580N Manual de Servicio Retroexcavadora

580N
580SN-WT
580SN
590SN
Tractor Loader Backhoe
SERVICE MANUAL
Printed in U.S.A. Part number 84516378

English
Copyright © 2011 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. July 2011
Racine Wisconsin 53404 U.S.A. Replaces part number 84390833
Contents
INTRODUCTION
HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS A
PRIMARY HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.A
SECONDARY HYDRAULIC POWER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.12.A
ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A
ENGINE AND PTO IN ................................................................... B

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A
TRANSMISSION, DRIVE AND PTO OUT ........................................ C

TRANSMISSION Power Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.C
TRANSMISSION Powershift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.E
AXLES, BRAKES AND STEERING................................................. D

FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.10.A
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.12.A
STEERING Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.20.C
SERVICE BRAKE Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.30.C
PARKING BRAKE Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.B

WHEELS AND TRACKS Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.C
FRAME AND CAB ........................................................................ E

FRAME Primary frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.10.B
SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.20.A
USER CONTROLS AND SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.A
USER CONTROLS AND SEAT Operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.C
USER PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.34.A
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ENVIRONMENT CONTROL Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.40.C
FRAME POSITIONING ................................................................. F

STABILISING Working stabilising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F.20.D
TOOL POSITIONING .................................................................... G

LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.10.A
HITCH AND WORKING TOOL ....................................................... H

BOOM Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.20.B
BOOM Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.20.D
DIPPER Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.25.B

DIPPER Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.25.F
ARM TOOL ATTACHMENT Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.30.C
EXCAVATING AND LANDSCAPING ............................................... J

DIGGING Non-articulated digging tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.20.B
CARRYING Articulated tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.50.C
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INTRODUCTION
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Contents
INTRODUCTION
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ELECTRONIC SYSTEM - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Heater - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Abbreviation Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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INTRODUCTION
Safety rules
DANGER
Improper operation or service of this machine can result in an accident.
Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have
read and understood the operation, lubrication, maintenance, and repair information.
Failure to comply will result in death or serious injury.
D0010A
WARNING
Maintenance hazard!
Always perform all service procedures punctually at the intervals stated in this manual. This ensures
optimum performance levels and maximum safety during machine operation.
Failure to comply could result in death or serious injury.
W0132A
WARNING
Pressurized system!
Before attempting any service procedure, it is your responsibility to know the number of accumulators
on the machine, and the correct procedure for releasing the pressure of each accumulator.
W0136A
NOTICE: Extreme working and environmental conditions require shortened service intervals.
Use Case fluids, lubricants, and filters for the best protection and performance of your machine. All fluids, lubricants,
and filters must be disposed of in compliance with environmental standards and regulations. Contact your dealer with
any questions regarding the service and maintenance of this machine.
Read the safety decals and information decals on the machine. Read the Operator’s Manual and safety manual.
Understand the operation of the machine before you start any service.
Before you service the machine, put a 'Do Not Operate' tag on the steering wheel or over the key switch. Ensure the
tag is at a location where everyone who might operate or service the machine may see clearly. One tag is included
with your new machine. Additional tags are available from your dealer.
Plastic and resin parts

• Avoid using gasoline, paint thinner, etc. when cleaning plastic parts, console, instrument cluster, etc.
• Use only water, mild soap, and a soft cloth when you clean these parts.
• Using gasoline, thinners, etc. can cause discoloration, cracking, or deformation of the part being cleaned.
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INTRODUCTION
Safety rules
Before you weld, cut, or drill holes on any part of this machine, make sure the part is not cast ductile iron. See your
dealer if you do not know if a part is cast ductile iron. The following are cast ductile iron parts:
• two wheel drive steering link
• dump links
• front axle
• stabilizers
• extendable dipper
• swing tower
• bucket linkage
Unauthorized modifications to cast ductile iron parts can cause injury or death. Welding, cutting, or drilling can cause
cast ductile iron to break. Do not weld, cut, or drill to repair or to attach items to cast ductile iron parts on this machine.
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INTRODUCTION
Safety rules
Before welding on the machine you must do the following.
If you have any questions about welding on the machine
contact your dealer.
• Disconnect the batteries.

