and drive the gland into the tube.
BD08B194-01
Fasten the tube in a vise with soft jaws. Start the
piston rod assembly into the tube, be careful not to
damage the seals.

Section
5005
FRONT AXLE TWO WHEEL DRIVE
5005

5005-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Toe-in Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5005-3
SPECIFICATIONS
Bolts for steering cylinder ....................................................................................................335 Nm (247 pound-feet)
Tie rod ball joint to steering cylinder ....................................................................................300 Nm (221 pound-feet)
Tie rod to steering knuckle ..................................................................................................165 Nm (122 pound-feet)
Jam nut for tie rod..................................................................................................................120 Nm (89 pound-feet)
Bolts for king pin ....................................................................................................................120 Nm (89 pound-feet)
Bolts for bearing caps ............................................................................................................120 Nm (89 pound-feet)
Bearing cap plug......................................................................................................................15 Nm (11 pound-feet)

5005-4
SPECIAL TOOLS
B4094188M
CAS-1842 WHEEL STUD REMOVAL AND INSTALLATION.
BT95H083
CAS2396 TRUNION BUSHING INSTALLER (PART OF
CAS40032 AXLE TOOL KIT) - USED TO INSTALL THE
TRUNION AXLE BUSHING.
B4097488M
CAS-2150 WRENCH TO LOOSEN AND TIGHTEN TIE RODS
FOR STEERING CYLINDER.

5005-5
AXLE
Disassembly STEP 4
STEP 1
BC03N174
Remove the wheel hub from the axle.

BC03N171 NOTE: Repeat steps 3 and 4 for the other wheel
Loosen and remove the tie rod ends from the swivel hub.
housings.
STEP 5
STEP 2
BC03N175
BC03N172 Remove the bearing cups from the wheel hubs.
Remove the steering cylinder, ball joints, and tie rod
ends from the axle. STEP 6
STEP 3
BC03N176
Remove the bearing cone from the swivel housing.

BC03N173
Attach suitable lifting equipment to the wheel hub.

Remove the wheel hub cover, bearing retainer plate
bolts, and bearing retainer plate.

5005-6
STEP 7 STEP 10
BC03N177 BC03N180
Attach suitable lifting equipment to the swivel If required, remove the upper bushing and lower
housing. Remove the upper and lower king pins. bearing cup for the king pins.
STEP 8 STEP 11
BC03N178 BC03N181
Remove the swivel housing from the axle beam. If required, remove the front and rear pivot seals and
bushings.
NOTE: Repeat steps 7 and 8 for the other swivel
housing.
STEP 9
BC03N179
Remove the bevelled washers from the axle beam.

5005-7
Inspection Assembly
STEP 12
2. Inspect the bearing cups and the rollers in the
wheel bearings for flat areas, pitting, scoring, and
other damage. Also check the bearing cones for
damage. If any of these defects are found, new
wheel bearing cups and cones must be installed.
3. Inspect king pin bushings and bearings for flat
areas, pitting, scoring, and other damage.
Replace as needed.
4. Inspect axle pivot bushings and pivot pin for flat
areas, pitting, scoring, and other damage.
Replace as needed.
BC03N181
5. Remove and discard all seals and O-rings.
Install bushings and seals in the pivot on the axle
beam.
NOTE: To ease installation, cool bushings to -100° C
(-148° F).
STEP 13
BC03N180
Install the upper bushing and lower bearing cup

using suitable bearing drivers.
NOTE: To ease installation, cool bushings and
bearing cups to -100° C (-148° F).

5005-8
STEP 14 STEP 17
BC03N179 BC03N176
Apply grease to the bevelled washers to assist Grease the bearing cone and install it onto the swivel
holding them in place during assembly. housing.
STEP 15 STEP 18
BC03N178 BC03N182
Use suitable lifting equipment and install the swivel Use suitable drivers and install new bearing cups and
housing on the axle. seal into wheel hub.
STEP 16 STEP 19
BC03N177 BC03N183
Make sure the bevelled washers are in place, install Use suitable lifting equipment and install wheel hub
the upper and lower king pins. Torque the bolts to onto the swivel housing.
120 Nm (89 pound-feet).

5005-9
STEP 20 STEP 23
BC03N184 BC03N187
Grease and install the outer bearing on the swivel Install the ball joints to the steering cylinder, torque
housing. Use Loctite 270 on the bolts, position the the ball joints to 300 Nm (221 pound-feet).
thrust washer, install and torque the bolts to 120 Nm
(89 pound-feet). STEP 24
STEP 21
BC03N188
Loosen the locking nut for the tie rod end, place the
BC03N185 swivel housing parallel with the axle. Adjust the tie
Install a new O-ring on the wheel hub cover, lubricate rod end so that it can be slipped into the swivel
the O-ring with grease. Use a suitable driver and housing.
install the wheel hub cover into the wheel hub.
STEP 25
STEP 22
BC03N171
BC03N186 Tighten the tie rod end to a torque of 165 Nm

Use Loctite 270 on the bolts, mount the steering (122 pound-feet).
cylinder and torque the bolts to 335 Nm
(247 pound-feet).

5005-10
Toe-in Adjustment STEP 29
STEP 26
BC03N192
Snug the jam nuts for the tie rods and recheck toe-in.
BC03N189
Place two one meter long (39.3 inches) bars on the STEP 30
wheel hubs with 500 MM. (19.65 inches) on each
side of the center line of the axle.
STEP 27
BC03N193
Torque the jam nut to 120 Nm (89 pound-feet).
BC03N190
Use lug nuts to hold the bars into place on the wheel
hub.
STEP 28
BC03N191
Measure the distance between the bars, adjust the

toe-in so that “A” is -12 to -24 MM.
(-0.47 to -0.94 inches).

Section
5006
5006
FRONT AXLE - FOUR WHEEL DRIVE
580M and 580SM SERIES 3

5006-2 580M AND 580SM ONLY
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SWIVEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replacing A Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIFFERENTIAL CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
MEASURING TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

580M AND 580SM ONLY 5006-3
SPECIFICATIONS
Backlash for ring gear.....................................................................................0.20 to 0.25 MM. (0.008 to 0.010 inch)
Rotating torque for pinion shaft without seal................................................... 1.1 to 2.3 Nm (10 to 20 pound-inches)
Lubricant 580M and 580SM
Special Torques
Studs for wheels..................................................................................................................70 Nm (52 pound-feet)
Allen head bolts for carrier ..................................................................................................25 Nm (19 pound-feet)
Self locking nut for tie rod ball joint..................................................................................165 Nm (122 pound-feet)
Jam nut for tie rod .............................................................................................................120 Nm (89 pound-feet)
Nut for ball joint for steering cylinder ...............................................................................300 Nm (221 pound-feet)
Bolts for steering cylinder ..................................................................................................120 Nm (89 pound-feet)
Jam nuts for steering stops .............................................................................................150 Nm (111 pound-feet)
Bolts for king pin................................................................................................................120 Nm (89 pound-feet)
Bolts for adjusting ring lock .......................................................................................... 13 Nm (120 pound-inches)
Bolts for bearing caps......................................................................................................266 Nm (197 pound-feet)
Bolts for hub for planetary ring gear ....................................................................................95 Nm (70 pound-feet)
Bolts for differential carrier ..............................................................................................169 Nm (125 pound-feet)
Oil drain plugs in axle housing ............................................................................................60 Nm (44 pound-feet)
Oil drain plugs in planetary ends.........................................................................................80 Nm (59 pound-feet)
Breather ......................................................................................................................... 10 Nm (89 pound-inches)
Grease zerks .................................................................................................................... 8 Nm (71 pound-inches)
Wheel nuts ...................................................................................................................... 350 Nm (258 pound feet)

5006-4 580M AND 580SM ONLY
SPECIAL TOOLS
1
2
5
4
3 6
B875432M B4094788M
1. CAS1839-1 GAUGE TUBE YOKE TO HOLD SHAFT.
2. CAS1839-2 GAUGE BLOCK
3. CAS1668 METRIC FEELER GAUGE
4. CAS2401 PILOT
5. CAS1596A-4 HANDLE
6. CAS1596A-7 STUD
CAS1839 PINION SETTING KIT.
B4094188M
CAS1842 WHEEL STUD REMOVAL AND INSTALLATION.
B4097388M
CAS1840C SPANNER WRENCH.
B4106888M
CAS1980 V-BLOCK. USED TO SUPPORT COUPLING WHEN
REPLACING A UNIVERSAL JOINT.
B4086290M
CAS2151A WRENCH FOR PINION NUT.

580M AND 580SM ONLY 5006-5
CAS2369 . . . . . . . . . . . . . . . . . . . . . . Seal protector

CAS2375 . . . . . . . . . . . . . . . . . . . . . . . Shaft adapter
CAS10468 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Puller
B4097488M
380100091 for all two wheel drive and the 580M,
580SM four wheel drive front axle.
38010092 for the 580SM+ and 590SM and 590SM+
four wheel drive front axle.

5006-6 580M AND 580SM ONLY
PLANETARY
Disassembly STEP 5
STEP 1
Raise the wheel(s) off the floor and use acceptable
supports to hold the machine in position.
STEP 2
Remove the nuts and hardened washers and remove
the wheel(s). Drain the oil from the carrier.
STEP 3
B9110716M
Remove the carrier.
STEP 6
B9110714M
Remove the two Allen head bolts that hold the

carrier.
STEP 4
B9110718M
Remove the snap ring.
STEP 7
B9110715M
Separate the carrier from the planetary housing.
B9110720M
Remove the thrust washer with the internal tabs.

580M AND 580SM ONLY 5006-7
STEP 8 STEP 11
B9110722M B9110734M
Remove the thrust plate with the external tabs. Remove the ring gear.
STEP 9 STEP 12
B9110724M B9110802M
Remove the bolts for the hub. Use an acceptable puller to remove the outer wheel
bearing from the swivel housing.
STEP 10
STEP 13
B7110732M
Install two 10 MM. bolts in the two threaded holes in B9110804M
the hub. Tighten the two bolts evenly until the ring Remove the planetar y housing and the wheel
gear is free of the swivel housing. bearing.

5006-8 580M AND 580SM ONLY
STEP 14 STEP 17
B9110806M BD01A10
Use prybars to remove the inner wheel bearing from Press the bushings from the hub only if new
the swivel housing. Be careful so that you do not bushing(s) are needed or a new hub is installed.
damage the inner wheel bearing.
STEP 18
STEP 15
B9110910M
BD01A008 Remove the snap rings.

Remove the retaining ring which fastens the hub in
the ring gear. STEP 19
STEP 16
B9110912M
Remove the retainer.

BD01A009
Remove the hub.

580M AND 580SM ONLY 5006-9
STEP 20 Inspection
2. Inspect the bearing cup and the rollers in the
other damage. Also check the inner race for
damage. If any of these defects are found, a new
wheel bearing and bearing cup must be installed.
3. Inspect the pinion shafts for wear and damage.
4. Inspect the teeth of the pinion gears, the axle
shaft, and the ring gear for wear, pitting, scoring,
and other damage. Use new parts as required.
B9110914M
5. Inspect the needles for the pinion gears for flat
Remove the pinion gears and thrust washers. Be areas, pitting, scoring, and other damage. If any
careful so that you do not lose the needles. of these defects are found, also inspect the bore
of the pinion gears and use new par ts as
required.
STEP 21
6. Inspect the thrust washer for the axle shaft in the
bore in the carrier. Do not remove the thrust
washer unless there is wear or damage. The
thrust washer is held in position with adhesive. If
replacement is necessary, use B500621 kit (324
Loctite and 707 Activator) to install the new
thrust washer. Use the instructions on the
container. Curing time is approximately five
minutes.
B9110920M
Press the pinion shafts out of the carrier.
STEP 22
B9110922M
Remove the bearing cups and the seal as necessary.

5006-10 580M AND 580SM ONLY
1
2
3 4
5
3
2
6
7
10
11 20
12 13 8
15 16
12 14
17
15
11 19
18
bs01b067
1. SEAL 6. RETAINING RING 11. THRUST WASHER 16. O-RING
2. WHEEL BEARING 7. HUB 12. SNAP RING 17. CARRIER
3. BEARING CUP 8. BOLT 13. RETAINER 18. ALLEN HEAD BOLT
4. PLANETARY HOUSING 9. RING GEAR 14. PINION GEAR 19. PINION SHAFT
5. STUD 10. THRUST PLATE 15. PIN 20. BUSHING

580M AND 580SM ONLY 5006-11
Assembly STEP 26
STEP 23
B9076127M
Apply petroleum jelly to one side and the bore of the

B9110924M
pinion gears.
If bearing cups were removed, use an acceptable
driver to press new bearing cups into the planetary STEP 27
housing.
STEP 24
B9076128M
Install a thrust washer.
BD00M486 STEP 28
The words “OUTSIDE” on the seal must be facing
up. Use the CAS2374A to drive the new seal into the
planetary housing. Use the flat side of the Hub Seal
Installer. Be careful not to damage the seal.
STEP 25
Press the pinion shafts into the carrier until the inner
end of the pinion shafts are 34.3 to 36.8 MM. (1.350
to 1.450 inch) from the machined surface on the
carrier.
B9076132M
Install 3 0 n eed les in e ach pinion gea r u sin g

petroleum jelly to hold the needles in place.

5006-12 580M AND 580SM ONLY
STEP 29 STEP 32
B9076021M BD01A011
Install the pinion gears so that each thrust washer is Press bushings into the hub as required.
toward the carrier.
STEP 33
STEP 30
BD01A009
B9110912M Install the hub.

Install the retainer.
STEP 34
STEP 31
BD01A008
B9110910M Install the retaining ring.
Install the snap rings.

580M AND 580SM ONLY 5006-13
STEP 35 STEP 38
B9111022M B9111028M
Install a wheel bearing on the swivel housing. Align the holes in the hub with the holes in the swivel
Installation will be easier if you heat the wheel housing and install the ring gear.
bearing slightly. Do not heat the wheel bearing higher
than 149° C (300° F). Use clean gear lubricant to STEP 39
lubricate the wheel bearing.
STEP 36
B9110724M
Put 270 Loctite in the female threads in the swivel

housing. Install and tighten the bolts evenly to pull
B9111024M the hub against the swivel housing. Tighten the bolts
Install the planetary housing. to a final torque of 95 Nm (70 pound-feet).
STEP 37 STEP 40
B9111026M B9110722M
Install the outer wheel bearing. Installation will be Install the thrust plate with the external tabs.
easier if you heat the wheel bearing slightly. Do not
heat the wheel bearing higher than 149° C (300° F).

5006-14 580M AND 580SM ONLY
STEP 41 STEP 44
B9110720M B9111104M
Install the thrust washer with the internal tabs. Install the carrier.
STEP 42 STEP 45
B9110718M B9110714M
Install the snap ring. Install and tighten the Allen head bolts to a torque of
STEP 43
STEP 46
See Specifications on page 3 for the correct lubricant
for the planetary.
STEP 47
Install the wheel(s), hardened washers, and nuts.
Tighten the nuts to specifications on page 3.
B9111102M
Install a new O-ring on the planetary housing.

580M AND 580SM ONLY 5006-15
SWIVEL HOUSING
Removal and Disassembly STEP 51
STEP 48
Do the necessar y steps under Disassembly of
Planetary for access to the swivel housing.
STEP 49
BK98E042
Loosen the bolts that hold the top king pin.
STEP 52
BK98E040
Loosen the nut.
STEP 50
BK98E045
Fasten acceptable lifting equipment as shown.

Remove the bolts and use acceptable tools to
remove the top king pin.
STEP 53
BK98E039
Repeat steps 51 and 52 for the bottom king pin.
Use the CAS10468 puller to loosen the ball joint.
swivel housing.

5006-16 580M AND 580SM ONLY
STEP 54 STEP 57
BK98E046 B9076233M
Remove the swivel housing. Use an acceptable puller and remove the top and
bottom bushings.
STEP 55
STEP 58
B98E047
Remove the belleville washer from the bottom of the B9076304M
axle housing. Use an acceptable puller and remove the seal.
STEP 56 STEP 59
BD08B189-01 B9076310M
Remove the belleville washer from the top of the axle Use an acceptable puller and remove the bushing.
housing. (See the illustration on page 22).

580M AND 580SM ONLY 5006-17
STEP 60 STEP 63
B9076338M B875405M
Use an acceptable puller and remove the seal from Press the bottom king pin out of the bushing.
the swivel housing.
Replacing A Universal Joint
STEP 61
STEP 64
B612414RM
Support the swivel housing on a sleeve and press B8260888M

the bushing out of the swivel housing. Remove the four snap rings.
STEP 62 STEP 65
B875399M
B9562088M
Use a hammer and a chisel that has a long taper to Use the CAS1980 V-block to support the coupling.
start the bushing off the bottom king pin. Adjust the Allen bolts in the V-block to hold the
coupling level and use additional suppor t as
required. Use an acceptable driver and press the
bottom bearing cap against the V-block.

5006-18 580M AND 580SM ONLY
STEP 66 STEP 69
B8261488M B9561288M
Fasten the bearing cap in a vise and drive the Remove the coupling from the bearing cap.
coupling off the bearing cap.
STEP 70
STEP 67
B8262388M
B9560488M Use an acceptable support and driver to press the

Use the V-block to support the coupling and press bottom bear ing cap out of the yoke as far as
the other bearing cap against the V-block. possible.
STEP 68 STEP 71
B9560688M B8262688M
Remove the long axle shaft (or short axle shaft) from Remove the yoke from the bearing cap. DO NOT hit
the coupling. the axle shaft in the seal area.

580M AND 580SM ONLY 5006-19
STEP 72 STEP 75
B8262988M B9552488M
Press the other bearing cap out of the yoke as far as Press a bearing cap into the yoke until the top of the
possible. bearing cap is 6 MM. (1/4 inch) above the top of the
yoke.
STEP 73
STEP 76
B8263288M
Remove the cross. B9552688M
Carefully install the cross in the bearing cap.

STEP 74
STEP 77
B8263588M
Use an acceptable driver and press the bearing cap B92552888M
out of the yoke. Press the other bearing cap into the yoke until the top
of the bearing cap is 9 MM. (3/8 inch) above the top
of the yoke.

5006-20 580M AND 580SM ONLY
STEP 78 STEP 81
B9553088M B9553688M
Carefully raise the cross into the bearing cap so that Install a snap ring.
the cross is in both bearing caps.
STEP 82
STEP 79 Repeat steps 78 and 79 for the other bearing cap.
STEP 83
B9553288M
Hold the cross and press the bearing caps into the
yoke. B9560288M
Use the V-block to support the coupling and press a

STEP 80 bearing cap into the coupling even with the OD of the
coupling.
STEP 84
B9553488M
Use an acceptable driver and press a bearing cap

into the yoke so that a snap ring can be installed.
B9561088M
Carefully install the cross in the bearing cap.

580M AND 580SM ONLY 5006-21
STEP 85 STEP 87
B9561688M B9562288M
Use an acceptable driver and press the other bearing Hold the cross and press the bearing cap into the
cap into the coupling until the top of the bearing cap coupling so that a snap ring can be installed.
is 6 MM. (1/4 inch) above the top of the coupling.
STEP 88
STEP 86
B9562488M
B9561888M Install a snap ring.

Carefully raise the cross into the top bearing cap so
that the cross is in both bearing caps. STEP 89
Repeat steps 85 and 86 for the other bearing cap.

5006-22 580M AND 580SM ONLY
2
6
5
8
3
1
8
BC01B066
1. BOLT 6. BUSHING
2. TOP KING PIN 7. SWIVEL HOUSING
3. BELLEVILLE WASHER 8. GREASE ZERK
4. BUSHING 9. BOTTOM KING PIN
5. SEAL

580M AND 580SM ONLY 5006-23
Assembly and Installation STEP 93
STEP 90
BK98E046
Install the belleville washer on the top of axle frame.

B9076313M
Then install the belleville washer on the bottom of the
Drive the bushing into the bore until the bushing is 8 axle frame (see illustration on page 22). Install the
MM. (5/16 inch) beyond the end of the bore. Then swivel housing.
install the seal.
STEP 94
STEP 91
BK98E043
B9076236M
Install the top king pin, belleville washer, spacer, and
Install the bushing for the top king pin on a driver that bolts. Tighten the bolts to a torque of 120 Nm (88.5
has a pilot and drive the bushing all the way into the pound-feet).
bore.
STEP 95
STEP 92
Repeat step 91 for the bottom bushing.
B9076215M
Install the bottom king pin, belleville washer and

self-locking bolts. Tighten the bolts to 120 Nm (88.5
pound-feet).
5006-24 580M AND 580SM ONLY
STEP 96 STEP 98
Repeat steps 89 through 96 for the opposite end of
the axle.
STEP 99
Lubricate the king pins.
STEP 100
Assemble the planetary according to instructions in
this section.
B9076403M
Install the ball joint and nut.
STEP 97
BK98E041
Tighten the nut to 165 Nm (122 pound-feet).

580M AND 580SM ONLY 5006-25
DIFFERENTIAL CARRIER
Removal STEP 104
STEP 101
Drain the lubricant from the center bowl.
STEP 102
B9076210M
Remove the nut and ball joint.
STEP 105
BK98E040
Loosen the nut.
STEP 103
BK98E042
Loosen and remove the bolts that hold the top king
pin.
STEP 106
BK98E039
Use the CAS10468 puller to loosen the ball joint.
BK98E045
Fasten suitable lifting equipment as shown and

remove the top king pin.

5006-26 580M AND 580SM ONLY
STEP 107 STEP 111
BK98E046 BD08B041-01
Remove the planetary and axle assembly. Remove the bolts.
STEP 108 STEP 112

the axle.
STEP 109
BD08B042-01
Remove the plug from the cylinder.
STEP 113
B9076526M
Use tool 380100091 and loosen and remove the right

tie rod.
STEP 110
Remove the fitting from the closed end of the
steering cylinder.
BD08B043-01
Remove the steering cylinder.

580M AND 580SM ONLY 5006-27
STEP 114 Disassembly
STEP 116
B9076610M
Remove the bolts.

B875529M
STEP 115 Fasten the differential carrier in a repair stand.
STEP 117
B9076614M
Use suitable lifting equipment and remove the

differential carrier. BK98E050
Prevent the pinion shaft from turning. Measure the

backlash of the ring gear. Record the reading.
STEP 118
BK98E052
Make an identification mark on the bearing cap and

leg on one side of the differential carrier.

5006-28 580M AND 580SM ONLY
STEP 119 STEP 122
BK98E053 BK98E056
Remove the bolt and lock that hold each adjusting Remove the 4 bolts. Use a hammer to loosen the 2
ring. bearing caps.
STEP 120 STEP 123
BK98E054 BK98E057
Loosen the bolts. Remove the adjusting rings, bearing cups and
differential.
STEP 121
STEP 124
If the bearing cups are to be used again, fasten an
identification tag to one bearing cup for the current
installation.
BS98E106
Loosen both adjusting rings.

580M AND 580SM ONLY 5006-29
STEP 125 STEP 128
B9076802M B9077007M
Remove the seal and cover. Remove the washer.
STEP 126 STEP 129
B9076803M B9077008M
Use a narrow chisel to push the nut out of the pinion Use a soft hammer and drive the pinion shaft out of
shaft. the outer bearing.
STEP 127 STEP 130
B8012388M B9077023M
Use the yoke and CAS2151 tool to remove the pinion Remove the flat washers and spacer. Discard the
nut. spacer. The spacer MUST NOT be used again.

5006-30 580M AND 580SM ONLY
STEP 131 STEP 134
B9077026M BP95F336
Press the pinion shaft out of the inner bearing. Use an acceptable puller and remove the seal from
the cover.
STEP 132
STEP 135
B9077030M
Remove the shim. BP95F338
Remove the O-ring from the cover.

STEP 133
B9077015M
Remove the bearing cups only if inspection indicates

the need for new parts.

580M AND 580SM ONLY 5006-31
DIFFERENTIAL
Disassembly STEP 139
STEP 136
B9076820M
Remove the thrust washer and side gear.

B9076806M
Remove the bolts. STEP 140
STEP 137
B9076825M
Remove the pinion shaft assembly and pin.

B9076811M
Remove the ring gear. STEP 141
STEP 138
B9076834M
Remove the side gear.

B9076814M
Separate the case halves.

5006-32 580M AND 580SM ONLY
STEP 142 Inspection
bearings for flat areas, pitting, scoring, and other
damage. Also check the inner race for damage.
If any of these defects are found, a new bearing
and bearing cup must be installed.
3. Inspect the teeth on the pinion gear and ring gear
for pitting, scoring, and broken teeth. The ring
gear and pinion gear must be replaced as a set.
4. Inspect the side gears, the pinion shaft, and the
teeth of the pinion gears for pitting, scoring, and
B9076835M other damage. Also inspect the thrust surfaces
Remove the thrust washer. and the bore of each pinion gear. Check the
splines in the side gears for wear. Use new parts
STEP 143 as required.
5. Inspect the thrust washers for pitting, scoring,
B9076903M
Remove and install new bushings in the case halves

as required.
STEP 144
B875533M
Remove the bearing from either case half as shown.

580M AND 580SM ONLY 5006-33
12 1
2
3
4
10
11 6
7
6
13
5
8
8
5
9
14 10
15
13
11
8
18
20
5
19
21
18
17 18 17
16
19
22
20 5
8
18
BS01B065
1. COVER 7. SPACER 13. LOCK 18. THRUST WASHER
2. SEAL 8. BEARING CUP 14. SHIM 19. SIDE GEAR
3. PINION NUT 9. DIFFERENTIAL CARRIER 15. PINION GEAR 20. PINION GEAR
4. WASHER 10. ADJUSTING RING 16. RING GEAR 21. PINION SHAFT
5. BEARING 11. BEARING CAP 17. CASE HALF 22. DOWEL PIN
6. FLAT WASHER 12. O-RING
DIFFERENTIAL

5006-34 580M AND 580SM ONLY
Assembly STEP 148
STEP 145
B9076835M
Install a thrust washer in the case half that has

B875533M
threaded holes.
Use the CAS2395 and press a new bearing onto
each case half. STEP 149
STEP 146
B9076834M
Install a side gear.

B9076906M
Find the case half that has the threaded holes. Make STEP 150
sure that the threads are free of lubricant.
STEP 147
B9076911M
Install the thrust washers and pinion gears on the

pinion shaft.
B9076908M
Lubricate the thrust washers, pinion gears and pinion

shaft with gear lubricant.

580M AND 580SM ONLY 5006-35
STEP 151 STEP 154
B9076829M B9076823M
Install the pin. Install the other side gear.
STEP 152 STEP 155
B9076825M B9076920M
Install the pinion shaft assembly. Install the other thrust washer in the other case half.
NOTE: For limited slip differentials install 5 reaction
STEP 153 and 4 friction plates starting with a reaction plate.
Make sure the special friction plate that is against the
side gear.
STEP 156
B9076918M
Apply 270 Loctite to the threads in the case half.
B9076814M
Using the two reference notches on the case halves,

assemble the two case halves.

5006-36 580M AND 580SM ONLY
STEP 157 STEP 158
B9076811M B9076922M
Make sure that the mounting surfaces for the ring Use the press to prevent the differential from turning
gear are clean and install the ring gear. and install and tighten the bolts to 95 Nm (70
pound-feet).

580M AND 580SM ONLY 5006-37
Assembly STEP 162
STEP 159
B9077101M
Install the gauge tube and bearing caps with marks

B9077021M aligned.
Use a suitable driver and drive the bearing cup(s)
into the differential carrier. STEP 163
STEP 160
Assemble the gauge block, pilot and stud from the
CAS1839 pinion setting kit
STEP 161
B9077106M
Tighten the bolts to 156 Nm (115 pound-feet).
STEP 164
B9077036M
Install the gauge block, pilot, bearings and handle.

See Special Tools on page 4. Tighten the handle
until the bearings become difficult to turn.
B9077108M
Use the metric feeler gauge and measure the space

between the gauge block and the gauge tube. Write
the measurement on line “b” in step 166.

5006-38 580M AND 580SM ONLY
STEP 165 STEP 168
B613024M B9077030M
Write the number on the end of the pinion shaft on Install the shim with the thickness specified in step
line “d” in step 166. 166. The chamfer on the ID of the shim must be
towards the pinion gear.
STEP 166
The number on line “a” does not change. Add line “a” STEP 169
and line “b” and write the answer on line “c”. Subtract
line “d” from line “c” and write the answer on line “e”.
Line “e” is the thickness of the shim to be installed on
the pinion shaft.
Example:
A. 109.75 MM A. 109.75 MM
B.+ MM B. + 0.45 MM
C. MM C. 110.20 MM
D. - MM D. -107.45 MM
E. MM E. 2.75 MM
USE 2.75 MM. THICK SHIM
STEP 167 B9077032M
Use the CAS2370 inner/outer pinion bearing cone

installer and press the inner bearing against the
shim.
STEP 170
B9077111M
Remove the bolts, bearing caps, gauge tube, handle,

gauge block assembly and the bearings.
B9077114M
Lubricate the bearings with gear lubricant.

580M AND 580SM ONLY 5006-39
STEP 171 STEP 174
B9077023M B9077126M
Install a new spacer and flat washers. The old spacer Install a new pinion nut
MUST NOT be used again.
STEP 175
STEP 172
B8011988M
B9077120M Use the yoke and the CAS2151 wrench and tighten
Install the pinion shaft and the outer bearing. the pinion nut to 68 Nm (50 pound-feet).
STEP 173 STEP 176

The pinion shaft and bearings will still be loose.
Tighten the pinion nut in SMALL amounts until the
bearings become seated.
IMPORTANT: If the pinion nut is tightened too much
(rotating torque more than specified), the pinion will
have to be removed and a new spacer installed on
the pinion shaft.
B9077122M
Install the washer.

5006-40 580M AND 580SM ONLY
STEP 177 STEP 179
B9077129M BP95F338
The photo above shows a socket being used, use the Install a new O-ring on the cover.
CAS2375 and a pound-inch torque wrench to check
the rotating torque of the pinion shaft. The rotating STEP 180
torque must be 1.7 to 2.2 Nm (15 to 20
pound-inches). If the rotating torque is less than
specified, tighten the pinion nut a SMALL amount
and check the rotating torque again.
STEP 178
BP95F337
Use a suitable driver and drive a new seal into the

cover.
STEP 181
B9077135M
When the rotating torque is as specified, use a

hammer and punch and drive part of the pinion nut
into the slot in the pinion shaft.
BK98E059
Put the CAS2369 seal protector on the pinion shaft

580M AND 580SM ONLY 5006-41
STEP 182 STEP 185
BK98E060 BK98E054
Lubricate the O-ring and the seal with clean oil. Tighten the bolts to pull the bearing caps against the
Install the cove differential carrier. Do not overtighten the bolts. The
bearings must be able to rotate.
STEP 183
STEP 186
BK98E057
Install the differential carrier and lubricate the BS98E106
bearings with gear lubricant. Install the adjusting rings.
STEP 184 STEP 187
BK98E049 BS98E106
Install the bearing cups and bearing caps with the Use the CAS1840C and tighten both adjusting rings
alignment marks. while making sure that there is clearance (backlash)
between the ring gear and pinion gear.

5006-42 580M AND 580SM ONLY
STEP 188 STEP 193
If the original ring gear and pinion gear are being
used, the backlash must be equal to the
measurement made during disassembly.
STEP 194
If a new ring and pinion gear are being used, the
backlash must be 0.002 to 0.0025 MM. (0.008 to
0.010 inch).
STEP 195
B9077301M
Use a dial indicator to check for end play.
STEP 189
If there is end play, tighten the adjusting ring on the
tooth side of the ring gear until there is no end play.
STEP 190
If there is no end play, loosen the adjusting ring on
the back face side of the ring gear to make sure that
there is clearance between the ring gear and pinion BS98E106
gear and tighten the opposite adjusting ring until If there is not enough backlash, use the CAS1840C
there is no end play. and loosen the adjusting ring on the back face side of
the ring gear one notch and tighten the opposite
STEP 191 adjusting ring one notch. Check the backlash again.
When there is no end play, tighten each adjusting Continue with this step until the backlash is correct
ring one notch.
STEP 196
STEP 192
B9077307M
BK98E050
If there is too much backlash, use the CAS1840C
Use the dial indicator and check the backlash for the and loosen the adjusting ring on the tooth side of the
ring gear at 90 degree intervals. If the readings are r ing gear one notch and tighten the opposite
not equal, adjust the backlash at the position that had adjusting ring one notch. Check the backlash again.
the smallest reading. Continue with this step until the backlash is correct.

580M AND 580SM ONLY 5006-43
STEP 199
BK98E055
When the backlash is correct, tighten the bolts to 266

Nm (197 pound-feet). B9077314M
Apply form-in-place gasket material

STEP 198
STEP 200
BK98E058
Install the lock, bolt and lock washer that hold each B9077317M
adjusting ring. Tighten the bolts to 13 Nm (120 Install the differential carrier.
pound-inches).
STEP 201
B9076610M
In stall and tigh te n the bo lts to 169 Nm (125

pound-feet).

5006-44 580M AND 580SM ONLY
STEP 202 STEP 206
Install the steering cylinder.
STEP 203
BK98E046
Install the planetary and axle assembly. It may be

necessary to have another person turn the pinion
BD08B040-01
shaft.
Install and tighten the bolts to 120 Nm (89
pound-feet). STEP 207
STEP 204
BK98E043
Install the top king pin, spacer, and bolts. Tighten the
bolts to a torque of 120 Nm (89 pound-feet).
Install and tighten the tie rod using the 380100091 for
the 580M and 580SM and torque to 300 Nm (222 STEP 208
pound-feet).
Install the bottom king pin, belleville washer and
bolts. Tighten the bolts to a torque of 120 Nm (89
STEP 205 pound-feet).
Install and tighten the fitting at the closed end of the
steering cylinder.

580M AND 580SM ONLY 5006-45
STEP 209 STEP 211
the axle.
STEP 212
See Specifications on page 3 for the correct lubricant
for the center bowl.
STEP 213
Lubricate the king pins with molydisulfide grease.
B9076403M
Install the ball joint and nut.
STEP 210
BK98E041
Tighten the nuts to 165 Nm (122 pound-feet).

5006-46 580M AND 580SM ONLY
MEASURING TOE-IN
1 1
3 2 3
A
B870171J
1. MARK AROUND CENTER OF TIRE NOTE: MEASUREMENT B MUST BE
2. STEERING CYLINDER EQUAL TO OR UP TO 5 MM (3/16
3. LOOSEN THE JAM NUT AND TURN THE
PISTON ROD AS REQUIRED
INCH) LESS THAN MEASUREMENT A

Section
5006
FRONT AXLE - FOUR WHEEL DRIVE

580SM+, 590SM AND 590SM+ SERIES 3
5006

5006-2 580SM+, 590SM, AND 590SM+ ONLY
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SWIVEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing a Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MEASURING TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

580SM+, 590SM, AND 590SM+ ONLY 5006-3
SPECIFICATIONS
Backlash for ring gear......................................................................................0.20 to 0.25 mm (0.008 to 0.010 inch)
Rotating torque for pinion shaft without seal................................................... 1.1 to 2.3 Nm (10 to 20 pound-inches)
Lubricant
580SM+
590SM and 590SM+
Capacity - each wheel end ......................................................................................0.65 liter (0.69 U.S. quarts)
Special Torques
Studs for wheels..................................................................................................................70 Nm (52 pound-feet)
Allen head bolts for carrier ..................................................................................................25 Nm (18 pound-feet)
Nut for ball joint for steering cylinder ...............................................................................300 Nm (221 pound-feet)
Bolts for steering cylinder ..................................................................................................120 Nm (89 pound-feet)
Jam nuts for steering stops .............................................................................................150 Nm (111 pound-feet)
Bolts for king pins ............................................................................................................190 Nm (140 pound-feet)
Bolts for adjusting ring lock .......................................................................................... 13 Nm (115 pound-inches)
Bolts for bearing caps......................................................................................................266 Nm (197 pound-feet)
Bolts for differential case .................................................................................................169 Nm (125 pound-feet)
Bolts for differential carrier ..............................................................................................169 Nm (163 pound-feet)
Oil drain plugs in axle housing ............................................................................................60 Nm (44 pound-feet)
Oil drain plugs in planetary ends.........................................................................................80 Nm (59 pound-feet)
Breather ......................................................................................................................... 10 Nm (89 pound-inches)
Grease zerks .................................................................................................................... 8 Nm (71 pound-inches)
Self locking nut for tie rod ball joint
580SM+ ......................................................................................................................165 Nm (122 pound-feet)
590SM.........................................................................................................................220 Nm (162 pound-feet)
Jam nut for tie rod
580 SM+ .......................................................................................................................120 Nm (89 pound-feet)
590 SM........................................................................................................................250 Nm (184 pound-feet)
Bolts for hub for planetary ring gear
580 SM+ .........................................................................................................................95 Nm (70 pound-feet)
590 SM..........................................................................................................................120 Nm (88 pound-feet)

5006-4 580SM+, 590SM, AND 590SM+ ONLY
SPECIAL TOOLS
1
2
5
4
3 6
B875432M BD07N444-01
1. CAS-1839-1 GAUGE TUBE YOKE TO HOLD SHAFT.
2. CAS-1839-2 GAUGE BLOCK
3. CAS-1668 METRIC FEELER GAUGE
4. CAS-2401 PILOT
5. CAS-1596A-4 HANDLE
6. CAS-1596A-7 STUD
CAS-1839 PINION SETTING KIT.
BD08B457-01
CAS-1842 WHEEL STUD REMOVAL AND INSTALLATION.
BD07N328-01
CAS-1840C SPANNER WRENCH.
BD08B458-01
CAS-1980 V-BLOCK. USED TO SUPPORT COUPLING WHEN
REPLACING A UNIVERSAL JOINT.
BD07N337-01
CAS-2151A WRENCH FOR PINION NUT.

580SM+, 590SM, AND 590SM+ ONLY 5006-5
B4097488M BD07N334-01
38010092 WRENCH TO LOOSEN AND TIGHTEN TIE RODS SEAL PROTECTOR CAS2369
FOR STEERING CYLINDER.
BD07N330-01
BD07N336-01
SEAL DRIVER 380002432

5006-6 580SM+, 590SM, AND 590SM+ ONLY
PLANETARY
Disassembly STEP 5
STEP 1
Raise the wheel(s) off the floor and use acceptable
supports to hold the machine in position.
STEP 2
Remove the nuts and hardened washers and remove
the wheel(s).
STEP 3
BD08B404-01
Remove the two Allen head bolts that hold the

carrier.
STEP 6
BD08B403-01
Remove the drain plug from carrier.
STEP 4
BD08B406-01
Use a soft-faced hammer to separate the carrier from

the planetary housing.
STEP 7
BD08B402-01
Drain the oil from the carrier.
BD08B407-01
Remove the carrier.

580SM+, 590SM, AND 590SM+ ONLY 5006-7
STEP 8 STEP 11
BD08B454-01 BD08B410-01
Discard O-ring. Remove the thrust washer with the external tabs.
STEP 9 STEP 12
BD08B408-01 BD08B411-01.
Remove the snap ring. Remove the bolts from the hub.
STEP 10 STEP 13
BD08B409-01 BD08B413-01
Remove the thrust washer with the internal tabs. Use two bolts that were removed from the hub and
install them in the two threaded holes in the hub.
Tighten the bolts evenly until the ring gear is free of
the wheel hub.

5006-8 580SM+, 590SM, AND 590SM+ ONLY
STEP 14 STEP 17
BD08B414-01 BD08B417-01
Remove the ring gear. Remove the palnetary housing from the wheel hub.
STEP 15 STEP 18
BD08B415-01 BD08B418-01
Use an acceptable puller to remove the outer wheel Use prybars to remove the inner wheel bearing from
bearing from the wheel hub. the swivel housing. Be careful so that you do not
damage the inner wheel bearing.
STEP 16
STEP 19
BD08B416-01
Remove the wheel bearing. BD08B422-01
Remove the retaining ring.

580SM+, 590SM, AND 590SM+ ONLY 5006-9
STEP 20 STEP 23
BD08B424-01 BD08B463-01
Remove the hub. Remove the retaining plate.
STEP 21 STEP 24
BD08B434-01 BD08B464-01
Press the bushings from the hub only if new Remove the pinion gears and thrust washers. Be
bushing(s) are needed or a new hub is installed. careful so that you do not lose the needles.
NOTE: Steps 22 through 24 is for the 580 SM+. NOTE: Steps 25 through 27 is for the 590 SM.
STEP 22 STEP 25
BD08B427-01
BD08B464-01
Remove the snap rings securing the retaining plate. Remove the snap rings from the pinion gears.

5006-10 580SM+, 590SM, AND 590SM+ ONLY
STEP 26 STEP 29
BD08B426-01 BD08B438-01
Remove the retainer. Remove the bearing cups and seal as required.
STEP 27
Inspection
other damage. Also check the inner race for
damage. If any of these defects are found, a new
wheel bearing and bearing cup must be installed.
3. Inspect the pinion shafts for wear and damage.
4. Inspect the teeth of the pinion gears, the sun
gear, and the ring gear for wear, pitting, scoring
BD08B432-01
Remove the pinion gears being careful not to lose 5. Inspect the needles for the pinion gears for flat
the needles. areas, pitting, scoring and other damage. If any
of these defects are found, also inspect the bore
STEP 28 of the pinion gears and use new par ts as
required.
6. Inspect the thrust washer for the axle shaft in the
bore in the carrier. Do not remove the thrust
washer unless there is wear or damage. The
thrust washer is held in position with adhesive. If
replacement is necessary, use B500621 kit (324
Loctite and 707 Activator) to install the new
thrust washer. Use the instructions on the
container. Curing time is approximately five
minutes.
BD08B436-01
Press the pinion shafts out of the carrier if new ones
are to be installed.

580SM+, 590SM, AND 590SM+ ONLY 5006-11
NOTES

5006-12 580SM+, 590SM, AND 590SM+ ONLY
3
2
7
4
8
9
13
12
11
14 10
15
16
28
29 27 26
17
18
19
25
20
21 24
22
23
BS08B214

580SM+, 590SM, AND 590SM+ ONLY 5006-13
1. AXLE SHAFT 9. RING GEAR 17. RETAINER 24. PLUG

2. SEAL 10. BOLT 18. PINION GEAR 25. O-RING
3. BEARING ASSEMBLY 11. BUSHING 19. NEEDLES 26. NUT
4. PLANETARY HOUSING 12. SNAP RING 20. O-RING 27. WASHER
5. STUD 13. THRUST PLATE 21. ALLEN HEAD BOLT 28. PIN
6. BEARING ASSEMBLY 14. THRUST PLATE 22. CARRIER 29. THRUST WASHER
7. RETAINING RING 15. THRUST WASHER 23. PINION SHAFT
8. HUB 16. SNAP RING
580SM+ PLANETARY

5006-14 580SM+, 590SM, AND 590SM+ ONLY
1
3 2
6
7
8
9 12
20
19
18
17
11
10
16
15
14
13
BS08B148
1. SEAL 8. HUB 15. CARRIER
2. BEARING ASSEMBLY 9. RING GEAR 16. THRUST BUTTON
3. PLANETARY HOUSING 10. BOLT 17. PINION SHAFT
4. STUD 11. BUSHING 18. PINION GEAR
5. O-RING 12. NEEDLES 19. RETAINER
6. BEARING ASSEMBLY 13. PLUG 20. SNAP RING
7. RETAINING RING 14. ALLEN HEAD BOLT
590SM PLANETARY

580SM+, 590SM, AND 590SM+ ONLY 5006-15
Assembly STEP 33
STEP 30
If bearing cups were removed, use a suitable driver
to press new bearing cups into the wheel hub.
STEP 31
BD08B437-01
Use seal driver 380002431 to drive the new seal into
the wheel hub. Be careful not to damage the seal.
STEP 34
BD08B456-01
Clean hub prior to seal installation.
STEP 32
BD08B442-01
If the pinion shafts were removed, use acceptable

tools to press the pinion shafts into the carrier until
the inner end of the pinion shafts are 34.3 to 36.8
mm (1.350 to 1.450 inch) from the machined surface
on the carrier.
BD08B439-01
The lip on the seal must be facing in towards bearing. NOTE: Steps 35 through 40 is for the 580 SM+.
STEP 35
BD08B459-01
Apply petroleum jelly to one side and the bore of the
pinion gears.
5006-16 580SM+, 590SM, AND 590SM+ ONLY
STEP 36 STEP 39
BD08B460-01 BD08B463-01
Install a thrust washer. Install the retainer.
STEP 37 STEP 40
BD08B461-01 BD08B462-01
Install 30 ne edles in e ach pinio n gear using Install the snap rings.
petroleum jelly to hold the needles in place.
NOTE: Steps 41 through 46 is for the 590 SM.
STEP 38 STEP 41
BD08B464-01
BD08B428-01
Install the pinion gears so that each thrust washer is
Apply petroleum jelly to the inside of the pinion
toward the carrier.
gears.

580SM+, 590SM, AND 590SM+ ONLY 5006-17
STEP 42 STEP 45
BD08B430-01 BD08B426-01
Install needles in each pinion gear using petroleum Install the retainer.
jelly to hold the needles in place.
STEP 46
STEP 43
BD08B427-01
BD08B431-01 Install the snap ring.

Install the pinion gears onto the pinion shafts.
STEP 47
STEP 44
BD08B435-01
BD08B453-01 Press bushings into the hub as required.

Install needles into the top of the pinion gears.

5006-18 580SM+, 590SM, AND 590SM+ ONLY
STEP 48 STEP 51
BD08B425-01 BD08B421-01
Install the hub. Lubricate the bearings with gear lubricant.
STEP 49 STEP 52
BD08B423-01 BD08B452-01
Install the retaining ring. Clean seal surface prior to wheel hub installation.
STEP 50 STEP 53
BD08B420-01 BD08B455-01
Install inner bearing on the swivel housing. Ensure the surface of the seal is clean and dry prior
to installing the wheel hub.

580SM+, 590SM, AND 590SM+ ONLY 5006-19
STEP 54 STEP 57
BD08B417-01 BD08B412-01
Install the wheel hub onto the swivel housing. Put Loctite 270 in the female threads in the wheel
hub. Install and tighten the bolts evenly to pull the
STEP 55 hub against the wheel hub. Tighten the bolts to a final
torque of 95 Nm (70 pound-feet).
STEP 58
BD08B416-01
Install outer bearing.
STEP 56 BD08B466-01
Ensure shaft is all the way out prior the installing
thrust washers and snap ring.
STEP 59
BD08B451-01
Align the holes in the hub with the holes in the swivel
housing and install the ring gear.
BD08B410-01
Install the thrust washer with the external tabs.

5006-20 580SM+, 590SM, AND 590SM+ ONLY
STEP 60
BD08B407-01
BD08B409-01 Install the carrier.
Install the thrust washer with the internal tabs.
STEP 63
STEP 61
BD08B405-01
BD08B408-01
Install and tighten the Allen head bolts to 80 Nm (59
Install the snap ring. pound-feet).
STEP 62 STEP 64
Fill the 580 SM+ planetary(ies) with SAE 80W/40
0.59 liters (0.63 U.S. quarts)
Fill the 590 SM planetary(ies) with SAE 80W/40
0.65 liters (0.69 U.S. quarts)
STEP 65
BD08B454-01
Install new O-ring on carrier.
BD08B403-01
Install the plug and torque to 80 Nm (59 pound-feet).

580SM+, 590SM, AND 590SM+ ONLY 5006-21
SWIVEL HOUSING
Removal and Disassembly STEP 69
STEP 66
Do steps 1 through 18 for access to the swivel
housing.
STEP 67
B9076210M
swivel housing.
STEP 70
B9076205M
Loosen but do not remove the tie rod nut.
STEP 68
B9076216M
Loosen and remove the self-locking bolts that hold

the top king pin.
STEP 71
B9076206M
Use the CAS-10468 puller to loosen the ball joint.
B9076220M
Remove the top king pin.

5006-22 580SM+, 590SM, AND 590SM+ ONLY
STEP 72 STEP 76
Repeat steps 70 and 71 for the bottom king pin.
STEP 73
B9076233M
Use an acceptable puller and remove the top and

bottom bushings.
B9076223M
Remove the swivel housing. STEP 77
STEP 74
B9076304M
Use an acceptable puller and remove the seal.

BD08B189-01
Remove the bellvile washer and spacer from the top. STEP 78
Remove the bellvile washer from the bottom. (See
the illustration on page 28.)
STEP 75
B9076310M
Use an acceptable puller and remove the bushing.
B9076223M
Remove the axle shaft.

580SM+, 590SM, AND 590SM+ ONLY 5006-23
STEP 79 STEP 81
B9076338M B875399M
Use an acceptable puller and remove the seal from Use a soft-faced hammer and a chisel that has a long
the swivel housing. taper to start the bushing off the bottom king pin.
STEP 80 STEP 82
B612414RM B875405M
Support the swivel housing on a sleeve and press Press the bottom king pin out of the bushing.
the bushing out of the swivel housing.
Replacing a Universal Joint
STEP 83
B8260888M
Remove the four snap rings.

5006-24 580SM+, 590SM, AND 590SM+ ONLY
STEP 84 STEP 87
B9562088M B9560688M
Use the CAS-1980 V-block to support the coupling. Remove the long axle shaft (or short axle shaft) from
Adjust the Allen bolts in the V-block to hold the the coupling.
coupling level and use additional suppor t as
required. Use an acceptable driver and press the STEP 88
bottom bearing cap against the V-block.
STEP 85
B9561288M
Use a soft-faced hammer to remove the coupling

from the bearing cap.
B8261488M
Fasten the bearing cap in a vise and use a soft-faced STEP 89

hammer to drive the coupling off the bearing cap.
STEP 86
B8262388M
Use an acceptable support and driver to press the

bottom bear ing cap out of the yoke as far as
B9560488M possible.
Use the V-block to support the coupling and press
the other bearing cap against the V-block

580SM+, 590SM, AND 590SM+ ONLY 5006-25
STEP 90 STEP 93
B8262688M B8263588M
Use a soft-faced hammer to remove the yoke from Use an acceptable driver and press the bearing cap
the bearing cap. DO NOT hit the axle shaft in the out of the yoke.
seal area.
STEP 94
STEP 91
B9552488M
B8262988M Press a bearing cap into the yoke 6 mm (1/4 inch)

Press the other bearing cap out of the yoke as far as from the top of the yoke.
possible.
STEP 95
STEP 92
B9552688M
B8263288M Carefully install the cross into the bearing cap.

Remove the cross.

5006-26 580SM+, 590SM, AND 590SM+ ONLY
STEP 96 STEP 99
B92552888M B9553488M
Press the other bearing cap into the yoke 9 mm (3/8 Use an acceptable driver and press a bearing cap
inch) from the top of the yoke. into the yoke so that a snap ring can be installed.
STEP 97 STEP 100
B9553088M B9553688M
Carefully raise the cross into the bearing cap so that Install a snap ring.
the cross is in both bearing caps.
STEP 101
STEP 102
B9553288M
Hold the cross and press the bearing caps into the
yoke. B9560288M
Use the V-block to support the coupling and press a

bearing cap into the coupling even with the OD of the
coupling.

580SM+, 590SM, AND 590SM+ ONLY 5006-27
STEP 103 STEP 106
B9561088M B9562288M
Carefully install the cross in the bearing cap. Hold the cross and press the bearing cap into the
coupling so that a snap ring can be installed.
STEP 104
STEP 107
B9561688M
Use an acceptable driver and press the other bearing B9562488M
cap into the coupling 6 mm (1/4 inch) from the top of Install a snap ring.
the coupling.
STEP 108
B9561888M
Carefully raise the cross into the top bearing cap so

that the cross is in both bearing caps.

5006-28 580SM+, 590SM, AND 590SM+ ONLY
1
6 5
8
1
BT98E002
1. BOLT 6. BUSHING
2. TOP KING PIN 7. SWIVEL HOUSING
3. BELLVILLE WASHER 8. GREASE ZERK
4. SPACER 9. BOTTOM KING PIN
5. SEAL

580SM+, 590SM, AND 590SM+ ONLY 5006-29
Assembly and Installation STEP 112
STEP 109
B9076317M
Use a soft-faced hammer to install the axle shaft.

B9076313M
Use a soft-faced hammer to drive the bushing into STEP 113

the bore until the bushing is 8 mm (5/16 inch) beyond
the end of the bore. Then install the seal.
STEP 110
B9076223M
Install the swivel housing.
STEP 114
B9076236M
Use a soft-faced hammer to install the bushing for

the top king pin on a driver that has a pilot and drive
the bushing all the way into the bore.
STEP 111
Repeat step 110 for the bottom bushing.
B9076318M
Install the top king pin, beveled washer, spacer, and

self-locking bolts.

5006-30 580SM+, 590SM, AND 590SM+ ONLY
STEP 115 STEP 118
B9076215M B9076403M
Tighten the self-locking bolts to 190 Nm (141 Install the ball joint and nut.
pound-feet).
STEP 119
STEP 116
B9076405M
B9076325M Tighten the nut to

Install the bottom king pin, beveled washer, and 580SM+ 165 Nm (122 pound-feet)
self-locking bolts. See the illustration on page 28.
590SM 220 Nm (162 pound-feet).
STEP 117
STEP 120
the axle.
STEP 121
Lubricate the king pins.
STEP 122
Assemble the planetary according to instructions in
this section.
B9076327M
Tighten the self-locking cap screws to 190 Nm (141

pound-feet).

580SM+, 590SM, AND 590SM+ ONLY 5006-31
Removal STEP 126
STEP 123
Drain the lubricant from the center bowl.
STEP 124
B9076210M
Remove the nut and ball joint.
STEP 127
B9076205M
Loosen but do not remove the nut.
STEP 125
BK98E083
Fasten suitable lifting equipment as shown and

r e m ove t h e b o l t s f r o m th e t o p k i n g p i n . U s e
acceptable tools and remove the top king pin.
STEP 128
B9076206M
Use an acceptable puller to loosen the ball joint.
B9076521M
Remove the bolts and use acceptable tools to

remove the bottom king pin.

5006-32 580SM+, 590SM, AND 590SM+ ONLY
STEP 129 STEP 133
B9076602M
BK98E084
Remove the bolts.
Remove the planetary and axle assembly.
STEP 134
STEP 130
the axle.
STEP 131
B9076604M
Use a soft-faced hammer to remove the steering

cylinder.
STEP 135
B9076526M
Use tool 38010092 and loosen and remove the right
tie rod.
STEP 132
Remove the fitting from the closed end of the
steering cylinder.
B9076610M
Remove the bolts.

580SM+, 590SM, AND 590SM+ ONLY 5006-33
STEP 136 Disassembly
STEP 137
B9076614M
Use suitable lifting equipment and remove the

differential carrier. B875529M
Fasten the differential carrier in a repair stand.
STEP 138
BK98E050
Prevent the pinion shaft from turning. Measure the

backlash of the ring gear. Record the reading.
STEP 139
BK98E052
Make an identification mark on the bearing cap and

leg on the ring gear side of the differential carrier.

5006-34 580SM+, 590SM, AND 590SM+ ONLY
STEP 140 STEP 143
BK98E053 BK98E056
Remove the bolt and lock that hold each adjusting Remove the 4 bolts. Use a soft-faced hammer to
ring. loosen the 2 bearing caps.
STEP 141 STEP 144
BK98E054 BK98E057
Remove the bolts. Remove the adjusting rings, bearing cups and
differential.
STEP 142
STEP 145
If the bearing cups are to be used again, fasten an
identification tag to one bearing cup for the current
installation.
BS98E106
Loosen both adjusting rings.

580SM+, 590SM, AND 590SM+ ONLY 5006-35
STEP 146 STEP 149
B9076802M B9077007M
Remove the seal and cover. Remove the washer.
STEP 147 STEP 150
B9076803M B9077008M
Use a narrow chisel to push the nut out of the pinion Use a soft hammer and drive the pinion shaft out of
shaft. the outer bearing.
STEP 148 STEP 151
B8012388M B9077023M
Use the yoke and CAS-2151 tool to remove the Remove the flat washers and spacer. Discard the
pinion nut. spacer. The spacer MUST NOT be used again.

5006-36 580SM+, 590SM, AND 590SM+ ONLY
STEP 152 STEP 155
B9077026M BP95F336
Press the pinion shaft out of the inner bearing. Use an acceptable puller and remove the seal from
the cover.
STEP 153
STEP 156
B9077030M
Remove the shim. BP95F338

STEP 154
B9077015M
Remove the bearing cups only if inspection indicates

the need for new parts.

580SM+, 590SM, AND 590SM+ ONLY 5006-37
DIFFERENTIAL
STEP 157
B9076820M
Remove the thrust washer and side gear.

B9076806M
Remove the bolts. STEP 161
STEP 158
B9076825M
Remove the pinion shaft assembly and pin.

B9076811M
Remove the ring gear. STEP 162
STEP 159
B9076834M
Remove the side gear.

B9076814M
Separate the case halves.

5006-38 580SM+, 590SM, AND 590SM+ ONLY
STEP 163 STEP 166
B9076835M BD03N016
Remove the thrust washer. Remove the reaction and friction plates.
NOTE: Step 164 through step 166 are for limited slip NOTE: The plate at the side gear must be kept in
differentials. that position.
STEP 164 STEP 167
BD03N018 B9076903M
Remove the pinion shaft assembly and pin. Remove and install new bushings in the case halves
as required.
STEP 165
STEP 168
BD03N017
Remove side gear. B875533M
Remove the bearing from either case half as shown.

580SM+, 590SM, AND 590SM+ ONLY 5006-39
Inspection 6. Limited slip differentials, check reaction and

friction plates for discoloration, scaring and
1. Clean all parts in cleaning solvent. chipping. Measure thickness of friction and
2. Inspect the bearing cup and the rollers in the separator plates, use new parts as required.
damage. Also check the inner race for damage.
If any of these defects are found, a new bearing
and bearing cup must be installed.
3. Inspect the teeth on the pinion gear and ring gear
for pitting, scoring, and broken teeth. The ring 1
gear and pinion gear must be replaced as a set.
4. Inspect the side gears, the pinion shaft and the
teeth of the pinion gears for pitting, scoring, and 3
other damage. Also inspect the thrust surfaces
and the bore of each pinion gear. Check the 2
splines in the side gears for wear. Use new parts
as required.
BC04A232
5. Inspect the thrust washers for pitting, scoring,
1. SEPARATOR PLATE NEW 1.5 ± 0.03 MM. (0.059 ± 0.001 IN)
and other damage. Use new parts as required. MINIMUM THICKNESS 1.4 MM. (0.055 IN)
2. FRICTION PLATE NEW 1.6 ± 0.03 MM. (0.063 ± 0.001 IN)
MINIMUM THICKNESS 1.45 MM. (0.057 IN)
3. FRICTION PLATE NEW 2.8 ± 0.03 MM. (0.11 ± 0.001 IN)
MINIMUM THICKNESS 2.7 MM. (0.10 IN)

5006-40 580SM+, 590SM, AND 590SM+ ONLY
12 1
2
3
4
10
11 6
7
6
13
5
8
8
5
9
14 10
15
13
11
8
18
20
5
19
21
18
17 18 17
16
19
22
20 5
8
18
BS01B065
1. COVER 7. SPACER 13. LOCK 18. THRUST WASHER
2. SEAL 8. BEARING CUP 14. SHIM 19. SIDE GEAR
3. PINION NUT 9. DIFFERENTIAL CARRIER 15. PINION GEAR 20. PINION GEAR
4. WASHER 10. ADJUSTING RING 16. RING GEAR 21. PINION SHAFT
5. BEARING 11. BEARING CAP 17. CASE HALF 22. DOWEL PIN
6. FLAT WASHER 12. O-RING
DIFFERENTIAL

580SM+, 590SM, AND 590SM+ ONLY 5006-41
1
12 3
4 5
8 6
7
2
4
9
7
6
10
5 11
9
1 8
4
2
BC03K006
1. LOCKING PLATE AND BOLT 5. REACTION PLATE (10) 9. SIDE AND PINION GEARS
2. RING NUT 6. FRICTION PLATE (8) 10. PIN
3. BEARING 7. FRICTION PLATE SPECIAL (2) 11. SHAFT
4. DIFFERENTIAL HOUSING 8. THRUST WASHER 12. BOLT (12)
LIMITED SLIP DIFFERENTIAL

5006-42 580SM+, 590SM, AND 590SM+ ONLY
Assembly STEP 171
STEP 169
B9076908M
Lubricate the thrust washers, pinion gears and pinion

B875533M
shaft with gear lubricant.
Use the CAS-2395 and press a new bearing onto NOTE: Step 172 through step 175 for limited slip
each case half. differential.
STEP 170 STEP 172
B9076906M BD03N015
Find the case half that has the threaded holes. Make Lubricate and place a reaction plate in the case half.
sure that the threads are free of lubricant.
STEP 173
BD03N014
Lubricate and place a friction plate in the case half,
alter reaction and friction plates until five reaction and
four friction plates are inside the case half.

580SM+, 590SM, AND 590SM+ ONLY 5006-43
STEP 174 STEP 177
BD03N013 B9076834M
Lubricate and place the side gear friction plate on the Install a side gear.
side gear.
STEP 178
STEP 175
B9076911M
BD03N018 Install the thrust washers and pinion gears on the
Work the side gear in a rotating motion until the gear pinion shaft.
has engaged all of the friction plates.
NOTE: Repeat steps 172 through step 175 for the STEP 179
other case half.
STEP 176
B9076829M
Install the pin.
B9076835M
Install a thrust washer in the case half that has

threaded holes.

5006-44 580SM+, 590SM, AND 590SM+ ONLY
STEP 180 STEP 183
B9076825M B9076920M
Install the pinion shaft assembly. Install the other thrust washer in the other case half.
STEP 181 STEP 184
B9076918M B9076814M
Apply 271 Loctite to the threads in the case half. Using the two reference marks on the case halves,
assemble the two case halves.
STEP 182
STEP 185
B9076823M
Install the other side gear. B9076811M
Make sure that the mounting surfaces for the ring

gear are clean and install the ring gear.

580SM+, 590SM, AND 590SM+ ONLY 5006-45
STEP 186
B9076922M
Use the press to prevent the differential from turning

and install and tighten the bolts to
580SM+ 95 Nm (70 pound-feet)
590SM 120 Nm (88 pound-feet).

5006-46 580SM+, 590SM, AND 590SM+ ONLY
Assembly STEP 190
STEP 187
B9077101M
Install the gauge tube and bearing caps with marks

B9077021M
aligned.
Use a soft-faced hammer and a suitable driver and
drive the bearing cup(s) into the differential carrier. STEP 191
STEP 188
Assemble the gauge block, pilot and stud from the
CAS-1839 pinion setting kit.
STEP 189
B9077106M
Tighten the bolts to 156 Nm (115 pound-feet).
STEP 192
B9077036M
Install the gauge block, pilot, bearings and handle.

See Special Tools on page 3. Tighten the handle
until the bearings become difficult to turn.
B9077108M


580SM+, 590SM, AND 590SM+ ONLY 5006-47
STEP 193 STEP 196
B613024M B9077030M
NOTE: The pinion gear shown is for a Powershift Install the shim with the thickness specified in step
transmission. The helix spiral is opposite of the 189. The chamfer on the ID of the shim must be
Carraro pinion gear. The procedure is the same. towards the pinion gear.
Write the number on the end of the pinion shaft on
line “d” in step 194. STEP 197
STEP 194
The number on line “A” does not change. Add line “A”
and line “B” and write the answer on line “C”.
Subtract line “D” from line “C” and write the answer
on line “E”. Line “E” is the thickness of the shim to be
installed on the pinion shaft.
Example:
A. 109.75 MM A. 109.75 MM
B.+ MM B. + 0.45 MM
C. MM C. 110.20 MM
D. - MM D. -107.45 MM
E. MM E. 2.75 MM B9077032M
Use the CAS-2370 inner/outer pinion bearing cone

USE 2.75 MM THICK SHIM
installer and press the inner bearing against the
shim.
STEP 195
STEP 198
B9077111M
Remove the bolts, bearing caps, gauge tube, handle, B9077114M

gauge block assembly and the bearings. Lubricate the bearings with gear lubricant.

5006-48 580SM+, 590SM, AND 590SM+ ONLY
STEP 199 STEP 202
B9077023M B9077126M
Install a new spacer and flat washers. The old spacer Install a new pinion nut.
MUST NOT be used again.
STEP 203
STEP 200
B8011988M
B9077120M Use the yoke and the CAS-2151A wrench and

Install the pinion shaft and the outer bearing. tighten the pinion nut to 68 Nm (50 pound-feet).
STEP 201 STEP 204

The pinion shaft and bearings will still be loose.
Tighten the pinion nut in SMALL amounts until the
bearings become seated.
NOTE: If the pinion nut is tightened too much
(rotating torque more than specified), the pinion will
have to be removed and a new spacer installed on
the pinion shaft.
B9077122M
Install the washer.

580SM+, 590SM, AND 590SM+ ONLY 5006-49
STEP 205 STEP 207
B9077129M BP95F338
The photo above shows a socket being used. Use Install a new O-ring on the cover.
the CAS-2375 and a pound-inch torque wrench to
check the rotating torque of the pinion shaft. The STEP 208
rotating torque must be 1.7 to 2.2 Nm (15 to 20
pound-inches). If the rotating torque is less than
specified, tighten the pinion nut a SMALL amount
and check the rotating torque again.
STEP 206
BP95F337
Use a soft-faced hammer and a suitable driver and

drive a new seal into the cover.
STEP 209
B9077135M
When the rotating torque is as specified, use a

soft-faced hammer and punch and drive part of the
pinion nut into the slot in the pinion shaft.
BK98E059
Put the CAS-2369 seal protector on the pinion shaft.

5006-50 580SM+, 590SM, AND 590SM+ ONLY
STEP 210 STEP 213
BK98E060 B9077214M
Lubricate the O-ring and the seal with clean oil. Install the bearing caps.
Install the cover.
NOTE: Align marks made during disassembly.
STEP 211 STEP 214
B9077208M
B9077215M
Install the differential carrier and lubricate the
Tighten the bolts to pull the bearing caps against the
bearings with gear lubricant.
differential carrier. Do not overtighten the bolts. The
bearings must be able to rotate.
STEP 212
STEP 215
B9077209 M
Install the bearing cups.

B9077220M
Install the adjusting rings.

580SM+, 590SM, AND 590SM+ ONLY 5006-51
STEP 216 STEP 221
B9077224M B9076722M
Use the CAS-1840C and tighten both adjusting rings Use the dial indicator and check the backlash for the
while making sure that there is clearance (backlash) ring gear at 90 degree intervals. If the readings are
between the ring gear and pinion gear. not equal, adjust the backlash at the position that had
the smallest reading.
STEP 217
STEP 222
If the original ring gear and pinion gear are being
used, the backlash must be equal to the
measurement made during disassembly.
STEP 223
If a new ring and pinion gear are being used, the
backlash must be 0.20 to 0.25 mm (0.008 to 0.010
inch).
STEP 224
B9077301M
Use a dial indicator and check for end play.
STEP 218
If there is end play, tighten the adjusting ring on
the tooth side of the ring gear until there is no end
play.
STEP 219
If there is no end play, loosen the adjusting ring on
the back face side of the ring gear to make sure that
there is clearance between the ring gear and pinion B9077306M
gear and tighten the opposite adjusting ring until If there is not enough backlash, use the CAS-1840C
there is no end play. and loosen the adjusting ring on the backface side of
the ring gear one notch and tighten the opposite
STEP 220 adjusting ring one notch. Check the backlash again.
When there is no end play, tighten each adjusting Continue with this step until the backlash is correct.
ring one notch.

5006-52 580SM+, 590SM, AND 590SM+ ONLY
STEP 228
B9077307M
If there is too much backlash, use the CAS-1840C

and loosen the adjusting ring on the tooth side of the B9077314M
r ing gear one notch and tighten the opposite Apply Loctite 510.
adjusting ring one notch. Check the backlash again.
Continue with this step until the backlash is correct.
STEP 229
STEP 226
B9077317M
Install the differential carrier.

B9077232M
When the backlash is correct, tighten the bolts to 266

STEP 230
Nm (197 pound-feet).
STEP 227
B9076610M
In stall and tigh te n the bo lts to 169 Nm (1 25

pound-feet).
B9077312M
Install the lock, bolt and lock washer that hold each
adjusting ring. Tighten the bolts to 13 Nm (120
pound-inches).
580SM+, 590SM, AND 590SM+ ONLY 5006-53
STEP 231 STEP 235
B9076605M BK98E084
Install the steering cylinder. Install the planetary and axle assembly. It may be
necessary to have another person turn the pinion
STEP 232 shaft.
STEP 236
B9076536M
Install and tighten the bolts to 120 Nm (88.5

pound-feet). BK98E080
Install the top king pin, belville washer, spacer, bolts
and lock washers. Tighten the bolts to a torque of
STEP 233
B9076529M
Install and tighten the tie rod using the 38010092 to a

torque of 300 Nm (222 pound-feet).
STEP 234
Install and tighten the fitting at the closed end of the
steering cylinder.

5006-54 580SM+, 590SM, AND 590SM+ ONLY
STEP 237 STEP 239
Install the bottom king pin, belville washer, bolts and Repeat steps 235 through 238 for the opposite end of
lock washers. Tighten the bolts to a torque of 190 Nm the axle.
(140 pound-feet).
STEP 240
STEP 238 F i l l t h e c e n t e r b o w l . R e f e r t o p a g e 3 fo r
Install the ball joint and nut. Tighten the nut to a specifications.
torque of for 580SM+ 165 Nm (122 pound-feet), for
590SM 220 Nm (162 puond-feet). STEP 241
Lubricate the king pins with molydisulfide grease.

580SM+, 590SM, AND 590SM+ ONLY 5006-55
MEASURING TOE-IN
1 1
3 2 3
A
B870171J
1. MARK AROUND CENTER OF TIRE NOTE: MEASUREMENT B MUST BE
2. STEERING CYLINDER EQUAL TO OR UP TO 5 MM (3/16 INCH)
3. LOOSEN THE JAM NUT AND TURN
THE PISTON ROD AS REQUIRED
LESS THAN MEASUREMENT A
MEASURING TOE-IN

5006-56 580SM+, 590SM, AND 590SM+ ONLY

SECTION INDEX
POWER TRAIN

Removal and Installation of Power Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6000
Standard Transmission Specifications, Pressure Checks, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .6002
Power Shift Transmission Specifications, Pressure Checks and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .6002
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6003
Rear Axle and Planetaries - 580M and 580SM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Rear Axle and Planetaries - 580SM+, 590SM and 590SM+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6004
Standard Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007
Power Shift Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6007

Section
6000
REMOVAL AND INSTALLATION

OF POWER TRAIN COMPONENTS
6000

6000-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
POWER SHIFT TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6000-3
SPECIFICATIONS
Special Torques
Mounting bolts for the rear axle................................................................ 610 to 678 Nm (450 to 500 pound-feet)
Cap screws for the rear drive shaft................................................................... 33 to 39 Nm (24 to 29 pound-feet)
Cap screws for the front drive shaft.................................................................. 33 to 39 Nm (24 to 29 pound-feet)
Wheel nuts for the rear wheels.................................................................................................. See Section 6003
Transmission insulator mounts ....................................................................... 90 to 100 Nm (67 to 73 pound-feet)
Cap screws for mounting transmission to the engine flywheel housing ........... 52 to 57 Nm (38 to 42 pound-feet)
Cap screws for mounting the torque converter to the flywheel..........................52 to 57 Nm (38 to 42 pound-feet)
Mounting bolts for the drive shaft guard ........................................................ 50 to 90 Nm (36.5 to 66 pound-feet)
Mounting bolt for the gear shift lever .......................................................... 125 to 150 Nm (93 to 112 pound-feet)
Fluid Capacities
Transmission
Standard Transmission
2 Wheel Drive
Total system capacity ............................................................................................... 17 liters (18 U.S. quarts)
Refill capacity with or without filter change ......................................................... 10.5 liters (11.1 U.S. quarts)
4 Wheel Drive
Total system capacity .......................................................................................... 19.4 liters (20.5 U.S. quarts)
Refill capacity with or without filter change ............................................................. 13 liters (13.7 U.S. quarts)
Powershift Transmission
4 Wheel Drive
Total system capacity ............................................................................................. 17.9 liters (19 U.S. quarts)
Refill capacity with or without filter change ............................................................. 11.3 liters (12 U.S. quarts)
Rear Axle
580M, 580SM
580SM+, 590SM, 590SM+

6000-4
MANUAL TRANSMISSION
Removal STEP 4
STEP 1
Par k the machine on a level surface. Put the 1
backhoe in the transport position with the stabilizers
down. Also put the loader bucket on the floor.
STEP 2
Raise the wheels off the floor high enough to remove
the transmission. Put suitable stands under both
sides of the machine at the front and rear.
NOTE: The rear wheels can be removed to ease the
transmission removal.
STEP 3
2
BC08A207-01
Disconnect the supply line (1) from the transmission,

disconnect the return line (2) from the transmission.
BD08A476
Drain the transmission oil. STEP 5

Disconnect the differential lock hose.

6000-5
STEP 6 STEP 8
Disconnect the wiring harness connector for the
transmission shift solenoid.
1
STEP 9
Disconnect the wiring harness for the transmission
temperature sender.
STEP 10
Disconnect the wiring harness for the SAHR parking
brake.
STEP 11
If equipped, disconnect the wiring harness for the
four wheel drive solenoid.
STEP 12
2
BC01C119
1. FRONT CAB FLOOR MAT
2. CAB FRONT FLOOR PLATE
If equipped, remove the front cab floor mat (1).

Remove the cab front floor plate (2).
STEP 7 1
3 BD01B361
Loosen and remove the cap screw and washer (1)

for the left rear mounting bracket on front drive shaft
guard through the access hole in the fuel tank.
STEP 13
2
1 2
GS98D600
1. RETURN SPRING
2. TRANSMISSION GEAR SHIFT LEVER BD01B363
3. TRANSMISSION SHIFTER MECHANISM Loosen and remove the bolts, washers, and nuts (2)
that fasten the left rear mounting bracket to front
Disconnect the return spring (1) for the shift lever.
drive shaft guard. Remove the left rear mounting
Disconnect the transmission gear shift lever (2) from
bracket.
the transmission shifter mechanism (3).

6000-6
STEP 14 STEP 19
BD01B362 BD03K031
Put a floor jack under the front drive shaft guard that Remove the starter from the engine. Remove the
will hold the guard in place when the caps screws are access cover from the bell housing.
removed. Loosen and remove the cap screws and
washers (3) from the remaining mounting brackets STEP 20
on the front drive shaft guard. Remove the front drive
shaft guard from the machine.
STEP 15
If equipped, remove the retainer and bolts that fasten
the front drive shaft to the transmission output shaft
yoke. Remove the front drive shaft from the splined
pinion shaft on the front axle.
NOTE: During installation apply Loctite 243 to the
bolts for the retainer. Tighten the bolts to 33 to 39 Nm
(24 to 29 pound-feet).
STEP 16 BC04A195
Remove the retainer and bolts that fasten the rear Install the engine turning tool, 380000988, to turn the
drive shaft to the transmission output shaft yoke. flywheel for access to the cap screws.
Remove the rear drive shaft from the splined pinion
shaft on the rear axle.
NOTE: During installation Loctite 243 to the bolts for
the retainer. Tighten the bolts to 33 to 39 Nm (24 to
29 pound-feet).
STEP 17
Tag and disconnect the transmission cooler inlet and
outlet hoses at the transmission. Install caps on the
transmission fittings and plugs in the hose ends.
STEP 18
Remove the hydraulic pump, see section 8001.

6000-7
STEP 21 STEP 24
Install a transmission jack under the transmission
and apply light pressure.
STEP 25
Re move b oth the le ft an d r igh t tra ns missio n
mounting cap screw.
mounting cap screws to a torque of 90 to 100 Nm
(67 to 73 pound-feet), install two nuts on the left
mount.
STEP 26
BD03K033
Carefully slide the transmission away from the
Loosen and remove the four cap screws that fasten
engine. Lower to the floor and remove from under the
the flywheel to the flex plate.
machine.
NOTE: During installation make sure that the
converter is in the correct position on the
transmission shaft. Align the holes in the flex plate
with the holes in the fly wheel. Install but do not
tighten all four cap screws, then final torque the cap
screws to 52 to 57 Nm (38 to 42 pound-feet).
STEP 22
Use acceptable stands or blocks to secure the
engine in place.
STEP 23
1
3
BT95K029
1. CAP SCREW 3. HEATER HOSE CLAMP

2. WASHER
Loosen and remove the 12 cap screws (1) and flat

washers (2) that fasten the transmission to the
engine. If equipped, move the heater hose and
clamps (3) out of the way.
NOTE: During installation tighten the 12 cap screws
to a torque of 52 to 57 Nm (38 to 42 pound-feet)

6000-8
8
7
4
6
5
1
3 9
2 10
11
12
12
13
BS08B328
1. NUT (2) 90 - 100 NM (67 - 73 LB-FT) 8. BACKING PLATE

2. TRANSMISSION 9. CAP SCREW (4) 52 - 57 NM (38 - 42 LB-FT)
3. BOLT (12) 52 - 57 NM (67 - 73 LB-FT) 10. BOLT (4) 52 - 57 NM (38 - 42 LB-FT)
4. DIPSTICK TUBE 11. NUT 90-100 NM (67 - 73 LB-FT)
5. CONVERTER 12. RUBBER TRANSMISSION MOUNT (2)
6. FLEX PLATE WITH CAGED NUT 13. CONSTANT TORQUE CLAMP (4) 5.6 - 7.9 NM (50 - 70 IN-LB)
7. FLEX PLATE

6000-9
NOTE: Install the transmission is the reverse of
removal.
STEP 27
BD03K031
Install the access cover on the bell housing. Install the
starter on the engine.
IMPORTANT: Before starting the engine do the
following.
BD03K033
NOTE: Rotate the torque converter through the

STEP 32
bottom hole of the bell housing and slide it against Make sure the transmission drain plug has been
the adapter plate. Align the bolt hole with the bosses installed and tightened.
on the torque converter.
STEP 33
STEP 28 Fill the transmission, see page 3 for capacities.
Install and hand tighten all four cap screws that NOTE: If removed, Install the rear wheels. See
fasten the flywheel to the torque converter. Section 6003 and tighten the rear wheel mounting
nuts.
STEP 29
Final torque the cap screws to 52 to 57 Nm (38 to 42 STEP 34
pound-feet). Remove the stands from under the machine and
lower the machine to the floor.
STEP 30
Remove the engine turning tool. STEP 35
With the machine parked on level ground and the
engine running at low idle, check the transmission oil
level. The oil level must be between the ADD and the
FULL marks on the dipstick. If the oil level is at the
ADD mark, add oil as required until the oil level is at
the FULL mark.

6000-10
POWER SHIFT TRANSMISSION
Removal STEP 5
STEP 1
Park the machine on a level surface. Put the backhoe
in the transport position with the stabilizers down.
Also put the loader bucket on the floor.
STEP 2 3
the transmission. Put suitable stands under both
sides of the machine at the front and rear.
NOTE: The rear wheels can be removed to ease the BD01B362
transmission removal.
Put a floor jack under the front drive shaft guard that
will hold the guard in place when the caps screws are
STEP 3 removed. Loosen and remove the cap screws and
washers (3) from the remaining mounting brackets
on the front drive shaft guard. Remove the front drive
shaft guard from the machine.
NOTE: Powershift transmission have spacers and
O-rings on the bolts, they are required for assembly.
STEP 6
Remove the retainer and bolts that fasten the front
drive shaft to the transmission output shaft yoke.
1 Remove the front drive shaft from the splined pinion
shaft on the front axle.
BD01B361 NOTE: During installation apply Loctite 243 to the
Loosen and remove the cap screw and washer (1) for bolts for the retainer. Tighten the bolts to 33 to 39 Nm
the left rear mounting bracket on front drive shaft (24 to 29 pound-feet).
guard through the access hole in the fuel tank.
STEP 4
BD01B363
Loosen and remove the bolts, washers, and nuts (2)

that fasten the left rear mounting bracket to front
drive shaft guard. Remove the left rear mounting
bracket.

6000-11
STEP 7 STEP 11
BD08B699-01 BD08B690-01
Remove the retainer and bolts that fasten the rear Disconnect the electr ical connector from the
drive shaft to the transmission output shaft yoke. transmission control valve harness, remove the
Remove the rear drive shaft from the splined pinion mounting bolt for the connector mounting bracket.
shaft on the rear axle.
NOTE: During installation apply Loctite 243 to the STEP 12
bolts for the retainer. Tighten the bolts to 33 to 39 Nm
(24 to 29 pound-feet).
1
STEP 8
BD08B700-01
Put a container under the drain plug that will hold

approximately 22 litres (6 U.S. gallons). Remove the
fill plug and the drain plug.
STEP 9
Remove hydraulic pump from transmission, see 2
section 8001.
BC08A207-01
STEP 10 Disconnect the supply line (1) from the transmission,

Tag and disconnect the transmission cooler inlet and disconnect the return line (2) from the transmission.
outlet hoses at the transmission. Install caps on the
transmission fittings and plugs in the hose ends. STEP 13
Disconnect the electrical connector for the SAHR
parking brake.
STEP 14
Disconnect the hose for the differential lock.

6000-12
STEP 15 STEP 17
BD03K031
Remove the starter from the engine. Remove the BD03K033
access cover from the bell housing. Loosen and remove the four cap screws that fasten
the flywheel to the flex plate.
STEP 16 NOTE: During installation make sure that the
converter is in the correct position on the
transmission shaft. Align the holes in the flex plate
with the holes in the fly wheel. Install but do not
tighten all four cap screws, then final torque the cap
screws to 52 to 57 Nm (38 to 42 pound-feet).
STEP 18
Use acceptable stands or blocks to secure the
engine in place.
STEP 19
Install a transmission jack under the transmission
BC04A195 and apply light pressure.
Install the engine turning tool, 380000988, to turn the
flywheel for access to the cap screws. STEP 20
Loosen and remove the 12 cap screws and flat
washers that fasten the transmission to the engine.
STEP 21
Re move b oth the le ft an d r igh t tra nsm ission
mounting cap screw.
mounting cap screws to a torque of 90 to 100 Nm
(67 to 73 pound-feet), install two nuts on the left
mount.
STEP 22
Carefully slide the transmission away from the
engine. Lower to the floor and remove from under the
machine.

6000-13
9
8
4
7
6
5
1 10
3
2
11
13 12
13
14
BBS08B327
1. NUT (2) 90 - 100 NM (67 - 73 LB-FT) 8. FLEX PLATE

2. TRANSMISSION 9. BACKING PLATE
3. BOLT (12) 52 -57 NM (38 - 42 LB-FT) 10. CAP SCREW (4) 52 -57 NM (38 - 42 LB-FT)
4. DIPSTICK TUBE 11. BOLT (4) 52 -57 NM (38 - 42 LB-FT)
5. BOLT (2) 27 - 31 NM (20 - 23 LB-FT) 12. NUT 90 -100 NM (67 73 LB-FT)
6. CONVERTER 13. RUBBER TRANSMISSION MOUNT (2)
7. FLEX PLATE WITH CAGED NUT 14. CONSTANT TORQUE CLAMP (4) 5.6 - 7.9 NM (50 - 70 IN-LB)

6000-14
Installation IMPORTANT: Before starting the engine. do the

following.
NOTE: Install the transmission in reverse of removal.
STEP 29
STEP 23 Make sure the transmission drain plug has been
Mount the transmission to the engine, torque the installed and tightened.
mounting bolts to 52 to 57 Nm (38 to 42 pound-feet).
STEP 30
STEP 24 Fill the transmission, see page 3 for capacities.
NOTE: If removed, install the rear wheels. See
Section 6003 and tighten the rear wheel mounting
nuts.
STEP 31
Remove the stands from under the machine and
lower the machine to the floor.
STEP 32
With the machine parked on level ground and the
engine running at low idle, check the transmission oil
BD03K033
level. The oil level must be between the ADD and the
NOTE: Rotate the torque converter through the FULL marks on the dipstick. If the oil level is at the
bottom hole of the bell housing and slide it against ADD mark, add oil as required until the oil level is at
the adapter plate. Align the bolt hole with the bosses the FULL mark.
on the torque converter.
STEP 25
Install and hand tighten all four cap screws that
fasten the flywheel to the torque converter.
STEP 26
Final torque the cap screws to 52 to 57 Nm (38 to 42
pound-feet).
STEP 27
Remove the engine turning tool.
STEP 28
BD03K031
Install the access cover on the bell housing. Install the
starter on the engine.

6000-15
REAR AXLE
Removal STEP 5
Install the drain plugs.
STEP 1
Park the machine on a level surface. Put the backhoe STEP 6
in the transport position with the stabilizers down.
Also put the loader bucket on the floor.
STEP 2
the rear axle from under the machine. Put suitable
stands under the frame at the rear of the machine.
STEP 3
1 BD08B699-01
Remove the retainer and bolts which fasten the rear

drive shaft to the transmission output shaft yoke.
STEP 7
2 Remove the rear drive shaft by sliding it off the rear
axle pinon shaft splines.
STEP 8
BD08A457
1. FILL PLUG
2. DRAIN PLUG
Drain the oil from the center differential section of the

rear axle using the following procedure:
1. Loosen the fill plug to relieve any pressure.
2. Remove the drain plug.
Use a container capable of containing 20 litres (22
U.S. quarts).
STEP 4
BD08B698-01
Disconnect the differential lock hose, plug the hose

and cap the fitting.
STEP 9
Raise the rear tires off of the ground, support the
machine with suitable stands.
STEP 10
Remove the tires from the machine.
BD08A463
Drain the brake hubs.

6000-16
STEP 15
Position the rear axle under the machine, slowly raise
the axle and align with the mounting holes in the
chassis wheel wells.
STEP 16
Install the bolts. Tighten the bolts evenly to pull the
axle against the frame, torque bolts to 610 to 678 Nm
(450 to 500 lb-ft).
STEP 17
BD08B471-01
Remove the mounting bolts for the brake hose guard,

disconnect the brake hose. Plug the hose and cap
the fitting.
STEP 12
Position a jack under the center of the rear axle and
apply light pressure.
STEP 13
Remove the rear axle mounting bolts from both
sides.
BD08B471-01
STEP 14 Connect the brake hose to the wheel cylinder, install

and tighten the hose guard mounting bolts.
Slowly lower the rear axle and remove from under the
machine. STEP 18
BD08B698-01
Connect the differential lock hose.
STEP 19
Install the rear drive shaft onto the rear axle by
sliding it on the rear axle pinon shaft splines. Tighten
drive shaft dust seal hand tight after assembling drive
shaft to the rear axle.

6000-17
STEP 20 STEP 23
BC08B681
BD08B699-01
Apply Loctite 243 to the bolts for the retainer. Tighten Install the wheel, do an initial torque of 136 Nm
the bolts to 33 to 39 Nm (24 to 29 pound-feet). (100 pound feet) in sequence shown, do a second
torque of 271 Nm (200 pound-feet) in sequence
STEP 21 shown, turn the lug nuts an additional 30°.
Fill the axle with oil, see page 3 for specifications.
STEP 24
STEP 22 Remove the stands from under the machine and
lower machine to the floor.
Bleed the brake according to instructions section
7000.

6000-18
NOTES

6002
Section
6002
STANDARD TRANSMISSION SPECIFICATIONS,


6002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pressure Test Ports 2 Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 WHEEL DRIVE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 WHEEL DRIVE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Test Ports 4 Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Machine Will Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4WD Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Machine Hesitates When Shifting Between Forward and Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Problem in Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transmission Oil Too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checking Supply Pump Pressure (4wd Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Checking Converter In Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Checking Regulated Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Checking Supply Pump Flow And Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Checking Converter Out Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Checking Lubrication Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Checking Differential Lock Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TWO WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Test One - Engine at Idle 900 to 1100 r/min (900 to 1100 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Test Two - Engine at 2200 r/min (2200 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FOUR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Test One - Engine at Idle 900 to 1100 r/min (900 to 1100 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Test Two - Engine at 2200 r/min (2200 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6002-3
SPECIFICATIONS
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 hours.
Your figures may differ slightly depending upon temperature, instrumentation variables, more that 20 engine hours,
etc.
Output of supply pump ............................................................................. 32 L/min to 68 L/min at 900 to 2200 r/min
(7.02 gpm to 18.5 gpm at 900 to 2200 rpm)
Pump supply pressure (4WD) .......................................... 1248 to 1551 kPa, 12.5 to 15.5 bars at 900 to 2200 r/min
(181 to 225 psi at 900 to 2200 rpm)
Regulated clutch pressure...................................................... 1103 to 1303 kPa, 11 to 13 bars at 900 to 2200 r/min
(160 to 189 psi at 900 to 2200 rpm)
Torque converter in pressure ......................................................... 48 to 903 kPa, 0.5 to 9 bars at 900 to 2200 r/min
(7 to 131 psi at 900 to 2200 rpm)
Torque converter out pressure..........................................................0 to 427 kPa, 0 to 4.3 bars at 900 to 2200 r/min
(0 to 62 psi at 900 to 2200 rpm)
Lubrication pressure .......................................................................40 to 303 kPa, 0.4 to 3 bars at 900 to 2200 r/min
(5.8 to 44 psi at 900 to 2200 rpm)
Transmission oil operating temperature (normal) ............................................................ 78 to 82° C (172 to 180° F)
Forward/Reverse clutch solenoids........................................................................... 4.7 ± 10% Ohm at 20° C (68° F)
Four wheel drive solenoid......................................................................................... 6.8 ± 10% Ohm at 20° C (68° F)
Park brake solenoid .............................................................................................................. 9.8 Ohm at 20° C (68° F)
Differential Lock Solenoid Valve Pressure
Without Differential Lock Solenoid Energized ....................................................................................0 psi (0 bars)
With Differential Lock Solenoid Energized (4WD) ............................................. 12.5 To 15.5 bars (181 to 225 psi)
With Differential Lock Solenoid Energized (2WD)
And Direction Control Lever in Forward or Reverse Position ...................................11 to 13 bars (160 to 189 psi)
Park brake check port.........................................................................................13.5 to 15.5 bar (195.8 to 217.6 psi)
IMPORTANT: Vehicle may move during park brake pressure check, check park brake pressure from inside of cab
by removing floor plate.

6002-4
SPECIAL TOOLS
B877558U BP95G002
CAS-1804 PRESSURE FITTING KIT CAS-40033 TRANSMISSION TOOL KIT
B797157M BP95G001
CAS-1808 FLOWMETER FITTING KIT CAS-2011 FILTER BASE ADAPTER USED WITH CAS-2383
FILTER ADAPTER TUBE FROM CAS-40033, “L” SERIES
TRANSMISSION TOOL KIT
B785789M
CAS-10280 FLOWMETER

6002-5
Pressure Test Ports 2 Wheel Drive
BC00M005
1. REVERSE CLUTCH PRESSURE 3. REGULATED CLUTCH PRESSURE

2. FORWARD CLUTCH PRESSURE 4. TORQUE CONVERTER PRESSURE

6002-6
2 WHEEL DRIVE SCHEMATIC
6
5
3 4 7
8
14 9
13 11 10
12
15
20
16 19
17
18
25 22
23
24
21
26 27
28
8
29
BC08B407

6002-7
1. PARK BRAKE SOLENOID 16. DIFFERENTIAL LOCK SOLENOID

2. SAHR PARK BRAKE 17. FLOW DIVIDER
3. TORQUE CONVERTER RELIEF VALVE 18. REGULATED CLUTCH PRESSURE
4. TORQUE CONVERTER 19. MODULATION SPOOL AND PISTON (REGULATES CLUTCH PRESSURE)
5. OIL COOLER 20. LUBRICATION TO BEARINGS AND CLUTCH PACKS
6. OIL TEMPERATURE SENDER (OIL COOLER) 21. REVERSE CLUTCH
7. LUBRICATION PRESSURE 22. REVERSE CLUTCH PRESSURE
8. LUBRICATION TO SYNCHRONIZERS AND GEARS 23. REVERSE CLUTCH SOLENOID
9. FORWARD CLUTCH 24. CONTROL VALVE ASSEMBLY
10. FORWARD CLUTCH PRESSURE 25. PRESSURE REGULATOR
11. FORWARD CLUTCH SOLENOID 26. FILTER (FULLFLOW/WITH BY-PASS, 15 MICRON)
12. FORWARD/REVERSE SHUTTLE SPOOL (DIRECTS 27. COLD OIL BY-PASS
FLOW TO FORWARD/REVERSE CLUTCHES) 28. SUPPLY PUMP
13. TORQUE CONVERTER INLET PRESSURE 29. STRAINER
14. MODULATOR CIRCUIT (PRESSURE MODULATION
FOR FORWARD/REVERSE)
15. TO DIFFERENTIAL LOCK (REAR AXLE)

6002-8
4 WHEEL DRIVE SCHEMATIC
6
5
3 4 7
8
14 9
13 11 10
12
15
20
16 19
17
18
25
22
31 23
24
32 21
30 26 27
28
33 29
BC08B408

6002-9
1. PARK BRAKE SOLENOID 18. REGULATED CLUTCH PRESSURE

2. SAHR PARK BRAKE 19. MODULATION SPOOL AND PISTON (REGULATES CLUTCH PRESSURE)
3. TORQUE CONVERTER RELIEF VALVE 20. LUBRICATION TO BEARINGS AND CLUTCH PACKS
4. TORQUE CONVERTER 21. REVERSE CLUTCH
5. OIL COOLER 22. REVERSE CLUTCH PRESSURE
6. OIL TEMPERATURE SENDER (OIL COOLER) 23. REVERSE CLUTCH SOLENOID
7. LUBRICATION PRESSURE 24. CONTROL VALVE ASSEMBLY
8. LUBRICATION TO SYNCHRONIZERS AND GEARS 25. PRESSURE REGULATOR
9. FORWARD CLUTCH 26. FILTER (FULLFLOW/WITH BY-PASS, 15 MICRON)
10. FORWARD CLUTCH PRESSURE 27. COLD OIL BY-PASS
11. FORWARD CLUTCH SOLENOID 28. SUPPLY PUMP
12. FORWARD/REVERSE SHUTTLE SPOOL (DIRECTS 29. STRAINER
FLOW TO FORWARD/REVERSE CLUTCHES) 30. CHECK VALVE
13. TORQUE CONVERTER INLET PRESSURE 31. SUPPLY PUMP PRESSURE FOR FOUR WHEEL DRIVE 4WD
14. MODULATOR CIRCUIT (PRESSURE MODULATION
32. FOUR WHEEL DRIVE SELECTOR VALVE
FOR FORWARD/REVERSE)
15. TO DIFFERENTIAL LOCK (REAR AXLE) 33. FOUR WHEEL DRIVE CLUTCH ()SPRING APPLIED, HUDRAULIC
RELEASED
16. DIFFERENTIAL LOCK SOLENOID
17. FLOW DIVIDER

6002-10
Pressure Test Ports 4 Wheel Drive
BC00M006/BC00M005
1. SUPPLY PUMP PRESSURE FOUR WHEEL DRIVE ONLY 4. REGULATED CLUTCH PRESSURE
2. REVERSE CLUTCH PRESSURE 5. TORQUE CONVERTER PRESSURE
3. FORWARD CLUTCH PRESSURE

6002-11
NOTE: All troubleshooting procedures must be done with oil at operating temperature.
e
Machine Will Not Move

Is oil level correct? Add oil as required. Troubleshooting complete. Find cause for
No
Is there still a problem. See Page 3. loss of oil.
Yes
Check for broken universal joint or drive

shaft and repair as required. Is there still a No Troubleshooting complete.
problem?
Yes
Check to see if drive shaft turns with

transmission directional control lever (FNR) Check electrical connections at transmission.
No
in forward or reverse and rear wheels off the Is there power to the clutch solenoids?
ground. Does the drive shaft turn?
No
Check the fuse panel. See

Section 4001.
Yes
Check pressure and pump flow. See page 22.

Is flow in specified range? No
Possible causes include:
1. Cold oil by-pass valve might be stuck or
damaged.
2. Pressure regulator could be bad.
Yes 3. Pump could be bad. See Section 6007 to
repair or replace as required.
There can be a problem in the transmission Check the transmission control valve. See
control valve. See page 17. Is the converter No Section 6007. Repair or replace as
In pressure in the specified range? required.
Yes
There can be a problem in the

forward/reverse solenoid valve. See page Check the transmission. See Section 6007.
No
18. Are the regulated clutch pressures for Repair or replace as required.
foward and reverse in the specified range?
Yes

6002-12
Check regulated clutch pressure at Test Port

3 . See page 18. Is the pressure in the No Possible causes include:
specified range? 1. If pressure remains at zero in forward,
neutral and reverse the problem could be
Yes
in the control valve.
Check the transmission. See Section 6007. 2. If pressure is low, problem could be in the
Repair or replace as required. control valve.
3. If pressure for forward and reverse are
the same, problem could be in the control
valve.
different, inspect individual clutch circuits.
See Section 4007 for repair.
4WD Does Not Work

Check for broken universal joint or front drive
shaft, and repair as required. Is there still a No Troubleshooting complete.
problem?
Yes
Check to see if front drive shaft turns with If the front drive shaft turned with the
transmission direction control lever (FNR) in directional control lever (FNR) in forward or
No
forward or reverse and the all wheels off the reverse, the problem is in the front axle. See
ground. Does the ront drive shaft turn? Section 5006. Repair as required.
Yes
Check electrical connection at 4WD solenoid

Check rocker switch connection and fuse
on the transmission. Is there power to the No
panel. See Section 4001.
solenoid?
Yes
Check 4WD solenoid for proper operation.

With no power to the solenoid the 4WD should
No See Section 6007. Repair or replace as
be engaged. See Section 4001 and check the
required.
4WD solenoid. Is solenoid performing
correctly?
Yes
Inspect the front drive shaft and clutch

engagement teeth for damage. See Section
6007. Repair as required.

6002-13
Machine Hesitates When Shifting Between Forward and Reverse

Is oil level correct? Add oil as required. Troubleshooting complete.
No
Is there still a problem? Find cause for loss of oil.
Yes
Check pump supply pressure at Test Port 10

4WD units. See page 17. Ports 1 and 2 on No Inspect pressure regulator. See Section 6007
2WD units. See Page 18. to repair or replace as required.
Is the pressure in the specified range?
Yes
Check regulated clutch pressure at Test Port

Inspect modulation spool and piston for
3 (4WD). See pages 18. No
sticking or damage.
Is the pressure in the specified range?
Yes No
Inspect input shaft sealing

rings and forward and
Troubleshooting complete. Yes reverse clutch piston seals.
See Section 6007 to repair
as required.
See Section 6007 to repair as required.

6002-14
Loss of Power
No
Yes
Is there a build up of mud or other foreign

material on inside of wheel wells or along
drive train? Clean or remove material.
Is there still a problem?
Yes
Do stall test according to instructions in

Section 2002. No Repair engine as required.
Is the engine good?
Yes
Inspect input shaft sealing rings and clutch

Check regulated clutch pressure. See page No piston seals. Also inspect forward and reverse
18. Is the pressure as specified? clutch friction discs. See Section 6007 to
repair as required.
Yes
See Machine will not Move on page 11.

6002-15
Problem in Parking Brake System

Does parking brake release? No Check the electrical and hydraulic circuits.
Hydraulic
Check differential lock

pressure, is pressure as
specified?
NOTE: Differential lock and
park brake are on the same
pressure circuit. Electrical
No
Troubleshoot and repair

transmission as needed,
see section 6007.
Yes
Check fuses, replace as needed.
Check switch operation, replace as needed.
Check solenoid, 9.8 Ohm @ 20° C (68° F)

replace as needed.
Test parking brake, see section 7002. See section 7000 for brake disc
No
Does parking brake hold machine? replacement.
Yes
Troubleshooting complete

6002-16
Transmission Oil Too Hot

No
Yes
Check transmission oil cooler for air flow

restriction. Clean exterior of transmission oil
cooler as required.
Yes
Check converter in pressure. See page 17.

No See Machine will not Move on page 11.
Is the pressure and flow as specified?
Yes
Check converter out pressure. See page 19. No See Machine will not Move on page 11.
Is the pressure as specified?
Yes
Check lube pressure. See page 19. Is the No If torque converter pressure is high and lube
pressure as specified? pressure is low, possible causes include:
Yes 1. The oil cooler is restricted. Replace the

oil cooler.
Troubleshooting complete. 2. The oil cooler circuit is restricted. Inspect
the oil cooler circ uit and repair as
required.
NOTE: The transmission oil cooler cannot be flushed or cleaned out, the transmission oil cooler must be
replaced if retricted or plugged.

6002-17
Checking Supply Pump Pressure Checking Converter In Pressure

(4wd Only)
Equipment Required
NOTE: Two wheel drive machines can only be tested
by performing flow meter test. CAS-1804 Pressure Fitting Kit
NOTE: See page 21 or 24 for test port identification.
Equipment Required
CAS-1804 Pressure Fitting Kit Test Procedure
NOTE: See page 24 for test port identification. 1. Engage the parking brake
2. Start the engine.
Test Procedure
3. Oil at operating temperature.
1. Engage the parking brake.
4. 200 psi (1379 kPa, 20 bar) gauge connected to
2. Start the engine. Test Port 6 for 2WD or 4WD.
3. Oil at operating temperature. 5. All transmission controls in neutral.
4. 600 psi (4137 kPa, 40 bar) gauge connected to 6. Read gauge and record pressure at idle, see
Test Port 10, see page 24. page 22 or 25.
5. Read gauge and record pressure at idle, see 7. Read gauge and record pressure at full throttle,
page 25. see page 23 or 26.
6. Read gauge and record pressure at full throttle,
see page 26. A
BD00M226
A. TEST PORT 6
BD00M228
A. TEST PORT 10 (4WD ONLY)

6002-18
Checking Regulated Clutch Checking Supply Pump Flow And

Pressure Relief Pressure
Equipment Required Equipment Required
CAS-1804 Pressure Fitting Kit CAS-1808 Flowmeter Fitting Kit
NOTE: See page 21 or 24 for test port identification. CAS-40033 Transmission Tool Kit
CAS-2011 Adapter with CAS-2383 Adapter Tube
Test Procedure
OEM-1239 (CAS-10280) Flowmeter
3. Oil at operating temperature. Test Procedure
4. 600 psi (4137 kPa, 40 bar) gauge connected to 1. Make sure all equipment is clean.
Test Port 3.
5. Move direction control lever to forward.
6. Read gauge and record pressure at idle, see
page 22 or 25.
5. Connect flowmeter and adapter to transmission
filter base at test ports 1 and 2. Completely open
see page 23 or 26.
load valve on flowmeter.
8. Repeat 6 and 7 with the control lever in reverse.
6. All transmission controls in neutral.
NOTE: Forward and Reverse clutch pressure can be
7. Read gauge and record the flow at idle, see page
recorded separately using Test Port 5 Forward and
22 or 25.
Test Port 4 Reverse.
8. Read gauge and record the flow at full throttle,
B see page 23 or 26.
9. At full throttle, close load valve until flow drops.
D C
R e a d a n d r e c o r d p r e s s u r e a t w h i c h f l ow
dropped.
BD00M226
A
A. TEST PORT 3
B. TEST PORT 4
C. TEST PORT 5
D. TEST PORT 6 B
BP95F282
A. FLOWMETER ADAPTER - TEST PORT 1
B. RETURN - TEST PORT 2

6002-19
Checking Converter Out Pressure Checking Lubrication Pressure

Equipment Required Equipment Required
CAS-1804 Pressure Fitting Kit CAS-1804 Pressure Test Kit
NOTE: See page 21 or 24 for test port identification. NOTE: See page 21 or 24 for test port identification.
Test Procedure Test Procedure

1. Engage the parking brake. 1. Engage the parking brake.
2. Start the engine. 2. Start the engine.
3. Oil at operating temperature. 3. Oil at operating temperature.
4. 200 psi (1379 kPa, 20 bar) gauge connected to 4. 600 psi (4137 kPa, 40 bar) gauge connected to
service tee at test port 1, as shown in photo. Test Port 9 for 2WD or 4WD.
5. All transmission controls in neutral. 5. All transmission controls in neutral.
6. Read gauge and record pressure at idle, see 6. Engine running at 2200 rpm (r/min).
page 22 or 25.
7. Read gauge and record pressure at full throttle, page 22 or 25.
see page 23 or 26.
see page 23 or 26.
A
A
BP95F397
A. SERVICE TEE - TEST PORT 8
BD00M233
A. TEST PORT 9 (2WD OR 4WD)

6002-20
Checking Differential Lock Valve 6. With the transmission shift lever in NEUTRAL put
the direction control lever in FORWARD or
Pressure REVERSE.
Equipment Required 7. All transmission controls in neutral.
CAS-1804 Pressure Test Kit 8. Engine running at 2200 rpm (r/min).
CAS-1808 Flowmeter Fitting Kit 9. Press and hold the differential lock switch,
located in the loader control lever.
page 22 or 25.
Test Procedure
see page 23 or 26.
2. Put transmission shift lever in NEUTRAL.
5. Connect a pressure test fitting and a 600 psi
(4137 kPa, 40 bar) gauge to Test Point 7.