• Disconnect the alternator terminal wires.
• Disconnect the instrument cluster.
• One connector for mechanical fuel injection
engines.
• Two connectors for HPCR (high pressure
common rail) engines.
• Disconnect the engine control unit (ECU), if
equipped (three connectors).
NOTE: The third connector is behind the hose in the
illustration.
RCPH10TLB046AAF 1
• Disconnect the controller for backhoe pilot controls,

if equipped (one connector).
• Disconnect the transmission controller, if equipped
(one connector, located under the front steering
cowling).
• Disconnect the controller for the loader 4 in 1 bucket
or auxiliary hydraulics, if equipped (one connector,
located under the loader valve at the rear, left un-
derside of the machine).
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INTRODUCTION
Safety rules
Unless otherwise instructed, always perform these steps before you service the machine:
1. Park the machine on a flat, level surface.
2. Place the backhoe in the transport position with the swing lock pin installed for transport.
3. Place the loader bucket on the ground, with the bottom of the loader bucket parallel to the surface.
4. Place the direction control lever and the transmission in neutral.
5. If you need to open the hood to perform service, raise the loader arms and install the support strut.
6. Shut down the engine.
7. Place a 'Do Not Operate' tag on the key switch so that it is visible to other workers or remove the key.
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INTRODUCTION
Battery - Basic instructions

WARNING
Explosive gas!
Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.
Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen
battery.
W0005A
WARNING
Hazardous chemicals!
Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation
and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash
hands after handling.
W0006A
• Do not run the engine with the alternator wires disconnected.

• Before using an electric welder, disconnect the alternator wires, instrument cluster and batteries. Disconnect
the ECU connectors.
• Do not use a steam cleaner or a cleaning solvent to clean the alternator.
• Keep the battery vents clean. Ensure the battery vents are not restricted.
Disconnect Battery
1. Park the machine on a level surface. Raise the
loader and lock the support strut to hold the loader
in the upright position. .
RCPH10TLB022AAL 1
2. Remove the battery cover hardware.
RCPH11TLB001AAM 2
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INTRODUCTION
3. Remove the battery cover.
RCPH11TLB002AAM 3
4. Disconnect the negative battery cable from the neg-

ative battery terminal.
RCPH11TLB003AAM 4
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INTRODUCTION
ELECTRONIC SYSTEM - Basic instructions

The diagnostic/service tool port is located in the fuse box at the side console. Connect the Electronic Service Tool
(EST) or DATAR to this port to update software and/or perform service and diagnostic tests.
1. Turn the thumb screws (1) to loosen the panel cover
(2) for the fuse box. Remove the panel cover.
RCPH10TLB437AAF 1
2. Unscrew the cap for the diagnostic/service tool port.

NOTE: You do not have to remove the fuse box
covers.
RCPH10TLB302AAF 2
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INTRODUCTION
Heater - Basic instructions

The heater coolant shutoff valve controls the flow of hot
coolant to the heater.
• In warm ambient temperatures, turn the shutoff

valve clockwise to stop hot coolant flow to the
heater.
• In cold ambient temperatures, turn the shutoff valve
counter-clockwise to allow hot coolant to flow to the
heater.
RCPH10TLB159AAF 1
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INTRODUCTION
Basic instructions
WARNING
Crushing hazard!
If you service the machine with the loader lift arms raised, always use the support strut. Remove the
retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support
strut. Lower the lift arms onto the support strut.
W0230A
Raise and support loader lift arms:

1. Empty the loader bucket.
2. Raise the loader lift arms to the maximum height.
RCPH10TLB230AAF 1
4. Remove the retaining pin.

5. Lower the support strut onto the cylinder rod.
6. Install the retaining pin.
RCPH10TLB221AAF 2
7. Start the engine.

8. Slowly lower the lift arms so that the end of the sup-
port strut rests on the cylinder.
RCPH10TLB227AAF 3
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INTRODUCTION
Lower supported loader lift arms:

1. Raise the lift arms so that the end of the support strut
no longer rests on the cylinder.
RCPH10TLB227AAF 4
3. Remove the retaining pin from the support strut.

4. Raise the support strut up to the storage position
and secure with the retaining pin, as shown.
RCPH10TLB231AAF 5

6. Lower the loader to the ground.
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INTRODUCTION
Basic instructions
Open the hood:
2. Turn the handle counter-clockwise to release the
hood latch.
RCPH10TLB166AAF 1
3. Lift the hood and rotate forward.
RCPH10TLB356AAF 2
NOTICE: To avoid damage to the hood parts, always close the hood before moving the loader.
Close the hood:
1. Lower the hood.
2. Turn the handle clockwise to lock the hood latch.
RCPH10TLB167AAF 3
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INTRODUCTION
Torque
Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC
and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite
lubricants, Molydisulfide greases, or other extreme pressure lubricants are used.
Decimal hardware
Grade 5 bolts, nuts, and studs
Size Nm lb in/lb ft
1/4 in 12 - 15 Nm 108 - 132 lb in
5/16 in 23 - 28 Nm 204 - 252 lb in
3/8 in 48 - 57 Nm 420 - 504 lb in
7/16 in 73 - 87 Nm 54 - 64 lb ft
1/2 in 109 - 130 Nm 80 - 96 lb ft
9/16 in 149 - 179 Nm 110 - 132 lb ft
5/8 in 203 - 244 Nm 150 - 180 lb ft
3/4 in 366 - 439 Nm 270 - 324 lb ft
7/8 in 542 - 651 Nm 400 - 480 lb ft
1 in 787 - 944 Nm 580 - 696 lb ft
1-1/8 in 1085 - 1193 Nm 800 - 880 lb ft
1-1/4 in 1519 - 1681 Nm 1120 - 1240 lb ft
1-3/8 in 1980 - 2278 Nm 1460 - 1680 lb ft
1-1/2 in 2631 - 2983 Nm 1940 - 2200 lb ft
Markings for Grade 5 hardware
Grade 8 bolts, nuts, and studs

Size Nm lb in/lb ft
1/4 in 16 - 20 Nm 144 - 180 lb in
5/16 in 33 - 39 Nm 288 - 348 lb in
3/8 in 61 - 73 Nm 540 - 648 lb in
7/16 in 95 - 114 Nm 70 - 84 lb ft
1/2 in 149 - 179 Nm 110 - 132 lb ft
9/16 in 217 - 260 Nm 160 - 192 lb ft
5/8 in 298 - 358 Nm 220 - 264 lb ft
3/4 in 515 - 618 Nm 380 - 456 lb ft
7/8 in 814 - 976 Nm 600 - 720 lb ft
1 in 1220 - 1465 Nm 900 - 1080 lb ft
1-1/8 in 1736 - 1953 Nm 1280 - 1440 lb ft
1-1/4 in 2468 - 2712 Nm 1820 - 2000 lb ft
1-3/8 in 3227 - 3688 Nm 2380 - 2720 lb ft
1-1/2 in 4285 - 4827 Nm 3160 - 3560 lb ft
Markings for Grade 8 hardware
NOTE: Use thick nuts with Grade 8 bolts.
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INTRODUCTION
Metric hardware
Grade 8.8 bolts, nuts, and studs
Size Nm lb in/lb ft
4 mm 3 - 4 Nm 24 - 36 lb in
5 mm 7 - 8 Nm 60 - 72 lb in
6 mm 11 - 12 Nm 96 - 108 lb in
8 mm 26 - 31 Nm 228 - 276 lb in
10 mm 52 - 61 Nm 456 - 540 lb in
12 mm 90 - 107 Nm 66 - 79 lb ft
14 mm 144 - 172 Nm 106 - 127 lb ft
16 mm 217 - 271 Nm 160 - 200 lb ft
20 mm 434 - 515 Nm 320 - 380 lb ft
24 mm 675 - 815 Nm 500 - 600 lb ft
30 mm 1250 - 1500 Nm 920 - 1100 lb ft
36 mm 2175 - 2600 Nm 1600 - 1950 lb ft
Markings for Grade 8.8 hardware
Grade 10.9 bolts, nuts and studs