6002-21
TWO WHEEL DRIVE
BD00M001
1. Flow meter adapter from charge pump to flow meter. (Use CAS-2011) Connect to CAS-10280 Flow Meter or
equivalent. Pump supply pressure on 2 wheel drive untits can only be taken with a flow meter connected to
ports 1 and 2.
2. Return from flow meter to transmission. (Use CAS-2383)
3. Regulated clutch pressure (common to forward or reverse). (Use CAS-2745 and CAS-2746)
4. Regulated reverse clutch pressure. (Use CAS-2745 and CAS-2746)
5. Regulated forward clutch pressure. (Use CAS-2745 and CAS-2746)
6. Torque converter in presure. (Use CAS-2745 and CAS-2746)
7. Differential lock pressure (Use CAS-2744)
8. Converter out to oil cooler. (Use CAS-2747)
9. Lubrication pressure, common to converter return. (Use CAS-2745 and CAS-2746) or (Use CAS-2747)

6002-22
Test One - Engine at Idle 900 to 1100 r/min (900 to 1100 rpm)
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 engine
hours, your figures may differ slightly.
Specifications -
Test Port Item 2 Wheel Drive Actual
1 and 2 Supply Pump Flow 27 to 28 L/min at 1379 kPa, 14
bar at 49° C (7.02 to 7.28 gpm
at 200 psi at 120° F)
1 and 2 Cold Oil By-Pass 2875 to 3137 kPa,
29.3 to 32.0 bar at 49° C
(417 to 455 psi at 120° F)
7 Differential Lock Pressure 1262 to 1317 kPa, 12.7 to
(FNR must be in forward or reverse) 13.4 bar (183 to 191 psi)
Forward
1 Pump Supply Pressure 1393 to 1427 kPa, 14.2 to
14.6 bar (202 to 207 psi)
4 Regulated Clutch Pressure 1276 to 1317 kPa, 13.0
to 13.4 bar (185 to 191 psi)
6 Torque Converter IN 545 to 607 kPa, 5.6
to 6.2 bar (79 to 88 psi)
8 Torque Converter OUT 393 to 414 kPa, 4.0
9 Lubrication Pressure 269 to 283 kPa, 2.7
to 2.9 bar(39 to 41 psi)
Neutral
1 Pump Supply Pressure 690 to 758 kPa, 7.0
to 7.7 bar (100 to 110 psi)
9 Lubrication Pressure 352 to 365 kPa 3.4
Reverse
14.6 bar (203 to 208 psi)
to 13.4 bar (185 to 191 psi)

6002-23
Test Two - Engine at 2200 r/min (2200 rpm)

Specifications -
bar at 49° C (16.3 to 18.5 gpm
at 200 psi at 120° F)
1 and 2 Cold Oil By-Pass 3034 to 3310 kPa, 30.9
to 33.7 bar at 49° C
(440 to 480 psi at 120° F)
7 Differential Lock Pressure 1262 to 1317 kPa, 12.7
(FNR must be in forward or reverse) to 13.4 bar (183 to 191 psi)
Forward
16.9 bar (230 to 240 psi)
to 14.1 bar (185 to 200 psi)
to 9.8 bar (120 to 140 psi)
8 Torque Converter OUT 434 to 455 kPa, to 4.4
4.6 bar (63 to 65 psi)
3.1 bar (42 to 44 psi)
Neutral
to 9.8 bar (125 to 140 psi)
to 8.8 bar (105 to 125 psi)
5.3 bar (70 to 73 psi)
4.4 bar (60 to 63 psi)
Reverse
16.6 bar (226 to 236 psi)
14.1 bar (185 to 200 psi)
9.8 bar (120 to 140 psi)
4.2 bar (57 to 60 psi)
9 Lubrication Pressure 241 255 kPa, 2.5
2.6 to bar (35 to 37 psi)

6002-24
FOUR WHEEL DRIVE
BD00M002LS
1. Flow meter adapter from charge pump to flow meter. (Use CAS-2011) Connect to CAS-10280 Flow Meter or
equivalent.
2. Return from flow meter to transmission. (Use CAS-2383)
3. Regulated clutch pressure, common to forward or reverse. (Use CAS-2745 and CAS-2746)
4. Regulated reverse clutch pressure. (Use CAS-2745 and CAS-2746)
5. Regulated forward clutch pressure. (Use CAS-2745 and CAS-2746)
6. Torque converter in presure. (Use CAS-2745 and CAS-2746)
7. Differential lock pressure (Use CAS-2744)
8. Converter out to oil cooler. (Use CAS-2747)
9. Lubrication pressure, common to converter return. (Use CAS-2745 and CAS-2746) or (Use CAS-2747)
10. Pump supply pressure, 4 wheel drive only. (Use CAS-2745 and CAS-2746)

6002-25
Test One - Engine at Idle 900 to 1100 r/min (900 to 1100 rpm)
Specifications -
bar at 49° C (7.02 to 7.28 gpm
at 200 psi at 120° F)
1 and 2 Cold Oil By-Pass 2875 to 3137 kPa,
29.3 to 32.0 bar at 49° C
(417 to 455 psi at 120° F)
7 Differential Lock Pressure 1262 to 1317 kPa, 12.7 to
Forward
10 Pump Supply Pressure 1393 to 1427 kPa, 14.2 to
14.6 bar (202 to 207 psi)
to 13.4 bar (185 to 191 psi)
Neutral
to 17.7 bar (194 to 202 psi)
9 Lubrication Pressure 352 to 365 kPa 3.4
Reverse
14.6 bar (203 to 208 psi)
to 13.4 bar (185 to 191 psi)

6002-26
Test Two - Engine at 2200 r/min (2200 rpm)

Specifications -
bar at 49° C (16.3 to 18.5 gpm
at 200 psi at 120° F)
1 and 2 Cold Oil By-Pass 3034 to 3310 kPa, 30.9
to 33.7 bar at 49° C
(440 to 480 psi at 120° F)
7 Differential Lock Pressure 1276 to 132 kPa, 13.0
Forward
16.9 bar (230 to 240 psi)
to 14.1 bar (185 to 200 psi)
to 9.8 bar (120 to 140 psi)
8 Torque Converter OUT 434 to 455 kPa, to 4.4
4.6 bar (63 to 65 psi)
3.1 bar (42 to 44 psi)
Neutral
to 14.9 bar (205 to 212 psi)
to 8.8 bar (105 to 125 psi)
5.3 bar (70 to 73 psi)
4.4 bar (60 to 63 psi)
Reverse
16.6 bar (226 to 236 psi)
14.1 bar (185 to 200 psi)
9.8 bar (120 to 140 psi)
4.2 bar (57 to 60 psi)
9 Lubrication Pressure 241 255 kPa, 2.5
2.6 to bar (35 to 37 psi)

6002
Section
6002
POWERSHIFT TRANSMISSION SPECIFICATIONS,


6002-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TEST PORT AND COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Left Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Right Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Top View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HEATING THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Machine Will Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission Oil Too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wheels Rotate When Vehicle is Raised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Transmission Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Irregular Clutch Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Gear Remains Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4WD Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Problem in Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6002-3
SPECIFICATIONS
Forward and reverse clutch pressures
At 2200 rpm............................................................................... 13.5 to 16.5 bar (196 to 240 psi), clutch activated
0 to 0.3 bar (0 to 4.3 psi), clutch released
Filter bypass valve .........................................................................................................8 to 11 bar (116 to 159.5 psi)
Lube pressure...................................................................................................................1 to 5 bar (14.5 to 72.5 psi)
Torque converter inlet pressure ......................................................................................3 to 9 bar (43.5 to 130.5 psi)
Differential lock ............................................................................................................14 to 17 bar (203 to 246.5 psi)
Brake booster port .......................................................................................................14 to 17 bar (203 to 246.5 psi)
Park brake pressure switch.........................................................................................9 to 11 bar (130.5 to 159.5 psi)
Park brake check port.........................................................................................13.5 to 15.5 bar (195.8 to 217.6 psi)
IMPORTANT: Vehicle may move during park brake pressure check, check park brake pressure from inside of cab
by removing floor plate.
Pump flow
At 900 rpm bench test before filter ............................................................................... 19 l/min. minimum (5 gpm)
1st gear clutch
At 900 rpm......................................................................................................11.5 to 14.5 bar (166.8 to 210.3 psi)
At 2200 rpm....................................................................................................13.0 to 15.5 bar (188.5 to 224.8 psi)
2nd gear clutch
3rd gear clutch
4th gear clutch
4 Wheel drive check port
Forward/Reverse clutch solenoids...................................................................................... 7.15 Ohm at 20° C (68° F)
Four wheel drive solenoid................................................................................................... 7.15 Ohm at 20° C (68° F)
Park brake solenoid .............................................................................................................. 9.8 Ohm at 20° C (68° F)
S 1/3 solenoid..................................................................................................................... 7.15 Ohm at 20° C (68° F)
S 2/4 solenoid..................................................................................................................... 7.15 Ohm at 20° C (68° F)
PWM 1/3 solenoid .............................................................................................................. 7.25 Ohm at 20° C (68° F)
PWM 2/4 solenoid .............................................................................................................. 7.25 Ohm at 20° C (68° F)
NOTE: All pressures and flows to be measured with oil temperature of 80° C (175° F).

6002-4
SPECIAL TOOLS
B877558U
CAS-1804 PRESSURE FITTING KIT B785789M
CAS-10280 FLOWMETER
B797157M
CAS-1808 FLOWMETER FITTING KIT

6002-5
TEST PORT AND COMPONENT LOCATIONS
1 2
8
7
6
BC08A224
LEFT SIDE VIEW
1. VALVE BODY 5. 2ND CHECK PORT

2. OIL FILTER BYPASS VALVE 6. 1ST CHECK PORT
3. SPEED PICKUP 7. LUBRICATION CHECK PORT
4. 4TH CHECK PORT 8. TORQUE CONVERTER INLET
PRESSURE TEST PORT

6002-6
9
10
11
BC08A225
FRONT VIEW
9. SPIN ON FILTER 11. DIP STICK PORT

10. OIL PUMP

6002-7
13
12
14
15
16
18 17
BC08A226
RIGHT SIDE VIEW
12. THERMOSTAT 16. 3RD CHECK PORT

13. OIL RETURN FROM COOLER 17. DRAIN PLUG
14. OIL PORT TO COOLER 18. ID PLATE
15. SUCTION FILTER

6002-8
19
24
20
23 21
22
BC08A227
REAR VIEW
19. BOOSTER PORT TO VEHICLE BRAKES 22. OIL RETURN PORT FROM VEHICLE BRAKES
20. HYDRAULIC PUMP MOUNT 23. PARK BRAKE PRESSURE TEST PORT
21. SAHR PARKING BRAKE HOUSING 24. PARK BRAKE RELEASE SOLENOID

6002-9
26 27 28
25
31
29
30
BC08A228
TOP VIEW
25. PRESSURE SENSOR 29. REVERSE CLUTCH TEST PORT

26. BREATHER 30. OIL CHECK PORT
27. LUBE PRESSURE TEST PORT 31. DIFFERENTIAL LOCK TEST PORT
28. FORWARD CLUTCH TEST PORT

6002-10
HEATING THE OIL

1. Check the oil level and type before proceeding. 6. Run the engine up to 1500 to 1700 rpm for a
duration of 30 seconds.
2. Activate the parking brake.
NOTE: DO NOT exceed 30 seconds.
7. Reduce engine rpm to low idle and place the
4. Place the gear selector into 4th gear.
FNR lever in neutral for 15 seconds.
5. Put the FNR selector in forward position.
8. Repeat this procedure until the oil temperature
reaches 78° to 82° C (172.5° to 176° F).
9. Refer to section 2002 and perform a stall test on
the engine before proceeding.

6002-11
NOTE: All troubleshooting procedures must be done with oil at operating temperature.
e
Machine Will Not Move

Is oil level correct? Add oil as required. Troubleshooting complete. Find cause for
No
Is there still a problem. loss of oil.
Yes
Check transmission oil pressure, check

Is the SAHR parking brake releasing. No
electrical supply to the solenoid.
Yes
Check for broken universal joint or drive

shaft and repair as required. Is there still a No Troubleshooting complete.
problem?
Yes
Check to see if drive shaft turns with

transmission directional control lever (FNR) No Check electrical connections at transmission.
in forward or reverse and rear wheels off the Is there power to the clutch solenoids?
ground. Does the drive shaft turn?
No
Check the fuse panel.

Yes
Check pressure and pump flow.

Is flow in specified range? No
Possible causes include:
1. Cold oil by-pass valve might be stuck or
damaged.
2. Pressure regulator could be bad.
Yes 3. Pump could be bad. See Section 6007 to
repair or replace as required.
There can be a problem in the transmission

Check the transmission control valve.
control valve. Is the converter In pressure in No
Repair or replace as required.
the specified range?
Yes

6002-12
There can be a problem in the

forward/reverse solenoid valve. Are the Check the transmission. See Section 6007.
No
clutch pressures for forward and reverse in Repair or replace as required.
the specified range?
Yes
Check clutch pressure. No

Is the pressure in the specified range? Possible causes include:
1. If pressure remains at zero in forward,
Yes neutral and reverse the problem could be
in the control valve.
Check the transmission. See Section 6007.
Repair or replace as required. 2. If pressure is low, problem could be in
the control valve.
d if fe r e n t, i n s p e c t i n d i v i d u a l c l u t c h
circuits. See Section 6007 for repair.
Loss of Power
No
Yes
Is there a build up of mud or other foreign

material on inside of wheel wells or along
drive train? Clean or remove material.
Yes
Do stall test according to instructions in

Section 2002. No Repair engine as required.
Is the engine good?
Yes
Check pressure. Is the pressure as specified? No See Section 6007 to repair as required.
Yes
See Machine will not Move on page 11.

6002-13
Transmission Oil Too Hot

No
Yes
Check transmission oil cooler for air flow

restriction. Clean exterior of transmission oil No Troubleshooting complete.
cooler as required.
Yes
Check converter in pressure.

No See Machine will not Move on page 11.
Is the pressure and flow as specified?
Yes
Check lube pressure. See page 9. Is the No If torque converter pressure is high and lube
pressure as specified? pressure is low, possible causes include:
Yes 1. The oil cooler is restricted. Replace the

oil cooler.
Troubleshooting complete. 2. The oil cooler circuit is restricted. Inspect
the oil cooler circ uit and repair as
required.
NOTE: The transmission oil cooler cannot be flushed or cleaned out, the transmission oil cooler must be
replaced if restricted or plugged.
Wheels Rotate When Vehicle is Raised

Is oil type correct? Change oil as required.
Yes
Is oil temperature low (high oil viscosity) Yes Wait for oil to reach operation temperature.
No
Control valve allowing pressure to clutches

Yes Replace control valve.
while in neutral position.

6002-14
Transmission Noisy
No
Yes
Damaged converter. Yes See Section 6007 and replace.
No
Damaged oil pump. Yes See Section 6007 and replace.
No
Yes See Section 6007 and repair/replace as

Seized or broken gears, shafts, bearing, etc.
required.
Irregular Clutch Activation

No
Yes
Check clutch pressure Inspect modulation spool and piston for

No
Is the pressure in the specified range? sticking or damage.
Yes
Check the transmission clutches. See

Check for TRAX fault codes
No Section 6007. Repair or replace as
Are fault codes present
required.
Yes
See section 4005 and this section for


6002-15
Gear Remains Engaged

No
Yes
Check clutch pressure in neutral position No Inspect modulation spool and piston for
Is the pressure in the specified range? sticking or damage.
Yes
Check the transmission clutches. See

required.
Yes

4WD Does Not Work

Check for broken universal joint or front drive
shaft, and repair as required. Is there still a No Troubleshooting complete.
problem?
Yes
Check to see if front drive shaft turns with

If the front drive shaft turned with the
transmission direction control lever (FNR) in
directional control lever (FNR) in forward or
forward or reverse, 4WD engaged, and the all No
reverse, the problem is in the front axle. See
wheels off the ground. Does the front drive
Section 5006. Repair as required.
shaft turn?
Yes
Check the transmission 4WD clutch. See

required.
Yes


6002-16

Does parking brake release. No Check the electrical and hydraulic circuits.
Hydraulic

pressure, is pressure as
specified?
No

see section 6007.
Yes
Check solenoid, 9.8 Ohm at 20° C (68° F),

replace as needed.
Test parking brake, see section 7002. See section 7000 for brake disc
No
Does parking brake hold machine? replacement.
Yes

6002-17
NOTES

6002-18
1 2 3 4 5 6
7 8
9 10
11 12 13
14
15
16
17 20
19 21 22
18
24
23 25
26
27 28 29
BS08A363

6002-19
1. SAHR PARKING BRAKE 16. OIL FLOW DIVIDER/PRESSURE REGULATOR VALVE

2. 4WD SAHR CLUTCH 17. SPIN-ON FILTER
3. 3RD GEAR CLUTCH 18. OIL FILTER RELIEF VALVE
4. 4TH GEAR CLUTCH 19. TRANSMISSION OIL PUMP
5. FORWARD CLUTCH 20. TORQUE CONVERTER
6. REVERSE CLUTCH 21. OIL COOLER
7. FORWARD CLUTCH PRESSURE CHECK PORT 22. TEMPERATURE THERMOSTAT
8. REVERSE CLUTCH PRESSURE CHECK PORT 23. AIR BREATHER
9. 1ST GEAR CLUTCH 24. SUCTION FILTER
10. 2ND GEAR CLUTCH 25. TORQUE CONVERTER PRESSURE RELIEF VALVE
11. 1ST GEAR CLUTCH PRESSURE CHECK PORT 26. BRAKE OIL PORT RETURN TO SUMP
12. 2ND GEAR CLUTCH PRESSURE CHECK PORT 27. OUTPUT SHAFTS LUBRICATION
13. DIFFERENTIAL LOCK PORT 28. PRIMARY SHAFT LUBRICATION
14. PARKING BRAKE SOLENOID VALVE 29. INPUT SHAFT LUBRICATION
15. AUXILIARY PORTS
HYDRAULIC COMPONENTS

6002-20
1 2 3 4
6 7 8
5
BC08A418
CONTROL VALVE
1. PULSE- WIDTH MODULATION 2/4 SOLENOID, PORT A 5. 4 WHEEL-DRIVE SOLENOID, PORT E

2. REVERSE SOLENOID, PORT B 6. 2ND/4TH SOLENOID, PORT F
3. FORWARD SOLENOID, PORT C 7. DIFFERENTIAL LOCK SOLENOID, PORT G
4. PULSE- WIDTH MODULATION 1/3 SOLENOID, PORT D 8. 3RD/4TH SOLENOID, PORT H
BD08B401-01
NOTE: Remove the floor plate to gain access to the connectors for the transmission, connector J1 (1) and
connector J2 (2).

6002-21
DEU_DT04-12P DEU_DT04-8P
CONNECTOR J1 CONNECTOR J2
CAV TO CAV COMPONENT CAV TO CAV COMPONENT

1 PIN 2 S 1/3 AND S 2/4 SOLENOID 1 PIN 1 FORWARD SOLENOID
2 PIN 1 S 1/3 SOLENOID 2 PIN 2 FORWARD SOLENOID
3 PIN 1 S 2/4 SOLENOID 3 PIN 1 REVERSE SOLENOID
4 PIN 2 4WD AND HDL SOLENOID 4 PIN 2 REVERSE SOLENOID
5 PIN 1 4WD SOLENOID 5 PIN 1 PWM 1/3 SOLENOID
DIFFERENTIAL LOCK 6 PIN 2 PWM 1/3 SOLENOID
6 PIN 1
SOLENOID
7 PIN 1 PWM 2/4 SOLENOID
7 PIN 1 RPM SENSOR
8 PIN 2 PWM 2/4 SOLENOID
8 PIN 3 RPM SENSOR
9 PIN 1 TEMP SENSOR
10 PIN 3 TEMP SENSOR NOTE: Readings are taken at 20° C (68° F).
11 PIN 1 PRESSURE SENSOR 1. Take an Ohm reading from pin 1 to pin 2 on
12 PIN 2 RPM/TEMP/PRESS SENSORS connector J2 for the forward solenoid, a reading
of 7.15 Ohm should be obtained.
2. Take an Ohm reading from pin 3 to pin 4 on
NOTE: Readings are taken at 20° C (68° F). connector J2 for the reverse solenoid, a reading
1. Take an Ohm reading from pin 1 to pin 2 on of 7.15 Ohm should be obtained.
connector J1 for the S 1/3 solenoid, a reading of 3. Take an Ohm reading from pin 5 to pin 6 on
7.15 Ohm should be obtained. connector J2 for the PWM 1/3 solenoid, a
2. Take an Ohm reading from pin 1 to pin 3 on reading of 7.25 Ohm should be obtained.
connector J1 for the S 2/4 solenoid, a reading of 4. Take an Ohm reading from pin 7 to pin 8 on
7.15 Ohm should be obtained. connector J2 for the PWM 2/4 solenoid, a
3. Take an Ohm reading from pin 4 to pin 5 on reading of 7.25 Ohm should be obtained.
connector J1 for the 4WD solenoid, a reading of
7.15 Ohm should be obtained.
4. Take an Ohm reading from pin 4 to pin 6 on
connector J1 for the differential lock solenoid, a
reading of 7.15 Ohm should be obtained.

6002-22
ELECTRICAL SCHEMATIC
2
1
3
4
14 5
22
6
21
7
20
8
19 9
10
15
11
16
18 12
13
17
1. FNR SHIFTIER 7. 1/3 SOLENOID 13. PRESSURE SENSOR 18. FRONT CONSOLE CAN
2. TRANSMISSION CONTROLLER 8. 2/4 SOLENOID 14. J2 CONNECTOR 19. CHASSIS 4WD CONNECTOR
3. FORWARD SOLENOID 9. 4WD SOLENOID 15. J1 CONNECTOR 20. LOADER LEVER HARNESS
4. REVERSE SOLENOID 10. DIFF LOCK SOLENOID 16. BRAKE PRESSURE SWITCHES 21. KICK DOWN SWITCH
5. PWM 1/3 SOLENOID 11. SPEED SENSOR 17. AUTO/MANUAL SWITCH 22. TO FRONT CONSOLE
6. PWM 2/4 SOLENOID 12. TEMP SENSOR
NOTE: See electrical schematic in rear pocket of manual for complete circuit.

Section
6003
6003
WHEELS AND TIRES

6003-2
TABLE OF CONTENTS
WHEEL NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580M and 580 Super M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580 Super M + . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
590 Super M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6003-3
WHEEL NUTS
General Information
When the machine is new or when a wheel is removed for service, check the wheel nut or bolt torques every 10
hours of operation until the wheel nuts or bolts remain tight.
IMPORTANT: The rear wheel mounting nuts on this machine are metric. Use only the mounting nuts shown in the
parts catalog for this machine.
Check the torque with a dial or click torque wrench. If the nut does not move on the following torques, it is tight and
does not need re-torqued:
Front wheel, two wheel drive ...............................................................................................156 Nm (115 pound-feet)
Front wheel, four wheel drive...............................................................................................251 Nm (185 pound-feet)
Rear wheel mounting nuts...................................................................................................305 Nm (225 pound-feet)
Torque Specifications
Front wheel, two wheel drive .........................................................................156 to 203 Nm (115 to 150 pound-feet)
Front wheel, four wheel drive...............................................................................................251 Nm (185 pound-feet)
Rear wheel mounting nuts...................................................................................................305 Nm (225 pound-feet)
Front Wheel Mounting Nut Torque Procedure
1. Install all eight (8) mounting nuts. Tighten all mounting nuts, in the sequence shown, until the wheel is snug
against the axle hub.
2. Tighten the mounting nuts, in the sequence shown, to a torque of 122 Nm (90 pound-feet).
3. Then turn each nut in the tightening direction, in the sequence shown, an additional 90 degrees to set the
required pre-load on the front wheel mounting nuts.
Rear Wheel Mounting Nut Torque Procedure
1. Install all ten (10) wheel mounting nuts. Tighten all mounting nuts, in the sequence shown, until the wheel is
snug against the axle hub.
2. Tighten the mounting nuts, in the sequence shown, to a torque of 136 Nm (100 pound-feet).
3. Then turn the mounting nuts again, in the sequence shown, to a torque of 271 Nm (200 pound-feet).
4. Then turn each mounting nut in the tightening direction, in the sequence shown, an additional 30 degrees to
set the required pre-load on the rear wheel mounting nuts.
1 8 1 8
5 5
4
4
9 10
3 3
6 6
7 7 2
2
BD00F102 BP98J086
FRONT WHEEL MOUNTING NUT TORQUE SEQUENCE REAR WHEEL MOUNTING NUT TORQUE SEQUENCE

6003-4
TIRE PRESSURE
580M and 580 Super M

Front Tires
11L x 16 (2wd), 10 PR, F3 .................................................................................................. 52 psi (358 kPa, 3.6 bar)
12 x 16.5 (4wd) 8 PR, Lug ...................................................................................................50 psi (345 kPa, 3.4 bar)
Rear Tires
16.9 x 28, 10 PR, R4 ...........................................................................................................32 psi (220 kPa, 2.2 bar)
17.5L x 24, 10 PR, R4 .........................................................................................................32 psi (220 kPa, 2.2 bar)
19.51L x 24, 10PR, R4 ........................................................................................................28 psi (193 kPa, 1.9 bar)
Optional Wide Track:
19.5 L x 24, 12 PR, R4 ........................................................................................................34 psi (230 kPa, 2.3 bar)
580 Super M +
Front Tires
14.5/75 x 16.1 (2wd), 10 PR.................................................................................................40 psi (276 kPa, 2.8 bar)
12.5/80 x 18 (4wd), 10 PR....................................................................................................60 psi (413 kPa, 4.1 bar)
Rear Tires
21L x 24, 10 PR....................................................................................................................26 psi (179 kPa, 1.8 bar)
590 Super M
Front Tires
14.5/75L x 16.1 (2wd), 10 PR, F3 ........................................................................................40 psi (276 kPa, 2.8 bar)
14 x 17.5 (4wd), 10PR, Lug .................................................................................................55 psi (380 kPa, 3.8 bar)
Rear Tires
21 L x 24, 10PR, R4 .............................................................................................................26 psi (179 kPa, 1.8 bar)

Section
6004
6004
REAR AXLE AND PLANETARIES
580M AND 580SM SERIES 3

CNH America LLC All rights reserved.
6004-2 580M AND 580SM ONLY
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WHEEL HUB AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassemble Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Differential Lock Fork Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Differential Lock Housing and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Differential Lock Fork Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Assemble Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pinion Gear Backlash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Differential Bearing Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pinion Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking the Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ring and Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Wheel Hub and Final Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

580M AND 580SM ONLY 6004-3
SPECIFICATIONS
Gear lubricant ..............................................................Wet Brake/Transmission Lubricant - SAE 80W140 MAT 3510
Capacity.......................................................................................................................... 13.6 liters (14.4 U.S. quarts)
Special Torques
Allen head bolts for hub housing ..................................................................................226 Nm (166.5 pound-feet)
Bolts for ring gear ............................................................................................................155 Nm (114 pound-feet)
Bolts for differential support long bolts ................................................................................80 Nm (59 pound-feet)
Bolts for differential support short bolts...........................................................................169 Nm (125 pound-feet)
Drain hole plugs at wheel hub .............................................................................................60 Nm (44 pound-feet)
Fill and drain hole plugs at differential.................................................................................80 Nm (59 pound-feet)
Ring nut for wheel hub ...............................................................................................1000 Nm (737.5 pound-feet)
Differential adjusting ring lock screws ......................................................................... 10 Nm (88.5 pound-inches)
Brake self adjuster shouldered bolt ........................................................................... 16 Nm (141.5 pound-inches)
Brake bleeder ............................................................................................... 8 to 12 Nm (71 to 106 pound-inches)
Differential pin plug..............................................................................................................25 Nm (18 pound-feet)
Differential lock plug ........................................................................................................180 Nm (133 pound-feet)
Wheel studs .....................................................................................................................70 Nm (51.5 pound-feet)
Pinion rotating torque (without seal) ............................................................ 2 to 2.4 Nm (17.7 to 21.2 pound-inches)
Differential bearing preload rotating torque (without seal) .............................. 2.6 to 3.3 Nm (23 to 29 pound-inches)
Backlash for ring gear........................................................................................0.2 to 0.29 mm (0.008 to 0.011 inch)

6004-4 580M AND 580SM ONLY
SPECIAL TOOLS
BD07N332-01
DIFFERENTIAL RING NUT WRENCH 380002433.
BD07N445-01
OEM4185 UNIVERSAL BEARING CUP INSTALLER -
USED TO INSTALL THE HUB BEARING CUPS.
1 2 3 4
BD07N333-01
PINION DEPTH GAUGE
1. CAS1596A-4
2. CAS1596A-7
3. CAS1596A-6
4. 380002436
BD07N446-01
CAS1716-3 HANDLE (PART OF CAS1716 AG TOOL KIT) -
USED WITH CAS2374 HUB SEAL INSTALLER.
BD07N337-01
CAS2151A OFFSET SPANNER WRENCH -
USED TO REMOVE AND INSTALL THE PINION NUT.
BD07N444-01
YOKE TO HOLD SHAFT. ORDER P/N 144279A1.

580M AND 580SM ONLY 6004-5
BD07N335-01
PINION DEPTH GAUGE BAR 380000407
BD07N331-01
SELF ADJUSTING BRAKE TOOLS 380002435.
BD07N336-01
WHELL HUB SEAL DRIVER 380002431
BD07N329-01
SOCKET FOR RING NUT ON WHEEL FLANGE 380002434.
BD07N330-01
BD07N334-01
SEAL PROTECTOR CAS2369
BD07N328-01
SPANNER WRENCH CAS1840C

6004-6 580M AND 580SM ONLY
BP95F672 BD08B441-01
CAS1968 STUD REMOVER/INSTALLER - USED TO REMOVE FABRICATE FROM LOCKING DIFFERENTIAL CYLINDER,
SHOULDER STUDS FROM WHEEL HUBS USED TO COMPRESS DIFFERENTIAL LOCK SPRING TO
REMOVE “C” CLIP

580M AND 580SM ONLY 6004-7
WHEEL HUB AND BRAKES
Disassembly
STEP 1 STEP 3
BD07N327-01
BD07N340-01
Remove the axle vent to relieve any pressure inside Place an oil receptacle under the differential carrier
of the axle. and drain the oil.
STEP 2 STEP 4
BD07N338-01
BD07N341-01
Place an oil receptacle under the outer housings of Remove all but two of the cap screws.
the axle and drain the oil. NOTE: Large amounts of Loctite was used during
assembly, remove cap screws slowly. If screw binds,
turn back in and then back out.

6004-8 580M AND 580SM ONLY
STEP 5 STEP 8
BD07N349-01 BD07N352-01
Insert 3 long dowel rods, (tool number), for in vehicle Slowly pull hub away from axle, make sure that the
service or two short dowel rods, (tool number), for brake disks and plates stay with the hub.
bench service.
STEP 9
STEP 6
BD07N353-01
BD07N350-01 Pull the half shaft out with the hub and brakes.
Remove the remaining cap screws.
STEP 10
STEP 7
BD07N354-01
BD07N351-01 Place the hub, brakes and half shaft on a suitable
Pry the hub from the axle using slots. work bench.

580M AND 580SM ONLY 6004-9
STEP 11 STEP 14
BD07N355-01 BD07N254-01
Stand the hub up, mark the reaction plat that was Loosen and remove the shouldered bolts, and spring
against the axle housing. Remove the reaction and washers from the brake self adjusters.
brake disks.
NOTE: Keep brake surfaces in same relationship to STEP 15
each other if being reused.
STEP 12
BD07N357-01
Check springs and shouldered bolt for damage. If
brakes are being replaced, replace springs and bolts
with kit.
BD07N253-01
Remove the half shaft from the planetary gears. STEP 16
STEP 13
BD07N256-01
Remove the lock ring.
BD07N320-01
Left hand shaft is 807 mm (31.7 in) long and the right
hand shaft is 701 mm (27.5 in) long.

6004-10 580M AND 580SM ONLY
STEP 17 STEP 19
BD07N257-01 BD07N361-01
Remove the self adjuster. If brakes are being Place the driver (tool number) onto self adjuster and
replaced replace adjusters. drive the spring clips from the adjuster.
NOTE: Once removed the self adjusters spring clips
must be replace with genuine parts, DO NOT use STEP 20
after market parts.
STEP 18
BD07N362-01
Inspect adjuster bushing for wear.
BD07N360-01
STEP 21
Place the self adjuster on (tool number).
NOTE: Place the tapered end of the self adjuster
into (tool number).
BD07N258-01
Use an acceptable flat bars and pry the brake piston
up from the hub.

580M AND 580SM ONLY 6004-11
STEP 22 STEP 25
BD07N371-01
BD07N259-01
Remove the piston from the hub. Remove and discard outer brake piston O-ring only if
machine has high hours.
STEP 23
STEP 26
BD07N377-01
Remove the inner cylinder. BD07N372-01
Remove and discard inner brake piston O-ring only if

STEP 24 machine has high hours.
STEP 27
BD07N260-01
The cylinder may remain in the housing, use pry bar
BD07N374-01
and remove the cylinder.
Remove and discard brake cylinder O-ring only if

6004-12 580M AND 580SM ONLY
STEP 28 STEP 31
BD07N261-01 BD07N263-01
Remove and discard the hub o-ring. Carefully raise the planetary set, hold the snap ring
open until it has cleared the end of the wheel flange
STEP 29 shaft.
STEP 32
Remove planetary set from the hub.
STEP 33
BD07N262-01
Attach lifting equipment to the planetary gears.
STEP 30
BD07N264-01
Remove planetary gear retainer snap rings.
STEP 34
BD07N277-01
Locate the snap ring slot and place snap ring pliers in
slot.
BD07N265-01
Remove planetary gear and bearings.

580M AND 580SM ONLY 6004-13
STEP 35 STEP 38
BD07N268-01 BD07N271-01
Place the wheel end in a press and lock the wheel Do not press directly against the sun gear pad.
hub so it can not turn.
NOTE: Do not use excessive force. STEP 39
STEP 36
BD07N272-01
Place the wheel hub in a press.

BD07N269-01
Use ring nut socket, 380002434, a torque multiplier, STEP 40

and loosen wheel flange ring nut.
STEP 37
BD07N273-01
Press the wheel flange from the wheel hub.
BD07N379-01
Remove ring nut from wheel hub.

6004-14 580M AND 580SM ONLY
STEP 41 STEP 44
BD07N274-01 BD07N385-01
Attach lifting equipment to hub housing and remove Remove the outer race.
from the wheel flange.
STEP 45
STEP 42
BD07N387-01
BD07N381-01 Remove spacer from wheel flange.

Remove the inner bearing race.
STEP 46
STEP 43
BD07N386-01
BD07N382-01 To remove the inner bearing, use a die grinder to cut

Remove the cassette seal. the roller retainer and race. Use a chisel in the slot
cut in the race to crack the race, remove the race.

580M AND 580SM ONLY 6004-15
Inspection Assembly
STEP 47 STEP 56
Clean all parts in cleaning solvent.
STEP 48
Discard all seals and O-rings.
STEP 49
Inspect the bearing cups and the rollers in the wheel
damage. Also check the inner race for damage. If you
find any of these defects, you must install new wheel
bearings and bearing cups.
STEP 50
BD07N383-01
Inspect the planetary shafts for wear and damage.
If the outer bearing cups were removed, use an
The planetary shaft bushings are not sold separately.
OEM-4185 Universal Bearing Cup Installer or other
If a shaft bushing is damaged, you must use a new
acceptable tool to install the bearing cups.
carrier.
NOTE: The above photo shows the cassette seal
STEP 51 installed, the cassette seal will be installed during a
Inspect the teeth on the planetary gears, the half later step.
shaft, and the ring gear for wear, pitting, scoring, and
other damage. Use new parts as required. STEP 57
STEP 52
Inspect the needle bearings for the planetary gears
for flat areas, pitting, scoring, and other damage. If
you find any of these defects, use new parts as
required.
STEP 53
Inspect the brake disks and reaction plates for pitting,
scoring, excessive surface wear, and other damage.
Use new parts as required.
STEP 54
BD07N384-01
Inspect brake pistons and cylinders for scaring on
If the inner bearing cups were removed, use an
sliding surfaces, brake pistons for pitting, scoring,
and excessive surface wear at brake contact point.
Use new pars as required.
STEP 55
Replace O-rings on brake cylinders and pistons.
IMPORTANT: Use only genuine parts. DO NOT use
after market O-rings, they will fail.

6004-16 580M AND 580SM ONLY
STEP 58 STEP 61
IMPORTANT: The words “OUTSIDE” on the hub seal Clean all sealing surfaces with an alcohol based
must be facing out. cleaner, if any oil residue is on sealing surfaces the
seal will leak.
STEP 62
BD07N275-01
Use the 380002431 hub seal installer with handle to
install the hub seal. Push only until the hub seal
BD07N274-01
makes contact with the shoulder inside the hub. Attach lifting equipment to hub and carefully install
Continued pushing can damage the hub seal. onto wheel flange.
STEP 59 NOTE: Use care and install the hub straight onto the
wheel flange, damage to seal can occur if angled.
DO NOT use excess force to seat hub onto wheel
flange.
STEP 63
BD07N386-01
Install the outer wheel flange bearing with a suitable
driver.
STEP 60
BD07N379-01
Install inner bearing with a suitable driver, install ring
nut.
NOTE: The ring nut can be installed with either side
up or down.
BD07N387-01
Install spacer on wheel flange.
580M AND 580SM ONLY 6004-17
STEP 64 STEP 67
Attach lifting equipment to planetary set and lower
into hub.
STEP 68
BD07N270-01
Use ring nut socket, 380002434, torque ring nut to
1000 Nm (737.5 pound-feet).
NOTE: The use of a torque multiplier as shown is
BD07N380-01
acceptable.
During installation the locking ears on the planetary
STEP 65 carrier must engage the ring nut as shown.
STEP 69
BD07N266-01
Use a suitable driver and press the planetary gears
BD07N277-01
onto the planet carrier.
Hold the snap ring open and lower the planetary
assembly into position.
STEP 66
BD07N267-01
Install the retaining snap rings on the carrier.

6004-18 580M AND 580SM ONLY
STEP 70 STEP 73
BD07N278-01 BD07N376-01
Make sure that the snap ring is fully closed, two tips Use hydraulic oil to lubricate the inner O-ring of the
touch, remove lifting equipment. brake piston, press the brake cylinder into the brake
piston.
STEP 71
STEP 74
BD07N279-01
Install a new O-ring onto the hub. BD07N378-01

Use hydraulic oil to lubricate the outer O-ring of the
STEP 72 brake piston.
STEP 75
BD07N375-01
Use hydraulic oil to lubricate the brake cylinder
O-ring. BD07N281-01
Use hydraulic oil to lubricate the brake cavity of the
hub housing.

580M AND 580SM ONLY 6004-19
STEP 76 STEP 79
BD07N373-01 BD07N364-01
Place the brake piston and cylinder onto the hub. Place aligning tool into brake adjuster tool, part of
tool kit 380002435.
NOTE: Use brake pins for guides.
STEP 80
STEP 77
BD07N365-01
BD07N283-01
Place the first adjuster ring onto aligning tool.
Use the three shouldered bolts and washers to pull
the brake piston and cylinder into the hub. NOTE: For ease of installation, look at the inside of
the adjuster ring, place tapered end down.
STEP 78
STEP 81
BD07N363-01
Place the brake adjuster with tapered edge facing up BD07N366-01
into depth setting tool, part of tool kit 380002435. Place the second adjuster ring onto aligning tool with
the slot at 90° from the slot of the first ring.

6004-20 580M AND 580SM ONLY
STEP 82 STEP 85
BD07N367-01 BD07N370-01
Place the third adjuster ring onto aligning tool with Drive the rings onto the adjuster until they are seated
the slot at 180° from the slot of the first ring. against the depth setting tool.
STEP 83 STEP 86
BD07N368-01 BD07N359-01
Place the fourth adjuster ring onto aligning tool with
Insert the adjuster into the brake piston, make sure
that the chaffered side is up.
STEP 84 STEP 87
BD07N369-01 BD08A496-01
Place driver tool onto aligning tool, driver part of tool Make sure the tips of the snap ring face the adjuster
kit 380002435. during installation.

580M AND 580SM ONLY 6004-21
STEP 88 STEP 91
BD07N256-01 BD07N358-01
Install the snap ring into the self adjuster bore. Hand tighten the shouldered bolt until seated into
adjuster, spring washers can become bound on the
STEP 89 shoulder of the bolt and be damaged.
STEP 92
BD07N282-01
Make sure the snap ring fully engages the grove in
the brake piston. BD07N255-01
To r q u e s h o u l d e r e d b o l t s t o 1 6 N m ( 1 4 1 . 4
STEP 90 pound-inches).
STEP 93
BD07N356-01
Place spring washers onto shouldered bolt facing as
shown. BD07N431-01
Put the half shaft and brake separator plate pins into
the axle housing.

6004-22 580M AND 580SM ONLY
STEP 94 STEP 96
BD07N432-01 BD07N434-01
Using the reference mark made during disassembly, Install the second brake separator, SM models only.
place the inner brake separator plate into the axle
NOTE: The thicker of the two separator plates is
housing.
used here.
NOTE: The thinner of the two separator plates is
used here. STEP 97
IMPORTANT: If using new brake disks they must be
soaked in oil for 24 hours prior to installation.
STEP 95
BD07N435-01
Place the outer brake disk onto the half shaft, do not
damage any of the splines or teeth.
BD07N433-01
STEP 98
Place the inner brake disk onto the half shaft, do not
NOTE: For the 580M there is only one brake disk, for
all Super M models there are two brake disks.
BD07N429-01
Make sure the slots of the inner and outer brake
disks are aligned with each other.

580M AND 580SM ONLY 6004-23
STEP 99 STEP 101
BD07N430-01 BD07N437-01
Install dowel rods into axle housing, two short rods Use a piece of rope and lift the axle shaft into the
for bench repair, three long for in vehicle repair. planetary gears while pushing the hub onto the axle.
NOTE: The input shaft for the differential may need
STEP 100 to be turned in order to align the splines on the half
shaft sun gear and the planetary gears.
STEP 102
BD07N436-01
Attach lifting equipment to hub assembly and guide
onto dowel rods.
NOTE: Care needs to be taken that the self BD07N339-01
adjusters are not damaged by falling plates or by Use Loctite 270 on thread of the bolts and torque to
hitting them on the housing when bringing hub into 226 Nm (166.5 pound-feet).
position.
STEP 103
Install and tighten drain plugs.
STEP 104
Fill the axle with oil, see page 3 for quantity and type.

6004-24 580M AND 580SM ONLY
DIFFERENTIAL
Carrier Removal STEP 4
STEP 1
Remove the wheel hubs and brakes, see Wheel
Hubs And Brakes Disassembly in this section.
STEP 2
BD07N315-01
Have an assistant hold the differential housing up
away from the axle housing, attach a lifting eye to the
bottom of the differential housing.
STEP 5
BD07N318-01
Remove the differential mounting bolts.
STEP 3
BD07N316-01
away from the axle housing, attach a lifting eye to the
top of the differential housing.
BD07N319-01
Use pry bars in slots. STEP 6
BD07N314-01
Attach lifting equipment to lifting eyes.

580M AND 580SM ONLY 6004-25
STEP 7 STEP 11
Remove the differential and place on a work bench.
Disassemble Differential
STEP 8
BD07N388-01
The bearing cups can be removed with a roll head
pry bar if replacement is needed.
STEP 12
BD07N308-01
Remove the bolts securing the ring nut.
STEP 9
BD07N390-01
Remove the locking ring.
STEP 13
BD07N306-01
Remove the ring nuts.
STEP 10
Remove the differential from the carrier.
BD07N391-01
Remove the differential housing cover, remove the
anti rotation pin.

6004-26 580M AND 580SM ONLY
STEP 14 STEP 17
BD07N392-01 BD07N395-01
The thrust washer may stay on the cover, remove the Remove the three pins securing the spider pins in the
thrust washer. differential.
STEP 15 STEP 18
BD07N393-01 BD07N397-01
Remove the gear from the housing. Remove the ring gear cap screws, remove the ring
gear.
STEP 16 NOTE: Large amounts of Loctite was used during
STEP 19
2
BD07N394-01
Remove three plugs from the differential. 1
BD07N398-01
Note the flat surface on pin (1) and spacer (2).

580M AND 580SM ONLY 6004-27
STEP 20 STEP 23
BD07N399-01 BD07N402-01
Push the pin towards the flat surface side noted in Remove the spider gear and thrust washer.
the previous step.
NOTE: DO NOT force the pin, it will not come out of STEP 24
the housing at this time.
STEP 21
BD07N403-01
Push one of the short spider pins out of the spacer by
pushing it through the hole in the spacer.
BD07N400-01 NOTE: Do not remove the pin at this time, leave the
Remove the spider gear and thrust washer. pin in far enough to support the spider gear and
thrust washer.
STEP 22
BD07N401-01
Push the pin out of the housing.

6004-28 580M AND 580SM ONLY
STEP 25 STEP 28
BD07N404-01 BD07N407-01
Push the other short spider pin out of the spacer by Remove the other pin, gear and thrust washer from
pushing it through the hole in the spacer. the housing.
NOTE: Do not remove the pin at this time, leave the
pin in far enough to support the spider gear and STEP 29
thrust washer.
STEP 26
BD07N409-01
Remove the gear and thr ust washer from the
housing.
BD07N405-01
Remove the spacer from the housing. STEP 30
STEP 27
BD07N303-01
Remove the differential locking pins from the
housing.
BD07N406-01
Remove the spider pin, gear and thrust washer from

the housing.

580M AND 580SM ONLY 6004-29
STEP 31 STEP 34
BD07N284-01 BD07N287-01
Remove the cover and seal from the carrier. Use the offset spanner, CAS2151A, and yoke P/N
144279A1 to remove the pinion gear ring nut.
STEP 32
STEP 35
Use a soft faced hammer and drive the pinion out of
the carrier housing.
STEP 36
BD07N285-01
The pinion gear nut is staked into place on the pinion
shaft.
STEP 33
BD07N288-01
Remove the crush sleeve and shims from the pinion
shaft.
STEP 37
BD07N286-01
Use a chisel punch to remove the stake from the
pinion shaft NUT.
BD07N289-01
Press the the bearing from the pinion shaft.

6004-30 580M AND 580SM ONLY
STEP 38 Differential Lock Fork Removal
NOTE: The differential lock fork may look different
for machines equipped with a Power Shift
transmission. The procedure is the same.
STEP 41
BD07N290-01
Remove the shim from the pinion.
STEP 39
BD07N293-01
Loosen the differential lock cylinder from the carrier.
STEP 42
BD07N291-01
Remove the outer bearing cup from the carrier.
STEP 40
BD07N294-01
Hold the differential lock fork down to catch a block
inside of the housing, remove the cylinder.
NOTE: Use caution removing the cylinder, it is under
spring pressure.
BD07N292-01
Remove the inner bearing cup from the carrier.

580M AND 580SM ONLY 6004-31
STEP 43 STEP 46
BD07N295-01 BD07N298-01
Place a flat washer over the shaft. Tighten the modified cylinder and press down on the
bushing, remove the snap ring.
STEP 44
STEP 47
BD07N296-01
Star t the modified cylinder into the differential BD07N299-01
housing. Remove the bushing.
STEP 45 STEP 48
BD07N300-01
BD07N297-01
Block the fork from moving. Remove the spring.

6004-32 580M AND 580SM ONLY
STEP 49 Differential Lock Housing and
Piston
STEP 51
BD07N301-01
Remove the shaft.
STEP 50
BD07N416-01
Install new O-rings on the piston. Lubricate the
O-rings with clean hydraulic oil. Install a new O-ring
on the cover for the differential lock.
STEP 52
Lubricate the bore in the cover for the piston with
clean hydraulic oil. Install the piston in the cover for
the differential lock.
BD07N417-01
Remove the fork, spring and bushing from the shaft.

580M AND 580SM ONLY 6004-33
Differential Lock Fork Installation STEP 55

NOTE: The differential lock fork will look different for
machines equipped with a Power Shift transmission.
The procedure is the same.
STEP 53
BD07N301-01
Install the shaft into the carrier.
STEP 56
bd07n418-01
When installing the bushings on the shaft make sure
the chamfer is over the snap ring.
STEP 54
1 BD07N300-01
Install the spring.
STEP 57
3
bd07n417-01
Lubricate the shaft with clean hydraulic oil. Install the
fork on the shaft with collar towards snap ring (1).
Install bushing (2) and spring (3) onto shaft
BD07N299-01
Place the bushing on the shaft, make sure the
chamfer in the bushing is facing out.

6004-34 580M AND 580SM ONLY
STEP 58 STEP 61
BD07N295-01 BD07N298-01
Place a flat washer over the shaft. Compress the spring by tightening the modified
cylinder and install the snap ring.
STEP 59
STEP 62
BD07N296-01
Star t the modified cylinder into the differential BD07N294-01
housing. Remove the block, push the fork into the carrier and
lock it behind the block inside of the carrier. Hand
STEP 60 start the locking cylinder.
STEP 63
BD07N297-01
Block the fork from moving.
BD07N304-01
To r q u e t h e l o ck i n g c y l i n d e r t o 1 8 0 N m ( 1 3 3
pound-feet).

580M AND 580SM ONLY 6004-35
Assemble Differential STEP 67
STEP 64
BD07N408-01
When installing the pins and thrust washers, align the
flats on the pins with the flats in the thrust washer.
bd07n439-01
Install new O-rings on the pins. Lubricate the O-rings
with clean hydraulic oil. STEP 68
STEP 65
BD07N407-01
Install the pin, thrust washer and spider gear.
BD07N302-01
Install the pins in the differential housing. NOTE: Push the pin in just far enough to hold the
thrust washer and spider.
STEP 66
BD07N409-01
Lubricate the gear and thrust washer with clean
hydraulic oil. Install the gear and thrust washer.

6004-36 580M AND 580SM ONLY
STEP 69 STEP 72
BD07N401-01
BD07N406-01
Place the spider gear and thrust washer into the
Install the pin, thrust washer and spider gear.
housing. Align the bushing with the pin and push the
NOTE: Push the pin in just far enough to hold the pin in as far as possible.
STEP 73
STEP 70
BD07N400-01
BD07N405-01 Install the spider gear and thrust washer, push the
Install the spacer as shown, push the pins into the pin into the gear and washer.
spacer.
STEP 74
STEP 71 Install the retaining pins for the spider gear pins into
the housing.
BD07N402-01
Make sure to install the pin so that the dowel pin hole
aligns with the dowel pin hole in the housing.

580M AND 580SM ONLY 6004-37
STEP 75 STEP 77
BP95F465-01 BD07N394-01
Install plugs and torque to 25 Nm (18.5 pound-feet).
STEP 78
BD07N438-01
The pinion gear and ring gear are a matched set.
Make sure the numbers on the pinion gear and ring
gear are the same. BD07N414-01
Use an acceptable driver and install a bearing cup
STEP 76 into the housing.
BD07N396-01
BD07N415-01
Use lOCTITE 270 on cap screws, install and torque
ring gear cap screws to 155 Nm (114 pound-feet). NOTE: The bearing cup will stay raised above the
housing even when properly seated.
NOTE: Torque cap screws in a staggered pattern in
order to draw the ring gear up flush.

6004-38 580M AND 580SM ONLY
STEP 79 STEP 82
BD07N393-01 BD07N391-01
Place the gear into the housing while aligning the Install the cover into the housing, install the locking
teeth. ring.
STEP 80 STEP 83
bd08a497-01
BD07N392-01 Use an acceptable driver and install the bearing cup.

Apply a light coat of grease to the thrust washer to
hold it in place on the differential housing cover. The STEP 84
ears of the thrust washer must align with the slots in
the cover.
STEP 81
BD07N415-01
Install the differential lock ring onto the housing. If it
is difficult to push down, reach through the housing
and rotate the spider gears until the differential lock
ring will go down.
BD07N410-01
When installing the differential housing cover, place
the pin in the slot of the cover and align it into the
grove in the housing during assembly.

580M AND 580SM ONLY 6004-39
STEP 85 STEP 88
BD07N345-01
BD07N411-01 Install depth gauge 380002436, adapter

Use an acceptable driver and install the inner bearing CAS1596A-6, and bolt CAS1596A-7 into the bearing.
cup.
STEP 89
STEP 86
BD07N347-01
CAS1596A-4 must be facing up as shown.

BD07N412-01
Use an acceptable driver and install the outer STEP 90
bearing cup.
STEP 87
BD07N348-01
Place the outer bearing on CAS1596-A as shown.
BD07N346-01
Install the inner bearing.

6004-40 580M AND 580SM ONLY
STEP 91 STEP 94
BD07N344-01
Tighten CAS1596A-4 and 380002436 until the bd07n438-01

bearings are tight. Find the number on the end of the pinion shaft. Write
this number on line “d” of the worksheet.
STEP 92
STEP 95
See the example and worksheet. The number on line
“a” does not change. Add line “a” and line “b” and
write the answer on line “c”. Subtract line “d” from line
“c” and write the answer on line “e”. Line “e” is the
thickness of the shim to be installed on the pinion
shaft.
Example
a. 74.6 mm a. Tool Constant
b. + 0.203 mm b. Gap Measurement
c. 74.803 mm c. Total Distance
BD07N343-01 d. - 68 mm d. Reading On Pinion
Place CAS1716-3 handle in bearing cradles of the e. 6.803 mm e. Required Shim Thickness
carrier housing.
NOTE: Make sure the carrier housing is level. Use 6.803 mm thick shim
STEP 93 Work Sheet

a. 74.6 mm Tool Constant
b. + mm Gap Measurement
c. mm Total Distance
d. - mm Reading On Pinion
e. mm Required Shim Thickness
a. 74.6 mm Tool Constant
STEP 96
Remove the special tools from the center section.
BD07N342-01


580M AND 580SM ONLY 6004-41
STEP 97 STEP 99
bd07n441-01 bd07n442-01
Install the shim with the thickness specified in step Use a suitable driver and press the inner bearing
95. The chamfer on the ID of the shim must be against the shim.
toward the pinion gear.
STEP 100
STEP 98
BD07N420-01
bd07n442-01
Lubricate the bearing with hydraulic oil. Install the
Put the inner bearing in position on the shaft. washers and a new collapsible spacer on the pinion
gear. The old collapsible spacer MUST NOT be used
again.
STEP 101
BD07N421-01
Lubricate the outer bearing with hydraulic oil. Install
the outer bearing.

6004-42 580M AND 580SM ONLY
STEP 102 STEP 105
Install the CAS2375 on the pinion shaft.
IMPORTANT: If the pinion nut is tightened too much
(rotating torque more than specified), pinion shaft
must be removed and a new collapsible spacer must
be installed.
STEP 106
BD07N422-01
Install the special washer, make sure to align the
washer with the slot in the pinion shaft.
STEP 103
BD07N425-01
Use the torque wrench to check the rotating torque of
the pinion gear. The rotating torque of the pinion gear
must be 2 to 2.4 Nm (17.7 to 21.1 pound-inches).
STEP 107
Remove the torque wrench and the CAS2375 from
the pinion shaft.
STEP 108
bd07n423-01
Lubricate the face of the nut, special washer and
threads with hydraulic oil. Install the pinion nut.
STEP 104
BD07N424-01
Use the yoke and the CAS2151A to tighten the pinion
nut in SMALL amounts as required. Repeat steps
104 through 108 until the rotating torque is as
specified in step 106.
BD07N424-01
Use the P/N 144279A1 Yoke and the CAS2151A to
start the pinion nut onto the pinion gear.

580M AND 580SM ONLY 6004-43
STEP 109 Pinion Gear Backlash Adjustment.
STEP 112
BD07N426-01
Stake the lip on the pinion nut into the slot in the
pinion shaft.
BD07N305-01
Mount a dial indicator onto the carrier, set the shaft of
STEP 110 the dial indicator onto the center of a tooth of the ring
gear.
STEP 113
Use your hand and move the ring gear back and forth
to check for backlash. Check back lash at three
points on the ring gear approximately 120° apart.
STEP 114
The pinion gear backlash must be 0.20 to 0.29 mm
(0.008 to 0.011 inch). If the backlash is not correct do
the following procedure.
BD07N413-01
Use an acceptable driver and install the bearings
onto the ring nuts.
STEP 111
BD07N306-01
Install the differential housing into the carrier. Tighten
the ring nuts evenly and center the differential
housing in the carrier.

6004-44 580M AND 580SM ONLY
STEP 115 Differential Bearing Preload
Adjustment
STEP 116
BD07N306-01
If there is not enough backlash, loosen (tur n
counterclockwise) the adjusting ring on the other side
of the center section one notch. tighten (tur n
clockwise) the adjusting ring one notch on the side bd07n427-01
shown. Continue with this step until the backlash is Install the CAS2375 on the pinion shaft. Check the
0.20 to 0.29 mm (0.008 to 0.011 inch). rotating torque of the pinion shaft. The rotating torque
I f t h e r e i s t o o m u c h b a ck l a s h , l o o s e n ( t u r n must be 2.6 to 3.3 Nm (23 to 29 pound-inches).
counterclockwise) the adjusting ring on the side
shown one notch. tighten (tur n clockwise) the STEP 117
adjusting ring one notch on the side opposite of that If the rotating torque is not correct do the following
shown. Continue with this step until the backlash is procedure.
0.20 to 0.29 mm (0.008 to 0.011 inch).
STEP 118
BD07N306-01
If the rotating torque is too high, loosen (tur n
counterclockwise) the adjusting ring one notch on
both sides. Continue with this step until the rotating
torque is 2.6 to 3.3 Nm (23 to 29 pound-inches).
If the rotating torque is too low, tighten (tur n
clockwise) the adjusting ring one notch on both
sides. Continue with this step until the rotating torque
is 2.6 to 3.3 Nm (23 to 29 pound-inches).

580M AND 580SM ONLY 6004-45
STEP 119 STEP 122
BD07N307-01 BD07N312-01
Secure the adjusting rings with the Allen screws, Put the CAS2369 Pinion Spline Seal Protector on the
torque the Allen screws to 10 Nm (88.5 pound pinion gear shaft.
inches).
STEP 123
Pinion Shaft Seal Installation
STEP 120
BD07N313-01
Lubricate the O-ring and the seal with clean oil.
Install the cover on the center section.
BD07N311-01
Use seal driver, 380002432, and drive the seal into STEP 124
the cover. The lips on the seal must be toward the Remove the CAS2369 from the pinion gear shaft.
inside of the cover.
STEP 121
BD07N310-01
Install a new O-ring on the cover.

6004-46 580M AND 580SM ONLY
Carrier Installation STEP 128
STEP 125
BD07N317-01
Use Loctite 638 on carrier bolts and torque the short

BD07N428-01
carrier bolts to 169 Nm (124.5 pound-feet). Torque
Apply a coat of Loctite 510 to the mating surface for the long carrier bolts to 80 Nm (59 pound-feet).
the carrier. NOTE: DO NOT use any thread locking compound
on these bolts.
STEP 126
Checking the Differential Lock
STEP 129
Connect a hand pump and gauge to the fitting on the
differential lock. Have someone turn the wheel hub
as slight pressure is applied to the hand pump. If the
differential lock is working correctly the wheel hub will
become hard to turn and the wheel hub on the
opposite side of the axle will turn at the same time.
NOTE: Make sure the air is removed from the brake
system when the axle is installed on the machine.
BD07N314-01
Attach lifting equipment to the carrier and place onto

the axle housing.
STEP 127
Remove the lifting equipment from the carrier, use a
rubber mallet and tap the carrier until the dowel pins
are fully seated.

580M AND 580SM ONLY 6004-47
ILLUSTRATIONS
4
3 5
3
6
7
BS08B003
1. VENT 3. PLUGS 5. SCREW M6X25 7. SCREW M12X100

2. AXLE HOUSING 4. PIN D15X35 6. DIFFERENTIAL SUPPORT 8. SCREW M12X1.75
AXLE HOUSING

6004-48 580M AND 580SM ONLY
1 3
4
2 5 10
6
7
8
9
11
12
13
14
15
16
BS08B009
1. LOCK RING 5. O-RING 9. HUB 13. BRAKE PLATE

2. SELF ADJUSTING KIT 6. BRAKE CYLINDER 10. AXLE HOUSING 14. BRAKE DISK
3. BRAKE PISTON 7. O-RING 11. PIN 15. BRAKE PLATE
4. O-RING 8. PIN 12. HALF SHAFT 16. BRAKE DISK
BRAKES

580M AND 580SM ONLY 6004-49
1
2
3
5
6
7
4
8
9
5
6
7
BS08B007
1. CYLINDER 4. PISTON O-RINGS 7. SPRING
2. CYLINDER O-RING 5. LOCKING RING 8. SHAFT
3. PISTON 6. BUSHING 9. FORK
DIFFERENTIAL LOCK

6004-50 580M AND 580SM ONLY
4 1
2
5 3
10 6
7
11 9
12 8
13
14 17
15
16
2
1 18
19
20
BS08B004
1. RING NUT 6. O-RING 11. SPIDER GEAR 16. LOCKING RING

2. BEARING 7. HOUSING 12. DIFFERENTIAL PIN 17. LOCKING SIDE SPIDER GEAR
3. SLEEVE 8. THRUST WASHER 13. PIN 18. DIFFERENTIAL PIN
4. CAP SCREW M12X25 9. PLUG 14. SPACER 19. SIDE SPIDER GEAR
5. PIN 10. THRUST WASHER 15. HOUSING COVER 20. PIN
DIFFERENTIAL

580M AND 580SM ONLY 6004-51
3
4
5
6
7 5
8
9
10
11
12
BS08B006
1. RING GEAR 5. WASHER 9. RING NUT

2. PINION GEAR 6. CRUSH SLEEVE 10. SEAL
3. SHIM 7. OUTER BEARING 11. O-RING
4. INNER BEARING 8. LOCK WASHER 12. CAP
RING AND PINION

6004-52 580M AND 580SM ONLY
1
3 2
4
6 5
8
9
10
12
11
14 13
15
18 16
17
19
BS08B005
1. RING NUT 6. SHIPPING PLUG 11. PAD 16. BEARING

2. INNER BEARING 7. HUB 12. WHEEL FLANGE 17. PLANETARY CARRIER
3. O-RING 8. SPACER 13. SNAP RING 18. BOLT
4. RING GEAR (NOT SERVICED) 9. OUTER BEARING 14. GEAR 19. STUD
5. BLEEDER VALVE 10. CASSETTE SEAL 15. SNAP RING
WHEEL HUB AND FINAL REDUCTION UNIT

Section
6004
6004
REAR AXLES AND PLANETARIES
580 SM+, 590 SM AND 590SM+

6004-2 580SM+, 590SM, AND 590SM+ ONLY
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WHEEL HUB AND BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassemble Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Differential Lock Fork Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Differential Lock Fork Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assemble Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pinion Gear Backlash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Differential Bearing Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pinion Shaft Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking the Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

580SM+, 590SM, AND 590SM+ ONLY 6004-3
SPECIFICATIONS
Gear lubricant ..............................................................Wet Brake/Transmission Lubricant - SAE 80W140 MAT 3510
Capacity.......................................................................................................................... 18.6 liters (19.7 U.S. quarts)
Special Torques
Bolts for ring gear ............................................................................................................155 Nm (114 pound-feet)
Bolts for differential support long bolts ................................................................................80 Nm (59 pound-feet)
Bolts for differential support short bolts...........................................................................169 Nm (125 pound-feet)
Ring nut for wheel hub ...............................................................................................1000 Nm (737.5 pound-feet)
Differential adjusting ring lock screws ......................................................................... 10 Nm (88.5 pound-inches)
Differential pin plug..............................................................................................................25 Nm (18 pound-feet)
Differential lock plug ........................................................................................................180 Nm (133 pound-feet)
Pinion rotating torque (without seal) ............................................................ 2 to 2.4 Nm (17.7 to 21.2 pound-inches)
Differential bearing preload rotating torque (without seal) .............................. 2.6 to 3.3 Nm (23 to 29 pound-inches)
Backlash for ring gear........................................................................................0.2 to 0.29 mm (0.008 to 0.011 inch)

6004-4 580SM+, 590SM, AND 590SM+ ONLY
SPECIAL TOOLS
BD07N332-01
DIFFERENTIAL RING NUT WRENCH 380002433.
BD07N445-01
OEM4185 UNIVERSAL BEARING CUP INSTALLER -
USED TO INSTALL THE HUB BEARING CUPS.
No Image
Available
BD07N333-01
FALSE PINION 380100090
BD07N446-01
CAS1716-3 HANDLE (PART OF CAS1716 AG TOOL KIT) -
USED WITH CAS2374 HUB SEAL INSTALLER.
BD07N337-01
380100093 OFFSET SPANNER WRENCH -
USED TO REMOVE AND INSTALL THE PINION NUT.
BD07N444-01
YOKE TO HOLD SHAFT. ORDER P/N 144279A1.

580SM+, 590SM, AND 590SM+ ONLY 6004-5
BD07N335-01
PINION DEPTH GAUGE BAR 380000407
BD07N331-01
SELF ADJUSTING BRAKE TOOLS 380002435.
BD07N336-01
WHELL HUB SEAL DRIVER 380002431
BD07N329-01
SOCKET FOR RING NUT ON WHEEL FLANGE 380002434.
BD07N330-01
BD07N334-01
SEAL PROTECTOR CAS2369
BD07N328-01
SPANNER WRENCH CAS1840C

6004-6 580SM+, 590SM, AND 590SM+ ONLY
WHEEL HUB AND BRAKES
Disassembly
STEP 1 STEP 3
BD07N327-01
BD07N340-01
Remove the axle vent to relieve any pressure inside Place an oil receptacle under the differential carrier
of the axle. and drain the oil.
STEP 2 STEP 4
BD07N338-01
BD07N341-01
Place an oil receptacle under the outer housings of Remove all but two of the cap screws.
the axle and drain the oil. NOTE: Large amounts of Loctite was used during

580SM+, 590SM, AND 590SM+ ONLY 6004-7
STEP 5 STEP 8
BD07N349-01 BD07N352-01
Insert dowel rods to guide the wheel hubs off. Slowly pull hub away from axle, make sure that the
brake disks and plates stay with the hub.
STEP 6
STEP 9
BD07N350-01
Remove the remaining cap screws. BD07N353-01
Pull the half shaft out with the hub and brakes.
STEP 7
STEP 10
BD07N351-01
Pry the hub from the axle using slots. BD07N354-01
Place the hub, brakes and half shaft on a suitable
work bench.

6004-8 580SM+, 590SM, AND 590SM+ ONLY
STEP 11 STEP 14
BD07N355-01 BD07N254-01
Stand the hub up, mark the reaction plat that was Loosen and remove the shouldered bolts, and spring
against the axle housing. Remove the reaction and washers from the brake self adjusters.
brake disks.
NOTE: Keep brake surfaces in same relationship to STEP 15
each other if being reused.
STEP 12
BD07N357-01
with kit.
BD07N253-01
Remove the half shaft from the planetary gears. STEP 16
STEP 13
BD07N256-01
Remove the lock ring.
BD07N320-01
Left hand shaft is 807 mm (31.7 in) long and the right

580SM+, 590SM, AND 590SM+ ONLY 6004-9
STEP 17 STEP 19
BD07N257-01 BD07N361-01
Remove the self adjuster. If brakes are being Place the driver 3800002435 onto self adjuster and
replaced replace adjusters. drive the spring clips from the adjuster.
NOTE: Once removed the self adjusters spring clips
must be replace with genuine parts, DO NOT use STEP 20
after market parts.
STEP 18
BD07N362-01
BD07N360-01
STEP 21
Place the self adjuster on 3800002435.
into 3800002435.
BD07N258-01
Use an acceptable flat bars and pry the brake piston
up from the hub.

6004-10 580SM+, 590SM, AND 590SM+ ONLY
STEP 22 STEP 25
BD07N371-01
BD07N259-01
STEP 23
STEP 26
BD07N377-01

STEP 24 machine has high hours.
STEP 27
BD07N260-01
The cylinder may remain in the housing, use pry bar
BD07N374-01
and remove the cylinder.
Remove and discard brake cylinder O-ring only if

580SM+, 590SM, AND 590SM+ ONLY 6004-11
STEP 28 STEP 31
BD07N261-01 BD07N263-01
Remove and discard the hub o-ring. Carefully raise the planetary set, hold the snap ring
open until it has cleared the end of the wheel flange
STEP 29 shaft.
STEP 32
Remove planetary set from the hub.
STEP 33
BD07N262-01
Attach lifting equipment to the planetary gears.
STEP 30
BD07N264-01
Remove planetary gear retainer snap rings.
STEP 34
BD07N277-01
Locate the snap ring slot and place snap ring pliers in
slot.
BD07N265-01
Remove planetary gear and bearings.

6004-12 580SM+, 590SM, AND 590SM+ ONLY
STEP 35 STEP 38
BD07N268-01 BD07N271-01
Place the wheel end in a press and lock the wheel Do not press directly against the sun gear pad.
hub so it can not turn.
NOTE: Do not use excessive force. STEP 39
STEP 36
BD07N272-01
Place the wheel hub in a press.

BD07N269-01
Use ring nut socket, 380002434, a torque multiplier, STEP 40

and loosen wheel flange ring nut.
STEP 37
BD07N273-01
Press the wheel flange from the wheel hub.
BD07N379-01
Remove ring nut from wheel hub.

580SM+, 590SM, AND 590SM+ ONLY 6004-13
STEP 41 STEP 44
BD07N274-01 BD07N385-01
Attach lifting equipment to hub housing and remove Remove the outer race.
from the wheel flange.
STEP 45
STEP 42
BD07N387-01
BD07N381-01 Remove spacer from wheel flange.

Remove the inner bearing race.
STEP 46
STEP 43
BD07N386-01
BD07N382-01 To remove the inner bearing, use a die grinder to cut

Remove the cassette seal. the roller retainer and race. Use a chisel in the slot
cut in the race to crack the race, remove the race.

6004-14 580SM+, 590SM, AND 590SM+ ONLY
Inspection Assembly
STEP 47 STEP 56
STEP 48
Discard all seals and O-rings.
STEP 49
Inspect the bearing cups and the rollers in the wheel
damage. Also check the inner race for damage. If you
find any of these defects, you must install new wheel
bearings and bearing cups.
STEP 50
BD07N383-01
Inspect the planetary shafts for wear and damage.
If the outer bearing cups were removed, use an
The planetary shaft bushings are not sold separately.
If a shaft bushing is damaged, you must use a new
carrier.
NOTE: The above photo shows the cassette seal
STEP 51 installed, the cassette seal will be installed during a
Inspect the teeth on the planetary gears, the half later step.
shaft, and the ring gear for wear, pitting, scoring, and
other damage. Use new parts as required. STEP 57
STEP 52
Inspect the needle bearings for the planetary gears
for flat areas, pitting, scoring, and other damage. If
you find any of these defects, use new parts as
required.
STEP 53
STEP 54
BD07N384-01
If the inner bearing cups were removed, use an
Use new pars as required.
STEP 55
IMPORTANT: Use only genuine parts. DO NOT use
after market O-rings, they will fail.

580SM+, 590SM, AND 590SM+ ONLY 6004-15
STEP 58 STEP 61
IMPORTANT: The words “OUTSIDE” on the hub seal Clean all sealing surfaces with an alcohol based
must be facing out. cleaner, if any oil residue is on sealing surfaces the
seal will leak.
STEP 62
BD07N275-01
Use the 380002431 hub seal installer with handle to
install the hub seal. Push only until the hub seal
BD07N274-01
makes contact with the shoulder inside the hub. Attach lifting equipment to hub and carefully install
Continued pushing can damage the hub seal. onto wheel flange.
STEP 59 NOTE: Use care and install the hub straight onto the
wheel flange, damage to seal can occur if angled.
DO NOT use excess force to seat hub onto wheel
flange.
STEP 63
BD07N386-01
Install the outer wheel flange bearing with a suitable
driver.
STEP 60
BD07N379-01
Install inner bearing with a suitable driver, install ring
nut.
NOTE: The ring nut can be installed with either side
up or down.
BD07N387-01
Install spacer on wheel flange.
6004-16 580SM+, 590SM, AND 590SM+ ONLY
STEP 64 STEP 67
Attach lifting equipment to planetary set and lower
into hub.
STEP 68
BD07N270-01
Use ring nut socket, 380002434, torque ring nut to
1000 Nm (737.5 pound-feet).
NOTE: The use of a torque multiplier as shown is
BD07N380-01
acceptable.
During installation the locking ears on the planetary
STEP 65 carrier must engage the ring nut as shown.
STEP 69
BD07N266-01
Use a suitable driver and press the planetary gears
BD07N277-01
onto the planet carrier.
Hold the snap ring open and lower the planetary
assembly into position.
STEP 66
BD07N267-01
Install the retaining snap rings on the carrier.

580SM+, 590SM, AND 590SM+ ONLY 6004-17
STEP 70 STEP 73
BD07N278-01 BD07N376-01
Make sure that the snap ring is fully closed, two tips Use hydraulic oil to lubricate the inner O-ring of the
touch, remove lifting equipment. brake piston, press the brake cylinder into the brake
piston.
STEP 71
STEP 74
BD07N279-01
Install a new O-ring onto the hub. BD07N378-01

STEP 72 brake piston.
STEP 75
BD07N375-01
Use hydraulic oil to lubricate the brake cylinder
O-ring. BD07N281-01
hub housing.

6004-18 580SM+, 590SM, AND 590SM+ ONLY
STEP 76 STEP 79
BD07N373-01 BD07N364-01
Place the brake piston and cylinder onto the hub. Place aligning tool into brake adjuster tool, part of
tool kit 380002435.
NOTE: Use brake pins for guides.
STEP 80
STEP 77
BD07N365-01
BD07N283-01
Place the first adjuster ring onto aligning tool.
Use the three shouldered bolts and washers to pull
the brake piston and cylinder into the hub. NOTE: For ease of installation, look at the inside of
STEP 78
STEP 81
BD07N363-01
Place the brake adjuster with tapered edge facing up BD07N366-01
into depth setting tool, part of tool kit 380002435. Place the second adjuster ring onto aligning tool with

580SM+, 590SM, AND 590SM+ ONLY 6004-19
STEP 82 STEP 85
BD07N367-01 BD07N370-01
Place the third adjuster ring onto aligning tool with Drive the rings onto the adjuster until they are seated
the slot at 180° from the slot of the first ring. against the depth setting tool.
STEP 83 STEP 86
BD07N368-01 BD07N359-01
STEP 84 STEP 87
BD07N369-01 BD08A496-01

6004-20 580SM+, 590SM, AND 590SM+ ONLY
STEP 88 STEP 91
BD07N256-01 BD07N358-01
Install the snap ring into the self adjuster bore. Hand tighten the shouldered bolt until seated into
adjuster, spring washers can become bound on the
STEP 89 shoulder of the bolt and be damaged.
STEP 92
BD07N282-01
Make sure the snap ring fully engages the grove in
the brake piston. BD07N255-01
To r q u e s h o u l d e r e d b o l t s t o 1 6 N m ( 1 4 1 . 4
STEP 93
BD07N356-01
Place spring washers onto shouldered bolt facing as
shown. BD07N431-01
Put the half shaft and brake separator plate pins into
the axle housing.

580SM+, 590SM, AND 590SM+ ONLY 6004-21
STEP 94 STEP 96
BD07N432-01 BD07N434-01
Using the reference mark made during disassembly, Install the second brake separator, SM models only.
place the inner brake separator plate into the axle
housing.
used here.
used here. STEP 97
IMPORTANT: If using new brake disks they must be
STEP 95
BD07N435-01
BD07N433-01
STEP 98
Place the inner brake disk onto the half shaft, do not
BD07N429-01

6004-22 580SM+, 590SM, AND 590SM+ ONLY
STEP 99 STEP 101
BD07N430-01 BD07N437-01
Install dowel rods into axle housing, two short rods Use a piece of rope and lift the axle shaft into the
for bench repair, three long for in vehicle repair. planetary gears while pushing the hub onto the axle.
STEP 100 to be turned in order to align the splines on the half
STEP 102
BD07N436-01
Attach lifting equipment to hub assembly and guide
onto dowel rods.
NOTE: Care needs to be taken that the self BD07N339-01
adjusters are not damaged by falling plates or by Use Loctite 270 on thread of the bolts and torque to
hitting them on the housing when bringing hub into 226 Nm (166.5 pound-feet).
position.
STEP 103
Install and tighten drain plugs.
STEP 104
Fill the axle with oil, see page 3 for quantity and type.

580SM+, 590SM, AND 590SM+ ONLY 6004-23
DIFFERENTIAL
Carrier Removal STEP 4
STEP 1
Remove the wheel hubs and brakes, see Wheel
Hubs And Brakes Disassembly in this section.
STEP 2
BD08B110-01
away from the axle housing, attach suitable lifting
equipment to the differential housing.
STEP 5
Remove the differential and place on a work bench.
BD08B112-01
Remove the differential mounting bolts.
Disassemble Differential
STEP 3
STEP 6
BD08B111-01
Use pry bars in slots to loosen the carrier from the BD08B118-01
axle housing. Remove the bolts securing the ring nut.

6004-24 580SM+, 590SM, AND 590SM+ ONLY
STEP 7 STEP 11
BD07N306-01 BD08B130-01
Remove the ring nuts. Use a plate just large enough to cover the side gear
and will not interfere with the removal of the
STEP 8 differential housing cover.
Remove the differential from the carrier.
STEP 12
STEP 9
BD08B133-01
Use an acceptable puller to remove the differential
BD08B141-01
housing cover.
Remove the differential lock sleeve.
STEP 10 STEP 13
BD08B134-01
BD08B131-01 Remove the cover.
Remove the locking ring.

580SM+, 590SM, AND 590SM+ ONLY 6004-25
STEP 14 STEP 17
BD08B138-01 BD08B140-01
Remove the bearing cup. Remove three plugs from the differential.
STEP 15 STEP 18
BD08B135-01 BD08B142-01
Remove the side gear. Remove the three pins securing the spider pins in the
differential.
STEP 16
STEP 19
BD08B137-01
Remove the anti-rotation pin. BD08B143-01
Note the flat surface on pin.

6004-26 580SM+, 590SM, AND 590SM+ ONLY
STEP 20 STEP 23
BD08B081-01 BD08B080-01
Push the pin towards the flat surface side noted in Remove the spider gear and thrust washer.
the previous step.
NOTE: DO NOT force the pin, it will not come out of STEP 24
the housing at this time.
STEP 21
BD08B652-01
Push one of the short spider pins out of the spacer by
pushing it through the hole in the spacer.
BD08B080-01 NOTE: Do not remove the pin at this time, leave the
Remove the spider gear and thrust washer. pin in far enough to support the spider gear and
thrust washer.
STEP 22
BD08B086-01
Push the pin out of the housing.

580SM+, 590SM, AND 590SM+ ONLY 6004-27
STEP 25 STEP 28
BD08B653-01 BD08B151-01
Push the other short spider pin out of the spacer by Remove the other pin, gear and thrust washer from
pushing it through the hole in the spacer. the housing.
NOTE: Do not remove the pin at this time, leave the
pin in far enough to support the spider gear and STEP 29
thrust washer.
STEP 26
BD08B068-01
Remove the gear from the housing.
BD08B149-01
STEP 30
Remove the spacer from the housing.
STEP 27
BD08B066-01
Remove the thrust washer from the housing.
BD08B151-01
Remove the spider pin, gear and thrust washer from

the housing.

6004-28 580SM+, 590SM, AND 590SM+ ONLY
STEP 31 STEP 34
BD08B122-01
BD08B053-01
Remove the ring gear cap screws, remove the ring. The pinion gear nut is staked into place on the pinion
shaft.
NOTE: Large amounts of Loctite was used during
assembly, remove cap screws slowly. If screws bind, STEP 35
STEP 32
BD08B123-01
Use a chisel punch to remove the stake from the
pinion shaft nut.
BD08B057-01
Remove the differential locking pins from the STEP 36
housing.
STEP 33
BD08B125-01
Use the offset spanner, 380100093, and yoke P/N
144279A1 to remove the pinion gear ring nut.
BD08B121-01
Remove the cover and seal from the carrier.

580SM+, 590SM, AND 590SM+ ONLY 6004-29
STEP 37 STEP 40
BD08B157-01 BD08B180-01
Use a soft faced hammer and drive the pinion out of
Remove the shim from the pinion.
the carrier housing.
STEP 41
STEP 38
BD08B185-01
BD08B160-01 Remove the outer bearing cup from the carrier.
Remove the crush sleeve and shims from the pinion
shaft.
STEP 42
STEP 39
BD08B184-01
Remove the inner bearing cup from the carrier.

BD08B179-01
Press the bearing from the pinion shaft.

6004-30 580SM+, 590SM, AND 590SM+ ONLY
Differential Lock Fork Removal STEP 46
STEP 43
BD08B170-01
Remove the differential cylinder plug from the carrier.

BD08B163-01
Remove elbow from the differential lock cylinder. STEP 47
STEP 44
BD08B171-01
Remove the differential lock fork.

BD08B164-01
Loosen the differential lock cylinder from the carrier. STEP 48
NOTE: Use caution removing the cylinder, it is under
spring pressure.
STEP 45
BD08B174-01
Place differential lock fork in a soft-jawed vise.
Tighten vise enough to gain access to the snap ring.
BD08B167-01
Loosen the differential cylinder plug.

580SM+, 590SM, AND 590SM+ ONLY 6004-31
STEP 49 Differential Lock Fork Installation
NOTE: When installing the bushings on the shaft,
make sure the chamfer is over the snap ring.
STEP 52
BD08B176-01
Remove the fork.
STEP 50
BD08B178-01
When installing the bushings on the shaft make sure
the chamfer is over the snap ring.
STEP 53
BD08B177-01
Remove the spring.
STEP 51
BD08B177-01
Install the spring onto the shaft.
BD08B178-01
Remove the spacer.

6004-32 580SM+, 590SM, AND 590SM+ ONLY
STEP 54 STEP 57
BD08B176-01 BD08B172-01
Install the fork onto the shaft with collar of fork Install the bushing and spring.
towards the retaining ring.
STEP 58
NOTE: Position fork as shown.
STEP 55
BD08B171-01
Position bushing in the opening in the carrier.
BD08B175-01
STEP 59
Place differential lock fork in a soft-jawed vise.
Tighten vise enough to gain access to the snap ring.
Install the snap ring.
STEP 56
BD08B170-01
Install a new O-ring on the plug for the differential
lock.
BD08B173-01
Install shaft into the carrier.

580SM+, 590SM, AND 590SM+ ONLY 6004-33
STEP 60 Assemble Differential
STEP 63
BD08B168-01
TIghten the differential lock plug to a torque of Nm
180 (133 Pound-feet).
bd08b055-01
Install ring gear.
STEP 61
STEP 64
BD08B164-01
Install and tighten the differential lock cylinder to a

BD08B058-01
torque of 180 Nm (133 Pound-feet) Use two Allen head screws to hold the ring gear in
place.
STEP 62
STEP 65
BD08B163-01
Install new O-ring on elbow. Install elbow to the
BD08B059-01
proper position and tighten jam nut to a torque of 30 Tighten the screws evenly to pull the ring gear
Nm (262 Pound-inches). partially into position.

6004-34 580SM+, 590SM, AND 590SM+ ONLY
STEP 66 STEP 69
BD08B060-01 BD08B063-01
Install two ring gear screws in the ring gear. Apply Loctite 270 on the screws. Install ring gear cap
screws.
STEP 67
STEP 70
BD08B061-01
Tighten the screws evenly to draw up the ring gear. BD08B054-01

Tighten cap screws to a torque of 155 Nm (114
STEP 68 Pound-feet).
STEP 71
BD08B062-01
Remove the two long Allen head screws.

BD08B067-01
Install the thrust washer.

580SM+, 590SM, AND 590SM+ ONLY 6004-35
STEP 72 STEP 75
BD08B068-01 BD08B074-01
Install the side gear with differential lock slots. Make sure to install the pin so that the pin hole aligns
with the pin hole in the housing.
STEP 73
STEP 76
BD08B073-01
When installing the pins and thrust washers, align the
flats on the pins with the flats in the thrust washer. BD08B076-01
Push the pin in just far enough to hold the thrust
washer and spider.
STEP 74
STEP 77
BD08B071-01
Lubricate thrust washer and spider gear. Install the BD08B077-01
spider gear. Install the pin, thrust washer and spider gear on the
opposite side.
NOTE: Push the pin in just far enough to hold the

6004-36 580SM+, 590SM, AND 590SM+ ONLY
STEP 78 STEP 81
BD08B084-01
BD08B078-01
Place the spacer between the spider gears as Align the bushing with the pin and push the pin into
shown. the bushing.
STEP 79 STEP 82
BD08B085-01
BD08B082-01
Make sure to install the pin so that the pin hole (1), Install the spider gear and thrust washer into the
aligns with the pin hole in the housing. housing.
NOTE: Notice the position of the shoulder (2), on the
pin.
STEP 83
STEP 80
BD08B086-01
Push the pin into the gear and washer.
BD08B080-01
Install the spider gear and thrust washer.

580SM+, 590SM, AND 590SM+ ONLY 6004-37
STEP 84 STEP 87
BD08B087-01 BD08B695-01
Install the pins for the spider gear shaft. Install thrust washer.
STEP 85 STEP 88
BD08B092-01 BD08B138-01
Install plugs and tighten to a toque of 25 Nm (221 Install bearing cup if removed.
Pound-inches).
STEP 89
STEP 86
BD08B137-01
BD08B093-01 Install anti-rotation pin.

Install side gear.

6004-38 580SM+, 590SM, AND 590SM+ ONLY
STEP 90 STEP 93
BD08B096-01 BD08B099-01
Align the notch in the bearing housing with the NOTE: Position differential lock sleeve with
anti-rotation pin. Install the bearing housing. chaffered side down.
STEP 94
STEP 91
BD08B100-01
BD08B097-01 Install the lock ring.

Install the retaining ring.
STEP 95
STEP 92
BD08B186-01
BD08B098-01 Install outer bearing cup into the carrier.
Install new O-rings on the differential lock pins.
Lubricate the O-rings with clean oil. Install pins.

580SM+, 590SM, AND 590SM+ ONLY 6004-39
STEP 96 STEP 98
3
2a
BD08B187-01 BD08B188-01
Install inner bearing cup into the carrier. Place special tool 380000407 (2a) in the differential
group supports (3).
STEP 99
BD07N438-01
The pinion gear and ring gear are a matched set.
BD08A427-01
Make sure the numbers on the pinion gear and ring U s e a d e p th g a ug e to m e a s u re d i s ta n c e “X ”
gear are the same. (distance between the axis of the differential bearings
and the point at which the pinion head is supported,
STEP 97 or the base of the bearing).
1a
8
7
1
9
2
BD08A426-01
BD08A428-01
Insert bearing (7) and (8) in the housing. Assemble
the false pinion 380100090 (1a), spacer (2), and ring To adjust bevel gear/pinion, measure the distance “A”
nut (1), on the differential carrier (9). with a depth gauge.
Tighten with the ring nut until the bearings are tight. Calculate the value “X” as follows:
X=(A+C)-B mm
Where “B” and “C” are known.
6004-40 580SM+, 590SM, AND 590SM+ ONLY
STEP 102
NOTE: Distance B was not known at time of printing,
measure the tool as shown above to obtain distance
B. Distance C is obtained by measuring the internal
distance from the bottom of the bearing support to
the top and divided by two (50 MM).
STEP 100
BD08B181-01
NOTE: The chamfer of the shim goes toward the

gear.
STEP 103
1a
BD07N438-01
8
S=(X-V) mm
In order to determine the necessary thickness value
(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head
(V = requested distance), from the measured value
7
(X). 1 9
STEP 101
2
BD08A426-01
Remove special tool 38000408 from the differential
group supports (9). Remove the ring nut (1), spacer
(2), and false pinion 30100090 (1a), and the bearings
(7) and (8).
STEP 104
BD08B180-01
Select the shim with the thickness value (S) among
the range of available shims.
Shim thickness-mm
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
bd08b182-01
Install the bearing on the shaft.

580SM+, 590SM, AND 590SM+ ONLY 6004-41
STEP 105 STEP 109
bd08b183-01 BD08B155-01
Use a suitable driver and press the bearing onto the Install the special washer, make sure to align the
shaft. washer with the slot in the pinion shaft.
STEP 106 STEP 110
BD08B160-01 bd08b154-01
Lubricate the bearing with hydraulic oil. Install the Lubricate the face of the nut, special washer and
washers and a NEW crush sleeve on the shaft. The threads with hydraulic oil. Install the pinion nut.
old collapsible spacer MUST NOT be used again.
STEP 111
STEP 107
Install shaft into the carrier.
STEP 108
BD08B125-01
Use the P/N 144279A1 Yoke and the 380100093 to
start the pinion nut onto the pinion gear.
BD08B158-01
Heat the outer bearing and install on the shaft.

6004-42 580SM+, 590SM, AND 590SM+ ONLY
STEP 112 STEP 115
BD08B107-01
BD08B126-01
Install the CAS2375 on the pinion shaft.
Use the yoke and the 380100093 to tighten the
IMPORTANT: If the pinion nut is tightened too much pinion nut in SMALL amounts as required. Repeat
(rotating torque more than specified), pinion shaft steps 111 through 115 until the rotating torque is as
must be removed and a new collapsible spacer must specified in step 113.
be installed.
STEP 116
STEP 113
BD08B122-01
BD08B692-01 Stake the lip on the pinion nut into the slot in the
Use the torque wrench to check the rotating torque of pinion shaft.
the pinion gear. The rotating torque of the pinion gear
must be 2 to 2.4 Nm (17.7 to 21.1 pound-inches). STEP 117
Use an acceptable driver and install the bearings
STEP 114 onto the ring nuts.
Remove the torque wrench and the CAS2375 from
the pinion shaft.

580SM+, 590SM, AND 590SM+ ONLY 6004-43
STEP 118 Pinion Gear Backlash Adjustment.
STEP 119
BD07N306-01
Install the differential housing into the carrier. Tighten
the ring nuts evenly and center the differential
BD08B101-01
housing in the carrier.
Mount a dial indicator onto the carrier, set the shaft of
the dial indicator onto the center of a tooth of the ring
gear.
STEP 120
BD08B102-01
Use your hand and move the ring gear back and forth
to check for backlash. Check back lash at three
points on the ring gear approximately 120° apart.
STEP 121
The pinion gear backlash must be 0.20 to 0.29 mm
(0.008 to 0.011 inch). If the backlash is not correct do
the following procedure.

6004-44 580SM+, 590SM, AND 590SM+ ONLY
STEP 122 Differential Bearing Preload
Adjustment
STEP 123
BD07N306-01
I f t h e r e i s t o o m u c h b a ck l a s h , l o o s e n ( t u r n
counterclockwise) the adjusting ring on the other side
of the center section one notch. tighten (tur n
clockwise) the adjusting ring one notch on the side bd08b107-01
shown. Continue with this step until the backlash is Install the CAS2375 on the pinion shaft.
0.20 to 0.29 mm (0.008 to 0.011 inch).
If there is not enough backlash, loosen (tur n STEP 124
counterclockwise) the adjusting ring on the side
shown one notch. tighten (tur n clockwise) the
adjusting ring one notch on the side opposite of that
shown. Continue with this step until the backlash is
0.20 to 0.29 mm (0.008 to 0.011 inch).
BD08B692-01
Check the rotating torque of the pinion shaft. The
rotating torque must be 2.6 to 3.3 Nm (23 to 29
pound-inches).
STEP 125
If the rotating torque is not correct do the following
procedure.

580SM+, 590SM, AND 590SM+ ONLY 6004-45
STEP 126 Pinion Shaft Seal Installation
STEP 128
BD07N306-01
If the rotating torque is too high, loosen (tur n
counterclockwise) the adjusting ring one notch on
BD07N311-01
both sides. Continue with this step until the rotating
torque is 2.6 to 3.3 Nm (23 to 29 pound-inches). Use seal driver, 380002432, and drive the seal into
the cover. The lips on the seal must be toward the
If the rotating torque is too low, tighten (tur n
inside of the cover.
clockwise) the adjusting ring one notch on both
sides. Continue with this step until the rotating torque
is 2.6 to 3.3 Nm (23 to 29 pound-inches).
STEP 129
STEP 127
BD07N310-01
Install a new O-ring on the cover.
BD08B106-01
Secure the adjusting rings with the Allen screws, STEP 130
torque the Allen screws to 10 Nm (88.5 pound
inches).
BD08B119-01
Put the CAS2369 Pinion Spline Seal Protector on the
pinion gear shaft.

6004-46 580SM+, 590SM, AND 590SM+ ONLY
STEP 131 Carrier Installation
STEP 134
BD08B128-01
Lubricate the O-ring and the seal with clean oil.
Install the cover on the center section. BD08B115-01
Apply a coat of Loctite 510 to the mating surface for

STEP 132 the carrier.
STEP 135
BD08B120-01
Use a soft-face hammer to seat the seal.
BD08B109-01
STEP 133 Attach lifting equipment to the carrier and place onto
Remove the CAS2369 from the pinion gear shaft. the axle housing.

580SM+, 590SM, AND 590SM+ ONLY 6004-47
STEP 136 Checking the Differential Lock
STEP 138
Connect a hand pump and gauge to the fitting on the
differential lock. Have someone turn the wheel hub
as slight pressure is applied to the hand pump. If the
differential lock is working correctly the wheel hub will
become hard to turn and the wheel hub on the
opposite side of the axle will turn at the same time.
NOTE: Make sure the air is removed from the brake
system when the axle is installed on the machine.
BD08B110-01
away from the axle housing, remove the lifting attach
equipment from the differential housing. Use a
soft-face hammer and tap the carrier until the dowel
pins are fully seated.
STEP 137
BD08B113-01
Use Loctite 638 on carrier bolts and torque the short

carrier bolts to 169 Nm (124.5 pound-feet). Torque
the long carrier bolts to 80 Nm (59 pound-feet).
NOTE: DO NOT use any thread locking compound
on these bolts.

6004-48 580SM+, 590SM, AND 590SM+ ONLY
ILLUSTRATIONS
4
3 5
3
6
7
BS08B003
1. VENT 3. PLUGS 5. SCREW M6X25 7. SCREW M12X100

2. AXLE HOUSING 4. PIN D15X35 6. DIFFERENTIAL SUPPORT 8. SCREW M12X1.75
AXLE HOUSING

580SM+, 590SM, AND 590SM+ ONLY 6004-49
1 3
4
2 5 10
6
7
8
9
11
12
13
14
15
16
BS08B009
1. LOCK RING 5. O-RING 9. HUB 13. BRAKE PLATE

2. SELF ADJUSTING KIT 6. BRAKE CYLINDER 10. AXLE HOUSING 14. BRAKE DISK
3. BRAKE PISTON 7. O-RING 11. PIN 15. BRAKE PLATE
4. O-RING 8. PIN 12. HALF SHAFT 16. BRAKE DISK
BRAKES

6004-50 580SM+, 590SM, AND 590SM+ ONLY
1
2
3
5
6
7
4
8
9
5
6
7
BS08B007
1. CYLINDER 4. PISTON O-RINGS 7. SPRING
2. CYLINDER O-RING 5. LOCKING RING 8. SHAFT
3. PISTON 6. BUSHING 9. FORK
DIFFERENTIAL LOCK

580SM+, 590SM, AND 590SM+ ONLY 6004-51
10
11 1
2
16
20
12 15
13
11 13
10 18 19
14
4 21
22
13
7
3
17
2 18
8
1 11 10
10
6 5
BS08C031
1. RING NUT 7. HOUSING 13. PIN 19. SIDE SPIDER GEAR

2. BEARING 8. THRUST WASHER 14. SPACER 20. PIN
3. SLEEVE 9. PLUG 15. HOUSING COVER 21. THRUST WASHER
4. CAP SCREW M12X25 10. THRUST WASHER 16. LOCKING RING 22. PLUG
5. PIN 11. SPIDER GEAR 17. LOCKING SIDE SPIDER GEAR
6. O-RING 12. DIFFERENTIAL PIN 18. DIFFERENTIAL PIN
DIFFERENTIAL

6004-52 580SM+, 590SM, AND 590SM+ ONLY
3
4
5
6
7 5
8
9
10
11
12
BS08B006
1. RING GEAR 5. WASHER 9. RING NUT

2. PINION GEAR 6. CRUSH SLEEVE 10. SEAL
3. SHIM 7. OUTER BEARING 11. O-RING
4. INNER BEARING 8. LOCK WASHER 12. CAP
RING AND PINION

580SM+, 590SM, AND 590SM+ ONLY 6004-53
1
3 2
4
6 5
8
9
10
12
11
14 13
15
18 16
17
19
BS08B005
1. RING NUT 6. SHIPPING PLUG 11. PAD 16. BEARING

2. INNER BEARING 7. HUB 12. WHEEL FLANGE 17. PLANETARY CARRIER
3. O-RING 8. SPACER 13. SNAP RING 18. BOLT
4. RING GEAR (NOT SERVICED) 9. OUTER BEARING 14. GEAR 19. STUD
5. BLEEDER VALVE 10. CASSETTE SEAL 15. SNAP RING
WHEEL HUB AND FINAL REDUCTION UNIT

6004-54 580SM+, 590SM, AND 590SM+ ONLY
NOTES

Section
6007
STANDARD TRANSMISSION
6007

6007-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRANSMISSION HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECONDARY SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PRIMARY SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
REVERSE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
FOUR-WHEEL DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
SHIFTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Shift Rods And Shift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
FOUR-WHEEL DRIVE VALVE (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
TRANSMISSION HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

6007-3
SPECIFICATIONS
Type of transmission oil ..................................................................................................... MS-1209, Hy-Tran® Ultra
Capacities
Two-wheel drive
Total system .............................................................................................................. 18.5 litres (19.5 U.S. quarts)
Refill capacity with or without filter change.................................................................... 16.0 litres (16.9 U.S. quarts)
Four-wheel drive
Total system ................................................................................................................. 21.0 litres (22 U.S. quarts)
Refill capacity with or without filter change.................................................................... 18.5 litres (19.5 U.S. quarts)
Clutch disc clearance ............................................................................................. 2.3 to 4.3 mm (0.09 to 0.17 inch)
SPECIAL TORQUES
Pipe plug in end of four-wheel drive shaft........................................................................ 30 Nm (266 pound-inches)
Solenoid valve in four-wheel drive valve .......................................................................... 22 Nm (195 pound-inches)
Nut for solenoid coils on transmission control valve .......................................... 7 to 10 Nm (62 to 89 pound-inches)
Fittings for four-wheel drive clutch tube ........................................................................... 30 Nm (265 pound-inches)
Allen head screws for valve plate on front housing.......................................................... 23 Nm (204 pound-inches)
Test port plugs ................................................................................................................. 23 Nm (204 pound-inches)
Detent plugs ........................................................................................................................... 80 Nm (59 pound-feet)
Bolts for rear cover ................................................................................................................. 50 Nm (37 pound-feet)
Bolt for output flange........................................................................................................... 139 Nm (103 pound-feet)
Allen head screws for shifter assembly ........................................................................... 23 Nm (204 pound-inches)
Hollow cap screws for tube on front housing ................................................................... 40 Nm (354 pound-inches)
Bolts to fasten front and rear housings ................................................................................... 50 Nm (37 pound-feet)
Bolts to fasten cover below four-wheel drive flange.......................................................... 23 Nm (204 pound-inches)
Bolt for four-wheel drive flange ............................................................................................139 Nm (103 pound-feet)
Bolts for oil pump .............................................................................................................. 23 Nm (204 pound-inches)
Fitting for oil filter .....................................................................................................................50 Nm (37 pound-feet)
Bolts to fasten four-wheel drive valve to front housing ..................................................... 23 Nm (204 pound-inches)
Bolts to fasten cover for oil screen.................................................................................... 23 Nm (204 pound-inches)
Bolts for transmission control valve .................................................................................. 23 Nm (204 pound-inches)
Drain plug ................................................................................................................................80 Nm (59 pound-feet)
Allen head screws to fasten pump support to pump housing ............................................. 10 Nm (89 pound-inches)
Nut for four-wheel drive solenoid coil.................................................................................... 8 Nm (71 pound-inches)
Allen head screws for modulation cover ............................................................................. 11 Nm (97 pound-inches)
Solenoid plunger in transmission control valve................................................................. 23 Nm (204 pound-inches)
Bolts to fasten pump mount to rear housing ........................................................................... 50 Nm (37 pound-feet)

6007-4
SPECIAL TOOLS
BD05A046
380040161 TEFLON SEAL INSTALLATION KIT M SERIES 2 TRANSMISSION
380001928 PUSHER NOT SHOWN

6007-5
BP95F658 BP95F659
CAS-2379 INPUT SHAFT HOLDER AND SPRING CAS-2378 TRANSMISSION LEG SET.
COMPRESSOR
Used to hold transmission during repairs. Not shown
in use in this section.
4
2
1
BP95F661
CAS-2381 SEAL DRIVER
BC04D094
EXISTING CAS2771A TEFLON SEAL
INSTALLATION TOOL KIT
TOOLS USED FOR 4 WHEEL DRIVE SHAFT
1. CAS2771-2 3. CAS2771-3 SPACER

SEAL EXPANDER/PROTECTOR 4. CAS2327 PUSHER
2. CAS2771-1 SEAL COMPRESSOR

6007-6
TRANSMISSION HOUSING
Disassembly STEP 3
NOTE: Some photos may not represent your
transmission, the procedures are the same.
STEP 1
BD01B009
Remove the two cap screws that fasten the cover for
the oil screen. Remove the cover.
BD01B002
STEP 4
Fasten the rear housing to acceptable suppor t
e q u i p m e n t . I t i s r e c o m m e n d e d t h a t yo u u s e
equipment that will let you rotate the transmission.
STEP 2
BD01B011
Remove the oil screen and the O-ring.

NOTE: Steps 8 through 10 are for four-wheel drive
transmissions only. If you are working on a
two-wheel drive transmission, go to step 11.
BD01B003
Remove the drain plug and drain the oil from the
transmission.
NOTE: The four-wheel drive transmission is shown.
On two-wheel drive transmissions, the drain plug is
at the rear of the transmission.

6007-7
STEP 5 STEP 7
BD01B016 BD01B017
Remove the oil filter. Remove the fitting for the oil filter.
STEP 6 transmissions only. If you are working on a two-wheel
drive transmission, go to step 11.
STEP 8
BD01B021
DO NOT remove the plug unless the plug is leaking.

The plug is sealed with Loctite 542 or Loctite 262 and
is difficult to remove. If removal is necessary, clean
BD01B019
all oil from the threads and apply Loctite 542 or
Remove the spool.
Loctite 262 (red) before installation.
STEP 9
BD01B020
Remove the spring.

6007-8
STEP 10 STEP 12
BP95F023 BP95F026
Use a blind hole puller to remove the four-wheel Remove the dipstick tube.
drive priority valve.
NOTE: The four-wheel drive priority valve is STEP 13
adjusted at the factory. DO NOT try to disassemble
or adjust the four-wheel drive priority valve. If any of
the parts are damaged, use a new four-wheel drive
priority valve.
STEP 11
BD01B176
Remove the fitting for the dipstick tube.
STEP 14
BP95F025
Remove the dipstick.
BD07J001-01
Remove the bolts that fasten the transmission control

valve to the front housing.

6007-9
STEP 15 STEP 19
Remove the transmission control valve and the
gasket.
STEP 16
BD07J006-01
Remove the pump mount housing.
STEP 20
BD07J002-01
Remove the three bolts that fasten the four-wheel

drive valve to the front housing.
STEP 17
Remove the four-wheel drive valve and the gasket.
STEP 18
BD07J007-01
Use a plastic mallet and tap the through shaft out of

the transmission rear housing.
STEP 21
BD07J005-01
Remove the seven bolts that fasten the pump mount

to the rear housing.
BD07J008-01
Pull the shaft from the transmission.

6007-10
STEP 22 STEP 25
BD03N036
Remove the seal from the shaft. BD07J009-01
Remove the pressure sensor switch from the brake

STEP 23 housing.
STEP 26
BD03N028
Remove the snap ring from the pump shaft.
STEP 24 BD07J010-01
Remove the solenoid from the brake housing.
STEP 27
BD03N027
Use a suitable driver and remove the bearing from

the pump drive shaft.
BD07J011-01
Make sure the orifice remains in the brake housing.

6007-11
STEP 28 STEP 31
BD07J012-01 BD07J015-01
Remove the three Allen head bolts that fasten the Remove three of the parking brake cover bolts.
shifter housing to the rear cover. Remove the shifter Loosen the remaining three bolts evenly one turn at a
assembly and the O-ring. time to relieve spring pressure in the brake housing.
STEP 29 WARNING: Housing is under spring

pressure, failure to follow instructions will
result in serious injury and damage to
equipment.
M1221
STEP 32
BD07J013-01
Remove the bolt and the output flange.
STEP 30
BD07J015-01
Remove the brake discs from the brake housing.
BD07J014-01
Remove the output flange.

6007-12
STEP 33 STEP 35
BD07J017-01 BD07J019-01
Rmove the brake disc flange from the output shaft.
STEP 34
BD07J020-01
BD07J018-01
Remove the rear cover mounting bolts.
BD07J021-01
At the three prying points, use pry bars and loosen

the rear cover from the transmission.

6007-13
STEP 36 STEP 40
BD07J022-01 BD01B063
Remove the rear cover from the transmission. Remove the two Allen head bolts that hold the plate
between the two shift rods.
STEP 37
Remove the seal from the rear cover. STEP 41
STEP 38
BD01B065
Remove the plate.

BD01B060
Use a punch to remove the pins that fasten the shift STEP 42
collars to the shift rods.
STEP 39
BD01B066
Remove the two shift interlock balls from the groove

between the two shift rods.
BD01B062
Remove the shift collars from the shift rods.

6007-14
STEP 43 STEP 46
Repeat steps 43 through 45 to remove the other
detent plug, spring, and ball.
NOTE: Rotate the transmission in the stand so the
shafts will not fall out when the snap ring is removed.
STEP 47
BD01B067
Remove one of the detent plugs from the right-hand

side of the rear housing.
STEP 44
BD01B069
Push the secondary shaft to the rear so that there is

clearance between the snap ring and the rear
housing. Remove the snap ring.
NOTE: If the bearing is not very tight on the
secondary shaft, parts could fall from the secondary
shaft when you remove the secondary shaft from the
rear housing. To prevent this, you can install a hose
clamp on the output end of the secondary shaft. This
will keep the bearing in position during removal of the
secondary shaft.
BD01B068
Remove the detent spring. STEP 48
STEP 45
BD01B023
Remove all of the housing bolts that are fastened

BP95G005 from the rear housing to the front housing. There are
Remove the detent ball. 13 of these bolts on the four-wheel drive and 14 on
the two-wheel drive. On the two-wheel drive, two of
the bolts are longer than the others. Record the
locations of these two.

6007-15
STEP 49 STEP 51
BD01B042
BD01B027
Rotate the transmission so that the front housing is
up. On four-wheel drive transmissions only, there are Remove the washer.
three bolts fastened from the front housing to the rear
housing. Remove these bolts. STEP 52
transmissions only. If you are working on a two-wheel
STEP 50
BD01B028
Remove the four-wheel drive flange.
STEP 53
BD01B025
Install two bolts in the four-wheel drive flange as

shown. Use a pry bar between the two bolts to hold
the four-wheel drive flange while you remove the bolt
from the four-wheel drive shaft.
BD01B029
Remove the O-ring from the four-wheel drive flange.

6007-16
STEP 54 STEP 57
BD01B031 BP95F350
Remove the three bolts that fasten the cover to the Remove the seal from the cover.
front housing.
STEP 58
STEP 55
BD07J026-01
BD01B033
Make a mark across the joint between the oil pump
Remove the cover. and the torque converter housing so that the oil
p u m p c a n b e a l i g n e d t h e s a m e w ay d u r i n g
installation.
STEP 56
STEP 59
BD01B034

BD07J027-01
Remove the six bolts that fasten the oil pump in

position.

6007-17
STEP 60 STEP 63
BD01B038 BD01B041
Use two pry bars to lift the oil pump evenly until the Remove the snap ring.
oil pump can be removed.
STEP 64
STEP 61
BD01B043
BD01B039 Fasten acceptable lifting equipment to the front

Remove the oil pump. housing as shown. Use pry bars at both ends of the
housings to separate the front housing from the rear
STEP 62 housing.
BD01B040
Pull up the input shaft to get clearance as you

release the snap ring.

6007-18
STEP 65 STEP 67
BP95F044 BP95F047
As you lift the front housing, continue to use the pry On machines with four-wheel drive, remove the
bar to make sure that the front housing comes up four-wheel drive shaft bearing from the front housing.
evenly. Also, it will probably be necessary to hit the
end of the four-wheel drive shaft, if so equipped, and STEP 68
the end of the input shaft with a soft hammer so that
the two shafts come down out of the front housing
and stay with the rear housing.
NOTE: The bearings in steps 66 and 67 are a close
slip fit. If a bearing is difficult to remove, the bearing
is probably not straight in the bore or on the shaft.
Push the bearing back into the installed position and
try again.
STEP 66
BP95F373
Remove the tube from the front housing only if the

tube is damaged or leaking.
STEP 69
BD01B047
The bearing for the primary shaft and the bearing for
the secondary shaft can stay with either the shafts or
the front housing. Remove the two bearings.
BP95F081
Remove the three O-rings from the flange of the rear

housing.

6007-19
STEP 70 STEP 72
BD01B047 BP95F066
On machines with four-wheel drive, remove the Rotate the rear housing so that the open side is up.
four-wheel drive shaft. Connect acceptable lifting equipment to the top gear
on the secondary shaft.
STEP 71
STEP 73
BP95F083
Remove the input shaft and the reverse shaft BP95F067
together. Use the lifting equipment to begin lifting the

secondary shaft while you use your hands to lift the
NOTE: Make a mark on the top end of the reverse
primary shaft. At the same time, move the primary
shaft so that you can install the reverse shaft with the
shaft back and forth to keep the primary shaft moving
same end up during Assembly.
freely. It can be necessary to tap the ends of the shift
rods (from below the rear housing) so that the shift
rod and fork assemblies continue to move freely.
When the primary shaft is free of the rear housing
and the secondary shaft, remove the primary shaft.

6007-20
STEP 74 NOTE: Steps 77 and 78 are for four-wheel drive
transmissions only. If you are working on a two-wheel
STEP 77
BP95F068
Continue to lift the secondary shaft until you can

move the secondary shaft out of the shift forks. Then
remove the secondary shaft.
BD01B076
STEP 75 Remove the four-wheel drive clutch gear.
STEP 78
BP95F069
Remove the shift rod and fork assembly for first and
second gear from the rear housing. BP95F073
Remove the bearing.

STEP 76
BP95F070
Remove the shift rod and fork assembly for third and
fourth gear from the rear housing. Remember that
this assembly was installed in the bore nearer the top
of the rear housing.
6007-21
STEP 79 STEP 82
1 2
1
1 3
BP95F074 BP95F370
It is not necessary to remove the test port plugs (1), Remove the three Allen head bolts that fasten the
the breather (2), or the temperature sender (3) from valve plate to the front housing.
the rear housing unless these parts are leaking or
damaged. STEP 83
STEP 80
Inspect the input shaft bore in the rear housing. If
there are grooves from the sealing rings, you must
use a new rear housing. Remove any sharp edges at
the ends of the input shaft bore and at the oil
distribution holes.
STEP 81
BP95F369
Remove the valve plate from the front housing.
STEP 84
BP95F366
Remove the four-wheel drive clutch tube (four-wheel

drive machines only) from the front housing only if
the front housing must be replaced or if the tube is
leaking or damaged.
BP95F371
Remove the gasket.