Size Nm lb in/lb ft
4 mm 4 - 5 Nm 36 - 48 lb in
5 mm 9 - 11 Nm 84 - 96 lb in
6 mm 15 - 18 Nm 132 - 156 lb in
8 mm 37 - 43 Nm 324 - 384 lb in
10 mm 73 - 87 Nm 54 - 64 lb ft
12 mm 125 - 150 Nm 93 - 112 lb ft
14 mm 200 - 245 Nm 149 - 179 lb ft
16 mm 310 - 380 Nm 230 - 280 lb ft
20 mm 610 - 730 Nm 450 - 540 lb ft
24 mm 1050 - 1275 Nm 780 - 940 lb ft
30 mm 2000 - 2400 Nm 1470 - 1770 lb ft
36 mm 3500 - 4200 Nm 2580 - 3090 lb ft
Grade 12.9 bolts, nuts, and studs

Size Nm lb in/lb ft
Typically the torque values specified for grade 10.9 hardware can be used satisfactorily on grade 12.9 hardware.
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INTRODUCTION
Steel hydraulic fittings

37° flare fitting
Tube outside diameter/Hose inside Thread size Nm lb in/lb ft
diameter
mm inch
6.4 mm 1/4 in 7/16-20 in 8 - 16 Nm 72 - 144 lb in
7.9 mm 5/16 in 1/2-20 in 11 - 22 Nm 96 - 192 lb in
9.5 mm 3/8 in 9/16-18 in 14 - 34 Nm 120 - 300 lb in
12.7 mm 1/2 in 3/4-16 in 20 - 57 Nm 180 - 504 lb in
15.9 mm 5/6 in 7/8-14 in 34 - 79 Nm 300 - 696 lb in
19.0 mm 3/4 in 1-1/16-12 in 54 - 108 Nm 40 - 80 lb ft
22.2 mm 7/8 in 1-3/16-12 in 81 - 135 Nm 60 - 100 lb ft
25.4 mm 1 in 1-5/16-12 in 102 - 158 Nm 75 - 117 lb ft
31.8 mm 1-1/4 in 1-5/8-12 in 169 - 223 Nm 125 - 165 lb ft
38.1 mm 1-1/2 in 1-7/8-12 in 285 - 338 Nm 210 - 250 lb ft
Straight threads with O-ring

Tube outside diameter/Hose inside Thread size Nm lb in/lb ft
diameter
mm inch
6.4 mm 1/4 in 7/16-20 in 16 - 26 Nm 144 - 228 lb in
7.9 mm 5/16 in 1/2-20 in 22 - 34 Nm 192 - 300 lb in
9.5 mm 3/8 in 9/16-18 in 34 - 54 Nm 300 - 480 lb in
12.7 mm 1/2 in 3/4-16 in 57 - 91 Nm 540 - 804 lb in
15.9 mm 5/6 in 7/8-14 in 79 - 124 Nm 58 - 92 lb ft
19.0 mm 3/4 in 1-1/16-12 in 108 - 174 Nm 80 - 128 lb ft
22.2 mm 7/8 in 1-3/16-12 in 136 - 216 Nm 100 - 160 lb ft
25.4 mm 1 in 1-5/16-12 in 159 - 253 Nm 117 - 187 lb ft
31.8 mm 1-1/4 in 1-5/8-12 in 224 - 357 Nm 165 - 264 lb ft
38.1 mm 1-1/2 in 1-7/8-12 in 339 - 542 Nm 250 - 400 lb ft
Split flange mounting bolts

Size Nm lb in/lb ft
5/16-18 in 20 - 27 Nm 180 - 240 lb in
3/8-16 in 27 - 34 Nm 240 - 300 lb in
7/16-14 in 47 - 61 Nm 420 - 540 lb in
1/2-13 in 74 - 88 Nm 55 - 65 lb ft
5/8-11 in 190 - 203 Nm 140 - 150 lb ft
O-ring face seal end

Nominal SAE Tube outside diameter Thread size Nm lb in/lb ft
dash size mm in
-4 6.4 mm 1/4 in 9/16-18 in 14 - 16 Nm 120 - 144 lb in
-6 9.5 mm 3/8 in 11/16-16 in 24 - 27 Nm 216 - 240 lb in
-8 12.7 mm 1/2 in 13/16-16 in 43 - 54 Nm 384 - 480 lb in
-10 15.9 mm 5/8 in 1-14 in 62 - 76 Nm 552 - 672 lb in
-12 19.0 mm 3/4 in 1-3/16-12 in 90 - 110 Nm 65 - 80 lb ft
-14 22.2 mm 7/8 in 1-3/16-12 in 90 - 110 Nm 65 - 80 lb ft
-16 25.41 mm 1.0 in 1-7/16-12 in 125 - 140 Nm 92 - 105 lb ft
-20 31.8 mm 1-1/4 in 1-11/16-12 in 170 - 190 Nm 125 - 140 lb ft
-24 38.1 mm 1-1/2 in 2-12 in 200 - 254 Nm 150 - 180 lb ft
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INTRODUCTION
O-ring boss end fitting or lock nut

Nominal SAE Tube outside diameter Thread size Nm lb in/lb ft
dash size mm in
-4 6.4 mm 1/4 in 7/16-20 in 23 - 27 Nm 204 - 240 lb in
-6 9.5 mm 3/8 in 9/16-18 in 34 - 41 Nm 300 - 360 lb in
-8 12.7 mm 1/2 in 3/4-16 in 61 - 68 Nm 540 - 600 lb in
-10 15.9 mm 5/8 in 7/8-14 in 81 - 88 Nm 60 - 65 lb ft
-12 19.0 mm 3/4 in 1-1/16-12 in 115 - 122 Nm 85 - 90 lb ft
-14 22.2 mm 7/8 in 1-13/16-12 in 129 - 136 Nm 95 - 100 lb ft
-16 25.41 mm 1.0 in 1-5/16-12 in 156 - 169 Nm 115 - 125 lb ft
-20 31.8 mm 1-1/4 in 1`-5/6-12 in 201 - 217 Nm 150 - 160 lb ft
-24 38.1 mm 1-1/2 in 1-7/8-12 in 258 - 271 Nm 190 - 200 lb ft
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INTRODUCTION
Abbreviation Measurements
Typical applications Metric unit Imperial unit
Name Symbol Name Symbol
Area (Land area)

hectare ha acre ac
square meter m² square foot ft²
square inch in²
square millimeter mm² square inch in²
Electricity
ampere A ampere A
volt V volt V
microfarad µF microfarad µF
ohm Ω ohm Ω
Force
kilonewton kN pound lb
newton N pound lb
Force per length
newton per meter N/m pound per foot lb/ft
pound per inch lb/in
Frequency
megahertz MHz megahertz MHz
kilohertz kHz kilohertz kHz
hertz Hz hertz Hz
Frequency − Rotational
revolution per minute r/min revolution per minute r/min ª
rpm rpm
Length
kilometer km mile mi
meter m foot ft
centimeter cm inch in
millimeter mm inch in
micrometer µm
Mass
kilogram kg pound lb
gram g ounce oz
milligram mg
Power
kilowatt kW horsepower Hp
watt W Btu per hour Btu/hr
Btu per minute Btu/min
Pressure or stress (Force per area)
kilopascal kPa pound per square inch psi
inch of mercury inHg
pascal Pa inch of water inH2O
megapascal MPa pound per square inch psi
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INTRODUCTION
Typical applications Metric unit Imperial unit