6007-22
12
13 16 17
15
11 11
10 14
10
9 18
7 8
6
20
5 19
21
4
3 7
19
2
20 22
1
9 23
2
3 21 24
BS08B406
1. TUBE 9. FITTING 17. BOLT

2. HOLLOW BOLT 10. COPPER WASHER 18. REAR COVER
3. COPPER WASHER 11. TEST PORT PLUG 19. BOLT
4. COPPER WASHER 12. PARK BRAKE PRESSURE TUBE 20. DOWEL PIN
5. PLUG 13. BREATHER 21. DRAIN PLUG
6. PLUG 14. BREATHER PIPE 22. REAR HOUSING
7. PLUG 15. PTO FLANGE 23. FOUR-WHEEL DRIVE CLUTCH TUBE
8. O-RING 16. O-RING 24. FRONT HOUSING
FOUR-WHEEL DRIVE TRANSMISSION

6007-23
14 15
12
13
9
10
8
8
7
11
16
4 6
4
5
4
18
17
3
2
11 17
4
1 19
20 4
2 3
BS08B405
1. TUBE 6. O-RING 11. DOWEL PIN 16. O-RING
2. HOLLOW BOLT 7. SEALING WASHER 12. PARK BRAKE PRESSURE TUBE 17. BOLT
3. COPPER WASHER 8. TEST PORT PLUG 13. REAR COVER 18. DRAIN PLUG
4. PLUG 9. BREATHER 14. PTO FLANGE 19. REAR HOUSING
5. COPPER WASHER 10. BREATHER PIPE 15. BOLT 20. FRONT HOUSING
TWO-WHEEL DRIVE TRANSMISSION

6007-24
INPUT SHAFT
14
13
12
11
10
9
8
7
6
4 5
12
3 13
2 14
15
1
16
17
18
21 25
24
23
20 7
19 5
18
22 29
17
7
16
8
15 9
28
11 26 27
10
BC04B062
1. SEAL RING 11. CLUTCH PLATE (12) 21. RIVET
2. SNAP RING 12. LOCK RING 22. GEAR
3. BEARING 13. LOCK-SPRING COVER 23. BEARING
4. SPACER 14. SPRING 24. SNAP RING
5. NEEDLE BEARING 15. CLUTCH SLEEVE 25. SEAL RINGS
6. GEAR 16. CLUTCH PISTON 26. SNAP RING
7. THRUST WASHER 17. SEAL RING 27. BEARING
8. LOCK RING 18. SEAL RING 28. PUMP DRIVE SHAFT
9. CLUTCH PLATE LOCK RING 19. INNER SHAFT 29. SEAL RING
10. CLUTCH DRIVE PLATE (14) 20. SPLIT PIN

6007-25
Disassembly STEP 88
NOTE: Do steps 85 and 86 before you disassemble
the input shaft. This will help to locate any problems.
After you assemble the input shaft, the tests will be
done again to make sure that the input shaft is
working correctly.
STEP 85
See the illustration above. Apply compressed air of
approximately 620 kPa (90 psi) to the forward clutch
passage. Listen to hear the forward piston moving to
lock the forward clutch pack. Try to move the forward
gear. The forward gear must not turn on the input
shaft. Try to move the reverse gear. The reverse gear BD01B147
must turn freely on the input shaft. If the clutches do Remove the sealing ring.
not work correctly, inspect the parts closely during
disassembly so that you can find and correct the STEP 89
problem.
STEP 86
See the illustration above. Apply compressed air of
approximately 620 kPa (90 psi) to the reverse clutch
passage. Listen to hear the reverse piston moving to
lock the reverse clutch pack. Try to move the reverse
gear. The reverse gear must not turn on the input
shaft. Try to move the forward gear. The forward gear
must turn freely on the input shaft. If the clutches do
not work correctly, inspect the parts closely during
disassembly so that you can find and correct the
problem.
BD01B146
Remove the snap ring above the bearing.
STEP 87
BD01B145
Use the bottom piece of CAS-2379 special tool as

shown to fasten the input shaft in the vise so that the
reverse clutch is up.
STEP 90

6007-26
STEP 92
BD01B148
Install a bear ing separator under the gear as BD01B150
shown. DO NOT install the bearing separator Remove the spacer.

between the gear and the bearing. Install a puller
on the bearing separator. Use a shaft protector STEP 93
between the puller and the end of the input shaft.
Use molydisulfide grease to lubricate the shaft
protector and the end of the puller. Make sure that
you pull only until the bearing is free. Pulling any
farther can damage the parts.
STEP 91
BD01B151
Remove the gear.
STEP 94
BD01B149
Remove the bearing.
BD01B152
Remove the needle bearing.
STEP 95

6007-27
STEP 98
BD01B153
Remove the thrust washer. BD01B156
Tap lightly on the thrust plate to move the thrust

STEP 96 plate down so that there is clearance between the
snap ring and the thrust plate. Remove the snap
ring.
STEP 99
BD01B154
Remove the roll pin.
STEP 97
BD01B157
Install the top piece of the CAS-2379 special tool

as shown. Use the three threaded rods and nuts to
fasten the two pieces together.
BD01B155
Tap lightly on the thrust plate to move the thrust

plate down so that there is clearance between the
snap ring and the thrust plate.

6007-28
STEP 100 STEP 103
BD01B160 BP95F093
Tighten the nuts evenly to compress the spring. Use pry bars to lift the thrust plate evenly.
Compress the spring just enough to get access to
the snap ring. STEP 104
STEP 101
BD01B178
Lift the thrust plate and the steel discs and the
BD01B158 friction discs out of the housing as a complete unit.
Remove the snap ring. Set the complete unit on top of the body.
STEP 102
BD01B160
Loosen the nuts and the threaded rods to release

the tension from the spring. Remove the top piece
of the CAS-2379 special tool.

6007-29
STEP 105 STEP 107
BKOOC514 BK00C518
Remove the pressure plate and spring.
STEP 108
BK00C515
Place a mark below the groove on the housing.

Place a mark on each steel and friction disc and
the thrust plate. These marks will be used for BD01B175
reference during the reassembly procedure. Remove the sleeve.
STEP 106 IMPORTANT: Use an air hose with a safety on/off

control nozzle with 2.1 bar (30 psi) maximum at the
nozzle. Wear face protection.
STEP 109
BK00C517
Place a mark on top of the thrust plate and each

steel and friction disc as they are removed. These
m a r k s w i l l b e u s e d fo r r e fe r e n c e d u r i n g t h e
BD01B163
reassembly procedure.
Use compressed air in the port shown to remove
the piston.

6007-30
STEP 110 STEP 113
BD01B164 BP95F105
Remove the piston. Remove the snap ring.
STEP 111 STEP 114
BP95F103 BP95F106
Put the input shaft in the bottom piece of the Install a bear ing separator under the gear as
CAS-2 379 sp ecial to ol as shown so th at the shown. DO NOT install the bearing separator
forward clutch is up. between the gear and the bear ing. Install an
acceptable puller on the bearing separator. Use a
STEP 112 shaft protector between the puller and the end of
th e in pu t sh af t. Us e m oly disu lfide gre ase to
lubricate the shaft protector and the end of the
puller. Make sure that you pull only until the
bearing is free. Pulling any farther can damage the
parts.
BD03N042
Remove the four sealing rings (1).

6007-31
STEP 115 STEP 118
BP95F107 BP95F112
Remove the bearing. Remove the needle bearing.
STEP 116 STEP 119
BP95F108 BP95F113
Remove the thrust washer. Remove the thrust washer.
NOTE: It is possible that the gear moved partially out STEP 120
of the clutch pack when the bearing was removed. If
this occurs, it can be difficult to remove the roll pin.
Move the gear as necessary to remove the roll pin.
STEP 117
BP95F115
Tap lightly on the end plate to move the end plate

down so that there is clearance between the snap
ring and the end plate.
BP95F110
Remove the gear.

6007-32
STEP 121 STEP 124
BP95F114 BP95F118
Remove the snap ring. Install the top piece of the CAS-2379 special tool
as shown. Use the three threaded rods and nuts to
STEP 122 fasten the two pieces together.
STEP 125
BP95F116
Use pry bars to lift the end plate evenly. Remove

the end plate. BP95F119
Tighten the nuts evenly to compress the spring.

STEP 123 Compress the spring just enough to get access to
the snap ring.
STEP 126
BP95F117
BP95F120

6007-33
STEP 127 STEP 130
BP95F121 BP95F124
Loosen the nuts and the threaded rods to release Lift the thrust plate and the steel discs and the
the tension from the spring. Remove the top piece friction discs out of the housing as a complete unit.
of the CAS-2379 special tool. Set the complete unit on top of the body.
STEP 128 STEP 131

Follow the same procedure as Step 105 and Step
106 for marking the top of the thrust plate and the
steel and friction discs as they are removed from
the housing.
STEP 132
BP95F122
Remove the retainer plate.
STEP 129
BD01B174
Remove the sleeve.
BP95F123
Remove the spring.

6007-34
IMPORTANT: Use an air hose with a safety on/off STEP 134
control nozzle with 2.1 bar (30 psi) maximum at the
nozzle. Wear face protection.
STEP 133
BD01B164
Remove the piston.
STEP 135
BD01B167
Use compressed air in the port shown to remove

the piston.
BD01B173
Remove the sealing ring from the OD and the ID of

the each piston.

6007-35
14
13
12
11
10
9
8
7
6
4 5
12
3 13
2 14
15
1
16
17
18
21 25
24
23
20 7
19 5
18
22 29
17
7
16
8
15 9
28
11 26 27
10
BC04B062
1. SEAL RING 11. CLUTCH PLATE (12) 21. RIVET
2. SNAP RING 12. LOCK RING 22. GEAR
3. BEARING 13. LOCK-SPRING COVER 23. BEARING
4. SPACER 14. SPRING 24. SNAP RING
5. NEEDLE BEARING 15. CLUTCH SLEEVE 25. SEAL RINGS
6. GEAR 16. CLUTCH PISTON 26. SNAP RING
7. THRUST WASHER 17. SEAL RING 27. BEARING
8. LOCK RING 18. SEAL RING 28. PUMP DRIVE SHAFT
9. CLUTCH PLATE LOCK RING 19. INNER SHAFT 29. SEAL RING
10. CLUTCH DRIVE PLATE (14) 20. SPLIT PIN

6007-36
Inspection STEP 140

Check the ball bearings and the needle bearings
STEP 136 for flat areas, pitting, and other damage. Use new
Check the springs for broken or cracked coils. parts as required.
Compare the heights of the two springs. If the two
springs are not approximately the same height, STEP 141
use new springs. The correct spring height is
approximately 85.5 mm (3.4 inches). Use new
parts as required.
STEP 137
Check the sealing ring grooves (large and small)
for wear and damage. Use new parts as required.
STEP 138
C h e ck t h e t e e t h o n t h e g e a r s fo r w e a r a n d
damage. If a tooth is badly damaged, be sure to
inspect the gear or spline that is in mesh with the
damaged gear. Use new parts as required. BD01B172
If the clutch discs are to be used again, keep the

STEP 139 clutch packs separate and record which clutch
Check the splines on the output shaft for wear and pack goes with each clutch. Use new par ts as
damage. Check the passages in the output shaft to required.
be sure that the passages are open and free of
foreign material. Use new parts as required.

6007-37
STEP 142 STEP 143
Inspect the bore and the shaft in the input shaft
1 housing for damage that will cause leakage when
the clutch is assembled. Check the slots in the side
of the input shaft housing for damage from the
t a n g s o n t h e s t e e l d i s c s. U s e n ew p a r t s a s
required during assembly.
STEP 144
BP95F130
BD03N041
Inspect the end of the clutch pack housing line bore

holes, if a rivet is coming out of the housing (arrow),
replace the rivet.
BP95F131
Use a straight edge to check each steel disc (1)

and each friction disc (2) to be sure each part is
flat. If a steel disc (1) or a friction disc (2) is not flat,
a new part must be installed during assembly. If
the friction discs (2) are smooth or almost smooth,
use new par ts during assembly. If the friction
material is damaged or appears burned, use new
parts during assembly. Also, check the splines for
wear. Inspect the steel discs (1) for pitting, scoring,
or other damage. If there is any damage, use new
par ts during assembly. If you will be using new
friction discs, soak the friction discs in clean
t r a n s m i s s i o n o i l fo r a t l e a s t a n h o u r b e fo r e
assembly. If you are using the old friction discs,
make sure that the friction surfaces are coated
with transmission oil before assembly.

6007-38
Assembly STEP 148
STEP 145
BD01B174
Use clean transmission oil to lubricate the edge

BP95F127
and the bore of the piston. Install the piston.
Use clean transmission oil to lubricate the sealing
rings. Install new sealing rings in each piston. STEP 149
STEP 146
BP95F207
Install the spring.

BD01B170
Slide the 380001926 piston installation tool on the STEP 150

input shaft.
STEP 147
Use clean transmission oil to lubricate the edge
and the bore of the piston. Install the piston.
Remove the 380001926 piston installation tool
from the input shaft.
BP95F208
Install the retainer plate. The side that has a raised

area around the bore goes down.

6007-39
STEP 151 STEP 153
BP95F209 BP95F211
Install the top piece of the CAS-2379 special tool. Use clean transmission oil to lubricate the thrust
Use the three threaded rods and nuts to fasten the washer. Install the thrust washer so that the notch
two pieces together. Tighten the nuts evenly to in the inner edge fits over the pin. Make sure that
compress the spring just enough to get access to the side with the oil grooves is up.
the snap ring groove in the input shaft. Install the
snap ring. Loosen the nuts to relieve the spring STEP 154
tension and remove the CAS-2379 special tool.
Make sure that the outer edge of the snap ring is
seated in the groove in the retainer plate.
STEP 152
BP95F213
Use clean transmission oil to lubricate the needle

bearings. Install the needle bearing.
BP95F210
Install the pin.

6007-40
STEP 155 STEP 157
BP95F232 BP95G003
To assemble the clutch pack, start with the gear on Install one steel disc with reference mark on top of
the bench. Install the thrust plate so that the the steel disc towards the gear.
reference mark on top of the plate made during
disassembly is facing towards the gear. STEP 158
Repeat steps 156 and 157 until all the clutch discs
STEP 156 are installed. The assembled clutch pack must
contain seven steel discs and six friction discs.
STEP 159
BP95F234
Install one steel disc with reference mark on top of

the steel disc towards the gear followed by one
friction disc with the reference mark on top towards BP95F226
the gear. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold
NOTE: If you will be using new friction discs, soak the clutch pack together so that the parts do not
the friction discs in clean transmission oil for at least move and rotate the clutch pack so that the clutch
an hour before assembly. If you are using the old discs are down. Put the clutch pack on the clutch
friction discs, make sure that the friction surfaces are h o u s i n g a s s h ow n s o t h a t t h e t a b s w i t h t h e
coated with transmission oil before assembly. reference marks on the steel discs are almost
ready to start into the slot in the clutch housing
with the reference mark.

6007-41
STEP 160 STEP 162
BP95F227 BP95F229
Use two screwdrivers in opposite slots in the clutch Install the snap ring.
housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the STEP 163
clutch pack down slowly and evenly, making sure
that all the tabs are going into the slots. Make sure
all of the tabs with reference marks are aligned in
the slot in the housing with the reference mark.
Also make sure that the gear moves down with the
clutch pack.
STEP 161
BP95F230
Use two screwdrivers to move the thrust plate up

until the thrust plate is against the snap ring. There
is a recess in the outer edge of the thrust plate.
When the thrust plate is up all the way, the inner
edge of the snap ring will fit in this recess.
BP95F228
When all the clutch discs are down, and the gear is
down as far as the thrust plate will permit, remove
the screwdrivers. Use a punch and a hammer to
move the thrust plate down evenly just far enough
to get access to the snap ring groove in the clutch
housing.

6007-42
STEP 164 NOTE: For clarity of the Teflon sealing ring
installation procedure the following photos do not
show the clutch pack, gear, spacer, bearing, and
snap ring installed on the input shaft. Steps 145
through 166 must be performed before installing the
Teflon sealing ring on the input shaft.
STEP 167
BP95F108
Use clean transmission oil to lubricate the thrust

washer. Install the thrust washer so that the notch
in the inner edge fits over the pin. Make sure that
the side with the oil grooves is down.
STEP 165
BD05A032
Place the 380001929 spacer into the 380001933

expander/protector.
STEP 168
BP95F231
Use an acceptable driver to drive the bearing onto

the input shaft until the bearing makes contact with
the thrust washer.
STEP 166 BD05A072
Slide the 380001933 expander/protector and the

spacer onto the shaft. Heat the Teflon sealing ring
to 80° to 100° C (176° to 212° F). Install the Teflon
sealing ring onto the expander/protector.
BP95F105

6007-43
STEP 169 STEP 171
BD05A079 BD05A081
Install the 380001928 pusher over the Turn the seal compressor around and slide the end
expander/protector and slide the sealing ring until with the narrow chamfer over the shaft and over
it reaches the groove in the shaft. Remove the the sealing ring. Leave the seal compressor in
pusher, protector, and spacer from the shaft. place for 15 minutes until the sealing ring has
cooled and is properly sized and seated in the
STEP 170 groove. After the sealing ring has cooled, remove
the seal compressor from the shaft.
STEP 172
BD05A080
Install the end of the 380001927 seal compressor

with the deep chamfer onto the shaft and over the
sealing ring. Use a back and forth twisting motion BD05A033
to allow the seal compressor to slip over the top of Place the 380001930 spacer into the 380001933
the sealing ring and seat the sealing ring into the expander/protector.
groove. Be careful not to damage the sealing ring.
After the sealing ring is seated in the groove,
remove the seal compressor from the shaft.

6007-44
STEP 173 STEP 175
BD05A073 BD05A080
Slide the expander/protector and the spacer onto Install the end of the 380001927 seal compressor
the shaft. Heat the Teflon sealing ring to 80° to with the deep chamfer onto the shaft and over the
100° C (176° to 212° F). Install the Teflon sealing sealing ring. Use a back and forth twisting motion
ring onto the expander/protector. to allow the seal compressor to slip over the top of
the sealing ring and seat the sealing ring into the
STEP 174 groove. Be careful not to damage the sealing ring.
STEP 176
BD05A078
Install the 380001928 pusher over the

expander/protector and slide the sealing ring until
it reaches the groove in the shaft. Remove the
pusher, expander/protector, and spacer from the BD05A081
shaft. Turn the seal compressor around and slide the end
with the narrow chamfer over the shaft and over
the sealing ring. Leave the seal compressor in
place for 15 minutes until the sealing ring has
groove. After the sealing ring has cooled, remove

6007-45
STEP 177 STEP 179
BD05A034 BD05A077
Place the 380001931 spacer into the 380001933 Install the 380001928 pusher over the
expander/protector. expander/protector and slide the sealing ring until
STEP 178 pusher, expander/protector, and spacer from the
shaft.
STEP 180
BD05A074
Slide the expander/protector and the spacer onto

the shaft. Heat the Teflon sealing ring to 80° to
100° C (176° to 212° F). Install the Teflon sealing BD05A080
ring onto the expander/protector. Install the end of the 380001927 seal compressor
sealing ring. Use a back and forth twisting motion
to allow the seal compressor to slip over the top of

6007-46
STEP 181 STEP 183
BD05A081 BD05A075
Turn the seal compressor around and slide the end Slide the expander/protector and the spacer onto
with the narrow chamfer over the shaft and over the shaft. Heat the Teflon sealing ring to 80° to
the sealing ring. Leave the seal compressor in 100° C (176° to 212° F). Install the Teflon sealing
place for 15 minutes until the sealing ring has ring onto the expander/protector.
groove. After the sealing ring has cooled, remove STEP 184
STEP 182
BD05A076

BD05A035 it reaches the groove in the shaft. Remove the
Place the 380001932 spacer into the 380001933 pusher, expander/protector, and spacer from the
expander/protector. shaft.

6007-47
STEP 185 STEP 187
BD05A080 BD05A037
Install the end of the 380001927 seal compressor Put the input shaft in the bottom piece of the
with the deep chamfer onto the shaft and over the CAS2379 special tool so that the reverse clutch
sealing ring. Use a back and forth twisting motion h o u s i n g i s u p. S l i d e t h e 3 8 0 0 0 1 9 2 6 p i s t o n
to allow the seal compressor to slip over the top of installation tool on the input shaft.
groove. Be careful not to damage the sealing ring. STEP 188
After the sealing ring is seated in the groove, Use clean transmission oil to lubricate the edge
remove the seal compressor from the shaft. and the bore of the piston. Install the piston.
Remove the piston installation tool.
STEP 186
STEP 189
BD05A081
Turn the seal compressor around and slide the end BK00C519
with the narrow chamfer over the shaft and over Install the sleeve.

6007-48
STEP 190 STEP 192
BK00C518 BP95F239
Install the pressure plate and the spring. The Install the pin.
raised area around the bore of the pressure plate
must go down. The side that has the groove STEP 193
around the bore should face up. The outer edge of
the snap ring must fit in the groove after the parts
are assembled.
STEP 191
BP95F240

washer. Install the thrust washer so that the notch
in the inner edge fits over the pin. Make sure that
the side with the oil grooves is up.
BP95F237
Install the top piece of the CAS-2379 special tool.

Use the three threaded rods and nuts to fasten the
two pieces together. Tighten the nuts evenly to
compress the spring just enough to get access to
the snap ring groove in the input shaft. Install the
snap ring. Loosen the nuts to relieve the spring
tension and remove the CAS-2379 special tool.
Make sure that the outer edge of the snap ring is
seated in the groove in the retainer plate.

6007-49
STEP 194 NOTE: If you will be using new friction discs, soak
the friction discs in clean transmission oil for at least
an hour before assembly. If you are using the old
friction discs, make sure that the friction surfaces are
coated with transmission oil before assembly.
STEP 196
BD01B152
Use clean transmission oil to lubricate the needle

bearing. Install the needle bearing.
STEP 195
BP95F234

the steel disc towards the gear followed by one
friction disc with the reference mark on top towards
the gear.
STEP 197
BP95F232
To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the
reference mark on top of the plate made during
disassembly is facing towards the gear.
BP95G003

the steel disc towards the gear.
STEP 198
Repeat steps 196 and 197 until all the clutch discs
are installed. The assembled clutch pack must
contain seven steel discs and six friction discs.

6007-50
STEP 199 STEP 201
BP95F242 BP95F244
Make sure that the tabs with reference marks on all When all the clutch discs are down, and the gear is
the steel discs are aligned with each other. Hold down as far as the thrust plate will permit, remove
the clutch pack together so that the parts do not the screwdrivers. Use a punch and a hammer to
move and rotate the clutch pack so that the clutch move the thrust plate down evenly just far enough
discs are down. Put the clutch pack on the clutch to get access to the snap ring groove in the clutch
h o u s i n g a s s h ow n s o t h a t t h e t a b s w i t h t h e housing.
reference marks on the steel discs are almost
ready to start into the slot in the clutch housing STEP 202
with the reference mark.
STEP 200
BP95F245
BP95F243
Use two screwdrivers in opposite slots in the clutch

housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the
clutch pack down slowly and evenly, making sure
that all the tabs are going into the slots. Make sure
all of the tabs with reference marks are aligned in
the slot in the housing with the reference mark.
Also make sure that the gear moves down with the
clutch pack.

6007-51
STEP 203 STEP 205
BP95F246 BP95F077
Use two screwdrivers to move the thrust plate up Install the snap ring.
until the thrust plate is against the snap ring. There
NOTE: For clarity of the Teflon sealing ring
is a recess in the outer edge of the thrust plate.
installation procedure the following photos do not
When the thrust plate is up all the way, the inner
show the clutch pack, gear, spacer, bearing, and
edge of the snap ring will fit in this recess.
snap ring installed on the input shaft. Steps 187
through 205 must be performed before installing the
STEP 204 Teflon sealing ring on the input shaft.
STEP 206
3
BP95F248
Use clean transmission oil to lubricate the spacer

(1) and install the spacer (1) on the input shaft.
BD05A038
Install the bearing (2) onto the input shaft. Use an
Place the 380001429 spacer into the 380001428
acceptable driver (3) to drive the bearing onto the
expander/protector.
input shaft until the bearing (2) makes contact with
the spacer (1).

6007-52
STEP 207 STEP 209
BD05A070 BD05A082
Slide the expander/protector and spacer onto the Install the end of the 380001427 seal compressor
input shaft. Heat the Teflon sealing ring to 80° to with the deep chamfer onto the shaft and over the
ring onto the 380001428 expander/protector. to allow the seal compressor to slip over the top of
STEP 210
BD05A071


6007-53
STEP 211
]
BP95F249
Measure the clutch disc clearance for each clutch

assembly. The end cover must be all the way up
against the snap r ing. Use a feeler gauge to
measure the distance between the end cover and
the first metal disc. The distance must be 2.3 to 4.3
mm (0.09 to 0.17 inch). If the distance is not within
specification, the clutch is probably assembled
w r o n g . C l u t c h p l a t e we a r w i l l n o t c a u s e t h e
distance to be outside the specification.
5 4 3
6
2 1
7
2 1
5 4
BS01B056
1. FORWARD CLUTCH PASSAGE 4. FORWARD CLUTCH PACK 6. REVERSE GEAR

2. REVERSE CLUTCH PASSAGE 5. REVERSE CLUTCH PACK 7. INPUT SHAFT
3. FORWARD GEAR
NOTE: The above art shows a clutch pack without the PTO through shaft, the procedures for steps 212 and 213
are the same.

6007-54
STEP 212 STEP 213
See the illustration above. Apply compressed air of See the illustration above. Apply compressed air of
approximately 620 kPa (90 psi) to the forward approximately 620 kPa (90 psi) to the reverse
clutch passage. Listen to hear the forward piston clutch passage. Listen to hear the reverse piston
moving to lock the forward clutch pack. Try to move moving to lock the reverse clutch pack. Try to move
the forward gear. The forward gear must not turn the reverse gear. The reverse gear must not turn
on the input shaft. Try to move the reverse gear. on the input shaft. Try to move the forward gear.
The reverse gear must turn freely on the input The forward gear must turn freely on the input
s h a f t . I f t h e c l u t c h e s d o n o t wo r k c o r r e c t l y, s h a f t . I f t h e c l u t c h e s d o n o t wo r k c o r r e c t l y,
disassemble the clutches to find the problem. disassemble the clutches to find the problem.
SECONDARY SHAFT
STEP 214
BD01B125
Install a bear ing separator under the gear as

BD01B124
shown. DO NOT install the bearing separator
Suppor t the secondar y shaft on blocks on the between the gear and the bearing. If the bearing
bench as shown. separator has a beveled edge, the beveled edge
must be down. Do not tighten the bearing
separator so much that the bearing separator
pushes the synchronizer down. Install an
shaft protector between the puller and the end of
the secondary shaft. Use molydisulfide grease to
puller. Make sure that you pull only until the
bearing is free. Pulling any farther can damage the
parts.

6007-55
STEP 216 STEP 218
BD01B126 BD01B128
Remove the bearing. Remove the third gear from the shaft.
STEP 217 STEP 219
BD01B127 BD01B129
Remove the thrust washer. Remove the synchronizer assembly.

6007-56
STEP 220 STEP 221
BD03N039
Remove the clutch ring from each side of the

synchronizer assembly.
STEP 222
BC01C095
BD03N038
Remove the tapered friction ring from each side of

1 the synchronizer assembly.
STEP 223
3 2
BD01C003
1. CLUTCH RING 3. CLEARANCE

2. TAPERED FRICTION RING
BC03N037
be twee n the clutch r ing and the edg e of the
Inspect the clutch ring teeth for wear, wear in excess
tapered friction ring. This clearance should be
of 0.5 mm (0.02 inch) the ring must be replaced.
approximately 1.0 mm (0.04 inch) with used parts
in good condition. If the clearance is 0.5 mm (0.02
inch) or less, use new parts as required. Repeat
the measurement for the opposite side of the
synchronizer assembly before disassembly.
6007-57
STEP 226
NOTE: The parts may fly out of the hub when you do
the following step. Putting the synchronizer assembly
in a cardboard box during this step can prevent loss
of parts.
STEP 224
BD01B130
Remove fourth gear.
STEP 227
BK00C536
Remove the sleeve from the synchronizer hub.

When the sleeve is removed from the synchronizer
hub the spring plates, hub pins and hub springs
will be released from the synchronizer hub. Be
careful not to lose any of these parts.
STEP 225
1
2 BD01B131
3 Turn the secondary shaft over so that second gear

is at the top. You can use a vise with soft jaws to
4 hold the secondary shaft in position.
2 3 3 2
1
1
BP95F168
This photo shows the relationship of the balls (1),

the spring plates (2), the springs (3), and the hub
(4).

6007-58
STEP 228 STEP 230
BD01B132 BD01B134
Install a bearing separator under the bearing race Remove the snap ring from the shaft.
as shown. If the bearing separator has a beveled
edge, the beveled edge must be down. Do not STEP 231
tighten the bearing separator so much that the
bearing separator pushes the synchronizer down.
I n s t a l l a n a c c e p t a bl e p u l l e r o n t h e b e a r i n g
separator. Use a shaft protector between the puller
and the end of the secondary shaft. Use
molydisulfide grease to lubricate the shaft
protector and the end of the puller. Make sure that
you pull only until the bearing race is free. Pulling
any farther can damage the parts.
STEP 229
BD01B135
Remove the shim(s) and the thrust washer.
STEP 232
BD01B133
Remove the bearing race from the shaft.
BD01B136
Remove the pin.

6007-59
STEP 233 STEP 236
3
4
BD01B137
Remove second gear.
STEP 234
5
BD01B138 BC01C094
Remove the spacer. 1. TAPERED FRICTION RING 4. SYNCHRONIZER RING
2. BRONZE RING 5. CLEARANCE
STEP 235 3. STEEL RING
between the bottom of the teeth on the
synchronizer ring and the edge of the sleeve on
the outside of the synchronizer assembly. This
clearance should be approximately 1.0 mm (0.04
inch) with used par ts in good condition. If the
clearance is 0.5 mm (0.02 inch) or less, use new
parts as required. Repeat the measurement for the
opposite side of the synchronizer assembly before
disassembly.
BD01B139
Remove the synchronizer ring and the first-second

synchronizer as an assembly.

6007-60
STEP 237 STEP 240
1
1
2 2
BP95F164 BP95F164
Remove the steel ring (1) and the bronze ring (2) Remove the steel ring (1) and the bronze ring (2)
together. together.
STEP 238 STEP 241
BP95F165 BP95F165
Remove the tapered friction ring. Remove the tapered friction ring.
NOTE: The parts will fly out of the hub when you do
STEP 239 the following step. Putting the synchronizer assembly
in a cardboard box during this step can prevent loss
of parts.
BP95F163
Turn the synchronizer assembly over and remove

the synchronizer ring from the other side.

6007-61
STEP 242 STEP 245
BP95F167 BD01B141
Support the sleeve on blocks. Push down on the If equipped with four wheel drive, remove the snap
hub while you use a punch to push the detent ring from the 4 wheel drive gear.
assemblies out of the sleeve and hub. Remove the
sleeve from the hub. STEP 246
STEP 243
1
2
3
4
2 3 3 2
1 BD01B142
1 Remove the 4 wheel drive gear, if equipped. On
BP95F168 two-wheel drive transmissions, there is a raised
This photo shows the relationship of the balls (1), area on the shaft.
the spring plates (2), the springs (3), and the hub
(4). STEP 247
STEP 244
BD01B143
If equipped with four wheel drive, do not remove

BD01B140 the snap ring for the 4 wheel drive gear unless the
Remove first gear. snap ring is damaged.

6007-62
5
4
3 16
1 2
6
7
15 8
13 14 9
10 20
12 21
11 15
10 14
9
8
7 13
6 28
12 27
21 11
20
19
26
18
25
24
23
21 22
17
BS00E042
1. LOCK RING 8. STEEL RING 15. SLEEVE 22. THRUST WASHER

2. BEARING 9. COATED RING 16. GEAR 23. BEARING
3. SHIM 10. TAPERED FRICTION RING 17. SPLIT PIN 24. SEAL
4. THRUST WASHER 11. HUB 18. SECONDARY SHAFT 25. FLANGE
5. GEAR 12. SPRING 19. GEAR 26. WASHER
6. SPACER 13. BALL 20. CLUTCH RING 27. O-RING
7. SYNCHRONIZER RING 14. LOCK SPRING PLATE 21. SYNCHRONIZER RING 28. BOLT

6007-63
Inspection Assembly
NOTE: Before each gear is installed on the
STEP 248 secondary shaft, make sure that the bore of the gear
C h e ck t h e t e e t h o n t h e g e a r s fo r w e a r a n d and the outside diameter of the secondary shaft are
damage. If a tooth is badly damaged, be sure to completely lubricated with clean transmission oil.
damaged gear. NOTE: When you install snap rings on the
secondary shaft, make sure that the ends of each
snap ring are seated in the snap ring groove. Do not
STEP 249
install a snap ring so that the ends extend into an
Check the splines on the secondary shaft for wear axial slot on the secondary shaft.
and damage. Check the passages in the
secondary shaft to be sure that the passages are
STEP 253
open and free of foreign material.
STEP 250
Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
STEP 251
Check the teeth in the synchronizer assemblies for
wear and damage. Replace as necessary.
STEP 252
Check for wear or damage to the steel rings and
the bronze rings from the synchronizer assemblies.
BD01B143
Check the springs in the synchronizer assemblies
fo r w e a r, c r a ck s, h e a t d i s t o r t i o n , a n d o t h e r If equipped with four wheel drive, if the snap ring
damage. Replace as necessary. was removed from the shaft, install the snap ring
as shown.
STEP 254
BD01B142
Put the secondary shaft on the bench so that the

first-second gear end is up. You can use a vise with
soft jaws to hold the secondary shaft in position.
Install the four-wheel drive gear, if equipped.
STEP 255

6007-64
STEP 258
BD01B141
If equipped with four wheel drive, install the snap BP95F172

ring for the four wheel drive gear. This photo shows the correct positions of the hub,
the sleeve, the springs, the blocks, and the balls
STEP 256 prior to final assembly.The springs are installed in
the hub, and the blocks are on the springs. The
blocks are not yet pushed down into the sleeve
and are holding the hub up out of the sleeve. The
balls are loose in the recesses of the blocks.
STEP 259
BP95F159
Install first gear.
STEP 257
1
3 BP95F173
Use a punch or screwdriver to push the balls into

3 the blocks and to push the blocks down so that the
2
balls are on the flat faces of the teeth, but not into
the detent grooves. When all the balls are in
2 2 position, push the hub and the blocks down until
the balls move into the detent groove.
1
3 1
BP95F169
This photo shows the correct relationship between

t h e h u b a n d t h e s l e eve fo r a s s e m bl y o f t h e
first-second synchronizer. The tabs (1) in the
inside diameter of the sleeve fit into the small
recesses (2) in the outside diameter of the hub.
The large recesses (3) in the hub are for the detent
assemblies, that are not yet installed.

6007-65
STEP 260 STEP 263
BP95F165 BP95F165
Install the tapered friction ring on the synchronizer Turn the synchronizer assembly over and install
assembly. the tapered friction ring on the other side.
STEP 261 STEP 264
2 2
1
1
BP95F164 BP95F164
Use clean transmission oil to lubricate the bronze Use clean transmission oil to lubricate the bronze
ring (1) and the steel ring (2). Install the bronze ring (1) and the steel ring (2). Install the bronze
ring (1) and the steel ring (2) as shown. ring (1) and the steel ring (2) as shown.
STEP 262
BP95F163
Install the synchronizer ring as shown. The flat

sides of the teeth must be up.

6007-66
STEP 265 STEP 267
Install the top synchronizer ring on the
synchronizer assembly. Make sure that the teeth
on the top synchronizer ring are aligned with the
teeth on the inside of the sleeve. Push the sleeve
up until the sleeve engages the teeth on the top
synchronizer ring. To do this, you must use enough
force to overcome the strength of the detent
springs and balls. When the synchronizer ring and
the sleeve are completely engaged, the detent
must hold the sleeve in this position. Push the
sleeve back down to the neutral position, turn the
s y nc h ro n i ze r as s e m bl y over, an d r e pe a t th e
procedure with the bottom synchronizer ring. If the
sleeve does not engage the teeth smoothly or does BD01B138
not stay in position when moved to any of the three Install the spacer.
positions, the synchronizer assembly has
damaged parts or was not assembled correctly. STEP 268
Disassemble the synchronizer assembly to find the
problem.
STEP 266
BD01B137
Install and second gear. The teeth in the inside

diameter of the spacer must engage the teeth on
the bottom of second gear before second gear is
BD01B139 installed.
Install the synchronizer ring and the first-second
synchronizer as an assembly. Make sure the top STEP 269
synchronizer ring is installed so that the flat sides
of the teeth are up.
NOTE: There is a groove in the bore at one end of
the synchronizer hub. The synchronizer assembly
must be installed so that the groove is down.
BD01B136
Install the pin.

6007-67
Backlash Adjustment STEP 273
STEP 270
BD01B135
Use clean transmission oil to lubricate the shim(s)

BD01B134
and the thrust washer. Install the shim(s). Install
Install the thrust washer and snap ring. the thrust washer on top of the shim(s). Make sure
that the side with the oil grooves is down.
STEP 271
STEP 274
Use a feeler gauge and measure the backlash
between the gear and the thrust washer. Record
this measurement (a). Subtract the recorded
measurement (a) from 0.20 to 0.42 mm (0.0079 to
0.0165 inch) (b). Select the shim(s) required (c).
Sample
a. 1.14 mm 0.0449 inch
b. −0.31 mm 0.0122 inch
c. 0.83 mm 0.0327 inch
Use 0.83 ± 0.11 mm (0 .0327 ± 0.0043 inch)
shim(s).
STEP 272 BD01B133
Put the bearing race on the shaft.
STEP 275
BD01B134
Remove the snap ring and thrust washer.
BD01B144
Use an acceptable driver to drive the bearing race

onto the secondary shaft until bearing race makes
contact with the snap ring.

6007-68
STEP 276 STEP 278
BD01B130 BP95F173
Turn the secondary shaft over so that second gear Install the 3 sets of hub springs, hub pins, and
i s a t t h e b o t t o m . U s e bl o ck s t o s u p p o r t t h e spring plates into the synchronizer hub. Use a
secondar y shaft. Install the four th gear on the punch or screwdriver to push the spring plates as
secondary shaft. the synchronizer hub is installed into the sleeve.
Be sure that the spring plates are aligned with the
STEP 277 grooves in the sleeve.
3 1 STEP 279
1
2 2 3
1
BD01C004
This photo shows the correct relationship between

t h e h u b a n d t h e s l e eve fo r a s s e m bl y o f t h e BK00C535
third-fourth synchronizer. The tabs (1) in the inside Install the friction ring on each side the
diameter of the sleeve fit into the small recesses synchronizer assembly.
(2) in the outside diameter of the hub. The large
r e c e s s e s ( 3 ) i n t h e h u b a r e fo r t h e d e t e n t
assemblies, shown installed.

6007-69
STEP 280 STEP 282
BK00C534 BD01B129
Use clean transmission oil to lubricate and install Install the synchronizer assembly onto the shaft.
the clutch ring on each side of the synchronizer
assembly. STEP 283
STEP 281
BD01B128
Install the third gear on the shaft.

BD01C003
Install the top synchronizer ring on the STEP 284

synchronizer assembly. Make sure that the teeth
on the top synchronizer ring are aligned with the
teeth on the inside of the sleeve. Push the sleeve
up until the sleeve engages the teeth on the top
s y n c h r o n i ze r r i n g . To d o t h i s, yo u m u s t u s e
enough force to overcome the strength of the
detent springs and balls. When the synchronizer
ring and the sleeve are completely engaged, the
detent must hold the sleeve in this position. Push
the sleeve back down to the neutral position, turn
the synchronizer assembly over, and repeat the
procedure with the bottom synchronizer ring. If the
sleeve does not engage the teeth smoothly or
does not stay in position when moved to any of the
BD01B127
three positions, the synchronizer assembly has
damaged parts or was not assembled correctly.
washer. Install the thrust washer onto the shaft.
Disassemble the synchronizer assembly to find the
problem.

6007-70
STEP 285 STEP 286
BD01B126 BP95F193
Put the bearing in position on the secondary shaft. Use an acceptable driver to drive the bearing onto
Make sure that the snap ring groove is at the top. the secondar y shaft until the bear ing makes
contact with the thrust washer.
NOTE: If the bearing is not very tight on the
secondary shaft, parts could fall from the secondary
shaft when you install the secondary shaft in the rear
housing. To prevent this, you can install a hose clamp
on the output end of the secondary shaft. This will
keep the bearing in position during installation of the
secondary shaft.
STEP 287
Check for correct operation of both synchronizer
assemblies. If they do not shift smoothly, with the
teeth on the synchronizer ring aligned with the
s p l i n e s o n t h e s l e ev e , t h e r e i s a p r o b l e m .
D i s a s s e m bl e a s n e c e s s a r y, a n d c o r r e c t t h e
problem.

6007-71
PRIMARY SHAFT
NOTE: The following photos show an early primary shaft. See the line art on page 72 for the correct shaft. Use the
following procedure for your shaft.
STEP 288
BP95F196
Remove the bearing.

BP95F194
Put the primary shaft on the bench so that the end STEP 291
with the bearing attached is up. Remove the snap
ring.
STEP 289
BP95F197
Remove the thrust washer.
BP95F195
Install a bear ing separator under the gear as

shown. DO NOT install the bear ing separator
between the gear and the bear ing. Install an
shaft protector between the puller and the end of
the primary shaft. Use molydisulfide grease to
puller. Pull the bearing from the primary shaft.

6007-72
STEP 292 Inspection
STEP 293
C h e ck t h e t e e t h o n t h e g e a r s fo r w e a r a n d
damage. If a tooth is badly damaged, be sure to
damaged gear.
STEP 294
Check the splines on the primary shaft for wear
and damage.
STEP 295
BP95F200 Check the bearings for flat areas, pitting, and other
Install a bearing separator under the lip of the damage. Replace as necessary.
bearing race as shown. Install an acceptable puller
on the bearing separator. Use a shaft protector
between the puller and the end of the primar y
shaft. Use molydisulfide grease to lubricate the
shaft protector and the end of the puller. Pull the
bearing race from the primary shaft.
BS00E040
1. BALL BEARING 2. PRIMARY SHAFT 3. ROLLER BEARING

6007-73
Assembly STEP 298
STEP 296
BP95F196
Put the bearing into position so that the snap ring

BP95F201
groove on the outside diameter of the bearing is at
Use an acceptable driver to drive the bearing race the top.
all the way onto the primary shaft.
STEP 299
STEP 297
BP95F203
BP95F197
Use an acceptable driver to drive the bearing onto
Use clean transmission oil to lubricate the thrust the primary shaft until the bearing makes contact
washer. Install the thrust washer so that the side with the thrust washer.
with the oil grooves is down.
STEP 300
BP95F194

6007-74
REVERSE SHAFT
1
1
BS00E039
1. BEARING 2. REVERSE SHAFT
Disassembly Inspection
The bearings are the only serviceable parts on the C h e ck t h e t e e t h o n t h e g e a r s fo r w e a r a n d
reverse shaft. If you remove the bearings, use a damage. If a tooth is badly damaged, be sure to
shaft protector between the puller and the end of inspect the gear that is in mesh with the damaged
the reverse shaft. Use molydisulfide grease to gear.
Check the bearings for flat areas, pitting, and other
puller.
damage. Replace as necessary.
Assembly
Use an acceptable driver to drive each bearing
onto the reverse shaft until the bearing makes
contact with the shoulder on the reverse shaft.

6007-75
3
4
4
6
5
4 8
14 9
15 16 10
13
17 19
18 5
21 11
13
12
22
21
20
BT95G179 23
BS00E044
1. BOOT 7. O-RING 13. DETENT BALL 19. SHIFT ROD FOR THIRD AND FOURTH GEAR
2. BAND 8. SPRING 14. DETENT PLUG 20. SHIFT ROD FOR FIRST AND SECOND GEAR
3. SHIFT LEVER 9. BUSHING 15. WASHER 21. ROLL PIN
4. PIN 10. SNAP RING 16. DETENT SPRING 22. SHIFT FORK FOR THIRD AND FOURTH GEAR
5. ALLEN HEAD SCREW 11. SHIFT COLLAR 17. BOLT 23. SHIFT FORK FOR FIRST AND SECOND GEAR
6. SHIFTER HOUSING 12. PLATE 18. COPPER WASHER

6007-76
OIL PUMP
NOTE: Bolts (6), O-Rings, bushings and seals are the only serviceable components in the oil pump. Complete
disassembly of the oil pump is shown for reference only.
STEP 301
BP95F253
Separate the pump suppor t from the pump

BP95F251
housing.
Remove the O-ring.
STEP 304
STEP 302
BP95F254
BP95F252
Remove the large gear from the pump housing.
Remove the two Allen head bolts that fasten the
pump support to the pump housing.

6007-77
NOTE: Install a plastic plug in the bearings to keep STEP 307
the bearings from falling out when the small gear is
removed from the pump housing.
STEP 305
BP95F257
Turn the pump housing over and use blocks to

suppor t the pump housing. Use an acceptable
driver to drive the bushing from the bore of the
BP95F255 pump housing.
Remove the small gear from the pump housing.
NOTE: Be careful when removing the plastic plug STEP 308
from the small gear the needle bearings will fall out.
Make a record of the number of needle bearings
remove from the small gear for use during assembly.
STEP 306
BP95F262
Support the large gear on blocks as shown. Use a

punch and a hammer to drive the bushing from the
large gear.
BP95F256
STEP 309
Remove the seal from the pump housing.
BP95F264
Use an acceptable dr iver to push the needle

bearing out of the small gear.
6007-78
STEP 310 STEP 313
BP95F261 BP95F268
Remove the shaft for the small gear only if the Remove the plug, the spring, and the ball for the
shaft is damaged. The shaft will probably be torque converter relief valve.
difficult to remove.
STEP 314
STEP 311
BP95F269
BP95F265 Remove the roll pin for the oil pump relief valve. Be
Use a blind hole puller and a slide hammer to pull very careful because the large amount of spring
the bushing from the shaft of the pump support. tension will force the parts out when the roll pin is
removed.
STEP 312
STEP 315
BP95F267
Remove the roll pin for the torque converter relief BP95F599
valve. Remove the plug, the spring, the pin, and the
plunger for the oil pump relief valve.

6007-79
Inspection Assembly
STEP 316 STEP 322
Inspect the large gear and the small gear for wear
and damage. If the teeth on a gear have scoring,
excessive wear, or sharp edges, use a new gear.
Check for damage to the lugs on the large gear. If
there is damage, check the hub on the torque
converter for similar damage. Replace the large
gear and the torque converter as necessary.
STEP 317
Inspect the gear pockets in the pump housing for
wear or damage. If the gear pockets have scoring
or excessive wear, use a new oil pump.
BP95F603
STEP 318
Install the plunger for the oil pump relief valve.
Inspect the splines on the shaft for wear and
damage. If you find damage, inspect the part that
is installed on the shaft.
STEP 323
STEP 319
Inspect all passages to be sure that the passages
are open and free of foreign material.
STEP 320
Check the needle bearing for wear, pitting, or other
damage.
STEP 321
Inspect the par ts of the torque conver ter relief
valve and the oil pump relief valve for wear and
damage. BP95F602
Install the pin for the oil pump relief valve. The
machined end of the pin must be toward the
plunger. Make sure that the pin goes into the bore
of the plunger.
STEP 324
BP95F601
Install the spring.

6007-80
STEP 325 STEP 328
BP95F600 BP95F271
Install the plug. Install the roll pin through the holes in the pump
support and the hole in the plug.
STEP 326
STEP 329
BP95F269
This step will be difficult because the spring will be BP95F266
under heavy tension. Push the plug in until the Use an acceptable driver to install a new bushing
plug is to the inside of the hole for the roll pin. in the shaft of the pump support.
Install the roll pin.
STEP 330
STEP 327
BP95F264
BP95F268 Use an acceptable driver to install a new needle

Install the ball, the spring, and the plug for the bearing in the small gear. Push the needle bearing
torque converter relief valve. Make sure that the until the needle bearing is approximately centered
hole in the plug is aligned with the hole for the roll in the bore of the gear.
pin.
6007-81
STEP 331 STEP 334
BP95F261 BP95F260
If the shaft for the small gear was removed, clean Use an acceptable driver to install the bushing.
the mating surfaces and apply either Loctite 640
(green) or Loctite 642 (amber) before installation. STEP 335
STEP 332
BP95F259
Use an acceptable driver to install a new seal in

BP95F263 the end of the pump housing.
Support the large gear on blocks so that the side
with the lugs is down. Use an acceptable driver to STEP 336
push the new bushing to the end of the bore.
STEP 333
1
2
BP95F255
Use clean transmission oil to lubricate the small

gear, the needle bearing, and the bore in the pump
BP95F258 housing. Install the small gear on the shaft in the
Put a new bushing into position so that the recess pump housing. Install the same number of needle
(1) in the bushing is aligned with the oil drain hole bearings that were removed between the small
(2) in the pump housing. gear and the shaft.
6007-82
STEP 337 STEP 340
Install a large worm gear clamp (radiator hose
clamp) around the outside of the pump housing
and the pump support. The clamp must cover the
joint between the two parts and be in contact with
both parts. Tighten the clamp.
Tap the housing with a soft hammer. Tighten the
clamp again.
Tap the housing again with a soft hammer. Tighten
the clamp again.
Tighten the Allen head bolts to 10 Nm (89
pound-inches). Remove the clamp.
BP95F254
Use clean transmission oil to lubricate the large

STEP 341
gear, the bushing in the large gear, and the bore in Put the oil pump on a clean work surface so that
the pump housing. Install the large gear so that the the pump housing is up. Insert a small screwdriver
side with the lugs is down. or punch through the hole in the torque converter
hub and rotate the large gear by pushing against
STEP 338 one of the lugs. The large gear must rotate freely. If
the large gear does not rotate freely, loosen the
Allen head bolts and repeat step 340.
If the large gear rotates freely, fill the oil pump with
clean transmission oil and rotate the large gear
three revolutions before you install the oil pump on
the transmission.
STEP 342
BP95F253
Install the pump suppor t on the pump housing.

Make sure that all the bolt holes are aligned.
STEP 339
BP95F251
Install a new O-ring.
BP95F252
Install the two Allen head bolts to fasten the pump

support to the pump housing. Tighten the Allen
head bolts until they are just snug.
6007-83
FOUR-WHEEL DRIVE SHAFT
STEP 343
BK00C527
Remove the snap ring from the shaft.

BK00C525
There is a pipe plug at the bottom of the hole in the STEP 346
end of the shaft (see arrow). DO NOT remove the
pipe plug unless the pipe plug is damaged.
STEP 344
BK00C528
Remove the spacer.
STEP 347
BK00C526
Use an acceptable tool to press the spring retainer

down until you have access to the snap ring (see
arrow). Remove the snap ring from the groove.
Release the tension and remove the tool.
NOTE: The tool used in the photo above is a piece
of round tubing with a rectangular access hole cut
out to provide access to the snap ring.
BK00C529
Remove the special washer.
STEP 348

6007-84
STEP 351
BK00C530
Remove the springs. BK00C532
Remove the two Teflon sealing rings from the

STEP 349 shaft.
Inspection
STEP 352
Inspect the lugs on the sleeve for peening or other
damage. If you find damage to the lugs, also
inspect the four-wheel drive clutch gear (see step
77).
STEP 353
Check the splines on the shaft and inside the
sleeve for wear and damage.
BK00C531
Remove the sleeve. STEP 354

Check the passages in the shaft to be sure that the
STEP 350 passages are open and free of foreign material.
STEP 355
Check the springs for wear, cracks, heat distortion,
and other damage. Replace as necessary.
BK00C532
Remove the two O-rings from the shaft.

6007-85
11
10
8
7
6
3
5
1
4
1 2 3
14 16
3
13
12 15
BS00E043
1. BOLT 7. BEARING 13. SLEEVE

2. WASHER 8. TEFLON SEALING RING 14. PIPE PLUG
3. O-RING 9. SPECIAL WASHER 15. SHAFT
4. FOUR-WHEEL DRIVE FLANGE 10. SNAP RING 16. FOUR WHEEL DRIVE CLUTCH GEAR
5. COVER 11. SPACER
6. SEAL 12. SPRING

6007-86
Assembly STEP 358

NOTE: Special tools used up to step 361 are from
the tool set CAS2771A, standard transmission
without rear pump drive.
STEP 356
BK00E012
Heat the Teflon sealing ring to 80° to 100° C (176°

to 212° F). Install the Teflon sealing ring onto the
CAS2771-2 expander/protector.
STEP 359
BK00C532
I n s t a l l n ew O - r i n g s o n t h e s h a f t . U s e c l e a n
transmission oil to lubricate the O-rings.
STEP 357
BK00E014
Install the CAS2327 pusher over the

pusher and expander/protector from the shaft.
BK00E011
Install the CAS2771-2 expander/protector on the

shaft.
NOTE: For clarity, the following photo does not show
the use of a heat resistant glove. To prevent injury be
sure to wear a heat resistant glove when installing
the Teflon sealing ring.
STEP 360

6007-87
STEP 362
BK00E015
Install the end of the CAS2771-7 seal compressor BK00E017

with the deep chamfer onto the shaft and over the Place the CAS2771-3 spacer against the end of
sealing ring. Use a back and forth twisting motion the shaft.
the sealing ring and seat the sealing ring into the STEP 363
STEP 361
BK00E018
Slide the CAS2771-2 expander/protector over the

CAS2771-3 spacer. The expander/protector will
stop in the correct position to install the sealing
ring in the groove.
BK00E016
Turn the seal compressor around and slide the end


6007-88
NOTE: For clarity, the following photo does not show STEP 366
the use of a heat resistant glove. To prevent injury be
sure to wear a heat resistant glove when installing
the Teflon sealing ring.
STEP 364
BK00E022
Install the end of the CAS2771-1 seal compressor

BK00E019 the sealing ring and seat the sealing ring into the
Heat the Teflon sealing ring to 80° to 100° C (176° groove. Be careful not to damage the sealing ring.
to 212° F). Install the Teflon sealing ring onto the After the sealing ring is seated in the groove,
CAS2771-2 expander/protector. remove the seal compressor from the shaft.
STEP 365 STEP 367
BK00E021 BK00E023
Install the CAS2327 pusher over the Turn the seal compressor around and slide the end
pusher, expander/protector, and spacer from the place for 15 minutes until the sealing ring has
shaft. cooled and is properly sized and seated in the

6007-89
STEP 368 STEP 371
BK00C531 BK00C528
Install the sleeve on the shaft. Be careful not to Install the spacer onto the shaft.
damage the Teflon sealing rings and the O-rings
while installing the sleeve. STEP 372
STEP 369
BK00C527
Install the snap ring onto the shaft.

BK00C530
Install the springs.
STEP 370
BK00C529
Install the special washer.

6007-90
STEP 373 STEP 374
BK00C526 BP95F279
Use an acceptable tool to press the spring retainer If the pipe plug at the bottom of the hole in the end
down until you have access to the snap ring groove of the shaft (see arrow) was removed, apply Loctite
(see arrow). Install the snap ring in the groove. 242 or Loctite 262 to the threads of the new pipe
Release the tension and remove the tool. Make plug before installation. Tighten the pipe plug to a
sure that the snap ring is seated in the recess in torque of 30 Nm (266 pound-inches).
the spring retainer.
NOTE: The tool used in the photo above is a piece
of round tubing with a rectangular access hole cut
out.

6007-91
SHIFTER HOUSING
STEP 375
BP95F343
Remove the two pins (one on either side of the

BP95F341
shifter housing). Use a screwdriver to lift each pin
Use side cutters as shown to release the catch on as shown until you can reach the pin with your
the ba nd that faste ns th e b oo t to th e sh ifter fingers. Then pull the pin out.
housing. Remove the band.
STEP 378
STEP 376
BP95F345
BP95F342
Remove the snap ring from the shift lever.
Remove the boot from the shifter housing.
STEP 379
BP95F349
Remove the bushing from the shift lever.

6007-92
STEP 380 Shift Rods And Shift Forks
STEP 382
BP95F347
Remove the spring.

BP95F132
STEP 381 If disassembly is required, remove the roll pins and
separate the shift forks from the shift rods. Make
sure that you remember how the par ts are
assembled and which parts go together. The forks
are the only parts that are not interchangeable.
Inspect all par ts for burrs and excessive wear.
Assembly is the reverse of disassembly.
BP95F346
Remove the shift lever from the shifter housing.

6007-93
3
4
4
6
5
4 8
14 9
15 16 10
13
17 19
18 5
21 11
13
12
22
21
20
BT95G179 23
BS00E044
1. BOOT 7. O-RING 13. DETENT BALL 19. SHIFT ROD FOR THIRD AND FOURTH GEAR
2. BAND 8. SPRING 14. DETENT PLUG 20. SHIFT ROD FOR FIRST AND SECOND GEAR
3. SHIFT LEVER 9. BUSHING 15. WASHER 21. ROLL PIN
4. PIN 10. SNAP RING 16. DETENT SPRING 22. SHIFT FORK FOR THIRD AND FOURTH GEAR
5. ALLEN HEAD SCREW 11. SHIFT COLLAR 17. BOLT 23. SHIFT FORK FOR FIRST AND SECOND GEAR
6. SHIFTER HOUSING 12. PLATE 18. COPPER WASHER

6007-94
Assembly STEP 373
STEP 371
BP95F347
Install the spring.

BP95F346
Apply lithium grease to the ball of the shift lever. STEP 374
Install the shift lever in the shifter housing.
STEP 372
2
4
BP95F349
Install the bushing.

1
BP95F352 STEP 375
The correct alignment of the shift lever and the
shifter housing is shown above. The slot (1) in the
shift lever must be toward the flat side (2) of the
flange on the shifter housing. The slots (3) on each
side of the shift lever must be aligned with the
holes (4) in each side of the shifter housing.
BP95F344
Put the snap ring on the shift lever. Use a deep

well socket to push the snap ring into the snap ring
groove.

6007-95
STEP 376 STEP 378
BP95F343 BP95F341
Install the pins through the holes in the shifter Install the band or clamp on the boot. Use the side
housing so that the pins engage the slots in the cutters to engage the catch on the band.
shift lever.
STEP 377
BP95F342
Install the boot so that the end of the boot fits over
the ends of the pins. Be careful so that the pins do
not fall out during this step.

6007-96
FOUR-WHEEL DRIVE VALVE (IF EQUIPPED)
STEP 379
BD01B083
Remove the check valve from the solenoid valve

BD01B077
body. DO NOT try to disassemble the check valve.
Remove the nut. There are no ser viceable par ts. If there is a
problem, use a new check valve.
STEP 380
STEP 383
BD01B080
BD01B084
Remove the solenoid coil.
Remove the three O-rings from the solenoid valve.
STEP 381
BD01B081
Remove the solenoid valve.

6007-97
10
9
2
8
1
11
3
7
5
12
BT95G182
BC05D053
1. BOLT 5. CHECK VALVE 9. SOLENOID COIL

2. PLUG 6. GASKET 10. CONNECTOR
3. COPPER WASHER 7. O-RINGS 11. NUT
4. SOLENOID VALVE BODY 8. SOLENOID VALVE BODY 12. JUMPER WIRE
NOTE: Items 7 through 11 are not serviced separately, for early production M Series 2 machines item 12 will be
required for replacement of the solenoid.

6007-98
Assembly STEP 387
STEP 384
BD01B080
Install the solenoid coil on the solenoid valve.

BD01B084
Install the three new O-rings on the solenoid valve. STEP 388
Use clean transmission oil to lubricate the O-rings.
STEP 385
BD01B079
Install the nut.
BD01B083 STEP 389

Install the check valve in the valve body as shown.
STEP 386
BD01B078
Tighten the nut to a torque of 8 Nm (71

pound-inches).
BD01B082
Install the solenoid valve in the solenoid valve

body. Tighten the solenoid valve to a torque of 22
Nm (195 pound-inches).

6007-99
TRANSMISSION CONTROL VALVE

NOTE: Some of the photos in the following
procedure may not be the same as the model you are
repairing. The repair procedure is the same.
STEP 390
BD01B092
Remove the first solenoid coil.
STEP 393
BD01B085
Remove the nut for the forward/reverse solenoid.
STEP 391
BD01B093
Remove the O-ring from the either the solenoid coil

or the solenoid plunger.
STEP 394
BD01B087
Remove the seal.
BD01B094
Remove the second solenoid coil.

6007-100
STEP 395 STEP 397
BD01B095 BP95F293
Remove the O-ring from the second solenoid coil. Remove the retainer from the rear of the connector
for the solenoid coils.
STEP 396 NOTE: Before removing any wires from the
connector, you may want to record the locations of
the wires for reference during assembly.
STEP 398
BD01B096
The remaining O-ring can stay with either the

solenoid coil or the solenoid plunger. Remove the
remaining O-ring.
NOTE: Step 397 to 400 are for early production M BP95F295
Series 2 machines, current production have a 2 wire Use a small punch to release the locking tab on the
connector per solenoid. terminal.
STEP 399
BP95F296
Pull the wire and the terminal from the connector.

6007-101
STEP 400 STEP 404
Repeat steps 397 and 399 for the remaining wires
and terminals.
STEP 401
BD01B106
Remove the O-rings from the solenoid plunger.
STEP 405
BD01B101
Remove the nut for the differential lock solenoid.
STEP 402
BD01B107
Loosen and remove the solenoid plunger with the

forward/reverse spool attached.
BD01B103 STEP 406

Remove the solenoid coil.
STEP 403
BP95F335
Use a small screwdriver to push down the spring

as shown so that you can disengage the notched
BD01B104 end of the forward/reverse spool from the post on
Loosen and remove the solenoid plunger. the end of the solenoid plunger.

6007-102
STEP 407 STEP 410
7 10 11
1
1
2
3
4
8 5 6
9
2 3
4
BP95F333 BD01B112
Separate the solenoid plunger (1), the spring (2), Remove the outer modulation piston (1) from the
the spring spacer (3), and the forward/reverse modulation cover (2). Remove the two cover
spool (4). gaskets (3) and the spacer gasket (4). Remove the
check ball (5) and spring (6). Remove the outer
STEP 408 modulation piston spring (7), the inner (8) and
outer spring (9), and the inner modulation piston
pin (10) and piston (11).
STEP 411
BP95F334
Remove the O-ring from the solenoid plunger.
STEP 409
BD01B118
Loosen the plug at the opposite end of the bore.
BD01B104
Remove the four Allen head bolts that fasten the

modulation cover to the control valve body.

6007-103
STEP 412 STEP 415
3
2
4
5 1
BD01B114 BD01B121
Remove the plug (1), snap ring (2), flow divider Remove the spring spacer.
shaft (3), the spring (4), and the flow divider piston
(5) from the bore. STEP 416
STEP 413
1 1
1
1
BD01B122
Remove the four hex head plugs (1) and the Allen
BD01B119 head plug (2) only if the plugs are damaged or
Remove the plug from the bore for the leaking. There are copper washers under the
forward/reverse spool. plugs.
STEP 414
BD01B120
Remove the spr ing from the bore for the

forward/reverse solenoid.

6007-104
22 4 1
31 5 2 7
23
25
21 3 8
5
3
6
0 2 3
25 3 9
18 11 10
20 19 9
12
13
19 14
15
26
27 16
19 17
26
3
25
9
24
29
19 23
28
7
32
25 3
30
9
BC05D030
1. NUT 9. GASKET 17. SNAP RING-NOT REMOVABLE 25. PLUG

2. SEAL 10. PLATE 18. BALL 26. SPRING SPACER
3. O-RING 11. OUTER MODULATION PISTON 19. SPRING 27. FORWARD/REVERSE SPOOL
4. CONNECTOR 12. SMALL SPRING 20. CONTROL VALVE BODY 28. FLOW DIVIDER PISTON
5. SOLENOID COIL 13. MEDIUM SPRING 21. BOLT 29. FLOW DIVIDER SHAFT
6. SOLENOID PLUNGER 14. LARGE SPRING 22. HEX HEAD PLUG 30. VALVE PLATE
7. ALLEN HEAD BOLT 15. PISTON PIN 23. COPPER WASHER 31. DIFFERENTIAL LOCK
8. MODULATION COVER 16. INNER MODULATION PISTON 24. ALLEN HEAD PLUG SOLENOID VALVE
32. SNAP RING

6007-105
Inspection Assembly
NOTE: Some of the photos in the following
STEP 417 procedure may not be the same as the model you are
Use cleaning solvent to clean all metal parts. repairing. The repair procedure is the same.
STEP 418 STEP 422

Check the springs for wear, cracks, heat distortion,
and other damage. Replace as necessary. 1
1 1
STEP 419
Inspect the spool and the pistons for damage or 1
wear. Make sure that the or ifice in the outer
modulation piston is open. Use new par ts as
necessary.
2
STEP 420
I n s p e c t t h e c o n t r o l v a l v e b o d y fo r c r a c k s ,
corrosion, and wear. Inspect the bores for wear.
Find the bore from which the ball was removed.
BD01B122
There is a very small orifice in one side of this
If the four hex head plugs (1) and the Allen head
bore. Make sure that this orifice is open. If the
plug (2) were removed, install the copper washers
control valve body is bad, you must use a new
and the plugs.
transmission control valve.
STEP 421 STEP 423

Find the plate that held the ball in position. Put the
ball on the hole in the plate so that the ball is in 1
contact with the edge that has the radius. Hold the 4
plate and the ball up to a bright light and look at
the bottom side of the plate and the ball. There
must be no light visible between the plate and the
ball. If light is visible, use a new plate.
2
3 5
BD01B114
Use clean transmission oil to lubricate the flow

divider shaft (1). Install the flow divider shaft (1).
The closed end of the flow divider piston (1) must
be toward the inside of the control valve body. Use
clean transmission oil to lubricate the flow divider
piston (3). Install the spring (2), flow divider piston
(3), and the snap ring (4) in the bore. Install a new
O-ring on the plug (5). Use clean transmission oil
to lubricate the O-ring on the plug (5). Install the
plug (5).

6007-106
STEP 424 STEP 426
BD01B118 BD01B104
Tighten the plug at the in the bore. Install the modulation cover onto the valve body.
Install the four Allen head bolts into the cover.
STEP 425 Tighten the four Allen head bolts to a torque of 11
Nm (97 pound-inches).
7 10 11
1 STEP 427
8 5 6
9
2 3
4
BD01B112
Lubricate the new inner modulation piston (11)

with clean transmission oil. Install the new inner
piston (11) so that the end with the deeper bore is BP95F334
towards the outside of the valve body. Install the Install a new O-ring on the solenoid plunger. Use
spring (6) into the small bore. Install one cover clean transmission oil to lubricate the O-ring.
gasket (3) on the valve body. Install the check ball
(5) on top of the spring (6) in the small bore. Install
the spacer (4) so the coined (radius) side contacts
the ball. Install the remaining cover gasket (3) onto
the spacer (4). Install the inner modulation piston
pin (10) the inner (8) and outer (9) spring and the
outer modulation piston spring (7) into the bore.
Lubricate the outer modulation piston (1) with
clean transmission oil and install the piston (1) into
the modulation cover (2) with the closed end
towards the modulation cover.

6007-107
STEP 428 STEP 430
2
3
4
BP95F333 BD01B108
Assemble the solenoid plunger (1), the spring (2), Install the solenoid plunger and the
the spring spacer (3), and the forward/reverse forward/reverse spool in the control valve body.
spool (4) as shown above. One side of the spring
spacer (3) has a chamfer in the bore. Install the STEP 431
spring spacer (3) so that the chamfer is toward the
forward/reverse spool (4).
STEP 429
BD01B107
Tighten the solenoid plunger to a torque of 23 Nm

(204 pound-inches).
NOTE: The following photos do not show the
BP95F335
forward/reverse solenoid installed. The
Use a small screwdriver to push down the spring
forward/reverse solenoid must be installed before
as shown so that you can engage the notched end
doing steps 432, 433 and 434.
of the forward/reverse spool with the post on the
end of the solenoid plunger. When the notched
end and the post are fully engaged, release the
s p r i n g t o h o l d t h e fo r wa r d / r eve r s e s p o o l i n
position.

6007-108
STEP 432 STEP 434
BD01B121 BD01B119
Install the spring spacer in the bore as shown. One I n s t a l l a n ew O - r i n g o n t h e p l u g . U s e c l e a n

side of the spring spacer has a chamfer in the transmission oil to lubricate the O-ring. Install the
bore. Install the spring spacer so that the chamfer plug in the bore.
is toward the inside of the control valve body. Make
sure that the end of the forward/reverse spool STEP 435
comes through the hole in the spring spacer.
STEP 433
BD01B107
Install new O-rings on the differential lock solenoid

plunger. Use clean transmission oil to lubricate the
BD01B120 O-rings.
Install the spring.
STEP 436
BD01B107
Install and tighten the differential lock solenoid

plunger to a torque of 15 Nm (133 pound-inches).

6007-109
STEP 439
NOTE: Step 437 to 439 are for early production M
Series 2 machines, late production have a 2 wire
connector per solenoid.
STEP 437
BP95F293
After all the terminals are in the connector, install

the retainer on the rear of the connector.
STEP 440
BP95F298
Before inserting a terminal in the connector, use a

small screwdriver to push the locking tab out
slightly so that the locking tab will engage the
plastic tab in the connector when you insert the
terminal.
STEP 438
BD01B089
Install the differential lock solenoid coil on the

solenoid plunger.
STEP 441
BP95F296
Push each terminal into the connector until the

locking tab and the plastic tab engage, locking the
terminal into the connector.
BD01B088
Install the nut. Tighten the nut to a torque of 7 to

10 Nm (62 to 89 pound-inches).

6007-110
STEP 442 STEP 445
BP95F291 BD01B093
Install a new O-ring on the solenoid plunger at the Install a new O-ring on the solenoid plunger. Use
control valve body. Use clean transmission oil to clean transmission oil to lubricate the O-ring.
lubricate the O-ring.
STEP 446
STEP 443
BD01B092
BD01B095 Install the remaining solenoid coil on the solenoid

Install a new O-ring in the solenoid coil. Use clean plunger.
transmission oil to lubricate the O-ring.
STEP 444
BD01B094
Install the solenoid coil on the solenoid plunger.

6007-111
STEP 447 STEP 448
BD01B087 BD01B086
Install the sealing washer. Install the nut. Tighten the nut to a torque of 7 to 10
Nm (62 to 89 pound-inches).

6007-112
PARKING BRAKE
NOTE: Some of the following images may not

represent your transmission, the procedures are the
same.
STEP 449
BD08A033-01
Remove the O-ring and flange.
NOTE: The transmission was removed from the
machine for clarity only, it is not necessary to remove
the transmission.
BD08A031-01 STEP 452

Loosen the flange bolt.
STEP 450
BD08A501-01
Loosen brake housing bolts.
BD08A032-01
Remove the flange bolt and washer.

6007-113
STEP 453 STEP 456
BC08B292 BD08A504-01
Remove bolts (A), and alternately loosen bolts (B) to Remove back plate.
release the load of bellville washers.
STEP 457
WARNING: Housing is under spring
equipment.
M1221
STEP 454
BD08A505-01
Remove the springs and remove the friction disc.
STEP 458
BD08A502-01
Remove the brake cover from the transmission.
STEP 455
BD08A506-01
Remove the reaction plates.
BD08A503-01
Remove and discard the O-ring.

6007-114
STEP 459 STEP 462
BD08A507-01 BD08A510-01
Remove the hub. Use CAS2379 to compress the bellville washers,

remove the retaining ring.
STEP 460
STEP 463
BD08A508-01
Remove the retaining plate. BD08A511-01
Remove the piston from the brake housing.
STEP 461
STEP 464
BD08A509-01
Remove and discard the O-rings and backup ring BD08A512-01
from the retaining plate. Remove and discard the O-rings and backup rings
from the piston.

6007-115
STEP 465 Inspection
STEP 468
STEP 469
STEP 470
Inspect the bellville washer for cracking and
excessive surface wear at contact points. Use new
BD08A513-01 parts as required.
Remove the bellville washers from the brake
housing. STEP 471
Inspect brake pistons and housing for scaring on
STEP 466 sliding surfaces, brake pistons for pitting, scoring,
STEP 472
NOTE: Use only genuine parts. DO NOT use after
market O-rings, they will fail.
BD08A514-01
Remove the seal from the brake housing.
STEP 467
BD08A515-01
Remove and discard the O-ring from the brake
housing.

6007-116
Assembly STEP 476

same.
STEP 473
BD08A517-01
Install the backup ring, install the seal ring.
NOTE: Make sure that the seal ring does not twist
during installation.
BD08A516-01
STEP 477
Install a new O-ring on the brake housing.
STEP 474
BD08A511-01
Lubricate the piston seals with transmission fluid,
install the piston into the brake housing.
BD08A514-01
STEP 478
STEP 475
BD08A510-01
BC08B293 Use CAS2379 and compress the bellville washers,

Install the bellville washers as shown. install the retaining ring.
IMPORTANT: Make sure the retainer is properly
seated before removing spring compressor.

6007-117
STEP 479 STEP 482
BD08A509-01 BD08A506-01
Install new O-rings and backup ring in the retaining Install a reaction plate first.
plate.
STEP 483
STEP 480
BD08A505-01
BD08A508-01
Install a friction plate and a wave spring, continue to
Lubricate the O-rings on the retaining plate, install install a reaction plate, friction plate and wave spring
the plate into the brake housing. until all components are installed.
STEP 481 STEP 484
BD08A507-01 BD08A504-01
Install the hub onto the output shaft as shown. Install the back plate as shown.

6007-118
STEP 485 STEP 488
BD08A503-01 BD08A033-01
Install a new O-ring. Install the flange and a new O-ring.
STEP 486 STEP 489
BD08A502-01 BD08A032-01
Install the brake housing. Install the bolt and washer.
STEP 487 STEP 490
BD08A501-01 BD08A048-01
Install the bolts, use an alternately tightening pattern Torque bolt to 139 Nm (103 pound feet).
u n t i l t h e b r a ke h o u s i n g i s t i g h t a g a i n s t t h e
transmission. Torque the bolts to 50 Nm (37 pound
feet).

6007-119
TRANSMISSION HOUSING
Assembly STEP 493
STEP 491
BP95F366
Install plugs (foam ear plugs work well) in the three

BP95F366
oil passages in the edge of the front housing. (The
If the four-wheel drive clutch tube (four-wheel drive plugs have not been installed in the picture above.)
m a c h i n e o n l y ) w a s r e m o ve d f r o m t h e f r o n t Scrape all sealing mater ial fr om the sealing
housing, install the four-wheel drive clutch tube. surface of the front housing. Prepare the sealing
Tighten the fittings to a torque of 40 Nm (265 surface by rubbing with a 3M Scotch-Brite fiber
pound-inches). pad or equivalent. DO NOT use steel wool or
anything that can leave material on the sealing
surface. Flush the front housing with solvent.
STEP 492
STEP 494
BP95F374
Install plugs (foam ear plugs work well) in the three

BP95F371
oil passages in the edge of the rear housing.
Scrape all sealing mate r ial from the sealing Install the gasket for the valve plate on the front
surface of the rear housing. Prepare the sealing housing.
surface by rubbing with a 3M Scotch-Brite fiber
pad or equivalent. DO NOT use steel wool or
surface. Flush the rear housing with solvent.

6007-120
STEP 495 STEP 497
1 1 2
1
3
BP95F369 BP95F074
Put the valve plate into position. If the test port plugs (1), the breather (2), and the
temperature sender (3) were removed from the
STEP 496 rear housing, install these parts. Tighten the test
port plugs (1) to a torque of 23 Nm (204
pound-inches).
NOTE: Steps 498 through 499 are for four-wheel
drive transmissions only. If you are working on a
STEP 498
BP95F370
Install the three Allen head bolts to fasten the

valve plate to the front housing. Tighten the Allen
head bolts to a torque of 23 Nm (204
pound-inches).
BP95F073
Put the bearing for the four-wheel drive shaft into

position in the rear housing.

6007-121
STEP 499 STEP 501
BD01B076 BP95F067
Install the four-wheel drive clutch gear so that the As you lower the assembly into the rear housing,
side with the lugs is up. also begin to install the primary shaft so that the
gears on the primary shaft go into mesh with the
STEP 500 gears on the secondary shaft. Continue to lower
the parts, making sure that each part goes into the
correct bore in the rear housing. (Remember that
the shift rod and fork assembly for third and fourth
gear goes into the bore nearer the top of the rear
housing). When all of the par ts are in position,
disconnect the lifting equipment.
STEP 502
BP95F375
Connect acceptable lifting equipment to the top

gear on the secondary shaft. Lift the secondary
shaft over the rear housing. Engage the shift forks
with the synchronizers as shown. Begin to lower
the assembly into the rear housing.
BD01B069
Push the secondary shaft toward the rear of the

rear housing so that there is clearance between
the snap ring groove and the rear housing. Install
the snap ring.

6007-122
NOTE: In steps 503 through 505, the photos show STEP 505
the upper detent parts already installed. It is
necessary for you to install both the upper and lower
detent parts according to the instructions in the
procedure. Make sure that you start with both
shift rods in the NEUTRAL position.
STEP 503
BD01B067
Install the copper washer on the detent plug. Install

the lower detent plug. Tighten the lower detent
plug to a torque of 80 Nm (59 pound-feet).
STEP 506
Repeat steps 503 through 505 to install the upper
BP95G005
detent ball, spring, copper washer, and plug.
Install the lower detent ball.
STEP 507
STEP 504
BD01B066
BD01B068
Install the two detent balls in the groove between
Install the lower detent spring. the two shift rods.

6007-123
STEP 508 STEP 511
BD01B065 BD01B061
Install the plate over the two detent balls. Install the pins to fasten the shift collars to the shift
rods.
STEP 509
STEP 512
Scrape all sealing mater ial fr om the sealing
surface of the rear cover. Prepare the sealing
surface by rubbing with a 3M Scotch-Brite fiber
pad or equivalent. DO NOT use steel wool or
surface. Wipe the sealing surface with Loctite
Safety Solvent or equivalent. Apply a layer of
Loctite 518 or Super bond 539 to the sealing
surface.
STEP 513
BD01B064
Apply Loctite 542 or Super bond 321 to the threads

of the two Allen head bolts. Install the two Allen
head bolts to fasten the plate in position. Tighten
the two Allen head bolts to a torque of 50 Nm (37
pound-feet).
STEP 510
]
BD07J018-01
Put the rear cover in position. Make sure that the

dowel (1) is installed in the rear housing and
through the hole in the rear cover. Install the seven
bolts to fasten the rear cover to the rear housing. If
necessary, tap the rear cover with a soft faced
hammer to close the gap between the rear housing
and the rear cover before you tighten the bolts.
Tighten the seven bolts sequentially to a torque of
BD01B062 50 Nm (37 pound-feet).
Install the shift collars on the shift rods.
NOTE: The above photo shows the shifter installed,
the shifter should not be installed at this time.

6007-124
STEP 514 STEP 516
BD01B056 BP95F373
Install a new O-ring on the shifter assembly. Use If the tube was removed from the front housing,
clean oil to lubricate the O-ring. Put the shifter install the tube now. Tighten the hollow bolts to a
assembly into position on the rear cover. torque of 40 Nm (354 pound-inches).
STEP 515 STEP 517
BD01B055 BP95F083
Install the three Allen head bolts to fasten the I n s t a l l t h e i n p u t s h a f t a n d t h e r eve r s e s h a ft

shifter assembly to the rear cover. Tighten the together as shown. If you are using the same
three Allen head bolts to a torque of 23 Nm (204 reverse shaft, make sure that you install it with the
pound-inches). same end up as when it was removed.

6007-125
STEP 518 STEP 520
BD01B044 BP95F081
On machines with four-wheel drive, install the Remove the three plugs from the oil passages in
four-wheel drive shaft. Use clean transmission oil the rear housing (see arrows). Install three new
to lubricate the bearing surfaces on the four-wheel O-rings for the oil passages. Remove the three
drive shaft. Make sure that the four-wheel drive plugs from the oil passages in the front housing.
shaft goes through the four-wheel drive clutch
gear, the thrust washer, and the bearing. STEP 521
STEP 519
BD01B047
Use clean transmission oil to lubricate the bearing

BP95F378 for the pr imar y shaft and the bear ing for the
Wipe the sealing surface of the rear housing and secondary shaft. Install the bearings.
the front housing with Loctite Safety Solvent or
equivalent. Apply a layer of Loctite 518 or Super
b o n d 5 2 9 t o t h e s e a l i n g s u r fa c e o f t h e r e a r
housing.

6007-126
STEP 522 STEP 524
BD01B043 BP95F382
Install the front housing on the rear housing. Make Install the three bolts that fasten from the front
sure that the bearings on the shafts go straight into housing to the rear housing. Tighten the bolts to a
the bores in the front housing. Push the front torque of 50 Nm (37 pound-feet).
housing all the way down on the rear housing.
STEP 525
STEP 523
BP95F383
BD01B023 Use clean transmission oil to lubricate the bearing

Install all of the housing bolts that fasten the rear for the four-wheel drive shaft. Install the bearing on
housing to the front housing. There are 13 of these the four-wheel drive shaft.
bolts on four-wheel drive transmissions and 14 on
two-wheel drive transmissions. Tighten the bolts
evenly until the front housing and rear housing are
are together, then tighten the bolts to a torque of

6007-127
STEP 526 STEP 529
BP95F353 BD01B032
Use the CAS-2381 special tool to install a new seal Install the three bolts that fasten the cover to the
in the cover. Push just until the seal stops moving. front housing. Tighten the bolts to a torque of 23
DO NOT use excessive force. Fill the cavity under Nm (204 pound-inches).
the lip of the seal with high temperature wheel
bearing grease. STEP 530
STEP 527
BD01B029
Install a new O-ring in the four-wheel drive flange.

BD01B034 Use clean transmission oil to lubricate the O-ring.
Install a new O-r ing on the cover. Use clean
transmission oil to lubricate the O-ring.
STEP 531
STEP 528
BD01B028
BD01B033 Install the four-wheel drive flange on the four-wheel

Install the cover in the front housing. drive shaft.

6007-128
STEP 532 STEP 535
BD01B027 BP95F381
Install the washer. Install the snap ring on the bearing.
STEP 533 STEP 536
BK98D067 BP95F387
Install and tighten the cap screw in the four-wheel It will be easier to install the oil pump if you use a
drive shaft to a torque of 139 Nm (103 pound-feet). guide stud as shown above. You can make a guide
stud by cutting the head from an M8 bolt.
STEP 534
STEP 537
BP95F380
Pull the input shaft toward the front of the BP95F386
transmission to get clearance for the snap ring. Use clean transmission oil to lubricate the O-ring
on the oil pump. Install the oil pump. Make sure
that the alignment marks that you made during
disassembly are aligned.

6007-129
STEP 538 STEP 541
BD08A505-01
BD01B037
If you used a guide stud, remove the guide stud.
install a reaction plate, friction plate and wave spring
Install the six bolts that fasten the oil pump in
until all components are installed.
position. Tighten the bolts to a torque of 23 Nm
(204 pound-inches).
STEP 542
STEP 539
BD08A504-01
Install the back plate as shown.
BD08A507-01
Install the hub onto the output shaft as shown.
STEP 543
STEP 540
BD08A503-01
BD08A506-01
Install a reaction plate first.

6007-130
STEP 544 STEP 547
BD08A502-01 BD08A032-01
STEP 545 STEP 548
BD08A501-01 BD08A048-01
transmission. Torque the bolts to 50 Nm (37 pound STEP 549
feet).
STEP 546
BD07J011-01
Make sure the orifice is in the brake housing, install
new O-rings.
BD08A033-01
Install the flange and a new O-ring.

6007-131
STEP 550 STEP 553
BD07J010-01 BD05E089
Install the brake solenoid, torque the solenoid to Heat the Teflon sealing ring to 80° to 100° C (176°
20 Nm (15 pound feet). to 212° F). Install the Teflon sealing ring onto the
380001428 expander/protector.
STEP 551
STEP 554
BD07J009-01
Install the pressure sensor switch into the brake BD05E090
housing. Install the 380001928 pusher over the

STEP 552 it reaches the groove in the shaft. Remove the
pusher and expander/protector from the shaft.
BD05E088
Slide the expander/protector onto the pump drive

shaft.

6007-132
STEP 555 STEP 558
BD05E091 BD07J006-01
Install the end of the 380001427 seal compressor Install the PTO shaft into the transmission.
sealing ring. Use a back and forth twisting motion STEP 559
to allow the seal compressor to slip over the top of Scrape all sealing mater ial fr om the sealing
the sealing ring and seat the sealing ring into the surface of the pump mount and rear cover. Prepare
groove. Be careful not to damage the sealing ring. the s ea li n g s u rface by r ubbi ng w i th a 3M
After the sealing ring is seated in the groove, Scotch-Brite fiber pad or equivalent. DO NOT use
remove the seal compressor from the shaft. steel wool or anything that can leave material on
the sealing surface. Wipe the sealing surface with
STEP 556 Loctite Safety Solvent or equivalent. Apply a layer
of Loctite 518 or Super bond 539 to the sealing
surface.
STEP 560
BD05E092

BD07J005-01
Install the pump mount on the rear housing, torque
bolts to 50 Nm (37 pound-feet).
STEP 557
Install the bearing and snap ring on the pump drive
shaft, install the shaft in the rear housing.

6007-133
STEP 561 STEP 563
BD01B176 BP95F025
Install the fitting for the dipstick tube. Install the dipstick.
STEP 562 drive transmissions only. If you are working on a
NOTE: The following photo shows the four-wheel
drive priority valve installed and is for reference for
the plug only.
STEP 564
BP95F026
Install the dipstick tube.
BD01B021
If the plug was removed, make sure that the

threads are clean and apply Loctite 543 or Loctite
262 (red) to the threads before installation. Tighten
the plug to a torque of 40 Nm (354 pound-inches).

6007-134
STEP 565 STEP 568
BP95F389 BD01B018
Install the four-wheel drive priority valve in the oil Install the fitting for the oil filter. Tighten the fitting
filter bore. to a torque of 50 Nm (37 pound-feet).
STEP 566 STEP 569
BD01B020 BD01B016
Install the spring. Use clean transmission oil to lubricate the gasket
on the oil filter. Install the oil filter.
STEP 567 NOTE: Steps 570 through 572 are for four-wheel
STEP 570
BD01B019
Install the spool.
BK98D055
Install the gasket for the four-wheel drive valve.

6007-135
STEP 571 STEP 574
BD01B014 BD01B010
Put the four-wheel drive valve in position on the Install the cover for the oil screen. Install the two
gasket. bolts that fasten the cover for the oil screen.
T i g ht en th e b ol t s t o a to r qu e o f 23 N m ( 20 4
STEP 575
BD01B013
Install the three bolts that fasten the four-wheel

drive valve to the front housing. Tighten the bolts BD01B007
to a torque of 23 Nm (204 pound-inches). Install the gasket for the transmission control
valve. Put the transmission control valve in position
STEP 573 on the gasket.
BD01B011
Install a new O-ring on the oil screen. Use clean

transmission oil to lubricate the O-ring. Install the
oil screen and O-ring.

6007-136
STEP 576 STEP 577
BD01B006 BD01B003
Install the bolts that fasten the transmission control Install a new O-ring on the drain plug. Lubricate
valve to the front housing. Tighten the bolts in a the O-ring with clean transmission oil. Install the
pattern alternating from front to back and side to drain plug. Tighten the drain plug to a torque of 80
side until all the bolts are at a torque of 23 Nm (204 Nm (59 pound-feet).
pound-inches).
NOTE: The following photo shows the drain plug for
four wheel drive machines. See the illustration on
page 138 for correct location for machines with two
wheel drive.

6007-137
12
13 16 17
15
11 11
10 14
10
9 18
7 8
6
20
5 19
21
4
3 7
19
2
20 22
1
9 23
2
3 21 24
BS08B406
1. TUBE 9. FITTING 17. BOLT

2. HOLLOW BOLT 10. COPPER WASHER 18. REAR COVER
3. COPPER WASHER 11. TEST PORT PLUG 19. BOLT
4. COPPER WASHER 12. PARK BRAKE PRESSURE TUBE 20. DOWEL PIN
5. PLUG 13. BREATHER 21. DRAIN PLUG
6. PLUG 14. BREATHER PIPE 22. REAR HOUSING
7. PLUG 15. PTO FLANGE 23. FOUR-WHEEL DRIVE CLUTCH TUBE
8. O-RING 16. O-RING 24. FRONT HOUSING
FOUR-WHEEL DRIVE TRANSMISSION

6007-138
14 15
12
13
9
10
8
8
7
11
16
4 6
4
5
4
18
17
3
2
11 17
4
1 19
20 4
2 3
BS08B405
1. TUBE 6. O-RING 11. DOWEL PIN 16. O-RING
2. HOLLOW BOLT 7. SEALING WASHER 12. PARK BRAKE PRESSURE TUBE 17. BOLT
3. COPPER WASHER 8. TEST PORT PLUG 13. REAR COVER 18. DRAIN PLUG
4. PLUG 9. BREATHER 14. PTO FLANGE 19. REAR HOUSING
5. COPPER WASHER 10. BREATHER PIPE 15. BOLT 20. FRONT HOUSING
TWO-WHEEL DRIVE TRANSMISSION

Section
6007
POWERSHIFT TRANSMISSION
6007

6007-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PTO Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Housing Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Primary Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1st, 3rd, and 4th Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Wheel Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Oil Seals, Gaskets, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Gears and Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Housing, Covers, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Forward and Reverse Clutch Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1st Gear Clutch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2nd Gear Clutch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3rd Gear Clutch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4th Gear Clutch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4WD Clutch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 Wheel Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1st Gear Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4th Gear Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Assembling 1st Gear Onto The Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3rd Gear Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2nd Gear Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Reverse Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Forward and Reverse Clutch Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transmission Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PTO Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Lubrication and Clutch Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6007-3
SPECIFICATIONS
Type ......................................................................................................................... Carraro TLB2 PB CD 4WD 2WS
Lubricant
Total system capacity .................................................................................................... 17.9 liters (19 U.S. quarts)
Refill capacity with or without filter change ................................................................... 11.3 liters (12 U.S. quarts)
Type of Fluid .......................................................................................................... Case AKCELA Hy-Tran® Ultra

6007-4
SPECIAL TOOLS
BD05A046
380040161 TEFLON SEAL INSTALLATION KIT M SERIES 2 TRANSMISSION
380001928 PUSHER NOT SHOWN
380002211
380002211 HANDLE 380040161 TEFLON SEAL RING PROTECTOR AND SHIMS
1ST, 3RD, 4TH AND 4WD SHAFTS

6007-5
380100081 380100084
380100081 TEFLON SEAL RING PROTECTOR AND SHIMS 380100084 TEFLON SEAL RING SIZER
2ND GEAR 1ST GEAR
380100082 380100085
380100082 TEFLON SEAL RING SIZER 380100085 TEFLON SEAL RING PROTECTOR AND SHIM
2ND GEAR 1ST GEAR BUSHING
380100083 380100086
380100083 TEFLON SEAL RING PROTECTOR 380100086 TEFLON SEAL RING SIZER
1ST GEAR 1ST GEAR BUSHING

6007-6
380100087
380100087 HOLDER BUSHING BP95F658
4WD SHAFT CAS2379 HOLDER AND SPRING COMPRESSOR
380100088
380100088 SHAFT PULLER/INSTALLER

6007-7
SPECIAL TORQUES
BS08A446

6007-8
BS08A447

6007-9
TRANSMISSION DISASSEMBLY
Housings STEP 4
STEP 1
Clean exterior of the transmission and place on a
suitable stand.
STEP 2
BD07N500-01
Remove the cover, filter, and O-ring.
STEP 5
BD07N498-01
Remove the drain plug and drain the oil from the
transmission.
STEP 3
BD07N501-01
Remove the filter.
STEP 6
BD07N499-01
Remove the two cap screws which fasten the cover

for the oil suction filter.
BD07N510-01
If necessary remove the connector for the filter.
STEP 7

6007-10
STEP 10
BD07N502-01
Loosen the oil filter bypass valve. BD07N505-01
Remove forward clutch test port plug if O-ring is

STEP 8 leaking, replace O-ring and torque to 30 Nm (22
pound feet).
STEP 11
BD07N503-01
Remove the filter bypass valve.
STEP 9 BD07N506-01
Remove reverse clutch test port plug if O-ring is

leaking, replace O-ring and torque to 30 Nm (22
pound feet).
STEP 12
BD07N504-01
Remove the breather from the transmission only if

the breather is damaged or leaking.
BD07N507-01
Remove lubrication pressure test port plug if O-ring is

leaking, replace O-ring and torque to 30 Nm (22
pound feet).

6007-11
STEP 13 STEP 16
BD07N508-01 BD08A017-01
Remove the speed sensor. Remove the cap screws securing the pump in the
transmission.
STEP 14
STEP 17
BD07N509-01
Remove the thermostat. BD08A018-01
Loosen the pump from the transmission with two pry

STEP 15 bars.
STEP 18
BD08A016-01
Remove the torque converter from the transmission.

BD08A019-01
Remove the pump from the transmission.

6007-12
STEP 19 STEP 22
3
1
2 4
BD08A020-01 BD08A028-01
Remove the O-ring from the pump. Tag and remove the 4th gear tube (1), 2nd gear tube
(2), 3rd gear tube (3), and the 1st gear tube.
STEP 20
STEP 23
BD08A021-01
Remove the seal from the pump. BD08A029-01
Tag and remove the lubrication tube.

STEP 21
STEP 24
BD08A026-01
Tag and remove the lubrication tube. BD08A031-01
Loosen the front flange cap screw.

6007-13
STEP 25 STEP 28
BD08A030-01 BD08A032-01
Remove the cap screw and the front flange. Remove the flange bolt and washer.
STEP 26 STEP 29
BD08A034-01 BD08A033-01
Remove the seal from the housing. Remove the O-ring and flange.
Parking Brake machine for clarity only, it is not necessary to remove
the transmission.
STEP 27
STEP 30
BD08A031-01
Loosen the flange bolt. BD08A501-01
Loosen brake housing bolts.

6007-14
STEP 31 STEP 34
BC08B292 BD08A504-01
IMPORTANT: The housing is under spring pressure, STEP 35
failure to follow these instructions could damage the
transmission.
STEP 32
BD08A505-01
STEP 36
BD08A502-01
STEP 33
BD08A506-01
BD08A503-01

6007-15
STEP 37 STEP 40
BD08A507-01 BD08A510-01

STEP 38
STEP 41
BD08A508-01
STEP 39
STEP 42
BD08A509-01
from the piston.

6007-16
STEP 43 PTO Shaft
STEP 46
BD08A513-01
housing. BD08A035-01
Remove the mounting screws for the pump flange.

STEP 44
STEP 47
BD08A514-01
Remove the seal from the brake housing. BD08A036-01
Remove the flange from the transmission.

STEP 45
STEP 48
BD08A515-01
Remove and discard the O-ring from the brake BD08A037-01

housing. Remove the PTO shaft from the transmission.

6007-17
STEP 49 Housing Separation
STEP 52
BD08A038-01
Remove the teflon seal ring from the PTO shaft.

BD08A041-01
STEP 50 Remove the cap screws that fasten the front and rear
housings together.
STEP 53
BD08A039-01
Remove the snap ring from the PTO shaft.
STEP 51 BD08A042-01
Use pry bars in the slots t loosen the front housing

from the rear housing.
STEP 54
BD08A040-01
Use a suitable driver and remove the bearing from

the PTO shaft.
BD08A043-01
Attach suitable lifting equipment to the front housing

and remove it from the transmission.

6007-18
STEP 55 STEP 58
BD08A044-01 BD08A119-01
Remove and discard the O-rings from the rear Attach lifting bracket 380100088 to the shafts,
housing. remove them from the transmission.
STEP 56 Input Shaft
STEP 59
BD08A053-01
Pull the input shaft and reverse shaft together.

BD08A054-01
STEP 57 Remove the teflon seal ring.
STEP 60
BD08A118-01
Remove the cap screws and the shield from the 4

wheel drive clutch pack. BD08A055-01

6007-19
STEP 61 STEP 64
BD08A056-01 BD08A059-01
Install a bearing puller under the gear as shown, do Remove the gear.
not install the bearing puller between the gear and
the bearing. Insert a shaft protector between the STEP 65
puller and the end of the input shaft.
STEP 62
BD08A060-01
BD08A057-01 STEP 66
Remove the bearing.
STEP 63
BD08A061-01
Remove the thrust washer.
BD08A058-01
Remove the spacer.

6007-20
STEP 67 STEP 70
BD08A061-01 BD08A065-01
Remove the roll pin. Remove the clutch plates and the clutch discs.
STEP 68 STEP 71
BD08A063-01 BD08A066-01
Remove the lock ring. Place a mark below a groove on the clutch housing.
STEP 69 STEP 72
BD08A064-01 BD08A067-01
Use pry bars t lift and remove the thrust plate. Place a mark on each thrust plate and the lock ring.

6007-21
STEP 73
BD08A068-01 Remove the pressure plate and spring.

Install the top piece of the CAS2379 special tool
(not shown). Use the three threaded rods and nuts STEP 76
to fasten the two pieces together.
STEP 74
BD08A071-01
Remove the sleeve.
BD08A069-01
STEP 77
STEP 75
BD08A072-01
Use compressed air in the piston pressure port to

remove the piston.
BD08A068-01
Loosen the nuts and the threaded rods to release IMPORTANT: Use an air hose with a safety on/off
the tension from the spring. Remove the top piece control nozzle with 2.1 bar (30 psi) maximum at the
of the CAS2379 special tool (not shown). nozzle. Wear face protection.

6007-22
STEP 78 STEP 81
BD08A073-01 BD08A076-01
Remove the piston seal rings and backup rings. Insert a shaft protector between the puller and the
end of the input shaft. Remove the bearing.
STEP 79
STEP 82
BD08A074-01
Turn the clutch housing over, remove the teflon BD08A077-01
seal rings. Remove the bearing and thrust washer.
STEP 80 STEP 83
BD08A075-01 BD08A078-01
Remove the snap ring. Remove the gear.

6007-23
STEP 84 STEP 87
BD08A079-01 BD08A084-01
Remove the needle bearing. Turn the shaft over and insert a shaft protector
between the puller and the end of the reverse shaft.
STEP 85 Remove the bearing.
Repeat steps 68 to 78 and disassemble the clutch.
Primary Shaft
Reverse Shaft
STEP 88
STEP 86
BD08A120-01
BD08A083-01
Remove the teflon seal ring from the primary shaft.
Insert a shaft protector between the puller and the
end of the reverse shaft. Remove the bearing. STEP 89
BD08A121-01
Install a puller on the gear as shown.

6007-24
STEP 90 STEP 93
BD08A122-01 BD08A125-01
Remove the bearing and gear. Remove the roll pin.
STEP 91 STEP 94
BD08A123-01 BD08A126-01
Remove the snap ring. Remove the gear.
STEP 92 STEP 95
BD08A124-01 BD08A127-01
Remove the thrust washer. Remove the needle bearings and thrust washer.

6007-25
STEP 96 STEP 99
BD08A128-01 BD08A131-01
Remove the roll pin and spacer. Remove the thrust plate from the clutch pack.
STEP 97 STEP 100
BD08A129-01 BD08A132-01
Drive the thrust plate down away from the lock ring. Remove discs and plates from the clutch pack.
STEP 98 STEP 101
BD08A130-01 BD08A133-01
Remove the lock ring. Install the top piece of the CAS2379 special tool
(not shown). Use the three threaded rods and nuts
to fasten the two pieces together.

6007-26
STEP 102 STEP 105
BD08A134-01 BD08A136-01
Remove the snap ring. Remove the sleeve.
STEP 103 STEP 106
BD08A133-01 BD08A137-01
Loosen the nuts and the threaded rods to release Use compressed air and remove the piston from the
the tension from the spring. Remove the top piece clutch pack.
of the CAS2379 special tool (not shown).
STEP 107
STEP 104
BD08A073-01
BD08A135-01 Remove the piston seal rings and backup rings.

Remove the retaining ring and spring.

6007-27
STEP 108 STEP 111
BD08A138-01 BD08A161-01
Remove the teflon seal ring. Remove the bushing.
STEP 109 STEP 112
BD08A139-01 BD08A162-01
Use a puller and remove the bearing from the shaft. Remove the gear and clutch from the shaft.
1st, 3rd, and 4th Gear Shaft STEP 113
STEP 110
BD08A163-01
Push down on the thrust plate.

BD08A160-01
Use a puller and remove the bearing.

6007-28
STEP 114 STEP 117
BD08A164-01 BD08A167-01
Remove the lock ring. Install the top piece of the CAS2379 special tool
STEP 115 to fasten the two pieces together, remove the snap
ring.
STEP 118
BD08A165-01
Remove the thrust plate.
STEP 116 BD08A168-01

STEP 119
BD08A166-01
Remove discs and plates from the clutch pack.
BD08A169-01
Remove the snap ring, retaining ring, and spring.

6007-29
STEP 120 STEP 123
BD08A170-01 BD08A173-01
Use compressed air and remove the piston from the Use a puller and remove the gear.
clutch pack.
STEP 124
STEP 121
BD08A174-01
BD08A171-01 Remove the needle bearings and spacer.

Remove the teflon ring and O-ring from the piston.
STEP 125
STEP 122
BD08A175-01
BD08A172-01 Remove the O-rings from inside the spacer.
Remove the teflon seal ring and O-ring from the
clutch housing.

6007-30
STEP 126 STEP 129
BD08A176-01 BD08A179-01
Remove the teflon rings from the outside of the Remove the thrust washer.
spacer.
STEP 130
STEP 127
BD08A180-01
BD08A177-01 Push down on the thrust plate.

Remove the gear.
STEP 131
STEP 128
BD08A181-01
BD08A178-01 Remove the lock ring.

6007-31
STEP 132 STEP 135
BD08A182-01 BD08A068-01
Remove the thrust plate. Install the top piece of the CAS2379 special tool
STEP 133 to fasten the two pieces together.
STEP 136
BD08A183-01

BD08A069-01
STEP 134 Remove the snap ring.
STEP 137
BD08A184-01

BD08A068-01


6007-32
STEP 138 STEP 141
BD08A186-01 BD08A073-01
Remove the snap ring, retaining ring, and spring. Remove the piston seal rings and backup rings.
STEP 139 STEP 142
BD08A187-01 BD08A189-01
Used compressed air to remove the piston. Turn the shaft over and remove the teflon seal rings.
STEP 140 STEP 143
BD08A188-01 BD08A190-01
Remove the piston and sleeve from the clutch Use a puller and remove the bearing.
housing.

6007-33
STEP 144 STEP 147
BD08A191-01 BD08A194-01
Remove the thrust washer. Remove the roll pin.
STEP 145 STEP 148
BD08A192-01 BD08A180-01
Remove the gear. Push down on the thrust plate.
STEP 146 STEP 149
BD08A193-01 BD08A181-01
Remove the needle bearing and thrust washer. Remove the lock ring.

6007-34
STEP 150 STEP 153
BD08A182-01 BD08A068-01
Remove the thrust plate. Install the top piece of the CAS2379 special tool
STEP 151 to fasten the two pieces together.
STEP 154
BD08A183-01

BD08A069-01
STEP 152 Remove the snap ring.
STEP 155
BD08A184-01

BD08A068-01


6007-35
STEP 156 STEP 159
BD08A186-01 BD08A195-01
Remove the snap ring, retaining ring, and spring. Remove the piston seal rings and backup rings.
STEP 157 4 Wheel Drive Shaft
STEP 160
BD08A187-01
Used compressed air to remove the piston.

BD08A229-01
STEP 158 Remove the teflon seals.
STEP 161
BD08A188-01
Remove the piston and sleeve from the clutch

housing. BD08A230-01
Use a puller and remove the bearing, remove the

spacer.

6007-36
STEP 162 STEP 165
BD08A231-01 BD08A234-01
Remove the gear. Remove shims and thrust washer.
STEP 163 STEP 166
BD08A232-01 BD08A235-01
Remove the needle bearing. Remove the bellville washers and spacer.
STEP 164 STEP 167
BD08A233-01 BD08A236-01
Locally fabricate a pipe with notch to access the snap Push down on the thrust plate and remove the lock
ring as shown. Remove the snap ring. ring.

6007-37
STEP 168 STEP 171
BD08A240-01
Remove thrust plate, discs, and plates from the Remove the O-rings from the piston.
clutch pack.
STEP 172
STEP 169
BD08A241-01
BD08A238-01 Remove the O-rings from the pistons.

STEP 170
BD08A239-01
Use a punch and remove the pistons.

6007-38
CLEANING AND INSPECTION

Cleaning Oil Seals, Gaskets, etc.
Clean all par ts thoroughly using solvent type Replacement of spring load oil seals, O-rings, metal
cleaning fluid. It is recommended that par ts be sealing rings, gaskets, and snap rings is more
immersed in cleaning fluid and moved up and down e c o n o m i c a l w h e n u n i t i s d i s a s s e m bl e d t h a n
slowly until all old lubricant and foreign material is premature overhaul to replace these parts at a future
dissolved and parts are thoroughly cleaned. time. Further loss of lubricant through a worn seal
may result in failure of other more expensive parts of
Bearings the assembly. Sealing members should be handled
carefully, particularly when being installed. Cutting,
Remove bearings from cleaning fluid and strike flat scratching, or curling under of lip of seal seriously
against a block of wood to dislodge solidified impairs its efficiency. When assembling new metal
particles of lubricant. Immerse again in cleaning fluid type sealing rings, same should be lubricated with
to flush out particles. Repeat above operation until coat of chassis grease to stabilize rings in their
bearings are thoroughly clean. Dry bearings using grooves for ease of assembly of mating members.
moisture-free compressed air. Be careful to direct air Lubricate all O-rings and seals with recommended
stream across bearing to avoid spinning. Do not spin type transmission fluid before assembly.
bearings when drying. Bearings may be rotated
slowly by hand to facilitate drying process.
Gears and Shafts
Housings Examine teeth on all gears carefully for wear, pitting,
chipping, nicks, cracks, or scores. If gear teeth show
Clean interior and exterior of housings, bearing caps, spots where case hardening is worn through or
etc., thoroughly. Cast parts may be cleaned in hot cracked, replace with new gear. Small nicks may be
solution tanks with mild alkali solutions providing removed with suitable hone. Inspect shafts and quills
these parts do not have ground or polished surfaces. to make certain they are not sprung, bent, or splines
Parts should remain in solution long enough to be twisted, and that shafts are true.
thoroughly cleaned and heated. This will aid the
evaporation of the cleaning solution and rinse water.
Housing, Covers, etc.
Parts cleaned in solution tanks must be thoroughly
rinsed with clean water to remove all traces of alkali. Inspect housings, covers and bearing caps to be
Cast parts may also be cleaned with steam cleaner. certain they are thoroughly clean and that mating
All par ts cleaned must be thoroughly dried surfaces, bearing bores, etc., are free from nicks or
immediately by using moisture-free compressed air burrs. Check all parts carefully for evidence of cracks
or soft, lint free absorbent wiping rags free of or condition which would cause subsequent oil leaks
abrasive mater ials such as metal fillings, or failures.
contaminated oil, or lapping compound.
Clutches
Inspection
Verify the total thickness of the clutch kit is within the
The importance of careful and thorough inspection of wear limits, if not, replace the clutch kit. Verify that all
all parts cannot be overstressed. Replacement of all the clutch plates do not appear burned or that the
par ts showing indication of wear or stress will friction material is not damaged and the splines are
eliminate costly and avoidable failures at a later date. intact. If using new clutch kit, soak the clutch plates in
clean transmission fluid for at least one hour before
Bearings assembly.
Carefully inspect all rollers, cages and cups for wear,

chipping, or nicks to determine fitness of bearings for
further use. Do not replace a bearing cone or cup
individually without replacing the mating cup or cone
at the same time. After inspection, dip bearings in
clean transmission fluid and wrap in clean lint free
cloth or paper to protect them until installed.

6007-39
Forward and Reverse Clutch Kits 3rd Gear Clutch Kit
NUMBER OF CLUTCH PLATES 6 NUMBER OF CLUTCH PLATES 8
NUMBER OF STEEL PLATES 6 NUMBER OF STEEL PLATES 8
NOMINAL CLUTCH PLATE 2.40 ± 0.05 MM NOMINAL CLUTCH PLATE 2.00 ± 0.05 MM
THICKNESS (0.095 ± 0.002 INCHES) THICKNESS (0.078 ± 0.002 INCHES)
MAXIMUM CLUTCH PLATE 0.25 MM MAXIMUM CLUTCH PLATE 0.20 MM
WEAR (0.010 INCHES) WEAR (0.008 INCHES)
NOMINAL CLUTCH KIT *29.00 TO 29.20 MM NOMINAL CLUTCH KIT *30.50 TO 30.70 MM
THICKNESS (1.14 TO 1.15 INCHES) THICKNESS (1.20 TO 1.21 INCHES)
3.0 MM 3.2 MM
MAXIMUM CLUTCH KIT WEAR MAXIMUM CLUTCH KIT WEAR
(0.12 INCHES) (0.13 INCHES)
* MEASURED UNDER A LOAD OF * MEASURED UNDER A LOAD OF
163 KG (360 POUND FORCE) 163 KG (360 POUND FORCE)
1st Gear Clutch Kit 4th Gear Clutch Kit

THICKNESS (1.08 TO 1.09 INCHES) THICKNESS (0.62 TO 0.63 INCHES)
1.8 MM 1.6 MM
2nd Gear Clutch Kit 4WD Clutch Kit

THICKNESS (1.20 TO 1.21 INCHES) THICKNESS (1.33TO 1.34 INCHES)
3.2 MM 2.7 MM

6007-40
TRANSMISSION ASSEMBLY
4 Wheel Drive Shaft
4
3
2
5
18
17
13
1 16
15
14
23
22
12
11 21
10
20
9 19
7 8
BS08A458
1. BEARING 9. O-RING 17. LOCK RING

2. RING 10. PIN 18. GEAR
3. SHIM 11. O-RING 19. NEEDLE BEARING
4. WASHER 12. CLUTCH HOUSING 20. SPACER
5. BELLVILLE WASHERS 13. PLUG 21. BEARING
6. BUSHING 14. COUNTER DISK 22. SEAL RING
7. O-RING 15. CLUTCH PACK 23. SEAL RING
8. CLUTCH PISTON 16. THRUST PLATE

6007-41
STEP 173 STEP 176
BD08A240-01 BD08A243-01
Install new seal rings on clutch piston. Lubricate the piston and pin O-rings with
transmission fluid.
STEP 174
STEP 177
BD08A241-01
Install new O-rings on the pins. BD08A244-01
Use a soft faced hammer and drive the clutch piston

STEP 175 into the clutch housing.
STEP 178
BD08A242-01
Install the pins on the clutch piston.

BD08A245-01
Turn the clutch housing over, install the counter disk

in the clutch housing with the tapered edge facing
down.

6007-42
STEP 179 STEP 182
BD08A246-01 BD08A249-01
Install the clutch kit star ting with a drive plate Align the clutch discs using a screwdriver then install
followed by a clutch disc, continue to install until all the gear.
clutch plates and discs are installed.
STEP 183
STEP 180
BD08A250-01
BD08A247-01 Install the needle bearing and the spacer.