Name Symbol Name Symbol
Temperature (other than Thermodynamic)

degrees Celsius °C degrees Fahrenheit °F
Time
hour h hour h
minute min minute min
second s second s
Torque (includes Bending moment, Moment of force, and Moment of a couple)
newton meter Nm pound foot lb ft
pound foot lb in
Velocity
kilometer per hour km/h mile per hour mph
meter per second m/s foot per second ft/s
millimeter per second mm/s inch per second in/s
meter per minute m/min foot per minute ft/min
Volume (includes Capacity)
cubic meter mm³ cubic yard yd³
cu yd
liter l cubic inch in³
liter l US gallon US gal
UK gallon UK gal
US quart US qt
UK quart UK qt
milliliter ml fluid ounce fl oz
Volume per time (includes Discharge and Flow rate)
cubic meter per m³/min cubic foot per minute ft³/min
minute
liter per minute l/min US gallon per minute US gal/min
milliliter per minute ml/min UK gallon per minute UK gal/min
Sound power level and Sound pressure level
decibel dB decibel dB
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INTRODUCTION
Capacities
Engine crank case
Specification: Case Akcela No. 1 15W-40, API CI-4/SL
Capacity:
With filter change 13.6 l (14.4 US qt)
Fuel tank
Specification: No. 2 diesel
Capacity: 159 l (42 US gal)
Cooling system
Specification: 50 % water and 50 % ethylene glycol
Capacity:
580N
Without heater 16.1 l (17.0 US qt)
With heater 16.8 l (17.8 US qt)
580SN, 580SN-WT, 590SN

Without heater 17.3 l (18.3 US qt)
With heater 18.0 l (19.0 US qt)
Hydraulic system
Specification: Case Akcela Hy-Tran® Ultra
Capacity:
580N
Total system 106.0 l (112.0 US qt)
Total system with Extendahoe 111.7 l (118.0 US qt)
Reservoir with filter change 47.1 l (12.45 US gal)
Reservoir without filter change 45.2 l (11.95 US gal)
580SN
Total system 119.2 l (126 US qt)
Total system with Extendahoe 124.9 l (132 US qt)
580SN-WT
Total system with Extendahoe 130.6 l (138.0 US qt)
590SN
Total system 132 l (139 US qt)
Total system with Extendahoe 137.7 l (145 US qt)
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INTRODUCTION
Transmission
Specification: Case Akcela Hy-Tran® Ultra
Capacity:
Manual (powershuttle)
Two wheel drive Four wheel drive
Total system 17.0 l (18 US qt) 19.4 l (21 US qt)
Refill (with or without filter change) 10.5 l (11 US qt) 13.0 l (14 US qt)
Powershift S-type
Two wheel drive Four wheel drive
Total system 21.7 l (23 US qt) 20.7 l (22 US qt)
Refill (with or without filter change) 15.3 l (16 US qt) 14.3 l (15 US qt)
Powershift H-type
Four wheel drive only
Refill (with or without filter change) 11.4 l (12 US qt)
Front drive axle - Two wheel drive

Specification: Case Akcela Transaxle SAE 80W140
Capacity:
Each hub 0.8 l (0.8 US qt)
Front drive axle - Four wheel drive

Specification: Case Akcela Transaxle SAE 80W140
Capacity:
580N, 580SN
Differential 7.7 l (8.1 US qt)
Each planetary hub 0.5 l (0.5 US qt)
580SN-WT, 590SN
Differential 8.6 l (9.1 US qt)
Each planetary hub 1.0 l (1.1 US qt)
Rear axle (differential)

Specification: Case Transaxle Akcela
Capacity:
580N, 580SN 13.6 l (14.4 US qt)
580SN-WT, 590SN 18.6 l (19.7 US qt)
Brake master cylinder

Brake fluid supplied by the transmission.
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INTRODUCTION
Consumables
Engine oil recommendations
AKCELA NO. 1 ENGINE OIL 15W-40 is recommended
for use in your machine's engine. The recommended
oil will lubricate your engine correctly under all operating
conditions. If the recommended oil is not available in a
multi-viscosity grade engine oil, it is okay to use a single
grade engine oil in the recommended oil brand.
If the recommended engine oil is not available in multi-

viscosity or single grade, only use oil meeting API engine
oil service category CH-4.
RCPH10TLB244ACL 1
Refer to the chart for recommended viscosity at ambient

air temperature ranges.
NOTE: Do not put Performance Additives or other oil ad-
ditive products in the engine crankcase. The oil intervals
given in the operators manual and service chart are ac-
cording to tests with CASE AKCELA lubricants.
RCPH10TLB022FAL 2
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 Unit of Comments Usage
measurement
12 Volt Ultra Violet
380002254 Black Light — —
Light
Glows Green in Black Engine Oil /
380002357 Dye-uniglow F2HF 10 ml (0.34 US fl oz)
Light Crankcase
Glows Yellow in Black
380002358 Dye-uniglow F4HF 65 ml (2.2 US fl oz) Hydraulic Oil
Light
Glows Purple in Black
380002359 Dye-uniglow 1750 10 ml (0.34 US fl oz) Transmission Oil
Light
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.
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INTRODUCTION
1. Prior to adding dye, connect the black light to the

machines battery and investigate suspected areas.
2. Once suspected leak areas are found, attempt to
trace the leak completely to the origin.
NOTE: At the origin, the leak should be the brightest
in color.
3. After confirmation of the suspected leak, thoroughly
clean the area of the leak to remove any existing flu-
ids. Recheck the area with the black light to assure
the area is clean. Good cleaning is important for the
following reasons:
• Fluids captured by threaded joints or other
cavities will continue to show signs of leakage
unless completely clean. RCPH10TLB245ACL 3
• Casting surfaces can hold residual oil.

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 71 °C
(160 °F), 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 sumps.
7. View traces of dyed fluid on the cloth under the black
light to ensure good samples.
8. Use these 3 samples as your baseline when inspect-
ing the unit with the black light.
NOTE: High hour engine oil can reduce the effec-
tiveness of the dye. In this event change the oil.
9. Avoid common errors.
• Fan airflow blowing leaking fluid.
• Gravity pulling leak paths down.
• When paint at a joint is not broken, the joint is
not leaking.
NOTE: It is not necessary to change oils after this
check.
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INTRODUCTION
Diesel fuel
Use No. 2 diesel fuel in the engine of this machine. The Specifications for acceptable No. 2 Diesel Fuel
use of other fuels can cause the loss of engine power and API gravity (minimum) 34
high fuel consumption.
Flash point (minimum) 60 °C (140 °F)
In very cold temperatures, a mixture of No. 1 and No. 2 * Cloud point (maximum) -20 °C (-4 °F)
diesel fuels is temporarily permitted. * Pour point (maximum) -26 °C (-15 °F)
Viscosity (at) 88 °C (190 °F)
NOTICE: See your fuel dealer for winter fuel requirements
Centistokes (2.0) to (4.3)
in your area. If the temperature of the fuel is below the
cloud point (wax appearance point), wax crystals in the Saybolt Seconds Universal (32) to (40)
fuel will cause the engine to lose power or not start. * Refer to the Notice on this page.
The diesel fuel used in this machine must meet the specifi-
cations in the chart or Specification D975-81 of the Amer-
ican Society for Testing and Materials.
Fuel Storage
If you keep fuel in storage for a period of time, you can get
foreign material or water in the fuel storage tank. Many
engine problems are caused by water in the fuel.
Keep the fuel storage tank outside and keep the fuel as
cool as possible. Remove water from the storage con-
tainer at regular periods of time.
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SERVICE MANUAL
HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS
580N
580SN WT
580SN
590SN
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Contents
HYDRAULIC, PNEUMATIC, ELECTRICAL,