Install the thrust plate.
STEP 184
STEP 181
BD08A251-01
BD08A248-01 Use a suitable driver and install the bearing.

Install the retaining ring.

6007-43
STEP 185 STEP 188
BD08A252-01 BD08A255-01
Tur n the clutch pack over. Make sure that the Subtract from X a known value of S1 (S1=1.80MM),
disk/counter disk pack and the piston are seated. the result is S for the shim thickness required.
(X-1.80)=Shims required.
STEP 186
STEP 189
BD08A253-01
Install the spacer and washer.

BD08A256-01
Select the shim thickness value among the range of

STEP 187 available shims.
NOTE: Make sure there will be a stroke of 1.70 to
1.90 MM after shims are installed.
STEP 190
BD08A254-01
Using a thickness gauge measure the gap between

the washer and lock ring (X).
BD08A257-01
Remove the lock ring and washer from the shaft.

6007-44
STEP 191 STEP 194
BD08A258-01 BD08A261-01
Install the bellville washers, the washer must be Use a suitable driver and install the bearing.
installed with the outer rings touching and the inner
rings have a gap. STEP 195
STEP 192
BD08A262-01
Use pusher 380001928 to install the teflon seal rings.

BD08A259-01 Using spacer and protector for the inner ring and
Install the washer an d the shim (s) that was spacer for the outer ring from kit 380040161. Size the
determined in step 188. seal rings using sizer 380001427.
STEP 193 STEP 196
BD08A260-01 BD08A264-01
Locally fabricate a pipe with notch to access the snap Mount a dial indicator as shown. Apply 10 Bar (145
ring as shown. Compress the bellville washers and psi) to the piston port, the stroke should be between
install the lock ring. 2.3 to 2.4 MM (0.090 to 0.095 inches).

6007-45
8 9 26 27 28
6 7 25
24
5 22 23
42
3 4 41
21
2 20 40
1 39
17 38
16 19 37
14 15
36
13
12 35
11 18
10 34
33 55
32 45 54
31
44 52 53
30
43
51
50
49
48
47
29 46
BS08A457
1. BEARING 15. TEFLON SEAL RING 29. 4TH GEAR CLUTCH 43. O-RING
2. THRUST WASHER 16. SEAL RINGS 30. THRUST PLATE 44. BUSHING
3. GEAR 17. PLUG 31. LOCK RING 45. O-RING
4. LOCK RING 18. SPRING PIN 32. GEAR 46. ROLLER BEARING
5. THRUST PLATE 19. SPRING PIN 33. ROLLER RETAINER 47. BUSHING
6. 3RD GEAR CLUTCH 20. GEAR 34. GEAR 48. TEFLON SEAL RING
7. ROLLER RETAINER 21. TEFLON SEAL RING 35. LOCK RING 49. TEFLON SEAL RING
8. THRUST WASHER 22. TEFLON SEAL RING 36. THRUST PLATE 50. TEFLON SEAL RING
9. SNAP RING 23. CLUTCH PISTON 37. 1ST GEAR CLUTCH 51. GEAR
10. RETAINING PLATE 24. BUSHING 38. LOCK RING 52. ROLLER BEARING
11. SPRING 25. SPRING 39. RETAINING PLATE 53. BUSHING
12. BUSHING 26. RETAINING PLATE 40. SPRING 54. THRUST BUSHING
13. CLUTCH PISTON 27. LOCK RING 41. CLUTCH PISTON 55. BEARING
14. TEFLON SEAL RING 28. THRUST WASHER 42. TEFLON SEAL RING
1ST, 3RD, 4TH GEAR SHAFT

6007-46
1st Gear Clutch Pack STEP 200
STEP 197
BD08A199-01
Apply clean transmission fluid to the seal rings, install

BD08A196-01 the piston.
On the 1st gear clutch, install a new teflon seal ring
using protector 380100083 and pusher 380001928. STEP 201
STEP 198
BD08A200-01
Insert the spring, thrust washer, and snap ring.
BD08A197-01 STEP 202

Size the teflon seal ring using sizer 380100084.
STEP 199
BD08A168-01
Place the clutch in CAS2379 special tool (not

shown), and compress the spring.
BD08A198-01
Install a new teflon seal ring and O-ring on the clutch

piston.

6007-47
STEP 203 STEP 206
BD08A167-01 BD08A164-01
Install the snap ring, make sure the snap ring is Install the retaining ring, make sure the retaining ring
properly seated. is properly seated.
STEP 204 STEP 207
BD08A201-01 BD08A203-01
Remove the top plate of the spring compressor Apply air pressure to the clutch pack to seat the
CAS2379. thrust plate against the retaining ring and release the
air pressure. Use a feeler gauge and measure the
STEP 205 distance between the thrust plat and the first clutch
disc, a measurement of 1.725 to 2.375 mm (0.068 to
0.094 inches) should be obtained. If the distance is
not within specification, check the clutch assembly.
BD08A202-01
Starting with a reaction plate, install 6 reaction plates

and 6 friction discs. Then install the thrust plate into
the clutch housing.

6007-48
4th Gear Clutch Pack STEP 211
STEP 208
BD08A144-01
Install the spring sleeve.

BD08A073-01
Install new O-rings and backup rings on the 4th gear STEP 212
piston.
STEP 209
BD08A204-01
Install the spring and thrust washer.
BD08A142-01 STEP 213

Apply a thin film of grease on the piston rings.
STEP 210
BD08A146-01

shown), and compress the spring.
BD08A143-01
Use 380001926 clutch pack piston installer to protect

the inner seal and install the clutch piston.

6007-49
STEP 214 STEP 217
BD08A147-01 BD08A206-01
Install the snap ring, make sure the snap ring is Apply a thin coat of grease to the bottom of the thrust
properly seated. washer to keep the washer in place while turning the
shaft.
STEP 215
STEP 218
BD08A146-01
Remove the top plate of the spring compressor BD08A207-01
CAS2379. Align the slot in the thrust washer with the roll pin.
STEP 216 STEP 219
BD08A205-01 BD08A208-01
Install a new roll pin in the shaft. Starting with a reaction plate, install 9 reaction plates
and 9 friction discs.

6007-50
STEP 220 STEP 223
BD08A209-01 BD08A212-01
Install the needle bearing and the thrust plate. Use a feeler gauge and measure the distance
between the thrust plat and the first clutch disc, a
STEP 221 measurement of 1.50 to 1.95 mm (0.060 to 0.075
inches) should be obtained. If the distance is not
within specification, check the clutch assembly.
STEP 224
BD08A210-01
Install the retaining ring, make sure the retaining ring

is properly seated.
STEP 222 BD08A213-01
Install the clutch hub into the clutch pack, make sure
the clutch hub seats completely.
Assembling 1st Gear Onto The Shaft
STEP 225
BD08A211-01
Apply air pressure to the clutch pack to seat the

thrust plate against the retaining ring and release the
air pressure. Align the clutch disc splines.
BD08A214-01
Put 1st gear clutch hub onto the shaft.

6007-51
STEP 226 STEP 229
BD08A162-01 BD08A217-01
Put 1st gear clutch pack onto 1st gear clutch hub, Install new teflon seal rings on the bushing with
make sure the clutch hub seats completely. protector and shim set 380100085, use pusher
380001928.
STEP 227
STEP 230
BD08A215-01
Use a suitable driver and install the bushing onto the BD08A218-01
shaft, install the needle bearing. Size the teflon seal rings using 380100086 sizer.
STEP 228 STEP 231
BD08A216-01 BD08A219-01
Remove the old teflon seal rings from the bushing. With the reference marks up, install the bushing into
the clutch pack.

6007-52
STEP 232 STEP 235
BD08A220-01 BD08A142-01
Use a suitable driver and install the bushing onto the Apply a thin film of grease on the piston rings.
shaft, install the needle bearing.
STEP 236
STEP 233
BD08A143-01
BD08A221-01 Use 380001926 clutch pack piston installer to protect

Use a suitable driver and install the bearing. the inner seal and install the clutch piston.
3rd Gear Clutch Pack STEP 237
STEP 234
BD08A222-01

BD08A073-01
Install new O-rings and backup rings on the piston.

6007-53
STEP 238 STEP 241
BD08A223-01 BD08A146-01
Install the spring and thrust washer. Remove the top plate of the spring compressor
CAS2379.
STEP 239
STEP 242
BD08A146-01
Place the clutch in CAS2379 special tool (not BD08A224-01
shown), and compress the spring. Install a new roll pin.
STEP 240 STEP 243
BD08A147-01 BD08A208-01
Install the snap ring, make sure the snap ring is Starting with a reaction plate, install 8 reaction plates
properly seated. and 8 friction discs.

6007-54
STEP 244 STEP 247
BD08A209-01 BD08A212-01
Install the thrust plate. Use a feeler gauge and measure the distance
STEP 245 measurement of 2.20 to 3.05 mm (0.085 to 0.120
STEP 248
BD08A210-01
Install the retaining ring, make sure the retaining ring

is properly seated.
STEP 246 BD08A225-01
Install the thrust washer and roller bearing.
STEP 249
BD08A153-01
Apply air pressure to the clutch pack to seat the

air pressure. Align the clutch disc splines. BD08A226-01
Install the clutch hub, make sure the clutch hub seats
completely.

6007-55
STEP 250 STEP 252
BD08A227-01 BD08A109-01
Install the thrust washer. Install the teflon seal rings starting with the inner
most ring first. Use protector and shims as required
STEP 251 from 380040161 and pusher 380001928. Size the
seal rings using sizer 380001427.
BD08A228-01
Use a suitable driver and install the bearing.

6007-56
11 12
10
9
8
7
6
5
4
3 22 25
2 24
1
23
21
14
20
19
18
17
15 16
13
BC08B329
1. SEAL 8. GEAR 15. SNAP RING 22. SHAFT

2. SEAL 9. LOCK RING 16. RETAINING WASHER 23. SPRING PIN
3. BEARING 10. THRUST PLATE 17. SPRING 24. BEARING
4. GEAR 11. CLUTCH DISCS 18. SLEEVE 25. TEFLON SEAL RING
5. LOCK RING 12. REACTION PLATES 19. CLUTCH PISTON
6. WASHER 13. WASHER 20. TEFLON SEAL RING
7. ROLLER RETAINER 14. SPACER 21. TEFLON SEAL RING
2nd Gear Clutch Pack
STEP 253
BD08A140-01

6007-57
STEP 254 STEP 257
BD08A141-01 BD08A143-01
Install the teflon seal ring. Use protector and shims Use 380001926 clutch pack piston installer to protect
as required from 380040161 and pusher 380001928. the inner seal and install the clutch piston.
Size the seal rings using sizer 380001427.
STEP 258
STEP 255
BD08A222-01
BD08A073-01 Install the spring sleeve.

Install new O-rings and backup rings on the piston.
STEP 259
STEP 256
BD08A223-01
BD08A142-01 Install the spring and thrust washer.

Apply a thin film of grease on the piston rings.

6007-58
STEP 260 STEP 263
BD08A146-01 BD08A148-01
Place the clutch in CAS2379 special tool (not Starting with a reaction plate, install 8 reaction plates
shown), and compress the spring. and 8 friction discs.
STEP 261 STEP 264
BD08A147-01 BD08A149-01
Install the snap ring, make sure the snap ring is Install the spacer and the roll pin.
properly seated.
STEP 265
STEP 262
BD08A150-01
BD08A146-01 Align the slot on the thrust washer with the roll pin,
Remove the top plate of the spring compressor install the thrust washer and the needle bearing.
CAS2379.

6007-59
STEP 266 STEP 269
BD08A151-01 BD08A154-01
Install the thrust plate and drive it down evenly to the Install the clutch hub, make sure the clutch hub seats
clutch disc. completely.
STEP 267 STEP 270
BD08A152-01 BD08A155-01
Install the retaining ring, make sure the retaining ring Install the roll pin.
is properly seated.
STEP 271
STEP 268
BD08A156-01
BD08A153-01 Align the slot on the thrust washer with the roll pin,
Apply air pressure to the clutch pack to seat the install the thrust washer and the snap ring.
air pressure. Align the clutch disc splines.

6007-60
STEP 272 STEP 274
BD08A212-01 BD08A159-01
Use a feeler gauge and measure the distance Install the teflon seal rings starting with the inner
between the thrust plat and the first clutch disc, a most ring first. Use protector and shims as required
measurement of 2.20 to 3.05 mm (0.085 to 0.120 from 380040161 and pusher 380001928. Size the
inches) should be obtained. If the distance is not seal rings using sizer 380001427.
STEP 273
BD08A158-01
Install the gear with the large hub down, use a

suitable driver and install the bearing.

6007-61
Reverse Shaft
STEP 275
BD08A114-01
Use a suitable driver and install a bearing on one end

of the shaft.
STEP 276
BD08A115-01
Turn the shaft over and install a bearing on the other

end of the shaft.

6007-62
2
13 29
12 28
11 27
00
1 10
25 26
9
8
7 24
6
5 23
4 22
3
40
39
21 38
20 36 37
19 35
18 34
17
16
33
14 32
15 30 31
BS08A456
1. BEARING 11. THRUST PLATE 21. SPLIT PIN 31. CLUTCH DRIVE PLATES
2. BEARING 12. CLUTCH DRIVE PLATES 22. SPLIT PIN 32. THRUST PLATE
3. TEFLON SEAL 13. CLUTCH PLATES 23. TEFLON SEAL RING 33. LOCK RING
4. SNAP RING 14. SNAP RING 24. O-RING 34. RETAINING PLATE
5. BEARING 15. LOCK WASHER 25. CLUTCH PISTON 35. GEAR
6. SPACER 16. SPRING 26. SLEEVE 36. NEEDLE CAGE
7. NEEDLE CAGE 17. SLEEVE 27. SPRING 37. RETAINING PLATE
8. GEAR 18. CLUTCH PISTON 28. LOCK WASHER 38. BEARING
9. RETAINING PLATE 19. TEFLON SEAL RING 29. SNAP RING 39. SNAP RING
10. LOCK RING 20. O-RING 30. CLUTCH PLATES 40. TEFLON SEAL RING

6007-63
Forward and Reverse Clutch Packs STEP 280
STEP 277
BD08A222-01

BD08A073-01
Install new O-rings and backup rings on the piston. STEP 281
STEP 278
BD08A223-01
Install the spring and thrust washer.

BD08A142-01
Apply a thin film of grease on the piston rings. STEP 282
STEP 279
BD08A146-01

BD08A143-01 shown), and compress the spring.
Use 380001926 clutch pack piston installer to protect
the inner seal and install the clutch piston.

6007-64
STEP 283 STEP 286
BD08A147-01 BD08A089-01
Install the snap ring, make sure the snap ring is Align the slot on the thrust washer with the roll pin,
properly seated. install the thrust washer.
STEP 284 STEP 287
BD08A146-01 BD08A090-01
Remove the top plate of the spring compressor Install the needle bearing.
CAS2379.
STEP 288
STEP 285
BD08A091-01
BD08A088-01 Place the clutch hub on a bench, install the thrust

Install the roll pin. plate on the hub.

6007-65
STEP 289 STEP 292
BD08A092-01 BD08A058-01
Starting with a friction disc, install 6 friction discs and Install the spacer.
6 reaction plates.
STEP 293
STEP 290
BD08A095-01
BD08A093-01 Heat the bearing to 80° to 100° C (176° to 212° F),

Install the clutch pack in the clutch housing. use a suitable driver and install the bearing.
STEP 291 STEP 294
BD08A094-01 BD08A096-01
Install the retaining ring, make sure the retaining ring Install the snap ring.
is properly seated.

6007-66
STEP 295 STEP 297
BD05A038 BD05A071
STEP 296 pusher, expander/protector, and spacer from the
shaft.
STEP 298
BD05A070
Slide the expander/protector and spacer onto the

input shaft. Heat the Teflon sealing ring to 80° to
100° C (176° to 212° F). Install the Teflon sealing BD05A082
ring onto the 380001428 expander/protector. Install the end of the 380001427 seal compressor

6007-67
STEP 299 STEP 302
BD05A039 BD08A105-01
Turn the seal compressor around and slide the end Install the roll pin, align the slot on the thrust washer
with the narrow chamfer over the shaft and over with the roll pin, install the thrust washer.
place for 15 minutes until the sealing ring has STEP 303
STEP 300
BD08A106-01
STEP 304
BD08A104-01
Use a feeler gauge and measure the distance

measurement of 1.60 to 2.45 mm (0.063 to 0.097
STEP 301
Turn the shaft over and repeat steps 277 to 291 and
assemble the other clutch pack.
BD08A107-01

6007-68
STEP 305 STEP 307
BD05A032 BD05A079
STEP 306 pusher, protector, and spacer from the shaft.
STEP 308
BD05A072
Slide the 380001933 expander/protector and the

spacer onto the shaft. Heat the Teflon sealing ring BD05A080
to 80° to 100° C (176° to 212° F). Install the Teflon Install the end of the 380001927 seal compressor
sealing ring onto the expander/protector. with the deep chamfer onto the shaft and over the
WARNING: Always wear heat protective to allow the seal compressor to slip over the top of
gloves to prevent burning your hands when the sealing ring and seat the sealing ring into the
handling heated parts. groove. Be careful not to damage the sealing ring.
SM121A After the sealing ring is seated in the groove,

6007-69
STEP 309 STEP 311
BD05A081 BD05A073
Turn the seal compressor around and slide the end Slide the expander/protector and the spacer onto
with the narrow chamfer over the shaft and over the shaft. Heat the Teflon sealing ring to 80° to
the sealing ring. Leave the seal compressor in 100° C (176° to 212° F). Install the Teflon sealing
place for 15 minutes until the sealing ring has ring onto the expander/protector.
groove. After the sealing ring has cooled, remove STEP 312
STEP 310
BD05A078

BD05A033 it reaches the groove in the shaft. Remove the
Place the 380001930 spacer into the 380001933 pusher, expander/protector, and spacer from the
expander/protector. shaft.

6007-70
STEP 313 STEP 315
BD05A080 BD05A034
Install the end of the 380001927 seal compressor Place the 380001931 spacer into the 380001933
with the deep chamfer onto the shaft and over the expander/protector.
to allow the seal compressor to slip over the top of STEP 316
STEP 314
BD05A074
Slide the expander/protector and the spacer onto

the shaft. Heat the Teflon sealing ring to 80° to
100° C (176° to 212° F). Install the Teflon sealing
ring onto the expander/protector.
BD05A081


6007-71
STEP 317 STEP 319
BD05A077 BD05A081
Install the 380001928 pusher over the Turn the seal compressor around and slide the end
pusher, expander/protector, and spacer from the place for 15 minutes until the sealing ring has
shaft. cooled and is properly sized and seated in the
STEP 318 the seal compressor from the shaft.
STEP 320
BD05A080
Install the end of the 380001927 seal compressor

with the deep chamfer onto the shaft and over the BD05A035
sealing ring. Use a back and forth twisting motion Place the 380001932 spacer into the 380001933
to allow the seal compressor to slip over the top of expander/protector.

6007-72
STEP 321 STEP 323
BD05A075 BD05A080
Slide the expander/protector and the spacer onto Install the end of the 380001927 seal compressor
the shaft. Heat the Teflon sealing ring to 80° to with the deep chamfer onto the shaft and over the
ring onto the expander/protector. to allow the seal compressor to slip over the top of
STEP 324
BD05A076


6007-73
Transmission Housings STEP 328
STEP 325
BD08A053-01
Install the forward and reverse clutch pack and the

BD08A116-01 reverse shaft into the housing as an assembly.
Lubricate the bores of the transmission housing
that house teflon sealing rings. STEP 329
STEP 326
BD08A117-01
Start the bearing of the reverse shaft into its bore in

BD08A119-01 the housing and mesh the gears at the same time.
Attach lifting bracket 380100088 to the three shafts
as shown, install the shafts into the housing. STEP 330
STEP 327
BD08A045-01
Apply a thin coat of Loctite 510 to the mating surface

BD08A118-01 of the transmission housing.
Install the 4WD clutch cover as shown, apply Loctite
542 to the threads and torque cap screws to 50 Nm
(37 pound feet).

6007-74
STEP 331 STEP 334
BD08A044-01 BD08A046-01
Install new O-rings in the housing. Install and hand tighten all of the transmission
housing cap screws.
STEP 332
Lubr icate the bores of the front transmission STEP 335
housing that house teflon sealing rings.
STEP 333
BD08A041-01
Torque the housing cap screws to 50 Nm (37 pound

feet).
BD08A043-01
Attach lifting equipment to the front housing, lower

the front housing onto the rear housing.
NOTE: Do not bind the shafts to prevent damaging
the teflon seal rings.

6007-75
PTO Shaft STEP 338
STEP 336
BD05E090

BD05E088 expander/protector and slide the sealing ring until
Slide the expander/protector onto the pump drive it reaches the groove in the shaft. Remove the
shaft. pusher and expander/protector from the shaft.
STEP 337 STEP 339
BD05E089 BD05E091
Heat the Teflon sealing ring to 80° to 100° C (176° Install the end of the 380001427 seal compressor
to 212° F). Install the Teflon sealing ring onto the with the deep chamfer onto the shaft and over the
380001428 expander/protector. sealing ring. Use a back and forth twisting motion

6007-76
STEP 340 STEP 344
BD05E092 BD08A037-01
Turn the seal compressor around and slide the end Clean the housing, use Loctite 518 sealer on the
with the narrow chamfer over the shaft and over mating surfaces.
place for 15 minutes until the sealing ring has STEP 345
STEP 341
Install the bearing and snap ring on the PTO shaft.
STEP 342
BD08A035-01
Install the pump mount on the rear housing, torque

bolts to 50 Nm (37 pound-feet).
BD08A037-01
Put the PTO shaft into the transmission.
STEP 343
Scrape all sealing mate r ial from the sealing
surface of the pump mount and rear cover. Prepare
the s ea li ng s ur face by r ubbi ng w it h a 3 M
Scotch-Brite fiber pad or equivalent. DO NOT use
steel wool or anything that can leave material on
the sealing surface. Wipe the sealing surface with
Loctite Safety Solvent or equivalent. Apply a layer
of Loctite 518 or Super bond 539 to the sealing
surface.

6007-77
Parking Brake STEP 349
STEP 346
BD08A517-01
BD08A516-01 NOTE: Make sure that the seal ring does not twist
Install a new O-ring on the brake housing. during installation.
STEP 347 STEP 350
BD08A514-01
BD08A511-01
STEP 348
STEP 351
BC08B293
Install the bellville washers as shown.

BD08A510-01
Use CAS2379 and compress the bellville washers,
install the retaining ring.

6007-78
STEP 352 STEP 355
BD08A509-01 BD08A506-01
plate.
STEP 356
STEP 353
BD08A505-01
BD08A508-01
STEP 354 STEP 357
BD08A507-01 BD08A504-01

6007-79
STEP 358 STEP 361
BD08A503-01 BD08A033-01
STEP 359 STEP 362
BD08A502-01 BD08A032-01
STEP 360 STEP 363
BD08A501-01 BD08A048-01
feet).

6007-80
Lubrication and Clutch Tubes STEP 367
STEP 364
BD08A023-01
When installing the pump align the pump holes.

BD08A029-01
Install tubes and torque to 30 Nm (22 pound-feet). STEP 368
Pump
STEP 365
BD08A024-01
Lubricate the teflon seal ring with clean transmission

fluid.
BD08A020-01 STEP 369

STEP 366
BD08A025-01
Lubricate the O-ring with clean transmission fluid.
BD08A022-01
Install the seal.

6007-81
STEP 370
BD07N511-01
BD08A019-01 Install a new suction filter.
Push the pump into position.
STEP 373
STEP 371
BD07N499-01
BD08A017-01 Install the cover and torque the bolts to 23 Nm
Install and torque bolts to 23 Nm (17 pound-feet). (17 pound-feet).
STEP 372
BD08A016-01
Install the torque converter.

6007-82
STEP 374 STEP 377
BD07N498-01 BD07N509-01
Install and torque drain plugs to 80 Nm Install and torque the thermostat to 30 Nm
(59 pound-feet). (22 pound-feet).
STEP 375 STEP 378

Install a new oil filter.
STEP 379
F i l l t r a n s m i s s i o n w i t h f l u i d , s e e p a g e 3 fo r
specifications.
BD07N503-01
Install and torque the filter bypass to 23 Nm

(17 pound-feet).
STEP 376
BD07N508-01
Install and torque the speed sensor to 50 Nm

(37 pound-feet).

6007-83
NOTES

6007-84

SECTION INDEX
BRAKES

Removal and Installation of Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000
Hydraulic Brake Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7002

Section
7000

OF BRAKE COMPONENTS
7000

7000-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE PEDAL HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVING AIR FROM THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
VEHICLE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DISSABLED VECHICLE PARK BRAKE RELEASE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Activate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7000-3
SPECIFICATIONS
Rear Axle
580M, 580SM
580SM+, 590SM
Axle Special Torques
Wheel Nuts Special Torques
Initial torque..................................................................................................................... 136 Nm (100 pound feet)
2nd torque ....................................................................................................................... 271 Nm (200 pound feet)
NOTE: Turn nuts an additional 30 degrees after second torque.
Transmission Special Torques
Park brake housing ............................................................................................................. 50 Nm (37 pound feet)
Output flange bolt ............................................................................................................ 139 Nm (103 pound feet)
Park brake solenoid............................................................................................................. 20 Nm (15 pound feet)
SPECIAL TOOLS
BD07N331-01 BP95F658
SELF ADJUSTING BRAKE TOOLS 380002435 CAS-2379 INPUT SHAFT HOLDER AND SPRING
COMPRESSOR
NOTE: Part of rear axle service tools.
NOTE: Part of transmission service tools.

7000-4
MASTER CYLINDER
Removal STEP 6
STEP 1
STEP 2
Open the hood.
STEP 3
Disconnect the electrical connectors for the air
restriction switch.
STEP 4 BD01B329

the hole in the cur tain. Remove the bolts, flat
washers, and insulator curtain that covers the master
cylinders.
STEP 7
Remove any dirt from the master cylinder and the
area around the master cylinder.
STEP 8
BD01B323
Loosen the clamp on the air cleaner hose.

Disconnect the hose from the turbo. Put a shop cloth
in the turbo opening.
STEP 5
BD08A430-01
Disconnect the supply and return hoses from the

master cylinder. Put caps on the fittings and plugs in
the hoses.
NOTE: Supply hose and fitting are located behind
the return elbow.
BD01B307
Remove the bolts and flat washers that fasten the

fixed hood to the uprights. Remove the fixed hood

7000-5
STEP 9 Installation
STEP 12
Hold the master cylinder in alignment with the holes
in the frame and install the nuts that fasten the
master cylinder to the frame.
STEP 13
BD08A430-01
Disconnect the tubes from the master cylinder. Put

caps on the fittings and plugs in the tubes.
STEP 10
BD08A430-01
Connect the tubes to the master cylinder.
STEP 14
2
1
4
BD08A429-01
3
Remove the cotter pins and clevis pins. Loosen and
remove the nuts that fasten the master cylinder to the
frame.
STEP 11
Remove the master cylinder from the frame.
BC08A207-01
Connect the supply line (1) from the transmission to

the supply fitting (2) on the master cylinder, connect
the return line (3) to the return fitting (4).

7000-6
STEP 15 STEP 20
bd01b307
BD08A429-01 Put the fixed hood and air cleaner assembly in
Put the clevis on the master cylinder in position on position on the uprights. Install the bolts and flat
the brake pedal. Install the clevis pin that fastens the washers that fasten the fixed hood to the uprights.
clevis to the brake pedal. Install the cotter pin in the
clevis pin. STEP 21
STEP 16
Adjust the push rods in order to achieve 1 to 3 MM
(0.039 to 0.118 inches) of free play measured at the
pedal pad.
STEP 17
See page 9 and remove the air from the brake
system.
STEP 18
Check for leakage at the master cylinder. BD01B323
Remove the shop cloth from the turbo. Connect the

STEP 19 air cleaner hose to the turbo. Tighten the clamp on
the air cleaner hose.
STEP 22
Connect the electrical connector for the air restriction
switch.
BD01B329

the hole in the curtain. Put the insulator curtain into
position and install the washers and bolts.

7000-7
BRAKE PEDAL HEIGHT ADJUSTMENT

STEP 1 STEP 2
Adjust the master cylinder push rods in order to
achieve 1 to 3 MM (0.039 to 0.118 inches) of free
play measured at the pedal pad.
BC08A206-01
Using the adjustment bolts, adjust the LH and RH

pedals to 90 to 92 MM (3.54 to 3.62 inches).

7000-8
1 2 3 4 5 6 7
8
9 12
10 11
18
17 16
13
14
15
BC08A205-01
1. BOLT 7. BOLT 13. HEIGHT ADJUSTING BOLT

2. PIVOT PIN 8. 60 MM (2.35 INCHES) 14. SPRING
3. SPACER 9. 27 MM (1.06 INCHES) 15. BRALKE LIGHT SWITCH
4. SHIM 10. CLEVIS PIN 16. RIGHT PEDAL
5. SELF LOCKING NUT 11. COTTER PIN 17. LEFT PEDAL
6. BUSHINGS 12. MASTER CYLINDER 18. PEDAL LOCKING PIN

7000-9
REMOVING AIR FROM THE BRAKE SYSTEM

NOTE: Two people are required to perform this STEP 8
procedure, one to actuate the master cylinder and Repeat for LH side.
the other to open and close the brake bleeder valve
on the rear axle.
STEP 9
Verify that the park brake is not engaged. Ensure that
STEP 1
the service brakes will stop both rear wheels with the
Raise the machine up with the stabilizers at full tractor in 2nd gear at 1500 rpm with the brake pedal
height. Suppor t back end of machine with pads 30mm (1.181inches) above the top of the floor
appropriate stands. plate (37mm [1.456 inches] above the top of the floor
plate for units that will be equipped with a floormat).
STEP 2
If the service brakes do not stop the wheels as noted
Remove rear wheels.
above, open each bleeder and repeat steps 7 and 8
until columns of oil without air bubbles are observed
STEP 3 in the LH and RH bleeder hoses. Verify that the
Attach clear brake bleeding hoses to the LH and RH service brakes hold the tractor in 2nd gear at 1500
bleeding ports. rpm as noted above.
STEP 4 STEP 10
Loosen LH and RH brake bleeders. Shut engine off.
STEP 5 STEP 11
Start engine and leave at low idle. Ensure that the Remove brake bleeding hoses.
transmission oil level is correct.
STEP 12
STEP 6 Replace covers on LH and RH brake bleeders.
Fully stroke both pedals together 15 times.
STEP 7
Fully stroke the RH pedal individually until clear
columns of oil without air bubbles are observed in the
clear plastic tube. Close RH bleeder.

7000-10
VEHICLE BRAKES
Disassembly
STEP 1 STEP 6
Park the machine on a level surface, apply the
parking brake.
STEP 2
Raise the rear tires off of the ground, support the
machine with suitable stands.
STEP 3
Remove the tires from the machine.
STEP 4
BD07N341-01
Place an oil receptacle under the outer housings of
the axle and drain the oil.
STEP 7
BD08B471-01
Remove the mounting bolts for the brake hose guard,

disconnect the brake hose. Plug the hose and cap
the fitting.
STEP 5
BD07N327-01
Place an oil receptacle under the differential carrier
and drain the oil.
BD07N340-01
Remove the axle vent to relieve any pressure inside
of the axle.
STEP 8

7000-11
STEP 11
BD07N338-01
Remove all but two of the cap screws. BD07N351-01
NOTE: Large amounts of Loctite was used during Pry the hub from the axle using slots.
turn back in and then back out. STEP 12
STEP 9
BD07N352-01
Slowly pull hub away from axle, make sure that the
BD07N349-01
brake disks and plates stay with the hub.
Insert 3 long dowel rods, (tool number), for in vehicle
service or two short dowel rods, (tool number), for STEP 13
bench service.
STEP 10
BD07N353-01
Pull the half shaft out with the hub and brakes.
BD07N350-01
Remove the remaining cap screws.
STEP 14
7000-12
STEP 17
BD07N354-01
Place the hub, brakes and half shaft on a suitable BD07N320-01
work bench. Left hand shaft is 807 mm (31.7 in) long and the right
STEP 15
STEP 18
BD07N355-01
Stand the hub up, mark the reaction plat that was BD07N254-01
against the axle housing. Remove the reaction and Loosen and remove the shouldered bolts, and spring
brake disks. washers from the brake self adjusters.
NOTE: Keep brake surfaces in same relationship to
each other if being reused. STEP 19
STEP 16
BD07N357-01
BD07N253-01 with kit.
Remove the half shaft from the planetary gears.

7000-13
STEP 20 STEP 22
BD07N256-01 BD07N360-01
Remove the lock ring. Place the self adjuster on (tool number).
STEP 21 into (tool number).
STEP 23
BD07N257-01
Remove the self adjuster. If brakes are being
replaced replace adjusters.
BD07N361-01
NOTE: Once removed the self adjusters spring clips Place the driver (tool number) onto self adjuster and
must be replace with genuine parts, DO NOT use drive the spring clips from the adjuster.
after market parts.
STEP 24
BD07N362-01

7000-14
STEP 25 STEP 28
BD07N258-01 BD07N260-01
Use an acceptable flat bars and pry the brake piston The cylinder may remain in the housing, use pry bar
up from the hub. and remove the cylinder.
STEP 26 STEP 29
BD07N371-01
BD07N259-01
STEP 27
STEP 30
BD07N377-01


7000-15
STEP 31 Inspection
STEP 33
STEP 34
STEP 35
BD07N374-01
Remove and discard brake cylinder O-ring only if Use new parts as required.
STEP 36
STEP 32 Replace O-rings on brake cylinders and pistons.
BD07N261-01
Remove and discard the hub o-ring.

7000-16
Assembly STEP 40
STEP 37
BD07N378-01
BD07N279-01 brake piston.
Install a new O-ring onto the hub.
STEP 41
STEP 38
BD07N281-01
BD07N375-01
Use hydraulic oil to lubricate the brake cylinder hub housing.
O-ring.
STEP 42
STEP 39
BD07N373-01
BD07N376-01
Place the brake piston and cylinder onto the hub.
Use hydraulic oil to lubricate the inner O-ring of the NOTE: Use brake pins for guides.
brake piston, press the brake cylinder into the brake
piston.

7000-17
STEP 43 STEP 46
BD07N283-01 BD07N365-01
Use the three shouldered bolts and washers to pull Place the first adjuster ring onto aligning tool.
the brake piston and cylinder into the hub.
NOTE: For ease of installation, look at the inside of
STEP 44
STEP 47
BD07N363-01
Place the brake adjuster with tapered edge facing up
BD07N366-01
into depth setting tool, part of tool kit 380002435.
Place the second adjuster ring onto aligning tool with
STEP 45
STEP 48
BD07N364-01
Place aligning tool into brake adjuster tool, part of
BD07N367-01
tool kit 380002435.
Place the third adjuster ring onto aligning tool with

7000-18
STEP 49 STEP 52
BD07N368-01 BD07N359-01
STEP 50 STEP 53
BD07N369-01 BD08A496-01
STEP 51 STEP 54
BD07N370-01 BD07N256-01
Drive the rings onto the adjuster until they are seated Install the snap ring into the self adjuster bore.
against the depth setting tool.

7000-19
STEP 55 STEP 58
BD07N282-01 BD07N255-01
Make sure the snap ring fully engages the grove in To r q u e s h o u l d e r e d b o l t s t o 1 6 N m ( 1 4 1 . 4
the brake piston. pound-inches).
STEP 56 STEP 59
BD07N356-01 BD07N431-01
Place spring washers onto shouldered bolt facing as Put the half shaft and brake separator plate pins into
shown. the axle housing.
STEP 57 STEP 60
BD07N358-01 BD07N432-01
Hand tighten the shouldered bolt until seated into Using the reference mark made during disassembly,
adjuster, spring washers can become bound on the place the inner brake separator plate into the axle
shoulder of the bolt and be damaged. housing.
used here.

7000-20
IMPORTANT: If using new brake disks they must be STEP 63
STEP 61
BD07N435-01
BD07N433-01
Place the inner brake disk onto the half shaft, do not STEP 64
STEP 62
BD07N429-01
STEP 65
BD07N434-01
Install the second brake separator, SM models only.
used here.
BD07N430-01
Install dowel rods into axle housing, two short rods
for bench repair, three long for in vehicle repair.

7000-21
STEP 66 STEP 68
BD07N436-01 BD07N339-01
Attach lifting equipment to hub assembly and guide Use Loctite 270 on thread of the bolts and torque to
onto dowel rods. 226 Nm (166.5 pound-feet).
NOTE: Care needs to be taken that the self
adjusters are not damaged by falling plates or by STEP 69
hitting them on the housing when bringing hub into Install and tighten drain plugs and torque to 60 Nm
position. (44 pound-feet).
STEP 67 STEP 70
Fill the axle with oil, see section 1002 for quantity and
type.
BD07N437-01
Use a piece of rope and lift the axle shaft into the
planetary gears while pushing the hub onto the axle.
to be turned in order to align the splines on the half

7000-22
STEP 71 STEP 73
BD08B471-01 BC08B681
Connect the brake hose to the wheel cylinder, install Install the wheel, do an initial torque of 136 Nm
and tighten the hose guard mounting bolts. (100 pound feet) in sequence shown, do a second
torque of 271 Nm (200 pound-feet) in sequence
STEP 72 shown, turn the lug nuts an additional 30°.
Bleed the brake according to instructions in this
section.

7000-23
PARKING BRAKE
Disassembly STEP 7

same.
STEP 1
Park the machine on a level surface, apply the
parking brake.
STEP 2
Block the wheels to keep the machine from moving.
STEP 3 BD08A033-01
Drain the transmission. Remove the O-ring and flange.

STEP 4 machine for clarity only, it is not necessary to remove
Remove the rear drive shaft. the transmission.
STEP 5 STEP 8
BD08A031-01 BD08A501-01
Loosen the flange bolt. Loosen brake housing bolts.
STEP 6
BD08A032-01
Remove the flange bolt and washer.

7000-24
STEP 9 STEP 12
BC08B292 BD08A504-01
STEP 13
WARNING: Housing is under spring
equipment.
M1221
STEP 10
BD08A505-01
STEP 14
BD08A502-01
STEP 11
BD08A506-01
BD08A503-01

7000-25
STEP 15 STEP 18
BD08A507-01 BD08A510-01

STEP 16
STEP 19
BD08A508-01
STEP 17
STEP 20
BD08A509-01
from the piston.

7000-26
STEP 21 Inspection
STEP 24
STEP 25
STEP 26
Inspect the bellville washer for cracking and
excessive surface wear at contact points. Use new
BD08A513-01 parts as required.
housing. STEP 27
Inspect brake pistons and housing for scaring on
STEP 22 sliding surfaces, brake pistons for pitting, scoring,
STEP 28
BD08A514-01
Remove the seal from the brake housing.
STEP 23
BD08A515-01
Remove and discard the O-ring from the brake
housing.

7000-27
Assembly STEP 32
same.
STEP 29
BD08A517-01
NOTE: Make sure that the seal ring does not twist
BD08A516-01
STEP 33
Install a new O-ring on the brake housing.
STEP 30
BD08A511-01
BD08A514-01
STEP 34
STEP 31
BD08A510-01
BC08B293 Use CAS2379 and compress the bellville washers,

Install the bellville washers as shown. install the retaining ring.

7000-28
STEP 35 STEP 38
BD08A509-01 BD08A506-01
plate.
STEP 39
STEP 36
BD08A505-01
BD08A508-01
STEP 37 STEP 40
BD08A507-01 BD08A504-01

7000-29
STEP 41 STEP 44
BD08A503-01 BD08A033-01
STEP 42 STEP 45
BD08A502-01 BD08A032-01
STEP 43 STEP 46
BD08A501-01 BD08A048-01
feet).

7000-30
DISSABLED VECHICLE PARK BRAKE RELEASE PROCEDURES
Release STEP 4
STEP 1
Block the wheels of the vehicle to prevent any
movement.
STEP 2
BS08A223
Turn the solenoid 90° and torque the solenoid to 20

Nm (15 pound feet). Pump grease into the grease
fitting until the brake releases.
IMPORTANT: Do not use excess pressure or
damage can be done to internal components.
BD08A301
Remove the floor plates in the cab to gain access to

the brake solenoid.
STEP 3
BD08A302
Remove the solenoid mounting bolts, remove the

solenoid from the transmission.

7000-31
Activate STEP 9
Activate and release the brake several times to
STEP 5 remove excess grease from the system.
Slowly remove the bolts from the brake solenoid to
release the pressure. STEP 10
Change the transmission filter, check the oil level in
NOTE: DO NOT unscrew the grease fitting to
the transmission, add oil as required. See section
release the pressure.
1002 for specifications.
STEP 6 STEP 11
C l e a n ex c e s s gr e a s e f r o m t h e s o l e n o i d a n d
Replace the floor plates in the cab.
transmission housing.
STEP 7
Install new O-rings on the transmission.
STEP 8
BD08A302
Install the solenoid on the transmission, torque the

solenoid to 20 Nm (15 pound feet).

7000-32
NOTES

7002
Section
7002
BRAKE TROUBLESHOOTING

7002-2
TABLE OF CONTENTS
TESTING THE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Vehicle Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Problem in Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Problem in Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING THE LEFT AND RIGHT BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7002-3
TESTING THE BRAKE SYSTEM
Vehicle Brakes Parking Brake

NOTE: Check brake pedal free travel before
proceeding, see section 7000. Check the brake STEP 1
system for leaks or damaged lines, repair or replace Apply the parking brake.
as necessary.
STEP 2
STEP 1 Lock the brake pedals with the brake pedal locking
Place the back hoe in the travel lock position, use the pin.
stabilizers and raise the rear wheels off of the floor. IMPORTANT: Be prepared to stop the machine in
case of sudden movement.
STEP 2
Lock the brake pedals with the brake pedal locking STEP 3
pin. Place the gear slector in 3rd gear on manual
tranmission machines. For power shift transmission,
STEP 3 place the auto/manual switch to manual, select 3rd
Place the range selector in 2nd gear, release the gear on the FNR lever.
parking brake and place the FNR selector in F or R
position. STEP 4
NOTE: Make sure the differential lock is not With engine running at low idle place the selector
engaged. lever in F position.
STEP 4 STEP 5
Slowly apply the brakes, both tires should stop Raise engine RPM to 1500, the machine should not
rotating at the same time. move.
STEP 5 STEP 6
Move the machine to a clear level area with sufficient Repeat the procedure with the selector in the R
space to accelerate the machine to 5 km/hr (3 mph). position.
NOTE: If the machine moves the parking brake will
STEP 6 have to be repaired, see secion 7000.
Once the machine has reached 5 km/hr (3 mph),
quickly apply the brakes, both tires should lock and
slide.
STEP 7
Accelerate the machine to 5 km/hr (3 mph).
STEP 8
Slowly apply th e b rakes, there sho uld be no
chattering, growling, or squealing sound from the
brake system.
STEP 9
Unlock the brake pedal locking pin.
STEP 10
Accelerate the machine to 1 km/hr (0.5 mph), quickly
apply the right brake, the right tire should lock and
the machine should pull to the right.
NOTE: Repeat the step for the left brake.

7002-4
TROUBLESHOOTING TABLES
Problem in Brake System

See Troubleshooting “Left and Right Brake
Do brakes stop machine evenly. No
Circuit” in this section.
Yes
Is excess pressure required to stop the See section 7000 for brake disc
Yes
machine. replacement.
No
Is the brake pedal soft or spongy when See section 7000 for bleeding the brake
Yes
applied. system.
No
See section 7000 for brake disc

Are brakes noisy during operation. Yes
replacement.

7002-5

Does parking brake release. No Check the electrical and hydraulic circuits.
Hydraulic

pressure, see section 6002,
is pressure as specified?
No

see section 6007.
Yes
Check solenoid, 9.8 Ohm at 20° C (68° F),

replace as needed.
Test parking brake per procedures this

See section 7000 for brake disc
section. No
replacement.
Does parking brake hold machine?
Yes

7002-6
TROUBLESHOOTING THE LEFT AND RIGHT BRAKE CIRCUIT

NOTE: Check brake pedal free travel before STEP 10
proceeding, see section 9001. Have another person apply the brakes and observe
the pressure readings, the pressure readings should
STEP 1 be the same on both gauges.
Place the back hoe in the travel lock position, use the
NOTE: If pressure readings are not equal, replace
stabilizers and raise the rear wheels off of the floor.
the master cylinder with the lower reading, see
section 7000.
STEP 2
Place stands under the machine, lower the machine STEP 11
onto the stands making sure the wheels remain off of
Hold the pedals in place for one minute, the pressure
the floor.
should stay the same on both gauges.
STEP 3 NOTE: If one of the pressure readings begins to
Attach a hose to the right bleeder valve, place the drop replace that master cylinder, see section 7000.
other end in a clear container.
STEP 12
STEP 4 Remove the gauges from the hoses, plug the hoses.
Have an assistant press the left brake pedal. Open
th e ble ed e r va l ve fo r o n e m i nu te a n d ta ke a STEP 13
measurement of hydraulic fluid from the system. Remove one of the caps from the axle and connect a
hand pump and gauge to the brake section. Loosen
STEP 5 the air bleeder screw and pump the hand pump until
Attach a hose to the left bleeder valve, place the oil with no air flows from the air bleeder screw.
other end in a clear container. Tighten the air bleeder screw to 12 Nm (108
pound-inches). Apply 10 342 kPa (1500 psi) pressure
to the brake and turn off the valve on the hand pump.
STEP 6
Have an assistant press the right brake pedal. Open
STEP 14
th e ble ed e r va l ve fo r o n e m i nu te a n d ta ke a
measurement of hydraulic fluid from the system. Observe the pressure reading for one minute, the
pressure should not drop.
NOTE: If measurements are not equal there is a
restriction on the side with the lesser amount of fluid. NOTE: If pressure drops the brake piston seal is
Check lines from axle to master cylinder and from leaking and needs to be replaced, see section 6004.
brake reservoir to master cylinder. If no oil was NOTE: Repeat the procedure for the other side of
present, check the feed line to the reservoir from the the axle.
oil filter.
STEP 15
STEP 7 Connect the hoses to the axle and bleed the brakes,
Stop the engine. see section 7000.
STEP 8 STEP 16
Disconnect the brake lines from the axle, cap the Adjust the parking brake, see section 9001.
fittings on the axle, attach pressure gauges capable
of reading pressure of 3500 kPa (500 psi) to both
hoses.
STEP 9
Lock the brake pedals with the brake pedal locking
pin.

SECTION INDEX
HYDRAULICS

Removal and Installation of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks Mechanical Linkage Machines
580M, 580SM and 590SM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8002
Hydraulic Specifications, Troubleshooting, and Pressure Checks Pilot Control Machines 580M and 580SM. . .8002
Hydraulic Specifications, Troubleshooting, and Pressure Checks 580SM+ and 590SM+ . . . . . . . . . . . . . . . . . .8002
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8003
Hydraulic Pump - 580SM and 590SM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8004
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8006
Backhoe Control Valve Mechanical Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Backhoe Control Valve Pilot Controls 580M and 580SM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8007
Accumulator for Machines with Optional Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8009
Solenoid Valve for Machines with Optional Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8010
Boom Lock Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8011
Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8012
Swing Dampening Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8013
Pilot Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8014
Proportional Pilot Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8015
.

8001
Section
8001

OF HYDRAULIC COMPONENTS
M SERIES 3

8001-2
TABLE OF CONTENTS
REMOTE CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LOADER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CLAM CONTROL PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HYDRAULIC PUMP 580M, 580SM AND 590SM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HYDRAULIC PUMP 580SM+ AND 590SM+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PILOT COLTROLS BACKHOE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MECHANICAL CONTROLS BACKHOE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8001-3
BCF03F043
PILOT CONTROL COLOR CODES

8001-4
REMOTE CONTROL VALVES
Removal STEP 5
STEP 1
Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
IMPORTANT: Turn on the ignition switch and the pilot
control switch. Move the backhoe control lever back
and forth several times to release any hydraulic
pressure in the pilot control circuit.
STEP 2
BD04A010
Place the pilot control switch and the ignition switch
in the OFF position. Remove the tilt adjusting knob from rear of tower.
STEP 3 STEP 6
Remove the rear floor mat (if equipped) and floor
boards.
STEP 7
BD04A008
Remove the wrist wrest, pull the rubber boot up and

remove two mounting screws and the retaining plate.
STEP 4 BD04A011
Disconnect the electrical connector for the tower,

remove the boot from the tower.
STEP 8
Remove the heat shield from inside of the control
tower.
BD04A009
On the right tower (facing rear of machine) remove

the tilt levers.

8001-5
STEP 9 STEP 11
BD04A012 BC03N011
Remove the control mounting bolts, pivot adjusting Check to ensure all hoses have the proper plastic tie
knob and pivot bolt from the tower. markers, see illustration on page 3, prior to removal.
Disconnect one at a time from the remote control
STEP 10 valve. Install plugs in the hoses and caps on the
fittings.
STEP 12
Remove the remote control valve from the control
tower.
BD03N010
Disconnect electrical connector from control handle,

remove the upper housing for the tower.

8001-6
Start the machine and operate the hydraulics.
STEP 13
Install new O-rings on the adapters for the remote STEP 20
control valve. Make sure that the remote control valve operates the
backhoe correctly.
STEP 14
Remove the plugs from the hoses and the caps from STEP 21
the fittings and connect the hydraulic hoses to the Check for leaks at the remote control valve.
fittings according to the identification tags.
STEP 22
STEP 15 Turn the machine off.
Connect the electrical connectors for the remote
control valve. STEP 23
Install the heat shield in the tower.
STEP 16
STEP 24
BD04A012
BD04A011
Place the upper housing around the control handle, Install cover on tower, connect electrical connector.
install the pivot bolt and pivot adjusting knob into
tower.
STEP 25
STEP 17
Install the control mounting screws in the tower.
STEP 18
BD04A009
On the right tower (facing rear of machine) install the

tilt levers.
BD04A013
Stand cover up beside control tower, connect

electrical connector to chassis harness.

8001-7
STEP 26 STEP 27
Install the wrist rest.
STEP 28
Install floor boards and floor mat (if equipped).mat
STEP 29
Start the machine and place the pilot control switch in
the on position.
STEP 30
Operate the remote control valves for ten minutes to
BD04A008 remove any air from the system.
Install the retaining plate, two mounting screws and
washers. Pull the rubber boot down and secure it to STEP 31
the retaining plate.
Check the level of hydraulic oil in the reservoir and
add as required.

8001-8
LOADER CONTROL VALVE
Removal STEP 6
hoses and wires. Close disconnected hoses and
fittings with caps and plugs.
STEP 1
parking brake.
STEP 2
Lower the loader bucket to the floor and stop the
engine.
bd08b697-01
STEP 3
Remove the boot retaining screw.
Move the loader control lever in all directions to
release the pressure from the loader hydraulic
STEP 7
circuits.
STEP 4
BD01B301
Pull the cover off of the louver assembly.

BD01B305
STEP 8
Remove the two screw from the right hand side of the
floor mat.
STEP 5
BD01B299
Push the four tabs inward while pulling the louver

assembly out.
BD01B292
Pull the floor mat away from the loader control cover.

8001-9
STEP 9 STEP 12
2 3
1
1
1
BD01B300 BD01B291
Pull the louver assembly off of the hose and push the
hose back into the cover.
STEP 10
BD01B288
1. BOLT 2. FRONT PLATE 3. REAR PLATE
Remove the bolts from the loader control plate.

Remove the front plate first then back plate.
BD01B297
Pull the rubber boot upward turning it inside out. This NOTE: The back plate is sealed with silicone
will allow the boot to slide through the hole in the sealant.
cover.
STEP 11
Remove the three bolts which fasten the loader
control cover to the cab frame. Remove the cover.

8001-10
STEP 13 STEP 16
1
BD08B687
If machine is equipped with a pilot controlled clam

bucket, tag and disconnect hoses to clam controls.
STEP 17
2
BC01B030
1. CAB FLOORMAT 3. LOADER CONTROL LEVER
2. FRONT CAB SPLIT FLOOR PLATE
FLOOR PLATE
Remove front cab floor plate (2).
STEP 14
Disconnect the lever linkage rods from the valve.
STEP 15
BD03K025
Remove skid plate from machine.
STEP 18
BD01B308
1. CAP
Remove the cap from the hydraulic reservoir. This

will reduce the hydraulic oil loss as the hoses and
tubes are removed from the loader control valve. BD03K026
Disconnect the wiring for the magnetic detent located

on the bucket section of the loader control valve.

8001-11
1 STEP 23
Use acceptable lifting equipment to put the loader
control valve into position in the machine.
3
STEP 24
2
2
BD03K027
Disconnect and remove tubes (1), disconnect hoses

1
(2), and disconnect tubes (3) from the fittings on the
loader control valve. Install caps on the fittings and 3
plugs in the tubes and hoses.
NOTE: Cab is removed for clarity only.
STEP 20 BC04A122
1. BOLT (3)
Connect acceptable lifting equipment to the loader 2. WASHER (3)
control valve. 3. SPACER (3)
STEP 21 Install the bolts, washers, and spacers to fasten the

loader control valve to the chassis.
2 STEP 25
Remove the lifting equipment from the loader control
valve.
1 STEP 26
3 1
3
BC04A122
1. BOLT (3)
2. WASHER (3)
3. SPACER (3)
2
Loosen and remove the bolts and washers that
fasten the loader control valve to the chassis.
BD03K027
NOTE: Do not loose spacers that are behind loader Remove caps from the fittings and plugs from the
valve. tubes and hoses. Connect tubes (3), connect hoses
(2), install and connect tubes (1) to the fittings on the
STEP 22 loader control valve.,
Remove the loader control valve from the machine.
NOTE: Cab is removed for clarity only.

8001-12
STEP 27 STEP 29
GS99F840
BD03K026 BD01B308
Connect the wiring for the magnetic detent.

Install the hydraulic reservoir cap.
STEP 28 STEP 30
Connect the lever linkage rods to the valves.
STEP 31
3
BD03K025 2
Install skid plate on machine.
1
BC01B030
1. FRONT CAB FLOOR PLATE 3. FLOORMAT
2. LOADER CONTROL LEVER SPLIT
FLOOR PLATE
BD08B687 Install front cab floor plate (1).

If machine is equipped with a pilot controlled clam
bucket, connect hoses to clam controls, remove tags
install during disassembly.

8001-13
STEP 32 STEP 34
2 3
1
1
1
BD01B291 BD01B301
Push the cover on the louver assembly.
STEP 35
BD01B288

Put a bead of RTV silicone sealant on the mating
surface of the back plate and install. Install the front bd08b697-01
plate and tighten the bolts Install the boot and retaining screw.
STEP 33
BD01B300
1. LOUVER ASSEMBLY
2. HOSE
Put the louver assembly on the hose and push into

the cover.

8001-14
STEP 36 STEP 37
Start the engine and let it run at low idle. Activate the
loader control lever for both the bucket and lift
function. If equipped, activate the clam function. Hold
in each position for 15 to 20 seconds.
STEP 38
engine.
STEP 39
Check for oil leakage at the loader control valve.
BD01B305 STEP 40
Put the floor mat back into place and install the two Check the oil level in the hydraulic reservoir. Add oil
screws. as required. See Section 1002 for specification.
NOTE: See Section 9001, adjust the loader control
linage as required.

8001-15
CLAM CONTROL PILOT VALVE
hoses and wires. Close disconnected hoses and STEP 8
fittings with caps and plugs. Install the control block on the loader valve guard.
STEP 1 STEP 9
Park the machine on a level surface and apply the Connect hoses and solenoid wires, remove tags
parking brake. installed during removal.
STEP 2 STEP 10
Lower the loader bucket to the floor and stop the Start and operate clam control, open and close the
engine. clam three times.
STEP 3 STEP 11
Move the loader control lever in all directions to Stop the machine, check the valve for leaks.
release the pressure from the loader hydraulic
circuits. STEP 12
Check oil level in the reservoir, add oil as required.
STEP 4
Turn the ignition switch to the ON position and
activate the clam control several time to release any
pressure in the accumulator, turn the ignition switch
OFF.
STEP 5
Tag and disconnect hoses from the clam control
block.
STEP 6
Tag and disconnect the electrical connectors from
the solenoids.
STEP 7
Remove the mounting bolts, remove the clam control
block from the loader valve guard.

8001-16
2 3
1
8
4
6
5
BS08B325
SM+ MACHINES
1. RETURN TO RESERVOIR 4. ACCUMULATOR 7. PRESSURE HOSE TO SPOOL

2. PRESSURE HOSE TO SPOOL 5. DRAIN HOSE FROM PILOT MANIFOLD 8. LOADER VALVE
3. PRESSURE TO CLAM MANIFOLD 6. CLAM CONTOL BLOCK

8001-17
2
1
BC08B636
M AND SM MACHINES
1. RETURN TO RESERVOIR 4. CLAM CONTORL BLOCK 6. PRESSURE HOSE TO SPOOL

2. PRESSURE HOSE TO SPOOL 5. ACCUMUALTOR 7. PRESSURE TO CLAM MANIFOLD
3. LOADER VALVE

8001-18
HYDRAULIC PUMP 580M, 580SM AND 590SM
Removal STEP 7
STEP 1
parking brake.
STEP 2
engine.
BD03K019
Remove the Allen head screw and loosen the hose

STEP 3
clamp on the inlet hose to the pump.
Move the loader and backhoe control levers in all
directions to release the pressure from the hydraulic
STEP 8
circuits.
NOTE: For pilot control machines, turn on ignition
switch and pilot control switch, move pilot handles in
all directions several times to release hydraulic and
accumulator pressure.
STEP 4
BD03K020
Disconnect the two rear pump pressure hoses from

the left side of the pump.
NOTE: Not on 580 M.
STEP 9
BD01B308

tubes are removed from the hydraulic pump.
STEP 5
Remove the drive shaft from the transmission to the
rear axle.
STEP 6
Remove floor mat (if equipped), remove front center BD03K021
floor plate. If machine is equipped with ride control, remove ride

control return line.

8001-19
STEP 10 STEP 13
BD03K022 BD03K024
Remove the two lower mounting nuts, (powershift Remove the two upper mounting nuts, (powershift
transmissions), or bolts (manual transmissions). transmissions), or bolts (manual transmissions).
STEP 11 STEP 14
Attach suitable lifting equipment to the pump. Slide the pump to the rear off of the drive splines,
remove the pump from the machine.
STEP 12
1
4
2
3
BD03K023
Remove the two upper Allen screws from the pump

inlet, disconnect hoses from fittings 2, 3, and 4.

8001-20
NOTE: Clean and lubricate pump splines with
1
Molykote G4700 Extreme Pressure Synthetic grease,
part number 331-240, do not substitute. 4
STEP 15
Use a new “O” ring on pump flange, slide the pump 2
onto the drive splines. 3
STEP 16
BD03K023
Install but do not tighten the two upper Allen screws

in the pump inlet, connect and tighten hoses to
fittings 2, 3, and 4.
STEP 20
BD03K024
Install but do not tighten the two upper mounting

nuts, (powershift transmissions), or bolts (manual
transmissions).
STEP 17
BD03K021
If machine is equipped with ride control, install ride

control return line.
STEP 21
BD03K022
Install and tighten the two lower mounting nuts,

(powershift transmissions), or bolts (manual
transmissions), tighten the upper mounting
nuts/bolts.
STEP 18
BD03K020
Remove lifting equipment to the pump.
Connect the two rear pump pressure hoses to the left
side of the pump.
NOTE: Not on 580 M.

8001-21
STEP 22 STEP 23
Install the drive shaft to the rear axle.
IMPORTANT: The hydraulic pump must be filled
with oil. Do the following procedure to fill the
hydraulic pump with oil:
A. Fill the hydraulic reservoir Make sure the oil
level in the hydraulic reservoir is correct.
B. Remove the cap from the hydraulic reservoir.
C. Use a nozzle and shop air to pressurize the
hydraulic reservoir. Wrap a shop cloth around
the end of the hose at the nozzle.
BD03K019
Install the Allen screw and tighten all three Allen NOTE: 34.5 kPa (5 psi) to 69.0 kPa (10 psi) is all
screws with equal pressure, tighten the hose clamp that is required to move the oil. Pressure above 69.0
on the inlet hose to the pump. kPa (10 psi) can damage the hydraulic reservoir.
D. Have another person start and run the engine
at low idle while shop air is being applied to
the hydraulic reservoir.
STEP 24
Operate all hydraulic circuits, stop the engine and
check for leaks. Fill the hydraulic reser voir as
required.
STEP 25
Install floor plate, (if equipped) install floor mat.

8001-22
HYDRAULIC PUMP 580SM+ AND 590SM+
Removal STEP 7
STEP 1
parking brake.
STEP 2
engine.
BD08B691-01
STEP 3
Disconnect the case drain, output hose, and load
Move the loader and backhoe control levers in all sense hose.
directions to release the pressure from the hydraulic
circuits.
STEP 8
NOTE: Turn on ignition switch and pilot control Remove the two lower mounting bolts.
switch, move pilot handles in all directions several
times to release hydraulic and accumulator pressure, STEP 9
if equipped with clam bucket operate clam controls.
Disconnect the inlet hose.
STEP 4 STEP 10
Attach suitable lifting equipment to the pump.
STEP 11
Remove the two upper mounting bolts.
STEP 12
Slide the pump to the rear off of the drive splines,
remove the pump from the machine.
BD01B308

tubes are removed from the hydraulic pump.
STEP 5
Remove the drive shaft from the transmission to the
rear axle.
STEP 6
Remove floor mat (if equipped), remove front center
floor plate.

8001-23
NOTE: Clean and lubricate pump splines with
Molykote G4700 Extreme Pressure Synthetic
grease, part number 331-240, do not substitute.
STEP 13
Use a new “O” ring on pump flange, slide the pump
onto the drive splines.
STEP 14
Install but do not tighten the two upper mounting
bolts.
BC08B566
STEP 15 Use a hand pump filled with MS1207 and connect it
Install and tighten the two lower mounting bolts, to the quick coupler on the side of the pump, fill the
tighten the upper mounting nuts/bolts. pump with approximately 1 liter (1 quart) of oil.
STEP 16 STEP 21
Remove lifting equipment to the pump.
STEP 17
Connect the inlet hose.
STEP 18
BD08A525
Disconnect the two top connectors from the engine
controller.
STEP 22
Crank the engine over for 5 seconds, turn the ignition
switch off, crank the engine again for 5 seconds.
BD08B691-01
Connect the case drain, output hose, and load sense

hose. STEP 23
Tu r n t h e i g n i t i o n sw i t c h o f f a n d c o n n e c t t h e
connector to the engine controller.
STEP 19
Install the drive shaft to the rear axle.
STEP 24
Connect a quick coupler and hose to the fitting on the
attenuator hose located at the left side of the
backhoe vale.

8001-24
STEP 25 STEP 30
Attached a needle valve to the hose. Wait for a minimum of fifteen seconds before cycling
hydraulic circuits.
STEP 26 NOTE: Oil level will drop in the reservoir, refill
Star t and operate the machine at low idle for a reservoir as necessary to maintain oil level in the
minimum of five seconds. sight gauge.
NOTE: The system will have noise until all of the air
is purged. STEP 31
Cycle any functions that were disconnected or
STEP 27 drained of hydraulic fluid three complete cycles.
Using the needle valve, slowly open and allow oil to Bottom the cylinder out inn each cycle.
flow from the valve until there are no noticeable air NOTE: If no function was disconnected, cycle two of
bubbles in the stream and the stream is a solid color. the following for three complete cycles: backhoe
dipper, extend-a-hoe, backhoe bucket, or loader
STEP 28 bucket.
Close the needle valve, stop the engine, remove the
hose and quick coupler from the attenuator hose. STEP 32
Stop the engine and check for leaks. Fill the
STEP 29 hydraulic reservoir as required.
Start the engine and advance the throttle to mid
position. STEP 33
Install floor plate, (if equipped) install floor mat.

8001-25
PILOT COLTROLS BACKHOE VALVE
Removal STEP 9
STEP 1
Park the machine on a level surface, lower stabilizers
and loader bucket to the floor.
STEP 2
Turn off the engine, turn the ignition switch to the on
position and the pilot control switch to the on
position.
STEP 3
Move the pilot controls in all directions several times BD03N006
to release the accumulator pressure, move the

loader controls in all directions to release pressure
on the loader.
STEP 4
Turn pilot control switch and ignition switch off.
STEP 5
Remove the ROPS Cab/Canopy from the machine,
see section 9001.
STEP 6 BD03N007
Disconnect the hydraulic hoses at the swing Disconnect the backup alarm.
cylinders that come from the swing cushioning valve,
cap the fittings and plug the hoses. STEP 10
Attach suitable lifting equipment to the pilot control,
STEP 7 remove the mounting bolts from the pilot control.
Tag and disconnect all hydraulic hoses from the IMPORTANT: Do not attach lifting equipment to any
control valve, cap and plug all hoses and fittings. hydraulic tubes.
STEP 8 STEP 11
Loosen and remove the mounting bolts from the pilot
control mounting bracket.
STEP 12
Slowly raise the control unit from the machine, make
sure control unit does not become entangled on the
frame.
STEP 13
Place the control unit on a bench, block unit to
ensure that no tubing is bent.
BD03N008
Disconnect the electrical connectors for the pilot unit.

8001-26
STEP 14
Attach suitable lifting equipment to the pilot control.
IMPORTANT: Do not attach lifting equipment to any
hydraulic tubes.
STEP 15
Slowly lower the control unit into the machine, make
sure control unit does not become entangled on the
frame.
BD03N008
STEP 16
Connect the electrical connectors for the pilot unit.
Install and tighten the mounting bolts for the pilot
control bracket.
STEP 19
Remove caps and plugs, connect all hydraulic hoses
STEP 17
to the control valve.
STEP 20
Connect the hydraulic hoses to the swing cylinders.
STEP 21
Install the ROPS Cab/Canopy on the machine, see
section 9001.
STEP 22
Start the machine and place the pilot control switch in
the on position.
BD03N007
STEP 23
Operate the pilot control valves for ten minutes to
remove any air from the system.
STEP 24
Check the level of hydraulic oil in the reservoir and
add oil as required.
BD03N006
Connect the backup alarm.

8001-27
MECHANICAL CONTROLS BACKHOE VALVE
Removal STEP 8
NOTE: Put identification tags on all disconnected 3
hoses and tubes. Close disconnected hoses, tubes
and fittings with caps and plugs. 1
2
STEP 1 1
Park the machine on a level surface and lower the
loader bucket to the floor.
1
STEP 2
If the backhoe is equipped with an Extendahoe,
install the Extendahoe lock pin.
bd01b304
STEP 3 1. BOLTS 2. FRONT COVER 3. REAR COVER
Lower the stabilizers until the stabilizer pads just Remove the bolts which fasten the backhoe control
touch the floor. tower covers.
STEP 4 STEP 9
Extend the backhoe straight behind the machine with
the backhoe bucket resting on the ground.
1
STEP 5
Stop the engine and apply the parking brake.
3
STEP 6
Move the backhoe control levers in all directions until
all hydraulic pressure has been removed from the 2
backhoe hydraulic circuits.
STEP 7
BD01B302
1. RUBBER BOOT 2. FRONT COVER 3. REAR COVER

Pull the rubber boot up and remove the rear cover
and front cover.
STEP 10
Remove the backhoe control tower covers.
BD01B303
Remove the four retaining screws.

8001-28
STEP 11 STEP 14
Remove the bolts which fasten the backhoe control
1 tower assembly to the valve mounting brackets.
STEP 15
Remove the backhoe control tower assembly from
the machine.
STEP 16
BC01B029
1. CAB FLOORMAT 2. REAR CAB FLOOR PLATE
If equipped, remove the cab floormat. Remove the
rear cab floor plate.
STEP 12
Attach identification tags to the linkage for the bd01b308
backhoe control valve. Remove the cap from the hydraulic reservoir. This
STEP 13 tubes are removed from the valve.
Disconnect the linkage rods from the spools on the
backhoe control valve. STEP 17
Disconnect the hoses and tubes from the backhoe
control valve. Install caps on the fittings and plugs in
the hoses and tubes.
STEP 18
Connect acceptable lifting equipment to the backhoe
control valve.
STEP 19
Remove the bolts that fasten the backhoe control
valve right and left mounting brackets to the chassis.
STEP 20
R e m ove t h e b a ck h o e c o n t r o l va l ve f r o m t h e
machine.

8001-29
3
STEP 21
Using acceptable lifting equipment, place the 1
backhoe control valve in the machine. 2
1
STEP 22
Align the left and right valve mounting brackets with
the chassis mounting holes. Install the bolts. 1
STEP 23
Remove the lifting equipment.
BD01B304
STEP 24 1. BOLT 2. FRONT COVER 3. REAR COVER
Connect all hoses and tubes. Install the backhoe control tower assembly covers.
STEP 25 STEP 31
Install the hydraulic reservoir cap.
STEP 26
Install the backhoe control tower assembly. Use the
bolts to fasten the backhoe control tower to the valve
mounting brackets.
STEP 27
Connect the linkage rods to the spools on the
backhoe control valve.
STEP 28
BD01B303
2 Install the four retaining screws.
STEP 32
BC01B029
1. REAR CAB FLOOR PLATE 2. CAB FLOORMAT
Install the rear cab floor plate. If equipped, install the GS99F842
cab floormat. Start the engine and activate each of the backhoe
control levers. Hold each lever over relief in each
STEP 29 direction for 15 to 20 seconds.
If the machine is equipped with auxiliary hydraulics,
connect the control cables to the backhoe control
tower.

8001-30
STEP 33 STEP 34
Stop the engine. Check for oil leakage at the backhoe Check the oil level in the hydraulic reservoir. Add oil
control valve. as required. See Section 1002 for oil specifications.
3
2
1 4
5
9
11
8
10
BC04A121
1. HOSES SWING CONTROL 4. RETURN TO FILTER 7. PRESSURE TO BACKHOE VALVE 10. RIGHT STABILIZER HOSES
2. BACKHOE VALVE 5. HYDRAULIC FILTER 8. SWING CUSHION VALVE
11. RIGHT STABILIZER LOAD CHECK
3. LEFT STABILIZER LOAD
6. LOADER VALVE 9. LEFT STABILIZER HOSES VALVE
CHECK VALVE

8002
Section
8002
HYDRAULIC SPECIFICATIONS, TROUBLESHOOTING,

AND PRESSURE CHECKS FOR
580M, 580SM, AND 590SM SERIES 3
WITH MECHANICAL CONTROLS

8002-2 580M, 580SM, AND 590SM SERIES 3 WITH MECHANICAL CONTROLS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in all Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Single Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in the 4X1 Clam Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
580SM and 590SM Pump Output Test Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
580M Pump Output Test Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Machine Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Loader Main Relief and Backhoe Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Large Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Loader Control Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Small Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Backhoe Control Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Steering/Bucket Lock Valve Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering/Bucket Lock Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RELIEF VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Backhoe Circuit Relief Valves for Bucket, Swing, Boom and Dipper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPTIONAL RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Right Solenoid Valve for Ride Control (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Left Solenoid Valve for Ride Control (Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHARGING THE ACCUMULATOR WITH DRY NITROGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SWING CUSHION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Troubleshooting The Swing Cushion Valve For Swing Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
580SM and 590SM Series 3 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
580M Series 3 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Standard Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Optional Comfort Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clam Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Backhoe and Loader Quick Coupler Single Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Backhoe and Loader Quick Coupler Dual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FLOWMETER CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

580M, 580SM, AND 590SM SERIES 3 WITH MECHANICAL CONTROLS 8002-3
SPECIFICATIONS
Output of Hydraulic Pump 580M ..........................................................................108 L/min at 207 bar at 2200 r/min
(28.5 U.S. gpm at 3000 psi at 2200 rpm)
Output of Hydraulic Pump 580SM
Rear section .....................................................................................................108 L/min at 207 bar at 2200 r/min
Front section.......................................................................................................36 L/min at 207 bar at 2200 r/min
Front section...................................................................................................... 42 L/min at 207 bar at 2200 r/min
Pressure Settings
Main relief valve ......................................................................................................... 210 ± 3 bar (3050 ± 50 psi)
Accumulator for ride control (Nitrogen charge) ................................................................ 25 ± 1bar (362 ± 15 psi)
Circuit relief valves (Hand pump setting only)
Backhoe bucket A (upper) port.................................................................................... 262 ± 3 bar (3800 ± 50 psi)
Backhoe bucket B (lower) port .................................................................................... 221 ± 3 bar (3205 ± 50 psi)
Swing A (upper) and B (lower) ports ........................................................................... 207 ± 3 bar (3000 ± 50 psi)
Loader bucket A (upper) and B (lower) ports .............................................................. 221 ± 3 bar (3205 ± 50 psi)
Boom A (upper) port.................................................................................................... 221 ± 3 bar (3205 ± 50 psi)
Boom B (lower) port ................................................................................................... 331 ± 3 bar (4800 ± 50 psi)
Dipper A (upper) port and B (lower) port..................................................................... 238 ± 3 bar (3450 ± 50 psi)
Steering relief pressures........................................................................................ 172 +0 -10 bar (2500 +0 -150 psi)

SPECIAL TOOLS
B785789M B877895M
CAS-10280 FLOWMETER CAS-10090 HAND PUMP
B797157M 94L95
CAS-1808 FLOWMETER FITTING KIT CAS-10899 NITROGEN CHARGING KIT
B877558U
CAS-1804 PRESSURE FITTING KIT

TROUBLESHOOTING PROCEDURES
Visual Check
Visually check the machine for oil leakage
and damaged or missing parts. Repair or
replace any damaged or missing parts.
Check the oil level in the hydraulic reservoir. Fill the hydraulic reservoir with the oil
No
Is the oil level correct? specified in Section 1002.
Yes
See Section 9001 and check all control

linkages. Heat the oil in the hydraulic system to
No operating temperature. Operate the machine
Check the operation of the machine again.
Does the machine operate correctly? to find which circuits have problems.
Yes
Troubleshooting complete.
Problem in all Circuits

Check the main relief valve. Is the pressure
No Adjust the main relief valve
correct?
Yes
Do a pump test. Is the pump good? No Repair or replace the hydraulic pump.
Yes
Do a stall test according to the instructions

in Section 2002. Is there still a problem?
Yes
See Section 8003 and check for

No See the following topics for other circuits
contaminated oil. Is the oil contaminated?
Yes
Clean or replace the oil. See Section 8003.

Problem in a Single Circuit

Check the machine for missing or damaged
parts. If equipped with ride control, make sure
the ride control button is in the OFF position
Check the operation of the problem circuit. Do Check the spool travel. Is the spool traveling
No
the cylinder(s) move in both directions? in both directions?
No
Adjust the linkage as

Yes necessary to get the correct
spool travel.
Yes
The control valve can have internal wear or
damage. Repair or replace the control valve
as necessary.
Check the O-ring on the end of the circuit

No Replace the O-ring.
relief valve or plug. Is the O-ring good?
Yes
Check the setting of the circuit relief valve, if

used, for the problem circuit. Is the setting No Replace the circuit relief valve.
correct?
Yes
NOTE: Boom cylinder only. A check valve is

installed in the piston. The problem in the
Check the cylinder piston packing. Is the boom circuit can be the check valve instead of
No
cylinder piston packing good the cylinder piston packing.
See Section 8006 and repair the cylinder as
necessary.
Yes
The control valve has internal wear or

as necessary.

Problem in the 4X1 Clam Circuit

Check for power at controller. Is power
No Check fuse, check wiring to controller.
present at controller?
Yes
Disconnect solenoids, activate circuit. Is

No Check wiring to solenoids.
power present at solenoids?
Yes
Take an Ohm reading on the solenoids, a

reading of 5.4 Ohm at 20° C (68° F) should No Replace solenoids.
be obtained. Are the readings correct?
Yes
Check pilot pressure at pilot manifold, a

reading of 24 to 34.5 bar (350 to 500 psi) No Replace pressure reducing cartridge.
should be obtained. Is the pressure correct?
Yes
Does the pilot accumulator hold a charge.

To check the accumulator, open the clam so
the weight of the clam is on the cylinders,
raise the loader and hold under pressure for
No Replace the accumulator.
30 seconds. Stop the engine, turn the
ignition switch to accessory, activate the
clam switch to the close position. Does the
clam drop?
Yes
Remove and inspect the spool and loader

Check for operation of the spool in both
No valve for damage. Repair or replace the
directions. Is the spool operation correct?
spool or valve section as necessary.
Yes
Check the cylinder piston packing. Is the See Section 8006 and repair the cylinder as
No
cylinder piston packing good necessary.

SYSTEM TESTING
2
1 3
6
7
5
10
9 4
8
BC04C128
580SM AND 590SM PUMP OUTPUT TEST HOSE CONNECTIONS
1. PUMP 5. LOADER VALVE 9. “CF” PORT OUTPUT HOSE

2. “EF” PRESSURE TEST PORT 6. FLOWMETER OUTLET HOSE 10. “T” FITTING
3. FLOWMETER INLET HOSE CONNECTION 7. CAP
FOR LARGE PUMP SECTION 8. FLOWMETER INLET HOSE CONNECTION
4. FLOWMETER FOR “CF” PORT
IMPORTANT: Remove hydraulic tank filler cap and place flowmeter outlet hose (6) below oil level, SECURE
HOSE. Use cap (7) to cap “T” fitting during “CF” port flow test.

3
6 7
4
BC04C127
580M PUMP OUTPUT TEST HOSE CONNECTIONS
1. PUMP 4. FLOWMETER 7. CAP

2. “EF” PRESSURE TEST PORT 5. LOADER VALVE 8. NOT USED
3. FLOWMETER INLET HOSE 6. FLOWMETER OUTLET HOSE 9. “CF” PORT
HOSE.

NOTE: Make copies of the Flowmeter Check Sheet ● When flow reaches 0 gpm (l/min), a pressure
in the rear of this section and use it to record the reading of 3000 to 3100 psi (207 to 214 bar)
readings. should be obtained. Record this reading on line 2b
on check sheet.
Machine Preparation NOTE: If pressure is not as specified adjust main
● Park the machine on a level surface. Put the relief valve. If 2a reading is not within 10% of the 2b
backhoe in the transport position and lower the reading, replace the relief valve.
● Remove pressure testing adapter from pump EF Large Pump Efficiency
port (2), connect flowmeter input hose (3) to the Test 3a
fitting.
● Holding the loader on demand, fully open the load
● Remove screen from reservoir and secure the valve, adjust engine to 2000 rpm (r/min), read the
flowmeter return hose below oil level. flow gauge and record the reading. Record this
● The oil must be at operating temperature. To heat reading on line 3a on check sheet.
the oil, do the following steps:
Test 3b
A. With the engine running at full throttle, close
● Continue to run the engine at 2000 rpm (r/min).
the relief valve on the flowmeter to at least
Slowly close the load valve until the pressure is
1500 psi (103.4 bar).
2000 psi (138 bar), read the flow gauge and record
B. Hold the loader control lever in the the reading. Record this reading on line 3b on
ROLLBACK position for 15 seconds. check sheet.
C. Put the loader control lever in the NEUTRAL ● Divide the flow reading at 2000 psi (138 bar) (3b)
position for 15 seconds. by the flow reading 0 psi (3a).
D. Repeat steps A and B until the temperature of NOTE: This answer multiplied by 100 is the percent
the oil is 125°F (51°C) or the side of the efficiency of the pump. If the efficiency of the large
reservoir is very warm. pump is less than 70 percent, repair or replace the
pump. If the efficiency of the pump is more than 70
Stall Test percent, the pump is good.
● Refer to section 2002 and perform an engine stall
test, record the results on line 1a through 1e on Loader Control Valve Leakage
check sheet. ● Continue to run the engine at 2000 rpm (r/min) and
increase pressure on flowmeter to 2000 psi (138
Loader Main Relief and Backhoe Relief bar).
● Run the engine at high idle. Raise the loader and Test 4a
hold in the raised position.
● Hold the loader in the raised position. Record gpm
● Slowly open the load valve on the flowmeter until (l/min) on line 4a on check sheet.
the pressure reading is zero.
Test 4b
Test 2a
● Lower the loader and hold the loader in the lower
● Slowly close the load valve on the flowmeter position. Record gpm (l/min) on line 4b on check
observing the flow. sheet.
● Record the pressure when the flow drops
Test 4c
dramatically by several gpm (L/min). Record this
reading on line 2a on check sheet. ● With the loader approximately eighteen inches
from the ground, hold the bucket in the rollback
Test 2b position. Record gpm (l/min) on line 4c on check
● Continue to close the load valve on the flowmeter sheet.
observing the flow.
Test 4d
● Hold the bucket in the dump position. Record gpm
(l/min) on line 4d on check sheet.

Test 4e Test 6d
● Hold the clam in the open position. Record gpm ● Retract and hold the extend-a-hoe in. Record gpm
(l/min) on line 4e on check sheet. (l/min) on line 6d on the check sheet.
Test 4f Test 6e
● Close and hold the clam in the closed position. ● Raise the left stabilizer. Record gpm (l/min) on line
Record gpm (l/min) on line 4f on check sheet. 6e on the check sheet.
NOTE: If flow reading between test 3b and tests 4a Test 6f
through 4f varies more that 1 gpm (3.8 l/min) there is ● Raise the right stabilizer. Record gpm (l/min) on
a problem in that circuit. line 6f on the check sheet.
Small Pump Efficiency Test 6g
NOTE: Tests 5a and 5b are for SM machines only. NOTE: During stabilizer lower test, evenly lower
both stabilizers to full stroke and raise the machine.
● Continue to run engine at 2000 rpm (r/min) and
hold the backhoe bucket on demand. ● Lower the left stabilizer. Record gpm (l/min) on line
6g on the check sheet.
Test 5a
Test 6h
● Close the load valve on flowmeter to 300 psi (20.5
● Lower the right stabilizer. Record gpm (l/min) on
bar). Record gpm (l/min) on line 5a on the check
sheet. line 6h on the check sheet.
Test 5b Test 6i
● Roll the backhoe bucket to the dump position.
Slowly close the load valve until the pressure is Record gpm (l/min) on line 6i on the check sheet.
2000 psi (138 bar). Record gpm (l/min) on line 5b Test 6j
on the check sheet.
● Roll the backhoe bucket to the dig position. Record
● Use pump efficiency calculation on the Flowmeter gpm (l/min) on line 6j on the check sheet.
Check Sheet to calculate the small pump
efficiency. Test 6k
● Hold the dipper in the full extended position.
NOTE: If the efficiency of the small pump is less
Record gpm (l/min) on line 6k on the check sheet.
than 70 percent, repair or replace the pump before
continuing. If the efficiency of the pump is more than Test 6l
70 percent, the pump is good. ● Hold the dipper in the full in position. Record gpm
(l/min) on line 6l on the check sheet.
Backhoe Control Valve Leakage
Test 6m
● Continue to run the engine at 2000 rpm (r/min) and
● Hold the boom in the lower position. Record gpm
the flowmeter at 2000 psi (138 bar). Hold each
function on demand at the end of the stroke. (l/min) on line 6m on the check sheet.
NOTE: If equipped with uni-directional valve, the Test 6n

valve must be off. ● Hold the boom in the raise position. Record gpm
(l/min) on line 6n on the check sheet.
Test 6a
● Swing the backhoe to the left. Record gpm (l/min) Test 6o
on line 6a on the check sheet. ● If equipped with bi-directional auxiliary hydraulics,
unhook hydraulic quick disconnects or cap lines,
Test 6b
hold the lever out. Record gpm (l/min) on line 6o
● Swing the backhoe to the right. Record gpm (l/min) on the check sheet.
on line 6b on the check sheet.
Test 6p
Test 6c
● Reverse directions on the bi-directional valve.
● If equipped, extend and hold the extend-a-hoe out. Record gpm (l/min) on line 6p on the check sheet.
Record gpm (l/min) on line 6c on the check sheet.
NOTE: If flow reading between test 5b and tests 6a
through 6p varies more that 1 gpm (3.8 l/min) there is
a problem in that circuit.
Steering/Bucket Lock Valve Flow Test 7e
● Open the flowmeter and stop the engine. Remove ● Continue to close the load valve on the flowmeter
the caps and plugs and reconnect the auxiliary observing the flow.
hydraulics. ● When flow reaches 0 gpm (l/min), record the
● Connect the flowmeter to the “CF” port on the pressure on line 7e on the check sheet.
hydraulic pump. NOTE: A pressure reading of 2700 to 2800 psi (186
Test 7a to 193 bar) should be obtained. If pressure is not as
specified adjust quick coupler relief valve.
● Start and run engine at high idle close the load
valve on the flowmeter. Record the pressure
reading on line 7a on the check sheet. Steering/Bucket Lock Valve Leakage
● Holding the steering wheel against the left stop,
NOTE: A pressure reading of 2500 +0 –150 psi (172
close the load valve on the flowmeter to a reading
+0 –10 bar) should be obtained.
of 1800 psi (124 bar), adjust engine rpm to 2000.
Test 7b
Test 8a
● Turn the steering wheel full right and hold against
● Turn the steering wheel to full right. Record gpm
the stop.
(l/min) on line 8a on the check sheet.
● Open the load restrictor on the flowmeter to a
reading of 1000 psi (69 bar). Test 8b
● Holding the steering wheel against the stop, slowly ● Turn the steering wheel to full left. Record gpm
close the load valve observing the flowmeter. (l/min) on line 8b on the check sheet.
● When the flow drops dramatically by several gpm ATTENTION: When performing the loader bucket
(L/min) record the pressure on line 7b of the check or backhoe bucket coupler test, keep all personnel
sheet. clear of the area.
● Extend the backhoe bucket all the way to the dump
Test 7c
position. Place the loader and the backhoe bucket
● Continue to close the load valve on the flowmeter on the ground.
observing the flow.
Test 8c
● When flow reaches 0 gpm (l/min), record the
pressure on line 7c on the check sheet. ● Retract the loader lock pins. Record gpm (l/min) on
line 8c on the check sheet.
● Turn the steering wheel to the neutral position.
Test 8d
NOTE: A pressure reading of 172 +0 -10 bar (2500
+0 -150 psi) should be obtained. If pressure reading ● Extend the loader lock pins. Record gpm (l/min) on
is low see section 5001 for steering system line 8d on the check sheet.
troubleshooting. Test 8e
Test 7d ● Retract the backhoe bucket lock pins. Record gpm
● Fully open the load valve on the flowmeter. (l/min) on line 8e on the check sheet.
ATTENTION: When performing the loader bucket Test 8f

or backhoe bucket coupler test, keep all personnel ● Extend the backhoe bucket lock pins. Record gpm
clear of the area. (l/min) on line 8f on the check sheet.
● Extend the backhoe bucket all the way to the dump NOTE: If any flow readings between tests varies
position. Place the loader and the backhoe bucket more that 1 gpm (3.8 l/min) there is a problem in that
on the ground. circuit.
● If equipped, engage the front or rear hydraulic ● Open the flowmeter and stop the engine. Remove
coupler, slowly close the load valve on the all test equipment from the machine and reconnect
flowmeter observing the flow. all hydraulic systems. Check hydraulic level, add
● When the flow drops dramatically by several gpm hydraulic fluid as required.
(L/min) record the pressure on line 7d on the
check sheet.

RELIEF VALVE TEST
Main Relief Valve Adjustment

Pressure Check 1. The main relief valve is in the inlet section of the
loader control valve. Loosen the lock nut (1) on
1. Park the machine on a level surface. Put the the main relief valve. Turn the adjusting screw
backhoe in the transport position and lower the (2) clockwise to increase the pressure and
loader bucket to the floor. counterclockwise to decrease the pressure.
2. The oil must be at operating temperature. To 2. Check the pressure again.
heat the oil, do the following steps:
3. If the main relief valve pressure is very low, and
A. With the engine running at full throttle, hold steering relief pressure is normal, repeat the
the loader control lever in the ROLLBACK main relief test with backhoe bucket bottomed
position for 15 seconds. out. If the pressure goes up, inspect the check
B. Put the loader control lever in the NEUTRAL valve in the loader valve outlet.
4. When the pressure is correct, tighten the lock
C. Repeat steps A and B until the temperature of nut.
1
3. Use a pressure gauge with a capacity of at least
27 580 kPa, 276 bar (4000 psi). Connect the 2
pressure gauge to the quick disconnect fitting. 3
NOTE: The quick disconnect fitting is located at the
rear of the pump.
4. Run the engine at full throttle. Hold the loader
control lever in the RAISE position until the
loader stops moving. 4
5
5. Hold the loader control lever in the RAISE
position and read the pressure gauge. Then
release the loader control lever and decrease the
engine speed to low idle. Stop the engine.
6. Compare the reading with the specification on
6 7
page 3. If the reading is not correct, adjust the
main relief valve.
8
BC03M081
1. LOCK NUT 5. SPRING

2. ADJUSTING SCREW 6. POPPET
3. PLUG 7. POPPET
4. BODY 8. POPPET

1 2 3 4
5 6 7 8
BC03M052
1. SWING B 3. DIPPER B 5. SWING A 7. DIPPER A

2. BOOM B 4. BUCKET B 6. BOOM A 8. BUCKET A
Backhoe Circuit Relief Valves for Replacement

Bucket, Swing, Boom and Dipper 1. Remove the circuit relief valve from the test
block.
Pressure Check
2. Lubricate “O” ring with hydraulic oil.
34 475 kPa, 345 bar (5000 psi). Connect the 3. Install valve and torque to 48 ± 5 lb-ft
pressure gauge and the (TBA) Husco test block (65 ± 6.7 Nm).
to the CAS-10090 hand pump.
2. Actuate the hand pump and record the highest
pressure reading. Check the pressure setting
several times to be sure of the reading.
3. Compare the reading with the specifications on
page 3.
4. If the pressure setting is not correct, replace the
circuit relief valve.

OPTIONAL RIDE CONTROL
2
1
3
4
BC03N002
1. RIGHT SOLENOID VALVE FOR RIDE CONTROL 4. TUBE FROM RIGHT SOLENOID VALVE TO ACCUMULATOR
(ACCUMULATOR)
2. LEFT SOLENOID VALVE FOR RIDE CONTROL (TANK) 5. ELBOW FITTING, REPLACE WITH ADJUSTABLE TEE FITTING
3. ACCUMULATOR (PART NUMBER 218-5286) FOR PRESSURE TEST-
CONNECT HOSE AND PRESSURE GAUGE HERE.
Right Solenoid Valve for Ride 3. Put the loader control lever in the NEUTRAL
position.
Control (Accumulator)
4. Disconnect the tube between the right solenoid
1. Make sure that the oil side of the accumulator is valve and the accumulator at the right solenoid
completely discharged by doing the following: valve.
A. Put the ride control switch in the ON position. 5. Remove the adjustable elbow fitting from the
B. Lower the loader to the floor. Put the loader right solenoid valve.
control lever in the float position. 6. Install an adjustable Tee fitting (part number
C. Stop the engine. Put the key switch in the ON 218-5286) in the right solenoid valve.
position. 7. Connect the tube from the accumulator to the
D. Move the loader control lever in all directions adjustable Tee fitting in the right solenoid valve.
to release any pressure in the hydraulic 8. Use a hose and fittings from the CAS-1804
circuits. Put the loader control lever in the float Pressure Fitting Kit or the CAS-1808 Flowmeter
position. Fitting Kit to make the following connections.
2. Put the ride control switch and key switch in the
OFF position.

9. Connect a hose and a pressure gauge with a Left Solenoid Valve for Ride
capacity of at least 27 580 kPa, 276 bar (4000
psi) to the adjustable Tee fitting in the right
Control (Tank)
solenoid valve. 1. Put the ride control switch in the ON position.
10. Put ride control switch in the OFF position, start 2. Move the loader control lever to the LOWER
and run the engine at low idle. position until the loader bucket is on the floor,
11. Move the loader control lever to the RAISE continue to lower the loader bucket to raise the
position while you read the pressure gauge. The machine off the floor. The loader must not be
pressure gauge should read approximately 0 able to lift and hold the machine off the floor. If
kPa, 0 bar (0 psi). the loader can lift and hold the machine see
section 4001 for electrical troubleshooting or
NOTE: If the pressure gauge indicates more than section 8009 and repair or replace the left
172 kPa, 1.7 bar (25 psi) see section 8009 and repair solenoid valve.
or replace the right solenoid valve.
3. If required, lower the machine to the floor.
12. Lower the loader bucket to the floor.
4. Put the ride control switch in the OFF position.
13. Put the ride control switch in the ON position.
5. Move the loader control lever to the LOWER
14. Move the loader control lever to the RAISE position until the loader bucket is on the floor,
position while you read the pressure gauge. The continue to lower the loader bucket to raise the
pressure gauge should indicate approximately machine off the floor. The loader must be able to
3448 kPa, 34.5 bar (500 psi). lift and hold the machine off the floor. If the
NOTE: If the pressure gauge does not indicate loader cannot lift and hold the machine off the
approximately 3448 kPa, 34.5 bar (500 psi) see f l o o r s e e s e c t i o n 4 0 0 1 fo r e l e c t r i c a l
section 4001 for electrical troubleshooting or section troubleshooting or section 8009 and repair or
8009 and repair or replace the right solenoid valve replace the left solenoid valve.
for ride control. 6. If required, lower the machine to the floor.

CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR

D. Move the loader control lever in all directions
to release any pressure in the hydraulic
E circuits. Put the loader control lever in the
C FLOAT position.
E. Leave the ride control switch and key switch in
the ON position.
F. Leave the loader control lever in the FLOAT
F position.
2. Close valves B and C on the nitrogen charging
kit.
3. Turn the stem out of valve F until the stem stops.
B
D A 4. Remove the cap screws and guard from the
94L95 accumulator.
1. Make sure that the oil side of the accumulator is
5. Remove the cap from the valve stem on the
completely discharged by doing the following:
accumulator.
A. Put the ride control switch in the ON position.
6. Connect valve F to the valve stem.
B. Lower the loader to the floor. Put the loader
7. Make sure that valve D is open.
control lever in the FLOAT position.
8. Turn the stem into valve F and read the pressure
C. Stop the engine. Put the key switch in the ON
on gauge E.
position.
The pressure must be 2413 to 2580 kPa, 24 to 26
bar (350 to 375 psi). If the pressure is too low, charge
the accumulator with dry nitrogen.
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

5. Slowly turn valve A clockwise and read gauge E
until the pressure is 2413 to 2580 kPa, 24 to 26
E bar (350 to 375 psi). Stop turning valve A.
C 6. If the pressure increases above 2580 kPa, 26
bar (375 psi), quickly open and close valve D and
read gauge E. If the pressure is still too high, turn
valve A counterclockwise a small amount and
F quickly open and close valve D. The pressure
shown on gauge E is the charge pressure.
7. Connect valve F to the valve stem on the
accumulator. Turn the stem into valve F until the
B stem stops moving and open valve D to charge
D A the accumulator.
94L95
8. After the accumulator stops charging, turn the
Check the pressure in the accumulator according to
stem out of valve F until the stem stops moving.
the instructions in this section. Keep the nitrogen
charging kit connected to the accumulator. 9. Close valve B and disconnect the nitrogen
c h a r g i n g k i t f r o m t h e v a l ve s t e m i n t h e
1. Slowly turn valve A counterclockwise to lower the
accumulator.
pressure.
Install the cap on the valve stem. Install the guard
2. Open valve B. Close valves C and D.
and cap screws.
3. Turn the stem out of valve F until the stem stops
moving. Disconnect valve F from the valve stem
on the accumulator.
4. Connect the nitrogen charging kit to a dry
nitrogen tank.
SWING CUSHION VALVE
Troubleshooting The Swing 15. For machines with swing drift that is similar in
both directions do the following check:
Cushion Valve For Swing Drift
A. Remove the hoses from the fittings at the
1. Make sure the hydraulic oil is at operating swing cushion valve. Install caps on the
temperature, 52° C (125° F). fittings and plugs in the hoses.
2. Park the machine on a level surface. B. Repeat steps 2 through 13 above.
3. Put the loader bucket flat on the ground. Lower 16. If swing drift still occurs. See Section 8006 and
the stabilizers until the rear tires are repair the swing cylinders as required.
approximately 152.4 mm (6 inches) off the
ground. 17. If swing drift does not occur, do the following.
4. Move the backhoe from the transport position. A. Remove the swing cushion valve.
Fully extend the dipper and bucket and lower the B. Connect the swing hoses to the swing
boom until the backhoe bucket is approximately sections in the backhoe control valve.
304.8 mm (12 inches) off the ground.
C. Repeat steps 2 through 13 of this procedure.
NOTE: If the machine is equipped with an
extendahoe, make sure the extendahoe is 18. If swing drift does not occur, the problem is in the
completely retracted. swing cushion valve. Replace the swing cushion
valve.
5. Use one stabilizer to lower one side of the
machine until the tire on that side of the machine 19. If swing drift still occurs. See Section 8007,
just makes contact. Measure the angle of the inspect and repair the swing section of the
backhoe frame. Raise or lower the stabilizers as backhoe control valve as required.
required until the machine is setting at 10° from 20. For machines with swing drift in only one
level from side to side. direction do the following check:
6. Lower the boom until the backhoe bucket is A. Disconnect the swing cushion valve from the
touching the ground. Make a identification mark swing section in the backhoe control valve.
as to the location of the backhoe bucket.
B. Connect the hoses to the swing sections in the
7. Raise the boom until the backhoe bucket is backhoe control valve.
approximately 1824 m (6 feet) above the ground.
C. Repeat steps 2 through 13 of this procedure
8. Stop the engine. for the side of the machine with swing drift.
9. Wait for five minutes. 21. If swing drift does not occur, the problem is in the
10. After five minutes, start the machine. Lower the swing cushion valve. Replace the swing cushion
boom until the backhoe bucket touches the valve.
ground. 22. If swing drift still occurs, do the following:
11. Measure the distance between where the bucket A. Inspect the anti-cavitation check valve in the
is sitting and the mark at step 6. swing valve. Replace as required.
12. Make a record of this measurement. The B. Inspect the O-ring for the swing circuit relief
measurement should not exceed 203.2 mm (8 valve in the swing valve section for the side of
inches). the machine with swing drift. Replace the
13. Repeat steps 2 through 12 to measure the swing O-ring as required.
drift in the other direction.
14. If the swing drift exceeds the recommendations
in step 12, and is similar in both directions go to
s t e p 1 5 . I f t h e sw i n g d r i f t ex c e e d s t h e
recommendations in step 12, but only drifts in
one direction go to step 20.

ILLUSTRATIONS
7 8
5
3
6
1
2
BC05F010
580SM AND 590SM SERIES 3 HYDRAULIC PUMP
1. LARGE SECTION 4. INLET 7. EF PORT

2. SMALL SECTION 5. LOAD SENSING PORT 8. CF PORT
3. SMALL PUMP PORT 6. PRIORITY VALVE

3 2
BC05F009
580M SERIES 3 HYDRAULIC PUMP
1. INLET 2. EF PORT 3. CF PORT 4. LOAD SENSING PORT 5. PRIORITY VALVE

8 2
7
3
4 5
1
6 8 7
1 2
4 3
5
BC05F008
FILTER
1. INLET 3. TO OIL COOLER 5. FILTER 7. CONDITION INDICATOR

2. TO RESERVOIR 4. FROM STEERING CONTROL VALVE 6. FILTER BYPASS VALVE 8. COOLER BYPASS VALVE

7
6
5
4
8
2 3 1
4
4
7
2 1
5 6
BC05F007/BC00N172
STANDARD STEERING CONTROL VALVE
1. INLET 3. LOAD SENSE 5. SPOOL AND SLEEVE ASSEMBLY 7. GEROTOR 9. ANTI-CAVITATION

2. OUTLET 4. CHECK VALVE 6. DRIVE LINK 8. STEERING RELIEF VALVE CHECK VALVE

12
11 10 9
BC08B040

1 3
BC00N139
3
2
7
5 4
BC00H150
CLAM LOCK VALVE
1. CLAM CYLINDERS 4. TO CLAM CYLINDERS 6. PITON PISTON

2. CLAM LOCK VALVE 5. PILOT SIGNAL 7. CHECK VALVE CARTRIDGE
3. TO LOADER CONTROL VALVE
IMPORTANT: The clam control valve can be under pressure. See the Service Manual for instructions on releasing
pressure in the clam hydraulic circuit before disconnecting any hoses from the clam control valve.

5
7
9
2
6 1
8
3
4
BC05F011
7 8
1 4
3
6
5
BC05F027
BACKHOE AND LOADER QUICK COUPLER SINGLE VALVE
1. A PORT - TO RETRACT SIDE OF 4. TO TANK 7. 2 POSITION - 2 WAY SOLENOID VALVE TO

CYLINDER 5. PRESSURE PORT CONTROL PILOT PRESSURE
2. B PORT - TO EXTEND SIDE OF 6. LOAD SENSING PORT 8. 2 POSITION - 4 WAY SOLENOID VALVE TO
CYLINDER CONTROL CYLINDER
3. PRESSURE RELIEF VALVE 9. ORIFICE AND CHECK VALVE

5 1
8
7
9
2
3
8
6
4
BC05F012
7 8 8
2 2
1 1
3
4
6
5
BC05F028
BACKHOE AND LOADER QUICK COUPLER DUAL VALVE


FLOWMETER CHECK SHEET

NOTE: This flowmeter sheet can be used on 580M, 580SM, and 590SM machines with mechanical backhoe
controls only. For 580M only, skip 5a and 5b.
Owner:______________________________ Date:____________________________
Serial No:____________________________ Hours:___________________________
Stall Test
NOTE: Make sure that all systems are at operating temperature before testing is conducted.
Oil temperature at start of test:_________________ Oil temperature at end of test:__________________
1a. Low idle________________________________ rpm 1b. Full throttle (no load)______________________ rpm
1c. Converter stall___________________________ rpm 1d. Hydraulic stall (ldr)________________________ rpm
1e. Combined stall (converter/ldr)_______________ rpm
Relief Valve Test Engine at High Idle
2a. Loader relief begins to open @ ______________ psi 2b. Fully open @ _____________________ psi
Large Pump Section Efficiency Test @ 2000 rpm
3a. __________________ gpm @ minimum psi 3b. __________________ gpm @ 2000 psi
3b flow divided by 3a flow = xxx xxx multiplied by 100 =% efficiency large pump
Loader Control Valve Leakage Test @ 2000 rpm @ 2000 psi
4a. Loader raise _______________ gpm 4b. Loader lower _______________ gpm
4c. Bucket rollback _____________ gpm 4d. Bucket dump _______________ gpm
4e. Clam Open ________________ gpm 4f. Clam close _________________ gpm

Super M Section Pump Test @ 2000 rpm
5a. ________________________ gpm @ 300 psi 5b. _________________________ gpm @ 2000 psi
Pump Efficiency Calculation
Large pump Combined pumps
3a. ______gpm 5a. ______gpm minus 5a. ______gpm = 5d. _______gpm small pump
3b. ______gpm 5b. ______gpm minus 5b. ______gpm = 5c. _______gpm small pump
3b flow divided by 3a flow = xxx 5d flow divided by 5c flow = xxx
xxx multiplied by 100 =% efficiency large pump xxx multiplied by 100 =% efficiency small pump
Backhoe Control Valve Leakage Test @ 2000 rpm
6a. Swing left __________________________ gpm 6b. Swing right _________________________ gpm
6c. Extend-a-hoe out ____________________ gpm 6d. Extend-a-hoe in _____________________ gpm
6e. Left stabilizer raise __________________ gpm 6f. Right stabilizer raise __________________ gpm
6g. Left stabilizer lower __________________ gpm 6h. Right stabilizer lower _________________ gpm
6i. Bucket dump ________________________ gpm 6j. Bucket curl __________________________ gpm
6k. Dipper out __________________________ gpm 6l. Dipper in ____________________________ gpm
6m. Boom lower ________________________ gpm 6n. Boom raise__________________________ gpm
6o. Auxiliary forward ____________________ gpm 6p. Auxiliary reverse _____________________ gpm
Steering/Bucket Lock Valve Flow Test High Idle
7a. Steering stand by ____________________ psi
7b. Steering relief begins to open @ ________ psi 7c. Fully open @ ________________________ psi
7d. Coupler relief begins to open @ _________ psi 7e. Fully open @ ________________________ psi
Steering/Bucket Lock Valve Leakage Test @ 2000 rpm @ 1800 psi
8a. Steering right ________________________ gpm 8b. Steering left _________________________ gpm
8c. Loader bucket retract __________________ gpm 8d. Loader bucket extend _________________ gpm
8e. Backhoe bucket retract ________________ gpm 8f. Backhoe bucket extend ________________ gpm

8002
Section
8002

580M AND 580SM SERIES 3 WITH PILOT CONTROLS

8002-2 580M AND 580SM SERIES 3 WITH PILOT CONTROLS
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in a Backhoe Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Single Function Will Not Work Independently From Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Intermittent Stabilizer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pilot Functions Continue After Release of Handle or Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Noise From the Backhoe Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
All Pilot Controls Stop Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pilot Pattern Change Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fault Codes for Pilot Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
580SM Pump Output Test Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
580M Pump Output Test Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pilot Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Loader Relief and Backhoe Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Large Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Small Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Steering and Bucket Lock Valve Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Steering and Bucket Lock Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
RELIEF VALVE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Loader Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Backhoe Circuit Relief Valves for Bucket, Swing, Boom, Dipper, and Backhoe Auxiliary Hydraulics . . . . . . . 24
Load Sense Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
580SM Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
580M Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Clam Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Backhoe or Loader Quick Coupler Single Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Backhoe And Loader Quick Coupler Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pilot Manifold Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

580M AND 580SM SERIES 3 WITH PILOT CONTROLS 8002-3
SPECIFICATIONS
Output of Hydraulic Pump 580M ..........................................................................108 L/min at 207 bar at 2200 r/min
Front section.......................................................................................................36 L/min at 207 bar at 2200 r/min
Pressure Settings
Loader main relief valve 1st stage............................................................................... 210 ± 3 bar (3050 ± 50 psi)
Loader main relief valve 2nd stage ....................................................................248 to 276 bar (3600 to 4000 psi)
Load sense relief valve................................................................................................ 210 ± 3 bar (3050 ± 50 psi)
Pilot pressure ..........................................................................................................24 to 34.5 bar (350 to 500 psi)
Quick coupler ........................................................................................................... 189.5 ± 3 bar (2750 ± 50 psi)
Auxiliary (Bi-directional) .....................................................................................219 to 225 bar (3176 to 3263 psi)
Backhoe bucket A (upper) port.................................................................................... 262 ± 3 bar (3800 ± 50 psi)
Backhoe bucket B (lower) port .................................................................................... 221 ± 3 bar (3205 ± 50 psi)
Swing A (upper) and B (lower) ports ........................................................................... 207 ± 3 bar (3000 ± 50 psi)
Boom A (upper) port.................................................................................................... 221 ± 3 bar (3205 ± 50 psi)
Boom B (lower) port ................................................................................................... 331 ± 3 bar (4800 ± 50 psi)
Dipper A (upper) port and B (lower) port..................................................................... 238 ± 3 bar (3450 ± 50 psi)
Pilot Manifold Accumulator (Nitrogen charge) ....................................................................... 7 ± 1 bar (100 ± 15 psi)

SPECIAL TOOLS
B785789M BD05G002
CAS-10280 FLOWMETER. 1. PRESSURE PORT 3. CIRCUIT RELIEF VALVES
2. TANK PORT
380002493 TEST BLOCK REXROTH ONLY
B797157M
CAS-1808 FLOWMETER FITTING KIT.
B877895M
CAS-10090 HAND PUMP.
B877558U
CAS-1804 PRESSURE FITTING KIT.
94L95
CAS-10899 NITROGEN CHARGING KIT

Visual Check
No
Yes
See Section 9001 and check the loader

Heat the oil in the hydraulic system to
linkages, check for ease of movement of the
operating temperature. Operate the
pilot controls. No
machine to find which circuits have
problems.
Does the machine operate correctly?
Yes

No Adjust the main relief valve.
correct?
Yes
Yes

Yes

No See the following topics for other circuits.
Yes

Problem in a Loader Circuit

parts. If equipped with ride control, make
sure the ride control button is in the OFF
position.
Check the operation of the problem circuit. Check for operation of the spool in both
No
Do the cylinder(s) move in both directions? directions. Is the spool operation correct?
No

Y es valve for damage. Repair or replace the
spool or valve as necessary.

No Adjust the main relief valve.
correct?
Yes

Yes
Check the setting of the circuit relief valve,

if used, for the problem circuit. Is the setting No Replace the circuit relief valve.
correct?
Yes
No
Yes

as necessary.


Yes

Yes

reading of5.4 Ohm at 20° C (68° F) should No Replace solenoids.
Yes

Yes

clam drop?
Yes

Yes
No

Problem in a Backhoe Circuit

position.
Operations slow or not working correctly.
Check pilot pressure at pilot control

Replace the pressure reducing catridge. Is
manifold. Reading should be 350 to 500 psi No
the pressure correct?
(24 to 34.5 bar). Is pilot pressure correct?
No
Remove and inspect the check valve and

Y es
orifice. Refer to section 8015.
Remove and examine for contamination

Inlet compensator stuck open. Does jamming the valve open. If contaminated
No
compensator move freely? replace compensator. Clean hydraulics,
refer to section 8003.
Yes
Load sensing relief not set correctly or

contaminated. Take pressure reading at “M”
Adjust the LS relief setting. If relief cannot
port on backhoe valve by operating a No
be achieved, replace the LS relief valve.
stabilizer over relief. Is the pressure setting
correct, 3000 to 3100 psi (207 to 214 bar)?
Yes

if used, for the problem circuit. Is the setting No Replace the circuit relief valve.
correct?
Yes
Low pilot pressure at backhoe valve pilot

Is the function controlled by the hydraulic
port for the specific function. Reading
No joystick or by an electrically controlled
should be 350 to 500 psi (24 to 34.5 bar). Is
solenoid?
the pilot pressure correct?
Yes Hydraulic Electrical
Continued Continued Continued

Hydraulic
If pressure is less than 350

psi (24 bar) and pilot
pressure at the pilot
manifold pressure is OK,
Electrical
replace the joystick control
valve. If the problem is not
fixed replace the pressure
Yes reduction manifold.
Check the electronic control-

ler for error codes, repair
faults. If the problem is not
reduction manifold.
Remove the end cap of the pilot spool

Replace the valve section. See section
chamber and check that the spool moves No
8007.
freely. Does the spool move freely?
Yes
NOTE: Boom cylinder only. A check valve is

installed in the piston. The problem in the
Check the cylinder piston packing. Is the boom circuit can be the check valve instead of
No
cylinder piston packing good the cylinder piston packing.
necessary.

Single Function Will Not Work Independently From Other Functions

Sectional pressure compensator plugged or Replace sectional compensator or valve
jammed. section. See section 8007.
Intermittent Stabilizer Operation

Operating stabilizers too soon after Make sure that the electronic controls are in
powering up the system. Is operator waiting the neutral position when placing the pilot
No
1 to 2 seconds before operating the stabilizers system switch to the “ON” position.
after powering up the system?
Yes
Check the connectors at the proportional

control solenoids and switches for good No Repair connectors.
contacts. Are the contacts good?
Yes
Check proportional control valves for sticking. NOTE: Check for operation within the 6 small
Remove the solenoid, attach a 12V system holes in the stem. There is only a slight
to the solenoid connectors. Connect and movement of the plunger.
No
disconnect power while watching for
plunger movement. Does the plunger Replace the solenoid.
move?

Pilot Functions Continue After Release of Handle or Switch

Examine swivel mechanism. Are the swivel If shafts are bent ore knuckles are distorted,
No
shafts or the knuckle joints undamaged? replace swivel assembly.
Yes
If solenoids have power but are not returning

Do electrically controlled component
to neutral, replace control solenoids, if
operations stop after release of switch, No
solenoids do not have power, replace the
stabilizer, extend-a-hoe, auxiliary hydraulics?
switch.
Yes
Pull up the boot on the handle, examine Disassemble pilot control handles, see
valves for free movement. Check with section 8014, and check for defects or
machine off then check with machine on and No contamination. If contaminated, clean,
pilot controls energized. Do spools return to reassemble and test, if defects found, replace
neutral freely? handle assembly.
Yes
Connect a tee into the pilot circuit that is not

returning to neutral, attach a 1000 psi (70 bar)
gauge. Full stroke the function and record No If pressure does not drop to 0 to 6 psi
pressure, release the function. Does pressure (0 to 0.4 bar) replace the control handle.
drop instantaneously?
Yes
Remove spool and check for contamination,

Remove pilot spool end cap. Does spool clean the components, reassemble and
No
move freely? test. If defects are found replace defective
components.
Yes
Remove pilot spool end cap. Are spool If defects are found replace defective
No
centering springs free of defects? components.

Noise From the Backhoe Hydraulic System

Air in the pilot system or system pressure is
low. See procedures below for bleeding air
Does the system operate normally without from the pilot system.
No
noise? NOTE: This is common as not all of the air
will be worked out of the system during
testing at the factory or system repair.
Crack open the pilot lines on the pilot end caps at the backhoe valve, operate each function until no air spits or
bubbles out of the lines.
Start the machine and operate the backhoe, fully stroking each function back and forth. Continuously operate
the systems until the oil is at operating temperature. If noise persists, shut down the machine and allow to cool
and repeat the procedure.
Low pilot pressure will not fully shift the

spool. Reading should be 350 to 500 psi (24 No Replace the pressure reducing catridge.
to 34.5 bar). Is the pilot pressure correct?
All Pilot Controls Stop Working

Check fuse. Is the fuse serviceable? No Replace the fuse.
Yes
Check relay for proper connection. Is the No Reconnect relay.

relay properly connected?
Yes
Check enable switch for proper connection.

No Reconnect enable switch.
Is the enable switch properly connected?

Pilot Pattern Change Does Not Function

NOTE: Pattern change problems will only
affect boom and dipper functions.
Check for power to the switch, if power is

Change the switch from #1 setting to the #2 present change the switch, if no power is
No
setting. Does pattern change light illuminate? present see section 4001 for electrical
troubleshooting.
Yes
Disconnect the pattern change solenoids and

check for power. Is there power at both of the No Check wiring and connectors.
pattern change solenoids?
Yes
Remove and check O-rings on solenoids. Are

No Replace O-rings.
O-rings serviceable?
Yes
Check the torque on the solenoid coil

mounting nuts, torque should be 15 to 20 lb-in
Swap the solenoids and check operation. (1.7 to 2.2 Nm).
No
Did bad operation reverse?
NOTE: Overtorquing will cause the solenoid
to bind and stick.
Yes
Replace the solenoids.

Fault Codes for Pilot Controller

NOTE: Pilot controller is located above and to the left hand side of the rear axle, codes will flash on 0.25
seconds, off 0.25 seconds and will pause for 2 seconds between codes.
Fault code 1: Stabilizer, extend-a-hoe or

auxiliary hydraulics control shorted to ground .
or open circuit.
Check wiring from stabilizer, extend-a-hoe or

auxiliary control to module, is there still a No Troubleshooting complete.
problem?
Yes
Test solenoids, 5.5 Ohms at 68° F (20° C),

replace as needed. Is there still a problem?
Yes
Replace control module.

.
auxiliary hydraulics control shorted to Vbat.

problem?
Yes
Fault code 3: Interlock for stabilizer,

.
extend-a-hoe or auxiliary hydraulics controls.
Check that all function switches are in the off

position or are not depressed, turn the pilot
power off and back on. Is there still a
problem?
Yes
Test Is there still a problem? No Troubleshooting complete.
Yes

Fault code 4: Driver fault. .

problem?
Yes

Yes
Fault light on with no blink. .
Replace control module, is there still a

problem?
Yes
Call technical support.
Fault light off. .
No power to module or faulty control module.
Check fuse and pilot control relay, is there still

a problem?
Yes

2
4
BC04A201
1. CAP FOR TEST PORT “M” 9/16-18 37 DEGREE 3. LOAD SENSE RELIEF VALVE
2. PILOT MANIFOLD TEST PORT 4. CONTROL MODULE
NOTE: Connect a gauge capable of 5000 psi (345 bar) to “M” port (1), use adapter 101792A1, and one to the “EF”
port on the pump. Connect a gauge capable of 1000 psi (69 bar) to the pilot manifold pressure test port (2).
ATTENTION: If at anytime during testing you need to change pressure gauge locations, stop the engine, place the
ignition switch and pilot control switch to the on position, operate pilot controls and loader controls to relieve any
pressure in the system prior to disconnecting gauges.
1
2
3
BD05E482 BD05E483
NOTE: Tee connection for pilot pressure tests at end 3. PRESSURE REDUCING
1. ORIFICE 2. CHECK VALVE
caps. CARTRIDGE
NOTE: When installing check valve (2), make sure
the small ring of holes face away from the pressure
reducing cartridge (3).

SYSTEM TESTING
2
1 3
6
11
7
5
10
9 4
8
BC04C128
580SM PUMP OUTPUT TEST HOSE CONNECTIONS
1. PUMP 5. LOADER VALVE 9. “CF” PORT OUTPUT HOSE

2. “EF” PRESSURE TEST PORT 6. FLOWMETER OUTLET HOSE 10. “T” FITTING
3. FLOWMETER INLET HOSE 11.
7. CAP
CONNECTION FOR LARGE PUMP
SECTION 8. FLOWMETER INLET HOSE
CONNECTION FOR “CF” PORT
4. FLOWMETER
HOSE. Use cap (7) to cap “T” fitting during “CF” port flow test.

3
6 7
4
BC04C127
580M PUMP OUTPUT TEST HOSE CONNECTIONS
1. PUMP 4. FLOWMETER 7. CAP

2. “EF” PRESSURE TEST PORT 5. LOADER VALVE 8. NOT USED
3. FLOWMETER INLET HOSE 6. FLOWMETER OUTLET HOSE 9. “CF” PORT
HOSE.
NOTE: Make copies of the Flowmeter Check Sheet ● Remove pressure testing adapter from pump EF
in the rear of this section and use it to record the port (2), connect flowmeter input hose (3) to the
readings. fitting.
● Remove screen from reservoir and secure the
Machine Preparation flowmeter return hose (6) below oil level.
● Park the machine on a level surface. Put the ● The oil must be at operating temperature. To heat
backhoe in the transport position and lower the the oil, do the following steps:
A. With the engine running at full throttle, close
● Stop the engine, turn on the ignition switch and the relief valve on the flowmeter to at least
pilot control switch, operate pilot controls and 1500 psi (103.4 bar).
loader controls to relieve any pressure in the
B. Hold the loader control lever in the
system.
ROLLBACK position for 15 seconds.
● Connect a gauge capable of 1000 psi (69 bar) to
C. Put the loader control lever in the NEUTRAL
the pilot pressure test port.
● Using a 9/16-18 quick coupler fitting, part number
D. Repeat steps A and B until the temperature of
101792A1, connect a gauge capable of 5000 psi
(345 bar) to the “M” port on the backhoe valve.

Stall Test ● Slowly close the load valve on the flowmeter
observing the flow.
● Refer to section 2002 and perform an engine stall
test, record the results on line 1a through 1e on ● Record the pressure when the flow drops
check sheet. dramatically by several gpm (L/min). Record this
reading on line 3c on check sheet.
Pilot Manifold Pressure Test 3d
Test 2a ● Continue to close the load valve on the flowmeter
● Start and run the engine at low idle, do not activate observing the flow.
any backhoe controls. Record this reading on line ● When flow reaches 0 gpm (l/min), a pressure
2a on check sheet. reading of 3000 to 3100 psi (207 to 214 bar)
should be obtained. Record this reading on line 3d
NOTE: A pressure reading of 225 to 300 psi (15.5 to
on check sheet.
20.5 bar) should be obtained. If pressure is not as
specified, replace the priority spring in the pump. See NOTE: If 3c reading is not within 10% of the 3d
section 8004 for 580M or 580SM. reading, replace the load sense relief valve cartridge.
Test 2b
Large Pump Efficiency
● Enable the backhoe pilot system switch.
Test 4a
● Place any backhoe function on demand. Record
this reading on line 2b on check sheet. ● Holding the loader on demand open the load valve
and adjust engine to 2000 rpm (r/min), read the
NOTE: A pressure reading of 350 to 500 psi (24 to flow gauge and record the reading. Record this
34.5 bar) should be obtained. If pressure is not as reading on line 4a on check sheet.
specified, replace pressure reducing valve. See
section 8015. Test 4b
Loader Relief and Backhoe Relief Slowly close the load valve until the pressure is
● Run the engine at high idle. Raise the loader and 2000 psi (138 bar), read the flow gauge and record
hold in the raised position. the reading. Record this reading on line 4b on
check sheet.
● Slowly open the load valve on the flowmeter until
● Divide the flow reading at 2000 psi (138 bar) by the
the pressure reading is zero.
flow reading at 0 psi.
Test 3a
NOTE: This answer multiplied by 100 is the percent
● Slowly close the load valve on the flowmeter efficiency of the pump. If the efficiency of the large
observing the flow. pump is less than 70 percent, repair or replace the
● Record the pressure when the flow drops pump before continuing. If the efficiency of the pump
dramatically by several gpm (L/min). Record this is more than 70 percent, the pump is good.
reading on line 3a on check sheet.
Test 3b Loader Control Valve Leakage
● Continue to close the load valve on the flowmeter ● Continue to run the engine at 2000 rpm (r/min) and
observing the flow. increase pressure on flowmeter to 2000 psi (138
bar).
● When flow reaches 0 gpm (l/min), a pressure
reading of 3000 to 3100 psi (207 to 214 bar) Test 5a
should be obtained. Record this reading on line 3b ● Hold the loader in the raised position. Record gpm
on check sheet. (l/min) on line 5a on check sheet.
NOTE: If pressure is not as specified adjust main Test 5b
relief valve. If 3a reading is not within 10% of the 3b
● Lower the loader and hold the loader in the lower
reading, replace the relief valve.
position. Record gpm (l/min) on line 5b on check
Test 3c sheet.
NOTE: Test 3c and 3d, measure these pressures at
the backhoe “M” port.
● Fully open load valve on flowmeter. Curl the
backhoe bucket and hold in the curled position.
Test 5c Test 7b
● With the loader approximately eighteen inches ● Swing the backhoe to the right. Record gpm (l/min)
from the ground, hold the bucket in the rollback on line 7b on the check sheet.
position. Record gpm (l/min) on line 5c on check
Test 7c
sheet.
● If equipped, extend and hold the extend-a-hoe out.
Test 5d Record gpm (l/min) on line 7c on the check sheet.
Test 7d
(l/min) on line 5d on check sheet.
● Retract and hold the extend-a-hoe in. Record gpm
Test 5e (l/min) on line 7d on the check sheet.
● Hold the clam in the open position. Record gpm
Test 7e
(l/min) on line 5e on check sheet.
● Raise the left stabilizer. Record gpm (l/min) on line
Test 5f 7e on the check sheet.
● Close and hold the clam in the closed position.
Test 7f
Record gpm (l/min) on line 5f on check sheet.
● Raise the right stabilizer. Record gpm (l/min) on
NOTE: If flow reading between test 4b and test 5a line 7f on the check sheet.
through test 5f varies more that 1 gpm (3.8 l/min)
there is a problem in that circuit. Test 7g
NOTE: During stabilizer lower test, evenly lower both
Small Pump Efficiency stabilizers to full stroke and raise the machine.
NOTE: Test 6a and 6b are for SM machines only. ● Lower the left stabilizer. Record gpm (l/min) on line
● Continue to run engine at 2000 rpm (r/min) and 7g on the check sheet.
hold the backhoe bucket on demand. Test 7h
Test 6a ● Lower the right stabilizer. Record gpm (l/min) on
● Close the load valve on flowmeter to 300 psi (20.5 line 7h on the check sheet.
bar). Record gpm (l/min) on line 6a on the check Test 7i
sheet.
Test 6b Record gpm (l/min) on line 7i on the check sheet.
● Continue to run the engine at 2000 rpm (r/min). Test 7j
2000 psi (138 bar). Record gpm (l/min) on line 6b
gpm (l/min) on line 7j on the check sheet.
on the check sheet.
● Use pump efficiency calculation on the Flowmeter Test 7k
Check Sheet to calculate the small pump ● Hold the dipper in the full extended position.
efficiency. Record gpm (l/min) on line 7k on the check sheet.
NOTE: If the efficiency of the small pump is less Test 7l
than 70 percent, repair or replace the pump. If the ● Hold the dipper in the full in position. Record gpm
efficiency of the pump is more than 70 percent, the (l/min) on line 7l on the check sheet.
pump is good.
Test 7m
Backhoe Control Valve Leakage ● Hold the boom in the lower position. Record gpm
● Continue to run the engine at 2000 rpm (r/min) and (l/min) on line 7m on the check sheet.
the flowmeter at 2000 psi (138 bar). Hold each Test 7n
function on demand at the end of the stroke.
● Hold the boom in the raise position. Record gpm
NOTE: If equipped with uni-directional valve, the (l/min) on line 7n on the check sheet.
valve must be off.
Test 7a
● Swing the backhoe to the left. Record gpm (l/min)
on line 7a on the check sheet.

Test 7o Test 8d
● If equipped with bi-directional auxiliary hydraulics, ● Fully open the load valve on the flowmeter.
ATTENTION: When performing the loader bucket or
hold the button in the out position. Record gpm
backhoe bucket coupler test, keep all personnel clear
(l/min) on line 7o on the check sheet.
of the area.
Test 7p ● Extend the backhoe bucket all the way to the dump
● Reverse directions on the bi-directional valve. position. Place the loader and the backhoe bucket
Record gpm (l/min) on line 7p on the check sheet. on the ground.
NOTE: If flow reading between test 6b and tests 7a ● If equipped, engage the front or rear hydraulic
through 7p varies more that 1 gpm (3.8 l/min) there is coupler, slowly close the load valve on the
a problem in that circuit. flowmeter observing the flow.
● When the flow drops dramatically by several gpm
Steering and Bucket Lock Valve Flow (L/min) record the pressure on line 8d on the
● Open the flowmeter and stop the engine. Remove check sheet.
the caps and plugs and reconnect the auxiliary Test 8e
hydraulics.
● Continue to close the load valve on the flowmeter
NOTE: Reconnecting hoses is only required for SM observing the flow.
machines. Refer to illustration on page 17. ● When flow reaches 0 gpm (l/min), record the
● Disconnect flowmeter inlet from port EF and place pressure on line 8e on the check sheet.
test adapter (2) on fitting.
NOTE: A pressure reading of 2700 to 2800 psi (186
● Disconnect hose from “T” fitting (10). Place a cap to 193 bar) should be obtained. If pressure is not as
(7) onto the “T” fitting and connect the “CF” specified adjust quick coupler relief valve.
pressure hose (9) to the flowmeter inlet hose (8).
Test 8a Steering and Bucket Lock Valve Leakage
● Start and run engine at high idle close the load ● Holding the steering wheel against the left stop,
valve on the flowmeter. Record the pressure close the load valve on the flowmeter to a reading
reading on line 8a on the check sheet. of 1800 psi (124 bar), adjust engine rpm to 2000.
NOTE: A pressure reading of 172 +0 -10 bar (2500 Test 9a

+0 -150 psi) should be obtained. ● Turn the steering wheel to full right. Record gpm
Test 8b (l/min) on line 9a on the check sheet.
● Turn the steering wheel full right and hold against Test 9b
the stop. ● Turn the steering wheel to full left. Record gpm
● Open the load restrictor on the flowmeter to a (l/min) on line 9b on the check sheet.
reading of 1000 psi (69 bar). ATTENTION: When performing the loader bucket or
● Holding the steering wheel against the stop, slowly backhoe bucket coupler test, keep all personnel clear
close the load valve observing the flowmeter. of the area.
● When the flow drops dramatically by several gpm ● Extend the backhoe bucket all the way to the dump
(L/min) record the pressure on line 8b of the check position. Place the loader and the backhoe bucket
sheet. on the ground.
Test 8c Test 9c
● Continue to close the load valve on the flowmeter ● Retract the loader lock pins. Record gpm (l/min) on
observing the flow. line 9c on the check sheet.
● When flow reaches 0 gpm (l/min), record the Test 9d
pressure on line 8c on the check sheet.
● Extend the loader lock pins. Record gpm (l/min) on
● Turn the steering wheel to the neutral position. line 9d on the check sheet.
NOTE: A pressure reading of 2050 to 2200 psi (141 Test 9e
to 152 bar) should be obtained.
● Retract the backhoe bucket lock pins. Record gpm
(l/min) on line 9e on the check sheet.

Test 9f ● Open the flowmeter and stop the engine. Conduct
● Extend the backhoe bucket lock pins. Record gpm any repairs needed and retest that circuit.
(l/min) on line 9f on the check sheet. ● Remove all test equipment from the machine and
reconnect all hydraulic systems. Check hydraulic
NOTE: If any flow readings between tests on a
level, add hydraulic fluid as required.
circuit varies more that 1 gpm (3.8 l/min) there is a
problem in that circuit.

RELIEF VALVE TESTS
Loader Main Relief Valve Adjustment

NOTE: Pressure test port is located at the rear of the NOTE: Only the first stage of the pressure relief
pump. valve is adjustable, if second stage only is low
replace the pressure relief valve.
Pressure Check
1. The main relief valve is in the inlet section of the
1. Park the machine on a level surface. Put the loader control valve. Loosen the pipe on the
backhoe in the transport position and lower the fitting (1) and lock nut (3) on the main relief valve.
loader bucket to the floor. Turn the adjusting plug (2) clockwise to increase
2. The oil must be at operating temperature. To the pressure and counterclockwise to decrease
heat the oil, do the following steps: the pressure.
A. With the engine running at full throttle, hold NOTE: Thin wall wrenches will be needed to adjust
the loader control lever in the ROLLBACK this valve.
B. Put the loader control lever in the NEUTRAL
1
the oil is 125°F (51°C) or the side of the 2
reservoir is very warm. 3
3. Use a pressure gauge with a capacity of at least 4
27 580 kPa, 276 bar (4000 psi). Connect the
pressure gauge to the quick disconnect fitting at
Test Por t 1. The quick disconnect fitting is 5
located at the hydraulic pump.
6
4. Run the engine at full throttle. Hold the loader
control lever in the RAISE position until the
loader stops moving.
5. Hold the loader control lever in the RAISE
position and read the pressure gauge. Lower the
loader.
8 7
6. Compare the reading with the specification for
the 1st stage relief on page 3. If the reading is BC03M078
not correct, adjust the main relief valve.
1. FITTING 5. SPRING
7. Continue to run the engine at high idle and hold 2. ADJUSTING PLUG 6. BODY
the stabilizer circuit in the raised position. 3. JAM NUT 7. POPPET
4. PLUG 8. POPPET
8. While holding the stabilizer in the raised position,
2. Check the pressure again.
raise the loader read the pressure gauge.
3. If the main relief valve pressure is very low,
9. Release the stabilizer, lower the loader and
check the steering relief valve pressure. If it is
decrease the engine speed to low idle. Stop the
also low, do a pump flow test.
engine.
4. If the main relief valve pressure is very low, and
10. Compare the reading with the specification for
steering relief pressure is normal, repeat the
the 2nd stage relief on page 3. If the reading is
main relief test with backhoe bucket bottomed
not correct, adjust the main relief valve.
out. If the pressure goes up, inspect the check
valve in the loader valve inlet.
5. When the pressure is correct, tighten the lock
nut.

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
BC03N006
1. SWING SECTION 7. EXTEND-A-HOE SECTION 13. 238 ± 3 BAR (3450 ± 50 PSI)

2. BOOM SECTION 8. AUXILIARY HYDRAULICS SECTION 14. 238 ± 3 BAR (3450 ± 50 PSI)
3. LEFT STABILIZER SECTION 9. 207 ± 3 BAR (3000 ± 50 PSI) 15. 221 ± 3 BAR (3205 ± 50 PSI)
4. RIGHT STABILIZER SECTION 10. 207 ± 3 BAR (3000 ± 50 PSI) 16. 262 ± 3 BAR (3800 ± 50 PSI)
5. DIPPER SECTION 11. 331 ± 3 BAR (4800 ± 50 PSI) 17. 220 +5 -1BAR (3190 +72.5 -14.5 PSI)
6. BUCKET SECTION 12. 221 ± 3 BAR (3205 ± 50 PSI) 18. 220 +5 -1 BAR (3190 +72.5 -14.5 PSI)
Backhoe Circuit Relief Valves for Adjustment

Bucket, Swing, Boom, Dipper, and 1. Remove locking cover from circuit relief to be
Backhoe Auxiliary Hydraulics adjusted.
2. Loosen the lock nut on the adjusting screw.
Pressure Check
3. Turn the adjusting screw clockwise to increase
NOTE: If necessary, use fittings from the CAS-1804
the pressure setting or counterclockwise to
Pressure Fitting Kit to make the following
decrease the pressure setting.
connections:
4. Check the pressure setting again. When the
pressure setting is correct, tighten the lock nut
and install locking cover.
pressure gauge and the 380002493 test block to
the CAS-10090 hand pump. Replacement
2. Refer to illustration on page 4 and install the 1. Loosen and remove the circuit relief from the test
circuit relief valve in the test block. block.
3. Actuate the hand pump and record the highest 2. Lubricate the o-rings on the circuit relief valve
pressure reading. Check the pressure setting with clean oil.
3. Install the circuit relief valve in the valve section
4. Compare the reading with the specifications on bore.
page 3.
4. Torque the valve to 70 ± 7 Nm (51.5 ± 5 lb-ft).
5. If the pressure setting is not correct, adjust the

Load Sense Relief Valve Adjustment

Pressure Check 1. Remove locking cover from the load sense relief
valve.
1. Park the machine on a level surface. Put the
backhoe in the transport position and lower the 2. Loosen the lock nut on the adjusting screw.
loader bucket to the floor. 3. Turn the adjusting screw clockwise to increase
2. Stop the engine, turn on the ignition switch and the pressure setting or counterclockwise to
pilot control switch, operate pilot controls and decrease the pressure setting.
loader controls to relieve any pressure in the 4. Check the pressure setting again. When the
system. pressure setting is correct, tighten the lock nut
3. Connect a pressure gauge with a capacity of at and install locking cover.
least 345 bar (5000 psi) to the “M” port, use Replacement
adapter 101792A1, on the backhoe valve, see
page 16. 1. Loosen and remove the load sense relief valve.
4. The oil must be at operating temperature. To 2. Lubricate the o-rings on the load sense relief
heat the oil, do the following steps: valve with clean oil.
A. With the engine running at full throttle, hold 3. Install the load sense relief valve in the inlet
the loader control lever in the ROLLBACK section bore.
4. Torque the valve to 45.5 ± 4.5 Nm
B. Put the loader control lever in the NEUTRAL (33.5 ± 3.5 lb-ft).
5. Start and run the engine at high idle, hold a
stabilizer over relief, record the reading.
page 3.
load sense relief valve.

2
1
3
4
BC03N002
1. RIGHT SOLENOID VALVE FOR RIDE CONTROL (ACCUMULATOR) 4. TUBE FROM RIGHT SOLENOID VALVE TO ACCUMULATOR
2. LEFT SOLENOID VALVE FOR RIDE CONTROL (TANK) 5. ELBOW FITTING, REPLACE WITH ADJUSTABLE TEE FITTING
3. ACCUMULATOR (PART NUMBER 218-5286) FOR PRESSURE TEST- CONNECT
HOSE AND PRESSURE GAUGE HERE.
Right Solenoid Valve for Ride 3. Put the loader control lever in the NEUTRAL
position.
Control (Accumulator)
1. Make sure that the oil side of the accumulator is valve and the accumulator at the right solenoid
completely discharged by doing the following: valve.
A. Put the ride control switch in the ON position. 5. Remove the adjustable elbow fitting from the
B. Lower the loader to the floor. Put the loader right solenoid valve.
control lever in the float position. 6. Install an adjustable Tee fitting (part number
C. Stop the engine. Put the key switch in the ON 218-5286) in the right solenoid valve.
position. 7. Connect the tube from the accumulator to the
D. Move the loader control lever in all directions adjustable Tee fitting in the right solenoid valve.
to release any pressure in the hydraulic 8. Use a hose and fittings from the CAS-1804
circuits. Put the loader control lever in the float Pressure Fitting Kit or the CAS-1808 Flowmeter
position. Fitting Kit to make the following connections.
OFF position.

9. Connect a hose and a pressure gauge with a Left Solenoid Valve for Ride
capacity of at least 27 580 kPa, 276 bar (4000
Control (Tank)
solenoid valve. 1. Put the ride control switch in the ON position.
10. Put the ride control switch in the OFF position, 2. Move the loader control lever to the LOWER
start and run the engine at low idle. position until the loader bucket is on the floor,
11. Move the loader control lever to the RAISE continue to lower the loader bucket to raise the
position while you read the pressure gauge. The machine off the floor. The loader must not be
pressure gauge should read approximately 0 able to lift and hold the machine off the floor. If
kPa, 0 bar (0 psi). the loader can lift and hold the machine see
NOTE: If the pressure gauge indicates more than section 8009 and repair or replace the left
172 kPa, 1.7 bar (25 psi) see section 8009 and repair solenoid valve.
4. Put the ride control switch in the OFF position.
5. Move the loader control lever to the LOWER
14. Move the loader control lever to the RAISE position until the loader bucket is on the floor,
position while you read the pressure gauge. The continue to lower the loader bucket to raise the
pressure gauge should indicate approximately machine off the floor. The loader must be able to
3448 kPa, 34.5 bar (500 psi). lift and hold the machine off the floor. If the
NOTE: If the pressure gauge does not indicate loader cannot lift and hold the machine off the
approximately 3448 kPa, 34.5 bar (500 psi) see f l o o r s e e s e c t i o n 4 0 0 1 fo r e l e c t r i c a l
section 4001 for electrical troubleshooting or section troubleshooting or section 8009 and repair or
8009 and repair or replace the right solenoid valve for replace the left solenoid valve.
ride control. 6. If required, lower the machine to the floor.


C FLOAT position.
the ON position.
F position.
kit.
B
94L95 accumulator.
accumulator.
on gauge E.
position.
The pressure must be 2413 to 2580 kPa, 24 to 26 bar
(350 to 375 psi). If the pressure is too low, charge the
accumulator with dry nitrogen.

C 6. If the pressure increases above 2580 kPa, 26 bar
(375 psi), quickly open and close valve D and
read gauge E. If the pressure is still too high,
close valve A (turn counterclockwise) a small
F amount and quickly open and close valve D. The
pressure shown on gauge E is the charge
pressure.
B accumulator. Turn the stem into valve F until the
D A stem stops moving and open valve D to charge
94L95 the accumulator.
charging kit connected to the accumulator.
9. Close valve B and disconnect the nitrogen
pressure.
accumulator.
3. Turn the stem out of valve F until the stem stops and cap screws.
on the accumulator.
nitrogen tank.
SWING CUSHION VALVE
1. Make sure the hydraulic oil is at operating swing cushion valve. Install caps on the fittings
temperature, 52° C (125° F). and plugs in the hoses.
valve.

ILLUSTRATIONS
7 8
5
3
6
2 1
BC05F010
580SM HYDRAULIC PUMP
1. LARGE SECTION 4. INLET 7. EF PORT

2. SMALL SECTION 5. LOAD SENSING PORT 8. CF PORT
3. SMALL PUMP PORT 6. PRIORITY VALVE

3 2
4
5
BC05F009
580M HYDRAULIC PUMP
1. INLET 2. EF PORT 3. CF PORT 4. LOAD SENSING PORT 5. PRIORITY VALVE

8 2
7
3
4 5
1
6 8 7
1 2
4 3
5
BC05F008
FILTER


7
6
5
4
8
2 3 1
4
4
7
2 1
5 6
BC05F007/BC00N172


12
11 10 9
BC08B040

1 3
BC00N139
3
2
7
5 4
BC00H150
CLAM LOCK VALVE
1. CLAM CYLINDERS 4. TO CLAM CYLINDERS 6. CHECK VALVE OPEN SPOOL


5
7
9
2
6 1
8
3
4
BC05F011
7 8
1 4
3
6
5
BC05F027
BACKHOE OR LOADER QUICK COUPLER SINGLE VALVE
1. A PORT - TO RETRACT SIDE OF 4. TO TANK 7. 2 POSITION - 2 WAY SOLENOID VALVE TO CONTROL

CYLINDER 5. PRESSURE PORT PILOT PRESSURE
2. B PORT - TO EXTEND SIDE OF 6. LOAD SENSING PORT 8. 2 POSITION - 4 WAY SOLENOID VALVE TO CONTROL
CYLINDER CYLINDER

5 1
8
7
9
2
3
8
6
4
BC05F012
BACKHOE AND LOADER QUICK COUPLER SCHEMATIC
7 8 8
2 2
1 1
3
4
6
5
BC05F028
1. A PORT - TO RETRACT SIDE OF 4. TO TANK 7. 2 POSITION - 2 WAY SOLENOID VALVE TO CONTROL

CYLINDER 5. PRESSURE PORT PILOT PRESSURE
2. B PORT - TO EXTEND SIDE OF 6. LOAD SENSING PORT 8. 2 POSITION - 4 WAY SOLENOID VALVE TO CONTROL
CYLINDER CYLINDER

1 2
3 4 5 11
6 9
7
10 12
8 3 4 5 11
BC05F015
PILOT MANIFOLD SCHEMATIC
1. ACCUMULATOR 7. PRESSURE REDUCING VALVE

2. DIAGNOSTIC PORT 8. PILOT CONTROL ON OFF SOLENOID
3. RIGHT HAND STABILIZER 9. ORIFICE
4. LEFT HAND STABILIZER 10. CHECK VALVE
5. EXTEND-A-HOE 11. AUXILIARY HYDRAULICS
6. PATTERN SELECTION SOLENOIDS 12. SCREEN
NOTE: Early production machines were not equipped with a screen on items 3, 4, 5, and 11.


NOTE: This flowmeter sheet can be used on 580M and 580SM Series 3 with or without pilot controls. It can also
be used on the 590SM Series 3 with mechanical controlled backhoe.
For mechanical controlled backhoe machines skip 2a, 2b, 3c, and 3d. For 580M only, skip 6a and 6b.
Owner:______________________________ Date:____________________________
Serial No:____________________________ Hours:___________________________
Stall Test
Pilot/Flow Regulator Pressure Engine at Low Idle
2a. Flow regulator (stand by pressure)___________ psi 2b. Pilot pressure_____________________ psi
3c. Backhoe relief begins to open @ _____________ psi 3d. Fully open @ _____________________ psi
Large Pump Section Efficiency Test @ 2000 rpm

Super M Section Pump Test @ 2000 rpm
6a. ________________________ gpm 6b. _________________________ gpm
Pump Efficiency Calculation
Large pump Combined pumps
4a. ______gpm 6a. ______gpm minus 4a. ______gpm = 6d. _______gpm small pump
4b. ______gpm 6b. ______gpm minus 4b. ______gpm = 6c. _______gpm small pump
4b flow divided by 4a flow = xxx 6d flow divided by 6c flow = xxx
xxx multiplied by 100 =% efficiency large pump xxx multiplied by 100 =% efficiency small pump

8002
Section
8002

580SM+ AND 590SM+ SERIES 3

8002-2 580SM+ AND 590SM+ SERIES 3
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Visual Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Problem in a Loader Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem in a Backhoe Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Single Function Will Not Work Independently From Other Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Intermittent Stabilizer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pilot Functions Continue After Release of Handle or Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Noise From the Backhoe Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
All Pilot Controls Stop Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pilot Pattern Change Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fault Codes for Pilot Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pilot Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Backhoe Relief (Load Sense) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Steering and Bucket Lock Valve Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Steering and Bucket Lock Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Backhoe Valve Flow Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Low Pressure Standby Regulator Test #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Low Pressure Standby Regulator Test #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
RELIEF VALVE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Backhoe Circuit Relief Valves for Bucket, Swing, Boom, Dipper, and Backhoe Auxiliary Hydraulics . . . . . . . 24
Load Sense Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cutaway View of the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Clam Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Clam Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Backhoe or Loader Quick Coupler Single Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Backhoe And Loader Quick Coupler Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Pilot Manifold Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

580SM+ AND 590SM+ SERIES 3 8002-3
SPECIFICATIONS
Output of Hydraulic Pump 580SM+ ......................................................................150 L/min at 207 bar at 2200 r/min
(40 U.S. gpm at 3000 psi at 2200 rpm)
Output of Hydraulic Pump 590SM+ ......................................................................158 L/min at 207 bar at 2200 r/min
(42 U.S. gpm at 3000 psi at 2200 rpm)
Pressure Settings
Delta pressure at pump ................................................................................................ 20 ± 1 bar (290 ± 14.5 psi)
Minimum flow bypass valve .......................................................................................... 26 ± 1 bar (377 ± 14.5 psi)
Load sense relief valve................................................................................................ 210 ± 3 bar (3050 ± 50 psi)
Back pressure valve ........................................................................................................................5 bar (72.5 psi)
Backhoe pilot pressure............................................................................................24 to 34.5 bar (350 to 500 psi)
Clam control pilot pressure .....................................................................................24 to 34.5 bar (350 to 500 psi)
Quick coupler ........................................................................................................... 189.5 ± 3 bar (2750 ± 50 psi)
Auxiliary (Bi-directional) ................................................................................ 220 +5 -1 bar (3191 +72.5 -14.5 psi)
Backhoe bucket A (upper) port..................................................................... 260 +24 -1 bar (3770 +350 -14.5 psi)
Backhoe bucket B (lower) port ..................................................................... 240 +24 -1 bar (3480 +350 -14.5 psi)
Swing A (upper) and B (lower) ports ............................................................. 205 +5 -1 bar (2973 +72.5 -14.5 psi)
Boom A (upper) port.................................................................................. 195 +19 -1 bar (2828 +275.5 -14.5 psi)
Boom B (lower) port .................................................................................... 330 +29 -1 bar (4785 +420 -14.5 psi)
Dipper A (upper) port and B (lower) port...................................................... 240 +24 -1 bar (3480 +350 -14.5 psi)
Backhoe Pilot Manifold Accumulator (Nitrogen charge) ........................................................ 7 ± 1 bar (100 ± 15 psi)
Clam Control Manifold Accumulator (Nitrogen charge) ......................................................... 7 ± 1 bar (100 ± 15 psi)

8002-4 580SM+ AND 590SM+ SERIES 3
SPECIAL TOOLS
B785789M BD05G002
CAS10280 FLOWMETER. 1. PRESSURE PORT 3. CIRCUIT RELIEF VALVE
2. TANK PORT
380002493 TEST BLOCK FOR ADJUSTABLE RELIEFS ONLY
380100095 TEST BLOCK, (NOT SHOWN) FOR ADJUSTABLE
TEST RELIEFS AND NON ADJUSTABLE RELIEFS
B797157M
CAS1808 FLOWMETER FITTING KIT.
B877895M
CAS10090 HAND PUMP.
B877558U
CAS1804 PRESSURE FITTING KIT.
94L95
CAS10899 NITROGEN CHARGING KIT

580SM+ AND 590SM+ SERIES 3 8002-5
Visual Check
No
Yes
See Section 9001 and check the loader

Heat the oil in the hydraulic system to
linkages, check for ease of movement of the
operating temperature. Operate the
pilot controls. No
machine to find which circuits have
problems.
Does the machine operate correctly?
Yes

Yes

Yes

No See the following topics for other circuits.
Yes

8002-6 580SM+ AND 590SM+ SERIES 3
Problem in a Loader Circuit

position.
Check the operation of the problem circuit. Check for operation of the spool in both
No
Do the cylinder(s) move in both directions? directions. Is the spool operation correct?
No

Y es valve for damage. Repair or replace the
spool or valve as necessary.

Yes

if used, for the problem circuit. Is the setting No Adjust circuit reliefs.
correct?
Yes
No
Yes

damage. Repair or replace the individual
section or control valve as necessary.

580SM+ AND 590SM+ SERIES 3 8002-7

Yes

Yes

reading of 5.4 Ohm at 20° C (68° F) should No Replace solenoids.
Yes

Yes

clam drop?
Yes

Yes
No

8002-8 580SM+ AND 590SM+ SERIES 3
Problem in a Backhoe Circuit

position.
Operations slow or not working correctly.
Check pilot pressure at pilot control

Replace the pressure reducing catridge. Is
manifold. Reading should be 350 to 500 psi No
the pressure correct?
(24 to 34.5 bar). Is pilot pressure correct?
No
Remove and inspect the check valve and

Y es
orifice. Refer to section 8015.

To check the accumulator, extend the
dipper out from the machine so the weight
of the dipper is on the cylinder, curl the
bucket and hold under pressure for 30 No Replace the accumulator.
seconds. Stop the engine, turn the ignition
switch to accessory, activate the pilot
controls, pull the dipper control lever. Does
the dipper drop?
Yes
Remove and examine for contamination

Is the minimum displacement bypass valve jamming the valve open. If contaminated
No
stuck open. Does valve move freely? replace valve. Clean hydraulics, refer to
section 8003.
Yes
Load sensing relief not set correctly or

contaminated. Take pressure reading at “M”
Adjust the LS relief setting. If relief cannot
port on backhoe valve by operating a No
be achieved, replace the LS relief valve.
stabilizer over relief. Is the pressure setting
correct, 3000 to 3100 psi (207 to 214 bar)?
Yes

if used, for the problem circuit. Is the setting No Replace or adjust the circuit relief valve.
correct?
Yes
Continued

580SM+ AND 590SM+ SERIES 3 8002-9
Low pilot pressure at backhoe valve pilot

Is the function controlled by the hydraulic
port for the specific function. Reading
No joystick or by an electrically controlled
should be 350 to 500 psi (24 to 34.5 bar). Is
solenoid?
the pilot pressure correct?
Hydraulic
If pressure is less than 350

psi (24 bar) and pilot
pressure at the pilot
manifold pressure is OK,
Electrical
replace the joystick control
valve. If the problem is not
Yes reduction manifold.
Check the electronic control-

ler for error codes, repair
faults. If the problem is not
reduction manifold.
Remove the end cap of the pilot spool

Replace the valve section. See section
chamber and check that the spool moves No
8007.
freely. Does the spool move freely?
Yes
Check the boom section regenerative spool.

To check extend the boom out behind the
Replace the boom section in the backhoe
machine about 3 foot from the ground, with Yes
valve.
the engine at high idle raise the boom. Does
the boom go down slightly before raising?
No
Is engine load excessive when a hydraulic

function is stalled? (Pump does not
destroke) Adjust the pump compensator to 20 bar
Yes (290 PSI) and minimum displacement
NOTE: Oil that is cold, below 4° C (40° F),
bypass to 26 bar (377 PSI).
will have the same affect, heat hydraulic oil
according to instructions in the operators
manual.
No
NOTE: Boom cylinder only. A cushion relief

valve is installed in the piston. The problem in
Check the cylinder piston packing. Is the the boom circuit can be the cushion relief
No
cylinder piston packing good valve instead of the cylinder piston packing.
necessary.

8002-10 580SM+ AND 590SM+ SERIES 3
Single Function Will Not Work Independently From Other Functions

Sectional pressure compensator plugged or Replace sectional compensator or valve
jammed. section. See section 8007.
Intermittent Stabilizer Operation

Operating stabilizers too soon after Make sure that the electronic controls are in
powering up the system. Is operator waiting the neutral position when placing the pilot
No
1 to 2 seconds before operating the stabilizers system switch to the “ON” position.
after powering up the system?
Yes
Check the connectors at the proportional

control solenoids and switches for good No Repair connectors.
contacts. Are the contacts good?
Yes
Check proportional control valves for sticking. NOTE: Check for operation within the 6 small
Remove the solenoid, attach a 12V system holes in the stem. There is only a slight
to the solenoid connectors. Connect and movement of the plunger.
No
disconnect power while watching for
plunger movement. Does the plunger Replace the solenoid.
move?

580SM+ AND 590SM+ SERIES 3 8002-11
Pilot Functions Continue After Release of Handle or Switch

Examine swivel mechanism. Are the swivel If shafts are bent ore knuckles are distorted,
No
shafts or the knuckle joints undamaged? replace swivel assembly.
Yes
If solenoids have power but are not returning

Do electrically controlled component
to neutral, replace control solenoids, if
operations stop after release of switch, No
solenoids do not have power, replace the
stabilizer, extend-a-hoe, auxiliary hydraulics?
switch.
Yes
Pull up the boot on the handle, examine Disassemble pilot control handles, see
valves for free movement. Check with section 8014, and check for defects or
machine off then check with machine on and No contamination. If contaminated, clean,
pilot controls energized. Do spools return to reassemble and test, if defects found, replace
neutral freely? handle assembly.
Yes
Connect a tee into the pilot circuit that is not

returning to neutral, attach a 1000 psi (70 bar)
gauge. Full stroke the function and record No If pressure does not drop to 0 to 6 psi
pressure, release the function. Does pressure (0 to 0.4 bar) replace the control handle.
drop instantaneously?
Yes
Remove spool and check for contamination,

Remove pilot spool end cap. Does spool clean the components, reassemble and
No
move freely? test. If defects are found replace defective
components.
Yes
Remove pilot spool end cap. Are spool If defects are found replace defective
No
centering springs free of defects? components.

8002-12 580SM+ AND 590SM+ SERIES 3
Noise From the Backhoe Hydraulic System

Air in the pilot system or system pressure is
low. See procedures below for bleeding air
Does the system operate normally without from the pilot system.
No
noise? NOTE: This is common as not all of the air
will be worked out of the system during
testing at the factory or system repair.
Crack open the pilot lines on the pilot end caps at the backhoe valve, operate each function until no air spits or
bubbles out of the lines.
Start the machine and operate the backhoe, fully stroking each function back and forth. Continuously operate
the systems until the oil is at operating temperature. If noise persists, shut down the machine and allow to cool
and repeat the procedure.
Low pilot pressure will not fully shift the

spool. Reading should be 350 to 500 psi (24 No Replace the pressure reducing catridge.
to 34.5 bar). Is the pilot pressure correct?
All Pilot Controls Stop Working

Check fuse. Is the fuse serviceable? No Replace the fuse.
Yes
Check relay for proper connection. Is the No Reconnect relay.

relay properly connected?
Yes
Check enable switch for proper connection.

No Reconnect enable switch.
Is the enable switch properly connected?

580SM+ AND 590SM+ SERIES 3 8002-13
Pilot Pattern Change Does Not Function

NOTE: Pattern change problems will only
affect boom and dipper functions.
Check for power to the switch, if power is

Change the switch from #1 setting to the #2 present change the switch, if no power is
No
setting. Does pattern change light illuminate? present see section 4001 for electrical
troubleshooting.
Yes
Disconnect the pattern change solenoids and

check for power. Is there power at both of the No Check wiring and connectors.
pattern change solenoids?
Yes
Remove and check O-rings on solenoids. Are

No Replace O-rings.
O-rings serviceable?
Yes
Check the torque on the solenoid coil

mounting nuts, torque should be 15 to 20 lb-in
Swap the solenoids and check operation. (1.7 to 2.2 Nm).
No
Did bad operation reverse?
NOTE: Overtorquing will cause the solenoid
to bind and stick.
Yes
Replace the solenoids.

8002-14 580SM+ AND 590SM+ SERIES 3
Fault Codes for Pilot Controller

NOTE: Pilot controller is located above and to the left hand side of the rear axle, codes will flash on 0.25
seconds, off 0.25 seconds and will pause for 2 seconds between codes.

auxiliary hydraulics control shorted to ground .
or open circuit.

problem?
Yes

Yes

.
auxiliary hydraulics control shorted to Vbat.

problem?
Yes
Fault code 3: Interlock for stabilizer,

.
extend-a-hoe or auxiliary hydraulics controls.
Check that all function switches are in the off

position or are not depressed, turn the pilot
power off and back on. Is there still a
problem?
Yes
Test Is there still a problem? No Troubleshooting complete.
Yes

580SM+ AND 590SM+ SERIES 3 8002-15
Fault code 4: Driver fault. .

problem?
Yes

Yes
Fault light on with no blink. .
Replace control module, is there still a

problem?
Yes
Call technical support.
Fault light off. .
No power to module or faulty control module.
Check fuse and pilot control relay, is there still

a problem?
Yes

8002-16 580SM+ AND 590SM+ SERIES 3
SYSTEM TESTING
BC04A201
1. CAP FOR TEST PORT “M” 9/16-18 37 DEGREE 3. LOAD SENSE RELIEF VALVE
2. PILOT MANIFOLD TEST PORT 4. CONTROL MODULE
NOTE: Connect a gauge capable of 5000 psi (345 bar) to “M” port (1), use adapter 101792A1. Connect a gauge
capable of 1000 psi (69 bar) to the pilot manifold pressure test port (2).
ATTENTION: If at anytime during testing you need to change pressure gauge locations, stop the engine, place the
ignition switch and pilot control switch to the on position, operate pilot controls and loader controls to relieve any
pressure in the system prior to disconnecting gauges.

580SM+ AND 590SM+ SERIES 3 8002-17
1
2
3
BD05E482 BD05E483
NOTE: Tee connection for pilot pressure tests at 3. PRESSURE REDUCING

1. ORIFICE 2. CHECK VALVE
end caps. CARTRIDGE
NOTE: When installing check valve (2), make sure
the small ring of holes face away from the pressure
reducing cartridge (3).
BD08B038
NOTE: Tee connection for load sense pressure

tests.
BD08B039
NOTE: A Tee connection will have to be installed at

“D” port on the loader valve for steering and quick
coupler pressure tests. Fitting is 1/2 X 37° Fl.

8002-18 580SM+ AND 590SM+ SERIES 3
1 2 3 4
6
5
8
7
9
BC08B192
580SM+ AND 590SM+ PUMP OUTPUT TEST HOSE CONNECTIONS
1. LOAD SENSE HOSE 6. TO HYDAULIC FILTER

2. RETURN HOSE FROM LOADER VALVE 7. ATTENUATOR HOSE
3. PRESSURE TO BACKHOE VALVE 8. FITTING 1 1/16 X 12 X 37° JIC
4. ATTENUATOR HOSE TO HYDRAULIC PUMP 9. TEST ADAPTER
5. BACK PRESSURE CHECK VALVE
NOTE: Remove fitting (8) and connect the flow meter input hose to the attenuator hose.
HOSE.
NOTE: Make copies of the Flowmeter Check Sheet in the rear of this section and use it to record the readings.

580SM+ AND 590SM+ SERIES 3 8002-19
Machine Preparation Backhoe Relief (Load Sense)
● Park the machine on a level surface. Put the ● Run the engine at high idle. Raise the loader and
backhoe in the transport position and lower the hold in the raised position.
loader bucket to the floor. ● Slowly open the load valve on the flowmeter until
● Stop the engine, turn on the ignition switch and the pressure reading is zero.
pilot control switch, operate pilot controls and
Test 3a
system. ● Slowly close the load valve on the flowmeter
observing the flow.
the pilot pressure test port, see page 16. ● Record the pressure when the flow drops
dramatically by several gpm (L/min). Record this
● Using a 9/16-18 quick coupler fitting, part number
reading on line 3a on check sheet.
101792A1, connect a gauge capable of 5000 psi
(345 bar) to the “M” port on the backhoe valve, see Test 3b
page 16. ● Continue to close the load valve on the flowmeter
● Remove pressure testing adapter from the observing the flow.
attenuator hose, connect flowmeter input hose to ● When flow reaches 0 gpm (l/min), a pressure
the attenuator hose, see page 18. reading of 3000 to 3100 psi (207 to 214 bar)
● Remove screen from reservoir and secure the should be obtained. Record this reading on line 3b
flowmeter return hose below oil level. on check sheet.
● The oil must be at operating temperature. To heat NOTE: If pressure is not as specified adjust main
the oil, do the following steps: relief valve. If 3a reading is not within 10% of the 3b
A. With the engine running at full throttle, close reading, replace the relief valve.
the relief valve on the flowmeter to at least
1500 psi (103.4 bar). Pump Efficiency
B. Hold the loader control lever in the Test 4a
ROLLBACK position for 15 seconds.
● Holding the loader on demand open the load valve
C. Put the loader control lever in the NEUTRAL and adjust engine to 2000 rpm (r/min), read the
position for 15 seconds. flow gauge and record the reading. Record this
D. Repeat steps A and B until the temperature of reading on line 4a on check sheet.
the oil is 125°F (51°C) or the side of the Test 4b
Stall Test
2000 psi (138 bar), read the flow gauge and record
● Refer to section 2002 and perform an engine stall the reading. Record this reading on line 4b on
test, record the results on line 1a through 1e on check sheet.
check sheet.
● Divide the flow reading at 2000 psi (138 bar) by the
flow reading at 0 psi.
Pilot Manifold Pressure
NOTE: This answer multiplied by 100 is the percent
Test 2a efficiency of the pump. If the efficiency of the pump is
● Start and run the engine at low idle, do not activate less than 70 percent, repair or replace the pump
any backhoe controls. Record this reading on line before continuing. If the efficiency of the pump is
2a on check sheet. more than 70 percent, the pump is good.
Test 2b
● Enable the backhoe pilot system switch.
● Place any backhoe function on demand. Record
this reading on line 2b on check sheet.
NOTE: A pressure reading of 350 to 500 psi (24 to
34.5 bar) should be obtained. If pressure is not as
specified, replace pressure reducing valve. See
section 8015.

8002-20 580SM+ AND 590SM+ SERIES 3
Loader Control Valve Leakage Test 6e
● Continue to run the engine at 2000 rpm (r/min) and ● Raise the left stabilizer. Record gpm (l/min) on line
increase pressure on flowmeter to 2000 psi (138 6e on the check sheet.
bar). Test 6f
Test 5a ● Raise the right stabilizer. Record gpm (l/min) on
● Hold the loader in the raised position. Record gpm line 6f on the check sheet.
(l/min) on line 5a on check sheet. Test 6g
Test 5b NOTE: During stabilizer lower test, evenly lower
● Lower the loader and hold the loader in the lower both stabilizers to full stroke and raise the machine.
position. Record gpm (l/min) on line 5b on check ● Lower the left stabilizer. Record gpm (l/min) on line
sheet. 6g on the check sheet.
Test 5c Test 6h
● With the loader approximately eighteen inches ● Lower the right stabilizer. Record gpm (l/min) on
from the ground, hold the bucket in the rollback line 6h on the check sheet.
position. Record gpm (l/min) on line 5c on check
sheet. Test 6i
Test 5d
Record gpm (l/min) on line 6i on the check sheet.
(l/min) on line 5d on check sheet. Test 6j
Test 5e
gpm (l/min) on line 6j on the check sheet.
● Hold the clam in the open position. Record gpm
(l/min) on line 5e on check sheet. Test 6k
Test 5f ● Hold the dipper in the full extended position.

Record gpm (l/min) on line 6k on the check sheet.
● Close and hold the clam in the closed position.
Record gpm (l/min) on line 5f on check sheet. Test 6l
● Hold the dipper in the full in position. Record gpm
NOTE: If flow reading between test 4b and test 5a
through test 5f varies more that 1 gpm (3.8 l/min) (l/min) on line 6l on the check sheet.
there is a problem in that circuit. Test 6m
● Hold the boom in the lower position. Record gpm
Backhoe Control Valve Leakage (l/min) on line 6m on the check sheet.
● Continue to run the engine at 2000 rpm (r/min) and
Test 6n
the flowmeter at 2000 psi (138 bar). Hold each
function on demand at the end of the stroke. ● Hold the boom in the raise position. Record gpm
(l/min) on line 6n on the check sheet.
NOTE: If equipped with uni-directional valve, the
valve must be off. Test 6o
Test 6a ● If equipped with bi-directional auxiliary hydraulics,
● Swing the backhoe to the left. Record gpm (l/min)
hold the button in the out position. Record gpm
on line 6a on the check sheet.
(l/min) on line 6o on the check sheet.
Test 6b
Test 6p
● Swing the backhoe to the right. Record gpm (l/min)
● Reverse directions on the bi-directional valve.
on line 6b on the check sheet.
Record gpm (l/min) on line 6p on the check sheet.
Test 6c
NOTE: If flow reading between test 4b and tests 6a
● If equipped, extend and hold the extend-a-hoe out. through 6p varies more that 1 gpm (3.8 l/min) there is
Record gpm (l/min) on line 6c on the check sheet. a problem in that circuit.
Test 6d
● Retract and hold the extend-a-hoe in. Record gpm
(l/min) on line 6d on the check sheet.
580SM+ AND 590SM+ SERIES 3 8002-21
Steering and Bucket Lock Valve Flow ● When flow reaches 0 gpm (l/min), record the
pressure on line 7e on the check sheet.
NOTE: Install a “T” fitting at “D” port on the loader
valve, see page 17. Connect the flow meter to the “T” NOTE: A pressure reading of 2700 to 2800 psi (186
fitting. to 193 bar) should be obtained. If pressure is not as
specified adjust quick coupler relief valve.
Test 7a
● Start and run engine at high idle close the load Steering and Bucket Lock Valve Leakage
valve on the flowmeter. Record the pressure
● Holding the steering wheel against the left stop,
reading on line 7a on the check sheet.
close the load valve on the flowmeter to a reading
NOTE: A pressure reading of 200 to 250 psi (13.8 to of 1800 psi (124 bar), adjust engine rpm to 2000.
17.2 bar) should be obtained.
Test 8a
Test 7b ● Turn the steering wheel to full right. Record gpm
● Turn the steering wheel full right and hold against (l/min) on line 8a on the check sheet.
the stop.
Test 8b
● Open the load restrictor on the flowmeter to a
● Turn the steering wheel to full left. Record gpm
reading of 1000 psi (69 bar).
(l/min) on line 8b on the check sheet.
● Holding the steering wheel against the stop, slowly
close the load valve observing the flowmeter. ATTENTION: When performing the loader bucket
or backhoe bucket coupler test, keep all personnel
● When the flow drops dramatically by several gpm clear of the area.
(L/min) record the pressure on line 7b of the check
sheet.
position. Place the loader and the backhoe bucket
Test 7c on the ground.
● Continue to close the load valve on the flowmeter Test 8c
observing the flow.
● Retract the loader lock pins. Record gpm (l/min) on
● When flow reaches 0 gpm (l/min), record the line 8c on the check sheet.
pressure on line 7c on the check sheet.
Test 8d
● Turn the steering wheel to the neutral position.
● Extend the loader lock pins. Record gpm (l/min) on
NOTE: A pressure reading of 2500 +0 –150 psi (172 line 8d on the check sheet.
+0 –10 bar) should be obtained.
Test 8e
Test 7d
● Retract the backhoe bucket lock pins. Record gpm
● Fully open the load valve on the flowmeter. (l/min) on line 8e on the check sheet.
ATTENTION: When performing the loader bucket Test 8f
or backhoe bucket coupler test, keep all personnel
● Extend the backhoe bucket lock pins. Record gpm
clear of the area.
(l/min) on line 8f on the check sheet.
position. Place the loader and the backhoe bucket NOTE: If any flow readings between tests on a
on the ground. circuit varies more that 1 gpm (3.8 l/min) there is a
problem in that circuit.
● If equipped, engage the front or rear hydraulic
coupler, slowly close the load valve on the ● Open the flowmeter and stop the engine. Conduct
flowmeter observing the flow. any repairs needed and retest that circuit.
● When the flow drops dramatically by several gpm ● Remove all test equipment from the machine and
(L/min) record the pressure on line 7d on the reconnect all hydraulic systems. Check hydraulic
check sheet. level, add hydraulic fluid as required.
Test 7e
● Continue to close the load valve on the flowmeter
observing the flow.

8002-22 580SM+ AND 590SM+ SERIES 3
Backhoe Valve Flow Regulator Test Low Pressure Standby Regulator Test #2
● Connect a gauge capable of 1000 psi (69 bar) to ● With the engine off, lower the loader and bucket to
the attenuator hose test port, see page 18. Install the ground, move the control lever in all directions
a shut off valve in the hose. to relieve any pressure in the system.
● Disconnect the LS hose from the pump, install a ● Disconnect the bucket cylinder circuit hoses at the
“T” fitting with a test port connector. Connect a right hand loader pivot, cap the lines to the
gauge capable of 1000 psi (69 bar) to the load cylinder.
sense test port, see page 17. Install a shut off ● Loop the bucket circuit at the machine with a high
valve in the hose. pressure hose.
● Start engine and run at low idle, DO NOT activate ● Connect a gauge capable of 1000 psi (69 bar) to
any controls. the attenuator hose test port, see page 18. Install
Test 9a a shut off valve in the hose.
● Record the pressure at the end of attenuator hose, ● Disconnect the LS hose from the pump, install a
record the reading on line 9a. “T” fitting with a test port connector. Connect a
gauge capable of 1000 psi (69 bar) to the load
Test 9b sense test port, see page 17. Install a shut off
● Record the pressure at the load sense port, record valve in the hose.
the reading on line 9b. ● Start engine and run at low idle, activate the
● The difference in the pressure reading is the Bucket Rollback control.
backhoe valve flow regulator setting.
Test 11a
Low Pressure Standby Regulator Test #1 ● Record the pressure at the end of attenuator hose,
record the reading on line 11a.
the attenuator hose test port, see page 18. Install Test 11b
a shut off valve in the hose. ● Record the pressure at the load sense port, record
● Disconnect the LS hose from the pump, install a the reading on line 11b.
“T” fitting with a test port connector. Connect a ● The difference in the pressure reading is the Low
gauge capable of 1000 psi (69 bar) to the load Pressure Standby Pressure.
sense test port, see page 17. Install a shut off
valve in the hose.
● Start engine and run at low idle, activate the
Bucket Rollback control.
Test 10a
● Record the pressure at the end of attenuator hose,
record the reading on line 10a.
Test 10b
● Record the pressure at the load sense port, record
the reading on line 10b.
● The difference in the pressure reading is the Low
Pressure Standby Pressure.

580SM+ AND 590SM+ SERIES 3 8002-23
RELIEF VALVE TESTS
4
3 5
6
1 2 7 8
9 10 11
12 13 14 15 16 17 18 19 20 21
BS08A499
1. SWING SECTION 8. AUXILIARY HYDRAULICS SECTION 15. 195 +19 -1 BAR (2828 +275.5 -14.5 PSI)
2. BOOM SECTION 9. MINIMUM FLOW BYPASS VALVE 16. 240 +24 -1 BAR (3480 +350 -14.5 PSI)
3. LEFT STABILIZER SECTION 10. LOAD SENSE DRAIN ORIFICE 17. 240 +24 -1 BAR (3480 +350 -14.5 PSI)
4. RIGHT STABILIZER SECTION 11. LOAD SENSE RELIEF VALVE 18. 240 +24 -1 BAR (3480 +350 -14.5 PSI)
5. DIPPER SECTION 12. 205 +5 -1 BAR (2973 +72.5 -14.5 PSI) 19. 260 +24 -1 BAR (3770 +350 -14.5 PSI)
6. BUCKET SECTION 13. 205 +5 -1 BAR (2973 +72.5 -14.5 PSI) 20. 220 +5 -1BAR (3190 +72.5 -14.5 PSI)
7. EXTEND-A-HOE SECTION 14. 330 +29 -1 BAR (4785 +420 -14.5 PSI) 21. 220 +5 -1 BAR (3190 +72.5 -14.5 PSI)

8002-24 580SM+ AND 590SM+ SERIES 3
Backhoe Circuit Relief Valves for

2 Bucket, Swing, Boom, Dipper, and
1 Backhoe Auxiliary Hydraulics
Pressure Check
NOTE: If necessary, use fittings from the CAS1804
Pressure Fitting Kit to make the following
connections:
pressure gauge and the 380002493 test block to
the CAS10090 hand pump.
3
2. Refer to illustration on page 4 and install the
circuit relief valve in the test block.
3. Actuate the hand pump and record the highest
pressure reading. Check the pressure setting
page 3.
Adjustment
NOTE: Only the swing and auxiliary circuit relief
BC08B506 valves are adjustable. Adjustable relief valves are
1. FLOW REGULATOR available for the boom, dipper, and bucket sections
2. LOAD SENSE RELIEF for field service.
3. MINIMUM FLOW BYPASS VALVE
1. Remove locking cover from circuit relief to be
adjusted.
3. Turn the adjusting screw clockwise to increase
the pressure setting or counterclockwise to
decrease the pressure setting.
4. Check the pressure setting again. When the
pressure setting is correct, tighten the lock nut
Replacement
1. Loosen and remove the circuit relief from the test
block.
2. Lubricate the o-rings on the circuit relief valve
with clean oil.
3. Install the circuit relief valve in the valve section
bore.
4. Torque the valve to 70 ± 7 Nm (51.5 ± 5 lb-ft).

580SM+ AND 590SM+ SERIES 3 8002-25
Load Sense Relief Valve

Pressure Check 1
1. Park the machine on a level surface. Put the
backhoe in the transport position and lower the
loader bucket to the floor. 2
2. Stop the engine, turn on the ignition switch and
pilot control switch, operate pilot controls and
3
system.
3. Connect a pressure gauge with a capacity of at
least 345 bar (5000 psi) to the “M” port, use
adapter 101792A1, on the backhoe valve, see 4
page 16.
4. The oil must be at operating temperature. To 5
heat the oil, do the following steps:
A. Run the engine at full throttle, with the boom in 6
the travel lock position, hold the boom control
lever in the LOWER position (lever pushed 5
away from seat) for 15 seconds.
B. Put the boom control lever in the NEUTRAL
C. Repeat steps A and B until the temperature of 7
8
5. Start and run the engine at high idle, hold a
stabilizer over relief, record the reading.
6. Compare the reading with the specifications on 5
page 3.
load sense relief valve. BC08B025
1. ADJUSTING SCREW 5. O-RING

Adjustment 2. JAM NUT 6. SPRING
3. BODY PLUG 7. POPPET
1. Remove locking cover from the load sense relief 4. BODY 8. BACKUP RING
valve.
Replacement
3. Turn the adjusting screw clockwise to increase 1. Loosen and remove the load sense relief valve.
the pressure setting or counterclockwise to 2. Lubricate the o-rings on the load sense relief
decrease the pressure setting. valve with clean oil.
4. Check the pressure setting again. When the 3. Install the load sense relief valve in the inlet
pressure setting is correct, tighten the lock nut section bore.
4. Torque the valve to 45.5 ± 4.5 Nm
(33.5 ± 3.5 lb-ft).

8002-26 580SM+ AND 590SM+ SERIES 3
1
2
BC08B028
1. LEFT SOLENOID VALVE FOR RIDE CONTROL (TANK 4. TUBE FROM RIGHT SOLENOID VALVE TO ACCUMULATOR
2. RIGHT SOLENOID VALVE FOR RIDE CONTROL 5. ELBOW FITTING, REPLACE WITH ADJUSTABLE TEE FITTING
(ACCUMULATOR)) (PART NUMBER 218-5286) FOR PRESSURE TEST-
3. ACCUMULATOR CONNECT HOSE AND PRESSURE GAUGE HERE.

580SM+ AND 590SM+ SERIES 3 8002-27
Right Solenoid Valve for Ride 14. Move the loader control lever to the RAISE
position while you read the pressure gauge. The
Control (Accumulator) pressure gauge should indicate approximately
1. Make sure that the oil side of the accumulator is 3448 kPa, 34.5 bar (500 psi).
completely discharged by doing the following: NOTE: If the pressure gauge does not indicate
A. Put the ride control switch in the ON position. approximately 3448 kPa, 34.5 bar (500 psi) see
section 4001 for electrical troubleshooting or section
B. Lower the loader to the floor. Put the loader 8009 and repair or replace the right solenoid valve
control lever in the float position. for ride control.
position. Left Solenoid Valve for Ride
D. Move the loader control lever in all directions Control (Tank)
circuits. Put the loader control lever in the float
position. 2. Move the loader control lever to the LOWER
position until the loader bucket is on the floor,
continue to lower the loader bucket to raise the
OFF position.
machine off the floor. The loader must not be
3. Put the loader control lever in the NEUTRAL able to lift and hold the machine off the floor. If
position. the loader can lift and hold the machine see
section 8009 and repair or replace the left
valve and the accumulator at the right solenoid
solenoid valve.
valve.
5. Remove the adjustable elbow fitting from the
right solenoid valve. 4. Put the ride control switch in the OFF position.
6. Install an adjustable Tee fitting (part number 5. Move the loader control lever to the LOWER
218-5286) in the right solenoid valve. position until the loader bucket is on the floor,
continue to lower the loader bucket to raise the
7. Connect the tube from the accumulator to the
machine off the floor. The loader must be able to
adjustable Tee fitting in the right solenoid valve.
lift and hold the machine off the floor. If the
8. Use a hose and fittings from the CAS-1804 loader cannot lift and hold the machine off the
Pressure Fitting Kit or the CAS-1808 Flowmeter f l o o r s e e s e c t i o n 4 0 0 1 fo r e l e c t r i c a l
Fitting Kit to make the following connections. troubleshooting or section 8009 and repair or
replace the left solenoid valve.
9. Connect a hose and a pressure gauge with a
capacity of at least 27 580 kPa, 276 bar (4000 6. If required, lower the machine to the floor.
solenoid valve.
10. Put the ride control switch in the OFF position,
start and run the engine at low idle.
11. Move the loader control lever to the RAISE
position while you read the pressure gauge. The
pressure gauge should read approximately 0
kPa, 0 bar (0 psi).
NOTE: If the pressure gauge indicates more than
172 kPa, 1.7 bar (25 psi) see section 8009 and repair

8002-28 580SM+ AND 590SM+ SERIES 3

C FLOAT position.
the ON position.
F position.
kit.
B
94L95 accumulator.
accumulator.
on gauge E.
position.
The pressure must be 2413 to 2580 kPa, 24 to 26
bar (350 to 375 psi). If the pressure is too low, charge
the accumulator with dry nitrogen.

C 6. If the pressure increases above 2580 kPa, 26
bar (375 psi), quickly open and close valve D and
read gauge E. If the pressure is still too high,
close valve A (turn counterclockwise) a small
F amount and quickly open and close valve D. The
pressure shown on gauge E is the charge
pressure.
B accumulator. Turn the stem into valve F until the
D A stem stops moving and open valve D to charge
94L95 the accumulator.
charging kit connected to the accumulator.
9. Close valve B and disconnect the nitrogen
pressure.
accumulator.
3. Turn the stem out of valve F until the stem stops and cap screws.
on the accumulator.
nitrogen tank.
580SM+ AND 590SM+ SERIES 3 8002-29
SWING CUSHION VALVE
1. Make sure the hydraulic oil is at operating swing cushion valve. Install caps on the
temperature, 52° C (125° F). fittings and plugs in the hoses.
valve.

8002-30 580SM+ AND 590SM+ SERIES 3
ILLUSTRATIONS
5
2
1
8 7 6
6 2
BC08B683
HYDRAULIC PUMP
1. PORT M2 (NOT USED) 5. HIGH PRESSURE CUTOFF SPOOL (NOT USED)

2. OUTLET PORT 6. CASE DRAIN PORT
3. LOAD SENSE COMPENSATOR SPOOL 7. INLET PORT
4. LOAD SENSE PORT 8. CASE DRAIN OVERPRESSURE BYPASS VALVE

580SM+ AND 590SM+ SERIES 3 8002-31
BC08B684
CUTAWAY VIEW OF THE HYDRAULIC PUMP

8002-32 580SM+ AND 590SM+ SERIES 3
8 2
7
3
4 5
1
6 8 7
1 2
4 3
5
BC05F008
FILTER


580SM+ AND 590SM+ SERIES 3 8002-33
7
6
5
4
8
2 3 1
4
4
7
2 1
5 6
BC05F007/BC00N172


8002-34 580SM+ AND 590SM+ SERIES 3
12
11 10 9
BC08B040

580SM+ AND 590SM+ SERIES 3 8002-35
1 3
BC00N139
3
2
7
5 4
BC00H150
CLAM LOCK VALVE
1. CLAM CYLINDERS 4. TO CLAM CYLINDERS 6. CHECK VALVE OPEN SPOOL


8002-36 580SM+ AND 590SM+ SERIES 3
2 3
1
8
4
6
5
BS08B325
CLAM CONTROL VALVE
1. RETURN TO RESERVOIR 4. ACCUMULATOR 7. PRESSURE HOSE TO SPOOL

2. PRESSURE HOSE TO SPOOL 5. DRAIN HOSE FROM PILOT MANIFOLD 8. LOADER VALVE
3. PRESSURE TO CLAM MANIFOLD 6. CLAM CONTOL BLOCK

580SM+ AND 590SM+ SERIES 3 8002-37
5
7
9
2
6 1
8
3
4
BC05F011
7 8
1 4
3
6
5
BC05F027
BACKHOE OR LOADER QUICK COUPLER SINGLE VALVE


8002-38 580SM+ AND 590SM+ SERIES 3
5 1
8
7
9
2
3
8
6
4
BC05F012
BACKHOE AND LOADER QUICK COUPLER SCHEMATIC
7 8 8
2 2
1 1
3
4
6
5
BC05F028


580SM+ AND 590SM+ SERIES 3 8002-39
1 2
3 4 5 11
6 9
7
10 12
8 3 4 5 11
BC05F015
PILOT MANIFOLD SCHEMATIC


8002-40 580SM+ AND 590SM+ SERIES 3
NOTES

580SM+ AND 590SM+ SERIES 3 8002-41

NOTE: This flowmeter sheet can be used on 580SM+ and 590SM+ machines only.
Owner:______________________________ Date:____________________________
Serial No:____________________________ Hours:___________________________
Stall Test
Pilot/Flow Regulator Pressure Engine at Low Idle
2a. Flow regulator (stand by pressure)___________ psi 2b. Pilot pressure_____________________ psi
3c. Backhoe relief begins to open @ _____________ psi 3d. Fully open @ _____________________ psi
Pump Efficiency Test @ 2000 rpm

8002-42 580SM+ AND 590SM+ SERIES 3
Backhoe Valve Flow Regulator Test
9a. __________________ psi 9b. __________________ psi
9a minus 9b = _______ psi Backhoe Valve Flow Regulator Setting
Low Pressure Standby Regulator Test #1
10a. __________________ psi 10b. __________________ psi
10a minus 10b = _______ psi Low Pressure Standby Pressure
Backhoe Valve Flow Regulator Test
11a. __________________ psi 11b. __________________ psi
11a minus 11b = _______ psi Low Pressure Standby Pressure

Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM
Copyright © 2003 CNH Ameica LLC.

Racine, WI 53404 U.S.A. Bur 7-49641 Issued April, 2003 Revised August, 2006
8003-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TYPES OF CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8003-3
SPECIAL TOOLS
806128
CAS10508, fitting kit.
806127
CAS101162A, filter unit, portable.
TR98H032
CAS10192, vacuum pump.

8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major 1. Cylinder rod seals leak.
cause of the malfunction of hydraulic components.
2. Control valve spools do not return to neutral.
Contamination is any foreign material in the hydraulic
oil. Contamination can enter the hydraulic system in 3. Movement of control valve spools is difficult.
several ways.
4. Hydraulic oil becomes too hot.
1. When you drain the oil or disconnect any line.
5. Pump gears, housing, and other parts wear
2. When you disassemble a component. rapidly.
3. From normal wear of the hydraulic components. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraulic systems operate with some
contamination. The design of the components in this If your machine has any of these problems, check the
hydraulic system permits efficient operation with a hydraulic oil for contamination. See types of
small amount of contamination. An increase in this contamination below. If you find contamination, use
amount of contamination can cause problems in the the Portable Filter to clean the hydraulic system.
hydraulic system. The following list includes some of
these problems.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic 3. Visible contamination is foreign material that can
and visible. be found by sight, touch, or odor. Visible
contamination can cause a sudden failure of
1. Microscopic contamination occurs when very fine
components. Examples of visible contamination:
particles of foreign material are in suspension in
the hydraulic oil. A. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. B. Air in the oil
Microscopic contamination can be found by
C. The oil is dark and thick.
identification of the following problems or by
t e s t i n g i n a l a b o r a t o r y. E x a m p l e s o f t h e D. The oil has an odor of burned oil.
problems:
E. Water in the oil. See page 7.
A. Cylinder rod seal leak.
B. Control valve spools do not return to
NEUTRAL.
C. The hydraulic system has a high operating
temperature.

8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. Using the fitting kit shown on page 3, install the
following steps: valve in the hole for the drain plug. Make sure
that the valve is closed.
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter. 9. Stop the vacuum pump.
B. Remove the filter element from the portable 10. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
C. Remove all hydraulic oil from the portable
filter. 11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler
D. Clean the inside of the housing for the filter
cap.
element.
12. Install the outlet hose for the portable filter in the
2. You must know whether the contamination is
hydraulic reservoir filler neck.
microscopic or visible. See types of
contamination on page 4. 13. Open the valve that is installed in the hole for the
drain plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON
A. Check the maintenance schedule for the
position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be
(r/min).
changed. If needed, change the hydraulic oil.
See Section 1002 for specifications. Change 15. Run the portable filter for 10 minutes.
the hydraulic filter.
16. Continue to run the portable filter. Increase the
B. Do steps 6 through 35. engine speed to full throttle. Heat the oil to
operating temperature by doing the following
4. If the contamination is visible:
steps:
A. Change the hydraulic oil and hydraulic filter. A. Hold the blade control lever in the TILT
See Section 1002 for specifications. position for five seconds.
B. Do steps 5 through 35. B. Return the blade control lever in the
5. Check the amount of contamination in the NEUTRAL position for five seconds.
hydraulic system by doing the following steps: C. Repeat steps A and B until the oil in the
hydraulic system is at operating temperature.
A. Disassemble one cylinder in two different
circuits. Check for damage to seals, scoring of 17. Continue to run the engine at full throttle.
the cylinder wall, etc. Repair the cylinders as Continue to run the portable filter.
necessary.
18. Operate each hydraulic circuit to completely
B. If, in your judgment, the damage to the extend and retract the cylinders. Continue to
cylinders was caused by sever contamination operate each hydraulic circuit two times, one
and is not the result of normal wear, it is after the other for 45 minutes.
necessary to remove, clean and repair valves,
19. Decrease the engine speed to low idle.
pump, lines, cylinders, hydraulic reservoir, etc.
in the hydraulic system. 20. Continue to run the portable filter for 10 minutes.
6. Remove the breather from the reservoir and 21. Stop the portable filter.
connect the vacuum pump to the opening. Start
22. Stop the engine.
the vacuum pump.
23. Remove the hose from the hydraulic reservoir.
7. Loosen and remove the drain plug from the
reservoir.

8003-6
24. Close the valve that is installed in the hole for the 30. Stop the vacuum pump. Disconnect the vacuum
drain plug. pump from the opening in the reservoir and
install the breather.
25. Disconnect the inlet hose for the portable filter
from the valve. Remove the outlet hose from the 31. Remove the hydraulic filter elements from the
reservoir filler neck and replace filler cap. machine.
26. Connect a vacuum pump to the breather hose of 32. Install new hydraulic filter elements on the
the hydraulic reservoir. machine.
27. Start the vacuum pump. 33. Start the engine. Check for oil leakage around
the new hydraulic filters.
28. Remove the valve from the hole for the drain
plug. 34. Stop the engine.
29. Install the drain plug. 35. Check the oil level in the hydraulic reservoir. Add
o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.

8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 13. Slowly move each control lever in both directions
until oil begins to flow from the open line. Hold
2. Completely retract the cylinders of all
the control lever in place until clean oil flows from
attachments on the machine. Angle the blade to
the open line.
the right, the right cylinder will be fully retracted
and the left will be fully extended. Stop the 14. Stop the engine.
engine.
15. Connect the system line to the CLOSED end of
each cylinder.
WARNING: If retracting the cylinder rods
causes the attachments to be raised, block 16. Connect a suitable drain line to the OPEN end of
the attachments in place before proceeding each cylinder and place the other end in an
to the next step! acceptable container for contaminated oil.
39-4
17. Start the engine and run the engine at low idle.
NOTE: Any attachment or part of an attachment that 18. Slowly and completely extend all cylinders. As
is raised must be supported with acceptable the piston rod comes in/out of the cylinder, oil will
equipment to prevent the attachment from falling. be pushed out of the OPEN end of the cylinders.
3. Move each control lever in both directions to NOTE: Any attachment or part of an attachment that
release pressure in the hydraulic circuits. is raised must be supported with acceptable
4. Loosen and remove the filler cap from the equipment to prevent the attachment from falling.
reservoir. 19. Support any attachments that will be in the
5. Drain the hydraulic oil from the reservoir. RAISED position.
A. See Section 1002 for capacity specifications. 20. Stop the engine.
B. Have available acceptable equipment to drain 21. Disconnect the drain lines and connect the
the hydraulic oil. system lines to the cylinders.
C. Remove the drain plug from the bottom of the 22. Check the oil level in the hydraulic reservoir. Add
reservoir. o i l a s r e q u i r e d . S e e S e c t i o n 1 0 0 2 fo r
specifications.
6. Remove the hydraulic filter elements from the
machine. 23. Install the filler cap on the reservoir.
7. Install new hydraulic filter elements on the 24. Remove the hydraulic filter elements from the
machine. machine.
8. Install the drain plug in the bottom of the 25. Install new hydraulic filter elements on the
reservoir. machine.
9. Fill the hydraulic reservoir with hydraulic fluid. 26. Start and run the engine at 1500 rpm (r/min),
See Section 1002 for specifications. operate each hydraulic circuit to completely
extend and retract the cylinders.
10. Disconnect the line from the OPEN end and
CLOSED end of each cylinder. 27. Stop the engine and check for leaks. Check the
oil level in the hydraulic reservoir. Add oil as
11. Be sure all control levers are in the NEUTRAL required. See Section 1002 for specifications.
position.
12. Start and run the engine at low idle.
IMPORTANT: Check the oil level in the hydraulic
reservoir frequently while doing step 13. Have
another person hold a container under the hydraulic
lines while you do step 13.

8003-8
NOTES

Section
8004
8004
HYDRAULIC GEAR PUMP
580SM, SM + AND 590 SM

8004-2
TABLE OF CONTENTS
LOAD SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRUALIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8004-3
LOAD SENSOR
STEP 1 STEP 4
BD04A039 BD04A044
Loosen and remove load sensor fitting from hydraulic Inspect the springs for damaged or broken coils,
pump. c h e ck s p o o l a n d b o r e fo r s c a r i n g . R e p l a c e
components as needed.
STEP 2
BD04A041
Remove the springs from the pump.
STEP 3
BD04A043
Use a magnet and pull the spool from the pump.

8004-4
Assembly STEP 7
STEP 5
BD04A040
Tighten load sensor fitting.

BD04A042
Lubricate spool and carefully install into bore.
STEP 6
BD04A041
Place springs into spool and push spool into pump

body.

8004-5
HYDRUALIC PUMP
Disassembly STEP 3
STEP 1
BD04A048
Remove the closed end cover.

BD04A037
Clean the outside of the hydraulic pump. Fasten the STEP 4

hydraulic pump in a vise with soft jaws. Make
alignment marks on each section of the hydraulic
pump.
STEP 2
BD04A049
Remove the quad ring.
STEP 5
BD04A046
Loosen and remove the bolts and the flat washers

that fasten the closed end cover.
BD04A050

8004-6
STEP 6 STEP 9
BD04A051 BD04A054
Remove the driven and drive gear. Remove the quad ring.
STEP 7 STEP 10
BD04A052 BD04A055
Remove the closed end gear housing. Remove the thrust plate.
STEP 8 STEP 11
BD04A053 BD04A056
Remove the center housing. Remove the driven and drive gear.

8004-7
STEP 12 STEP 16
BD04A057 BD04A070
Remove the shaft end gear housing. Remove the outer seal and carrier from the shaft end
cover.
STEP 13
STEP 17
BP9502052
If the thrust plate stayed with the end housing, BD04A066
remove the thrust plate. Remove the inner seal from the shaft end cover.
STEP 14 STEP 18
Remove the quad ring from the bottom of the shaft
end gear housing.
STEP 15
BD04A072
Remove the seals from the thrust plates.
BD04A071
Remove the snap ring from the shaft end cover.

8004-8
Inspection STEP 21
Discard all seals and quad rings. Clean all parts in
cleaning solvent. Check all machined surfaces for
damage or wear.
STEP 19
BP9502022
BP9502021
Hold a straightedge across each gear housing and

use a feeler gauge to measure the amount of wear
caused by the gear teeth in the gear pocket. If the
wear in any gear pocket is more than 0.18 MM.
(0.007 inch), use a new gear housing.
BP9502055
STEP 20
Inspect the gears for wear and damage. There must
be no scoring on the gear hubs or on the outside
edges of the gear teeth. There must be no more than
0.05 MM. (0.002 inch) wear in the seal area of the
drive shaft. There must be no damage to the splines
of the drive shaft or the coupling. If any gear must be
discarded, you must use a new hydraulic pump.
BP9502023
Inspect the thrust plates for scoring, pitting, or other

damage.

8004-9
Assembly STEP 25
STEP 22
Install new quad rings in the grooves in the gear
housings. Use petroleum jelly to hold the quad rings
in position.
STEP 23
BD04A065
Press the carrier into the end cover until the snap
ring can be installed in the groove.
STEP 26
BD04A067
Press the seal, with the metal side up, into the shaft
end cover until the seal is even with the top of the
seal recess.
STEP 24
BD04A071
STEP 27
BD04A069
Install a new seal into the carrier, replace O-ring on

carrier.
BP9502057
Install new seals in the thrust plates.

8004-10
STEP 28 STEP 31
BD04A058 BP9502064
Install the thrust plate so that the seal is down and Install the thrust plate so that the seal is up. The seal
the open ends of the rectangular relief groove on the must be toward the outlet side of the hydraulic pump.
face of the thrust plate are toward the outlet side of
the hydraulic pump. STEP 32
STEP 29
BD04A079
Install the quad ring.

BD04A080
Fasten the shaft end cover in the vise with soft jaws. STEP 33
Install the shaft end gear housing.
STEP 30
BD04A078
Install the center housing.
BD04A056 STEP 34
Install the drive and the driven gear. Install the thrust plate in the closed end gear housing
so that the seal is down. The seal must be toward the
outlet side of the hydraulic pump.

8004-11
STEP 35 STEP 38
BD04A077 BD04A076
Install the closed end gear housing. Install the quad ring.
STEP 36 STEP 39
BD04A051 BD04A047
Install the drive and the driven gear. Install the closed end cover. Install the bolts and the
flat washers. Tighten the bolts evenly to a torque of
STEP 37 250 lb-ft (339 Nm).
BD04A050
Install the thrust plate so that the seal is up. The seal
must be toward the outlet side of the hydraulic pump.

8004-12
6 6 11
2 3 4 8 10
5 5 5
7 7
9
1
18
18
12
13
14 15 16 17
BC03N009
1. INPUT SHAFT 7. PUMP GEAR 13. VENT

2. RETAINING RING 8. THRUST PLATE (4) 14. FRONT GEAR HOUSING
3. O RING 9. CONNECTOR SHAFT 15. BEARING CARRIER HOUSING
4. SEAL 10. THRUST PLATE SEAL 16. REAR GEAR HOUSING
5. BEARING 11. LOAD SENSING INPUT 17. REAR SECTION
6. QUAD RING 12. FRONT HOUSING 18. CAP SCREWS
NOTE: Torque cap screws (18) to 250 lb-ft (339 Nm).

8004-13
2 4
3
5 6
BC03N007
1. INPUT SHAFT 3. SEAL RETAINER 5. SEAL

2. RETAINING RING 4. O-RING 6. SEAL
NOTE: Seal (6) must be pressed flush with face of

recess with lip toward gear as shown.

8004-14
NOTES

Section
8006
CYLINDERS
8006

8006-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ALL CYLINDERS EXCEPT THE BOOM CYLINDERS, 590 SUPER M DIPPER CYLINDER, SWING CYLINDERS,
AND QUICK COUPLER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
580M BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
580 SUPER M, SUPER M + AND 590 SUPER M BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
590 SUPER M DIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
590 SUPER M EXTENDABLE DIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
QUICK COUPLER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SWING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8006-3
SPECIFICATIONS
Torque Specifications For Piston Bolt With 243 Loctite On The Threads.
CYLINDER
DESCRIPTION 580M 580 Super M 580 Super M +
Loader Cylinders
340 to 380 Nm 340 to 380 Nm 340 to 380 Nm
Bucket
(250 to 280 Pound-Feet) (250 to 280 Pound-Feet) (250 to 280 Pound-Feet)
810 to 925 Nm 810 to 925 Nm 810 to 925 Nm

Lift
810 to 925 Nm 810 to 925 Nm 810 to 925 Nm
Clam
Backhoe Cylinders
1600 to 1830 Nm 2170 to 2440 Nm 2170 to 2440 Nm
Boom
2170 to 2440 Nm 2830 to 3220 Nm 2830 to 3220 Nm

Dipper
1600 to 1830 Nm 1600 to 1830 Nm 1600 to 1830 Nm

Bucket
340 to 380 Nm 340 to 380 Nm 340 to 380 Nm
Extendable Dipper
810 to 925 Nm 810 to 925 Nm 810 to 925 Nm
Swing
1600 to 1830 Nm 1600 to 1830 Nm 1600 to 1830 Nm

Stabilizer
CYLINDER CYLINDER
DESCRIPTION 590 Super M DESCRIPTION 590 Super M
Loader Cylinders Backhoe Cylinders
340 to 380 Nm 2170 to 2440 Nm
Bucket Boom
(250 to 280 Pound-Feet) (1600 to 1800 Pound-Feet)
810 to 925 Nm 2830 to 3220 Nm
Lift Dipper
810 to 925 Nm 1600 to 1830 Nm

Clam Bucket
340 to 380 Nm
Extendable Dipper
(250 to 280 Pound-Feet)
810 to 925 Nm
Swing
1600 to 1830 Nm
Stabilizer

8006-4
SPECIAL TOOLS
B795329M
B786441M THE TORQUE MULTIPLIER IS USED TO LOOSEN AND

TIGHTEN THE PISTON BOLT.
THIS TOOL IS USED TO REMOVE AND INSTALL THE GLAND CAS-1039
ON CASE CYLINDERS.
CAS-1456.
B505802M
THE TOOL SHOWN IS USED TO INSTALL THE SEAL IN THE

GLANDS OF THE CYLINDERS.

8006-5
ALL CYLINDERS EXCEPT THE BOOM CYLINDERS, 590 SUPER M DIPPER

CYLINDER, SWING CYLINDERS, AND QUICK COUPLER CYLINDER
NOTE: Refer to illustration on page 6. 1. Clean the piston (4), gland (3), piston rod (6),
tube (1), hardened washer (8), and bolt (7) in
Clean the outside of the cylinder. If the hoses
cleaning solvent.
were removed with the cylinder, remove the hoses
from the cylinder. 2. Discard the parts that were removed from the
piston (4) and the gland (3).
1. Fasten the tube (1) in a vise or other holding
equipment. Be careful to prevent damage to the 3. Illuminate the inside of the tube (1). Inspect the
tube (1). inside of the tube (1) for deep grooves and other
damage. If there is damage to the tube (1), a
2. Loosen and remove the lock screw (2) from the
new tube (1) must be used.
gland (3) and tube (1).
4. Check to be sure that the piston rod (6) is
3. Use the gland wrench shown on page 4 to
straight. If the piston rod (6) is not straight, install
loosen and remove the gland (3) from the tube
a new piston rod (6).
(1).
5. Remove small scratches on the inside of the
4. Pull the piston rod (6) straight out of the tube (1)
tube (1) with emery cloth of medium grit. Use the
to prevent damage to the tube (1).
emery cloth with a rotary motion.
5. Fasten the piston rod eye (5) in a vise and put a
6. Inspect the bushing (18) in the piston rod eye (5)
support below the piston rod (6) near the piston
and the closed end of the tube (1), replace as
(4). Use a shop cloth between the support and
required.
the piston rod (6) to prevent damage to the
piston rod (6). 7. Inspect the gland (3) for rust and clean and
remove rust as required.
6. Loosen and remove the bolt (7) and hardened
washer (8) that holds the piston (4). Use the 8. Inspect the gland end of the tube (1) for sharp
torque multiplier shown on page 4 for bolts that edges that will cut the gland O-ring (12), remove
have a high torque value. as required.
7. Remove the piston (4) from the piston rod (6).
8. Remove the gland (3) from the piston rod (6).
9. Remove the seal (9), backup ring (10), and wear
ring (11) from the piston (4)
10. Remove the O-ring (12), backup ring (13), wiper
(14), rod seal (15), buffer seal (16), and bushing
(17) from the gland (3).

8006-6
18
6
14
15
17 16 2
3
13
12
11 4
10
7 9
8 1
18
BC03N108
1. TUBE 6. PISTON ROD 11. WEAR RING 16. BUFFER SEAL
2. LOCK SCREW 7. BOLT 12. O-RING 17. BUSHING
3. GLAND 8. HARDENED WASHER 13. BACKUP RING 18. BUSHING
4. PISTON 9. SEAL 14. WIPER
5. PISTON ROD EYE 10. BACKUP RING 15. ROD SEAL
TYPICAL CYLINDER

8006-7
Assembly 14. Install the bolt (7). Tighten the bolt (7) to the
torque value on page 3 for the cylinder that is
NOTE: Refer to illustration on page 6 and 8. being repaired. A torque multiplier can be used
NOTE: If a new gland (3) is being installed, put the to help tighten the bolt.
part number of the cylinder on the new gland (3). 15. Install a new wear ring (11) in the end groove on
1. Install the bushing (17) in the gland (3). the outside of the piston (4).
2. Install the buffer seal (16) in the gland (3). The 16. Install a new backup ring (10) in the center
side of the buffer seal (16) with the lip must be groove on the outside of the piston (4).
toward the small end of the gland (3). 17. Install a new seal (9) on top of the backup ring
3. Install the rod seal (15) in the gland. The rod seal (10) on the outside of the piston (4).
(15) is to be installed so that the lips of the rod 18. Lubricate the inside of the tube (1) and the piston
seal (15) are toward the small end of the gland (4) with clean oil. Use a piston ring compression
(3). The wide seal (15) can be difficult to install. tool to hold the new wear ring (11) in place.
Use the tool shown on page 4.
19. Push the tube (1) straight onto the piston (4).
4. Install a new wiper (14) in the gland (3). The lips
of the wiper (14) must be toward the large end of 20. Start the tube (1) onto the piston rod assembly.
the gland (3). Push the tube onto the piston rod assembly until
the compression tool is pushed off the piston rod
5. Install a new backup ring (13) in the groove on assembly. Be careful not to damage the wear
the outside of the gland (3). If both sides of the ring and seal.
backup ring (13) are not flat, the side that is not
flat must be toward the small end of the gland 21. When the piston (4) is in the smooth part of the
(3). tube (1), start the gland (3) into the tube (1).
6. Install the O-ring (12) next to the backup ring (13) 22. Lubricate the O-ring (12) on the gland (3) with
in the groove on the outside of the gland (3). The clean oil.
O-ring (12) must be toward the small end of the 23. Tighten the gland (3) to 135 to 542 Nm (100 to
gland (3). 400 pound-feet). If the lock screw (2) holes
7. Fasten the piston rod eye (5) in the vise. become aligned in this torque range, install the
lock screw (2). Tighten the lock screw (2) to 2.3
8. Remove any marks and sharp edges on the Nm (20 pound-inches). If the lock screw (2) holes
chamfer at the end of the piston rod (6). are not aligned, do steps 25 through 27.
9. Lubricate the bore of the gland (3) with clean oil. 24. Tighten the gland (3) to 135 to 542 Nm (100 to
10. Push the gland (3) onto the piston rod (6). If 400 pound-feet).
necessary, use a soft hammer to drive the gland 25. Use a No. 26 drill and drill a hole half in the gland
(3) onto the piston rod (6). (3) and half in the tube (1). Drill to a depth of 11
11. Put a support below and near the end of the mm (7/16 inch). Do not drill in line with a hole in
piston rod (6). Use a shop cloth between the the gland (3) for the gland wrench.
support and the piston rod (6) to prevent damage 26. Install the lock screw (2). Tighten the lock screw
to the piston (4). (2) to 2.3 Nm (20 pound-inches).
12. Put the piston (4) on the end of the piston rod (6). 27. If the hoses were removed with the cylinder,
13. Clean the threads on the end of the piston rod install new O-rings, if equipped, on the hose
and the threads of the bolt using Loctite cleaning fittings. Lubricate the O-rings with clean oil.
solvent. Allow to dry. Apply Loctite 243 to the Install the hoses.
piston rod threads, 6.4 mm (1/4 inch) from the
open end of the piston rod so that there is 12.7
mm (1/2 inch) of Loctite 242 on the piston rod
threads. DO NOT apply Loctite to the first 6.4
mm (1/4 inch) of the piston rod threads.

8006-8
9 11
10
BS01C123
12
3 13
14 15
16 17
BS01C122
3. GLAND 12. O-RING 17. BUSHING
4. PISTON 13. BACKUP RING
9. SEAL 14. WIPER
10. BACKUP RING 15. ROD SEAL
11. WEAR RING 16. BUFFER SEAL
TYPICAL CYLINDER

8006-9
580M BOOM CYLINDER
NOTE: Refer to illustration on page10 and 12. 1. Clean the piston (4), gland (3), piston rod (6),
tube (1), washer (8), and bolt (7) in cleaning
Clean the outside of the cylinder. If the hoses were
solvent.
removed with the cylinder, remove the hoses from
the cylinder 2. Discard the parts that were removed from the
(1).
6. Inspect the bushings (19) in the piston rod eye
(5) and the closed end of the tube (1). Replace
as required.
6. Loosen and remove the bolt (7) and washer (8)
th at ho ld s t he pi sto n ( 4 ). Use th e t or q ue 8. Inspect the gland end of the tube (1) for sharp
multiplier shown on page 4 for bolts that have a edges that will cut the gland O-ring (13) and
high torque value. remove as required.
7. Remove the piston (4) from the piston rod (6). 9. Inspect the piston (4) for damage and wear. If the
piston (4) is damaged or worn, a new piston (4)
must be used.
9. Remove the seal (9), backup ring (10), wear ring
(11), and the piston ring (12) from the piston (4).
(18), wide seal (17), buffer seal (16), and
bushing (15) from the gland (3).

8006-10
5
19
20
19
18
17
16
3
15
14
12
13 11
4
10
2
9
19
1
20 19
BC03N109
2. LOCK SCREW 7. BOLT 12. PISTON RING 17. WIDE SEAL
3. GLAND 8. HARDENED WASHER 13. O-RING 18. WIPER
4. PISTON 9. SEAL 14. BACKUP RING 19. BUSHING
5. PISTON ROD EYE 10. BACKUP RING 15. BUSHING 20. GREASE FITTING
580M BOOM CYLINDER

8006-11
NOTE: Refer to illustration page 10 and 12. being repaired. A torque multiplier can be used
1. Install the bushing (15) in the gland (3). to help tighten the bolt (7).
2. Install the buffer seal (16) in the gland (3). The 15. Install a new wear ring (11) in the groove in the
side of the buffer seal (16) with the lip must be center of the piston (4).
toward the small end of the gland (3). 16. Install a new seal (9) in the groove on the outside
3. Install the wide seal (17) in the gland (3). The end of the piston (4). The seal (9) must be in the
wide seal (17) is to be installed so that the lips of groove at the end of the piston (4) with the large
the wide seal (17) are toward the small end of bore.
the gland (3). The wide seal (17) can be difficult 17. Install a backup ring (10) over the seal (9) on the
to install. Use the tool shown on page 4. piston (4).
4. Install a new wiper (18) in the gland (3). The lips 18. Install the piston ring (12) in the remaining
of the wiper (18) must be toward the large end of groove in the outside of the piston (4).
the gland (3).
5. Install a new backup ring (14) in the groove on equipment. Be careful to prevent damage to the
the outside of the gland (3). If both sides of the tube (1).
backup ring (14) are not flat, the side that is not
flat must be toward the small end of the gland 20. Lubricate the inside of the tube (1) and the piston
(3). (4) with clean oil.
6. Install the O-ring (13) next to the backup ring (14) 21. Push the piston (4) straight into the tube (1).
in the groove on the outside of the gland (3). The 22. When the piston (4) is in the smooth part of the
O-ring (13) must be toward the small end of the tube (1), start the gland (3) into the tube (1).
gland (3).
23. Lubricate the O-ring (13) on the gland (3) with
7. Fasten the piston rod eye (5) in the vise. clean oil.
8. Remove any marks and sharp edges on the 24. Tighten the gland (3) to 135 to 542 Nm (100 to
chamfer at the end of the piston rod (6). 400 pound-feet). If the lock screw (2) holes
9. Lubricate the bore of the gland (3) and the piston become aligned in this torque range, install the
rod (6) with clean oil. lock screw (2). Tighten the lock screw (2) to 2.3
Nm (20 pound-inches). If the lock screw (2) holes
10. Push the gland (3) onto the piston rod (6). If are not aligned, do steps 26 through 28.
necessary, use a soft hammer to drive the gland
(3) onto the piston rod (6). 25. Tighten the gland (3) to 135 to 542 Nm (100 to
400 pound-feet).
11. Put a support below and near the end of the
piston rod (6). Use a shop cloth between the 26. Use a No. 26 drill and drill a hole half in the gland
support and the piston rod (6) to prevent damage (3) and half in the tube (1). Drill to a depth of 11
to the piston (4). mm (7/16 inch). Do not drill in line with a hole in
the gland (3) for the gland wrench.
12. Put the piston (4) on the end of the piston rod (6).
27. Install the lock screw (2). Tighten the lock screw
13. Clean the threads on the end of the piston rod (2) to 2.3 Nm (20 pound-inches).
and the threads of the bolt using Loctite cleaning
solvent. Allow to dry. Apply Loctite 243 to the 28. If the hoses were removed with the cylinder,
piston rod threads 6.35 mm (1/4 inch) from the install new O-rings, if equipped, on the hose
open end of the piston rod so that there is 12.7 fittings. Lubricate the O-rings with clean oil.
mm (1/2 inch) of Loctite 243 on the piston rod Install the hoses.

8006-12
2 1
20 17 13
14
3
18
19 6
16 15
11 10
1 12 8 20
6
9 7
4
19
B9501087T
2. LOCK SCREW 7. BOLT 12. PISTON RING 17. WIDE SEAL
3. GLAND 8. HARDENED WASHER 13. O-RING 18. WIPER
4. PISTON 9. SEAL 14. BACKUP RING 19. BUSHING
5. PISTON ROD EYE 10. BACKUP RING 15. BUSHING 20. GREASE FITTING
580M BOOM CYLINDER

8006-13
580 SUPER M, SUPER M + AND 590 SUPER M BOOM CYLINDER
NOTE: Refer to illustrations on page 14 and 16. 1. Clean the piston (4), gland (3), piston rod (6),
cleaning solvent. Make sure the orifice in the
piston (4) is open.
the cylinder
piston (4), check valve (12), and the gland (3).
equipment. Be careful to prevent damage to the
tube (1). 3. Illuminate the inside of the tube (1). Inspect the
inside of the tube (1) for deep grooves and other
(1).
5. Fasten the piston rod eye (5) in a vise and put a emery cloth with a rotary motion.
6. Inspect the bushing (20), if equipped, in the
piston rod eye (5) and the closed end of the tube
(1), and replace as required.
piston rod (6).
7. Inspect the gland (3) for rust and clean and
6. Remove the check valve (12) from the piston.
8. Inspect the gland end of the tube (1) for sharp
washer (8) that holds the piston (4). Use the
edges that will cut the gland O-ring (14) and
torque multiplier shown on page 4 for bolts that
remove as required.
have a high torque value.
9. Inspect the piston (4) for damage and wear. If the
9. Remove the gland (3) from the piston rod (6). must be used.
NOTE: If the boom cylinder is being disassembled
for repair because of poor performance and the seals
(10) on the piston (4) are good, replace the check
valve (12) and the O-ring (13). If the seals (10) are
damaged, do the next step.
10. Remove the wear ring (9), seals (10), and the
backup rings (11) from the piston (4).
12. Remove the O-ring (13) from the check
valve(12).

8006-14
Assembly 15. Clean the threads on the end of the piston rod (6)
and the threads of the bolt using Loctite cleaning
NOTE: If a new gland (3) is being installed, put the solvent. Allow to dry. Apply Loctite 243 to the
part number of the cylinder on the new gland. piston rod threads 6.35 mm (1/4 inch) from the
1. Install the bushing (16) in the gland (3). open end of the piston rod so that there is 12.7
2. Install the buffer seal (17) in the gland (3). The threads. DO NOT apply Loctite to the first 6.35
side of the buffer seal (17) with the lip must be mm (1/4 inch) of the piston rod threads.
toward the small end of the gland (3).
16. Install the bolt (7). Tighten the bolt (7) to the
3. Install the wide seal (18) in the gland (3). The torque value on page 3 for the cylinder that is
wide seal (18) is to be installed so that the lips of being repaired. A torque multiplier can be used
the wide seal (18) are toward the small end of to help tighten the bolt (7).
the gland (3). The wide seal (18) can be difficult
to install. Use the tool shown on page 4. 17. Install a new wear ring (9) in the groove in the
center of the piston (4).
4. Install a new wiper (19) in the gland (3). The lips
of the wiper (19) must be toward the outside of 18. Install a new backup ring (11) in each groove on
the gland (3). the outside ends of the piston (4).
5. Install a new backup ring (15) in the groove on 19. Install a new seal (10) over each backup ring
the outside of the gland (3). If both sides of the (11) on the outside ends of the piston (4).
backup ring (15) are not flat, the side that is not 20. Lubricate the inside of the tube (1) and the piston
flat must be toward the small end of the gland (4) with clean oil.
(3).
21. Push the tube (1) straight onto the piston (4).
6. Install the O-ring (14) next to the backup ring (15)
in the groove on the outside of the gland (3). The 22. Start the tube (1) onto the piston rod assembly.
O-ring (14) must be toward the small end of the Be careful not to damage the wear ring and seal.
gland (3) 23. When the piston (4) is in the smooth part of the
7. Fasten the piston rod eye (5) in the vise. tube (1), start the gland (3) into the tube (1).
8. Remove any marks and sharp edges on the 24. Lubricate the O-ring (12) on the gland (3) with
chamfer at the end of the piston rod (6) clean oil.
9. Lubricate the bore of the gland (3) and the piston 25. Tighten the gland (3) to 135 to 542 Nm (100 to
rod (6) with clean oil. 400 pound-feet). If the lock screw (2) holes
become aligned in this torque range, install the
10. Push the gland (3) onto the piston rod (6). If lock screw (2). Tighten the lock screw (2) to 2.3
necessary, use a soft hammer to drive the gland Nm (20 pound-inches). If the lock screw (2) holes
(3) onto the piston rod (6). are not aligned, do steps 28 through 30.
11. Put a support below and near the end of the 26. Tighten the gland (3) to 135 to 542 Nm (100 to
piston rod (6). Use a shop cloth between the 400 pound-feet).
support and the piston rod (6) to prevent damage
to the piston (4). 27. Use a No. 26 drill and drill a hole half in the gland
(3) and half in the tube (1). Drill to a depth of 11
12. Install a new O-ring (13) on the check valve (12). mm (7/16 inch). Do not drill in line with a hole in
Apply a thin strip of Loctite 243 to the threads of the gland (3) for the gland wrench.
the check valve (12). Lubricate the O-ring (13)
with clean oil. 28. Install the lock screw (2). Tighten the lock screw
(2) to 2.3 Nm (20 pound-inches).
13. Install the check valve (12) in the piston (4).
Tighten the check valve (12) to 27 to 34 Nm (239 29. If the hoses were removed with the cylinder,
to 301 pound-inches). install new O-rings, if equipped, on the hose
fittings. Lubricate the O-rings with clean oil.
14. Put the piston (4) on the end of the piston rod (6). Install the hoses.

8006-15
20 21
20
6
5
3 19
18
17
15
14
16 10 11
4
9 2
10 11
13
8 12
7
20
1
20
21
BC03N110
1. TUBE 7. BOLT 13. O-RING 19. WIPER
2. LOCK SCREW 8. HARDENED WASHER 14. O-RING 20. BUSHING
3. GLAND 9. WEAR RING 15. BACKUP RING 21. GREASE FITTING
4. PISTON 10. SEAL 16. BUSHING
5. PISTON ROD EYE 11. BACKUP RING 17. BUFFER SEAL
6. PISTON ROD 12. CHECK VALVE 18. WIDE SEAL
580 SUPER M AND 590 SUPER M BOOM CYLINDER

8006-16
2 1
21 18 17 15 14
6
19
3
5
20 16
4 11 10 9 10 11
6 8
20 21
7
12 13
B9501089T
1. TUBE 7. BOLT 13. O-RING 19. WIPER
2. LOCK SCREW 8. HARDENED WASHER 14. O-RING 20. BUSHING
3. GLAND 9. WEAR RING 15. BACKUP RING 21. GREASE FITTING
4. PISTON 10. SEAL 16. BUSHING
5. PISTON ROD EYE 11. BACKUP RING 17. BUFFER SEAL
6. PISTON ROD 12. CHECK VALVE 18. WIDE SEAL
580 SUPER M AND 590 SUPER M BOOM CYLINDER

8006-17
590 SUPER M DIPPER CYLINDER
solvent.
(1).
the piston rod (6) to prevent damage to the 7. Inspect the gland end of the tube (1) for sharp
piston rod (6). edges that will cut the gland O-ring (12) and
remove as required.
th at ho ld s t he pi sto n ( 4 ). Use th e t or q ue 8. Inspect the piston (4) for damage and wear. If the
multiplier shown on page 4 for bolts that have a piston (4) is damaged or worn, a new piston (4)
high torque value. must be used.
9. Remove the seal (9), backup ring (10), and wear
ring (11) from the piston (4).
(17), rod seal (16), buffer seal (15), and bushing
(14) from the gland (3).

8006-18
1. Install the bushing (14) in the gland (3). being repaired. A torque multiplier can be used
2. Install the buffer seal (15) in the gland (3). The to help tighten the bolt (7).
side of the buffer seal (15) with the lip must be 15. Install a new wear ring (11) in the groove in the
toward the small end of the gland (3). center of the piston (4).
3. Install the rod seal (16) in the gland (3). The rod 16. Install a new seal (9) in the groove on the outside
seal (16) is to be installed so that the lips of the end of the piston (4). The seal (9) must be in the
rod seal (16) are toward the small end of the groove at the end of the piston (4) with the large
gland (3). The rod seal (16) can be difficult to bore.
install. Use the tool shown on page 4.
17. Install a backup ring (10) over the seal (9) on the
4. Install a new wiper (17) in the gland (3). The lips piston (4).
of the wiper (17) must be toward the outside of
the gland (3). 18. Fasten the tube (1) in a vise or other holding
5. Install a new backup ring (13) in the groove on tube (1).
the outside of the gland (3). If both sides of the
(3). 20. Push the piston (4) straight into the tube (1)
6. Install the O-ring (12) next to the backup ring (13) 21. When the piston (4) is in the smooth part of the
in the groove on the outside of the gland (3). The tube (1), start the gland (3) into the tube (1).
O-ring (12) must be toward the small end of the
gland (3) 22. Lubricate the O-ring (12) on the gland (3) with
clean oil.
7. Fasten the piston rod eye (5) in the vise.
23. Tighten the gland (3) to 135 to 542 Nm (100 to
8. Remove any marks and sharp edges on the 400 pound-feet). If the lock screw (2) holes
chamfer at the end of the piston rod (6) become aligned in this torque range, install the
9. Lubricate the bore of the gland (3) and the piston lock screw (2). Tighten the lock screw (2) to 2.3
rod (6) with clean oil. Nm (20 pound-inches). If the lock screw (2) holes
are not aligned, do steps 25 through 27.
10. Push the gland (3) onto the piston rod (6). If
necessary, use a soft hammer to drive the gland 24. Tighten the gland (3) to 135 to 542 Nm (100 to
(3) onto the piston rod (6). 400 pound-feet).
11. Put a support below and near the end of the 25. Use a No. 26 drill and drill a hole half in the gland
piston rod (6). Use a shop cloth between the (3) and half in the tube (1). Drill to a depth of 11
support and the piston rod (6) to prevent damage mm (7/16 inch). Do not drill in line with a hole in
to the piston (4). the gland (3) for the gland wrench.
12. Put the piston (4) on the end of the piston rod (6). 26. Install the lock screw (2). Tighten the lock screw
(2) to 2.3 Nm (20 pound-inches).
13. Clean the threads on the end of the piston rod
and the threads of the bolt using Loctite cleaning 27. If the hoses were removed with the cylinder,
solvent. Allow to dry. Apply Loctite 242 to the install new O-rings, if equipped, on the hose
piston rod threads 6.4 mm (1/4 inch) from the fittings. Lubricate the O-rings with clean oil.
open end of the piston rod so that there is 12.7 Install the hoses.

8006-19
17
16
15
14
3
2
13
12
4
10
9
11
8 1
7
BC03N112
1. TUBE 7. BOLT 13. BACKUP RING
2. LOCK SCREW 8. WASHER 14. BUSHING
3. GLAND 9. SEAL 15. ROD SEAL
4. PISTON 10. BACKUP RING 16. ROD SEAL
5. PISTON ROD EYE 11. WEAR RING 17. WIPER
6. PISTON ROD 12. O-RING
590 SM DIPPER CYLINDER

8006-20
590 SUPER M EXTENDABLE DIPPER CYLINDER
solvent.
(1).
6. Inspect the bushings (18) in the piston rod eye
(5) and the closed end of the tube (1). Replace
as required.
th at ho ld s th e pis to n ( 4 ). U se th e t or q ue 8. Inspect the gland end of the tube (1) for sharp
multiplier shown on page 4 for bolts that have a edges that will cut the gland O-ring (12) and
high torque value. remove as required.
7. Remove the piston (4) from the piston rod (6). 9. Inspect the piston (4) for damage and wear. If the
must be used.
9. Remove the seal (9), ring (10), and wear ring
(11) from the piston (4).
(14), rod seal (15), seal (16), and bushing (17)
from the gland (3).

8006-21
1. Install the bushing (17) in the gland (3). being repaired. A torque multiplier can be used
2. Install the buffer seal (16) in the gland (3). The to help tighten the bolt (7).
side of the buffer seal (16) with the lip must be 15. Install a new wear ring (9) in the groove in the
toward the small end of the gland (3). center of the piston (4).
3. Install the rod seal (15) in the gland (3). The rod 16. Install a new seal (9) in the groove on the outside
seal (15) is to be installed so that the lips of the end of the piston (4). The seal (9) must be in the
rod seal (15) are toward the small end of the groove at the end of the piston (4) with the large
gland (3). The rod seal (15) can be difficult to bore.
install. Use the tool shown on page 4.
17. Install a ring (10) over the seal (9) on the piston
4. Install a new wiper (14) in the gland (3). The lips (4).
of the wiper (14) must be toward the outside of
the gland (3). 18. Install the wear ring (11) on the piston (4).
5. Install a new backup ring (13) in the groove on 19. Fasten the tube (1) in a vise or other holding
the outside of the gland (3). If both sides of the equipment. Be careful to prevent damage to the
backup ring (13) are not flat, the side that is not tube (1).
flat must be toward the small end of the gland 20. Lubricate the inside of the tube (1) and the piston
(3). (4) with clean oil.
6. Install the O-ring (12) next to the backup ring (13) 21. Push the piston (4) straight into the tube (1)
in the groove on the outside of the gland (3). The
O-ring (12) must be toward the small end of the 22. When the piston (4) is in the smooth part of the
gland (3). tube (1), start the gland (3) into the tube (1).
7. Fasten the piston rod eye (5) in the vise. 23. Lubricate the O-ring (12) on the gland (3) with
clean oil.
8. Remove any marks and sharp edges on the
chamfer at the end of the piston rod (6) 24. Tighten the gland (3) to 135 to 542 Nm (100 to
400 pound-feet). If the lock screw (2) holes
9. Lubricate the bore of the gland (3) and the piston become aligned in this torque range, install the
rod (6) with clean oil. lock screw (2). Tighten the lock screw (2) to 2.3
10. Push the gland (3) onto the piston rod (6). If Nm (20 pound-inches). If the lock screw (2) holes
necessary, use a soft hammer to drive the gland are not aligned, do steps 25 through 27.
(3) onto the piston rod (6). 25. Tighten the gland (3) to 135 to 542 Nm (100 to
11. Put a support below and near the end of the 400 pound-feet).
piston rod (6). Use a shop cloth between the 26. Use a No. 26 drill and drill a hole half in the gland
support and the piston rod (6) to prevent damage (3) and half in the tube (1). Drill to a depth of 11
to the piston (4). mm (7/16 inch). Do not drill in line with a hole in
12. Put the piston (4) on the end of the piston rod (6). the gland (3) for the gland wrench.
13. Clean the threads on the end of the piston rod 27. Install the lock screw (2). Tighten the lock screw
and the threads of the bolt using Loctite cleaning (2) to 2.3 Nm (20 pound-inches).
solvent. Allow to dry. Apply Loctite 243 to the 28. If the hoses were removed with the cylinder,
piston rod threads 6.4 mm (1/4 inch) from the install new O-rings, if equipped, on the hose
open end of the piston rod so that there is 12.7 fittings. Lubricate the O-rings with clean oil.
mm (1/2 inch) of Loctite 243 on the piston rod Install the hoses.

8006-22
18
18
14
13 15
12 16
3
17
4
10
2
9
11
8
7
18
1
18
BC03C113
1. TUBE 7. BOLT 13. BACKUP RING
2. LOCK SCREW 8. WASHER 14. WIPER
3. GLAND 9. SEAL 15. SEAL
4. PISTON 10. RING 16. BUFFER SEAL
5. PISTON ROD EYE 11. WEAR RING 17. BUSHING
6. PISTON ROD 12. O-RING 18. BUSHING
590 SM EXTENDABLE DIPPER CYLINDER

8006-23
QUICK COUPLER CYLINDER
NOTE: Refer to illustrations on page 24. 1. Install the wiper seal (11) in the gland (5). The
lips must be toward the small end of the gland
1. Remove the snap ring (2) from the gland (5).
(5).
Then push the gland (5) slightly into the cylinder.
2. Install the seal (13) and bushing (12) in the gland
2. Remove the spacer (3).
(5).
3. Remove the snap ring (4) from the tube (1).
3. Install the backup ring (15) and O-ring (14) on
4. Install the plastic service ring into the snap ring the outside of the gland (5).
groove in the tube (1).
4. Install a new O-ring (10), ring (9), ring (8), and
IMPORTANT: See illustration on this page for seal (7) on the piston.
orientation of the plastic service ring.
5. Lubricate the bore of the gland (5) with clean oil
5. Pull the rod assembly (6) out of the tube (1). and push the gland assembly onto the piston rod
(6). The wide end of the gland (5) should contact
6. Remove the plastic service ring from the tube
the piston.
(1).
6. Do steps 1 through 5 for the other gland (5) and
7. Remove the gland (5) from the rod (6).
piston rod (6).
8. Fasten the rod (6) in a vise with soft jaws.
7. Lubricate the seals of the piston rod (6) and the
9. Remove the seal (7), ring (8), ring (9), and O-ring gland (5) with clean oil. Push the piston rod and
(10) from the piston. gland sub-assembly into the bore of the tube (1)
far enough to allow the installation of the snap
10. Remove the wiper seal (11), bushing (12), seal
ring (4). If necessary, use a soft hammer to drive
(13), O-ring (14), and backup ring (15) from the
the piston rod (6) and gland (5) into the tube (1).
gland (5).
8. Install the snap ring (4) in the tube (1).
11. Do steps 1 through 10 for the other side.
9. Pull the rod (6) outwards until the gland (5) is
Inspection seated against the snap ring (4).
1. Clean the glands (5), piston rods (6) and tube (1) 10. Install the spacer (3) on the gland (5).
in cleaning solvent. 11. Install the snap ring (2) on the gland (5).
2. Discard the parts that were removed from the 12. Do steps 7 through 12 for the other side.
pistons and the glands (5).
3. Illuminate the inside of the tube (1). Inspect the
inside of the tube (1) for deep grooves and other TUBE END
new tube (1) must be used. See section 8001 for
removal of cylinder tube.
5. Check to be sure that the piston rods (6) are
straight. If a piston rod (6) is not straight, install a
new piston rod (6).
BS00C112
PLASTIC SERVICE RING ORIENTATION

8006-24
2
3
4
1
BS01C100
1. TUBE 3. SPACER 5. GLAND
2. SNAP RING 4. SNAP RING
7 9
6
10
12 11
BS01C101
6. PISTON ROD 9. RING 13

7. SEAL 10. O-RING
8. RING 14 15
COUPLER CYLINDER PISTON
BS01C109
11. WIPER SEAL 13. SEAL 15. BACKUP RING

12. BUSHING 14. O-RING
COUPLER CYLINDER GLAND

8006-25
SWING CYLINDERS
NOTE: Refer to illustrations on page 26 and 28. 1. Clean the piston (4), gland (3), piston rod (6),
Clean the outside of the cylinder. If the hoses
cleaning solvent. Make sure the orifice in the
were removed with the cylinder, remove the hoses
piston (4) is open.
from the cylinder.
piston (4), gland (3) and the end cap (21).
tube (1). 3. Illuminate the inside of the tube (1). Inspect the
(1).
5. Remove small scratches on the piston rod (6) or
inside the tube (1) with emery cloth of medium
5. Fasten the piston rod eye (5) in a vise and put a grit. Use the emery cloth with a rotary motion.
6. Inspect the bushing (22) and snap rings (23) in
the piston rod eye (5) and bushings (22) on the
trunnions on the tube (1), replace as required.
piston rod (6).
washer (8) that holds the piston (4). Use the
torque multiplier shown on page 4 for bolts that 8. Inspect the gland end of the tube (1) for sharp
have a high torque value. edges that will cut the gland O-ring (13), remove
as required.
9. Remove the wear ring (9), seal (10), backup ring
(11), and piston ring (12) from the piston (4).
11. Remove the end cap (21) from the tube (1).
12. Remove the backup ring (19) and O-ring (20)
from the end cap (21).

8006-26
Assembly 15. Install a new piston ring (12) in the groove at the
bolt end of the piston (4).
NOTE: If a new gland (3) is being installed, put the
part number of the cylinder on the new gland. 16. Install a new wear ring (9) in the center grove on
the outside of the piston (4).
1. Install the bushing (18) in the gland (3).
17. Install a new backup ring (11) in the groove on
2. Install the buffer seal (17) in the gland (3). The the outside of the piston (4).
side of the buffer seal (17) with the lip must be
toward the small end of the gland (3). 18. Install a new seal (10) on top of the backup ring
(11) on the outside of the piston (4).
3. Install the wide seal (16) in the gland. The wide
seal (16) is to be installed so that the lips of the 19. Fasten the tube (1) in a vise or other holding
wide seal (16) are toward the small end of the equipment. Be careful to prevent damage to the
gland (3). The wide seal (16) can be difficult to tube (1).
install. Use the tool shown on page 4. 20. Install a new backup ring (19) and O-ring (20) in
4. Install a new wiper (15) in the gland (3). The lips the groove on the outside of the end cap (21).
of the wiper (15) must be toward the large end of 21. Lubricate the O-ring (20) on the end cap (21)
the gland (3). with clean oil.
5. Install a new backup ring (14) in the groove on 22. Install the end cap (21) in the tube (1).
the outside of the gland (3). If both sides of the
(3). 24. Use a piston ring compression tool to hold the
6. Install the O-ring (13) next to the backup ring (14) new wear ring (9) in place.
in the groove on the outside of the gland (3). The 25. Push the tube (1) straight onto the piston (4).
O-ring (13) must be toward the small end of the
gland (3). 26. Start the tube (1) onto the piston rod assembly.
Push the tube onto the piston rod assembly until
7. Fasten the piston rod eye (5) in the vise. the compression tool is pushed off the piston rod
8. Remove any marks and sharp edges on the assembly. Be careful not to damage the wear
chamfer at the end of the piston rod (6). ring (9) and seal (10).
9. Lubricate the bore of the gland (3) with clean oil. 27. Lubricate the O-ring (13) on the gland (3) with
clean oil.
10. Push the gland (3) onto the piston rod (6). If
necessary, use a soft hammer to drive the gland 28. Tighten the gland (3) to 135 to 542 Nm (100 to
(3) onto the piston rod (6). 400 pound-feet). If the lock screw (2) holes
become aligned in this torque range, install the
11. Put a support below and near the end of the lock screw (2). Tighten the lock screw (2) to 2.3
piston rod (6). Use a shop cloth between the Nm (20 pound-inches). If the lock screw (2) holes
support and the piston rod (6) to prevent damage are not aligned, do steps 30 through 32.
to the piston (4).
29. Tighten the gland (3) to 135 to 542 Nm (100 to
12. Put the piston (4) on the end of the piston rod (6). 400 pound-feet).
13. Clean the threads on the end of the piston rod 30. Use a No. 26 drill and drill a hole half in the gland
and the threads of the bolt using Loctite cleaning (3) and half in the tube (1). Drill to a depth of 11
solvent. Allow to dry. Apply Loctite 243 to the mm (7/16 inch). Do not drill in line with a hole in
piston rod threads 6.35 mm (1/4 inch) from the the gland (3) for the gland wrench.
open end of the piston rod so that there is 3.7
mm (1/2 inch) of Loctite 243 on the piston rod 31. Install the lock screw (2). Tighten the lock screw
threads. DO NOT apply Loctite to the first 6.35 (2) to 2.3 Nm (20 pound-inches).
mm (1/4 inch) of the piston rod threads. 32. If the hoses were removed with the cylinder,
14. Install the bolt (7). Tighten the bolt (7) to the install new O-rings, if equipped, on the hose
torque value on page 3 for the cylinder that is fittings. Lubricate the O-rings with clean oil.
being repaired. A torque multiplier can be used Install the hoses.
to help tighten the bolt.

8006-27
23
22
5
24
6 23
15
16 18
14
3 13
17
11
10
9
4 22
12 2
7 8
2
20
19 24
9501092T
21
22
1
BC03N111
1. TUBE 7. BOLT 13. O-RING 19. BACKUP RING

2. LOCK SCREW 8. HARDENED WASHER 14. BACKUP RING 20. O-RING
3. GLAND 9. WEAR RING 15. WIPER 21. END CAP
4. PISTON 10. SEAL 16. WIDE SEAL 22. BUSHING
5. PISTON ROD EYE 11. BACKUP RING 17. BUFFER SEAL 23. SNAP RING
6. PISTON ROD 12. PISTON RING 18. BUSHING 24. GREASE FITTING
SWING CYLINDER

8006-28
24 6 1
2
22
3
15
16
5 17
18
23
12 2
8 7
1 11 10 9
20 19
21
BC03N114
1. TUBE 7. BOLT 13. O-RING 19. BACKUP RING
2. LOCK SCREW 8. HARDENED WASHER 14. BACKUP RING 20. O-RING
3. GLAND 9. WEAR RING 15. WIPER 21. END CAP
4. PISTON 10. SEAL 16. WIDE SEAL 22. BUSHING
5. PISTON ROD EYE 11. BACKUP RING 17. BUFFER SEAL 23. SNAP RING
6. PISTON ROD 12. PISTON RING 18. BUSHING 24. GREASE FITTING
SWING CYLINDER

Section
8007
BACKHOE CONTROL VALVE

MECHANICAL CONTROLS
8007

Racine, WI 53404 U.S.A. Bur 6-74931 Issued January, 2004 Revised July, 2005
8007-2 MECHANICAL LINKAGE BACKHOE MACHINES ONLY
TABLE OF CONTENTS
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Spool Valve Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
End Cap and Auxiliary Hydraulics Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low Leak Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve Cut Away View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Circuit Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BACKHOE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

MECHANICAL LINKAGE BACKHOE MACHINES ONLY 8007-3
SPECIAL TORQUES
Relief valves, item numbers 1, 2, 3, 4, and 14.....................................................................48 ± 5 lb-ft (65 ± 6.7 Nm)
Check valves, item number 7..............................................................................................90 ± 9 lb-ft (122 ± 12 Nm)
Anti void assembly, item number 6 ......................................................................................48 ± 5 lb-ft (65 ± 6.7 Nm)
End cap inner mounting bolts, item number 36 ...................................................................48 ± 5 lb-ft (65 ± 6.7 Nm)
End cap outer mounting bolt, item number 18.................................................................74 ± 8 lb-ft (100 ± 10.8 Nm)
Check valve assembly, item number 40...............................................................................48 ± 5 lb-ft (65 ± 6.7 Nm)
Center spring and seal retainer plate mounting screws, item numbers 32 and 37...............7 ± 1 lb-ft (9.4 ± 1.3 Nm)
Centering spring retaining bolt, item number 46...................................................................7 ± 1 lb-ft (9.4 ± 1.3 Nm)
1 2 3 4
5
6 19 20 21 22 23 18
24
7
25 26 27 28 29 30
1 4 3 17
14 5
8 9 10 11 13
12 15 16
BC03M052
1. RELIEF VALVE 3000 PSI (206.8 BAR) 11. STABILIZER SPOOL 21. DIPPER B PORT
2. RELIEF VALVE 4800 PSI (331 BAR) 12. DIPPER SPOOL 22. BUCKET B PORT
3. RELIEF VALVE 3450 PSI (237.8 BAR) 13. BUCKET SPOOL 23. EXTEND-A-HOE B PORT
4. RELIEF VALVE 3205 PSI (221 BAR) 14. RELIEF VALVE 3800 PSI 24. AUXILIARY HYDRAULICS B PORT
5. PLUG ASSEMBLY 15. EXTEND-A-HOE SPOOL 25. SWING A PORT
6. ANTI VOID ASSEMBLY 16. AUXILLIARY HYDRAULICS SECTION 26. BOOM A PORT
7. CHECK VALVE 17. END CAP 27. DIPPER A PORT
8. SWING SPOOL 18. END CAP OUTER MOUNTING BOLT 28. BUCKET A PORT
9. BOOM SPOOL 19. SWING B PORT 29. EXTEND-A-HOE A PORT
10. STABILIZER SPOOL 20. BOOM B PORT 30. AUXILIARY HYDRAULICS A PORT
NOTE: Relief valves are pre set and have a tolerance of ± 35 PSI (2.4 bar).

33 34
32
35
31
36
36
37
38 39
BC03M053
31. INLET PORT 34. RIGHT STABILIZER A PORT 37. SPOOL END CAP RETAINER SCREWS
32. SPOOL SEAL RETAINER PLATE SCREWS 35. OUTLET PORT 38. LEFT STABILIZER B PORT
33. LEFT STABILIZER A PORT 36. END CAP INNER MOUNTING BOLTS 39. RIGHT STABILIZER B PORT

7
40
41
43 44 45 46
42
BC03M057
40. LOW LEAK VALVE ASSEMBLY 43. LOWER SPOOL SEAL 46. CENTERING SPRING RETAINING BOLT
41. UPPER SPOOL SEAL 44. SEAL RETAINER PLATE 47. SPOOL END CAP
42. SEAL RETAINER PLATE 45. CENTERING SPRING
NOTE: The low leak valves (40) are only in the boom and dipper sections.

Pressure Relief Valves Check Valves

1. Remove valve from valve body. 1. Remove the check valve (7).
2. Lubricate “O” ring with hydraulic oil. NOTE: Make sure all components of check valve
come out of the valve body, see cutaway view on
3. Install valve and torque to 48 ± 5 lb-ft
page 5.
(65 ± 6.7 Nm).
2. Lubricate “O” ring with hydraulic oil.
Spool Valve Seals 3. Install check valve (7) and torque to 90 ± 9 lb-ft
1. Disconnect the linkage to the spool to be (122 ± 12 Nm).
removed.
End Cap and Auxiliary Hydraulics
2. Remove the spool end cap retainer screws (37),
spool end cap (47), and seal retaining plate (44). Section
3. Remove the spool from the valve body. 1. Remove end cap mounting bolts (18 and 36),
remove end cap (17), and if equipped auxiliary
4. Remove the spool seal retainer plate mounting hydraulic section (16).
screws (32), spool seal retainer plate (42), and
spool seal (41). 2. Replace all “O” rings.
5. Remove the spool centering spring retaining bolt 3. Place bolts through end cap (17) and if equipped
(46) and centering spring with caps (45) from the auxiliary hydraulic section (16).
spool. 4. Install bolts into main valve body and torque
6. Clean and inspect spool and spool bore for outer bolt (18) to 74 ± 8 lb-ft (100 ± 10.8 Nm) and
scoring or scratches, repair or replace as inner bolts (36) to 48 ± 5 lb-ft (65 ± 6.7 Nm).
necessary.
7. Lubricate the spool with clean hydraulic oil,
Low Leak Valve
install the spool in the valve body. 1. Remove the low leak valve (40).
8. Install the lower spool seal (43) and seal retainer NOTE: Make sure all components of low leak valve
plate (44). come out of the valve body, see cutaway view on
IMPORTANT: When replacing spool seals, place page 5.
spool in section, insert seal into section. Do not place 2. Lubricate “O” ring with hydraulic oil.
seal in first and install spool, this will damage the
seal. 3. Install low leak valve (40) and torque to 48 ± 5
lb-ft (65 ± 6.7 Nm).
9. Install the centering spring with caps (45),
centering spring retaining bolt and torque to
7 ± 1 lb-ft (9.4 ± 1.3 Nm).
10. Install the spool end cap (47), spool end cap
retaining screws (37) and torque to 7 ± 1 lb-ft
(9.4 ± 1.3 Nm).
11. Install the upper seal (41), upper seal retaining
plate (42) and torque to 7 ± 1 lb-ft (9.4 ± 1.3 Nm).
12. Connect linkage to the spool.

BC03M054
VALVE CUT AWAY VIEW
BC03M055
VALVE SCHEMATIC

3 4
5 6 7 8
15 11 10 9
14 13 12
BC03M084
1. POPPET 6. BACK-UP RING 11. BACK-UP RING

2. SLEEVE 7. O-RING 12. SHIM 0.050 IN (0.127 CM)
3. O-RING 8. SPRING 13. SHIM 0.020 IN (0.0508 CM)
4. SPRING 9. RETAINING RING 14. SHIM 0.007 IN (0.0177 CM)
5. SCREW 10. O-RING 15. SHIM 0.005 IN (0.0127 CM)
CIRCUIT RELIEF VALVE

BACKHOE VALVE
IMPORTANT: Do not remove more than one spool at STEP 5
a time from the valve body.
STEP 1
Clean the valve body.
STEP 2
BD05E133
Loosen the plug.
STEP 6
BD05E128
If equipped, remove the cap screws from the

auxiliary section centering spring cover.
STEP 3
BD05E135.TIF
Remove the plug from the valve section.
STEP 7
BD05E130
Remove the centering spring cover.
STEP 4
BD05E136
Loosen the end cap bolts.
BD05E131
Remove the spool from the section.

STEP 8 STEP 11
BD05E138.TIF BD05E141
Remove the end cap and if equipped, auxiliary Remove the spring.
section.
STEP 12
STEP 9
BD05E142
BD05E139 Remove the spool.

Lay the end cap and auxiliary section on to the
bench, remove the bolts. STEP 13
NOTE: Make a note of the size and location of the
bolts.
STEP 10
BD05E145
Remove the seal retaining plate, remove and discard

seal and wiper.
BD05E140
Remove the end cover from the auxiliary section.

STEP 14 STEP 18
BD05E148 BD05E152
Number the valve body and the components. If equipped, loosen the plug from the extend-a-hoe
section.
NOTE: The relief valves are set at different
pressures and must be placed back in the same
location from which they were removed. STEP 19
STEP 15
BD05E154
Remove the plug from the valve body.

BD05E149
Loosen the relief valve. STEP 20

Repeat steps 15 though 19 for the other side of the
STEP 16 valve body.
STEP 21
BD05E151
Remove the relief valve from the valve body.

BD05E155
STEP 17 Make sure to mark the centering spring covers with

identification numbers.
Repeat steps 15 and 16 for the remaining relief
valves.

STEP 22 STEP 26
BD05E156 BD05E160
Loosen the cap screws for the centering spring cover. Make a note on the valve body of the color of the
spring.
STEP 23
STEP 27
BD05E158
Remove the centering spring cover. BD05E161
Remove the spool from the valve body.

STEP 24
Repeat steps 22 and 23 for the remaining centering STEP 28
spring covers.
STEP 25
BD05E166
Remove the seal from the spool.
BD05E159
Note any color coding on the centering springs.

STEP 29 STEP 32
BD05E165 BD05E171
Remove the wipe seal from the spool. Reassemble the spool and insert back into the valve
body, make sure the wiper seal faces out towards the
STEP 30 retainer plate.
STEP 33
BD05E164
Remove the seal retaining plate.

BD05E162
STEP 31 Remove the spool from the valve body.
STEP 34
BD05E169
Remove the spool end.

BD05E168
Remove the O-ring from the spacer.

STEP 35 STEP 38
BD05E167 BD05E164
Remove the spacer from the spool. Remove the seal retaining plate.
STEP 36 STEP 39
BD05E166 BD05E171
Remove the seal from the spool. Reassemble the spool and insert back into the valve
body, make sure the wiper seal faces out towards the
STEP 37 retainer plate.
STEP 40
Repeat steps 27 though 39 for the remaining spools.
STEP 41
BD05E165
Remove the wipe seal from the spool.
BD05E184
Remove the cap screws for the seal retaining plate.

STEP 42 STEP 45
BD05E185 BD05E188
Remove the seal retaining plate. Install a new spool seal.
STEP 43 STEP 46
BD05E186 BD05E190
Remove the wiper seal. Install a new wiper seal.

NOTE: Make sure the lip of the wiper seal is facing
STEP 44 out towards the seal retaining plate.
STEP 47
BD05E187
Remove the spool seal.

BD05E185
Install the seal retaining plate.

STEP 48 STEP 51
BD05E183 BD05E192
Install seal retaining plate cap screws and torque to Torque the check valve to 90 ± 9 lb-ft (122 ± 12 Nm).
7 ± 1 lb-ft (9.4 ± 1.3 Nm).
STEP 52
STEP 49 Repeat steps 49 to 51 for the remaining check
Repeat steps 41 through 48 for the remaining spool valves.
seals.
STEP 53
BD05E193
Loosen and remove the check valve. BD05E453
Loosen the anti void plug.

STEP 50
STEP 54
BD05E194
Install the check valve and spring into the valve body, BD05E372
replace the O-ring on the plug. Hand tighten the plug Replace the O-rings and backup ring on the anti void
into the valve body making sure not to bind the valve. valve and plug.

STEP 55 STEP 58
BD05E454 BD05E197
Install and hand tighten the plug into the valve body Remove the plug, spacer, spring, and valve from the
making sure not to bind the valve. valve body.
STEP 56 STEP 59
BD05E452 BD05E198
Torque the anti void to 48 ± 5 lb-ft (65 ± 6.7 Nm). Install the valve.
STEP 57 STEP 60
BD05E195 BD05E199
Loosen the plug for the check valve. Install the spring.

STEP 61 STEP 64
BD05E200 BD05E157
Install the spacer. Install centering spring covers and torque to 7 ± 1

lb-ft (9.4 ± 1.3 Nm).
STEP 62
STEP 65
BD05E202
Make sure the washer is seated flat on the spring. BD05E153
Install a new O-ring on the plug and torque to 48 ± 5

STEP 63 lb-ft (65 ± 6.7 Nm).
STEP 66
BD05E196
Install a new O-ring on the plug, install the plug and

torque to 48 ± 5 lb-ft (65 ± 6.7 Nm). BD05E150
Install new O-rings on relief valves and torque to 48 ±

5 lb-ft (65 ± 6.7 Nm).

STEP 67 STEP 70
BD05E147 BD05E143
Install a new O-ring. Replace the O-ring.
STEP 68 STEP 71
BD05E146 BD05E142
Install a new spool seal and wiper seal. Install the valve.
STEP 69 STEP 72
BD05E144 BD05E141
Install the seal retaining plate and cap screws, torque Install the spring.
cap screws to 7 ± 1 lb-ft (9.4 ± 1.3 Nm).

STEP 73 STEP 76
BD05E140 BD05E135
Place the end cap on the auxiliary section. Install a new O-ring on the plug.
STEP 74 STEP 77
BD05E139 BD05E134
Set the bolts through the end cover into the auxiliary Install and torque the plug to 48 ± 5 lb-ft
section. (65 ± 6.7 Nm).
NOTE: The larger of the three bolts goes into the top
hole. STEP 78
STEP 75
BD05E132
Install the spool in the valve body.

BD05E137
Pull the end cap and auxiliary section up evenly,

torque the end cover bolts to 74 ± 8 lb-ft
(100 ± 10.8 Nm).

STEP 79 STEP 80
BD05E130 BD05E129
Install the centering spring cover. Install and torque the cap screws to 7 ± 1 lb-ft
(9.4 ± 1.3 Nm).

NOTES

Section
8007
PILOT BACKHOE CONTROL VALVE FOR

580M AND 580SM SERIES 3
8007

8007-2 580M AND 580SM SERIES 3
TABLE OF CONTENTS
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CIRCUIT RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Valve Section Cutaway View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

580M AND 580SM SERIES 3 8007-3
CONTROL VALVE
STEP 1 STEP 5
Remove valve from machine, see section 8001.
STEP 2
Clean the valve.
STEP 3
BD05E223
Remove the springs.
STEP 6
BD05E220
Loosen the plug.

NOTE: During assembly torque to 66 to 81 lb-ft
(90 to 110 Nm).
STEP 4
BD05E224
Remove the spool.
STEP 7
BD05E222
Remove the plug.
BD05E225
Loosen the load sense relief valve.

(41 to 50 Nm).

STEP 8 STEP 11
BD05E226 BD05E230
Remove the load sense relief valve. Number the sections for correct assembly.
STEP 9 STEP 12
BD05E227 BD05E234
Loosen load sense drain orifice. Remove the nuts securing the sections.
NOTE: During assembly torque to 13 to 16 lb-ft NOTE: During assembly use new “O” rings in all
(18 to 22 Nm). sections and torque nuts to 31 ± 3 lb-ft (42 ± 4.2 Nm).
STEP 10 STEP 13
BD05E228 BD05E237
Remove the load sense drain orifice. Remove the end cover.

STEP 14 STEP 18
BD05E238 BD05E248
Continue to separate the working sections from inlet Remove the cap from the relief valve.
section.
STEP 19
STEP 15
BD05E250
BD05E244 Loosen the relief valve.

Unscrew the check valve plug.
(63 to 77 Nm).
STEP 16
STEP 20
BD05E246
Remove the check valve. Clean and inspect check

BD05E252
valve, replace as an assembly as needed.
Remove the relief valve from the section.
NOTE: During assembly use new “O” ring and
torque to 22 ± 2 lb-ft (30 ± 3 Nm). STEP 21
Repeat steps 18 through 20 and remove the other
STEP 17 pressure relief valve.
Repeat steps 15 and 16 for the other check valve.

STEP 22 STEP 25
BD05E253 BD05E258
Loosen and remove the end cap mounting screws. Remove the spool guide.
(9 to 11 Nm). STEP 26
Repeat steps 22 through 25 and remove the other
STEP 23 end cap.
STEP 27
BD05E255
Remove the end cap.

BD05E260
STEP 24 Remove the spool from the section.

IMPORTANT: Orient the spools with the groove at
the end towards “A” or “B” port as indicated below.
Function Grove
SWING N/A
STABILIZER B
BUCKET A
BOOM B
DIPPER A
EXTEND-A-HOE A
AUXILLAIRY A
BD05E256
Remove the spring.

STEP 28 STEP 30
BD05E263 BD05E268
Unscrew the compensator plug. Separate and inspect the dampened compensator.
NOTE: During assembly use new “O” ring and
torque to 40 to 49 lb-ft (54 to 66 Nm).
STEP 29
1
BD05E266
BD05E267
1. SOLID COMPENSATOR 2. DAMPENED COMPENSATOR

Remove the compensator piston. Clean and inspect
the piston and bore, use new parts as required.

CIRCUIT RELIEF VALVE

NOTE: The following procedures are for reference STEP 34
only, the relief valves are replaced as an assembly
and are not repairable.
STEP 31
BD05E272
Loosen the plug.
STEP 35
BD05E269
Loosen the jam nut on relief valve.
STEP 32
BD05E273
Remove the plug from the body.
STEP 36
BD05E270
Remove the adjusting screw and jam nut.
STEP 33
BD05E274
Remove the spring and poppet from the body.
BD05E271
Remove the spring and poppet.

MAIN RELIEF VALVE

STEP 37 STEP 39
BD05E275 BD05E277
Loosen the locking nut for the adjusting screw. Loosen the adjusting screw retaining nut.
STEP 38 STEP 40
BD05E276 BD05E278
Loosen the adjusting screw. Remove the locking nut from the adjusting screw,
remove the retaining nut from the adjusting screw,
NOTE: The adjusting screw will not come out
remove the spring and poppet from the body.
completely.

8007-10 580M AND 580SM SERIES 3
2
1
5 4
BS03K282
VALVE SECTION CUTAWAY VIEW
1. CIRCUIT RELIEF VALVE 4. SPOOL

2. DAMPENED COMPENSATOR 5. CENTERING SPRING
3. SOLID COMPENSATOR 6. CHECK VALVE

Section
8009
ACCUMULATOR FOR MACHINES WITH

8009

8009-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISCHARGING AN ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8009-3
SPECIFICATIONS
Accumulator charging valve cap torque .......................................................................................... 10 pound-inches
Weight (Approximate) ............................................................................................................... 10.8 pounds (4.9 kg)
SPECIAL TOOLS
94L95
CAS-10899 Nitrogen Charging Kit.

8009-4
DISCHARGING AN ACCUMULATOR
4. Turn the T-handle on valve F fully out.

WA R N I N G : D O N O T a t t e m p t t o
disassemble any accumulator until the 5. Remove the guard and cap from the accumulator
nitrogen charge is properly discharged. charging stem.
SM386 6. Connect valve F to the stem on the accumulator.
IMPORTANT: To help prevent equipment damage, 7. Turn the T-handle inward on valve F to engage
the low pressure gauge (valve C) MUST BE SHUT the pin in the valve stem.
OFF during high pressure (150 psi/10 bar and above) 8. Open valve D and check the charge pressure on
applications. gauge E.
1. Use the CAS-10899 accumulator charging kit to 9. To discharge the accumulator partially open
discharge the accumulator. the tool must be valve B. The accumulator charge will bleed down
disconnected from the nitrogen tank. through the regulator.
2. Close valves B, C and D. 10. Once the accumulator is fully discharged
3. Adjust the regulator A to the minimum pressure disconnect valve F from the accumulator stem.
setting by turning the knob counterclockwise. 11. The accumulator can now be disassembled.
4
6
8 1
2
94L95
1. Valve A 4. Valve D 7. To Nitrogen Tank
2. Valve B 5. Gauge E 8. To Accumulator
3. Valve C 6. Valve F

8009-5
DISASSEMBLY
1. Fasten the accumulator tube (1) in a vise with 4. Remove the seals (4) and quad ring (5) from the
soft jaws. Be careful not to damage the tube (1). piston (3).
IMPORTANT: The gland with the gas valve must be 5. Remove the O-rings (6) and, if used, the backup
removed first. rings (7) from the glands (2 or 14).
2. Loosen and remove the gland (2 and 14) from 6. Loosen and remove the cap screws (8 ) and
each end of the tube. guard (9).
3. Use a rod and push the piston (3) out of the gas 7. Loosen and remove the gas valve assembly (10).
valve end of the tube (1).
8. Remove the O-ring (6), cap (11) and valve core
(12) from the body (13).
14
6 7
3
4
6 7
10 11 12 13
6 8
BS96H067
1. Tube 5. Quad Ring 8. Cap Screw 11. Cap
2. Gland with Gas Valve 6. O-Ring 9. Guard 12. Valve Core
3. Piston 7. Backup Ring, If Used 10. Gas Valve Assembly 13. Body
4. Seal 14. Gland without Gas Valve

8009-6
INSPECTION
1. Discard parts removed from the gland (2 and 4) 5. Inspect the gland (9) for rust. Clean and remove
and piston (3) the rust as required.
2. Clean all parts in cleaning solvent. 6. Inspect the piston (3) for damage or wear. If the
piston(3) is damaged or worn a new accumulator
3. Inspect the inside of the tube (1) for deep
must be used.
grooves and other damage. If there is any
damage, a new accumulator must be used. 7. Inspect the gland ends of the tube (1) for sharp
edges that will cause damage to the seals (4),
4. Remove small scratches on the piston (3), gland
quad ring (5), or O-rings (6) s. Remove any
(2 and 14) or tube (1) with emery cloth of 400 on
sharp edges as required.
finer grit. Use the emery cloth with a rotary
motion.
ASSEMBLY
8. Install new quad ring (6) on the piston (3). 13. Install the O-ring (6) next to the backup ring (7)
as shown in the illustration above. If a backup
9. Install a new seals (4) on each end of the piston
ring (7) is not used, install a O-ring in the groove
(3).
on the piston.
10. Lubricate the bore of the tube (1) and the piston
14. Lubricate the O-ring (6) and backup ring (7) with
(3) with clean oil.
clean oil and start the gland (2) into the tube (1).
NOTE: The piston must be installed slowly to prevent 15. Fasten the tube (1) in the vise and tighten the
damage to the quad ring on the threads in the tube. gland (2).
11. Start the piston (3) into the gas valve end of the 16. Repeat steps 5 through 8 for the other end of the
tube (1). A soft hammer and wood block may be tube (1).
used to drive the piston (3) farther into the tube
17. Install a new O-ring (6) on the body (13) of the
(1). See the illustration below for correct piston
gas valve assembly (10).
(3) installation. Carefully drive the piston (3) at
least 2 inches (51 mm) into the tube (1). Keep 18. Install the valve core (12) in the body (13).
pressure against the piston (3) when driving the
19. Lubricate the O-ring (6) with clean oil and install
piston (3) into the tube (1), to prevent damage to
and tighten the gas valve assembly (10) in the
the quad ring (5).
gland (2).
12. If used, install a new back ring (6) on the gland
20. Install the cap (11).
(2). Make sure the backup ring (6) is installed as
shown in the illustration below. 21. Charge the accumulator with dry nitrogen
according to the instructions in Section 8002.
22. Install the guard (9) and cap screws (8).
6 7
To Threaded End of Gland

8009-7
14 4 3 4 2
1
8
9
10
11
12
13
15 6 7
6
5 7
BT96H068
1. Tube 5. Quad Ring 8. Cap Screw 11. Cap
2. Gland with Gas Valve 6. O-Ring 9. Guard 12. Valve Core
3. Piston 7. Backup Ring, If Used 10. Gas Valve Assembly 13. Body
4. Seal 14. Gland without Gas Valve

8009-8
NOTES

Section
8010
SOLENOID VALVE FOR MACHINES WITH

8010

8010-2
TABLE OF CONTENTS
SOLENOID VALVES FOR MACHINES WITH OPTIONAL RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8010-3
SOLENOID VALVES FOR MACHINES WITH OPTIONAL RIDE CONTROL
1. Remove ring nut (1) from solenoid. 1. Install a new O-rings (4) on the cartridge (3).
2. Remove the coil (2). 2. Lubricate the O-ring (4) on the cartridge (3) with
clean hydraulic oil. Install the cartridge (3) in the
3. Remove the cartridge (3) from the control block
control block (5). Tighten the cartridge.
(5).
3. Install the coil (2).
4. Remove and discard the O-rings (4) from the
cartridge (3). 4. Install and tighten the ring nut (1).
3
4
BC03M085
1. RING NUT 3. CARTRIDGE

2. COIL 4. O-RINGS

8010-4
BC03M086
1. RING NUT 2. COIL 3. CARTRIDGE 5. CONTROL BLOCK

RIDE CONTROL BLOCK

8011
Section
8011
BOOM LOCK SOLENOID VALVE

8011-2
TABLE OF CONTENTS
BOOM LOCK SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DISASSMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8011-3
BOOM LOCK SOLENOID VALVE
DISASSMBLY ASSEMBLY
1. Fasten the body of the solenoid valve in a vise 1. Install O-ring (3), backup ring (4), and relief valve
with soft jaws. Loosen and remove the relief seat (2), O-ring (6), poppet (5), inner spring (8),
valve body (1). outer spring (7), O-ring (10), and piston (9) into
the solenoid body (14).
2. Remove the piston (9), outer spring (7), inner
spring (8), poppet (5), relief valve seat (2), 2. Install the O-ring (13) onto the relief valve body
backup ring (4), and o-ring (3) from the solenoid (1).
body (14).
3. Install the relief valve body onto the solenoid
3. Remove O-ring (13) from the relief valve body body (14).
(1).
NOTE: The pressure setting of the repair circuit
4. Remove the O-ring from the piston (9). relief valve is not preset for this application. Adjust
the setting according to the instructions sent with the
5. Remove the O-ring from the poppet (5).
repair valve.
INSPECTION
1. Clean the relief body (1), piston (9), poppet (5),
and the relief valve seat in cleaning solvent.
2. Inspect parts for damage, replace as required.
3. Discard O-rings (13), (10), (6), (3), and backup
ring (4), replace with new parts.
NOTE: If the solenoid (15) is damaged it must be
replaced with a new solenoid.

8011-4
12
11
13
10
9
5
6
2
4
3
15
14
BS99D077
1. RELIF VALVE BODY 5. POPPET 9. PISTON 13. O-RING

2. RELIEF VALVE SEAT 6. O-RING 10. O-RING 14. BODY
3. ORING 7. OUTER SPRING 11. SCREW 15. SOLENOID
4. BACKUP RING 8. INNER SPRING 12. NUT

8012
Section
8012
HYDRAULIC BACKHOE QUICK COUPLER

8012-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC BACKHOE QUICK COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
QUICK COUPLER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8012-3
SPECIAL TOOLS
BD08B679 BD08B678
TOOL KIT 380100096 TOOL KIT 380100096

8012-4
HYDRAULIC BACKHOE QUICK COUPLER
Removal STEP 11
Use an acceptable driver being capable of 178 to 222
kilo newton (40,000 to 50,000 lbf) and drive the
cylinder tube (10) and the sleeve (11) out of the
STEP 1 coupler (15).
Remove the bucket from the backhoe.
STEP 12
STEP 2 Drive the other sleeve (23) out of the coupler (15).
Remove the retaining rings (1) from the sleeves (11
and 23). Installation
STEP 3 STEP 13
Extend the piston rods out.
Center the coupler (15) between the dipper ears (24).
STEP 4 STEP 14
Remove the groove pins (2) from the step pins (3).
Install the sleeve (23) with the groove for the outer
coupler set screws (4 and 5) towards the center of
STEP 5 the coupler (15).
Remove the step pins (3).
NOTE: Step pins can be difficult to remove, due to STEP 15
the fit of the step pin seal (14). Use an acceptable driver being capable of 178 to 222
kilo newton (40,000 to 50,000 lbf) and drive the
NOTE: If the cylinder (10) needs to be removed or
sleeve (23) into the coupler (15) until the groove is in
the tube is damaged follow steps 6 through 12. If only
the center of the set screw (4 and 5) holes.
the piston seals are to be replaced go to step 37.
STEP 16
STEP 6
Align the two slots in the cylinder tube (10) with the
Remove the two bolts (19) and two washers (20)
two tapped holes in the center of the coupler (15).
which fasten the cover (18) to the hose guard (6).
Make sure the hydraulic ports (12 and 13) in the
cylinder tube (10) line up with the openings in the
STEP 7 coupler (15). The smaller hydraulic port (12) should
Remove and discard the two countersunk head be towards the top of the coupler (15).
socket screws (17) that fasten the hose guard (6) to
the coupler (15) and retain the cylinder (10) in place. STEP 17
Install the cylinder (10), as indicated on illustration on
STEP 8 page 5, so that the smaller hydraulic port (12) is
Remove and discard the two outer set screws (4) and towards the top of the coupler (15) and the cylinder
two outer set screws (5) that fasten the sleeves (11 (10) it is up against the sleeve (23). Drive the sleeve
and 23) in place. (23) in or out, so that the hydraulic ports (12 and 13)
are in the center of the opening in the coupler (15).
STEP 9
Disconnect the hoses (7) from the 90° elbows (8) and STEP 18
plug the hoses. Use new screws, install two outer coupler set screws
(4 and 5) to hold the sleeve (23) in place. Tighten the
STEP 10 outer coupler set screws to a torque of 14 to 20 Nm
Remove the 90° elbows (8) and the adapters (9) from (124 to 177 pound - inches).
the cylinder (10).
STEP 19
NOTE: Adapters (9) are sealed in place with silicone Install the other sleeve (11) with the grooves for the
sealant. outer coupler set screws (4 and 5) towards the center
of the coupler (15).

8012-5
STEP 20 STEP 30
Use an acceptable driver being capable of 178 to 222 Install the hoses (7) around the coupler (15) as
kilo newton (40,000 to 50,000 lbf) and drive the other shown in the illustration on the bottom of page 5.
sleeve (11) into place until it contacts the cylinder
(10). STEP 31
Refer to the illustration on the bottom of page 6 and
STEP 21 connect the hoses (7) to the 90° elbows (8) so that
Use new screws, install two outer coupler set screws the hoses (7) are staggered to run on each side of
(4 and 5) to hold the sleeve (11) in place. Tighten the the coupler (15). Tighten the 90° elbows (8) so that
outer coupler set screws to a torque of 14 to 20 Nm there is a minimum of 5 MM. (0.12 inches) of
(124 to 177 pound - inches). clearance between the hoses (7) and each side of
the coupler (15). Tighten the hose connections on
STEP 22
the 90° elbows (8).
Place the step pin seal (14) in the groove on the
outside of each of the step pins (3). See step pin seal STEP 32
orientation (16) for proper step pin seal installation. Place a 6 MM. (0.24 inch) fillet bead of RTV silicone
sealant around the inside of the coupler (15) fitting
STEP 23
access slot and area around the adapters (9). The
Lubricate the outside diameters of both step pins (3)
RTV silicone sealant should not prevent access to
with Lubriplate prior to installation.
the fittings in the coupler (15). Fill the ends of the set
STEP 24 screw holes (4 and 5) with RTV silicone sealant.
With the piston rods extended out, install the step
STEP 33
pins (3) and push the step pins (3) into place.
See the illustration on page 5 and route the hoses (7)
STEP 25 for the proper machine application (21 and 22) under
Align the hole for the groove pin (2) in the step pins the clamp (25).
(3) with the hole in the piston rod and install the
STEP 34
groove pins (2). The groove pins (2) should be
Place 25 MM. (0.99 inches) ± 10 MM. (0.40 inches)
installed at least 2 MM. (0.08 inches) below the
of the cordura sleeve (26) under the clamp (25).
surface of the step pins (3) on each side.
STEP 35
STEP 26
Install the hose guard (6) and cover (18) on the
Push the step pins (3) inward enough to allow the
coupler (15). Install and tighten the bolt (19) and
retaining rings (1) to be installed on the inside
washer (20). Install two new countersunk head
retaining ring groove of the sleeves (11 and 23).
socket screws (17) which fasten the hose guard (6) to
Install the retaining rings (1) in the sleeves (11 and
the coupler (15). The two countersunk head socket
23).
screws (17) protrude into the grooves on the cylinder
STEP 27 tube (10) to hold the cylinder tube (10) in place within
Install the hoses (7) for the 580SM with the standard the coupler (15). Tighten the two flat head socket
dipper so that the hex on the fittings nearest to the screws (17).
bucket pivot touches the clamp (27). Tighten the
STEP 36
clamp (27).
Star t the engine and check for hydraulic leaks.
STEP 28 Rotate the coupler (15) at slow speed all the way
For the hose (7) installation on the 580SM and back to the bucket dump position. Stop the engine.
590SM machines equipped with the Extendahoe Make sure all the slack in the hoses (7) is taken up
option, see the illustration on page 6. Install the towards the clamp (25). Tighten the clamp (25).
hoses (7) on each side so that the hex on the fittings
nearest to the bucket pivot touches the isolator (2).
Tighten the clamps (1).
STEP 29
Install and tighten the two adapters (9) into the
proper hydraulic ports 12 and 13). Install the two 90°
elbows (8) on the adapters (9).

8012-6
16
BS02C051
14 1
10 12 3
23
13 2
10 4
BS02C050 15
11
3
14 24
1
2
5
BS02C052
21
22 15
25
7
4 4
19
27 20
26 6 17
8 18
17
9 17
12 8
9 5 5
13
BS02C053 BS02C106
1. RETAINING RING 10. CYLINDER TUBE 19. BOLT

2. GROOVE PIN 11. SLEEVE 20. WASHER
3. STEP PIN 12. 3/8 INCH - 24 UNF HYDRAULIC PORT 21. 580SM HOSE ROUTING (TOP VIEW)
4. OUTER COUPLER SET SCREWS (2) 13. 7/16 INCH - 20UNF HYDRAULIC PORT 22. 590SM HOSE ROUTING (TOP VIEW)
5. OUTER COUPLER SET SCREWS (2) 14. STEP PIN SEAL 23. SLEEVE
6. HOSE GUARD 15. COUPLER 24. DIPPER EARS
7. HOSES 16. STEP PIN SEAL ORIENTATION 25. CLAMP
8. 90° ELBOW 17. FLAT SOCKET HEAD SCREWS (2) 26. CORDURA SLEEVE
9. ADAPTER 18. COVER 27. CLAMP

8012-7
1 2 7
3 5
4
BS02C129
1. CLAMP 4. LOCK WASHER 7. HOSE(S) (1 EACH SIDE)

2. ISOLATOR 5. WASHER
3. BOLT 6. DIPPER TUBE (1 EACH SIDE)
580SM AND 590SM EXTENDAHOE HOSE ROUTING
8
8
1
1
7 7
15
elbows
BC02D014
1. 5 MM CLEARANCE (MINIMUM) 15. COUPLER

7. HOSES
8. 90° ELBOWS
COUPLER HOSE ROUTING

8012-8
BS02C107
1. COUPLER
2. FITTING ACCESS HOLE
COUPLER
1 5
2 6
3 7
3
4
4
BS02C105
1. CYLINDER TUBE 5. INTERNAL RETAINING RING

2. RETAINING RING 6. SPACER
3. ROD 7. EXTERNAL RETAINING RING
4. GLAND
COUPLER CYLINDER

8012-9
NOTE: Refer to illustrations on page 10.
STEP 47
STEP 37 Clean the glands (5), piston rods (6) and tube (1) in
cleaning solvent.
Remove the snap ring (2) from the gland (5). Then
push the gland (5) slightly into the cylinder.
STEP 48
STEP 38 Discard the parts that were removed from the pistons
and the glands (5).
Remove the spacer (3).
STEP 49
STEP 39
Illuminate the inside of the tube (1). Inspect the
Remove the snap ring (4) from the tube (1).
damage. If there is damage to the tube (1), a new
STEP 40 tube (1) must be used. See page 3 in this section for
Install the plastic service ring into the snap ring removal of cylinder tube.
groove in the tube (1).
IMPORTANT: See illustration on this page for STEP 50
orientation of the plastic service ring. Remove small scratches on the inside of the tube (1)
with emery cloth of medium grit. Use the emery cloth
STEP 41 with a rotary motion.
Pull the rod assembly (6) out of the tube (1).
STEP 51
STEP 42 Check to be sure that the piston rods (6) are straight.
Remove the plastic service ring from the tube (1). If a piston rod (6) is not straight, install a new piston
rod (6).
STEP 43 TUBE END
Remove the gland (5) from the rod (6).
STEP 44
Fasten the rod (6) in a vise with soft jaws.
STEP 45
Remove the seal (7), ring (8), ring (9), and O-ring
(10) from the piston.
STEP 46
Remove the wiper seal (11), bushing (12), seal (13),
O-ring (14), and backup ring (15) from the gland (5).
BS00C112
NOTE: Repeat steps 37 through 46 for the other PLASTIC SERVICE RING ORIENTATION
side.

8012-10
Assembly STEP 57
Lubricate the seals of the piston rod (6) and the
STEP 52 gland (5) with clean oil. Push the piston rod and
Install the wiper seal (11) in the gland (5). The lips gland sub-assembly into the bore of the tube (1) far
must be toward the small end of the gland (5). enough to allow the installation of the snap ring (4). If
necessary, use a soft hammer to drive the piston rod
(6) and gland (5) into the tube (1).
STEP 53
Install the seal (13) and bushing (12) in the gland (5).
STEP 58
Install the snap ring (4) in the tube (1).
STEP 54
Install the backup ring (15) and O-ring (14) on the
STEP 59
outside of the gland (5).
Pull the rod (6) outwards until the gland (5) is seated
against the snap ring (4).
STEP 55
Install a new O-ring (10), ring (9), ring (8), and seal
STEP 60
(7) on the piston.
Install the spacer (3) on the gland (5).
STEP 56
STEP 61
Lubricate the bore of the gland (5) with clean oil and
push the gland assembly onto the piston rod (6). The Install the snap ring (2) on the gland (5).
wide end of the gland (5) should contact the piston. NOTE: Repeat steps 57 through 61 for the other
NOTE: Repeat steps 52 through 56 for the other side.
gland (5) and piston rod (6).

8012-11
2
3
4
1
BS02C105
1. TUBE 3. SPACER 5. GLAND

2. SNAP RING 4. SNAP RING
7 9
6
10
12 11
BS01C110
13
6. PISTON ROD 9. RING
7. SEAL 10. O-RING
8. RING
14 15
COUPLER CYLINDER PISTON
BS01C109
11. WIPER SEAL 13. SEAL 15. BACKUP RING

12. BUSHING 14. O-RING
COUPLER CYLINDER GLAND

8012-12
NOTES

Section
8013
8013
SWING DAMPENING VALVE

8013-2
TABLE OF CONTENTS
SWING DAMPENING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8013-3
SWING DAMPENING VALVE
Disassembly STEP 3
NOTE: Your valve may appear different than that of
the following photos, the procedures are the same.
STEP 1
BD01B217
Remove the spring.
STEP 4
BD01B215
Fasten the swing cushion valve in the vise with soft

jaws. Loosen the plug for the crossover spool
assembly.
STEP 2
BD01B218
Remove the crossover spool.
STEP 5
BD01B216
Remove the plug.
BD01B219
Loosen and remove the Inline check valve.

8013-4
STEP 6 STEP 10
BD01B220 BD01B223
Loosen and remove the internal inline check valve. Loosen and remove the plug for the bi-directional
check valve.
STEP 7
STEP 11
BD01B221
Loosen and remove the orifice check valve. BD01B224
Loosen and remove the bi-directional check valve.

STEP 8
BD01B222
Loosen and remove the orifice plug.
STEP 9
Repeat steps 5 through 8 for the opposite end of the
swing cushion valve.

8013-5
Inspection STEP 14
STEP 12 2
2
2 3
4 2
4
1
1
3
BD01B227
1. ORIFICE CHECK VALVE 3. BACKUP RING

BD01B228 2. O-RING 4. ORIFICE PLUG
1. PLUG 3. SPRING Inspect the parts of the orifice check valve and orifice
2. O-RING 4. CROSSOVER SPOOL plug. Replace the O-rings and backup ring. Use new
Inspect the parts of the crossover spool assembly. parts as required.
Replace the O-ring on the plug. Replace parts as
required. STEP 15
STEP 13 4
1
3
3
2
4
2
1
2 2
BD01B225
3 2
1. BI-DIRECTIONAL CHECK VALVE 3. BACKUP RING
BD01B226 2. O-RING 4. PLUG
1. INLINE CHECK VALVE 3. BACKUP RING Inspect the parts of the bi-directional check valve and
2. O-RING 4. INTERNAL INLINE CHECK VALVE plug. Replace the O-rings and backup ring. Use new
Inspect the par ts of the inline check valve and parts as required.
internal inline check valve. Replace the O-rings
and backup ring. Use new parts as required.

8013-6
Assembly STEP 18
STEP 16
3
3
2
BD01B223
1
2 Install the plug for the bi-directional check valve.
BD01B225
Tighten the plug to a torque of 15 to 20 Nm (132 to
177 pound-inches).
1. BI-DIRECTIONAL CHECK VALVE 3. BACKUP RING
2. O-RING 4. PLUG
STEP 19
Use clean oil to lubricate the O-rings and backup
rings on the bi-directional check valve and plug.
2
STEP 17 2
3
2
4
BD01B227
1. ORIFICE CHECK VALVE 3. BACKUP RING

2. O-RING 4. ORIFICE PLUG
BD01B224
Use clean oil to lubricate the O-rings and backup
Install the bi-directional check valve. Tighten the rings on the orifice check valve and orifice plug.
bi-directional check valve to a torque of 5.4 to 6.7
Nm (48 to 59 pound-inches). STEP 20
BD01B222
Install the orifice plug. Tighten the orifice plug to a

torque of 8 to 11 Nm (71 to 97 pound-inches).

8013-7
STEP 21 STEP 23
BD01B221 BD01B220
Install the orifice plug. Tighten the orifice plug to a Install the internal inline check valve. Tighten the
torque of 29 to 33 Nm (257 to 292 pound-inches). internal inline check valve to a torque of 10 to 13
Nm (88 to 115 pound-inches).
STEP 22
STEP 24
1
2
4
2
3 2
BD01B226
1. INLINE CHECK VALVE 3. BACKUP RING BD01B219
2. O-RING 4. INTERNAL INLINE CHECK VALVE Install the inline check valve. Tighten the inline check
Use clean oil to lubricate the O-rings and backup valve to a torque of 29 to 33 Nm (257 to 292
rings on the inline check valve and internal inline pound-inches).
check valve.
STEP 25
the section.

8013-8
STEP 26 STEP 29
2
4
1
3
BD01B228 BD01B216
1. PLUG 3. SPRING Start the plug into the valve.

2. O-RING 4. CROSSOVER SPOOL
Use clean oil to lubricate the O-ring on the plug, the STEP 30
spring, and the crossover spool.
STEP 27
BD01B215
Tighten the plug to a torque of 25 to 30 Nm (221 to

265 pound-inches).
BD01B218
Install the crossover spool.
STEP 28
BD01B217
Install the spring.

8013-9
2
3 4
2 2
5 5 6
6
3 3
7 4
8
9
12
11
10
BS01B134
1. SWING CUSHION VALVE 5. INTERNAL INLINE CHECK VALVE 9. CROSSOVER SPOOL ASSEMBLY
2. INLINE CHECK VALVE 6. ORIFICE PLUG 10. PLUG
3. ORIFICE CHECK VALVE 7. PLUG 11. SPRING
4. BI-DIRECTIONAL CHECK VALVE ASSEMBLY 8. BI-DIRECTIONAL CHECK VALVE 12. CROSSOVER SPOOL
Swing Dampening Valve

8013-10
NOTES

Section
8014
8014
PILOT CONTROL UNIT

CASE, LLC Case is a registered trademark of Case, LLC.
8014-2
TABLE OF CONTENTS
PILOT CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8014-3
PILOT CONTROL UNIT

NOTE: Remove control unit from machine, see STEP 4
section 8001.
STEP 1
BD05E425
Remove the cardan from the control unit.
BS03K085 STEP 5
Loosen the handle jam nut, unscrew handle from
control unit.
NOTE: During assembly torque jam nut to
29.5 ± 3 pound feet (40 ± 4 Nm).
STEP 2
BD05E426
Keep all shims for the cardan together for use during
assembly.
NOTE: During assembly use Loctite 262 on threads
and torque cardan bolt to 29.5 ± 3 pound feet (40 ± 4
Nm).
BD05E423
Place the control handle in a soft jawed vise. STEP 6

STEP 3
BD05E427
Remove the retaining plate from the control unit.

BD05E424
Loosen the cardan.

8014-4
STEP 7 STEP 10
BD05E428 BD05E432
Mark the guides and the body so components will be Remove the regulation units.
placed into the same position.
STEP 11
STEP 8
BD05E437
BD05E429 Push down on the retainer cup and twist the plunger
Insert the end of a thin screwdriver between the out of the cup.
guide and the body, carefully lift the guide to remove
it from the body. STEP 12
STEP 9
BD05E438
Remove the spring and shims from the plunger.

BD05E431
Mark the retainer cups.

8014-5
STEP 13 STEP 15
1 2 3 4 5 6 7 8
BD05E436
BD05E439.TIF Remove and replace the “O” rings.
1. DUST BOOT 5. RETAINER CUP
2. PLUNGER 6. SPRING STEP 16
3. SPRING 7. PLUNGER
4. PLUNGER 8. SPRING
Inspect the regulation units, repair or replace as
necessary.
STEP 14
BD05E435
Install bolt and torque to 37 ± 3.5 pound feet (50 ± 5

Nm).
IMPORTANT: Make sure notches are aligned during
assembly.
BD05E434
Turn control unit over in the vise and remove the

lower body.

8014-6
NOTES

Section
8015
REGULATED MANIFOLD
8015

CASE, LLC. Case is a registered trademark of Case, LLC.
Racine, WI 53404 U.S.A. Bur 6-79960 Issued July, 2005
8015-2
TABLE OF CONTENTS
REGULATED MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Regulated Manifold Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Regulated Manifold Exploaded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8015-3
REGULATED MANIFOLD
Disassembly STEP 4
STEP 1
BD05E103
Remove the nut and solenoid for the cutoff valve.

BD05E101
Remove pressure reducing valve. STEP 5
STEP 2
BD05E105
Loosen and remove the cutoff valve.

BD05E483
Remove the check valve and orfice. STEP 6
STEP 3
BD05E107
Remove the nut and solenoid for the pattern change

BD05E102
valve.
Remove the accumulator.

8015-4
STEP 7 STEP 10
BD05E108 BD05E114
Remove the nut and solenoid for the pattern change Remove stabilizer mounting screws.
valve.
STEP 11
STEP 8
BD05E115
BD05E109 Remove the stabilizer solenoid.

Loosen and remove the pattern change valve.
STEP 12
STEP 9 Repeats steps 10 and 11 to remove the remaining
stabilizer solenoids.
Assembly
STEP 13
BD05E111
Loosen and remove the pattern change valve.
BD05E116
Replace all O-rings and backup rings.

8015-5
STEP 14 STEP 17
BD05E115 BD05E118
Lubricate the O-rings with hydraulic oil, install the Torque the pattern change valve to 20 Nm (14 lb-ft).
stabilizer solenoids into the manifold.
STEP 18
STEP 15 Repeat step 16 and 17 for the other pattern change
valve.
STEP 19
BD05E117
Install and torque the stabilizer mounting screws to

20 Nm (14 lb-ft).
BD05E119
STEP 16 Install the solenoids on the pattern change valves.
NOTE: Make sure the connectors are towards the
bottom of the manifold.
BD05E113
Lubricate the O-rings with hydraulic oil, install the

pattern change valve into the manifold.

8015-6
STEP 20 STEP 23
BD05E120 BD05E121
Torque the pattern change valve solenoids to 1.7 to Lubricate the O-rings with hydraulic oil, install the
2.2 Nm (15 to 20 lb-in). pressure reducing valve and torque to 20 Nm
(14 lb-ft).
NOTE: Overtorquing will cause the solenoid to bind
and stick.
STEP 24
STEP 21
1
3 BD05E106
Lubricate the O-rings with hydraulic oil, install the

BD05E483
cutoff valve into the manifold.
Install orfice (1) into the manifold. Install the O-ring
(2) onto check valve (3).
STEP 25
STEP 22
BD05E122
Torque the cutoff valve to 20 Nm (14 lb-ft).

BD05E505
Install the check valve into the manifold with the small
holes faceing away from the pressure reducing valve.

8015-7
STEP 26 STEP 27
BD05E123 BD05E124
Torque the cutoff valve solenoids to 1.7 to 2.2 Nm (15 Lubricate the O-ring with hydraulic oil, install and
to 20 lb-in). tighten the accumulator into the manifold.
NOTE: Overtorquing will cause the solenoid to bind
and stick.
1 2
3 4 5 11
6 9
7
10 12
8 3 4 5 11
BC05F015
REGULATED MANIFOLD SCHEMATIC

NOTE: Early production machines were not equipped with a screen on items 3, 4, 5, and 11.

8015-8
1
2
7 8
10
9
7 8
BS03K290
REGULATED MANIFOLD EXPLOADED VIEW
1. PATTERN CONTROL SELECTION SOLENOIDS 6. DIAGNOSTIC PORT

2. PRESSURE REDUCING VALVE 7. RIGHT STABILIZER CONTROL SOLENOIDS
3. WIRE MESH FILTER 8. LEFT STABILIZER CONTROL SOLENOIDS
4. CHECK VALVE 9. CUT OFF SOLENOID (EXCEPT STABILIZERS)
5. 1.8MM (0.070 IN) ORIFICE 10. ACCUMULATOR PORT

SECTION INDEX
MOUNTED EQUIPMENT

Pedals and Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001
Air Conditioning Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002
Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Air Conditioning Components Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006
ROPS Cab and Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007
Backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9008
Standard and Mechanical Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9009
Air Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9010
Rear Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9012

9001
Section
9001
PEDALS AND LEVERS

9001-2
TABLE OF CONTENTS
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENT FOR RETURN-TO-DIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUSTMENT OF ANTIROLLBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
THROTTLE LINKAGE ADJUSTMENT 580M ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
THROTTLE LEVER ADJUSTMENT 580M ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Throttle Linkage 580M Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BRAKE PEDAL HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ADJUSTMENT OF THE BACKHOE CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Backhoe Controls With Foot Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Backhoe Controls With Hand Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Loader Lift Bucket Control - SM+ Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Loader Lift Bucket Control - M and SM Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Boom Latch Mechanical Linkage Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Boom Latch Pilot Controlled Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Backhoe Auxiliary Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

9001-3
SPECIFICATION
Length of the rollback cable assembly for the anti rollback adjustment ................................ 702 mm (27.64 inches)
Brake pedal height
With floor matt.......................................................................................... 157 to 159 mm (6.18 to 6.25 inches)
With out floor matt....................................................................................... 177 to 179 mm (6.9 to 7.04 inches)
Brake pedal free travel ............................................................................................. 2 to 4 mm (0.08 to 0.15 inches)

9001-4
ADJUSTMENT FOR RETURN-TO-DIG

1. Park the machine on a level surface and apply 8. Check the position of the bucket on the floor.
the parking brake. When the bucket reaches a level surface the lip
should be flat within 38 mm (1.5 inches).
2. Lower the loader frame and put the bucket flat on
the floor or in the correct digging position. 9. If the bucket is not in the correct position, do
steps 11 through 14.
3. Stop the engine.
10. If the bucket is in the correct position, adjust the
4. Loosen the cap screws (1) and move the switch
pointer on the loader dump link to match the
bracket (2) and switch (3) until the roller on the
pointer on the guide link.
switch (3) touches the cam (4). Tighten the cap
screws (1). See the illustration on page 5. 11. Loosen the cap screws (1).
NOTE: Make sure the switch bracket is moved 12. Move the switch bracket (2) and switch (1)
toward the inside of the machine so that the roller forward if the bucket did not roll back far enough.
on the switch is fully in contact with the cam.
13. Move the switch bracket (2) and switch (1)
5. Start the engine. Raise the loader frame all the rearward if the bucket rolled back too far.
way and dump the bucket completely.
14. Repeat steps 5 through 13 until the bucket
6. Increase the engine speed to full throttle. returns to the correct position.
7. Put the loader control lever in the ROLLBACK
and then the float position. The loader frame will
lower to the floor and the bucket will roll back.

9001-5
5
4
GS99J900
1. CAP SCREW 3. SWITCH 5. WAVE WASHER

2. SWITCH BRACKET 4. CAM

9001-6
ADJUSTMENT OF ANTIROLLBACK
1. Check to see that the cable assembly, which 6. If the side cutting edge is not in the specified
includes the rollback cable (1), the nut (2), and position, adjust the nut (2) and the clevis (3) on
t h e c l ev i s ( 3 ) , i s a d j u s t e d t o a l e n g t h o f the rollback cable (1) to change the length of the
approximately 702 mm (27.64 inches). See the cable assembly. Lengthen the cable assembly to
illustration on page 7. increase the amount of rollback. Shorten the
cable assembly to decrease the amount of
2. Roll the bucket all the way back.
rollback.
3. Raise the loader frame all the way.
7. Use washers (5) as required to remove any
4. Look at the side cutting edge of the bucket. space between the bearings (6) and the snap
rings (7) at both ends of the rollback rod (8). If
5. The side cutting edge must be approximately
the washers are not required, leave on rollback
level.
rod (8) between the snap rings (7).
8. Tighten the cap screw (4) to 27 Nm (20
pound-feet).

9001-7
2
3
7
6
6 7
5 4
4
GS99J905
1. ROLLBACK CABLE 3. CLEVIS 5. WASHERS 7. SNAP RING

2. NUT 4. CAP SCREW 6. BEARING 8. ROLLBACK ROD

9001-8
THROTTLE LINKAGE ADJUSTMENT 580M ONLY

1. Disconnect the ball joint (1) from the lever on the 4. Connect the ball joint (1) to the lever on the fuel
fuel injection pump. See the illustration on page injection pump.
9.
5. Move the throttle lever (2) to the high idle
2. Use a photo tachometer or other tachometer of position. The ball joint (1) must obtain 1 mm
equal accuracy to check the engine speeds. If (0.039 inch) override at the injection pump lever
the engine speeds are not equal to the (11) on the fuel injection pump.
specifications in this section, adjust the engine
6. To obtain the required override, adjust the
speeds as required. See Special Tools in this
throttle cable jam nuts (8) at the engine.
section.
7. Check to see that the high and low idle engine
NOTE: Adjustment of high idle must be done by an
speeds are as specified. See Section 2002 for
authorized Case service person.
specifications.
3. Push the throttle lever (2) forward until the lever
(9) on the cross shaft (4) touches the fire wall. If
the lever (9) does not touch the fire wall, adjust
the cable clevis (14) until the lever (9) touches
the fire wall.
THROTTLE LEVER ADJUSTMENT 580M ONLY

Move the throttle lever (2) to the high idle position and then to the low idle position. The throttle lever (2) must move
smoothly and hold the setting for the throttle lever (2) when the throttle lever (2) is released. If the throttle lever (2)
does not move smoothly or hold the setting after the throttle lever (2) has been released, the throttle lever (2) must
be adjusted. The inner nut (15) must be torqued to 5.6 to 6.2 Nm (50 to 55 lb-in), then torque the outer jam nut (10)
to 3.3 to 5.7 Nm (24 to 42 lb-in).

9001-9
10
15
2
12
7 8
5
1
11
6 9
12 14 3
BC03N123
1. BALL JOINT 5. THROTTLE PEDAL 9. LEVER - FOOT THROTTLE 13. CABLE

2. THROTTLE LEVER 6. LEVER - HAND THROTTLE 10. JAM NUT 14. CLEVIS
3. CLEVIS 7. CABLE 11. INJECTION PUMP LEVER 15. LOCK NUT
4. CROSS SHAFT 8. CABLE JAM NUTS 12. CABLE JAM NUTS
THROTTLE LINKAGE 580M ONLY

9001-10
BRAKE PEDAL HEIGHT ADJUSTMENT

STEP 1 STEP 2
Adjust the master cylinder push rods in order to
achieve 1 to 3 MM (0.039 to 0.118 inches) of free
play measured at the pedal pad.
BC08A206-01
Using the adjustment bolts, adjust the LH and RH

pedals to 90 to 92 MM (3.54 to 3.62 inches).

9001-11
1 2 3 4 5 6 7
8
9 12
10 11
18
17 16
13
14
15
BC08A205-01
1. BOLT 7. BOLT 13. HEIGHT ADJUSTING BOLT

2. PIVOT PIN 8. 60 MM (2.35 INCHES) 14. SPRING
3. SPACER 9. 27 MM (1.06 INCHES) 15. BRALKE LIGHT SWITCH
4. SHIM 10. CLEVIS PIN 16. RIGHT PEDAL
5. SELF LOCKING NUT 11. COTTER PIN 17. LEFT PEDAL
6. BUSHINGS 12. MASTER CYLINDER 18. PEDAL LOCKING PIN

9001-12
ADJUSTMENT OF THE BACKHOE CONTROL LEVERS

1. All control levers (1) must be in alignment and 2. All control levers (1) must be within 71 to 73
centered in the slots in the control tower (2). See degrees from the floor plate as seen from the
the illustration below. right side of the backhoe.
Right Side Shown 2
BS00N131
1. CONTROL LEVERS 2. CONTROL TOWER 3. FLOOR PLATE 4. 71 TO 73 DEGREES

9001-13
INSTALLATION DRAWINGS
1
3
4
5
2
6
11
11
7
11
11
11
12
10
9
BS00N132
1. EXTENDAHOE (IF USED) 6. LH STABILIZER 11. SHIM WASHERS. USE AS NECESSARY BETWEEN THE CONTROL
2. SPACER (USED WITHOUT 7. RH STABILIZER LEVERS TO REMOVE END PLAY. USE AT LEAST ONE SHIM WASHER (11)
EXTENDAHOE) 8. LH SWING PEDAL BETWEEN EACH TWO CONTROL LEVERS.
3. BOOM 9. SWING CONTROL 12. CLEVIS. ADJUST SO THAT THE SWING PEDALS (8 AND 10) ARE AT AN
4. DIPPER SHAFT ANGLE OF 19 TO 21 DEGREES FROM THE FLOOR WHEN THE “J” LUG ON
5. BUCKET 10. RH SWING PEDAL THE SWING BELLCRANK (9) IS PARALLEL TO THE FLOOR.
BACKHOE CONTROLS WITH FOOT SWING

9001-14
7 8
4
9
11
2
10 3 6
GS99J913
1. BUCKET AND DIPPER 5. BOOM 9. CONTROL LEVER MOUNTING BRACKET

2. BUCKET 6. SWING 10. EXTENDAHOE CONTROL PEDAL (IF EQUIPPED)
3. DIPPER 7. RH STABILIZER 11. EXTENDAHOE CONTROL PIVOT (MOUNTED ON
4. BOOM AND SWING 8. LH STABILIZER RH SIDE OF BACKHOE CONTROL TOWER)
BACKHOE CONTROLS WITH HAND SWING

9001-15
6 7
1 2 3
5 8
1
9
4 1
2
15 10
4 11
20
11 12
30
12
14 13
29 2
14 2
4 16
21 21 19
18 4
28
1
22 17
27 4
26
1 23
4 24
25
BS08B583
1. BOLT 11. COTTER PIN 21. BELLOWS

2. NUT 12. PIN 22. CLEVIS PIN
3. BALLJOINT 13. WASHER 23. LOADER CONTROL VALVE
4. WASHER 14. BUSHING 24. SPACER
5. HANDLE SHAFT 15. U-BRACKET 25. THREADED INSERT
6. TWO BUTTON HANDLE (STANDARD TRANS) 16. BEARING 26. 0-RING
7. THREE BUTTON HANDLE (POWERSHIFT TRANS) 17. BEARING 27. ADJUSTABLE CLEVIS
8. BOOT 18. SHAFT 28. THIN NUT
9. SCREW 19. YOKE LINKAGE 29. PLUG
10. NUT 20. BUCKET CONTROL ROD 30. LIFT CONTROL ROD
LOADER LIFT BUCKET CONTROL - SM+ MACHINES
NOTE: Adjust length and offset of bucket control rod (20) and lift control rod (30) using clevis (27).

9001-16
6 7
8
5 9
1
1
10
2 11 11
15 2
3
12
4 13
4
3 14
4
12 14 4
4 1
16
2
19 2
20
27 18
17 1
26 2
2
1 21
25
22
11
2 23
24
BS08B582
1. BOLT 10. NUT 19. YOKE LINKAGE

2. WASHER 11. COTTER PIN 20. BUCKET CONTROL ROD
3. BALLJOINT 12. PIN 21. LOADER CONTROL VALVE
4. NUT 13. WASHER 22. SPACER
5. HANDLE SHAFT 14. BUSHING 23. THREADED INSERT
6. TWO BUTTON HANDLE (STANDARD TRANS) 15. U-BRACKET 24. PIN
7. THREE BUTTON HANDLE (POWERSHIFT TRANS) 16. BEARING 25. BELLOWS
8. BOOT 17. BEARING 26. PLUG
9. SCREW 18. SHAFT 27. LIFT CONTROL ROD
LOADER LIFT BUCKET CONTROL - M AND SM MACHINES

9001-17
BC03N121
BOOM LATCH MECHANICAL LINKAGE MACHINES

9001-18
BC03N122
BOOM LATCH PILOT CONTROLLED MACHINES

9001-19
BC03N120
1. CONTROL LEVER
BACKHOE AUXILIARY CONTROL

9001-20
NOTES

9002
Section
9002
AIR CONDITIONING TROUBLESHOOTING

AND SYSTEM CHECKS

9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Problem: Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem: Erratic Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Problem: System Makes Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blower and Compressor Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Visual and Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator/Heater Core Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SYSTEM TEMPERATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A/C RECOVERY AND CHARGING STATION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
QUICK REFERENCE TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Problem - No Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Problem - No Cooling or Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Problem - Not Enough Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Problem - Intermittent Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Problem - Noise in System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PRESSURE SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
AIR CONDITIONING CONTROL SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Current Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Sensing Line Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS

MANUAL. WHEN YOU SEE THIS SYMBOL, CREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
M171B
ATTENTION: Only authorized technicians certified 1. Always wear safety goggles when doing any
by an approved training and certification organization service work near an air conditioner system.
may service or repair motor vehicle or mobile air Liquid refrigerant getting into the eyes can cause
conditioning systems. It is mandatory that all ser ious injur y. Do the following if you get
refrigerant must be RECOVERED and RECYCLED refrigerant near or in your eyes:
when removed from a system during servicing.
A. Flush your eyes with water for 15 minutes.
Refrigerant HFC134a is the most stable, and easiest
B. See a physician immediately.
to work with of the refrigerants now used in air
conditioner systems. Refrigerant HFC134a does not 2. A drop of liquid refrigerant on your skin may
contain any chlorofluorocarbons (CFC’s) which are cause frostbite. Open the fittings carefully and
harmful to the earth’s ozone layer. slowly when it is necessary to service the air
conditioner system. Your skin must be treated for
Safety procedures must be followed when working
frostbite or a physician must be seen if you get
with Refrigerant HFC134a to prevent possible
refrigerant on your skin.
personal injury.
3. Keep refrigerant containers in the correct upright
position. Always keep refrigerant containers
away from heat and sunlight. The pressure in a
container will increase with heat.
4. Always reclaim refrigerant from the system, if you
are going to weld or steam clean near the air
conditioner system.
5. Always check the temperature and pressure of
the air conditioner system before reclaiming
refrigerant and when you test the system.
6. Dangerous gas can form when refrigerant comes
in contact with an open flame. Never permit
fumes to be inhaled.
7. Never leak test with compressed air or flame
testers. Tests have indicated that compressed
m i x t u r e s o f H F C 1 3 4 a a n d a i r c a n fo r m a
combustible gas.

9002-4
SPECIAL TOOLS
299L7C A22094
OEM-1036 Belt Tension Tool OEM-1415 Refrigerant Recovery, Recycling and

Charging Station
A22090
OEM-1437 Electronic Leak Detector BS03H012
Safety Goggles- Obtain Locally

In the USA and Canada order Service Tools from:
OTC Division/SPX Corporation
655 Eisenhower Drive
Owatonna, Minnesota 55060
phone: 507-455-7000
1-800-533-0492

9002-5
OPERATION
The refrigerant circuit of the air conditioning system The refrigerant still in a high pressure liquid form,
contains five major components: compressor, then flows from the receiver-drier to the expansion
condenser, receiver-drier, expansion valve and valve. The expansion valve then causes a restriction
evaporator. These components are connected by in flow of refrigerant to the evaporator core.
tubes and hoses and operate as a closed system.
As the refrigerant flows through the evaporator core
The air conditioner system is charged with HFC134a
the refrigerant is heated by the air around and flowing
refrigerant.
through the evaporator fins. The combination of
The compressor receives the refrigerant as a low increased heat and decreased pressure causes the
pressure gas. The compressor then compresses the air flow through the evaporator fins to become very
refrigerant and sends it in the form of a high pressure cool and the liquid refrigerant to become a low
gas to the condenser. The air flow through the pressure gas. The cooled air then passes from the
c o n d e n s e r t h e n r e m o ve s t h e h e a t f r o m t h e evaporator to the cab for the operator’s comfort.
refrigerant. As the heat is removed the refrigerant
The electrical circuit of the Air Conditioning System
changes to a high pressure liquid.
consists of a fan speed control, temperature control,
The high pressure refrigerant liquid then flows from three (3) mini relays, two (2) 10 amp circuit breakers,
t h e c o n d e n s e r t o t h e r e c e i v e r - d r i e r. T h e two (2) fan motors, a blower motor, blower resistor,
receiver-drier is a container filled with moisture compressor clutch, low pressure switch, high
removing material, which removes any moisture that pressure switch, and warning light.
may have entered the air conditioner system in order
to prevent corrosion of the internal components of
the air conditioner system.
5
4
208L95
1. EXPANSION VALVE 3. COMPRESSOR 5. RECEIVER-DRIER
2. EVAPORATOR 4. CONDENSER

9002-6
TROUBLESHOOTING
1. Perform a visual inspection of the machine. - Are there heavy accumulations of oil, or oily dust
Check the following and correct as necessary: around the fittings, indicating refrigerant leakage?
- - Obtain service history if possible. - Are air ducts undamaged, sealed properly and in
position?
- - Is compressor drive belt in place and tensioned?
- Condensate drain hoses and check valves present
- - Are grille screens, fan blades, condenser, air filter,
and unobstructed?
and evaporator unobstructed?
- Are there any sharp bends or kinks in the hoses?
Problem: No Cooling
COMPRESSOR RUNS COMPRESSOR DOES NOT RUN
INTERNAL SYSTEM PROBLEM MECHANICAL

See Pressure Testing, Page 13. See Mechanical Compressor Check Page 8.
ELECTRICAL
See Blower and Compressor Clutch Check Page 9.

9002-7
Problem: Not Enough Cooling Problem: Erratic Cooling
MECHANICAL
HEATER See Mechanical Compressor Check Page 8.
Make sure the heater control is OFF and that there is
no coolant flow through the heater core.
ELECTRICAL
See Blower and Compressor Clutch Check - Blower
Motor Check, Blower Switch Check and Compressor
Clutch Check on Page 9.
SEAL
Make sure the sealing material is correctly in place.
INTERNAL SYSTEM PROBLEMS

See Pressure Testing, Page 13.
MECHANICAL Problem: System Makes Noise

See Mechanical Compressor Check Page 8. See
Evaporator Heater Core Check Page 12.
MECHANICAL
See Mechanical Compressor Check Page 8.
ELECTRICAL
See Blower Motor Check Page 9.
See Blower and Compressor Clutch Check on Page
9.
ELECTRICAL
See Compressor Clutch Check Page 9.
REFRIGERANT
See Cab Temperature Check Page 10.
INTERNAL SYSTEM PROBLEM

INTERNAL SYSTEM PROBLEM


9002-8
SYSTEM CHECKS
Mechanical Compressor Check
Compressor and Fan Belts

1. Loose or broken drive belt - Adjust the tension on
a new belt. See Section 9005.
2. Too much belt wear - replace a worn belt,
because a wor n belt will cause too much
slippage.
Compressor Mounting Brackets

1. Loose bracket mounting bolts- tighten the bolts to
the correct torque.
2. Bracket has breaks or cracks - replace the
bracket.
Compressor Clutch
1. The compressor belt will slip on the compressor
pulley if there is compressor seizure. Remove
the compressor for service or replacement. See
Section 9005 of this service manual.
2. Remove the dust cover and check the air gap on
the compressor clutch. The gap between the
front plate and pulley assembly must be 0.41 to
0.79 mm (0.016 to 0.031 inch). See Section 9006
of this manual.
3. Use a socket wrench to slowly rotate the
compressor clockwise. Compressor rotation
should be smooth and not require much effort.
Pulley and Belt Alignment

1. The compressor pulley and the compressor drive
pulley must be aligned within 1.6 mm (1/16 inch)
of each other. Use a straight edge to check pulley
alignment. Adjust the compressor mounting
bracket if needed. The drive belt should be
located in the forward clutch groove.

9002-9
Blower and Compressor Clutch

Check
Compressor Clutch
1. If there is electrical system voltage to the clutch,
see Section 9005 and replace the clutch.
High/Low Pressure and Temperature Switches
1. The combination high/low pressure switch is
located at the evaporator and the temperature
switch is located at the receiver-dryer.
Blower Fuse (10 amp)
1. Check for damaged blower fuse.
Blower Fan Switch
1. Check switch operation. Switch must give four
different blower speeds: OFF, Low, Medium, and
High.
2. Check for loose connections or broken wires.
Repair or replace as necessary.
3. Check resistor board.
Blower Motor
1. Check the wiring to the blower motor. Make
repairs or replace items as necessary.
2. Check motor ground wire. Make sure motor
gr ou n d wire is m aking g o od contact w ith
mounting bracket.
Air Conditioner Switch
1. Turn switch to the AC position. Compressor
clutch must engage.
NOTE: Blower must be operating, since electrical
power to temperature control switch is received from
blower switch.
2. Turn the AC switch on and check for continuity
between the connector. If continuity is not
present, replace the switch.

9002-10
Cab Temperature Check
Air Louvers
1. Make sure louvers and recirculation vents are
fully open for most efficient air conditioning
operation. Defrost louvers must be closed.
2. Check blower; blower must be running.
Air Conditioning
1. Feel the air conditioning hoses. The high
pressure hoses (small line) must be warmer than
the low pressure hose (large line).
2. If no temperature difference, the system is low on
refr igerant, or compressor is not wor king
correctly.
Duct Temperature
1. Put a thermometer in the air duct behind the seat
and run the compressor for five minutes to make
temperature stable.
2. Duct temperature must not be above the Air
Louver Maximum Temperature for the Ambient
Temperature if the system is operating at
maximum efficiency. See the chart on Page 13.
NOTE: Ambient temperature must be 27 to 43
degrees C (80 to 110 degrees F).
3. If the duct temperature is above the Air Louver
M a x i m u m Te m p e r a t u r e fo r t h e A m b i e n t
Temperature (see the Chart on Page 14), the
system is low on refrigerant, there is a restriction
in the system, compressor is not wor king
correctly, or air ducts are not sealed correctly.
Temperature Sensing Probe Check
1. Turn the engine OFF, key switch ON, blower
switch ON and temperature control switch turned
fully clockwise.
2. Remove the temperature sensing probe from the
evaporator. Refer to Section 9004.
3. Put the end of the temperature sensing probe in
a container with ice and water.
4. When the sensing tube has cooled to the
temperature of the ice and water mixture, the
temperature control switch should interrupt the
current flow to the compressor. Check for current
at the control switch terminals as on previous
page. If current is not interrupted then replace
the control switch.

9002-11
Visual and Leak Check
Compressor Hoses
1. Make sure that all hose connections are tight.
2. Check hoses for bends or cracks. Replace all
hoses that have damage.
Leak Finding Check

1. Shut off the engine.
WARNING: When refrigerant comes in

contact with an open flame, it can form
dangerous gas. Never breathe these
fumes. SM109A
2. Use electronic leak detector OEM1437 to inspect

all connections. Use instr uctions from
manufacturer of leak finding tool.
NOTE: When checking compressor seal for a leak,
remove the dust cover and rotate the clutch shaft
clockwise.
NOTE: To properly check the expansion valve for leaks,

remove the insulation tape.
3. Repair all leaks and recharge the system. See
Section 9004.
Condenser
1. Make sure the condenser is clean and the seals
are in place. Make sure condenser fans run
when AC control switch is ON.

9002-12
Evaporator/Heater Core Check
Make sure heater valve is closed.

Evaporator/Heater Core
1. See Section 9004 for access to the
evaporator/heater core.
2. Inspect the fins on the evaporator/heater core. All
the fins that have bends or damage must be
made straight.
3. Inspect the evaporator/heater core for
restrictions. If the core is dry, use compressed air
or a brush and vacuum cleaner. If the core is wet
or filled with mud, flush the core with water using
a hose without pressure. Make sure the water
drains freely from the evaporator/heater core. DO
NOT USE STEAM.
WARNING: Do not steam clean any air

conditioning systems parts while the system
is charged. The heat will cause the
refrigerant to rise to a pressure that could
cause the system to explode. SM104A
Evaporator/Heater Core Sealing

1. See Section 9004 for access to the
evaporator/heater core.
2. Make sure seals are in place so blower will pull
air only through the evaporator/heater core and
not around the evaporator/heater core.
Filters
1. Make sure the filters are clean.

9002-13
Pressure Testing
Manifold Gauge Set
The manifold gauge set is the most important tool
used to service the air conditioning system. The
manifold gauge set is used to measure the high and
low pressures of the system, the correct refrigerant
charge, system diagnosis, and operating efficiency.
The manifold gauge set can read both the high
(discharge) and low (suction) sides at the same time,
since pressure must be compared in order to make a
diagnosis of system operation.
LOW PRESSURE GAUGE - The low pressure gauge
is a compound gauge. Under some conditions, air
conditioning systems can change from a pressure
into a vacuum on the low side. For this reason, it is
necessar y to use a compound gauge that will
indicate both pressure and vacuum.
During normal operation the low pressure gauge
must always indicate from 0.69 to 2.4 bar (10 to 35
psi) after the system has run 10 to 15 minutes.
HIGH PRESSURE GAUGE - The high pressure
gauge is used to indicate pressures in the high side
of the system. The gauge must indicate from 0 to
27.5 bar (0 to 400 psi) minimum.
During normal operation, the high pressure gauge
will normally indicate from 120 to 310 psi (8.3 to 21.3
bar). See pressure-temperature chart.
Pressure Test Connection

C o n n e c t t h e m a n i fo l d g a u g e s e t i n t o t h e a i r
conditioning system as shown. Make sure that both
valves in the manifold gauge set are closed.

9002-14
PRESSURE - TEMPERATURE CHART
33° Steel Fan (580M)

AMBIENT NORMAL LOW NORMAL HIGH AIR LOUVER (BEHIND
TEMPERATURE PRESSURE INDICATION PRESSURE INDICATION SEAT) MAXIMUM TEMP.
°F (°C) psi (bar) psi (bar) °F (°C)
80 (27) 16 to 19 195 to 215 53.6 (12)
(1.1 to 1.3) (13.4 to 14.8)
90 (32) 20 to 22 225 to 245 59 (15)
(1.38 to 1.51) (15.5 to 16.8)
95 (35) 22 to 24 260 to 280 60.8 (16)
(1.51 to 1.65 (17.9 to 19.3)
100 (38) 25 to 28 280 to 300 64.4 (18)
(1.72 to 1.93) (19.3 to 20.6)
105 (41) 26 to 30 310 to 330 64.4 (18)
(1.8 to 2.06) (21.3 to 22.7)
110 (43) 29 to 33 330 to 350 66.2 (19)
(1.99 to 2.27) (22.7 to 24.1)
39° Steel Fan (580M, 580SM, SM+)

80 (27) 16 to 18 190 to 210 53.6 (12)
(1.1 to 1.24) (13.1 to 14.4)
90 (32) 20 to 22 215 to 235 57.2 (14)
(1.38 to 1.51) (14.8 to 16.2)
95 (35) 21 to 23 235 to 255 59 (15)
(1.44 to 1.58 (16.2 to 17.5)
100 (38) 23 to 25 260 to 280 60.8 (16)
(1.58to 1.72) (17.9 to 19.3)
105 (41) 27 to 29 290 to 310 64.4 (18)
(1.86 to 1.99) (19.9 to 21.3)
110 (43) 29 to 32 310 to 330 66.2 (19)
(1.99 to 2.2) (21.3 to 22.7)

9002-15
Viscous Fan (590SM and Machines With Cab Convenience Package)

80 (27) 18 to 20 220 to 240 53.6 (12)
(1.24 to 1.37) (15.1 to 16.5)
90 (32) 25 to 27 275 to 295 62.6 (17)
(1.72 to 1.86) (18.9 to 20.3)
95 (35) 26 to 29 305 to 325 62.6 (17)
(1.8 to 1.99 (21 to 22.4)
100 (38) 27 to 30 320 to 340 64.4 (18)
(1.86 to 2.06) (22 to 23.4)
105 (41) 28 to 31 340 to 360 64.4 (18)
(1.93 to 2.13) (23.4 to 24.8)
110 (43) 30 to 32 355 to 375 66.2 (19)
(2.06 to 2.20) (24.4 to 25.8)
SYSTEM TEMPERATURE TESTING

NOTE: Use temperature chart that corresponds with 4. A/C switch on.
the type of fan on the machine, 580M, 33° steel fan,
5. Fan speed control in maximum position and all
580M, 580SM, SM+, 39° steel fan, all 590SM and
louvers open.
machines with cab convenience package, viscous
fan. 6. Cab temperature control set to maximum
cooling.
The pressure-temperature chart is based on the
following conditions: 7. All panels and access doors installed and closed.
1. Engine operating at 1800 RPM. 8. Cab filters clean and installed.
2. System charged at 3.26 lbs (1.48 Kg) of R134a. 9. Cab doors open and back windows down.
3. No engine load. 10. Heater valve at engine closed.
Measurements taken 15 minutes after start-up.

9002-16
A/C RECOVERY AND CHARGING STATION CONNECTIONS

NOTE: Photos may vary from machine being Connect the hose from the high pressure gauge to
serviced. the port on the discharge hose.
STEP 1 WARNING: Always wear safety goggles

when working with liquid refrigerant. Liquid
Clean the external surfaces of the compressor and
refrigerant in your eyes could cause
hoses. Remove the caps from the service ports on
blindness.
the suction and pressure hoses.
SM105A
WARNING: Do not steam clean any air Make sure the charging station manifold gauge
conditioning system parts while the system is valves are in the closed position.
charged. The heat will cause the refrigerant
to rise to a pressure that could cause the STEP 3
system to explode. Start the engine and run at 1500 rpm maximum
SM104A speed. Operate the air conditioner system at
maximum cooling setting and blower speed for 15
STEP 2 minutes with the cab door open. Observe the test
Connect the hoses from the test gauges to the gauges and check the chart on Page 14 against the
service ports. gauge readings.
Connect the hose from the low pressure gauge to the NOTE: The temperature control changes the vent
port on the suction hose. outlet temperatures by mixing heat with air
conditioning. If the temperature is too cold, the
temperature control can be turned clockwise to
increase temperature even though the air conditioner
is on. Any air conditioner tests should be run with this
control all the way counter-clockwise or with the
water valve on the engine turned off.
QUICK REFERENCE TROUBLESHOOTING CHART

LOW PRESSURE HIGH PRESSURE SEE
PROBLEM
GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 17
NO COOLING HIGH HIGH 18
NOT ENOUGH COOLING NORMAL TO HIGH NORMAL 20
NOT ENOUGH COOLING LOW LOW 21
NOT ENOUGH COOLING HIGH LOW 23
NOT ENOUGH COOLING HIGH HIGH 24
INTERMITTENT COOLING NORMAL NORMAL 25
NOISE IN SYSTEM NORMAL TO HIGH HIGH 26

9002-17
Problem - No Cooling
See pressure - temperature

VERY LOW VERY LOW chart, Page 13.
476L7
N o R e f r i g e ra n t o r L ow R e f r i g e ra n t C h a r g e - 1. Leak test the system, see Page 11. It may be

Indications: necessary to add refrigerant. See Section 9004.
A. Discharge air from evaporator warm.
B. Compressor does not run, or cycles off rapidly
after start-up. 2. Recover the remaining refrigerant from system.
See Section 9004.
3. Repair system leaks as needed. Follow the given

repair procedure.
4. Check level of oil in compressor - possible for

compressor to have an oil loss. See Section
9005.
5. Replace the receiver-drier. The moisture
removing material could be full to capacity with
moisture, refer to Section 9005.
6. Remove air and moisture from the system.

Replace Receiver-Drier. See Section 9004.
7. Charge system with new refrigerant. See Section

9004.
8. Continue performance test for other possible

problems.

9002-18
Problem - No Cooling or Not Enough Cooling

HIGH HIGH chart, Page 14.
476L7
Air in the System - Indications 1. Leak test system - possible leak permitted air to
enter the system.
A. Suction line warm to hand.
2. Recover the refrigerant from system. See
B. Discharge air from evaporator warm.
Section 9004.
3. Repair leaks as necessary.
4. Replace receiver-drier. See Section 9004.
5. Remove air and moisture from the system. See
Section 9004.
9004.
Condenser Malfunctioning - Indications: 1. Check for loose or worn compressor or engine
fan belt and proper condenser fan operation.
A. Liquid line (between evaporator and
condenser) is very hot. 2. Check to see that condenser is clean and
unobstructed and that the fins are straight.
3. Check system for too much refrigerant. Recover
the refrigerant for system until gauge pressure is
normal. See Section 9004.
4. Remove and check condenser for restrictions
caused by oil or reduced heat transfer.
A. Recover the refrigerant from the system. See
Section 9004.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See
section 9004.
5. Continue the performance test for other possible
problems.
(No Cooling Continued)

(Continued on next page)

9002-19
Expansion Valve Malfunctioning - Indications: HFC-134a Stable Saturation
A. Discharge air from heater/evaporator warm. Pressure/Temperature Chart
B. Much condensation on suction hose at Temperature °C (°F) Pressure Bar (PSIG)

compressor. 47 (116) 11.2 (162)
C. Much condensation on evaporator outlet. 48 (118) 11.5 (167)
Refrigerant Contamination - Indications 49 (120) 11.9 (172)
1. See table below and check stable saturation

pressures at given temperature to determine if
contamination exists.
A. Measure pressure from gauge on reclamation 1. Check the expansion valve. Disconnect the low
unit. pressure switch.
B. Measure temperature from refrigerant in 2. Test expansion valve:

reclamation tank. If refrigerant has been in A. Remove insulation material from top of valve.
reclamation unit for some time, use ambient With the engine running and the air
tem perature. The numbers in the table conditioner on maximum cooling, cool the top
represent the boiling point for HFC-134a. of the expansion valve with ice and check the
C. Pressure readings below range given in chart low pressure gauge for a decrease.
indicate contaminated refrigerant. B. Allow the top of the expansion valve to warm.
IMPORTANT: Do not use contaminated refrigerant or The valve should open and the pressure
mix with uncontaminated refrigerant. Dispose of in should rise at the low pressure gauge.
accordance with all applicable laws and local C. Repeat Step A. If there is little or no decrease
procedure. in the low pressure gauge, go to Step 3.
3. If the expansion valve did not operate correctly,
HFC-134a Stable Saturation
recover the refrigerant from the system, refer to
Pressure/Temperature Chart
Section 9004. Remove the expansion valve, refer
Temperature °C (°F) Pressure Bar (PSIG) to Section 9005.
10 (50) 3.1 (45) 4. Instal the new expansion valve, refer to section
13 (55) 3.5 (51) 9005. Remove the air and moisture and charge
the system with refrigerant, refer to Section
16 (60) 3.9 (57)
9004.
18 (65) 4.4 (64)
5. Connect the low pressure switch.
21 (70) 4.9 (71)
24 (75) 5.4 (78) 6. Continue performance test for other possible
problems.
27 (80) 6.1 (88)
29 (85) 6.6 (95)
32 (90) 7.2 (104)
35 (95) 7.9 (114)
38 (100) 8.6 (124)
39 (102) 8.9 (129)
40 (104) 9.2 (133)
41 (106) 9.5 (138)
42 (108) 9.8 (142)
43 (110) 10.1 (147)
44 (112) 10.5 (152)
46 (114) 10.8 (157)

9002-20
Problem - Not Enough Cooling

NORMAL TO
SLIGHTLY NORMAL chart, Page 14.
HIGH
476L7
Heater Control Valve not working - Indications 1. The heater control valve is not closed if the
hoses are hot.
A. Discharge air from evaporator only a little cool.
2. Shut off coolant flow to heater/evaporator core.
B. Heater hoses to cab are warmer than ambient
temperature. 3. Check air duct for temperature change.
4. Inspect the heater control cable and valve.
5. Continue performance test for possible other
problems.
Air in the System - Indications: 1. Test system for leaks. See Page 11. Possible
leak has let air enter; check compressor seal
A. Suction line warm to your hand.
carefully. See Section 9004.
B. Discharge air from heater/evaporator only a
little cool.
Section 9004.
3. Repair system leak as necessary.
4. Replace receiver-drier. The moisture removing
material in receiver-drier could be full to capacity
with mixture, refer to Section 9005.
5. Check compressor oil level. See Section 9005.
Section 9004.
9004.
Temperature Control Switch sensing tube low on

charge or out of calibration - Indications: 1. Inspect and repair the temperature control
A. Excessive or incorrect compressor cycling. switch, refer to Section 9004.
B. Compressor clutch not engaging.

9002-21

LOW LOW chart, Page 14.
476L7
Not Enough Refrigerant - Indications: 1. Leak test system - system has a loss of
refrigerant.
A. Discharge air from evaporator cool or warm -
not cold. NOTE: Normally, the system will lose 14.7 to 29.5
grams (1/2 to 1 ounce) of refrigerant between
seasons.
A. If leak is found, go to Step 2.
B. If no leak is found, go to Step 6.
Section 9004.
3. Repair system leaks as needed.
4. Check oil level in compressor - It is possible for
compressor to lose oil. See Section 9004.
5. Remove air and moisture from the system.
Replace Receiver-Drier. See Section 9005.
9004.
(Continued on next page)

9002-22
(Not Enough Cooling
High Side Restriction - Indications: 1. Recover the refrigerant from the system. A
A. Discharge air from heater/evaporator only a restriction in receiver-drier or liquid line must be
little cool. removed.
B. Condensation or frost on receiver-drier. 2. Remove and replace part with restriction.
C. Liquid line to receiver-drier cool, with frost or 3. Remove air and moisture from the system. See
condensation. Section 9004.
NOTE: The frost will form downstream from or at the 4. Charge system with new refrigerant. See Section
point of the restriction 9004.
Expansion Valve Not Operating - Indications: 1. Expansion valve outlet with condensation or frost
is an indication of a restriction in the expansion
A. Discharge air from evaporator warm or cool - valve. Replace expansion valve. See Section
not cold. 9005.
B. Condensation or frost on expansion valve 2. Inlet end of expansion valve is warm, indicating
inlet. expansion valve is not completely open. Replace
C. Inlet end of expansion valve is warm. expansion valve. See Section 9005.

9002-23

HIGH LOW chart, Page 14.
476L7
Compressor turning but not pumping properly -

Indications: 1. Recover the refrigerant from system. See
Section 9004.
A. System is fully charged.
2. Remove the compressor from the machine. See
B. Cool discharge air from evaporator.
Section 9004.
3. Before you start to repair compressor, check and
record compressor oil level. See Section 9005.
4. Remove compressor from machine because
there is indication of internal leak in compressor.
5. Repair or replace compressor as necessary. See
Section 9005.
6. Replace receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more
years.
C. Disassembly of compressor shows small
particles of moisture removing material (gold
or brown particles). See Section 9005 for
receiver-drier replacement.
7. Fill compressor with new refrigerant oil as shown

in Section 9004 and install compressor in
machine.
8. Charge the system with refrigerant. See Section
9004.
Expansion Valve stuck open 1. Replace expansion valve. See Section 9005.

9002-24

VERY LOW VERY LOW chart, Page 14.
476L7
Condenser Not Operating - Indications: 1. Check for loose or worn compressor belt and
proper condenser fan operation.
A. Liquid line very hot.
2. Check to see that condenser is clean and that
the fins are straight.
3. Check system for too much refrigerant.
A. Recover the refrigerant from system until
gauge pressure is below normal. See Section
9004.
B. Add refrigerant until gauge pressures are
C. If there is still a problem, do step 4.
4. Remove and inspect condenser for restrictions
caused by oil or reduced heat transfer.
A. Recover the refrigerant from system. See
Section 9003.
B. Use compressed air to remove oil from
condenser.
C. Replace receiver-drier. See Section 9004.
Air in the System - Indications: 1. Recover the refrigerant from system. See
Section 9004.
A. Warm discharge air from evaporator.
2. Replace receiver-drier.
Section 9004.
9004.

9002-25
Problem - Intermittent Cooling

NORMAL NORMAL chart, Page 14.
476L7
Moisture in System- Indications: 1. Recover the refrigerant from the system. If too
much moisture enters the orifice of the
A. Cooling is acceptable during cool part of day,
expansion valve, the freezing of this moisture can
but not acceptable during hot part of day.
stop refrigerant flow. See Section 9004.
2. Replace receiver-drier. The moisture removing

material could be full to capacity with moisture.
See Section 9005.
Section 9004.
NOTE: The time needed to remove a large amount
of moisture will be two to three hours minimum.

9004.

9002-26
Problem - Noise in System

NORMAL TO HIGH chart, Page 14.
HIGH
476L7
Too much Refrigerant in System - Indications: 1. Recover the refrigerant from system until gauge
readings are below normal. See Section 9004.
A. Cool discharge air from heater/evaporator.
2. Add new refrigerant until gauge readings are
B. Compressor makes noise.

9002-27
PRESSURE SWITCH CHECK

The low pressure switch is located in the roof of the Refer to pressure-temperature chart this section,
cab in the low pressure tube to the evaporator.The page 14. The low pressure switch is open whenever
high pressure switch is located at the front of the the pressure is above 2 to 6 PSI (14 to 41 kPa).
tractor and behind the grille. Below this the switch closes and sends a signal to
the relay to disengage the compressor clutch.
STEP 1 Check both terminals of the low pressure switch with
Engine OFF, key switch ON, blower switch ON, and a test lamp. If voltage is available at both terminals
temperature control switch turned fully clockwise. and pressure is not below 2 PSI (14 kPa), replace the
NOTE: With the engine OFF, system pressure will switch.
equalize on both sides of system to approximately 75
PSI (520 kPa) at room temperature. STEP 3
Both pressure switches should remain in the open
position.
To check system pressure, refer to Section 9004 in
this manual.
STEP 2
BD08B051-01
High pressure switch located at the condenser.
Check for 12 VDC at high pressure switch. If no
voltage, check temperature control switch. Refer to
Air Conditioner Control Switch in this section.
Check both terminals of high pressure switch with a
test lamp. If voltage is present at both terminals and
BD05H001 pressure is not above 385 PSI (2 654 kPa), replace
Low pressure switch located in cab roof. the switch.
Check for 12 VDC at low pressure switch with a test
lamp. If no voltage, check temperature control switch.
Refer to Air Conditioner Control Switch Check in this
section.

9002-28
AIR CONDITIONING CONTROL SWITCH CHECK
Current Check Sensing Line Check

The temperature control switch is located in the
instrument panel. STEP 2
The temperature control switch senses evaporator
temperature and controls current flow for compressor
clutch operation.
2
The switch interrupts current flow to the clutch at 33°
F to 37° F (0.6° C to 2.8° C) and will allow the clutch
to energize at 42° to 70° F (5.6° C to 21° C)
depending on switch position.
If the temperature control switch malfunctions,
1
replace it.
Remove instrument cluster to gain access to the
temperature control switch.
T97352
STEP 1 1. Container of Ice and Water
2. Sensing Line
Engine OFF, key switch ON, and blower switch ON.

Turn temperature control switch fully clockwise.
Remove sensing tube from evaporator.
Place end of sensing tube in a container with ice and
water mixture.
STEP 3
BD05H002
1. Temperature Control Switch
Engine OFF, key switch ON, and blower switch ON.

Turn temperature control switch fully clockwise.
Check voltage at temperature control switch terminal
for wire No. 85. If voltage is less than 5, check blower
switch.
Check Voltage at temperature control switch terminal
fo r w i re N o. 6 0 . If l e s s t ha n 5 vo l t s, re p l a c e BD05H002
temperature control switch. 1. Temperature Control Switch
When the sensing tube has cooled to the

temperature of the ice and water mixture, the
temperature control switch should interrupt the
current flow to the compressor.
Check for current at temperature control switch
terminal with the No. 60 and No. 85 wires. Use a test
lamp connected to a good ground.
If current is not interrupted, replace the temperature
control switch.

Section
9004
9004
AIR CONDITIONER SYSTEM SERVICE

9004-2
TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRESSURE - TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

9004-3
SPECIFICATIONS
Air conditioning system refrigerant capacity .................................................................................... 1.48 kg (3.26 lbs)
SPECIAL TOOLS
A22094 BS03H012
REFRIGERANT RECOVERY, RECYCLING AND RECHARGING SAFETY GOGGLES CAS-10073-3
STATION OEM-1415

9004-4
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system, if you
Refrigerant HFC-134a is the most stable and easiest conditioner system.
conditioning systems. Refrigerant HFC-134a does
not contain chlorofluorocarbons (CFC’s) which are
harmful to the Earth’s ozone layer.
with refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
mixtures of HFC-134a and air can for m a
Liquid refrigerant getting into the eyes can cause
combustible gas.
ser ious injur y. Do the following if you get
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air

9004-5
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refr igerant passes through an oil STEP 3
separator and a filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
If possible, run the air conditioning system for ten
minutes before starting the recovery process. Turn
the system off before proceeding.
STEP 1
A22114
Open the high and low valves.
STEP 4
BD03K012
Clean the external surfaces of the compressor and

hoses. Remove the caps from the service ports on
the suction and pressure hoses.
STEP 2
With the charging station manifold gauge valves in
the closed position, connect the hoses from the test A22107
gauges to the service ports. Make certain the refrigerant tank gas and liquid
Connect the hose from the low pressure gauge to the valves are open.
port on the suction hose. Turn in valve depressor.
Connect the hose from the high pressure gauge to
the por t on the discharge hose. Tur n in valve
depressor.

9004-6
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Slowly open the oil drain valve and drain the oil into
Move the main power switch to the ON position and the reservoir. When the oil stops draining, close the
depress the recovery start switch. oil drain valve completely.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 minutes and observe STEP 8
the manifold pressure gauges for a pressure rise. If
pressure rises above 0 psi (0 bar), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh SP-15 PAG oil

equal to the amount in the reservoir.
STEP 9
A22108
Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the
separator.
BD03K012
Remove the hoses from the service ports and install

the caps.

9004-7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or STEP 11
more of the following conditions occurs before you
remove the air and moisture from the system.
A. The system has been opened for service
before.
B. Receiver-drier has operated two or more
years.
C. Disassembly of compressor shows small
particles of moisture removing material (gold
or brown particles).
D. Large system leak (broken hose, break in
line). A22113
E. Too much air or moisture in system. Connect the main power plug to a 115 volt AC outlet.
Move the main power switch to the ON position. If
F. Removal of compressor caused the system to program and vacuum do not appear at the top of the
be open (uncapped) longer than 5 minutes. display press the vacuum key. Program a minimum of
45 minutes and press the Enter key. The display will
STEP 10 flash once indicating the programmed data has been
With the charging station manifold gauge valves in accepted.
the closed position, connect the hoses from the test
gauges to the service ports as follows: STEP 12
1. Connect the hose from the low pressure gauge
to the port on the suction hose.
2. Connect the hose from the high pressure gauge
to the port on the discharge hose.
3. Turn in both thumbscrews to depress the service
valves.
Removal of air and moisture from the system is
necessary after the refrigerant has been removed
after the system has been opened for maintenance.
Air enters the system when the system is opened. Air
has moisture that must be removed to prevent A22115
damage to the system components. Press the Charge key. “Program” and “Charge” will
appear on the display.
NOTE: The pump on the reclamation unit will not pull
a sufficient vacuum to remove air and moisture.
Air and moisture are removed from the system by a
va c u u m p u m p. A va c u u m p u m p i s t h e o n l y
equipment made to lower the pressure enough to
change the moisture to vapor that can be removed
from the system.
NOTE: Refer to the vacuum pump manufacturer’s
user manual for additional information.

9004-8
STEP 13 STEP 16
A22113 A22123
Program 3.75 lbs and press the enter key. The Press the Vacuum key. “Automatic” will appear on the
display will flash once indicating the programmed display. Vacuum will appear on the display and after
data has been accepted. a slight delay, the vacuum pump will star t. The
display will show the amount of time programmed
STEP 14 and begin a countdown to zero.
When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28 to
29-1/2 inches of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 10 minutes. A previously charged,
l e a k - f r e e s y s t e m w i l l l e a c h r e f r i g e ra n t f r o m
compressor oil and raise system pressure under
vacuum. If the system will not hold vacuum, a leak
exists that must be corrected before recharging can
begin. See Section 9002 in the manual for a leak
test.
A22114
Fully open the low and high pressure valves.

STEP 17
STEP 15
A22113
Press the charge key to begin refrigerant charging.

A22107
“Automatic” and “Charge” will appear on the display.
Open the red (vapor) and blue (liquid) valves on the The display shows the programmed amount and
tank. counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.

9004-9
STEP 18 STEP 20
A22114 A22117
Completely close the high and low pressure manifold Observe the pressure gauge readings to determine
valves. that the correct amount of refrigerant has entered the
system. See Temperature Pressure Chart page 10
ATTENTION: Check the OEM equipment manual
for temperature and pressure variations.
before performing Step 19 to avoid damaging the
recovery unit. The pressure reading should be
obtainable with valves closed. Damage may occur if STEP 21
the machine is started with the valves accidently Stop the engine, close any open valves and carefully
open or if either or both valves are opened while the remove the manifold gauge hoses.
A/C system is operating.
STEP 22
STEP 19
Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the
system pressure is too low or too high. The pressure
indicator lamp will illuminate when the relay is
actuated by a low or high pressure and the
compressor clutch will disengage. To restart the
compressor, the air conditioner control or blower
switch must be turned to the OFF position and then
to the ON position. BD03K012
Install the caps on the service ports on the suction

and discharge hoses.

9004-10
PRESSURE - TEMPERATURE CHART

80 (27) 9 to 12 145 to 165 55 (14)
(0.62 to 0.83) (10 to 11.5)
90 (32) 11 to 15 190 to 210 61 (18)
(0.76 to 1.04) (13.1 to 14.5)
95 (35) 16 to 18 210 to 230 63 (20)
(1.10 to 1.24) (14.5 to 15.8)
100 (38) 17 to 19 235 to 255 66 (22)
(1.17 to 1.31) (16.2 to 17.6)
105 (41) 20 to 21 260 to 280 68 (23)
(1.38 to 1.45) (17.9 to 19.3)
110 (43) 22 to 24 290 to 310 72 (25)
(1.93 to 2.14) (20 to 21.4)
The pressure-temperature chart is based on the 5. Both cab doors open

following conditions:
6. All panels and access doors installed and closed.
1. Engine operating at 1500 RPM
7. Cab filters clean and installed.
2. No engine load
8. Heater valve at engine closed.
3. Fan speed control in maximum position (full
9. Measurements taken 15 minutes after start-up.
clockwise) and all louvers open.
4. Cab temperature control set to maximum cooling
(full counterclockwise).

Section
9005
AIR CONDITIONER COMPONENT SERVICE
9005

9005-2
TABLE OF CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Belt Check And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
EXPANSION VALVE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EVAPORATOR AND EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONDENSER, RECEIVER-DRIER, AND TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EVAPORATOR CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

9005-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH. M171B
ATTENTION: Only authorized technicians certified 3. Keep refrigerant containers in the correct upright
by an approved training and certification organization position. Always keep refrigerant containers
may service or repair motor vehicle or mobile air away from heat and sunlight. The pressure in a
conditioning systems. It is mandatory that all container will increase with heat.
refrigerant must be RECOVERED and RECYCLED
4. Always reclaim refrigerant from the system if you
Refrigerant HFC-134a is the most stable, and easiest conditioner system.
conditioner systems. Refrigerant HFC-134a does not
contain any chlorofluorocarbons (CFC’s) which are
harmful to the earth’s ozone layer.
with Refrigerant HFC-134a to prevent possible
personal injury.
1. Always wear safety goggles when doing any
service work near an air conditioner system.
mixtures of HFC-134a and air can for m a
Liquid refrigerant getting into the eyes can cause
combustible gas.
ser ious injur y. Do the following if you get
refrigerant near or in your eyes: 8. Always reclaim refrigerant from the system
before removing any air conditioning component.
2. A drop of liquid refrigerant on your skin may
cause frostbite. Open the fittings carefully and
slowly when it is necessary to service the air

9005-4
SPECIAL TOOLS
T81574
A22094 COMPRESSOR SERVICE TOOL SET CAS10747A. ALSO USE

CAS2332 PULLER JAW SET
REFRIGERANT RECOVERY, RECYCLING AND CHARGING
STATION OEM-1415
BS03H012
SAFETY GOGGLES CAS-10073-3

9005-5
COMPRESSOR
Belt Check And Adjustment

Check interval . . . . . . Every 250 hours of operation
NOTE: Check the belt tension after the first 10 hours
of operation and then use the regular check interval.
BD08B052-01
Measure the compressor belt for correct tension

using a belt tension gage. Check the belt to the
following specifications.
Belt Tension 90 to 110 lbs (400 to 490 N)
BP9503119
Measure the compressor belt for correct tension To adjust the belt tension, loosen the pivot bolt,
using a belt tension gage. Check the belt to the loosen the slot bolt, loosen the jam nut on the
following specifications. adjusting bolt. Trun the adjusting bolt in until the
Belt Tension . . . . . . . . . . 45 to 55 lbs (200 to 245 N) proper tension for the belt is reached. Tighten the
jam nut, tighten the slot bolt, tighten the pivot bolt.
To adjust the belt tension, loosen the compressor
adjusting bolts and pivot bolt. Apply pressure to the
compressor until the correct tension for the belt is
reached. Tighten the compressor adjusting bolts and
pivot bolt.
! WARNING: ** Rotating fan and belts. Contact can injure. Keep clear! ** M150A

9005-6
Oil Level Check STEP 4

Check the oil level in the compressor when any of the
following has occurred:
A. Broken refrigerant hose.
B. Large refrigerant leak.
C. Compressor leak.
D. Damage to system components.
E. New compressor installed.
Use the following procedure to check the compressor
oil level.
BP9505113
STEP 1 Remove the oil filler plug.
Start the engine and run at 1500 RPM maximum.
Operate the air conditioner for 10 to 15 minutes at STEP 5
maximum cooling and high blower speed.
STEP 2
Stop the engine. Connect the compressor to the air
conditioner charging, recovery, and recycling station.
Discharge the system. See Section 9004 in this
service manual for complete instructions.
NOTE: Wear safety goggles when working with
refrigerant.
STEP 3
10317
Remove the dust cover and use a wrench to rotate

the clutch clockwise until the internal parts are in the
position shown above. This will permit the dipstick to
be inserted all the way.
7791288
Check the mounting angle of the compressor. Put the

angle gauge from the service tool set across the flat
surfaces of the two front mounting ears. Adjust the
gauge so that the bubble is between the center
marks. Read the mounting angle to the nearest
degree mark. Make a note of the degree reading for
reference later.

9005-7
STEP 6 STEP 8
If the oil level is not correct, add or subtract oil to the
correct level as shown in the above chart.
IMPORTANT: Use only SP-15 PAG oil.
STEP 9
85010
Put the dipstick in the oil filler hole to the stop

position. Make sure the dipstick is inserted all the BP9505114
way to the stop. Install a new O-ring on the oil filler plug. Install the
plug and tighten to a torque of 11 to 18 pound-feet
NOTE: The illustration shows the front view of the
(15 to 24 Nm).
compressor with the dust cover removed.
STEP 7
Remove the dipstick. Count the oil level marks on the
dipstick. Use the following table to find the correct oil
level for the mounting angle of the compressor.
COMPRESSOR OIL LEVELS
MOUNTING ANGLE DIPSTICK

(DEGREES) READING
0 4 to 6
10 6 to 8
20 7 to 9
30 8 to 10
40 9 to 11
50 9 to 11
60 9 to 12
90 9 to 12

9005-8
Clutch Disassembly STEP 13
STEP 10
A21253
Remove the retaining nut for the front plate. Use the
A21250
special spanner wrench from the service tool set to
See Section 9005 in this ser vice manu al for keep the plate and shaft from turning.
compressor removal. Clean the external surfaces of
the compressor before doing any work on the STEP 14
compressor.
STEP 11
A21254
Install the special puller from the service tool set on

the clutch front plate.
A21251
Remove the mounting bolts for the clutch dust cover. STEP 15
STEP 12
A21255
Turn the center screw to pull the clutch front plate.

A21252
Remove the clutch dust cover.

9005-9
STEP 16 STEP 19
A21256 A21260
Remove the shim(s) from the shaft. Remove the external snap ring for the bearing and
pulley assembly.
STEP 17
STEP 20
A21257
Remove the bearing dust cover. Be careful not to A21261
bend the dust cover. Install the special puller internal collars into the
groove in the pulley. Install the special tool onto the
STEP 18 shaft. Tighten the mounting screws finger tight.
STEP 21
A21258
Remove the key from the rotor shaft.

A21262
Turn the center screw on the puller.

9005-10
STEP 24
A21263
Remove the pulley and bearing assembly. A21266
Remove the clutch coil assembly.
STEP 22
STEP 25
A21265
Remove the snap ring for the clutch coil assembly. A21267
Remove the internal snap ring and remove the

bearing from the pulley.
STEP 23
A21264
Disconnect the clip for the lead wire.

9005-11
3
4 7 8
5
1016L93
1. COMPRESSOR 5. BEARING DUST COVER

2. COIL ASSEMBLY 6. FRONT PLATE
3. PULLEY 7. SHIM(S)
4. BEARING 8. DUST COVER
CLUTCH ASSEMBLY

9005-12
STEP 26 STEP 28
1
2
102L7 A21264
1. AMMETER 2. 12V BATTERY Install the clip for the coil lead wire.
Use a ammeter, voltmeter and a 12 volt battery to
check the amperage of the clutch coil. The current STEP 29
draw must be 3.6 to 4.2 amperes at 12 volts.
A reading of more than 4.2 amperes indicates a short
within the coil.
No amperage reading indicates an open circuit in the
coil.
Replace the clutch coil if the amperage reading is not
correct.
Clutch Assembly
STEP 27
A21265
Install the snap ring for the clutch coil assembly.
STEP 30
A21266
Install the clutch coil assembly. Align the detent ball

and socket on the coil and housing.
A21267
Install the bearing in the pulley and install the internal

snap ring.

9005-13
STEP 31 STEP 33
A21268 A21260
Put the pulley and bearing assembly on the front Install the external snap ring on the front housing
housing hub. Install a driver on the pulley assembly. hub.
Make sure that the tool is on the inner race of the
bearing. STEP 34
STEP 32
A21259
Install the key in the rotor shaft.

A21268
Support the compressor on the four mounting ears at STEP 35

the compressor rear. Use a hammer to tap the pulley
assembly onto the front housing hub. As the pulley is
tapped onto the hub you can hear the difference in
sound when the pulley is fully installed. Make sure
the bearing is against the bottom of the hub.
A21269
Place the bearing dust cover in the bore. Place driver

from special tool kit over the dust cover.

9005-14
STEP 36 STEP 39
A21270 A21272
Gently tap the dust cover until it is seated. Use a hammer to tap the plate onto the shaft. Make
sure the plate is against the clutch shims. As the
STEP 37 plate is tapped onto the shaft you can hear the
difference in sound when the plate is fully installed.
STEP 40
A21256
Install the shim(s) on the rotor shaft.
STEP 38 A21253
Install the nut on the rotor shaft. Use the spanner

wrench and a torque wrench to tighten the nut to a
torque of 15 to 20 Nm (11 to 15 lb ft).
A21271
Install the front plate on the rotor shaft. Make sure

the keyway in the plate is aligned with the key in the
shaft. Install the driver over the shaft.

9005-15
STEP 41 STEP 43
T97256 A21251
Use a feeler gauge to measure the gap between the Install and tighten the six bolts that hold the dust
front plate and pulley assembly. The gap must be cover to the compressor to 7 to 11 Nm (5 to 8 lb ft).
0.41 to 0.79 mm (0.016 to 0.031 inch). The gap must
be even all the way around the plate. If necessary,
lightly lift or push down on the plate to make the gap
even.
NOTE: If the gap does not meet the above
specifications remove the front plate and add or
subtract clutch shims as required.
STEP 42
A21252
Install the dust cover.

9005-16
EXPANSION VALVE TESTING

The following test is to be made with the expansion STEP 47
valve mounted in the system. No repair, cleaning or
adjustment is recommended for the valve.
STEP 44
BC04A125
Watch the low pressure gauge as ice is applied onto

the cap of the expansion valve.
The pressure must start to lower. When the pressure
BP9504011
reaches 4 PSI (28 kPa), the low pressure indicator
Remove headliner.
will illuminate and the compressor will stop. The relay
must be reset after the compressor has stopped
STEP 45 before the system will operate. To reset the relay,
Install low pressure hose to the low pressure service turn the air conditioner to the OFF position and then
port. Close both manifold valves. back to the desired temperature setting.
STEP 46 STEP 48
Make sure the flow of air continues through the War m the expansion valve and watch the low
evaporator core. Start the engine and run at 1500 pressure gauge.
RPM.Turn the Blower Switch to the HIGH position,
and with the temperature control valve turned fully Within minutes, the expansion valve will open and
clockwise, check the low pressure gauge reading. the pressure must rise at the low pressure gauge.
The pressure will rise to a range of 45 to 75 PSI (310
The low pressure reading will range from 26 to 51 to 520 kPa).
PSI (180 to 355 kPa) when the compressor is
operating STEP 49
If the pressure does not rise per step 48, the valve is
not operating. Replace the valve.

9005-17
EVAPORATOR AND EXPANSION VALVE

The refrigerant must be reclaimed from the system NOTE: Tighten all the connections. Use two
and all the black insulation must be removed from wrenches to prevent damage to the parts when
t h e f i t t i n g s a n d ex p a n s i o n va l ve b e fo r e t h e tightening tubes and hoses. Always replace O-rings
evaporator core or the expansion valve are replaced. and put clean refrigerant oil on the O-rings.
The expansion valve must be installed with the NOTE: SP-15 PAG OIL must be added whenever a
sensor toward the rear of the tractor. The por t component is replaced. Refer to the chart below for
nearest to the IN mark must point away from the recommended quantities.
evaporator core. Connect the evaporator core fittings
COMPONENT OIL AMOUNT
to the expansion valve. Install O-rings between the
evaporator core and the expansion valve. FL OZ CC
Evaporator 1.5 to 1.7 45 to 50
Connect the expansion valve to the evaporator inlet
tube. Install an O-ring between the expansion valve Condenser 1.2 to 1.3 35 to 40
inlet and the pressure hose from the receiver-drier. Receiver-Drier 0.7 to 0.8 20 to 25
Connect the suction hose to the evaporator outlet. Hoses (Normal
0.3 to 0.7 10 to 20
Install an O-ring between the fittings. Length)

9005-18
4
1 4
2
3 6
BC04A127
1. EVAPORATOR CORE 4. O-RINGS 7. PRESSURE SWITCH

2. EXPANSION VALVE 5. SUCTION TUBE 8. CONTROL SWITCH
3. O-RINGS 6. PRESSURE TUBE

9005-19
CONDENSER, RECEIVER-DRIER, AND TUBES
The receiver-drier must be installed with the inlet

WARNING: Do not steam clean any air connected to the hose from the condenser and the
conditioner system parts while the system is outlet connected to the tube going to the evaporator.
charged. The heat will cause the refrigerant Always install new O-rings when you connect the
to rise to a pressure that could cause the receiver-drier to the system.
system to explode.
SM104A Use the two hand, two wrench method to prevent
damage to the tubes and fittings when you loosen or
Keep the condenser fins clean and straight to make tighten the tube connections.
sure there is maximum flow through the condenser Always replace the O-rings when you separate
and radiator at all times. Use compressed air or a connections to make sure you get a good tight seal
rigid brush to clean the condenser. Also check and when you make the connections again. Apply clean
clean the grille screen and radiator. Maximum air refrigerant oil onto the O-rings.
flow will prevent the engine from getting too hot and
will give the most efficient operation of the air
conditioner system.
1
IMPORTANT: Because the condenser fins bend
easily, be careful when you clean the condenser.
Replace the receiver-drier every other time the
system is opened for repair or service. Replace the
receiver-drier each time the system is opened under
the following conditions: 2
A. In an area where there is high moisture 6
content in the air. 3 5
4
B. If the system has been open for a long period
BD08B051-01
of time because of a leak (broken hoses,
loose connections) that has permitted air and 1. Condenser 4. Receiver-Drier
moisture to enter the system. 2. High Pressure 5. Hose - Receiver-Drier
Switch to Cab
C. When the expansion valve is replaced 3. Hose - Condenser 6. Hose - Compressor to
(because of corrosion caused by moisture in to Receiver-Drier Condenser
the system).
D. When the receiver-drier or inlet and outlet
lines feel cool to your hand when the system
is operating. This condition is an indication of
too much moisture in the system.

9005-20
EVAPORATOR CORE
Removal STEP 54
If the insulation (1) has not been removed, remove it
STEP 50 now from the expansion valve and the evaporator
Remove the screws that hold the cover on the lines.
right-hand center post. Then remove the cover. To test the valve see Expansion Valve Testing in this
section. Discharge the A/C system to remove the
STEP 51 evaporator core. See Section 9004 of this manual.
STEP 55
BP9504011
Remove headliner
BC04A125
STEP 52 Disconnect the air conditioner suction and discharge

lines (1) at the expansion valve. Remove and discard
the O-rings. Cap and plug the lines to prevent dirt
and moisture from entering the system.
1
4 STEP 56
Remove the thermostat probe for the air conditioner
control that is in the evaporator core.
2 STEP 57
3
Remove the evaporator core from the housing and
put the evaporator on a clean bench. Remove the
1 expansion valve from the evaporator core. It can be
BP95F002 necessar y to use a back-up wrench to prevent
Remove the hose clamps (1) and disconnect the four damage to the tubes. Remove and discard the
drain hoses (2) at the housing. Disconnect the low O-rings from between the expansion valve and the
pressure switch (3). Remove the bolts (4) retaining evaporator core lines.
the air ducts and remove the air ducts. Disconnect
the blower.
STEP 53
Carefully remove the four nuts that hold the housing
to the roof of the cab and lower the housing including
t h e bl owe r, h e a t e r c o r e, a n d a i r c o n d i t i o n e r
evaporator to the front dash and steering wheel area.
NOTE: Be careful not to kink the air conditioner
lines, as this could cause premature failure of the
hoses.

9005-21
Install the expansion valve. Tighten the fittings to a
STEP 58 torque of 18 to 25 lb ft (25 to 34 Nm). It may be
Put new O-rings on the evaporator core lines. necessar y to use a backup wrench to prevent
Lubricate the O-rings with clean refrigerant oil. damage to the evaporator tubes.
STEP 60
Install the evaporator core in the housing
STEP 61
1
2
3
BC05D024
1. 1 inch (25 mm) 2. 6 inches (150 mm) 3. 3 inches (75 mm)

Install the thermostat probe for the air conditioner. STEP 63
NOTE: Position capillary tube so it does not interfere Connect the air conditioner discharge and suction
with the air filter during installation and removal. lines to the expansion valve. Wrap the valve and the
lines with insulation.
STEP 62
STEP 64
Install the evaporator core in the housing with the
heater core. Be sure the foam insulation strips are in
place to seal the plenum around the evaporator so air
is forced through the evaporator and the heater core.
STEP 65
Raise the housing into place, including the blower,
1 heater core and air conditioner evaporator. Fasten
with four nuts to the roof. Be sure the top insulation
strip is in place.
BC04A125
Install new O-rings on the discharge and suction

lines (1) at the expansion valve. Lubricate the
O-rings with clean refrigerant oil. Tighten the fittings
to a torque of 18 to 25 lb ft (25 to 34 Nm). It may be
necessar y to use a backup wrench to prevent
damage to the evaporator tubes.

9005-22
STEP 66 STEP 67
1
4
2
3
1
BP95F002 BP9504006
Connect the blower. Install the hose clamps (1) and Install headliner.
the air ducts using bolts (4). Make sure the seals on
the air ducts are in place. Connect the low pressure STEP 68
switch (3). Connect the four drain hoses (2) to the Install the cover on the center post
housing and tape in place to the air ducts. Connect
the blower. Make sure the seals are in place when
installing air ducts.

Section
9006
LOADER
9006

9006-2
TABLE OF CONTENTS
REPLACEMENT OF WELD-ON CUTTING EDGE FOR STANDARD BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . 3
WELD SPECIFICATIONS FOR STANDARD BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REPLACEMENT OF BOLT - ON CUTTING EDGE FOR STANDARD BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . 5
REPLACEMENT OF BOLT - ON CUTTING EDGE FOR CLAM BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REPLACEMENT OF TOOTH SHANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REPLACEMENT OF TOOTH POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOADER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bucket Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lift Cylinder Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bucket Cylinder Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clam Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clam Cylinder Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Antirollback Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

9006-3
REPLACEMENT OF WELD−ON CUTTING EDGE FOR STANDARD BUCKETS

1. If the bucket is not removed from the machine,
raise the bucket to a suitable height and use
suitable supports to hold the loader frame and
bucket in place.
2. If the bucket is equipped with bucket teeth, use
carbon arc rod to remove the bucket teeth.
3. Use carbon arc rod or an acetylene cutting torch
to remove the welds that hold the cutting edge.
Keep distortion to a minimum when removing the
cutting edge.
4. When removing the bottom rear weld for the 1
cutting edge DO NOT cut through the floor of the
bucket. 1. LONG LIP BUCKET 688MM (27.1 INCH)
BT95J196
7. Use E-7018 welding rod and weld the cutting

edge to the bucket.
8. When welding the floor of the bucket to the top of
the cutting edge:
A. Start at one end of the bucket and weld
toward the center until one welding rod is
1 used.
B. Start at the center of the bucket and weld in
both directions from center until one welding
rod is used.
C. Start at the other end of the bucket and weld
B633129M
1. LONG LIPPED BUCKET WELD toward the center until one welding rod is
used.
5. Use a grinder to remove any welds or extra metal
on the bucket that will prevent the new cutting D. Continue to weld the cutting edge to the
edge from fitting correctly. bucket using this method until welding is
complete.
6. Put the cutting edge in place and use C-clamps
to hold the cutting edge in place. See the 9. If bucket teeth were removed from the old cutting
illustration for the correct position of the cutting edge, install the bucket teeth according to
edge. instructions in this section.

9006-4
WELD SPECIFICATIONS FOR STANDARD BUCKET
2
2
3 1
B633129M B633122M
1. 6MM (1/4 INCH) FILLET
2. FILL GROOVE
3. FILL CORNER
B633125M

9006-5
REPLACEMENT OF BOLT - ON CUTTING EDGE FOR STANDARD BUCKET

1. If the bucket is not removed from the machine, 3. Thoroughly clean the mounting surface on the
raise the bucket to a suitable height and use bucket lip with a wire brush to remove any dirt or
suitable supports to hold the loader frame and debris.
bucket in place.
4. Install the new cutting edge using new mounting
2. Remove all bolt-on cutting edge retaining bolts. hardware.
NOTE: If the plow bolt threads or the nut is 5. Torque the cutting edge mounting bolt nuts to
damaged, it might be necessary to use an acetylene 461 - 569 Nm (340 - 420 pound - feet).
cutting torch to remove the plow bolts. DO NOT
apply heat to or cut on the bucket surface. To prevent
damage to the bucket surface, the use of a cutting
torch should be restricted to the cutting edge side
only.
BT95J173
1. CUTTING EDGE 2. PLOW BOLT 3. NUT

9006-6
REPLACEMENT OF BOLT - ON CUTTING EDGE FOR CLAM BUCKET

1. If The bucket is not removed from the machine, 3. Thoroughly clean the mounting surface on the
raise the bucket to a suitable height and use bucket lip with a wire brush to remove any dirt or
suitable supports to hold the loader frame and debris.
bucket in place.
4. Install the new cutting edge using new mounting
2. Remove all cutting edge retaining bolts. hardware.
NOTE: If the plow bolt threads or the nut is 5. Torque the cutting edge mounting bolt nuts to
damaged, it night be necessary to use an acetylene 461 - 569 Nm (340 - 420 pound-feet).
cutting torch to remove the plow bolts. DO NOT
apply heat to or cut on the bucket surface. To prevent
damage to the bucket surface, the use of a cutting
torch should be restricted to the cutting edge side
only.
3
4
4
2
1
3
2
BT95J172
1. CLAM BUCKET ASSEMBLY 3. PLOW BOLT
2. CUTTING EDGE 4. NUT

9006-7
REPLACEMENT OF TOOTH SHANK

NOTE: Bucket teeth are only availiable on bucket 4. See the following illustration for weld
with weld−on cutting edges. specifications and instructions.
to remove the welds that hold the tooth shank in
place.
2. Use a grinder to remove any welds or extra 1
material
that will prevent the tooth shank from fitting
correctly.
3. See the following illustration for the correct
location of the tooth shank on the cutting edge. 1
3
1 2 6
5
2
4
B902019J
Welding Instructions
1. 10MM (3/8 INCH) FILLET. WELD AROUND EACH CORNER
10MM (3/8 INCH). WELD TWO TIMES
2. 63MM (2-1/2 INCHES)
B861656J 3. 10MM (3/8 INCH) FILLET. WELD BOTH SIDES AND REAR
OF TOOTH SHANK, WELD TWO TIMES
1. 2362 MM (93 INCH) SHORT LIP AND CLAM BUCKET - 4. LONG LIP BUCKET
246 MM ( 9-11/16 INCH) 10MM (3/8 INCH) FILLET. WELD TWO TIMES
2. ALL BUCKETS −229 MM (9 INCH) 5. BENT AREAS OF TOOTH POINT
3. PUT TOOTH SHANK AS CLOSE TO CORNER AS 6. DO NOT WELD OVER EDGE OF BLADE.
POSSIBLE AND KEEP CORNER OF THE TOOTH POINT
EVEN WITH OUTER SURFACE OF CUTTING EDGE
REPLACEMENT OF TOOTH POINT

1. Heat the part of the tooth point that has been 5. Heat the part of the tooth point that will be
pressed into the dent on each side of the tooth pressed into the dent on each side of the tooth
shank. shank.
2. Bend the tooth point out of the dent on each side 6. Have another person hold the tooth point against
of the tooth shank. the tooth shank.
3. Use a pair of pliers to remove the tooth point 7. Use a suitable tool and drive the heated part of
from the tooth shank. the tooth point into the dent on each side of the
tooth shank.
4. Install a new tooth point on the tooth shank.

9006-8
LOADER FRAME
Removal 19. A wave washer and the self-leveling cam are

located between the loader frame and the
1. Raise the loader frame until the pivot pins for the machine chassis upright. Raise the loader frame
piston rod eyes of the lift cylinders are above the and remove these parts.
hood. Stop the engine.
20. Carefully move the machine out of the loader
2. Fasten suitable lifting equipment to the loader frame.
frame to hold the loader frame in place.
3. Remove the outer snap ring that holds the pivot Installation
pins for the piston rod eyes of the lift cylinders.
1. Carefully move the machine into the loader
4. Use suitable drivers and drive the pivot pins out frame.
of the loader frame. DO NOT remove the drivers
2. Lower the loader frame into alignment with the
at this time.
machine chassis upright.
5. Disconnect the lifting equipment and lower the
NOTE: It may be necessary to spread the loader
bucket to the floor.
arms to position them over the pivot tube in the
6. Hold the right lift cylinder and remove the driver. chassis uprights. Use caution. Do not over spread
Lower the lift cylinder onto the front axle. the loader frame arms.
7. Hold the left lift cylinder and remove the driver. 3. Install the wave washer and self-leveling cam
Lower the lift cylinder and strut onto the front between the machine chassis upright and the
axle. loader frame as shown.
8. Move the loader control lever to the right or left to
relieve any pressure in the bucket circuit.
2
9. Disconnect the bucket cylinder hoses from the 1
tubes on the right side of the machine chassis
upright. Fasten an identification tag to each tube.
10. Install a cap on each hose and a plug in each
tube. Thread size is 7/8-14.
11. If equipped, disconnect the clam cylinder hoses
from the tubes on the left side of the machine
chassis upright. Fasten an identification tag on
each tube.
12. Install a cap on each hose and a plug in each BT95J195
tube. Thread size is 7/8-14. 1. SELF-LEVELING CAM

2. WAVE WASHER
13. Remove both retaining bolts for the return-to-dig
switch mounting bracket. It is not necessary to 4. Start the pivot shaft into the loader frame from
disconnect the return-to-dig switch wiring. the left side of the machine chassis upright.
14. Disconnect the antirollback rod from the right 5. Drive the pivot all the way through into the right
bucket cylinder link. loader frame.
15. Disconnect the antirollback rod from the 6. Install the two flat hardened washers and the
self-leveling cam. Put the antirollback rod out of snap ring.
the way.
7. Install the antirollback rod. Make the connection
16. Remove the snap ring and the two hardened flat at the right bucket cylinder link as well as at the
washers from the right end of the loader lift frame self-leveling cam.
pivot shaft.
8. Install the return-to-dig switch mounting bracket
17. Fasten suitable lifting equipment to the loader using the 10x15 mm hex flange bolts. Torque to
frame to hold the loader frame in place. 26 - 31 Nm (19 - 23 pound−feet).
18. Use a suitable driver and drive the pivot shaft out 9. Replace any tie straps required to hold wiring
of the loader frame. harness in place.
9006-9
10. Connect the bucket cylinder hoses with the 14. Install the snap ring.
appropr iate tubes on the right side of the
15. Connect the right loader lift cylinder in the same
manner as the left lift cylinder. Install the snap
11. If equipped, connect the clam cylinder hoses with ring.
the appropriate tubes on the left side of the
16. Lubricate the pivot pins for the piston rod eyes of
the lift cylinders and the pivot shaft.
12. Move the loader control lever to the float
17. With the engine running at low idle, extend and
position.
retract all loader cylinders three times to remove
13. Raise the left loader lift cylinder and strut. any air from the circuits.
Position the pivot pin in the loader frame bore
and drive through the strut and cylinder piston
rod eye.

9006-10
BC08B127
LOADER FRAME

9006-11
BC08B129
BUCKET FRAME

9006-12
BC08B130
LIFT CYLINDER HYDRAULIC INSTALLATION

9006-13
BC08B131
BUCKET CYLINDER HYDRAULIC INSTALLATION

9006-14
BC08B128
CLAM CYLINDER CIRCUIT

9006-15
BC01B027
CLAM CYLINDER HYDRAULIC INSTALLATION

9006-16
BT95J197
BT95J197
ANTIROLLBACK LINKAGE

Section
9007
ROPS CAB AND ROPS CANOPY
9007

9007-2
TABLE OF CONTENTS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . 3
ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9007-3
TORQUE SPECIFICATIONS
ROPS cab and canopy mounting bolts......................................................... 298 to 358 Nm (220 to 264 pound-feet)
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY

If the machine has rolled over or the ROPS cab or After an accident, check for damage to the ROPS
ROPS canopy has been in some type of accident cab or ROPS canopy, the operators seat, the seat
(such as hitting an overhead object during transport), belt, and all accessories, wiring, in the ROPS cab or
you must replace the ROPS cab or ROPS canopy to ROPS canopy. Before operating the machine again,
get as much protection as you had originally. all damaged parts must be replaced.
Do not weld or try to straighten a ROPS cab or ROPS
canopy.
MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY

When necessary, check the torque of the ROPS
mounting bolts. Tighten the bolts to the correct WARNING: If you operate this machine
torque. without a ROPS and the machine rolls over,
you can be injured or killed. Remove the
WARNING: Improper ROPS inspection or ROPS only for service or replacement. Do
maintenance can cause injury or death. Do not operate this machine with the ROPS
the recommended ROPS inspection shown removed.
in the operator’s manual. If you replace the SA027
ROPS, ROPS parts, or ROPS mounting
hardware, use only the replacement parts WARNING: Adding additional weight
shown in the Case parts catalog for this (attachments, etc.) to the machine can cause
machine. injury or death. Do not exceed the gross
weight printed on the ROPS label.
SA029
SA028
WARNING: Do not modify ROPS in any
manner. Unauthorized modifications such as WARNING: You are protected by the ROPS
welding, drilling, cutting or adding system on this machine (Roll-over Protection
attachments can weaken the structure and Structure). The seat belt is an important part
reduce your protection. Replace ROPS if of the ROPS system. Before you operate this
subjected to roll-over or damage. Do not machine, always fasten the seat belt. If the
attempt to repair. machine rolls over and you DO NOT have
the seat belt fastened, you can be crushed
by the ROPS or the machine.
SA026
SA080

9007-4
ROPS CAB
Removal STEP 8
STEP 1
Park the machine on a level surface.
STEP 2
Raise the loader and lock the support strut to hold
the loader.
STEP 3
Lower the backhoe and stabilizers to the ground.
STEP 4 BD01B305
Apply the parking brake. Remove the screws from the right hand side and the
left hand side of the front floor mat.
STEP 5
Remove the bolts and washers that fasten the battery STEP 9
cover to the right side of the machine by the step. Remove the front floor mat from the machine.
STEP 6 STEP 10
Remove the battery cover.
STEP 7
BD01B301
Pull the cover off of the louver assembly.
BD08A453
Disconnect the negative ground cable from the

battery, be sure to move the ground cable away from
the battery.

9007-5
STEP 11 STEP 14
BD01B299 BD01B297
Push the four tabs inward while pulling louver Remove the boot from the loader control cover. Pull
assembly out. the boot up turning it inside out. This will allow the
boot to slide through the opening when the cover is
STEP 12 removed.
STEP 15
Remove the three screws from the loader control
cover and remove the cover.
STEP 16
1
1
2 3
BD01B300
Pull the louver assembly off of the hose. Push the 1

hose into the cover.
STEP 13
1
BD01B291
1. BOLT 2. FRONT PLATE 3. BACK PLATE

Remove the four bolts from the loader control lever
plates. Remove the front plate first then the back
plate.
NOTE: Back plate is sealed with silicone sealant.
BD08B697-01
Remove the screw from the loader control boot.

9007-6
STEP 17 STEP 19
3
2
1
BD01B346 BD01B303
1. SCREW Remove the four screws securing the rubber boot to

2. MAIN HARNESS TO SIDE CONSOLE HARNESS the backhoe control tower.
CONNECTOR
3. MAIN HARNESS TO SIDE OPTION HARNESS PLUG
STEP 20
Loosen the screw on the main harness to side
console harness connector and disconnect the 2
connector. Disconnect the main harness to side
option harness connector.
STEP 18
1
BD01B304
1. FRONT COVER 2. REAR COVER

Remove the bolt from the front cover and four bolts
from the rear cover on the backhoe tower.
BD01B290
STEP 21
Remove the bolts securing the loader control rods to
the control lever. Tie the control rods together.
NOTE: Your machine will have either a two spool or
three spool loader control valve.
2
1
BD01B302

Pull the rubber boot up. This will allow clearance
when removing the covers. Remove the front cover
and the rear cover.

9007-7
STEP 22 STEP 25
BD01B348 BD08B690-01
If equipped remove the rear floor mat. Remove the Disconnect powershift electrical connectors and
bolts on the rear floor plate and remove the plate. mounting brackets from cab.
NOTE: For powershift machines only.
STEP 23
STEP 26
BDO1B347
Remove the front floor plate.

BD08A489
Remove the grill from the machine. Slowly remove

STEP 24 the radiator cap. Install a hose on the drain valve and
drain the radiator into a clean container that holds
approximately 19 liters (5 U.S. gallon).
1 2
STEP 27
If equipped with air conditioning see section 9004 for
discharging the system.
BD01B337
1. BOLT 2. GEAR SHIFT LEVER 3. TRANSMISSION LEVER

Remove the bolt from the gear shift lever and remove
the gear shift lever from the transmission lever.

9007-8
STEP 28 STEP 31
BD08B702-01 BD01B295
Slowly loosen and disconnect the two brake tubes. Remove the bolt securing the boom lock cable to the
Cap the fittings and plug the brake tube ends. latch.
STEP 29 STEP 32
1
1
2
2
BD01B342 BS03K002
1. HEATER HOSE 2. AIR CONDITIONING HOSE Disconnect the throttle cable from the fuel injection
Put a container under the heater hoses to catch any pump.
remaining coolant when disconnected. Disconnect NOTE: 580M only.
the heater and air conditioning hoses. Cap the fittings
and plug the hoses.
STEP 33
STEP 30
BS03K001
Remove the throttle cable from the bracket.

BC03N122
Remove the cotter pin and clevis pin from the boom NOTE: 580M only.
lock lever.

9007-9
STEP 34 STEP 37
BD01B324 BD01B329
Tag and disconnect the wires for the air filter Push the wires for the air restriction switch through
restriction switch. the hole in the curtain. Remove the bolts from the
rubber curtain on the firewall and remove the curtain.
STEP 35
STEP 38
2
BD01B323
Loosen the clamp on the air cleaner hose. BD01B355

Disconnect the air cleaner hose from the turbo. Put a 1. SCREW 2. main harness to firewall connector
shop cloth in the turbo opening or the intake opening. Loosen the screw on the main harness to firewall
connector. Connector is located on the firewall under
STEP 36 the front console cover.
bd01b307
Remove the bolts that fasten the cover to the

uprights. Use acceptable lifting equipment and
remove the cover and air cleaner as an assembly.

9007-10
STEP 39 STEP 41
If your machine has a canopy go to Step 42. If the
1 machine has a cab go to Step 44.
2
NOTE: See illustration in Step 46.
STEP 42
4 in position. Remove the bolts (1) and washers (2)
that fasten the steering control valve (3) to the
steering column.
3
STEP 43
Go to Step 47.
BD08B701-01
1. POSITIVE WIRE
2. MAIN HARNESS TO FIREWALL CONNECTOR
STEP 44
3. FRONT CONSOLE OPTIONS HARNESS CONNECTOR Remove the bolts (4), washers (5), and mounts (6)
4. NEGATIVE WIRE that fasten the steering control valve (7) to the cab.
Disconnect the positive and negative wire on the
firewall. Disconnect the main harness to firewall STEP 45
connector. Disconnect the front console options Remove the steering control valve (7), mount (8), and
harness connector. spacer (9) from the cab.
STEP 40 STEP 46
Set the control valve out of the way.
6
5
4 7
1
2
3
BC01B088
BC08A207-01 1. BOLT 6. MOUNT
Disconnect the brake tubes from the brake master 2. WASHER 7. CONTROL VALVE
3. CONTROL VALVE 8. MOUNT
cylinder. Cap fittings and plug the brake tube ends.
4. BOLT 9. SPACER
5. WASHER

9007-11
STEP 47 NOTE: See illustration on page 12 for the following
Remove the nuts (1) and washers (2) from the rear step.
corners of the cab (10).
STEP 52
NOTE: See illustration on page 12 for Steps 47 to
Remove mounts (11 and 12) and washers (13) from
50.
the frame (14).
STEP 48
Remove the bolts (3) and washers (4).
STEP 49
Remove the nuts (5) and mounts (6) from the front
corners of the cab (10).
STEP 50
Remove the bolts (7) and washers (8 and 9).
STEP 51
1
1
BD01B368
BD01B369
1. LIFTING POINTS
Use acceptable lifting equipment and lift cab up and

off of machine. When lifting cab up make sure any
cables or hoses still connected to the cab are free
from the machine.
NOTE: Make sure cab is lifted high enough to clear
the backhoe control levers.

9007-12
10
3
14
4 7
8
12
9
13 11
2
6
1 5
BC00J080
1. NUT 6. MOUNT 11. MOUNT
2. WASHER 7. BOLT 12. MOUNT
3. BOLT 8. WASHER 13. WASHER
4. WASHER 9. WASHER 14. FRAME
5. NUT 10. CAB

9007-13
Installation STEP 9
Grease the splines on the steering column and
NOTE: See illustration on page 12 for the following
control valve. Put the spacer (1) and mounts (2) in
step.
place. Have another person hold the steering control
valve (3) in position.
STEP 1
Install washers (13) and mounts (12 and 11) on the STEP 10
frame (14).
Install the mounts (4), washers (5), and bolts (6) that
fasten the steering control valve (3) to the cab.
STEP 2
STEP 11
Go to Step 13.
STEP 12
BD01B369
Use acceptable lifting equipment and place cab on

the machine. Lower cab slowly and make sure all 1
wires and hoses are in there proper location.
NOTE: See illustration on page 12 for steps 3 to 7.
2
STEP 3
Install the washers (8 and 9) and bolts (7).
4
STEP 4 5
Install mounts (6) and nuts (5) on the front corners of
the cab (10). 6 3
9 7
STEP 5 8
Install the washers (4) and bolts (3). BC01B088
1. SPACER 6. BOLT
2. MOUNT 7. CONTROL VALVE
STEP 6 3. CONTROL VALVE 8. WASHER
Install the washers (2) and nuts (1) on the rear 4. MOUNT 9. BOLT
corners of the cab (10). 5. WASHER
Grease the splines on the steering column and

STEP 7
control valve. Have another person hold the steering
Tighten the four bolts which secure the cab to the control valve (7) in position. Install the washers (8)
f r a m e . To r q u e 2 9 8 t o 3 5 8 N m ( 2 2 0 t o 2 6 4 and bolts (9) that fasten the steering control valve (7)
pound-feet). to the steering column.
STEP 8
If your machine is equipped with a cab go to Step 9.
If it is equipped with a canopy go to Step 12.
NOTE: Refer to illustration in installation Step 12 .

9007-14
STEP 13 STEP 15
BD01B355
1. SCREW 2. MAIN HARNESS TO FIREWALL CONNECTOR

Tighten the screw on the main harness to firewall
connector.
STEP 16
BC08A207-01
Remove caps from fittings and plugs from brake

tubes. Connect the brake tubes to the brake master
cylinder.
BD01B329
STEP 14 Push the wires for the air restriction switch through
the hole the curtain. Install the curtain and bolts on
1 2
the fire wall.
STEP 17
BD08B701-01
1. POSITIVE WIRE
2. MAIN HARNESS TO FIREWALL CONNECTOR
3. FRONT CONSOLE OPTIONS HARNESS CONNECTOR
4. NEGATIVE WIRE
BD01B307
Connect the positive and negative wire on the
Put the cover and air cleaner assembly in position on
firewall. Connect the main har ness to firewall
the uprights. Install the bolts and flat washers that
connector. Connect the front console options
fasten the cover to uprights.
harness connector.

9007-15
STEP 18 STEP 21
BD01B323 BS03K002
Remove the shop cloth from the turbo opening or the Connect the throttle cable to the fuel injection pump.
intake opening. Connect the air cleaner hose to the
NOTE: 580M only.
turbo. Tighten the clamp on the air cleaner hose.
STEP 22
STEP 19
BD01B295
BD01B324
Install the bolt securing the boom lock cable to the
Connect the wires to the air restriction switch and
latch.
install a new tie strap.
STEP 23
STEP 20
BC03N122
BS03K001
Connect the cable to the boom lock lever. Install the
Connect the throttle cable to the bracket.
clevis pin and cotter pin.
NOTE: 580M only.

9007-16
STEP 24 STEP 27
1
1
1 2
2
2
BD01B342 BD01B337
1. HEATER HOSE 2. AIR CONDITIONING HOSE 1. BOLT 2. GEAR SHIFT LEVER 3. TRANSMISSION LEVER
Remove the caps and plugs from the hoses and Install the gear shift lever on the transmission lever
fittings. Connect the heater and air conditioning and tighten the bolt.
hoses.
STEP 28
STEP 25
3
1
BC04A148
1. REAR FLOOR PLATE MECHANICAL LINKAGE MACHINE
BD08B702-01
2. REAR FLOOR MAT MECHANICAL LINKAGE MACHINE
Remove the caps and plugs from the fittings and 3. REAR FLOOR PLATE PILOT CONTROLLED MACHINE
brake tubes. Connect the two brake line tubes.
Install the rear floor plate. If equipped install the rear
STEP 26 floor mat.
BD08B690-01
Connect powershift electrical connectors and

mounting brackets to cab.
NOTE: For powershift machines only.

9007-17
STEP 29 STEP 31
BD01B303
Install the four screws securing the rubber boot to the

backhoe control tower.
BC01B030 STEP 32
1. FRONT FLOOR PLATE
2. FRONT FLOOR MAT
Install the front floor plate.
STEP 30
2
BD01B290
Untie the control rods and install the bolts securing

the loader control rods to the control lever.
NOTE: Your machine will have either a two spool or
three spool loader control valve.
BD01B304

Put the covers on the backhoe control tower and
install the bolts.

9007-18
STEP 33 STEP 36
3
2
1
BD01B346 BD08B697-01
1. SCREW Put the loader control boot in place and install the
2. MAIN HARNESS TO SIDE CONSOLE HARNESS screw.
CONNECTOR
3. MAIN HARNESS TO SIDE OPTION HARNESS
CONNECTOR
STEP 37
Connect the main harness to side console harness
connector and tighten the screw. Connect the main
harness to side option harness connector.
STEP 34
1
1
2 3
BD01B300
1 Push the louver assembly on the hose and push the
assembly onto the cover.
1 STEP 38
BD01B291

Put a bead of RTV silicone sealant on the mating
surface of the back plate and install the plate. Install
the front plate and tighten the bolts.
STEP 35
Put the loader control cover in place and push the
vent hose through the hole in the cover. Install the
three bolts on the cover.
BD01B301
Push the cover onto the louver assembly.

9007-19
STEP 39 STEP 41
STEP 42
Install the washers and bolts that fasten the battery
cover to the machine.
STEP 43
Fill the radiator with the proper amount of coolant.
STEP 44
See Section 7000 for bleeding the brake system.
BD01B305
STEP 45
Put the front floor mat in place. Install the screws on
If equipped with air conditioning see Section 9004 for
the right hand side and the left hand side of the front
charging the system.
floor mat.
STEP 40
BD08A453
Connect the negative ground cable to the battery.

9007-20
NOTES

Section
9008
BACKHOE
9008

9008-2
TABLE OF CONTENTS
SWING TOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIPPER EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
580M WEAR PLATES FOR THE EXTENDABLE DIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
580 SM, SM + AND 590 SM WEAR PLATES
FOR THE EXTENDABLE DIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CUTTING EDGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Universal and Heavy Duty Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
High Capacity Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
BOOM LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
STABILIZERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9008-3
SWING TOWER
Removal 16. Remove the pivot pins.
1. Remove all dirt from the hose connections at the NOTE: There may be flat washers installed between
backhoe control valve. the boom and the swing tower. These flat washers fill
the gaps between the boom and the swing tower.
2. Start the engine and run the engine at 1000 rpm The flat washers also keep the boom centered in the
(r/min). Roll the bucket in all the way. Extend the swing tower. Put identification tags on these flat
dipper and the boom as far as possible in the washers so that they can be returned to the same
space that is available. Lower the bucket to the locations during installation.
floor and stop the engine.
17. Carefully move the machine away from the
3. Fasten acceptable lifting equipment to the boom boom.
and dipper pivot area to prevent the boom and
the dipper from falling when the boom is free of 18. Remove the snap ring and the flat washer(s)
the swing tower. from one end of the pivot pin for the rod eye of
each swing cylinder.
4. Move the backhoe control levers in both
directions to relieve any pressure in the circuits. 19. Use a hammer or hydraulic ram and an
acceptable driver to remove the pivot pins from
5. Disconnect the hoses from the backhoe control the swing tower.
valve and fasten an identification tag to each
hose. 20. Remove the snap ring and the flat washer(s)
from one end of the pivot pin for the boom latch.
6. Install a cap on each fitting and a plug in each
hose. 21. Drive the pivot pin out of the swing tower.
7. Remove the hardware which fastens the vertical 22. Move the boom latch out of the way.
clamps near the center of the swing tower. 23. Remove the snap ring and the flat washer(s)
Remove the vertical clamps. from the bottom of the bottom pivot pin for the
8. On 580 Super M, Super M+, and 590 Super M swing tower.
machines, there is a horizontal clamp to the rear 24. Fasten acceptable lifting equipment to the swing
of the vertical clamps. The 580M does not have tower to hold the swing tower when the pivot pins
this clamp. If your machine has this clamp, are removed.
remove the hardware and the clamp.
25. Use a hammer or hydraulic ram and an
9. Write an identification number on each clamp acceptable driver to remove the bottom pivot pin.
ring so that you can install the hoses in the
correct places during installation. 26. Remove the snap ring and the flat washer(s)
from the top of the top pivot pin for the swing
10. Fasten acceptable lifting equipment to the boom tower.
cylinder to hold the boom cylinder when the pivot
pin is removed. 27. Use a hammer or hydraulic ram and an
acceptable driver to remove the top pivot pin.
11. Remove the snap ring and the flat washer(s)
from one end of the pivot pin for the boom 28. Remove the swing tower from the frame.
cylinder. NOTE: Record the number and locations of any flat
12. Drive the pivot pin out of the swing tower. washers or shims that are found between the swing
tower and the frame so that the flat washers or shims
13. Lower the boom cylinder until the boom cylinder can be returned to the correct locations during
rests on the boom. Remove the lifting equipment. installation.
14. Fasten acceptable lifting equipment to the boom
to hold the boom when the pivot pins are
removed.
15. Remove the bolts, the hardened washers, and
the spacers that hold the pivot pins for the boom.

9008-4
Installation 18. Install the flat washer(s) and the snap ring to
fasten the pivot pin for the boom cylinder.
1. Install the swing tower in the frame. Make sure
that the thrust washer (the flat washer with the 19. If your machine has a horizontal hose clamp to
tab) is installed on top of the lower frame plate. the rear of the vertical hose clamps, install the
The tab must be up so that it engages the notch horizontal hose clamp on the hoses. Install the
in the swing tower. The flat washers or shims hardware.
that are used to decrease the clearance between 20. Install the vertical clamps and the hardware.
the swing tower and the frame must be installed
below the lower frame plate. 21. Connect the hoses to the backhoe control valve.
2. Install the top pivot pin for the swing tower so 22. Use molydisulfide grease to lubricate all pivot
that the grease fitting is down. pins.
3. Install the flat washer(s) and the snap ring to 23. Run the engine at 1000 rpm (r/min). Slowly
fasten the top pivot pin. operate the bucket, dipper, dipper extension (if
equipped), and boom cylinders through four
4. Install the bottom pivot pin for the swing tower so complete cycles to remove any air from the
that the grease fitting is up. circuits.
5. Install the flat washer(s) and the snap ring to 24. The boom latch lever should have 0 to 8 mm (0
fasten the bottom pivot pin. to 0.32 inch) of free play at the knob when boom
6. Put the boom latch in position. is un-latched.
7. Install the pivot pin for the boom latch.

8. Install the flat washer(s) and the snap ring to
fasten the pivot pin for the boom latch.
9. Move the swing cylinders as necessary to align
the rod eyes with the mounting holes in the swing
tower.
10. Install the pivot pins for the rod eyes of the swing
cylinders.
fasten each pivot pin.
12. Carefully move the machine to align the swing
tower with the boom.
13. If necessary, install flat washers between the
boom and the swing tower. The flat washers
should fill the gaps between the boom and the
swing tower. They should also keep the boom
centered in the swing tower.
14. Install the pivot pins for the boom. Turn the pivot
pins as necessary so that the hole in the ear of
each pivot pin is aligned with the hole in the
swing tower.
15. Install the spacers, the hardened washers, and
the bolts to fasten the pivot pins to the swing
tower.
16. Fasten acceptable lifting equipment to the boom
cylinder. Move the boom cylinder as necessary
so that the rod eye is aligned with the swing
tower.
17. Install the pivot pin for the boom cylinder.

9008-5
1
2 3
BC08B149
1. SWING TOWER - 580 SUPER M
2. SWING TOWER - 580 M
3. SWING TOWER - 590 SUPER M
4. SPACER - ONE USED ON 580M OR 580 SUPER M. TWO USED ON 590 SUPER M
5. SPACER - USED ON 580M AND 580 SUPER M ONLY
SWING TOWER AND SWING CYLINDER INSTALLATION

9008-6
BC04A154
580M SWING CYLINDER HYDRAULIC INSTALLATION MECHANICAL LINKAGE CONTROLLED BACKHOE

9008-7
BC08B150
ALL SM MACHINES SWING CYLINDER HYDRAULIC INSTALLATION MECHANICAL LINKAGE CONTROLLED BACKHOE

9008-8
BC04A155
SWING CYLINDER HYDRAULIC INSTALLATION PILOT CONTROLLED BACKHOE

9008-9
BOOM
Removal 16. Adjust the lifting equipment, if necessary, so that

the lifting equipment will hold the boom when the
1. Start the engine and run the engine at 1000 rpm pivot pin for the rod eye of the boom cylinder is
(r/min). Roll the bucket in all the way. removed.
2. Put the boom and the dipper in an acceptable 17. Fasten acceptable lifting equipment to the boom
position for removal of these parts. Make sure cylinder to hold the boom cylinder when the pivot
that the bucket is on the floor. pin is removed.
3. Stop the engine. Move the backhoe control 18. Remove the snap ring and the flat washer(s)
levers in both directions to relieve any pressure from one end of the pivot pin for the boom
in the circuits. cylinder.
4. For all machines except the 580M without 19. Drive the pivot pin out of the swing tower.
extendable dipper, disconnect the bucket
cylinder hoses at the connections inside the 20. Lower the boom cylinder until the boom cylinder
upper end of the boom. For 580M machines rests on the boom. Remove the lifting equipment
without extendable dipper, disconnect the bucket from the boom cylinder.
cylinder hoses at the bucket cylinder. 21. For 580 Super M and 590 Super M machines,
5. Install caps or plugs on all hoses and tubes. disconnect the backhoe hoses at the
connections inside the lower end of the boom.
6. If the machine has an extendable dipper, For 580M machines, disconnect the backhoe
disconnect the extension cylinder hoses at the hoses at the backhoe control valve. Fasten an
connections inside the upper end of the boom. identification tag to each hose.
7. Install caps or plugs on all hoses and tubes. 22. Install caps or plugs on all hoses and tubes.
8. Fasten acceptable lifting equipment to the dipper 23. On 580M machines only, remove the hardware
cylinder and to the boom or the dipper as which fastens the vertical clamps near the center
necessary to hold these parts when the pivot pin of the swing tower. Remove the vertical clamps.
is removed from the rod eye of the dipper
cylinder. 24. Adjust the lifting equipment, if necessary, to hold
the boom when the pivot pins for the boom are
9. Remove the snap ring and the flat washer(s) that removed.
hold the pivot pin for the rod eye of the dipper
cylinder. 25. Remove the bolts, the hardened washers, and
the spacers that hold the pivot pins for the boom.
10. Drive the pivot pin out of the dipper.
26. Remove the pivot pins.
11. Lower the dipper cylinder to the boom.
NOTE: There may be flat washers installed between
12. Adjust the lifting equipment, if necessary, so that the boom and the swing tower. These flat washers fill
the lifting equipment will hold the boom and the the gaps between the boom and the swing tower.
dipper when the pivot pin for the dipper is The flat washers also keep the boom centered in the
removed. swing tower. Put identification tags on these flat
13. Remove the self-locking nut and the hardened washers so that they can be returned to the same
washer that hold the pivot pin for the dipper. locations during installation.
NOTE: There may be one or more shims installed 27. Remove the boom from the machine. On 580M
between the hardened washer and the boom. If so, machines, carefully pull the backhoe hoses from
record the number and the location of the shims so the swing tower as you remove the boom.
that they can be returned to the correct location
14. Drive the pivot pin out of the boom.
15. Move the dipper out of the way.

9008-10
Installation 12. If there were shims installed between the

hardened washer and the boom, install the
1. Put the boom into position on the machine. On shims. The correct thickness of shims will cause
580M machines, carefully guide the backhoe the ears of the boom to be pulled together 1 to 3
hoses through the swing tower. mm (1/16 to 1/8 inch) when the self-locking nut is
2. If necessary, install flat washers between the tightened.
boom and the swing tower. The flat washers 13. Install the hardened washer and the self-locking
should fill the gaps between the boom and the nut for the pivot pin. Tighten the self-locking nut
swing tower. They should also keep the boom to a torque of 678 to 949 Nm (500 to 700
centered in the swing tower. pound-feet).
3. Install the pivot pins for the boom. Turn the pivot 14. Fasten acceptable lifting equipment to the dipper
pins as necessary so that the hole in the ear of cylinder. Move the dipper cylinder as necessary
each pivot pin is aligned with the hole in the so that the rod eye is aligned with the hole in the
swing tower. dipper.
4. Install the spacers, the hardened washers, and 15. Install the pivot pin for the dipper cylinder.
the bolts to fasten the pivot pins to the swing
tower. 16. Install the flat washer(s) and the snap ring to
fasten the pivot pin for the dipper cylinder.
5. On 580M machines only, install the vertical
clamps and the hardware. 17. If the machine has an extendable dipper,
connect the extension cylinder hoses at the
6. On 580M machines only, connect the backhoe connections inside the upper end of the boom.
hoses to the backhoe control valve. On 580
Super M and 590 Super M machines, connect 18. For all machines except the 580M without
the backhoe hoses at the connections inside the extendable dipper, connect the bucket cylinder
lower end of the boom. hoses at the connections inside the upper end of
th e bo om . For 5 80 M m ach in es with ou t
7. Fasten acceptable lifting equipment to the boom extendable dipper, connect the bucket cylinder
cylinder. Move the boom cylinder as necessary hoses at the bucket cylinder.
so that the rod eye is aligned with the swing
tower. 19. Use molydisulfide grease to lubricate all pivot
pins.
8. Install the pivot pin for the boom cylinder.
20. Run the engine at 1000 rpm (r/min). Slowly
9. Install the flat washer(s) and the snap ring to operate the bucket, dipper, dipper extension (if
fasten the pivot pin for the boom cylinder. equipped), and boom cylinders through four
10. Put the dipper in position on the boom. complete cycles to remove any air from the
circuits.
11. Install the pivot pin for the dipper.

9008-11
BS01B035
BOOM INSTALLATION - 580M

9008-12
BC04A158
BOOM CYLINDER HYDRAULIC INSTALLATION - 580M

9008-13
BC08B151
BOOM INSTALLATION - 580 SUPER M, SUPER M+

9008-14
BC08B152
BOOM INSTALLATION - 590 SUPER M, SUPER M+

9008-15
BC04A156
BOOM CYLINDER HYDRAULIC INSTALLATION - 580 SUPER M, SUPER M+, 590 SUPER M, SUPER M+

9008-16
DIPPER
Removal 8. Install caps or plugs on all hoses and tubes.
1. Start the engine and run the engine at 1000 rpm 9. If the machine has an extendable dipper,
(r/min). Put the bucket in position so that the disconnect the extension cylinder hoses at the
bucket teeth are just off the floor and below the connections inside the upper end of the boom.
pivot pin for the bucket. Stop the engine. 10. Install caps or plugs on all hoses and tubes.
2. Remove the snap ring and the flat washer(s) 11. Fasten acceptable lifting equipment to the dipper
from one end of the pivot pin for the bucket. cylinder and to the boom or the dipper as
3. Remove the pivot pin for the bucket. necessary to hold these parts when the pivot pin
is removed from the rod eye of the dipper
4. Start the engine and run the engine at 1000 rpm cylinder.
(r/min). Move the backhoe as necessar y to
disengage the coupler from the bucket. Move the 12. Remove the snap ring and the flat washer(s) that
bucket out of the way. hold the pivot pin for the rod eye of the dipper
cylinder.
5. Retract the bucket cylinder. Put the boom and
the dipper in an acceptable position for removal 13. Drive the pivot pin out of the dipper.
of the dipper. 14. Lower the dipper cylinder to the boom.
6. Stop the engine. Move the extension control 15. Adjust the lifting equipment, if necessary, so that
lever, if equipped, and the bucket control lever in the lifting equipment will hold the boom and the
both directions to relieve any pressure in the dipper when the pivot pin for the dipper is
circuits. removed.
7. For all machines except the 580M without 16. Remove the self-locking nut and the hardened
extendable dipper, disconnect the bucket washer that hold the pivot pin for the dipper.
cylinder hoses at the connections inside the
upper end of the boom. For 580M machines NOTE: There may be one or more shims installed
without extendable dipper, disconnect the bucket between the hardened washer and the boom. If so,
cylinder hoses at the bucket cylinder. record the number and the location of the shims so
that they can be returned to the correct location
17. Drive the pivot pin out of the boom.
18. Remove the dipper.

9008-17
Installation 9. For all machines except the 580M without

extendable dipper, connect the bucket cylinder
1. Put the dipper in position on the boom. hoses at the connections inside the upper end of
2. Install the pivot pin for the dipper. t h e b o o m . Fo r 5 8 0 M m a c h i n e s w i t h o u t
extendable dipper, connect the bucket cylinder
3. If there were shims installed between the hoses at the bucket cylinder.
hardened washer and the boom, install the
shims. The correct thickness of shims will cause 10. Put the bucket into position. Start the engine and
the ears of the boom to be pulled together 1 to 3 run the engine at 1000 rpm (r/min). Move the
mm (1/16 to 1/8 inch) when the self-locking nut is backhoe as necessary to engage the bucket with
tightened. the coupler. Then move the bucket as necessary
so that the pivot pin can be installed. Stop the
4. Install the hardened washer and the self-locking engine.
nut for the pivot pin. Tighten the self-locking nut
to a torque of 678 to 949 Nm (500 to 700 11. Install the pivot pin for the bucket.
pound-feet). 12. Install the flat washer(s) and the snap ring to
5. Fasten acceptable lifting equipment to the dipper fasten the pivot pin.
cylinder. Move the dipper cylinder as necessary 13. Use molydisulfide grease to lubricate all pivot
so that the rod eye is aligned with the hole in the pins.
dipper.
6. Install the pivot pin for the dipper cylinder. operate the bucket, dipper, dipper extension (if
7. Install the flat washer(s) and the snap ring to equipped), and boom cylinders through four
fasten the pivot pin for the dipper cylinder. complete cycles to remove any air from the
circuits.
8. If the machine has an extendable dipper,
connect the extension cylinder hoses at the
connections inside the upper end of the boom.

9008-18
BC08B153
DIPPER AND BUCKET INSTALLATION - 580M

9008-19
BC04A162
BUCKET CYLINDER HYDRAULIC INSTALLATION WITHOUT EXTENDABLE DIPPER - 580M

9008-20
BC04A161
DIPPER CYLINDER HYDRAULIC INSTALLATION - 580M

9008-21
BC08B154
DIPPER AND BUCKET INSTALLATION - 580 SUPER M, SUPER M+

9008-22
BC04A163
BUCKET CYLINDER HYDRAULIC INSTALLATION WITHOUT EXTENDABLE DIPPER - 580 SUPER M, SUPER M+

9008-23
BC04A159
DIPPER CYLINDER HYDRAULIC INSTALLATION - 580 SUPER M, SUPER M+

9008-24
BC01B039
DIPPER AND BUCKET INSTALLATION - 590 SUPER M, SUPER M+

9008-25
BC04A164
BUCKET CYLINDER HYDRAULIC INSTALLATION WITHOUT EXTENDABLE DIPPER - 590 SUPER M, SUPER M+

9008-26
BC04A160
DIPPER CYLINDER HYDRAULIC INSTALLATION - 590 SUPER M, SUPER M+

9008-27
DIPPER EXTENSION
1. Start the engine and run the engine at 1000 rpm 1. Put the dipper extension into position on the
(r/min). Put the bucket in position so that the dipper. Push the dipper extension onto the
bucket teeth are just off the floor and below the dipper until the rod eye of the extension cylinder
pivot pin for the bucket. Stop the engine. is aligned with the hole for the pivot pin for the
bottom ends of the guide links.
2. Remove the snap ring and the flat washer(s)
from one end of the pivot pin for the bucket. 2. Put the guide links into position and install the
pivot pin through the guide links, the dipper
3. Remove the pivot pin for the bucket.
extension, and the rod eye. Make sure that the
4. Start the engine and run the engine at 1000 rpm washer(s) and spacer(s) which were removed
(r/min). Move the backhoe as necessar y to are installed in the correct locations.
disengage the coupler from the bucket. Move the
3. Install the snap ring on the pivot pin.
bucket out of the way.
4. Connect the bucket cylinder hoses at the
5. Completely extend the dipper and raise or lower
the boom so that the end of the dipper is
approximately three feet (one meter) above the 5. Remove the block from under the bucket
floor. cylinder.
6. Retract the bucket cylinder. Stop the engine. 6. Put the bucket into position. Start the engine and
run the engine at 1000 rpm (r/min). Move the
7. Put a block under the bucket cylinder to hold the
backhoe as necessary to engage the bucket with
bucket cylinder when the pivot pin is removed
the coupler. Then move the bucket as necessary
from the bottom ends of the guide links.
so that the pivot pin can be installed. Stop the
8. Disconnect the bucket cylinder hoses at the engine.
7. Install the pivot pin for the bucket.
9. Remove the snap ring, the washer(s), and the
spacer(s) from one end of the pivot pin for the
fasten the pivot pin.
bottom ends of the guide links. Drive the pivot pin
out of the guide links and the dipper extension. 9. Use molydisulfide grease to lubricate all pivot
Record the number and locations of any washers pins.
or spacers on the pivot pin so that these parts
can be returned to the correct locations during
operate the bucket, dipper, dipper extension, and
installation.
boom cylinders through four complete cycles to
10. Install acceptable lifting equipment to hold the remove any air from the circuits.
dipper extension when the dipper extension is
removed from the dipper.
11. Insert a bar through the hole for the pivot pin for
the bucket. Use the bar to pull the dipper
extension from the dipper.

9008-28
BS01B041
EXTENDABLE DIPPER INSTALLATION - 580M

9008-29
BC04A167
BUCKET CYLINDER HYDRAULIC INSTALLATION WITH EXTENDABLE DIPPER - 580M

9008-30
BC04A168
EXTENSION CYLINDER HYDRAULIC INSTALLATION - 580M

9008-31
BS01B042
EXTENDABLE DIPPER INSTALLATION - 580 SUPER M, SUPER M+

9008-32
BC04A166
BUCKET CYLINDER HYDRAULIC INSTALLATION WITH EXTENDABLE DIPPER - 580 SUPER M, SUPER M+

9008-33
BC04A169
EXTENSION CYLINDER HYDRAULIC INSTALLATION - 580 SUPER M, SUPER M+

9008-34
BC01B043
EXTENDABLE DIPPER INSTALLATION - 590 SUPER M, SUPER M+

9008-35
BC04A165
BUCKET CYLINDER HYDRAULIC INSTALLATION WITH EXTENDABLE DIPPER - 590 SUPER M, SUPER M+

9008-36
BC04A170
EXTENSION CYLINDER HYDRAULIC INSTALLATION - 590 SUPER M, SUPER M+

9008-37
580M WEAR PLATES FOR THE EXTENDABLE DIPPER
Replacing 4. Select shims for the side wear plates so that the
total distance from one wear surface to the other
1. Remove the dipper extension according to the is 5.75 to 5.79 inches (146 to 147 mm). The wear
instructions in this section. surface of each side wear plate must be even
2. On 580M machines only, plastic pins are used to with or up to 0.030 inch (0.8 mm) beyond the
hold the wear plates and the shims in position rails on the dipper.
during assembly. Usually, these pins wear away 5. Use new plastic pins to install the side wear
during operation. Remove any remaining plastic plates and shims.
pins. Then remove the wear plates and the
shims. 6. Use new plastic pins to install the top and bottom
wear plates.
3. Remove the grease from the sides and the
bottom of the dipper and from the inside of the 7. Apply molydisulfide grease to the rails on the
dipper extension. dipper.
8. Install the dipper extension according to the
instructions in this section.
580 SM, SM + AND 590 SM WEAR PLATES

FOR THE EXTENDABLE DIPPER
Replacing 8. Install the shim(s), the side wear plates, the

stepped washers, and the bolts.
1. Remove the dipper extension according to the
instructions in this section. NOTE: On 590 Super M machines only, 9.5 mm (3/8
inch) flat washers are used in addition to the stepped
2. Remove the bolts, the washers, the wear plates, washers. Use a 9.5 mm (3/8 inch) flat washer ONLY
and the shims. when there are no more than three shims installed
3. Remove the grease from the sides and the under that top or bottom wear plate.
bottom of the dipper and from the inside of the 9. Tighten the cap screws to a torque of 70.5 to
dipper extension. 77.3 Nm (52 to 57 pound-feet).
4. Select shims for the side wear plates so that the 10. Apply molydisulfide grease to the rails on the
total distance from one wear surface to the other dipper.
is 146 to 147 mm (5.75 to 5.79 inches). The wear
surface of each wear plate must be even with or 11. Install the dipper extension according to the
up to 0.8 mm (0.030 inch) beyond the rails on the instructions in this section.
dipper.
5. Install the shim(s), the side wear plates, the
stepped washers, and the bolts.
NOTE: On 590 Super M machines only, 9.5 mm (3/8
inch) flat washers are used in addition to the stepped
washers. Use a 9.5 mm (3/8 inch) flat washer ONLY
when there is no more than one shim installed under
that side wear plate.
6. Tighten the bolts to a torque of 52 to 57
pound-feet (70.5 to 77.3 Nm).
7. Select shims for the top and bottom wear plates
so that the total distance from one wear surface
to the other is 234 to 235 mm (9.21 to 9.25
inches). The wear surface of each wear plate
must be even with or up to 0.8 mm (0.030 inch)
beyond the rails on the dipper.

9008-38
CUTTING EDGES
Universal and Heavy Duty Buckets

3
Replacing Bottom Cutting Edge
1. Remove the bucket teeth. Use carbon arc rod or 6
an acetylene cutting torch to remove the welds.
4
IMPORTANT: When you remove the bottom weld at
the rear of the bottom cutting edge, DO NOT cut 4
through the bottom of the bucket.
6
to remove the welds that hold the bottom cutting
edge. 5
3. Use a grinder to remove any welds or extra metal
still on the bucket so that the new bottom cutting 4
edge will fit the bucket. 2
4. Put the new bottom cutting edge in position and
make several tack welds to hold it.
5. See the following illustration for the weld
locations and specifications. DO NOT make any
welds on the inside of the bucket except the
bottom of the bucket to the bottom cutting edge. 1
Use E7018 welding rod to weld the bottom
cutting edge in position.
B8611750R
1. 14 MM (9/16 INCH)
2 2. 20 MM (3/4 INCH) NO WELD
3. NO WELD, TOP ONLY
4. FIRST WELD. 10 MM (3/8 INCH) FLARE
5 BEVEL WELD.
5 SECOND WELD. 10 MM (3/8 INCH)
FILLET WELD.
5. BOTTOM ALL AROUND 8 MM (3/4 INCH)
3 FILLET. WELD TWO TIMES.
6 6. 8 MM (5/16 INCH) FILLET. WELD TWO TIMES.
7. Weld the remaining bucket teeth to the bottom

4 1 cutting edge according to the instructions in this
section.
BT95M078
Replacing Side Cutting Edge
1. UNIVERSAL BUCKET - 147 MM (5.79 INCHES)
HEAVY DUTY BUCKET - 151 MM (5-15/16 INCHES) 1. Use carbon arc rod or an acetylene cutting torch
2. UNIVERSAL BUCKET - 44 MM (1.73 INCH) to remove the welds that hold the side cutting
HEAVY DUTY BUCKET - 47 MM (1-7/8 INCH) edge.
3. 10 MM (3/8 INCH) FILLET TOP AND BOTTOM
4. FILL GROOVE BETWEEN WEAR PLATES AND 2. Use a grinder to remove any welds or extra metal
BOTTOM CUTTING EDGE still on the bucket so that the new side cutting
5. 6 MM (1/4 INCH) FILLET ALL AROUND
6. TWO PASS 6 MM (1/4 INCH) WELD TO FILL VOID
edge will fit the bucket.
3. Use E7018 welding rod to weld the side cutting
6. See the following illustration. Install the corner edge to the bucket with a 6 mm (1/4 inch) fillet all
bucket teeth and weld the bucket teeth in around the side cutting edge.
position. Use E7018 welding rod.

9008-39
High Capacity Buckets Replacing Side Cutting Edge

Replacing Bottom Cutting Edge 1. Remove all welds that hold the side cutting edge
in position. Use carbon arc rod or an acetylene
1. Remove the bucket teeth. Use carbon arc rod or cutting torch to remove the welds.
an acetylene cutting torch to remove the welds.
2. Remove the side cutting edge from the bucket.
2. Remove all welds that hold the bottom cutting
edge in position. Use carbon arc rod or an 3. Use a grinder to remove any welds or extra metal
acetylene cutting torch to remove the welds. still on the bucket so that the new side cutting
edge will fit the bucket.
3. Remove the cutting edge from the bucket.
4. Put the side cutting edge in position and use a
4. Use a grinder to remove any welds or extra metal C-clamp to hold it.
still on the bucket so that the new cutting edge
will fit the bucket. 5. Use E7018 welding rod to weld the side cutting
edge to the bucket. Use a 6 mm (1/4 inch) fillet
5. Put the new bottom cutting edge in position and weld all around the side cutting edge.
use C-clamps to hold it.
6. See the following illustration for weld locations
and specifications. Use E7018 welding rod to
weld the bottom cutting edge to the bucket.
3 1
BS01B231
1. 48 MM (1-7/8 INCH)
2. 6 MM (1/4 INCH) FILLET TOP AND BOTTOM
3. FILL GROOVE BETWEEN WEAR PLATES AND
BOTTOM

9008-40
BUCKET TEETH
Replacing a Tooth Point
3
1. Use a hammer and a punch to remove the flex
pin from the tooth point.
2. Install a new tooth point and drive a new flex pin 6
into the tooth point. Install the flex pin so that the 4
shoulders are toward the cutting edge.
4
Replacing a Tooth Shank 6
to remove the welds that hold the tooth shank.
2. Use a grinder to remove any welds or extra metal 5
that will prevent the new tooth shank from fitting
correctly. 4
3. If a new cutting edge has been installed, see the
2
illustrations on the following page for correct
location of the bucket teeth.
4. See the following illustration for weld
specifications for all bucket teeth except the
corner bucket teeth for the universal and the
heavy duty buckets. Use E7018 welding rod to
weld the tooth shanks in position.
1
B8611750R
1. 14 MM (1/2 INCH)
3 3 2. 20 MM (7/8 INCH) NO WELD
2 3. NO WELD, TOP ONLY
4. FIRST WELD. 10 MM (7/16 INCH) FLARE
1 BEVEL WELD.
SECOND WELD. 10 MM (7/16 INCH)
FILLET WELD.
5. BOTTOM ALL AROUND 8 MM (5/16 INCH)
2 FILLET. WELD TWO TIMES.
6. 8 MM (5/16 INCH) FILLET. WELD TWO TIMES.
1 3
B861752R
1. 20 MM (7/8 INCH) NO WELD
2. NO WELD
3. 8 MM (5-16 INCH) FILLET BOTH SIDES.
WELD TWO TIMES
5. Universal and heavy duty buckets only. See the

following illustration for the weld specifications
for the corner bucket teeth. Use E7018 welding
rod to weld the tooth shanks in position.

9008-41
7
6
5
4
3
2 1
B872455J
1. CENTER TOOTH 5. 304 MM (12 INCH) BUCKET - 131.1 MM (5.16 INCH)

2. 12 MM (0.47 INCH) 406 MM (16 INCH) BUCKET - 182.2 MM (7.17 INCH)
3. 457 MM (18 INCH) BUCKET - 141.18 MM (5.56 INCH) 457 MM (18 INCH) BUCKET - 271.36 MM (10.68 INCH)
610 MM (24 INCH) BUCKET - 139.5 MM (5.49 INCH) 610 MM (24 INCH) BUCKET - 282.5 MM (11.12 INCH)
6. 914 MM (36 INCH) BUCKET - 573.7 MM (22.59 INCH
4. 914 MM (36 INCH) BUCKET - 295.7 MM (11.64 INCH) 7. 610 MM (24 INCH) BUCKET - 425.5 MM (16.75 INCH)
762 MM (30 INCH) BUCKET - 576 MM (22.68 INCH)
914 MM (36 INCH) BUCKET - 712.8 MM (28.06 INCH)
TOOTH LOCATIONS FOR UNIVERSAL AND HEAVY DUTY BUCKETS
4
2
1
B902038J
1. CENTERLINE
2. CENTER TOOTH
3. 610 MM (24 INCH) BUCKET -98 MM (3.86 INCH)
762 MM (30 INCH) BUCKET - 130.6 MM (5.14 INCH)
4. PUT TOOTH SHANK AS NEAR CORNER AS POSSIBLE AND KEEP TOOTH POINT
15 MM (0.59 INCH) OUTSIDE OF CUTTING EDGE
TOOTH LOCATIONS FOR HIGH CAPACITY BUCKETS

9008-42
BOOM LATCH
BC03N121
BOOM LATCH INSTALLATION - MECHANICAL CONTROLLED BACKHOE

9008-43
BC03N122
BOOM LATCH INSTALLATION - PILOT CONTROLLED BACKHOE

9008-44
STABILIZERS
BC08B156
580 M AND 580 SUPER M, SUPER M+ STABILIZER INSTALLATION

9008-45
BC08B155
590 SUPER M, SUPER M+ STABILIZER INSTALLATION

9008-46
BC04A171
STABILIZER HYDRAULIC INSTALLATION PILOT CONTROLLED BACKHOE

9008-47
BC04A172
STABILIZER HYDRAULIC INSTALLATION MECHANICAL CONTROLLED BACKHOE

9008-48
NOTES

Section
9009
SEARS
MECHANICAL AND STANDARD
SUSPENSION SEATS
9009

Racine, WI 53404 U.S.A. Bur 6-80000 Issued July, 2005
9009-2
TABLE OF CONTENTS
SEAT BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MECHANICAL SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassemble the Lumbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assemble the Lumbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble the Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspect the Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assemble the Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassemble the Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspect the Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assemble the Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassemble the Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspect the Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble the Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassemble the Recliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble the Recliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pivot Safety Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PEDASTAL SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassemble the Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspect the Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble the Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassemble the Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspect the Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble the Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassemble the Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspect the Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assemble the Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

9009-3
SEAT BELT INSTALLATION

Mount seat belts at an angle of 45° ± 5°.
BC05B042
BC05B044
Torque bolts to 69 to 78 lb-ft (94 to 106 Nm).

9009-4
MECHANICAL SUSPENSION SEAT
Disassemble the Lumbar STEP 4
STEP 1
BD05E005
Drive the roll pin out of the lumbar knob.

BD05E001
Push up on bottom seat cushion and remove. STEP 5
STEP 2
BD05E004
Remove the mounting screws, remove the knob.

BD05E002
Remove back cushion retaining screws. STEP 6
STEP 3
BD05E007
Drill out the rivets and remove the lumbar assembly.

BD05E003
Pull forward and lift the back cushion off of the

mounting tabs.

9009-5
Assemble the Lumbar STEP 10
STEP 7
BD05E087
Install the back seat cushion by aligning the retaining

BD05E007
tabs with the slots.
Place the lumbar assembly into position on the seat
back, install new rivets. STEP 11
STEP 8
BD05E002
Install and tighten the seat back retaining screws.

BD05E004
Put the knob and shaft bushing onto the shaft, mount STEP 12
the bushing to the seat back.
STEP 9
Align the retaining tabs with the slots and push the
seat bottom into position.
BD05E006
Install a new roll pin into the knob.

9009-6
Disassemble the Slide STEP 16
STEP 13
BD05E011
Remove the adjustable slide bushings from the right

BD05E008
side of the slide assembly.
Remove the mounting screws and stop plate from
the rear of the seat bottom. Inspect the Slide
STEP 14
BD05E012
Check position locking teeth for damage, if damaged

BD05E009
replace swivel and slide as an assembly.
Remove the seat from the slide assembly.
STEP 17
STEP 15
BD05E093
BD05E010
Check slide locking plate, springs, pivots, and rails
Remove the slide bushings from the left side of the
for damage, if damaged replace swivel and slide as
slide assembly.
an assembly.

9009-7
Assemble the Slide STEP 21
STEP 18
BD05E023
Align the adjuster holes with the adjustable bushings.

BD05E011
Install the adjustable slide bushings on the right side STEP 22

of the slide frame.
STEP 19
Install the non adjustable slide bushings on the left
side of the slide frame, lubricate the bushings with
molydisulfide grease.
STEP 20
BD05E085
Adjust the bushings for side to side motion of the

seat.
NOTE: If slides are adjusted to tight it will be hard to
adjust the seat for and aft.
BD05E008
Install the seat assembly and install the slide stop.

9009-8
Disassemble the Swivel STEP 26
STEP 23
BD05E015
Remove the nut from the swivel bolt.

BD05E008
Remove the slide stop and remove the seat from the STEP 27
swivel.
STEP 24
BD05E016
Remove the bushing from the swivel bolt, remove the

top half of the swivel assembly.
BD05E013
Remove the cotter pin from the swivel bolt. STEP 28
STEP 25
BD05E017
Remove the bearing separator from the lower swivel

BD05E014
half.
Place a suitable wedge under the bottom of the bolt
to hold it into the swivel assembly.
STEP 29

9009-9
Assemble the Swivel

STEP 31
BD05E018
Remove the bearings.
Inspect the Swivel BD05E020
Place the bearing separator plate onto the lower

STEP 30 portion of the swivel.
STEP 32
BD05E019
inspect bearing tracks, bearings, and bearing

separator plate for wear or damage, repair or replace BD05E021
as needed. Place the bearings into the separator plate, put the
top half of the swivel onto the lower half.
STEP 33
BD05E016
Place the bushing onto the bolt.

9009-10
STEP 34 Disassemble the Suspension
System
STEP 38
BD05E015
Install and hand tighten the swivel nut until there is

no play in the bearing, tighten the nut two more flats
and align the cotter pin hole.
BD05E029
Remove the roll pin from the height/weight adjuster,

STEP 35
remove the knob.
Remove the wedge holding the bolt into the lower
portion of the swivel.
STEP 39
STEP 36
BD05E030
Remove the upper tether mounting bolts and nuts.

BD05E013
Install the cotter pin, make sure that the pin is bent
STEP 40
over enough so it will not interfere with sliding
operations.
STEP 37
BD05E033
Remove the front swivel/slide mounting bolts.
BD05E008
Install the seat and slide stop.

9009-11
STEP 41 STEP 44
BD05E034 BD05E084
Remove the slide/swivel assembly. If replacing the boot, use side cutter and cut the
retaining pins. If reusing the boot, use the side
STEP 42 cutters to remove the buttons, get the cutting edge
close to the pressed in button shaft and pry them out.
STEP 45
BD05E037
Remove the lower mounting bolts and the tether

straps, keep all of the components together for the
tether straps. BD05E036
Remove the boot from the suspension assembly.

STEP 43
STEP 46
BD05E035
Remove the front mounting nuts and washers, BD05E038
remove the suspension assembly from the stand. Place the suspension assembly in a press, push
down on the suspension and remove the nut on the
shock.

9009-12
STEP 47 STEP 50
BD05E039 BD05E043
Remove the bolt from the shock. Pull the pivot bolt back just far enough to remove the
shock from the suspension assembly.
STEP 48
STEP 51
BD05E040
Slowly release the pressure on the suspension BD05E042
assembly. Remove the upper pivot bolt and the upper plate.
STEP 49 STEP 52
BD05E041 BD05E044
Remove the nut from the upper and lower pivots. Remove the lower pivot bolt.

9009-13
STEP 53 Inspect the Suspension System
STEP 54
BD05E045
Remove the scissor assembly.

BD05E046
Inspect the bushings for wear and damage, repair or

replace as needed.
STEP 55
BD05E047
Inspect the teeth and threads on the height/weight

adjusting assembly, repair or replace as needed.
STEP 56
BD05E048
Inspect the bushing on the bottom of the gear, repair

or replace as needed.

9009-14
STEP 57 Assemble the Suspension System
STEP 60
BD05E049
Inspect the rubber stops, repair or replace as

needed. BD05E075
During assembly pivot bolts must be inserted into the

STEP 58 slotted hole.
STEP 61
BD05E050
Inspect the shock for leaks and bushing for wear,

repair or replace as needed. BD05E074
During assembly the slider blocks must be installed

STEP 59 as shown.
Inspect spring for damage, repair or replace as
NOTE: DO NOT lubricate the slider blocks.
needed.
STEP 62
BD05E076
Lubricate the pivot bushing with molydisulfide

grease, install pivot bolt and nut. Tighten the nut.
NOTE: The “L” portion of the pivot bolt goes to the
inside of the suspension assembly.

9009-15
STEP 63 STEP 66
BD05E077 BD05E080
Lubricate the bushing with molydisulfide grease. Start the pivot bolt into the scissor assembly.
NOTE: The “L” portion of the pivot bolt goes to the
STEP 64 inside of the suspension assembly.
STEP 67
BD05E078
Lubricate the threads with molydisulfide grease.

BD05E081
STEP 65 Place the shock into position, insert the pivot bolt
completely, install and tighten the nut.
STEP 68
BD05E079
Lubricate the pivot bushing with molydisulfide

grease, place the lower half onto the upper half.
NOTE: DO NOT lubricate the slider blocks, make BD05E038
sure the slider blocks are in the proper position. Place the suspension assembly into a press,
compress the spring enough to mount the shock.

9009-16
STEP 69 STEP 72
BD05E082 BD05E037
Check for proper operation of the weight/height Install the components as shown for the tether straps
adjustment. on the rear of the stand.
NOTE: Turning the handle to the + will raise the
plate and will apply more pressure the spring, turn STEP 73
the handle to the - will lower the plate and will
decrease the pressure on the spring as shown in this
photo.
STEP 70
BD05E034
Place the slide/swivel assembly onto the suspension

assembly.
STEP 74
BD05E083
Install the boot retaining pins by tapping in with a

plastic or rubber hammer.
STEP 71
BD05E030
Install and tighten the upper tether mounting bolts

and nuts.
BD05E035
Place the suspension assembly onto the stand,

install and tighten the front mounting nuts and
washers,

9009-17
STEP 75 Disassemble the Recliner
STEP 77
BD05E033
Install and tighten the front swivel/slide mounting

bolts. BD05E026
Remove the cushions from the seat, remove the four

STEP 76 mounting bolts, remove the seat bottom and back
from the suspension assembly.
STEP 78
BD05E028
If removed, place the height/weight adjuster knob

onto the shaft and install a new roll pin.
BD05E072
Pivot the back rest forward and remove the four nuts
and two bolts mounting the seat bottom to the seat
back, remove the seat bottom.
STEP 79
BD05E071
Remove the spring retaining nut.

9009-18
STEP 80 STEP 83
BD05E070 BD05E056
Remove the washer. Remove the spring for the recliner handle from the
arm rest bracket.
STEP 81
STEP 84
BD05E069
Remove the spring from the pivot pin. BD05E065
Remove the handle return spring from the recliner.

STEP 82
STEP 85
BD05E068
Remove the arm rest from the seat back. BD05E064
Remove the nut from the recliner.

9009-19
STEP 86 STEP 89
BD05E063 BD05E058
Remove the washer from the recliner. Remove the two bolts from the recliner bracket,
remove the bracket.
STEP 87
STEP 90
BD05E062
Remove the bushing from the recliner, remove the BD05E059
arm rest from the seat back. Remove the retainer and recliner gear.
STEP 88
BD05E057
Remove the handle from the seat back.

9009-20
Assemble the Recliner STEP 94
STEP 91
BD05E061
Place the seat back onto the arm rest pivot.

BD05E060 NOTE: Align the handle pin into the recliner gear.
Place the gear onto the pivot, drive a new retainer
onto the pivot. STEP 95
NOTE: The gear must pivot freely.
STEP 92
BD05E062
Install the bushing onto the recliner.
BD05E058 STEP 96
Install the brackets, install and tighten the two bolts.
STEP 93
BD05E063
Install the washer onto the recliner.
BD05E057
Place the handle into the seat back.

9009-21
STEP 97 STEP 100
BD05E064 BD05E067
Install and tighten the nut onto the recliner. Make sure the handle return spring is completely
seated into the mounting hole.
STEP 98
STEP 101
BD05E065
Place the handle return spring into the recliner. BD05E068
Install the arm rest into the seat back.

STEP 99
STEP 102
BD05E066
Install the handle return spring into the mounting hole BD05E069
in the arm rest. Place the spring onto the pivot pin, hook the spring
onto the seat back.

9009-22
STEP 103 STEP 106
BD05E070 BD05E027
Install the washer. Place the spacers onto the slide/swivel assembly.
STEP 104 STEP 107
BD05E071 BD05E026
Install and tighten the self locking nut. Install and tighten the four mounting bolts, install the
cushions onto the seat.
STEP 105
STEP 108
Check the recliner for proper operation.
BD05E072
Place the seat bottom into the arm rests, install and
tighten the bolts and nuts.

9009-23
Pivot Safety Switch Replacement STEP 111
STEP 109
BD05E025
Place the wires onto the switch, install and tighten

BD05E024
the screws.
Remove the nuts from the screws, remove the
switch. STEP 112
STEP 110
BD05E024
Place the switch onto the screws, make sure that the
BD05E025
arm of the switch is to the rear of the seat, install
Remove the wires from the switch. washers, install and tighten the nuts.

9009-24
PEDASTAL SEAT
Disassemble the Slide STEP 4
STEP 1
BD05E461
Remove the adjustable bushings from the right side

BD05E455
of the slide assembly.
Remove the slide stop from the sat.
Inspect the Slide
STEP 2
STEP 5
BD05E456
Remove the seat from the slide. BD05E459
Check position locking teeth for damage, if damaged

STEP 3 replace swivel and slide as an assembly.
STEP 6
BD05E460
Remove the slide bushings from the left side of the

slide assembly. BD05E457
Check slide locking plate, springs, pivots, and rails for

damage, if damaged replace swivel and slide as an
assembly.

9009-25
Assemble the Slide STEP 10
STEP 7
BD05E023
Align the adjuster holes with the adjustable bushings.

BD05E461
Install the adjustable slide bushings on the right side STEP 11

of the slide frame.
STEP 8
Install the non adjustable slide bushings on the left
side of the slide frame, lubricate the bushings with
molydisulfide grease.
STEP 9
BD05E085
Adjust the bushings for side to side motion of the

seat.
NOTE: If slides are adjusted to tight it will be hard to
adjust the seat for and aft.
BD05E455
Install the seat assembly and install the slide stop.

9009-26
Disassemble the Swivel STEP 15
STEP 12
BD05E465
Remove the bushing from the swivel bolt, remove the

BD05E455
top half of the swivel assembly.
Remove the slide stop and remove the seat from the
swivel. STEP 16
STEP 13
BD05E467
Remove the bearing separator from the lower swivel

BD05E462
half.
Remove the cotter pin from the swivel bolt.
STEP 17
STEP 14 Remove the bearings.
Inspect the Swivel

STEP 18
BD05E463
Remove the nut from the swivel bolt.
BD05E468
Inspect bearing tracks, bearings, and bearing

separator plate for wear or damage, repair or replace
as needed.

9009-27
Assemble the Swivel STEP 23
STEP 19
BD05E013
Install the cotter pin, make sure that the pin is bent
BD05E466
over enough so it will not interfere with sliding
Place the bearing separator plate onto the lower operations.
portion of the swivel. Place the bearings into the
separator plate. STEP 24
STEP 20
Put the top half of the swivel onto the lower half.
STEP 21
BD05E455
Install the seat and slide stop.
BD05E465
Place the bushing onto the bolt.
STEP 22
BD05E464
Install and hand tighten the swivel nut until there is no

play in the bearing, tighten the nut two more flats and
align the cotter pin hole.

9009-28
Disassemble the Pedestal STEP 29
STEP 25
Remove the seat and swivel assembly.
STEP 26
BD05E474
Make sure you see all three of the height adjustment

holes, if not the pedestal is still under spring
pressure.
STEP 30
BD05E470
Place the pedestal in a press. Press down on the

pedestal assembly while holding out on the height
adjustment handle.
STEP 27
BD05E475
Remove the spring.
STEP 31
BD05E471
Loosen and remove the stop bolt.
STEP 28
BD05E476
Remove the upper bushing by spreading it at the slot.
BD05E473
Release the pressure on the press while holding out

on the height adjusting handle.

9009-29
STEP 32 STEP 35
BD05E477 BD05E479
Remove the lower bushing by spreading it at the slot. Remove the plunger and spring.
STEP 33 Inspect the Pedestal

STEP 36
Inspect the height spring for cracks or damaged
coils, repair or replace as needed.
STEP 37
Inspect the plunger and plunger spring for wear or
damage, repair or replace as needed.
STEP 38
Inspect the bushings for wear or damage, repair or
BD05E480 replace as needed.
Remove the self locking nut from the height adjusting
plunger. STEP 39
Inspect the height adjustment holes for elongation,
STEP 34 repair or replace pedestal as needed.
BD05E478
Hold out on the plunger out and remove the bolt.

9009-30
Assemble the Pedestal STEP 43
STEP 40
BD05E477
Install the lower bushing by spreading it at the slot

BD05E479
and sliding it onto the shaft.
Place the height plunger and spr ing into the
pedestal. STEP 44
STEP 41
BD05E476
Install the upper bushing by spreading it at the slot

BD05E478
and sliding it onto the shaft.
Hold out on the height adjustment plunger and insert
the handle bolt. STEP 45
STEP 42
BD05E475
Install the spring.

BD05E480
Install the self locking nut and tighten.

NOTE: Do not over tighten the nut and put a bind on
the handle lever.

9009-31
STEP 46 STEP 47
BD05E473 BD05E472
Press the pedestal together while holding out on the Use thread locking compound on the stop bolt, install
height adjusting handle. and tighten the stop bolt.
NOTE: Press down until the slot for the stop bolt can
be seen through its hole. STEP 48
Remove the seat from the press and assemble the
swivel assembly.

9009-32
NOTES

Section
9010
AIR SUSPENSION SEAT
9010

Racine, WI 53404 U.S.A. Bur 6-75111 Issued January, 2004 Revised July, 2005
9010-2
TABLE OF CONTENTS
AIR SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

9010-3
AIR SUSPENSION SEAT
Disassembly STEP 3
STEP 1
BK98C207
1.PLASTIC RETAINER
BK98C141 Push in on the plastic retainer and remove the

Loosen and remove the 4 bolts from the seat lumbar support adjustment knob.
assembly. Remove the seat assembly from the base.
STEP 4
STEP 2
BK98C206
BK98C205 1.MOUNTING SCREW
Place the seat assembly on the workbench. Cut and
remove the plastic clips from the backrest cover. Remove the mounting screw from the housing.
Remove the backrest cover.
STEP 5
BK98C206
Disconnect the cable from the lumbar suppor t.

Remove the cable and housing assembly.
9010-4
STEP 6 STEP 9
BK98C140 BK98C144
Tilt the right arm rest up until it is against the upper Loosen the 2 Allen head set bolts in the 2 slide pucks
stop. Push in on the arm rest as shown in the above on the right side of the upper slide plate.
photo. Rotate the arm rest counter-clockwise past
NOTE: Access for the set screws is through the 2
the upper stop.
holes in the side rail of the upper slide plate. Slide the
plate fore or aft until the set screws are visible.
STEP 7
STEP 10
BK98C139
Remove the arm rest as shown in the above photo.

BK98C146
Repeat the above procedure for the left arm rest.
Lift the handle to release the lock on the upper slide
plate.
STEP 8
STEP 11
BK98C142
Loosen and remove the 2 Allen head bolts from the

BK98C147
slide travel limiter. Remove the slide travel limiter
Move the upper slide plate forward and remove from
from the upper slide plate.
the slide swivel assembly.

9010-5
STEP 12 STEP 14
BK98C199 BK98C148
1. SLIDE CONTROL LEVER 2. SWIVEL CONTROL LEVER
Use a soft hammer and remove the slide pucks from
the slide swivel assembly.
Use acceptable tools and remove the roll pin and
retaining ring from the slide control lever. Remove the
return spring and the slide control lever from the
STEP 15
upper slide plate assembly. Repeat this procedure
and remove the swivel control lever from the upper
slide plate assembly.
STEP 13
BK98C150
Loosen and remove the 2 - 5/16 inch bolts from the

front side of the slide swivel assembly.
STEP 16
BK98C200
Use acceptable tools and remove the roll pin and

retaining ring from the slide latch. Remove the return
spring and the slide latch from the upper slide plate
assembly.
BK98C151
Loosen and remove the 2 - 3/8 inch bolts and 2 tether

straps from the rear of the slide swivel assembly.

9010-6
STEP 17 STEP 20
BK98C152 BK98C154
Remove the slide swivel assembly from the lateral Disconnect the wiring harness from the height
isolator plate. adjustment switch.
STEP 18 STEP 21
BK98C153 BK98C156
Loosen and remove the 2 bolts from the swivel Remove the 2 bolts from the switch bracket. Remove
contact switch assembly. Remove the switch from the the switch and bracket.
lateral isolator plate.
STEP 22
STEP 19
BK98C157
BK98C155 Press in on the top and bottom tabs on the rear of the
Remove the 2 screws from the swivel contact switch switch and push the switch forward until the tabs are
and remove the wiring harness from the switch. free from the bracket. Remove the switch from the
bracket.

9010-7
STEP 23 STEP 26
BK98C158 BK98C193
Loosen and remove the 4 bolts from the lateral Use acceptable tools and remove the nut from the
isolator plate. isolator shock.
STEP 24 STEP 27
BK98C159 BK98C194
Remove the isolator plate from the upper housing. Remove the top washer and rubber insulator from the
shock.
STEP 25
STEP 28
BK98C192
Tur n the isolator plate over and place on the BK98C195
workbench. Use acceptable tools and remove the 2 Use acceptable tools and remove the retaining ring
isolator springs from the isolator plate. from the lateral isolator shock.

9010-8
STEP 29 STEP 32
1
BK98C196 BK98C192
Remove the pin from the isolator shock. 1.ROLL PIN
STEP 30 Use acceptable tools and remove the 2 roll pins from
the lateral isolator control.
STEP 33
BK98C197
Remove the shock from the isolator plate.
STEP 31 BK98C192
1. BOLT 2. ISOLATOR CONTROL
Use acceptable tools and remove the bolts from the

isolator control mounting bracket. Remove the lateral
isolator control from the isolator plate.
BK98C198
Inspect the parts of the isolator shock for wear and

damage.

9010-9
STEP 34 STEP 36
BK98C192 BK98C161
1.ROLLER BEARING Loosen and remove the 2 bolts from the fore/aft
isolator shock mounting bracket. Remove the bracket
Slide bottom of the isolator plate to the left until the
from the upper housing plate. Allow the other end of
isolator roller bearings are exposed and remove the
the isolator shock to hang from the suspension arm.
rollers bearings from the shaft. Slide the bottom of
the isolator plate to the right until the isolator roller
bearings are exposed and remove the roller bearings STEP 37
from the shaft.
NOTE: The above photo is for reference only.
STEP 35
BK98C162
Loosen and remove the 2 bolts from the fore and aft
isolator control.
NOTE: Be sure to use the same screws during the
assembly procedure of the isolator control.
BK98C160
Remove the plastic pins from the boot assembly and

fold the boot down to the base plate. Note the
location of the tether straps behind the boot.

9010-10
STEP 38 STEP 41
BK98C163 BK98C166
Slide the upper housing to the rear and lift the Remove the 2 narrow roller bearings from the rear
housing free of the roller bearings on the rear suspension arms.
suspension arms.
STEP 42
STEP 39
BK98C167
BK98C164 Remove the bushing and the isolator control from the
Slide the upper housing forward and lift the housing suspension arm.
free of the roller bearings on the front suspension
arms. Note the location of the rubber bumpers on the STEP 43
upper housing.
STEP 40
BK98C190
1.ROLL PIN
BK98C165 Use acceptable tools and remove the roll pins from
Remove the 2 wide roller bearings from the front each end of the isolator control. Remove the 2 plastic
suspension arms. bushings and 2 springs and latch assembly from the
control.

9010-11
STEP 44 STEP 47
BK98C190 BK98C169
1.ROLL PIN Place an acceptable block between the suspension
assembly and the front of the lower h ousin g
Use acceptable tools and remove the roll pin from the
assembly.
control housing. Remove the isolator control knob
from the housing.
STEP 48
STEP 45
BK98C201
Note the location of the wire 3 wire ties on the lower

BK98C168
housing assembly.
Remove the 2 bushings and the isolator shock from
the suspension arm.
STEP 49
STEP 46
BK98C175
Cut and remove the 3 wire ties from the wiring

BK98C191
harness.
Inspect the parts of the isolator shock assembly for
wear and damage.

9010-12
STEP 50 STEP 53
BK98C170 BK98C173
Note the location of the 2 wire ties on the suspension L o o s e n a n d r e m ove t h e 2 b o l t s f r o m t h e a i r

assembly. Cut and remove the wire ties. compressor mounting bracket.
STEP 51 STEP 54
BK98C171 BK98C174
Disconnect the wiring harness from the air Remove the air compressor assembly.
compressor assembly.
STEP 55
STEP 52
BK98C177
BK98C172 Loosen and remove the 4 bolts from the pedestal
Loosen the air line fitting and allow the air to escape mounting plate. Remove the pedestal from the lower
from the air spring assembly. Remove the air line housing assembly.
from the air spring.

9010-13
STEP 56 STEP 59
BK98C178 BK98C180
Loosen and remove the lower screw from the air Cut and remove the plastic pins from the rubber boot.
spring.
STEP 60
STEP 57
BK98C181
BK98C176 Remove the rubber boot from the lower housing

Loosen and remove the bolt from the top of the air assembly.
spring.
STEP 61
STEP 58
BK98C189
BK98C179 Loosen and remove the nut from the shaft.
Remove the air spring assembly.

9010-14
STEP 62 STEP 65
BK98C188 BK98C183
Use acceptable tools and remove the shaft from the Remove the retaining clip from the isolator shock.
lower housing assembly. Remove the isolator shock and 2 plastic bushings
from the suspension assembly.
STEP 63
STEP 66
BK98C186
Tilt the suspension assembly forward. Turn the BK98C184
suspension assembly counter clockwise and remove Inspect the par ts of the isolator shock and the
from the lower housing. suspension assembly for wear and damage.
STEP 64 Inspection
1. Inspect the seat cushion, backrest cushion, arm
rests and lumbar support control for wear and
damage. Use new parts as required.
2. Inspect the upper slide plate assembly, swivel
control, slide control, and slide latch for wear and
damage. Use new parts as required.
3. Inspect the slide/swivel assembly and slide
pucks for wear and damage. Lubricate slide
pucks with molydisulfide grease. Use new parts
as required.
4. Inspect the swivel switch, height adjustment
BK98C182
switch, and wire harness for damage. Use new
Remove the 2 roller bearings from the shaft. Use parts as required.
acceptable tools and remove the 2 plastic bushings
from the tube.

9010-15
5. Inspect the lateral isolator plate, isolator shock,
bushings, springs, roller bearings, and control for
wear and damage. Lubricate the roller bearings
and contact points with molydisulfide grease.
6. Inspect the boot assembly for damage. Use new
parts as required.
7. Inspect the upper housing and rubber bumpers
fo r we a r a n d d a m a g e. U s e n ew p a r t s a s
required.
8. Inspect the suspension assembly and roller
bearings for wear and damage. Lubricate the
roller bearings and contact points with
molydisulfide grease. Use new parts as required.
9. Inspect the fore/aft isolator shock and bushings
required.
10. Inspect the fore/aft isolator control and bushing
required.
11. Inspect the suspension isolator shock and
bushings for wear and damage. Use new parts
as required.
12. Inspect the air compressor, air line, and wiring
harness for wear and damage. Use new parts as
required.
13. Inspect the air spring for wear and damage. Use
new parts as required.
14. Insect the lower housing, bearing shaft, and
rubber bumper for wear and damage.Lubricate
the contact points with molydisulfide grease. Use
new parts as required.
15. Inspect the pedestal for damage. Use new parts
as required.

9010-16
22
23
1
24
25 21
26
20 6
17
16
5 28
29
15
2
2
18 9
11
1
12 14
13
10
1
12
19
9
6 4
5 4
7 6
8
4
27
3
4
1
1 2
BT98C016
1. BOLT 11. TETHER STRAP 21. SEAT CUSHION
2. SPRING 12. ROLLER BEARING 22. BACKREST CUSHION
3. PIN 13. BUSHING 23. ARMREST
4. BRACKET 14. WASHER 24. BACK TILT KNOB
5. RETAINING RING 15. UPPER SLIDE PLATE ASSEMBLY 25. BACKREST COVER
6. LOCKNUT 16. SLIDE/SWIVEL ASSEMBLY 26. LUMBAR SUPPORT CONTROL
7. INSULATOR 17. SLIDE PUCK 27. HEIGHT ADJUSTMENT SWITCH
8. LATERAL ISOLATOR SHOCK 18. ADJUSTABLE SLIDE PUCK 28. SLIDE CONTROL LEVER
9. ROLL PIN 19. LATERAL ISOLATOR 29. SWIVEL LEVER
10. LATERAL ISOLATOR CONTROL 20. CHRISTMAS TREE CLIP

9010-17
24 26 22 23 27
29
1
23
14 23
8
22 1 2
25 27 17
9 8
9 18
23 1 1 19
28 16
22 21 20
14
2
32 14
16
15 12
1
16
1 10
11
31
16 12
15
9
13
14
30
7 8
6
4
5
2
1
3
BT98C017
1. BOLT 12. FITTING 23. ROLL PIN
2. WASHER 13. AIR LINE 24. ISOLATOR CONTROL
3. PEDESTAL 14. BUSHING 25. ISOLATOR KNOB
4. SHAFT 15. WIRE TIE 26. HOUSING
5. SWITCH 16. ROLLER BEARING 27. GUIDE
6. WIRE HARNESS 17. INSULATOR 28. KNOB
7. AIR SPRING 18. BRACKET 29. UPPER HOUSING
8. LOCK NUT 19. BOOT 30. LOWER HOUSING
9. RUBBER BUMPER 20. FORE/AFT ISOLATOR SHOCK 31. SUSPENSION ASSEMBLY
10. CHRISTMAS TREE CLIP 21. SUSPENSION SHOCK 32. RETAINING RING
11. AIR COMPRESSOR 22. SPRING

9010-18
Assembly Lubricate the 2 roller bearings with molydisulfide

grease and install onto the shaft. Install the 2 plastic
bushings into the tube.
STEP 67
STEP 70
BK98C184
Install the isolator shock and 2 plastic bushings onto

BK98C186
the suspension assembly.
Install the suspension assembly roller bearings into
the lower housing at a slight angle indicated in the
STEP 68
photo above. Tu r n the suspension assembly
clockwise and align the rear tube into the lower
housing.
STEP 71
BK98C185
Use acceptable tools and install the retaining clip

onto the shaft.
STEP 69 BK98C187
Install the shaft into the lower housing.
2
BK98C182
1. ROLLER BEARING 2. PLASTIC BUSHING

9010-19
STEP 72 STEP 75
BK98C189 BK98C178
Install and tighten the nut on the shaft. Install and tighten the screw into the bottom of the air
spring.
STEP 73
STEP 76
BK98C181
Install the rubber boot over the suspension assembly BK98C176
and onto the lower housing assembly. Install and tighten the bolt into the top of the air
spring.
STEP 74
STEP 77
BK98C179
Install the air spring into the suspension assembly. BK98C177
Install the pedestal onto the lower housing. Install the

tether straps between the rubber boot and lower
housing. Install and tighten the 4 bolts.

9010-20
STEP 78 STEP 81
BK98C172
BK98C202
Install the plastic pins into the lower mounting holes Install the air line into the fitting on the air spring.
of the rubber boot. Drive the pins into the mounting Tighten the fitting nut.
holes in the lower housing assembly.
STEP 82
STEP 79
BK98C171
BK98C174 Connect the air compressor wiring harness.

Install the air compressor into the suspension
assembly. STEP 83
STEP 80
BK98C201
Install the 5 wire ties for the wiring harness in the

BK98C173 proper locations as indicated in the photo above.
Install and tighten the 2 air compressor mounting
screws.

9010-21
STEP 84 STEP 87
BK98C168 BK98C166
Install the 2 plastic bushings and the isolator shock L u b r i c a t e t h e 2 n a r r ow r o l l e r b e a r i n g s w i t h
onto the suspension assembly. Make sure that the molydisulfide grease and install on the rear shafts of
white plastic bushing is on the outside. the suspension assembly.
STEP 85 STEP 88
BK98C190 BK98C165
Assemble the parts of the isolator control. Lubricate the 2 wide roller bearings with
molydisulfide grease and install on the front shafts of
STEP 86 the suspension assembly.
STEP 89
BK98C167
Install the isolator control and plastic bushing onto

the suspension assembly. BK98C164
Install the upper housing slide rail onto the wide roller
bearings on the suspension assembly. Make sure the
r ubber bumpers are facing to the rear of the
suspension assembly.
9010-22
STEP 90 STEP 93
BK98C163 BK98C203
Slide the upper housing to the rear until the narrow Slide the rubber boot into position on the upper
roller bearings will engage the slide rails of the upper housing. Install the plastic pins into the mounting
housing. holes in the rubber boot. Drive the pins into the
mounting holes in the upper housing.
STEP 91
STEP 94
BK98C162
Install and tighten the 2 bolts in the isolator control. BK98C192

1.ROLLER BEARING
NOTE: Be sure to use the same bolts that were
removed during the disassembly procedure. Slide the bottom of the isolator plate to the left.
Lubricate the 2 roller bearings with molydisulfide
STEP 92 grease. Install the roller bearings onto the shafts of
the isolator plate. Slide the isolator plate to the right
and repeat the above procedure.
NOTE: The above photo is for reference only.
BK98C161
Install and tighten the 2 bolts in the fore/aft isolator

shock bracket.

9010-23
STEP 95 STEP 98
BK98C192 BK98C195
1. BOLT 2. ISOLATOR CONTROL Install the retaining clip onto the pin.
Install the isolator control onto the isolator plate. STEP 99

Install and tighten the bolts in the mounting bracket.
Use acceptable tools and install the 2 roll pins in the
isolator control.
STEP 96
BK98C194
Install the rubber insulator and washer onto the

shock.
STEP 100
BK98C197
Install the isolator shock and 2 plastic bushings into

the mounting brackets on the isolator plate.
STEP 97
BK98C193
Install and tighten the lock nut on the shock.
BK98C196
Install the pin into the isolator shock.

9010-24
STEP 101 STEP 104
BK98C159 BK98C156
Turn the isolator plate over and install onto the upper Install and tighten the bolts in the switch bracket.
housing.
STEP 105
STEP 102
BK98C154
BK98C158 Connect the wiring harness.

Install and tighten the 4 bolts which mount the
isolator plate to the upper housing. STEP 106
STEP 103
BK98C155
Connect the wiring harness to the swivel switch.

BK98C157 Tighten the screws.
Install the height adjustment switch into the mounting
bracket.

9010-25
STEP 107 STEP 110
BK98C153 BK98C150
Install the 2 bolts in the swivel switch. Tighten the Install the 2 - 5/16 inch bolts into the swivel plate
screws. mounting holes. Tighten the bolts.
STEP 108 STEP 111
1
1
BK98C152 BK98C149
Install the swivel assembly on the lateral isolator 1.ADJUSTABLE SLIDE PUCK
plate.
Use a soft hammer and install the slide pucks on the
STEP 109 slide/swivel assembly. Make sure the adjustable slide
pucks are installed in the proper location as indicated
in the photo above.
BK98C151
Install the 2 - 3/8 inch bolts through the tether strap

mounting holes. Install the bolts into the swivel plate
mounting holes. Tighten the bolts.

9010-26
STEP 112 STEP 114
BK98C200 BK98C147
Use acceptable tools and install the slide latch, Lubricate the slide pucks and slide track on the upper
spring, roll pin, and retaining clip on the upper slide slide plate with molydisulfide grease. Install the upper
plate. slide plate over the front slide pucks on the swivel
assembly.
STEP 113
STEP 115
BK98C199
1. SLIDE CONTROL LEVER 2. SWIVEL CONTROL LEVER BK98C146
Lift the slide control and slide the upper slide plate
Use acceptable tools and install the spring, roll pin,
into position on the swivel assembly.
slide control lever, and retaining ring on the upper
slide plate. Repeat this procedure to install the swivel
control lever on the upper slide plate. STEP 116
BK98C143
Install the slide travel limiter on the upper slide plate.

9010-27
STEP 117 STEP 120
BK98C142 BK98C206
Install the 2 Allen head bolts in the slide travel limiter. Connect the cable assembly to the lumbar support
Tighten the bolts. assembly.
STEP 118 STEP 121
BK98C139 BK98C207
Install the right side arm rest as indicated in the 1. MOUNTING SCREW 2. ADJUSTMENT KNOB
photo above.
Install and tighten the mounting screw in the lumbar
STEP 119 suppor t housing. Install the lumbar suppor t
adjustment knob on the housing. Push the knob onto
the housing until the plastic retainer is locked in
position.
BK98C140
Rotate the arm rest clockwise past the upper stop.

Repeat the procedure for the left side arm rest.

9010-28
STEP 122 STEP 124
BK98C204 BK98C145
Place the backrest cover in position on the seat top. After the seat has been assembled, adjust the slide
Install the plastic clips in the mounting holes of the pucks to the desired lateral movement of the seat.
backrest cover. Drive the plastic clips into the
NOTE: After installing the seat into the machine,
mounting holes of the seat top with a soft hammer.
check the seat for proper operation.
STEP 123 STEP 125
BK98C141
BC05B042
Place the seat assembly into position on the seat
Mount seat belts at an angle of 45° ± 5°.
base. Install and tighten the 4 bolts.
STEP 126
BC05B043
Torque bolts in accordance with general bolt torque

specifications.

9012
Section
9012
REAR WINDOW REPLACEMENT

9012-2
TABLE OF CONTENTS
REAR WINDOW REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Top Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Middle Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bottom Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

9012-3
NOTES

9012-4
REAR WINDOW REPLACEMENT
Top Window Installation

NOTE: All instructions are written viewing the 1. If required, install the seal across the bottom of
machine from the rear. the top window and the top latch assembly (13)
on the right side of the top window as required.
Removal
2. Slide the top window (1) horizontally into the left
1. Park the machine on a level surface. Lower all channel where the flocked channel seal (2) was
attachments to the ground. Apply the parking removed from until the right side of the top
brake. window (1) can be moved into the channel on the
2. Raise the top window (1) to the closed position. right side of the frame (3).
3. Remove the lower flocked channel seal (2) from 3. Slide the top window (1) to the right into the
the left side of the frame (3). channel. Have another person to hold the top
window (1) in position while the left side latch
4. To remove the top window (1) from the cab frame assembly is installed on the window.
it is necessary to remove the latch assembly
from the left side of the top window (1). Have 4. Install the top latch assembly (13) on the left side
another person to hold the top window (1) in of the top window (1).
position while the left side latch assembly is 5. Slide the top window (1) up until it locks into the
removed from the window. Remove the latch closed position.
assembly from the left side of the top window (1).
6. Install the flocked channel seal (2) into the frame
5. Have another person lower the top window (1) (3).
from inside the cab until the top window (1) is in
the area where the flocked channel seal (2) was
removed from.
6. Move the top window (1) horizontally into the left
channel until the right side of the top window (1)
can be removed from the right channel.
NOTE: Be careful not to damage the window.
7. Remove the top window (1) from the frame (3).
8. If the top window (1) is not being replaced. Make
sure the flocked channel seal (2) is installed in
the left channel.

9012-5
7
3
13
1 2
8
5
4
A
4
11
12
9
6
9
10
BC01K063/BC02C117/BC02C118/BC02C108
1. TOP WINDOW 5. FLOCKED CHANNEL SEAL 9. MIDDLE LATCH ASSEMBLY

2. FLOCKED CHANNEL SEAL 6. BOTTOM WINDOW 10. GASKET
3. FRAME 7. FLOCKED CHANNEL SEAL 11. PLATE
4. MIDDLE WINDOW 8. RUBBER BLOCK 12. ALLEN HEAD SCREWS
13. TOP LATCH ASSEMBLY

9012-6
Middle Window Installation

Removal NOTE: If the existing gaskets (10) are being used,
inspect the protrusions in the gasket (10) closely.
1. Park the machine on a level surface. Lower all
attachments to the ground. Apply the parking 1. If required, install a new seal across the bottom
brake. of the middle window (4).
2. Slide the middle window (4) to the highest 2. Slide the middle window (4) horizontally into the
position. left channel where the flocked channel seal (5)
was removed from the frame (3) until the right
3. Remove the lower flocked channel seal (5) from side of the middle window (4) can be moved into
the left side of the frame (3). the channel on the right side of the frame (3).
4. Have another person to hold the middle window 3. Slide the middle window (4) to the right and up
(4) in this position. Remove the latch assembly until the middle window (4) is out of the way.
(9) from the left side of the middle window (4). Have a person on the inside of the machine hold
NOTE: If the middle latch assembly (9) was installed the middle window (4) in position.
using Permabond F246, you will need to apply heat 4. Do the following to install the middle latch
to the Permabond F246 to remove the middle latch assembly:
assembly (9) from the middle window (4). Use a heat
gun that does not exceed 399 to 538 °C (750 to A. Clean the mounting surface on the middle
1000 °F) at the tip. Apply heat to the window (4) with a commercial glass cleaner.
Permabond F246 until the middle latch assembly (9) B. Clean the mounting surface on the middle
can be removed from the middle window (4). Be latch assembly (9) with alcohol.
careful not to damage the cab.
IMPORTANT: The latch parts must be
WARNING: Always wear heat protective completely assembled within 3 minutes of
gloves to prevent burning your hands when applying the Permabond F246 adhesive.
handling heated parts C. Apply a thin film of the initiator to the mounting
SM121A
surface on the middle window (4).
5. Have another person lower the middle window
(4) from the inside of the machine until the NOTE: There is a slot in the mounting surface on
middle window (4) is in the area the flocked the latch. DO NOT get Permabond F246
channel seal (5) was removed from. adhesive into the slot in the latch.
6. Move the middle window (4) horizontally into the D. Apply a bead of Permabond F246 adhesive to
left channel until the right side of the middle the mounting surface on the middle latch
window (4) can be removed from the right assembly (9).
channel. E. Put the gasket (10) and plate (11) in position
NOTE: Be careful not to damage the window. on the outside of the middle window (4). Make
sure the protrusions on the gasket (10) fit into
7. Remove the middle window (4) from the the holes in the middle glass (4).
frame (3).
F. Put the middle latch assembly (9) in position
on the inside of the window.
G. Apply Loctite 243 to the threads on the Allen
head screws (12). Install and tighten the Allen
head screws (12) to 0.56 to 1.13 Nm (5 to 10
pound-inches). DO NOT overtighten the Allen
head screws (12) or damage to the glass can
result.
5. Install the flocking channel seal (5) into the frame
(3).

9012-7
7
3
13
1 2
8
5
4
A
4
11
12
9
6
9
10
BC01K063/BC02C117/BC02C118/BC02C108


9012-8
Bottom Window Installation

Removal 1. Install a new seal on the bottom of the bottom
window (6) as required.
1. Park the machine on a level surface. Lower all
attachments to the ground. Apply the parking 2. Slide the bottom window (6) into the left channel
brake. where the flocked channel seal (7) was removed
from the frame (3) until the right side of the
2. Remove the upper flocked channel seal (7) from bottom window (6) can be moved into the
the left side of the frame (3). channel on the right side of the frame (3).
3. A rubber block is located at the top of both sides 3. Slide the bottom window (6) to the right and
of the bottom window (6). Remove the rubber down until the bottom window (6) is in position.
blocks (8) from both sides of the frame (3).
4. Install the flocked channel seal (7) in the frame
4. Raise the bottom window (6) until the bottom (3).
window (6) is in the area the flocked channel seal
(7) was removed from. 5. Install the rubber blocks (8) on both sides of the
bottom window (6).
5. Move the bottom window (6) into the left channel
until the right side of the bottom window (6) can
be removed from the right channel.
6. Move right side of the bottom window (6) away
from the frame (3) until the bottom window (6)
can be removed from the frame (3).
NOTE: Be careful not to damage the window.
7. Remove the bottom window (6) from the frame
(3).
8. If the bottom window (6) is not being replaced.
Make sure the flocked channel seal shown (7) is
installed in the left channel.

9012-9
7
3
13
1 2
8
5
4
A
4
11
12
9
6
9
10
BC01K063/BC02C117/BC02C118/BC02C108


9012-10
NOTES

CHARGING CRANKING AND KEYSWITCH POWER RELAYS START RELAYS FUSE BLOCK 14D 14C 14B 14A INSTRUMENT CLUSTER AND ALARM INSTRUMENT CLUSTER SENDERS PARK BRAKE AND SEAT TRANSMISSION CONTROLS RETURN-TO-DIG WIPERS (CAB / ROPS WITH WINDSCREEN)
1D 1D 1D
1 4 3 3
15 16 18 AND SWITCHES POSITION SWITCHES 43 44
5 13D 13C 13B 13A 24
15 15 84
23F 12D 12C 12B 12A
18 29 32 33
#1
6 #2
12D 15
30A 15A
12A 12A 11D 11C 11B 11A

58
23 5
12B 12B 15 83 19N 15
10C
85 30 87 87a 86
15 10D 10B 10A
24
I B+ L G
45
5 12C 12C 20A 20A 10A
34 6
30A
16 19K 19F
#4 19E 9D 9C 9B 9A 9 2 3 4 6 7 1 5 36 19 X 20 22 21 10 16 24 12 13 35 9 8
31P 32T 31T
15 85 30 87 87a 86 85 30 87 87a 86 25 90 8D 8C 8B 8A 4 4 19E 47 48 53 49 50
31S 1 4 3 36H
7 12D 12 13
23
19C
20A
15A 13 60A 41 42C 37A 36R 3 25 25
26 16 7 19A 36F 24 19C 20
4 15 61
7D 7C 7B 7A
49 31C
L IG P
12B 11 6D 6C 6B 6A
16
12
11
42F
13 16
52 36 46
4
4
2 6 12A 85 30 87 87a 86 85 30 87 87a 86
15
10A 25A 10A 10A
T T
1 3 28 3 21C 10 30 5 63
B+
1E 12V R N F 19D 23 16
1
5D 5C
#3 12C 25
5B 5A
52 63A
GND 8 22 14 13 7 19B 4D 4C 4B 4A
64A 13 19 20 85 30 87 87a 86 40 (+) B L H (+) B L H
1K 10 8 21
14 10A
15A 10A 10A
17
23F 21 22 25 26 2 3 25A
23G 25C 26 63
1D
3D 3C 3B 3A
56 36H 27 36R 25B 54
25B 25A 21 20 19 57 2D 2C 2B 2A 19
32T 403 4 31 3
37 63
85 30 87 87a 86
21A 10 10 11 31P 30 51 67
19E
10A 10A
10A 15A
63 31T 400
19B
30 52 82
21C 8 1D 1C 1B 1A
10 36F 30
85 30 87 87a 86 85 30 87 87a 86 19E
19M 27 27 41 53 19F 66 81 62
12C 3 M
1L 402 402 402 30 34 35 69
0 23
1G 12C 38 85 30 87 87a 86
89 65
1B 1C
85 30 87 87a 86
M
12B
21B 8 8 1H 38 30 30 10 39
21B 22
1M 1J 52 52
4 21B 23 21A 8
1D
52 38 42
25 5 1H 1H 4 23F 20A
15 15 8 16 17 36R 36R
50 20
GND
12D 34 20B 20C 20 30 40A
1J 1J 12A 1
22 26
40B 40B 40B 40B 40B 40B
1A 1 31S
40D 40D 40D 40D 40D 40D 40D 40D 40D 40D
40E 40E 40E 40E 40E 40E 40E 40E 40E 40E
40A 40A 40A 40A 40A 40A 40A 40A 40A 40A
40C 40C 40C 40C 40C 40C 40C 40C 40C 40C
10 10 10 10 10 10 10 10 10
30 30 30 30 30 30 30 30 30 30
3
9 17
FRAME 1 FRAME 2 FRAME 3 FRAME 4 FRAME 5 FRAME 6 FRAME 7 FRAME 8 FRAME 9 FRAME 10
BC08C033-01A BC08C033-02A BC08C033-03A BC08C033-04A BC08C033-05A BC08C033-06A BC08C033-07A BC08C033-08A BC08C033-09A BC08C033-10A
BLOWER AND AIR CONDITIONING (CAB) DOME LAMP (CAB) FRONT ROAD LAMPS, REAR ROAD LAMPS, AND HORN TURN SIGNAL, FLASHER, AND BRAKE LAMP SWITCHES POWER PLUG OUTLETS ROTATING BEACON AND WORK LAMPS 4WD TRANSMISSION ELECTRICAL CIRCUIT UNI-DIRECTIONAL BACKHOE RADIO (OPTIONAL)
4 59 4 75 AIR COMPRESSOR SWITCH AND MOTOR 4 STANDARD TRANSMISSION AUXILIARY HYDRAULICS
85 57 58 4 4 4 66 70 72 M
65 5 19B 73 74 FOR AIR SUSPENSION SEAT (OPTIONAL) 79 80
61 4 49a 19D
88 87 M 49 R
67 68 4 4 4
92
86 19B L 88
64 56
41
24 24 19A 64A
64B 83 84 19N
85 63 56a
56b
48
64A 64B 64A 4
81 4
5
60C 46 10 82 85 24 602 75 4
56b
1 2 3 4 5 6 7 78 19K 4
31b
42F 87 56 93
55 87 31 76 77 25C
86 45L 10
19B 45R M 25E 6F
56 61 64A 41 47L 91 57
19B 71 47R 42F 4
5E
61B 19A 25E 94
60 64B 89
88 40B 4D
85 30 87 87a 86
88 83 84 86
10 4 40E 58 3C
71 20B 20C
5
64B 45R 45L 40D 40D 40E 40E 20 30 90 40B
60 40D 40E 19C 30
60A 42C
69 44 40D 5
40E 75
60B 45L 5 14 5
5 60A 45R 30 42C
62
5 42C
40B 40B 40B 40B 40B 40B 40B 40B
40D 40D 40D 40D
40E 40E 40E 40E 16
40A 40A 40A 40A 40A 40A
40C 40C 40C 40C 40C 40C
10 10 10 10 10 10
30 30 30 30 30 30 30 30 30
FRAME 11 FRAME 12 FRAME 13 FRAME 14 FRAME 15 FRAME 16 FRAME 17 FRAME 18 FRAME 19

BC08C033-11A BC08C033-12A BC08C033-13A BC08C033-14A BC08C033-15A BC08C033-16A BC08C033-17A BC08C033-18A BC08C033-19A
RIDE CONTROL AND BOOM LOCK (OPTIONAL) QUICK COUPLER (OPTIONAL) DIFFERENTIAL LOCK GRID HEATER (OPTIONAL) R PILOT CONTROLS R COMFORT STEER ELECTRO-HYDRAULIC CLAM
Y Y 139 (4-IN-1 BUCKET)
1 128 1
118 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2
100 104 105 B 3 3 B 700

2B 121 4 4
148
4
1 2 3 4 5 6 7 8 9 10 R 5 5 R 147
6 618 6 93 1 6 4 10
108 Y 609 Y 140
95 98 57 115 610 617 616
4
4
114 R 611
504A 4 B 616 B 150
501 504 30 612 601 7 2 5 8
57 57 122 613 141
30
RED1
RED2
502
YEL1
YEL2
85 30 87 87a 86
501 138
POW
GND
19B B 614
124 702
101 R 616 616
102 103 85 30 87 87a 86
116 N WB
GW W 609 30 608 149
96 13D 99 2A
A
607 623 701 151
401 B
109 P B LB N C 30 30 30
602 50
106 112 113 125 616 606 129 133 85 30 87 87a 86
624 152
103 25S R 601 142
50 110 111 300 A 117 1 2 3 4 5 6 30 605 615 602
W 19C
50 107 1M
A 30 146
7 B 610 130 134 137 3 6 8
143
50 97 31C 21B 35 123 N C 604
1 2 1 2
30 602
103 15
50 85 30 87 87a 86 85 30 87 87a 86
1 34 30 603 30 131 30 135 2 5 7 4
5 608 18 50
2 4
613
103 103 1 126 144 20
30 64B 30 701
120 132 136 58 90 1
64A 607 30
1 50 50 20 614 624
13 5
4
13 127 4
30 145
5
30 30 30 30 30 30 30
FRAME 20 FRAME 21 FRAME 22 FRAME 23 FRAME 24 FRAME 25 FRAME 26

BC08C033-20A BC08C033-21A BC08C033-22A BC08C033-23A BC08C033-24A BC08C033-25A BC08C033-26A
MAIN CHASSIS HARNESS TO FRONT CONSOLE HARNESS MAIN CHASSIS HARNESS TO SIDE CONTROL HARNESS FUSE LOCATION RELAY LOCATION
SPARE NOT NOT NOT

USED USED USED FLASHER STARTER
POWER POWER
RELAY RELAY
A B C D E F G H J K L M N PILOT RELAY RELAY
A B C D E F G H J K L M N SPARE POWER SPARE CONTROLS #1 #4
N L K J HM G F E D C B A
OUTLET BH AUX (OPTION)
_ _ 83
1 42F 25S _ _ _ _ _ _ _
_ 83 _ _ _ _ 19F 63 15 1D 1 1 1D 32T 63 _ _ _ _ 31T _ _ _ _ 38 _ _ _ _ 1 1 SHUTTLE
NEUTRAL
1 FRONT AIR SUSP POWER LDR LVR INTLK
2 19N 56 _ _ _ _ _ _ _ _ 84 _ _ _ _ 41 64A 25C _ _ 2 2 _ _ 25C 64A 41 _ _ _ _ 84 _ _ _ _ _ _ 31P 56 _ _ 2 2 POWER SEAT AIR COMP RETURN 10 10 10 20 20 TIMING RELAY
2 WORK OUTLET TO DIG RELAY DIFF LK
_ _ _ _ _ _ 27 48 _ _ 19C 3 (OPTION) RELAY
3 _ _ 57 _ _ 64B _ _ _ _ 3 3 19C 36F _ _ 34 _ _ _ _ _ _ _ _ _ _ 64B 57 _ _ 3 3 LIGHTS
15 20 25 10 30 30
#2 RELAY
__ REAR
4 _ _ _ _ 23F _ _ _ _ _ _ _ _ _ _ _ _ 26 45L 52 3 4 4 4 3 52 31S 402 _ _ 36R _ _ _ _ _ _ _ _ 23F _ _ 4 4 WORK
TRANSMISSION, SPARE DRIVING SHUTTLE
COMFORT STEER LIGHTS FORWARD
10 10 10 20 POWER CLUTCH INTLK
5 58 _ _ _ _ 25 _ _ _ _ _ _ _ _ _ _ 400 45R _ _ 21B 5 5 5 42G _ _ _ _ 400 403 _ _ _ _ _ _ _ _ 25 _ _ _ _ _ _ 5 5 LIGHTS
RELAY
RELAY
ROTATING RELAY RELAY
6 __ __ __
6 61 4 49 7 _ _ _ _ _ _ _ _ _ _ _ _ _ _ 69 __ 6 6 42C 25E _ _ _ _ _ _ _ _ 7 49 4 61 6 6 FUEL
BLOWER
DOME BEACON 15 10 10 15 10 15 #3
7 SHUTOFF LIGHT (OPTION)
7 _ _ 21A _ _ _ _ _ _ _ _ _ _ _ _ 67 44 _ _ 66 __ 7 7 _ _ 31C 42F _ _ _ _ _ _ _ _ _ _ _ _ 36H _ _ 21A _ _ 7 7 FAST STEER FAST STEER
SARA REVERSE
N M L K J H G F E D C B A INSTRUMENTS SIGNAL LIGHTS, 4WD POWER CUTOUT RELAY
N M L K J H G F E D C B A A B C D E F G H J K L M N HORN BRAKE
ALARM SYS. PARK BRAKE (OPTION) RELAY RELAY
RELAY (OPTIONAL) (OPTIONAL)
STARTING RADIO, RIDE CNOTRL,
RADIO (BATT) AC
TRANSMISSION QUICK COUPLER WIPERS
(OPTION) RELAY
CONTROL (OPTION)
(OPTION)
FRAME 27 FRAME 28 FRAME 29 FRAME 30

BC08C033-27A BC08C033-28A BC08C033-29A BC08C033-30A
FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER FRAME NUMBER - COMPONENT NUMBER
FRAME 1 COMPONENTS FRAME 4 COMPONENTS FRAME 7 COMPONENTS 8- 43. Clutch Cutout Switch (shift Handle) FRAME 11 COMPONENTS 13 - 67. Driving Lamps FRAME 16 COMPONENTS 18 - 90. Diode 103. Diode 116. Cold Start Relay 133. Auxiliary Reverse Solenoid
1 - 1. Battery 4 - 14. Diode 7 - 27. SAHR Brake Pressure Switch 8- 44. Clutch Cutout Switch Loader Handle 11 - 55. Blower Switch 13 - 68. Rear Stop And Tail Lamps 16 - 79. Rotation Beacon Switch 18 - 91. Auxiliary Backhoe Hydraulic Solenoid 104. Switch #A - Backhoe Quick Coupler 117. Fuse 300 AMP 134. Auxiliary Forward Solenoid FRAME 26 COMPONENTS
1 - 2. Alternator 4 - 15. Diode 7 - 28. SAHR ON/OFF Switch Standard Transmission 11 - 56. Air Conditioning Pressure Relay 13 - 69. Horn 16 - 80. Rotating Beacon 105 Switch #B - Backhoe Quick Coupler 118. Cold Start Controller 135. E’Hoe Retract Solenoid 150. Electro Hydraulic Clam Controller
1 - 3. Chassis Ground 4 - 16. Fuse Block 7 - 29. Seat Position Switch 11 - 57. Blower Motor Resistor Board And 16 - 81. Front Work Lamp Switch FRAME 19 COMPONENTS Solenoid 119. Not Used 136. E’Hoe Extend Solenoid 151. EVI Solenoid
7 - 30. SAHR Park Brake Solenoid FRAME 9 COMPONENTS Thermal Fuse FRAME 14 COMPONENTS 16 - 82. Front Work Lamps 92. Radio 106. Backhoe Quick Coupler 120. Cold Start Temperature Sender 137. Pilot ON/OFF Switch 152. EVK Solenoid
FRAME 2 COMPONENTS FRAME 5 COMPONENTS 7 - 31. SAHR Brake Relay 9 - 45. Return-to-Dig Limit Switch 11 - 58. Blower Motor 14 - 70. Hazard Flasher Switch 16 - 83. Rear Work Lamp Switch 93. Left Speaker 138. Pilot Control Relay
2 - 4. Starter and Starter Solenoid 5 - 17. Side Console Ground 9 - 46. Loader Valve Solenoid 11 - 59. Air Conditioner Compressor Clutch 14 - 71. Brake Lamp Switch 16 - 84. Rear Work Lamps 94. Right Speaker FRAME 22 COMPONENTS FRAME 24 COMPONENTS 139. Bi-Directional Forward Push Button
2 - 5. Power Junction 5 - 18. Instrument Cluster FRAME 8 COMPONENTS 11 - 60. Air Conditioner Temperature Switch 14 - 72. Flasher Relay 107. Loader Lever Differential Lock Engage 121. E’Hoe Extend Push Button 140. Bi-Directional Reverse Push Button
2 - 6. Power Relays 5 - 19. Warning Alarm 8 - 32. Shuttle Interlock Relay FRAME 10 COMPONENTS 11 - 61. Air Conditioner Low Pressure Switch 14 - 73. Front Turn Signal Lamps FRAME 17 COMPONENTS FRAME 20 COMPONENTS Switch - Standard Transmission 122. E’Hoe Retract Button 141. Pattern Change Switch
2 - 7. Fuel Shutoff Solenoid 8 - 33. Shuttle Interlock Timing Relay 10 - 47. Front Wiper Switch 11 - 62. Air Conditioner High Pressure Switch 14 - 74. Rear Turn Signal Lamps 17 - 85. 4WD Switch (If Equipped) 95. Ride Control Engage Switch 108. Differential Lock Enable Relay 123. Horn Switch 142. Pressure Reducing Valve Solenoid
2 - 8. Key Switch FRAME 6 COMPONENTS 8 - 34. Diode 10 - 48. Rear Wiper Switch 14 - 75. Turn Signal Indicator Lamps 17 - 86. Diode 96. Ride Control Solenoid (Accumulator) 109. Differential Lock Solenoid 124. LH Stabilizer Switch 143. Diode
2 - 9. Front Console Ground 6 - 20. Hydraulic Filter Restriction Switch 8 - 35. Diode 10 - 49. Front Windshield Washer Switch FRAME 12 COMPONENTS 17 - 87. 4WD Solenoid 97. Ride Control Solenoid (Tank) 125. RH Stabilizer Switch 144. Pattern Change Solenoids
6 - 21. Fuel Level Sender 8 - 36. Forward Relay (Cab/ROPS Windscreen) 12 - 63. Dome Lamp Switch (Door Switch) FRAME 15 COMPONENTS 98. Boom Lock Switch FRAME 23 COMPONENTS 126. LH Stabilizer Pressure Switch 145. Diode
FRAME 3 COMPONENTS 6 - 22. Engine Oil Pressure Switch 8 - 37. Reverse Relay 10 - 50. Rear Windshield Washer Switch 12 - 64. Dome Lamp With Switch 15 - 76. Power Plug #1 99. Boom Lock Solenoid 110. KKSB Cutout Female Connector 127. RH Stabilizer Pressure Switch
3 - 10. Starter Relay 6 - 23. Not Used 8 - 38. Diode (Cab/ROPS Windscreen) 15 - 77. Power Plug #2 FRAME 18 COMPONENTS 111. KKSB Cutout Male Connector 128. Electronic Pilot Controller FRAME 25 COMPONENTS
3 - 11. Neutral Start Relay 6 - 24. Air Filter Restriction Switch 8 - 39. Diode 10 - 51. Front Wiper Motor (Cab) FRAME 13 COMPONENTS 15 - 78. Air Suspension Seat - Air Compressor 18 - 88. Thumb Operated Rear Auxiliary FRAME 21 COMPONENTS 112. KKSB Cutout Relay 129. RH Stabilizer Down Solenoid 146. Comfort Steer Transmission Switch
3 - 12. Clutch Cutout Relay 6 - 25. Transmission Temperature Sender 8 - 40. Forward Solenoid 10 - 52. Rear Wiper Motor (Cab) 13 - 65. Rear Horn Switch Switch And Motor (Optional) Hydraulic Switch (Pilot Control) 100. Loader Quick Coupler Switch 113. Grid Heater Relay 130. RH Stabilizer Up Solenoid 147. Comfort Steer Power Relay
3 - 13. FNR Switch 6 - 26. Engine Temperature Sender 8 - 41. Reverse Solenoid 10 - 53. Rear Wiper Cut-Off Switch 13 - 66. Turn Signal, Driving Lamp, and Horn 18 - 89. Foot Operated Rear Auxiliary Hydraulic 101. Loader Quick Coupler Solenoid 114. Diode 131. LH Stabilizer Down Solenoid 148. Comfort Steer ON/OFF Switch
8 - 42. Backup Alarm 10 - 54. Windshield Washer Motor Switch Switch (Manual Control) 102. Load Sensing Solenoid 115. Grid Heater 132. LH Stabilizer Up Solenoid 149. Comfort Steer Valve Solenoid
ACTUATORS HOUSINGS FEMALE MALE CIRCUIT CONTINUATION WIRE IDENTIFICATION NOTES

SHOWS SPL-00 SHOWS CIRCUIT
T CONNECTOR CONNECTOR
V P 1 1 NOTE 1 See the REPAIR MANUAL for locations and
VACUUM PRESSURE
M TEMPERATURE
CIRCUIT SPLICE
CONNECTION
CROSSING
NOT CONNECTED CONNECTOR 2 2
3 3
Frame Number and Circuit
Number where Circuit
CIRCUIT TAGS
F11-C4 C1
Indicates constant power Troubleshooting information. ELECTRICAL SCHEMATIC
NUMBER continues.
SWITCH
LEVER HAND
CONTACT CONFIGURATIONS
FOOT COIL TEMP. DIODE PRESSURE FLOAT LIQUID LEVEL
MISCELLANEOUS SYMBOLS
SWITCH SWITCH LAMP MOTOR
CONNECTOR
45E 45D
RELAY REAR
INDICATES PARTIAL
C1 F19-C7 23
Indicates power when key switch is in on position

NOTE 2 Diagram shown with vehicle parked, Power OFF, and 580M LOADER BACKHOE
INDICATES INDICATES
CONNECTOR FRAME - CIRCUIT CIRCUIT
controls in OFF or Neutral position. Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical Publications Distribution System.
EXTERNAL INTERNALLY IDENTIFICATION 4 4 Frame Number
MOMENTARY 54 where Circuit NOTE 3 Sheet Numbers refer to the number at the bottom center The part number is 5-12380
GROUND GROUNDED CONNECTOR
18 18 NOT ALL continues. Indicates momentary power when key switch is in
MAINTAINED VARIABLE CIRCUIT MALE FEMALE COMPONENT
27 27
CONNECTIONS of each block.
GROUND COMPONENT NUMBER 32A 32B Circuit Number assigned to Circuit in Frame. Start position
S. P. S. T. S. P. D. T. D. P. S. T. D. P. D. T. CONTACTS RESISTOR RESISTOR FUSE BREAKER TERMINAL TERMINAL NUMBER ARE SHOWN
Copyright © 2008. CNH America, LLC. All Rights Reserved. BC08C033-00A
CHARGING CRANKING AND KEYSWITCH POWER RELAYS START AND CLUTCH RELAYS FUSE BLOCK 14D INSTRUMENT CLUSTER AND ALARM SAHR PARK BRAKE AND TRANSMISSION CONTROLS RETURN-TO-DIG WIPERS (CAB / ROPS WITH WINDSCREEN)
16
14C 14B 14A
1D 1D 1D
1 4 3 3
14 30A
17 18 SEAT POSITION SWITCHES 34 36 37 38
15 15 84
13D 13C 13B 13A
35
12D 12C 12B 12A
31 3 21C
#1
6 #2
12D 14 30A 15A
17 23 C1-2
C1-3
C1-4
C1-5
C1-6
C1-7
C1-8
C1-9
C1-10
C1-11
C1-12
C1-13
C1-14
C1-15
C1-16
C1-17
C1-18
C1-19
C1-20
C1-21
C1-22
C1-24
C1-25 C2-1
C2-3
C12-4
C2-6
C2-7
C2-13
C1-14
C2-15
C2-16
C2-17
C2-18
C2-19
C2-20
C2-21
C2-24
C2-25
12A 12A 11D 11C 11B 11A
58 5 85 30 87 87a 86 I B+ L G
5 15 83 19N
12B 12B
10C
15 10D 10B 10A
14 3 41 42C 60A C112 C114 38 402 C120 1P E35 32T C216 C218 C220 34 28 21C 24 45
28 12C 12C 20A 30A 20A 10A
34 6 19E 15 19K 9D 19F 8
21C 42F 44 C111 C113 21A 36H 36R C121 E34 C26 36F C217 C219 C221 20A
15 #4
90
9C 9B 9A
25 4 19E 47 48 53 49 50
24 25 8D 8C 8B 8A 1P 5 4
31S
85 30 87 87a 86 85 30 87 87a 86
5 36R
1 4 12D 9 27 20A
10A
12 2 12 15 10 3 6 243 4 27 1
13 3 6 15 22 19C
15A
19A 7 15 3 25 25 20 218 21
7D 7C 7B 13 6 27 19C
4 15 61
7A
12B 10 6D 6C 6B 6A 49 11 5 39 4
L IG P
2 12A
4
85 30 87 87a 86 10A 25A 15 19 20 23 30 10 30 5 28 28 63
6 85 30 87 87a 86
15
10A 10A
19D 21
1 3
1
B+
#3 1E 12C 1T 25
12V R N F
19B
5D 5C 5B 5A
P 28 25A 3 52 46 63A
GND 7 21 13 12 6 4D 4C 4B 4A 64A 12 26 85 30 87 87a 86 (+) B L H (+) B L H
1K 10 21 14 16 NO 30 2 41 53
7 10A
15A 10A 10A
25C
28 28 26 63
1D 57
3D 3C 3B 3A
56 1P C114 1P C113 1P C112 1P C111 29 33 3

25B 54
25B 25A 22 19 18 2D 2C 2B 2A 18 5 402 403 4
40 63
85 30 87 87a 86
21A 10 10 11 12 V 22 24 30 30 51 67
7 19E
10A 10A
10A 15A
63
9 C120 P 400
19B 52 82
21C 1D 1C 1B 1A
27
85 30 87 87a 86 85 30 87 87a 86 85 30 87 87a 86 19E NO 19M 27
42 66 81 62
12C 3 4 30 27 19F M
1L 22 101 32 43 43 69
0 1G 27 E17 E37 27 E32 27 12C 27 30 89 65
28
85 30 87 87a 86
23 85 30 87 87a 86
M
1B 1C 21C 12B 1T 2 28 4
1H 20D 30 30 30 10
21B 21B E29 27 28 7 7 16 21 26
1M 1J C120 30
4 5 21A 21A 7 1D
14 14 7 15 44
5 1H 1H 20B 20C 20 20A 20A 52 28
50 19
GND
12D 40A
1J 1J 12A 40B 40B 40B 40B 40B
1A
40D 40D 40D 40D 40D 40D 40D 40D 40D
40E 40E 40E 40E 40E 40E 40E 40E 40E
40A 40A 40A 40A 40A 40A 40A 40A 40A
40C 40C 40C 40C 40C 40C 40C 40C 40C
10 10 10 10 10 10 10 10
30 30 30 30 30 30 30 30 30
3
8 16
F1 F2 F3 F4 F5 F6 F7 F8 F9
BLOWER AND AIR CONDITIONING (CAB) DOME LAMP (CAB) FRONT ROAD LAMPS, REAR ROAD LAMPS, AND HORN TURN SIGNAL, FLASHER, AND BRAKE LAMP SWITCHES POWER PLUG OUTLETS ROTATING BEACON AND WORK LAMPS 4WD TRANSMISSION ELECTRICAL CIRCUIT UNI-DIRECTIONAL BACKHOE RADIO (OPTIONAL)
59 4 75 AIR COMPRESSOR SWITCH AND MOTOR 4 AUXILIARY HYDRAULICS
57 58 4 4 66 70 72 M
85 65 5 19B 73 74 FOR AIR SUSPENSION SEAT (OPTIONAL) 79 80 STANDARD POWERSHIFT
4 61 4 19D
87 M
49a
TRANSMISSION TRANSMISSION 92
86 19B
R
L
67 68 4 4 4
88
64 41
23 23 19A 64A
56
83 84
85 85
63 64B 56a 19N 48
HM L 85 56b
88
64A 64B 64A 4
81
5
60C 46 10 82 23 602 75
55 56b
1 2 3 4 5 6 7 78 19K
88
31b
76 77 42F 93
31
45L 10
87 19B 45R 25C 25C
86 61 M 6F
64A 41 47L
42F 25E 20 25E 20 91 56
56 19B 71 47R 4
5E
T 4 4
61B 19A 57 94
60 P
64B 5 5 89
40B 83 4D
4 49 5 84 4
10 4 40E 87 58 3C
85 30 87 87a 86 71 20B 20C
5
64B 45R 45L 40D 40D 40E 40E 30 90 4
60 40D 40E 19C
60A
P 42C 28
69 44 40D 5
40E 75 40B
60B 45L 5 13
5 60A 45R 30 42C
62 30 30
42C
40B 40B 40B 40B 5 20
40D 40D 40D 40D
40E 40E 40E 40E 15 40B 40B 40B 40B 40B 40B
40A 40A 40A 40A 40A 40A
40C 40C 40C 40C 40C 40C
10 10 10 10 10 10
30 30 30 30 30 30 30 30 30
F 10 F 11 F 12 F 13 F 14 F 15 F 16 F 17 F 18
RIDE CONTROL AND BOOM LOCK QUICK COUPLER (OPTIONAL) DIFFERENTIAL LOCK GRID HEATER (OPTIONAL) R PILOT CONTROLS R FAST STEERING FAST STEERING ELECTRO-HYDRAULIC CLAM
(OPTIONAL) Y Y 139 (STANDARD TRANSMISSION) (POWERSHIFT TRANSMISSION) (4-IN-1 BUCKET)
1 128 1
2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 2
MODELS WITHOUT MODELS WITH B 3 B
100 104 105 121
3 700
COLD START COLD START 4 4
148
4 R 5 5 R 147 150 151
6 618 6 93 1 6 4 10
109 Y 609 Y 140
95 98 57 610 617 616
4 4
611 B 85 30 87 87a 86 85 30 87 87a 86
504A 4 B 616
30 612 601 7 2 5 8 154
501 504 122 30
57 57 613 30 141
RED1
RED2
502 95
YEL1
YEL2
85 30 87 87a 86
501 138
POW
GND
19B 614
112 124 702
101 2B R 616 616
102 103 85 30 87 87a 86
111 W 609 30 608 94 311 152

96 13D 99
A
607 623 701 155
401 B 90
25S 110 E12 27 E12 27 N C 30 30 30
602 93 1 6 4 10
106 108 107 125 616 606 129 133 85 30 87 87a 86 28 28
103 R 624 142 97 156
50 113 615
601 4 97
W 30 605 602
50 A 30 146 19C
E75 27 E75 27 130 134 137 3 6 8
7 2 5 8
97 7 B 610 604 143
50 N C 701
30 602 149 95
103 123 123
50 603 30 131 30 135 2 5 7 4
17 50
608
300 A 117 613
103 103 126 144 20
30 1M 30 132 136
21 25S 58 90
30 64B 607 30 30
1 50 50 20 64A 614 624 30 30 153
28 28 C121 5
1 127 4
12 4
5 5 12
145
30 30 30 30 30 30 30 30 30
F 19 F 20 F 21 F 22 F 23 F 24 F 25 F 26
BC08C034-20A BC08C034-21A BC08C034-22A BC08C034-23A BC08C034-24A BC08C034-25A BC08C034-25A BC08C034-26A
157
102 103 105 106 108 109 110 111 112 117 129 132 134 135 137 140 142 175 189
E12 E29 E44 E37 E42 E89

4
E17 E32 E45 15 E75
3 3 3 22
30
22 3
28 5
5 28
E34
101 15 4
30 E35 E89
159
A B C D E F G H J 158
30 30
30 30
F 27
FRAME 1 COMPONENTS FRAME 4 COMPONENTS FRAME 6 COMPONENTS 7- 43. Diode 9- 54. Windshield Washer Motor 12 - 66. Turn Signal, Driving Lamp, and Horn 17 - 89. Foot Operated Rear Auxiliary Hydraulic 20. 101.
Loader Quick Coupler Solenoid 22. 113. Grid Heater Relay 23. 130. RH Stabilizer Up Solenoid 24. 147. Fast Steering Power Relay FRAME 28 COMPONENTS
1 - 1. Battery 4 - 14. Diode 6 - 29. SAHR Brake Pressure Switch 7- 44. Backup Alarm Switch Switch (Manual Control) 20. 102.
Load Sensing Solenoid 22. 114. Not Used 23. 131. LH Stabilizer Down Solenoid 24. 148. Fast Steering ON/OFF Switch 28. 160. Transmission Controller
1 - 2. Alternator 4 - 15. Fuse Block 6 - 30. SAHR ON/OFF Switch FRAME 10 COMPONENTS 12 - 67. Driving Lamps FRAME 15 COMPONENTS 17 - 90. Diode 20. 103.
Diode 22. 115. Not Used 23. 132. LH Stabilizer Up Solenoid 24. 149. Fast Steering Solenoid Valve 28. 161. FNR (Forward-Neutral-Reverse) Shifter
1 - 3. Chassis Ground 6 - 31. Seat Position Switch FRAME 8 COMPONENTS 10 - 55. Blower Switch 12 - 68. Rear Stop And Tail Lamps 15 - 79. Rotation Beacon Switch 17 - 91. Auxiliary Backhoe Hydraulic Solenoid 20. 104.
Switch #A - Backhoe Quick Coupler 22. 116. Not Used 23. 133. Auxiliary Reverse Solenoid 28. 162. Loader Lever Declutch
FRAME 5 COMPONENTS 6 - 32. SAHR Park Brake Solenoid 8 - 45. Return-to-Dig Limit Switch 10 - 56. Air Conditioning Pressure Relay 12 - 69. Horn 15 - 80. Rotating Beacon 20. 105
Switch #B - Backhoe Quick Coupler 22. 117. Fuse 300 AMP 23. 134. Auxiliary Forward Solenoid FRAME 25 COMPONENTS 28. 163. Auto/Manual Switch
FRAME 2 COMPONENTS 5 - 16. Side Console Ground 6 - 33. SAHR Brake Relay 8 - 46. Loader Valve Solenoid 10 - 57. Blower Motor Resistor Board And 15 - 81. Front Work Lamp Switch FRAME 18 COMPONENTS Solenoid 22. 118. Not Used 23. 135. E’Hoe Retract Solenoid 25. 150. Fast Steering Cutout Relay 28. 164. Brake Pressure Switches
2 - 4. Starter and Starter Solenoid 5 - 17. Instrument Cluster Connector C1 Thermal Fuse FRAME 13 COMPONENTS 15 - 82. Front Work Lamps 18. 92. Radio 20. 106. Backhoe Quick Coupler 22. 119. Not Used 23. 136. E’Hoe Extend Solenoid 25. 151. Fast Steering Power Relay
2 - 5. Power Junction 5 - 18. Instrument Cluster Connector C2 FRAME 7 COMPONENTS FRAME 9 COMPONENTS 10 - 58. Blower Motor 13 - 70. Hazard Flasher Switch 15 - 83. Rear Work Lamp Switch 18. 93. Left Speaker 22. 120. Not Used 23. 137. Pilot ON/OFF Switch 25. 152. Fast Steering ON/OFF Switch
2 - 6. Power Relays 5 - 19. UP-DOWN Switch 7 - 34. Shuttle Interlock Relay 9 - 47. Front Wiper Switch 10 - 59. Air Conditioner Compressor Clutch 13 - 71. Brake Lamp Switch 15 - 84. Rear Work Lamps 18. 94. Right Speaker FRAME 21 COMPONENTS 23. 138. Pilot Control Relay 25. 153. Fast Steering Solenoid Valve
2 - 7. Key Switch 5 - 20. ENTER-ESCAPE Switch 7 - 35. Shuttle Interlock Timing Relay 9 - 48. Rear Wiper Switch9 -49.Front 10 - 60. Air Conditioner Temperature Switch 13 - 72. Flasher Relay 21. 107. Loader Lever Differential Lock Engage FRAME 23 COMPONENTS 23. 139. Bi-Directional Forward Push Button
2 - 8. Front Console Ground 6 - 21. Hydraulic Filter Restriction Switch 7 - 36. Clutch Cutout Switch (shift Handle) Windshield Washer Switch (Cab/ROPS 10 - 61. Air Conditioner Low Pressure Switch 13 - 73. Front Turn Signal Lamps FRAME 16 COMPONENTS FRAME 19 COMPONENTS Switch - Standard Transmission 23. 121. E’Hoe Extend Push Button 23. 140. Bi-Directional Reverse Push Button FRAME 26 COMPONENTS
6 - 22. Air Filter Restriction Switch 7 - 37. Clutch Cutout Switch Loader Handle Windscreen) 10 - 62. Air Conditioner High Pressure Switch 13 - 74. Rear Turn Signal Lamps 16 - 85. 4WD Switch (If Equipped) 19. 95. Ride Control Engage Switch 21. 108. Loader Lever Differential Lock Engage 23. 122. E’Hoe Retract Button 23. 141. Pattern Change Switch 26. 154. Electro Hydraulic Clam Controller
FRAME 3 COMPONENTS 6 - 23. Warning Buzzer Standard Transmission 9 - 49. Front Windshield Washer Switch 13 - 75. Turn Signal Indicator Lamps 16 - 86. Not Used 19. 96. Ride Control Solenoid (Accumulator) Switch - Powershift Transmission 23. 123. Horn Switch 23. 142. Pressure Reducing Valve Solenoid 26. 155. EVI Solenoid
3 - 9. Clutch Cutout Relay 6 - 24. Fuel Level Sender 7 - 38. Clutch Cutout Loader Handle (Cab/ROPS Windscreen) FRAME 11 COMPONENTS 16 - 87. 4WD Solenoid 19. 97. Ride Control Solenoid (Tank) 21. 109. Differential Lock Enable Relay 23. 124. LH Stabilizer Switch 23. 143. Diode 26. 156. EVK Solenoid
3 - 10. Starter Relay 6 - 25. Transmission Temperature Sender (Powershift Transmission) 9 - 50. Rear Windshield Washer Switch 11 - 63. Dome Lamp Switch (Door Switch) FRAME 14 COMPONENTS 19. 98. Boom Lock Switch 21. 110. Differential Lock Solenoid 23. 125. RH Stabilizer Switch 23. 144. Pattern Change Solenoids
3 - 11. Neutral Start Relay 6 - 26. Hand Throttle Potentiometer 7 - 39. Forward Relay (Cab/ROPS Windscreen) 11 - 64. Dome Lamp With Switch 14 - 76. Power Plug #1 19. 99. Boom Lock Solenoid 23. 126. LH Stabilizer Pressure Switch 23. 145. Diode FRAME 27 COMPONENTS
3 - 12. Interlock Relay 6 - 27. Foot Throttle Potentiometer 7 - 40. Reverse Relay 9 - 51. Front Wiper Motor (Cab) 14 - 77. Power Plug #2 FRAME 17 COMPONENTS FRAME 22 COMPONENTS 23. 127. RH Stabilizer Pressure Switch 27. 157. Engine Control Unit
3 - 13. FNR Switch 6 - 28. Idle Validation Switch 7 - 41. Forward Solenoid 9 - 52. Rear Wiper Motor (Cab) FRAME 12 COMPONENTS 14 - 78. Air Suspension Seat - Air Compressor 17 - 88. Thumb Operated Rear Auxiliary FRAME 20 COMPONENTS 22. 111. Resistor 23. 128. Electronic Pilot Controller FRAME 24 COMPONENTS 27. 158. Diagnostic Connector
7 - 42. Reverse Solenoid 9 - 53. Rear Wiper Cut-Off Switch 12 - 65. Rear Horn Switch Switch And Motor (Optional) Hydraulic Switch (Pilot Control) 20. 100. Loader Quick Coupler Switch 22. 112. Grid Heater 23. 129. RH Stabilizer Down Solenoid 24. 146. Fast Steering Transmission Switch 27. 159. Water In Fuel Sensor

VACUUM PRESSURE
M TEMPERATURE
CIRCUIT SPLICE
CONNECTION
CROSSING
3 3
CIRCUIT TAGS
F11-C4 C1
NUMBER continues.
SWITCH
LEVER HAND
CONNECTOR
45E 45D
RELAY REAR
INDICATES PARTIAL
C1 F19-C7 23

NOTE 2 Diagram shown with vehicle parked, Power OFF, and 580SM, 580SM+, 590SM AND 590SM+ Series 3 LOADER BACKHOE
INDICATES INDICATES
MOMENTARY 54 where Circuit NOTE 3 Frame or Sheet Numbers refer to the number at the The part number is 5-12380
27 27
CONNECTIONS bottom center of each single Frame or Block.
160
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56
64A 305 21 359 301 357 303 30 312 218 358 330 355 30 25X 360 343 311 321 25S 31S 327
52 306 304 21 307 21C 322 25C 21 302 308 344 323 25T
161 4 1
SW1 SW2 SW3 SW4 SW5 1

N N
F
R F R
1 4 1 4
2 312
2 3 2 3
3 64A 25 25 311
4 321
5 323
6 21C
7 322
8 21 305 1
307 2
306 3
7 25B A 323
308 4
7 21C B 21C
304 5
7 25A C 322
308 6
21 21 D 21
359 7
21 25S E 25S
360 8
CARRAROSUB-HARNESSCONNECTORS
F
7 52 G 52
POWERSHIFT CONNECTION
ON FRONT CONSOLE HARNESS 321
DE-CLUTCH
162 7 218 A 218
321 B 321 321
21 25S C 25S 30 1
21 D 21 301 2
21 TO LOADER
302 3
LEVER HARNESS 30 4
25X 5
22
357 6
TO OPT.SERVO
218 218
330 7
POWER LDR.SERVO
HARNESS 21 8
DECLUTCH CONN.
343 9
16 218 25C 25C 10
30 355
16
TO CHASSIS HARNESS
344 11
4WD CONNECTION 30 40 12
30 327
27 E35 355
27 E34 327 327
FRONT CONSOLE
CAN CONNECTION 30 30 30
30 30
163 NO
9 3 1 6 4 10 25T CAB FIREWALL GROUND
P
358
7 2 5 8 325 164
358 358 NO
P
21 21
F 28
BC08C034-28A
MAIN CHASSIS HARNESS TO FRONT CONSOLE HARNESS MAIN CHASSIS HARNESS TO SIDE CONTROL HARNESS FUSE LOCATION RELAY LOCATION
SPARE NOT ENGINE NOT

USED CONTROLLER USED FLASHER STARTER
POWER INTERLOCK RELAY RELAY
A B C D E F G H J K L M N PILOT RELAY RELAY
A B C D E F G H J K L M N SPARE POWER SPARE CONTROLS #1
N L K J H G F E D C B A
M
OUTLET BH AUX (OPTION)
_ _ 83 _ _ _ _ _ _ 38 _ _
1 42F 25S _ E89 E35 E34 83 C216C218 19F 63 15 1D 1
_ 1 1D 32T 63 21C 44 __ 1 1 SHUTTLE
NEUTRAL
1 FRONT AIR SUSP POWER POWER INTLK
2 19N 56 E37 E17 E32 E29 84 C120C220 41 64A 25C _ _ 2 2 _ _ 25C 64A 41 _ _ _ _ 84 _ _ _ _ _ _ C216 56 __ 2 2 POWER SEAT AIR COMP RETURN 10 10 20 20 TIMING RELAY
2 WORK OUTLET TO DIG RELAY RELAY
(OPTION) RELAY
3 101 57 _ _ 64B _ _ _ _ _ _ _ _ _ _ 27 48 _ _ 19C 3 3 3 19C 36F _ _ 34 _ _ _ _ _ _ _ _ _ _ 64B _ _ 57 __ 3 3 LIGHTS
15 20 25 10 30 30
#2 #4
__ REAR
4 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 1P 26 45L _ _ 3 4 4 4 3 _ _ C220 402 1P 36R _ _ _ _ _ _ _ _ _ _ _ _ 4 4 WORK
TRANSMISSION, INSTRUMENT DRIVING SHUTTLE
COMFORT STEER ALARM SYSTEM LIGHTS FORWARD
10 10 10 5 20 30 POWER LDR LVR INTLK
5 58 _ _ _ _ 25 _ _ _ _ _ _ _ _ 21C 400 45R _ _ 21B 5 5 5 42C E35 C120 400 403 _ _ _ _ _ _ _ _ 25 _ _ _ _ __ 5 5 LIGHTS
RELAY
RELAY
ROTATING RELAY DIFF
6
6 61 4 49 7 _ _ _ _ _ _ _ _ _ _ _ _ _ _ 69 _ _ 6 6 42C E34 C121 315 25E _ _ _ _ _ _ _ _ 7 49 4 61 6 6 FUEL
BLOWER
DOME BEACON 15 10 10 15 10 15 #3 LOCK
7 SHUTOFF LAMP (OPTION)
7 _ _ 21A _ _ E46 E45 _ _ _ _ _ _ 67 44 _ _ 66 _ _ 7 7 _ _ C218 42F _ _ _ _ _ _ _ _ _ _ _ _ 36H _ _ 21A _ _ 7 7 FAST STEER FAST STEER
SARA REVERSE
N M L K J H G F E D C B A SIGNAL LIGHTS, 4WD CLUTCH POWER CUTOUT RELAY
N M L K J H G F E D C B A A B C D E F G H J K L M N SPARE HORN BRAKE
PARK BRAKE (OPTION) RELAY RELAY RELAY
RELAY (OPTIONAL) (OPTIONAL)
STARTING RADIO, RIDE CNOTRL,
RADIO (BATT) AC
TRANSMISSION QUICK COUPLER WIPERS
(OPTION) RELAY
CONTROL (OPTION)
(OPTION)
F 29 F 30 F 31 F 32
BC08C034-27A BC08C034-29A BC08C034-30A BC08C034-31A BC08C034-32A
FRAME 1 COMPONENTS FRAME 4 COMPONENTS FRAME 6 COMPONENTS 7- 43. Diode 9- 54. Windshield Washer Motor 12 - 66. Turn Signal, Driving Lamp, and Horn 17 - 89. Foot Operated Rear Auxiliary Hydraulic 20. 101.
Loader Quick Coupler Solenoid 22. 113. Grid Heater Relay 23. 130. RH Stabilizer Up Solenoid 24. 147. Fast Steering Power Relay FRAME 28 COMPONENTS
1 - 1. Battery 4 - 14. Diode 6 - 29. SAHR Brake Pressure Switch 7- 44. Backup Alarm Switch Switch (Manual Control) 20. 102.
Load Sensing Solenoid 22. 114. Not Used 23. 131. LH Stabilizer Down Solenoid 24. 148. Fast Steering ON/OFF Switch 28. 160. Transmission Controller
1 - 2. Alternator 4 - 15. Fuse Block 6 - 30. SAHR ON/OFF Switch FRAME 10 COMPONENTS 12 - 67. Driving Lamps FRAME 15 COMPONENTS 17 - 90. Diode 20. 103.
Diode 22. 115. Not Used 23. 132. LH Stabilizer Up Solenoid 24. 149. Fast Steering Solenoid Valve 28. 161. FNR (Forward-Neutral-Reverse) Shifter
1 - 3. Chassis Ground 6 - 31. Seat Position Switch FRAME 8 COMPONENTS 10 - 55. Blower Switch 12 - 68. Rear Stop And Tail Lamps 15 - 79. Rotation Beacon Switch 17 - 91. Auxiliary Backhoe Hydraulic Solenoid 20. 104.
Switch #A - Backhoe Quick Coupler 22. 116. Not Used 23. 133. Auxiliary Reverse Solenoid 28. 162. Loader Lever Declutch
FRAME 5 COMPONENTS 6 - 32. SAHR Park Brake Solenoid 8 - 45. Return-to-Dig Limit Switch 10 - 56. Air Conditioning Pressure Relay 12 - 69. Horn 15 - 80. Rotating Beacon 20. 105
Switch #B - Backhoe Quick Coupler 22. 117. Fuse 300 AMP 23. 134. Auxiliary Forward Solenoid FRAME 25 COMPONENTS 28. 163. Auto/Manual Switch
FRAME 2 COMPONENTS 5 - 16. Side Console Ground 6 - 33. SAHR Brake Relay 8 - 46. Loader Valve Solenoid 10 - 57. Blower Motor Resistor Board And 15 - 81. Front Work Lamp Switch FRAME 18 COMPONENTS Solenoid 22. 118. Not Used 23. 135. E’Hoe Retract Solenoid 25. 150. Fast Steering Cutout Relay 28. 164. Brake Pressure Switches
2 - 4. Starter and Starter Solenoid 5 - 17. Instrument Cluster Connector C1 Thermal Fuse FRAME 13 COMPONENTS 15 - 82. Front Work Lamps 18. 92. Radio 20. 106. Backhoe Quick Coupler 22. 119. Not Used 23. 136. E’Hoe Extend Solenoid 25. 151. Fast Steering Power Relay
2 - 5. Power Junction 5 - 18. Instrument Cluster Connector C2 FRAME 7 COMPONENTS FRAME 9 COMPONENTS 10 - 58. Blower Motor 13 - 70. Hazard Flasher Switch 15 - 83. Rear Work Lamp Switch 18. 93. Left Speaker 22. 120. Not Used 23. 137. Pilot ON/OFF Switch 25. 152. Fast Steering ON/OFF Switch
2 - 6. Power Relays 5 - 19. UP-DOWN Switch 7 - 34. Shuttle Interlock Relay 9 - 47. Front Wiper Switch 10 - 59. Air Conditioner Compressor Clutch 13 - 71. Brake Lamp Switch 15 - 84. Rear Work Lamps 18. 94. Right Speaker FRAME 21 COMPONENTS 23. 138. Pilot Control Relay 25. 153. Fast Steering Solenoid Valve
2 - 7. Key Switch 5 - 20. ENTER-ESCAPE Switch 7 - 35. Shuttle Interlock Timing Relay 9 - 48. Rear Wiper Switch9 -49.Front 10 - 60. Air Conditioner Temperature Switch 13 - 72. Flasher Relay 21. 107. Loader Lever Differential Lock Engage FRAME 23 COMPONENTS 23. 139. Bi-Directional Forward Push Button
2 - 8. Front Console Ground 6 - 21. Hydraulic Filter Restriction Switch 7 - 36. Clutch Cutout Switch (shift Handle) Windshield Washer Switch (Cab/ROPS 10 - 61. Air Conditioner Low Pressure Switch 13 - 73. Front Turn Signal Lamps FRAME 16 COMPONENTS FRAME 19 COMPONENTS Switch - Standard Transmission 23. 121. E’Hoe Extend Push Button 23. 140. Bi-Directional Reverse Push Button FRAME 26 COMPONENTS
6 - 22. Air Filter Restriction Switch 7 - 37. Clutch Cutout Switch Loader Handle Windscreen) 10 - 62. Air Conditioner High Pressure Switch 13 - 74. Rear Turn Signal Lamps 16 - 85. 4WD Switch (If Equipped) 19. 95. Ride Control Engage Switch 21. 108. Loader Lever Differential Lock Engage 23. 122. E’Hoe Retract Button 23. 141. Pattern Change Switch 26. 154. Electro Hydraulic Clam Controller
FRAME 3 COMPONENTS 6 - 23. Warning Buzzer Standard Transmission 9 - 49. Front Windshield Washer Switch 13 - 75. Turn Signal Indicator Lamps 16 - 86. Not Used 19. 96. Ride Control Solenoid (Accumulator) Switch - Powershift Transmission 23. 123. Horn Switch 23. 142. Pressure Reducing Valve Solenoid 26. 155. EVI Solenoid
3 - 9. Clutch Cutout Relay 6 - 24. Fuel Level Sender 7 - 38. Clutch Cutout Loader Handle (Cab/ROPS Windscreen) FRAME 11 COMPONENTS 16 - 87. 4WD Solenoid 19. 97. Ride Control Solenoid (Tank) 21. 109. Differential Lock Enable Relay 23. 124. LH Stabilizer Switch 23. 143. Diode 26. 156. EVK Solenoid
3 - 10. Starter Relay 6 - 25. Transmission Temperature Sender (Powershift Transmission) 9 - 50. Rear Windshield Washer Switch 11 - 63. Dome Lamp Switch (Door Switch) FRAME 14 COMPONENTS 19. 98. Boom Lock Switch 21. 110. Differential Lock Solenoid 23. 125. RH Stabilizer Switch 23. 144. Pattern Change Solenoids
3 - 11. Neutral Start Relay 6 - 26. Hand Throttle Potentiometer 7 - 39. Forward Relay (Cab/ROPS Windscreen) 11 - 64. Dome Lamp With Switch 14 - 76. Power Plug #1 19. 99. Boom Lock Solenoid 23. 126. LH Stabilizer Pressure Switch 23. 145. Diode FRAME 27 COMPONENTS
3 - 12. Interlock Relay 6 - 27. Foot Throttle Potentiometer 7 - 40. Reverse Relay 9 - 51. Front Wiper Motor (Cab) 14 - 77. Power Plug #2 FRAME 17 COMPONENTS FRAME 22 COMPONENTS 23. 127. RH Stabilizer Pressure Switch 27. 157. Engine Control Unit
3 - 13. FNR Switch 6 - 28. Idle Validation Switch 7 - 41. Forward Solenoid 9 - 52. Rear Wiper Motor (Cab) FRAME 12 COMPONENTS 14 - 78. Air Suspension Seat - Air Compressor 17 - 88. Thumb Operated Rear Auxiliary FRAME 20 COMPONENTS 22. 111. Resistor 23. 128. Electronic Pilot Controller FRAME 24 COMPONENTS 27. 158. Diagnostic Connector
7 - 42. Reverse Solenoid 9 - 53. Rear Wiper Cut-Off Switch 12 - 65. Rear Horn Switch Switch And Motor (Optional) Hydraulic Switch (Pilot Control) 20. 100. Loader Quick Coupler Switch 22. 112. Grid Heater 23. 129. RH Stabilizer Down Solenoid 24. 146. Fast Steering Transmission Switch 27. 159. Water In Fuel Sensor

VACUUM PRESSURE
M TEMPERATURE
CIRCUIT SPLICE
CONNECTION
CROSSING
3 3
CIRCUIT TAGS
F11-C4 C1
NUMBER continues.
SWITCH
LEVER HAND
CONNECTOR
45E 45D
RELAY REAR
INDICATES PARTIAL
C1 F19-C7 23

NOTE 2 Diagram shown with vehicle parked, Power OFF, and 580SM, 580SM+, 590SM AND 590SM+ Series 3 LOADER BACKHOE
INDICATES INDICATES
MOMENTARY 54 where Circuit NOTE 3 Frame or Sheet Numbers refer to the number at the The part number is 5-12380
27 27
CONNECTIONS bottom center of each single Frame or Block.
5
4 8
6
A B
9
14
2
C
B
A A A
7 P A 15
16
D B
E
1A D
A
1B 17
3 P1 1A 1B 2A 2B 3A 3B B C
E E
G 11
D D 10
I 18
J EVI
ACC F
T 2A A
A
G 19
F
ACC
E P H
A H B
2B
T
C C J
A C EVK
B
PB K
T LS P
C 20
C
B 3A
K V2 C2
P2
3B
21
V1 C1
4A
L
22
4B
B
12 B P See Note 1 V1 C1 23
27
B
A
A
P V2
B M N C2
5A
C
C H
13
24
D E T
E 5B
B B
B N
A
Q
6A 25
D P
6B
B
R
LS T
T
7A 26
29 29 28 S
7B
T
30
CF EF
B
T
32
A 8A
B 31 34
8B
U T
C LS
35
See Note 1
B
T
A C
33
COMPONENTS NOTES HYDRAULIC SYMBOLS

1. Machines will not be equipped with bi-directional
1 . STEERING CYLINDER G. ANTI CAVITATION VALVE 1 2 . UNI-DIRECTIONAL AUXILIARY F. BOOM A PORT CIRCUIT RELIEF Q. BUCKET A PORT CIRCUIT RELIEF 17. FLOATING ORIFICE E. LOADER QUICK COUPLER SOLENOID VALVE
and uni-directional auxiliary hydraulics on the
2 . STEERING CONTROL VALVE H. CLAM SPOOL HYDRAULICS WITH ANTI-CAVITATION CHECK VALVE WITH ANTI-CAVITATION CHECK VALVE 18. RIGHT-HAND SWING CYLINDER 28. LOADER QUICK COUPLER CYLINDER
same machine. Valves are shown for reference
A. ANTI CAVITATION VALVE J. PLUG A. FLOW CONTROL ADJUSTMENT 221 ± 3 BAR 262 ± 3 BAR 19. BOOM CYLINDER 29. TEST PORTS
only. PRESSURE
B. STEERING RELIEF VALVE 4 . BUCKET CYLINDERS B. UNI-DIRECTIONAL AUXILIARY ON/OFF 3205 ± 50 PSI 3800 ± 50 PSI 20. LEFT STABILIZER LOAD CHECK VALVE 30. HYDRAULIC PUMP
172 +0 -10 BAR 5 . LIFT CYLINDERS SOLENOID 21. LEFT-HAND STABILIZER CYLINDER 108 L/min @ 207 BAR COMPONENT CROSSING LINES CHECK VALVE FILTER OR SCREEN
G. BOOM SPOOL R. BUCKET B PORT CIRCUIT RELIEF
2500 +0 -150 PSI 6. CLAM CYLINDERS C. UNI-DIRECTIONAL AUXILIARY RELIEF 22. RIGHT STABILIZER LOAD CHECK 28.5 gpm @ 3000 PSI
H. LOW LEAK VALVE ASSEMBLY WITH ANTI-CAVITATION CHECK VALVE RETURN
C. CHECK VALVE 7 . 4-IN-1 BUCKET LOCK VALVE VALVE VALVE A. PRIORITY VALVE
3 . LOADER CONTROL VALVE 8 . R I D E C O N T R O L VA LV E D. PRIORITY SPOOL J. BOOM B PORT CIRCUIT RELIEF 221 ± 3 BAR 23. RIGHT-HAND STABILIZER CYLINDER B. DYNAMIC SENSING ORIFICE LOAD SENSE
A. MAIN RELIEF VALVE A. RIDE CONTROL SOLENOID VALVE (TANK) 13. HAMMER ATTACHMENT EXAMPLE 331 ± 3 BAR 3205 ± 50 PSI 24. DIPPER CYLINDER C. LS SIGNAL ORIFICE
210 ± 3 BAR B. RIDE CONTROL SOLENOID VALVE (ACCUMULATOR) 14. BACKHOE CONTROL VALVE 4800 ± 50 PSI S. EXTEND-A-HOE SPOOL 25. BUCKET CYLINDER 31. LOAD SENSE SHUTTLE VALVE PILOT PRESSURE
LINE CONNECTION RESTRICTOR OIL COOLER
3050 ± 50 PSI 9 . ACCUMULATOR FOR RIDE CONTROL A. SWING FLOW LIMITING ORIFICE K. LEFT STABILIZER SPOOL T. PLUG 26. EXTEND-A-HOE CYLINDER 32. HYDRAULIC RESERVOIR BREATHER
B. CHECK VALVE 1 0 . ELECTRO HYDRAULIC CLAM CONTROL B. LOAD CHECK VALVE L. RIGHT STABILIZER SPOOL U. BI-DIRECTIONAL SPOOL 27. QUICK COUPLER SOLENOID 33. HYDRAULIC RESERVOIR
C. LOAD CHECK VALVE A. CLAM CLOSE SOLENOID VALVE C. REGENERATION CHECK VALVE M. DIPPER SPOOL 15. SWING DAMPENING VALVE A. CHECK VALVE 34. OIL COOLER
D. DUMP CIRCUIT RELIEF VALVE B. PRESSURE REDUCING VALVE D. SWING SPOOL N. DIPPER CIRCUIT RELIEFS A. CHECK VALVE B. ORIFICE 35. HYDRAULIC FILTER HYDRAULIC SCHEMATIC FOR 580M SERIES 3
WITH ANTI-CAVITATION CHECK VALVE 24 TO 34.5 BAR E. SWING CIRCUIT RELIEFS WITH ANTI-CAVITATION CHECK VALVE B. SHUTTLE CHECK VALVE C. PILOT SIGNAL SOLENOID A. COOLER BYPASS WITH MECHANICAL CONTROLS
221 ± 3 BAR 350 TO 500 PSI WITH ANTI-CAVITATION CHECK VALVE 238 ± 3 BAR C. BACK PRESSURE VALVE D. QUICK COUPLER RELIEF VALVE B. FILTER BYPASS
Additional copies of this Hydraulic and Electrical Schematic can be ordered through
3205 ± 50 PSI C. CLAM OPEN SOLENOID VALVE 207 ± 3 BAR D. SWING CUSHION SPOOL 189.5 ± 3 BAR C. FILTER CONDITION SWITCH
3450 ± 50 PSI Technical Publications Distribution System. The Part Number is 5-12380
E. BUCKET SPOOL 1 1 . AC C U M U L ATO R 3000 ± 50 PSI E. SCREEN 2750 ± 50 PSI
F. LIFT SPOOL P. BUCKET SPOOL 16. LEFT-HAND SWING CYLINDER
BC08C035
4 5
8 P1 P2 19
T LS P
6
A B
A P2
T2
1
B
T ACC M
2 T1
9 C
7 D
A A
E A
20
14 See Note 2 15 See Note 2 21
11
3 10 F B
P1 PILOT 1A 1B 2A 2B 3A 3B I G B1 D
B B F EVI P P A
A ACC A B A B 22
H T T A1 C
G E
H
T ACC
E P 23
B
D G A
T E
C 1 3 2 4 1 3 2 4
A C EVK
B K
K J
A PB B2 24
C 12
C
C L A2
T LS P H
P2
25
V2 C2
M B3
26
B A3 V1 C1
E
13
32 B P
27
A B A
P V1 C1 28
17 N B4
C 18
16 A4 V2 C2
C B1 B3 B2 B4 ACC DIAG J B D H F E
E E See Note 1 T D
D
B D B C
A E
B
A
LS P 29
D Q B5
Q A5
E H
F G H J
A1 A3 A2 A4 T1 P A C G E
E
34 34 30
33 S R B6
T
A6
T H
35
CF EF
36 E
37
39 U 31
V B7
A
B A7
V H
LS
C 40
A B
E
C W
X B8
38
X A8
H
See Note 1
1. STEERING CYLINDER C. LOAD CHECK VALVE 10. ELECTRO HYDRAULIC CLAM CONTROL 16. REGULATED MANIFOLD E. LOAD CHECK VALVE Q. DIPPER CIRCUIT RELIEFS V. PLUG 27. RIGHT STABILIZER LOAD CHECK VALVE A. PRIORITY VALVE 1. Machines will not be equipped with bi-
2. STEERING CONTROL VALVE D. BUCKET SPOOL A. CLAM OPEN SOLENOID VALVE A. PATTERN CHANGE VALVE F. SWING SPOOL WITH ANTI-CAVITATION CHECK W. BI-DIRECTIONAL SPOOL 28. RIGHT-HAND STABILIZER CYLINDER B. DYNAMIC SENSING ORIFICE directional and uni-directional
A. ANTI CAVITATION VALVE E. LIFT SPOOL B. PILOT PRESSURE RELIEF VALVE B. CHECK VALVE G. SWING CIRCUIT RELIEFS VALVE X. AUXILIARY CIRCUIT RELIEFS 29. DIPPER CYLINDER C. LS SIGNAL ORIFICE auxiliary hydraulics on the same
B. STEERING RELIEF VALVE F. ANTI CAVITATION VALVE 24-34.5 BAR C. ORIFICE WITH ANTI-CAVITATION CHECK VALVE 238 ± 3 BAR WITH ANTI-CAVITATION CHECK VALVE 30. BUCKET CYLINDER 36. LOAD SENSE SHUTTLE VALVE machine. Valves are shown for PRESSURE
172 +0 -10 BAR G. CLAM SPOOL 350-500 PSI D. PILOT PRESSURE RELIEF VALVE 207 ± 3 BAR 3450 ± 50 PSI 220 +5 -1 BAR 31. EXTEND-A-HOE CYLINDER 37. HYDRAULIC RESERVOIR BREATHER reference only. CROSSING LINES CHECK VALVE FILTER OR SCREEN
COMPONENT
2500 +0 -150 PSI H. PLUG C. CLAM CLOSE SOLENOID VALVE 24-34.5 BAR 3000 ± 50 PSI R. BUCKET SPOOL 3191 +72.5 -14.5 PSI 32. QUICK COUPLER SOLENOID 38. HYDRAULIC RESERVOIR
C. CHECK VALVE 4 . BUCKET CYLINDERS 11. ACCUMULATOR 350-500 PSI H. COMPENSATOR S. BUCKET B PORT CIRCUIT 20. SWING DAMPENING VALVE A. CHECK VALVE 39. OIL COOLER 2. Pilot controls are listed with pattern RETURN
3. LOADER CONTROL VALVE 5. LIFT CYLINDERS 12. HAMMER ATTACHMENT EXAMPLE E. PILOT CONTROL ON OFF SOLENOID J. BOOM SPOOL RELIEF A. CHECK VALVE B. ORIFICE 40. HYDRAULIC FILTER change valves not activated. LOAD SENSE
A. TWO STAGE RELIEF VALVE 6. CLAM CYLINDERS 13. UNI-DIRECTIONAL AUXILIARY VALVE F. RIGHT STABILIZER CONTROL K. BOOM B PORT CIRCUIT RELIEF WITH ANTI-CAVITATION CHECK B. SHUTTLE CHECK VALVE C. PILOT SIGNAL SOLENOID A. COOLER BYPASS
FIRST STAGE 7. 4-IN-1 BUCKET LOCK VALVE A. FLOW CONTROL ADJUSTMENT G. LEFT STABILIZER CONTROL WITH ANTI-CAVITATION CHECK VALVE VALVE C. BACK PRESSURE VALVE D. QUICK COUPLER RELIEF VALVE B. FILTER BYPASS PILOT PRESSURE LINE CONNECTION RESTRICTOR OIL COOLER
210 ± 3 BAR 8. RIDE CONTROL VALVE B. UNI-DIRECTIONAL AUXILIARY ON/OFF SOLENOID H. EXTEND-A-HOE CONTROL 331 ± 3 BAR 221 ± 3 BAR D. SWING CUSHION SPOOL 189.5 ± 3 BAR C. FILTER CONDITION SWITCH
3050 ± 50 PSI A. RIDE CONTROL SOLENOID C. UNI-DIRECTIONAL AUXILIARY RELIEF VALVE J. BI-DIRECTIONAL AUXILIARY CONTROL 4800 ± 50 PSI 3205 ± 50 PSI E. SCREEN 2750 ± 50 PSI
SECOND STAGE VALVE (TANK) D. PRIORITY SPOOL 17. ACCUMULATOR L. BOOM A PORT CIRCUIT RELIEF T. BUCKET A PORT CIRCUIT 21. LEFT-HAND SWING CYLINDER E. LOADER QUICK COUPLER SOLENOID
248 TO 276 BAR B. RIDE CONTROL SOLENOID 14. LEFT-HAND JOYSTICK CONTROL 18. PILOT MANIFOLD TEST PORT WITH ANTI-CAVITATION CHECK VALVE RELIEF 22. FLOATING ORIFICE VALVE
3600 TO 4000 PSI VALVE (ACCUMULATOR) A. BOOM CONTROL 19. BACKHOE CONTROL VALVE WITH ANTI-CAVITATION CHECK 33. LOADER QUICK COUPLER CYLINDER
B. CIRCUIT RELIEF VALVE 9. ACCUMULATOR FOR RIDE B. SWING CONTROL A. BACKHOE RELIEF VALVE
221 ± 3 BAR
3205 ± 50 PSI VALVE
23. RIGHT-HAND SWING CYLINDER
24. BOOM CYLINDER 34. PUMP TEST PORTS HYDRAULIC SCHEMATIC FOR 580M SERIES 3
WITH ANTI-CAVITATION CONTROL 15. RIGHT-HAND JOYSTICK CONTROL B. LOAD SENSE DRAIN ORIFICE M. LEFT STABILIZER SPOOL 262 ± 3 BAR 25. LEFT STABILIZER LOAD CHECK VALVE 35. HYDRAULIC PUMP WITH PILOT CONTROLS
221 ± 3 BAR A. DIPPER CONTROL C. LOAD SENSING RELIEF VALVE N. RIGHT STABILIZER SPOOL 3800 ± 50 PSI 26. LEFT-HAND STABILIZER CYLINDER 108 L/min @ 207 BAR Additional copies of this Hydraulic and Electrical Schematic can be ordered through
3205 ± 50 PSI B. BUCKET CONTROL D. ORIFICE P. DIPPER SPOOL U. EXTEND-A-HOE SPOOL 28.5 gpm @ 3000 PSI Technical Publications Distribution System. The Part Number is 5-12380
BC08C036
1
5 6
2
9 P1 P2
7
A B
A A
10
1 2
T ACC
15
A C
3 B
P
2
8 A
16
D
17
1
3
E B
1A D
A
1B 18
4 P1 GP 1A 1B 2A 2B 3A 3B B C
E E
D G 11 12
D I
F 19
J EVI
T ACC G
A 13 A 20
2A
F ACC
21
B A E H P
A B H
C 2B
T
C 14
T LS P C B P J
PB EVK
See Note 1
K B
C
B
C A
K 22
P2 3A
V2 C2
3B
C
23
D E T
V1 C1
L
4A 24
4B V1 C1 25
B
32
M V2 C2
B
N
A B 5A
A 26 27
P 31 H
5B
C D B N See Note 2
See Note 3
P Q
B 28
B 6A
33
A B 6B
R
30
E
F S T
LS
7A 29
34 34
T 7B
T
35
EF CF LS
B
C 36 T
A
8A
B 38 8B
U
T
D E
F G See Note 1
39
A B
T
C
37

1. STEERING CYLINDER D. CIRCUIT RELIEF VALVE 10. ACCUMULATOR FOR RIDE CONTROL C. REGENERATION CHECK VALVE M. DIPPER SPOOL 16. SWING DAMPENING VALVE 27. 590SM DIPPER CYLINDER 34. PUMP TEST PORTS 36. HYDRAULIC RESERVOIR 1. Machines will not be equipped
2. STEERING CONTROL VALVE WITH ANTI-CAVITATION CHECK VALVE 11. ELECTRO HYDRAULIC CLAM CONTROL D. SWING SPOOL N. DIPPER CIRCUIT RELIEFS A. CHECK VALVE 28. BUCKET CYLINDER 35. HYDRAULIC PUMP BREATHER with bi-directional and uni-
WITH COMFORT STEER 221 ± 3 BAR A. CLAM OPEN SOLENOID VALVE E. SWING CIRCUIT RELIEFS WITH ANTI-CAVITATION CHECK VALVE B. SHUTTLE CHECK VALVE 29. EXTEND-A-HOE CYLINDER A. PRIORITY VALVE 37. HYDRAULIC RESERVOIR directional auxiliary hydraulics on PRESSURE
A, ANTI CAVITATION VALVE 3205 ± 50 PSI B. PILOT PRESSURE RELIEF VALVE WITH ANTI-CAVITATION CHECK VALVE 238 ± 3 BAR C. BACK PRESSURE VALVE 30. LOADER QUICK COUPLER CYLINDER B. DYNAMIC SENSING ORIFICE 38. OIL COOLER the same machine. Valves are
B. STEERING RELIEF VALVE E. BUCKET SPOOL 24-34.5 BAR 207 ± 3 BAR 3450 ± 50 PSI D. SWING CUSHION SPOOL 31. BACKHOE QUICK COUPLER CYLINDER C. LS SIGNAL ORIFICE 39. HYDRAULIC FILTER shown for reference only. COMPONENT CROSSING LINES CHECK VALVE FILTER OR SCREEN
172 +0 -10 BAR F. LIFT SPOOL 350-500 PSI 3000 ± 50 PSI P. BUCKET SPOOL E. SCREEN 32. QUICK COUPLER SOLENOID VALVE D. SMALL PUMP 580SM
A. COOLER BYPASS RETURN
2500 +0 -150 PSI G. ANTI CAVITATION VALVE C. CLAM CLOSE SOLENOID VALVE F. BOOM SPOOL Q. BUCKET A PORT CIRCUIT RELIEF 17. LEFT-HAND SWING CYLINDER A. CHECK VALVE 36 L/min @ 207 BAR 2. Only 590SM machines are
C. CHECK VALVE H. CLAM SPOOL 12. ACCUMULATOR WITH ANTI-CAVITATION CHECK VALVE 18. FLOATING ORIFICE B. ORIFICE 9.5 gpm @ 3000 PSI B. FILTER BYPASS
G. BOOM A PORT CIRCUIT RELIEF equipped with a cascading orifice LOAD SENSE
3. COMFORT STEER SOLENOID J. PLUG 13. HAMMER ATTACHMENT EXAMPLE 262 ± 3 BAR 19. RIGHT-HAND SWING CYLINDER C. QUICK COUPLER SOLENOID E. LARGE PUMP 580SM C. FILTER CONDITION SWITCH
WITH ANTI-CAVITATION CHECK VALVE cushion with check valve return PILOT PRESSURE LINE CONNECTION RESTRICTOR OIL COOLER
4 . LOADER CONTROL VALVE 5. BUCKET CYLINDERS 14. UNI-DIRECTIONAL AUXILIARY HYDRAULICS 221 ± 3 BAR 3800 ± 50 PSI 20. BOOM PISTON RELIEF D. BACKHOE QUICK COUPLER SOLENOID 108 L/min @ 207 BAR flow.
A. MAIN RELIEF VALVE 6. LIFT CYLINDERS A. FLOW CONTROL ADJUSTMENT 3205 ± 50 PSI R. BUCKET B PORT CIRCUIT RELIEF 21. BOOM CYLINDER VALVE 28.5 gpm @ 3000 PSI
210 ± 3 BAR 7. CLAM CYLINDERS B. UNI-DIRECTIONAL AUXILIARY ON/OFF H. LOW LEAK VALVE ASSEMBLY WITH ANTI-CAVITATION CHECK VALVE 22. LEFT STABILIZER LOAD CHECK E. QUICK COUPLER RELIEF VALVE F. SMALL PUMP 590SM
3050 ± 50 PSI 8. 4-IN-1 BUCKET LOCK VALVE SOLENOID 221 ± 3 BAR VALVE 189.5 ± 3 BAR 42 L/min @ 207 BAR 3. The 580SM does not have the
J. BOOM B PORT CIRCUIT RELIEF
B. P2 PORT CHECK VALVE 9. RIDE CONTROL VALVE C. UNI-DIRECTIONAL AUXILIARY RELIEF VALVE 331 ± 3 BAR 3205 ± 50 PSI 23. LEFT-HAND STABILIZER CYLINDER 2750 ± 50 PSI 11.0 gpm @ 3000 PSI cascading orifice cushion with HYDRAULIC SCHEMATIC FOR 580SM AND 590SM
C. LOAD CHECK VALVE A. RIDE CONTROL SOLENOID VALVE D. PRIORITY SPOOL 24. RIGHT STABILIZER LOAD CHECK VALVE F. LOADER QUICK COUPLER G. LARGE PUMP 590SM check valve return flow.
(TANK) 15. BACKHOE CONTROL VALVE
4800 ± 50 PSI S. EXTEND-A-HOE SPOOL
T. PLUG 25. RIGHT-HAND STABILIZER CYLINDER SOLENOID VALVE 119 L/min @ 207 BAR
SERIES 3 WITH MECHANICAL CONTROLS
K. LEFT STABILIZER SPOOL Additional copies of this Hydraulic and Electrical Schematic can be ordered through
B. RIDE CONTROL SOLENOID VALVE A. SWING FLOW LIMITING ORIFICE L. RIGHT STABILIZER SPOOL U. BI-DIRECTIONAL SPOOL 26. 580SM DIPPER CYLINDER 33. LOAD SENSE SHUTTLE VALVE 31.5 gpm @ 3000 PSI
(ACCUMULATOR) B. LOAD CHECK VALVE Technical Publications Distribution System. The Part Number is 5-12380
BC08C037
1
A A
5 6
9
P1 P2
10 20 T LS P
7
A B
A
3 P2
2
T2 B
T ACC 13 M
T1 C
1
3 8
D
14
B P See Note 1 A
E
B
21
12 15 See Note 2 16 See Note 2 22
4 P1 PILOT 1A 1B 2A 2B 3A 3B 11 F
I B
G A G B1 D
D D EVI P P
B A
ACC A A B 23
B J A T T C
G A1 E
A C T C H
F ACC
T LS P E H E T
P D 24
B
A A
T E
C C 1 3 2 4 1 3 2 4
EVK
PB J
K K B2
B C 25
C
L A2
P2 H
26 27
V2 C2
M B3
28
E A3 V1 C1
29
V1 C1 30
36 N B4
19
18
17 E A4 V2 C2
B B1 B3 B2 B4 ACC DIAG J B D H F
D
A B
A 35 A B
E
P
C
C D 31
Q P B5
37 D
Q A5
E H
F G H J
B B
A1 A3 A2 A4 T1 P A C G E
A E
38 38
34 R B6 32
S
E F
39 A6
EF CF LS H
LS T
T
C E
A
B V U B7 33
A7
V H
D E
42
E
40
W B8
X
43
X A8
A H
B
See Note 1
C
41

1. STEERING CYLINDER D. CIRCUIT RELIEF VALVE 11. ELECTRO HYDRAULIC CLAM CONTROL 17. REGULATED MANIFOLD F. SWING SPOOL Q. DIPPER CIRCUIT RELIEFS 21. SWING DAMPENING VALVE 35. BACKHOE QUICK COUPLER D. SMALL PUMP 1. Machines will not be
2. STEERING CONTROL VALVE WITH ANTI-CAVITATION CHECK VALVE A. CLAM OPEN SOLENOID VALVE A. PATTERN CHANGE VALVE G. SWING CIRCUIT RELIEFS WITH ANTI-CAVITATION CHECK VALVE A. CHECK VALVE CYLINDER 36 L/min @ 207 BAR equipped with bi-directional
A. ANTI CAVITATION VALVE 221 ± 3 BAR B. PILOT PRESSURE RELIEF VALVE B. ORIFICE WITH ANTI-CAVITATION CHECK VALVE 238 ± 3 BAR B. SHUTTLE CHECK VALVE 36. QUICK COUPLER SOLENOID VALVE 9.5 gpm @ 3000 PSI and uni-directional auxiliary
B. STEERING RELIEF VALVE 3205 ± 50 PSI 24-34.5 BAR C. CHECK VALVE 3450 ± 50 PSI C. BACK PRESSURE VALVE A. CHECK VALVE PRESSURE
207 ± 3 BAR E. LARGE PUMP hydraulics on the same
172 +0 -10 BAR E. BUCKET SPOOL 350-500 PSI D. PILOT PRESSURE REDUCING VALVE 3000 ± 50 PSI R. BUCKET SPOOL D. SWING CUSHION SPOOL B. ORIFICE 108 L/min @ 207 BAR machine. Valves are shown COMPONENT CROSSING LINES CHECK VALVE FILTER OR SCREEN
2500 +0 -150 PSI F. LIFT SPOOL C. CLAM CLOSE SOLENOID VALVE 24 to 34.5 BAR H. COMPENSATOR S. BUCKET B PORT CIRCUIT RELIEF E. SCREEN C. QUICK COUPLER SOLENOID 28.5 gpm @ 3000 PSI for reference only.
C. CHECK VALVE G. ANTI CAVITATION VALVE 12. ACCUMULATOR 350 to 500 PSI J. BOOM SPOOL WITH ANTI-CAVITATION CHECK VALVE 22. LEFT-HAND SWING CYLINDER D. BACKHOE QUICK COUPLER 40. HYDRAULIC RESERVOIR BREATHER RETURN
3. COMFORT STEER SOLENOID H. CLAM SPOOL 13. HAMMER ATTACHMENT EXAMPLE E. PILOT CONTROL ON OFF SOLENOID K. BOOM B PORT CIRCUIT RELIEF 221 ± 3 BAR 23. FLOATING ORIFICE SOLENOID VALVE 41. HYDRAULIC RESERVOIR
2. Pilot controls are listed with LOAD SENSE
4 . LOADER CONTROL VALVE J. PLUG 14. UNI-DIRECTIONAL AUXILIARY HYDRAULICS F. RIGHT-HAND STABILIZER CONTROL WITH ANTI-CAVITATION CHECK VALVE 3205 ± 50 PSI 24. RIGHT-HAND SWING CYLINDER E. QUICK COUPLER RELIEF VALVE 42. OIL COOLER
pattern change valves not
A. TWO-STAGE RELIEF VALVE 5. BUCKET CYLINDERS A. FLOW CONTROL ADJUSTMENT G. LEFT-HAND STABILIZER CONTROL 331 ± 3 BAR T. BUCKET A PORT CIRCUIT RELIEF 25. BOOM CYLINDER 189.5 ± 3 BAR 43. HYDRAULIC FILTER PILOT PRESSURE LINE CONNECTION RESTRICTOR OIL COOLER
activated.
FIRST STAGE 6. LIFT CYLINDERS B. UNI-DIRECTIONAL AUXILIARY ON/OFF SOLENOID H. EXTEND-A-HOE CONTROL 4800 ± 50 PSI WITH ANTI-CAVITATION CHECK VALVE 26. BOOM PISTON RELIEF 2750 ± 50 PSI A. COOLER BYPASS
210 ± 3 BAR 7. CLAM CYLINDERS C. UNI-DIRECTIONAL AUXILIARY RELIEF VALVE J. BI-DIRECTIONAL AUXILIARY CONTROL L. BOOM A PORT CIRCUIT RELIEF 262 ± 3 BAR 27. LEFT STABILIZER LOAD CHECK VALVE F. LOADER QUICK COUPLER B. FILTER BYPASS
3080 ± 50 PSI 8. 4-IN-1 BUCKET LOCK VALVE D. PRIORITY SPOOL 18. ACCUMULATOR WITH ANTI-CAVITATION CHECK VALVE 3800 ± 50 PSI 28. LEFT-HAND STABILIZER CYLINDER SOLENOID VALVE C. FILTER CONDITION SWITCH
SECOND STAGE 9. RIDE CONTROL VALVE 15. LEFT-HAND JOYSTICK CONTROL 19. PILOT MANIFOLD TEST PORT 221 ± 3 BAR U. EXTEND-A-HOE SPOOL 29. RIGHT STABILIZER LOAD CHECK VALVE 37. LOAD SENSE SHUTTLE VALVE
248 TO 276 BAR A. RIDE CONTROL SOLENOID VALVE A. BOOM CONTROL 20. BACKHOE CONTROL VALVE 3205 ± 50 PSI V. PLUG 30. RIGHT-HAND STABILIZER CYLINDER 38. PUMP TEST PORTS
3600 TO 4000 PSI (TANK) B. SWING CONTROL A. BACKHOE RELIEF VALVE M. LEFT STABILIZER SPOOL W. BI-DIRECTIONAL AUXILIARY SPOOL 31. DIPPER CYLINDER 39. HYDRAULIC PUMP HYDRAULIC SCHEMATIC FOR 580SM SERIES 3
B. P2 PORT CHECK VALVE B. RIDE CONTROL SOLENOID VALVE 16. RIGHT-HAND JOYSTICK CONTROL B. LOAD SENSE DRAIN ORIFICE N. RIGHT STABILIZER SPOOL X. AUXILIARY CIRCUIT RELIEFS 32. BUCKET CYLINDER A. PRIORITY VALVE
C. LOAD CHECK VALVE (ACCUMULATOR) A. DIPPER CONTROL C. LOAD SENSING RELIEF VALVE P. DIPPER SPOOL WITH ANTI-CAVITATION CHECK VALVE 33. EXTEND-A-HOE CYLINDER B. DYNAMIC SENSING ORIFICE WITH PILOT CONTROLS
10. ACCUMULATOR FOR RIDE CONTROL B. BUCKET CONTROL D. ORIFICE 220 +5 -1 BAR 34. LOADER QUICK COUPLER CYLINDER C. LS SIGNAL ORIFICE Additional copies of this Hydraulic and Electrical Schematic can be ordered through
E. LOAD CHECK VALVE Technical Publications Distribution System. The Part Number is 5-12380
3191 +72.5 -14.5 PSI
BC08C038
1
2
11
8
7
I
A A 9 10 12
EVI
ACC
A
2
6 B ACC A
P P2 ACC 20
C LS P
T
T
D A
1
3 EVK P2
B
2
K
P1 T T2 B
M
5
T1 C
1
3
D A
21
3A 3B 2A 2B 1A 1B M 15 See Note 2 16 See Note 2 22
4 T E B
A A D D F F F B1 D
T A B T T A B T
T A B T
P P A
A B A B 23
B T T C
F A1 E
A C J
B A B A B A G
T LS P 24
K
P A
D
1 3 2 4 1 3 2 4
C E G
B B L
DLS J H 25
B B2
H M 13 A2
D LS
K
G
26 27
V2 C2
L B3
28
D A3 V1 C1
14
B P See Note 1
B M
29
C
V1 C1 30
A
38
D N B4
18
17 19
E D A4 V2 C2
B B1 B3 B2 B4 ACC DIAG J B D H F
E T
A B F M
A 37
A B D
39 A P
A C
See Note 3 See Note 4
LS D P
Q B5
C D
B 41 A5
40 P Q
E F G H J G 31 32
B B
M2 A1 A3 A2 A4 T1 P A C G E
See Note 5 A D
C
36 R 33
E S B6
F
A6
T G
LS
D
T
D
T L2
V U 34
B7
A7
V G
44
D
42 35
W
X B8
45 A8
X G
A B
See Note 1
C T3
43

1. STEERING CYLINDER J. CHECK VALVE 12. RIDE CONTROL VALVE C. CHECK VALVE F. SWING CIRCUIT RELIEFS Q. DIPPER CIRCUIT RELIEFS A. CHECK VALVE 36. LOADER QUICK COUPLER CYLINDER B. HIGH PRESSURE CUTOFF SPOOL (NOT
2. STEERING CONTROL VALVE WITH K. PRIORITY VALVE A. RIDE CONTROL SOLENOID VALVE D. PILOT PRESSURE REDUCING VALVE WITH ANTI-CAVITATION CHECK VALVE WITH ANTI-CAVITATION CHECK VALVE B. SHUTTLE CHECK VALVE 37. BACKHOE QUICK COUPLER USED) 1. Machines will not be equipped with
COMFORT STEER L. DYNAMIC LOAD SENSE ORIFICE (ACCUMULATOR) 24 to 34.5 BAR 205 + 5 -1 BAR 240 + 24 -1 BAR C. BACK PRESSURE VALVE CYLINDER C. 580SM+ 71CC REV bi-directional and uni-directional
A. ANTI CAVITATION VALVE WITH SCREEN B. RIDE CONTROL SOLENOID VALVE (TANK) 350 to 500 PSI 2973 + 72.5 -14.5 PSI 3480 + 350 -14.5 PSI D. SWING CUSHION SPOOL 38. QUICK COUPLER SOLENOID VALVE (4.33 CUBIC INCHES) REV auxiliary hydraulics on the same
B. STEERING RELIEF VALVE M. STEERING LOAD SENSE CHECK 13. HAMMER ATTACHMENT EXAMPLE E. PILOT CONTROL ON OFF SOLENOID G. COMPENSATOR R. BUCKET SPOOL E. SCREEN A. CHECK VALVE 590SM+ 75CC REV machine. Valves are shown for PRESSURE
172 +0 -10 BAR VALVE 14. UNI-DIRECTIONAL AUXILIARY HYDRAULICS F. RIGHT-HAND STABILIZER CONTROL H. BOOM SPOOL S. BUCKET B PORT CIRCUIT RELIEF 22. LEFT-HAND SWING CYLINDER B. ORIFICE (4.58 CUBIC INCHES) REV reference only. CROSSING LINES CHECK VALVE FILTER OR SCREEN
COMPONENT
2500 +0 -150 PSI 5. 4-IN-1 BUCKET LOCK VALVE A. FLOW CONTROL ADJUSTMENT G. LEFT-HAND STABILIZER CONTROL J. BOOM B PORT CIRCUIT RELIEF WITH ANTI-CAVITATION CHECK VALVE 23. FLOATING ORIFICE C. QUICK COUPLER SOLENOID D. CASE DRAIN OVER PRESSURE 2. Pilot controls are listed with pattern
C. CHECK VALVE 6. CLAM CYLINDERS B. UNI-DIRECTIONAL AUXILIARY ON/OFF SOLENOID H. EXTEND-A-HOE CONTROL WITH ANTI-CAVITATION CHECK VALVE 240 + 24 -1 BAR 24. RIGHT-HAND SWING CYLINDER D. BACKHOE QUICK COUPLER BYPASS VALVE change valves not activated. RETURN
3. COMFORT STEERING SOLENOID 7. ELECTRO HYDRAULIC CLAM C. CHECK VALVE J. BI-DIRECTIONAL AUXILIARY CONTROL 330 + 29 -1 BAR 3480 + 350 -14.5 PSI 25. BOOM CYLINDER SOLENOID VALVE 41. LOAD SENSE TEST PORT 3. The 580SM+ does not have the
4 . LOADER CONTROL VALVE CONTROL D. ORIFICE 18. ACCUMULATOR T. BUCKET A PORT CIRCUIT RELIEF 26. BOOM PISTON RELIEF E. QUICK COUPLER RELIEF VALVE 42. HYDRAULIC RESERVOIR BREATHER LOAD SENSE
4785 + 420 -14.5 PSI cascading orifice cushion with
A. PLUG A. CLAM CLOSE SOLENOID VALVE E. UNI-DIRECTIONAL AUXILIARY RELIEF VALVE 19. PILOT MANIFOLD TEST PORT K. BOOM A PORT CIRCUIT RELIEF WITH ANTI-CAVITATION CHECK VALVE 27. LEFT STABILIZER LOAD CHECK VALVE 189.5 ± 3 BAR 3 to 5 BAR check valve return flow. PILOT PRESSURE
B. SECTIONAL COMPENSATOR F. PRIORITY SPOOL 20. BACKHOE CONTROL VALVE 260 + 24 -1 BAR 28. LEFT-HAND STABILIZER CYLINDER 2750 ± 50 PSI 6 TO 12 PSI LINE CONNECTION RESTRICTOR OIL COOLER
B. CHECK VALVE WITH ANTI-CAVITATION CHECK VALVE 4. Only 590SM+ machines are
C. CLAM SPOOL C. PRESSURE REDUCING VALVE 15. LEFT-HAND JOYSTICK CONTROL A. LOAD SENSE DRAIN ORIFICE 195 + 19 -1 BAR 3770 + 350 -14.5 PSI 29. RIGHT STABILIZER LOAD CHECK F. LOADER QUICK COUPLER 43. HYDRAULIC RESERVOIR equipped with a cascading orifice
D. CIRCUIT RELIEF VALVE 24 TO 34.5 BAR A. BOOM CONTROL 26 ±1 BAR 2828 + 275.5 -14.5 PSI U. EXTEND-A-HOE SPOOL VALVE SOLENOID VALVE 44. OIL COOLER cushion with check valve return
WITH ANTI-CAVITATION 350 TO 500 PSI B. SWING CONTROL 377 ±14.5 PSI L. LEFT STABILIZER SPOOL V. PLUG 30. RIGHT-HAND STABILIZER CYLINDER 39. PUMP TEST PORT 45. HYDRAULIC FILTER flow.
221 ± 3 BAR D. CLAM OPEN SOLENOID VALVE 16. RIGHT-HAND JOYSTICK CONTROL 15 LPM @ 2150 RPM M. ORIFICE W. BI-DIRECTIONAL AUXILIARY SPOOL 31. DIPPER CYLINDER 580SM+ A. ATTENUATOR HOSE A. COOLER BYPASS
5. Pump will only destroke to 7cc
3205 ± 50 PSI 8. ACCUMULATOR A. DIPPER CONTROL 4 GPM @ 2150 RPM N. RIGHT STABILIZER SPOOL X. AUXILIARY CIRCUIT RELIEFS 32. DIPPER CYLINDER 590SM+ 40. HYDRAULIC PUMP B. FILTER BYPASS (0.42 cubic inch) minimum
HYDRAULIC SCHEMATIC FOR
E. BUCKET SPOOL 9. BUCKET CYLINDERS B. BUCKET CONTROL B. MINIMUM FLOW BYPASS VALVE P. DIPPER SPOOL WITH ANTI-CAVITATION CHECK VALVE 33. BUCKET CYLINDER A. LOAD SENSE COMPENSATOR SPOOL
F. ANTI CAVITATION VALVES 10. LIFT CYLINDERS 17. REGULATED MANIFOLD C. LOAD SENSE RELIEF VALVE 220 + 5 -1 BAR 34. EXTEND-A-HOE CYLINDER DELTA PRESSURE 20 ±1 BAR
C. FILTER CONDITION SWITCH displacement. 580SM+ AND 590SM+ SERIES 3
G. LIFT SPOOL 11. ACCUMULATOR FOR RIDE A. PATTERN CHANGE VALVE D. LOAD CHECK VALVE 35. BACK PRESSURE VALVE (290 ±14.5 PSI) Additional copies of this Hydraulic and Electrical Schematic can be ordered through
3191 + 72.5 -14.5 PSI
H. RETURN TO DIG SOLENOID CONTROL B. NOT USED E. SWING SPOOL 5 BAR (72.5 PSI) Technical Publications Distribution System. The Part Number is 5-12380
21. SWING DAMPENING VALVE
BC08C039

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SECTION INDEX

Section Title Section Number

Copyright © 2008 CNH America LLC.

GENERAL TORQUE SPECIFICATIONS

Copyright © 2004 CNH America LLC.

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Pound- Newton Pound- Newton

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - METRIC HARDWARE

M6 96 to 108 11 to 12 M12 93 to 112 125 to 150

M8 228 to 276 26 to 31 M14 149 to 179 200 to 245

M10 456 to 540 52 to 61 M16 230 to 280 310 to 380

Pound- Newton M24 780 to 940 1050 to 1275

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting Straight Threads with O-ring

Split Flange Mounting Bolts

Bur 8-71603 Revised 7-05 Printed in U.S.A.

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

O-ring Boss End

Thread Pound- Newton

Nom. 1-1/16-12 85 to 90 115 to 122

Bur 8-71603 Revised 7-05 Printed in U.S.A.

FLUIDS AND LUBRICANTS

Copyright © 2008 CNH America LLC.

Bur 5-11920 Issued 3-08 Printed in U.S.A.

CAPACITIES AND LUBRICANTS

Bur 5-11920 Issued 3-08 Printed in U.S.A.

ENGINE OIL RECOMMENDATIONS

Bur 5-11920 Issued 3-08 Printed in U.S.A.

Bur 5-11920 Issued 3-08 Printed in U.S.A.

Specifications for Acceptable No. 2 Diesel Fuel

Bur 5-11920 Issued 3-08 Printed in U.S.A.

DYE AND BLACK LIGHT PROCEDURE FOR DETECTING OIL LEAKS

Part Number Description U/M Comments Usage

B. Casting surfaces can hold residual oil.

Bur 5-11920 Issued 3-08 Printed in U.S.A.

Bur 5-11920 Issued 3-08 Printed in U.S.A.

Copyright © 2003 Case, LLC. All rights reserved.

Bur 7-52590 Issued 4-03 Printed in U.S.A.

Area: sq. meter 10.763 91 square foot

Force: newton 3.596 942 ounce force

Length: millimeter 0.039 370 inch

Mass: kilogram 2.204 622 pound

Mass/Area: kilogram/hectare 0.000 466 ton/acre

Mass/Energy: gr/kW/hr. 0.001 644 lbs/hp/hr.

Mass/Volume: kg/cubic meter 1.685 555 lb/cubic yd.

Power: kilowatt 1.341 02 horsepower

Pressure: kilopascal 0.145 038 lb/sq. inch

Temperature: degree C 1.8 x C +32 degree F

Torque: newton meter 8.850 748 lb/inch

Velocity: kilometer/hr. 0.621 371 miles/hr.

Volume: cubic centimeter 0.061 024 cubic inch

Volume/Time: litre/min. 0.264 172 gallon/min. (US liquid)

Bur 7-52590 Issued 4-03 Printed in U.S.A.

Area: square foot 0.092 903 square meter

Force: ounce force 0.278 014 newton

Length: inch 25.4 * millimeter