ELECTRONIC SYSTEMS - A
PRIMARY HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.A

580N , 580SN WT , 580SN , 590SN
SECONDARY HYDRAULIC POWER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.12.A

580N , 580SN WT , 580SN , 590SN
ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A

580N , 580SN WT , 580SN , 590SN
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A

580N , 580SN WT , 580SN , 590SN
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PRIMARY HYDRAULIC POWER SYSTEM - 10.A
580N
580SN WT
580SN
590SN
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Contents
HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC

SYSTEMS - A
TECHNICAL DATA
PRIMARY HYDRAULIC POWER SYSTEM

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accumulator
General specification - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Special tools - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUNCTIONAL DATA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exploded view - Hydraulic gear pump, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exploded view Hydraulic Pump 580SN, 580SN WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exploded view - Hydraulic gear pump seal, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic schema Regulated manifold hydraulic schematic, Pilot Controls Only . . . . . . . . . . . . . . . . . . . 15
Exploded view - Regulated manifold, Pilot Controls only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exploded view 580N Pilot Machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exploded view 580SN, 580SN WT and 590SN machines with pilot controls . . . . . . . . . . . . . . . . . . . . . . . 18
Remote valve
Component diagram - Pilot control color codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drawing Remote Clam Valve for 580SN, 580SN WT and 590SN with Pilot Controlled Backhoe . . . . . . 20
Drawing 580N Mechanically Controlled Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drawing 580SN, 580SN WT and 590SN Mechanically Controlled Machines . . . . . . . . . . . . . . . . . . . . . . . 22
Relief valve
Drawing Swing and Bi-Dir Aux section, Backhoe Control Valves for 580N, 580SN, 580SN WT and 590SN
Pilot Controlled Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drawing Relief Valve, Loader Dump, Backhoe Swing on mechanically controlled Backhoes . . . . . . . . . 24
Drawing Relief Valve, 4000 psi Spike Clipper for Loader Valve on 580SN, 580SN WT and 590SN machines
with mechanical backhoe controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Drawing Single Stage Relief Valve, 580 Main Relief with mechanical backhoe controls . . . . . . . . . . . . . 26
Drawing Relief Valve, Main System Dual Stage for 580N with Pilot Controlled Backhoe . . . . . . . . . . . . . 27
Drawing Load Sense Relief Valve, 580N with Pilot Controlled Backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic pump
Sectional view Hydraulic Pump, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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Sectional view Hydraulic Pump, 580SN, 580SN WT and 590SN with Power Lift . . . . . . . . . . . . . . . . . . . 30
Drawing - Output Test Hose Connections, 580SN, 580SN WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . 31
Drawing Power Lift Valve 580SN, 580SN WT and 590SN machines with Mechanical Controls . . . . . . . 32
Drawing Power Lift Valve 580SN, 580SN WT and 590SN machines with Pilot Controlled Backhoe . . . 33
Filter
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Accumulator
Exploded view - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Detailed view - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Control valve
Drawing Backhoe Control Valve, 8 Spool, Extendahoe with Pilot Controls, 580SN, 580SN WT and 590SN
machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drawing Backhoe Control Valve, 8 Spool, Extendahoe with Pilot Controls, 580N machines . . . . . . . . . . 38
Drawing Loader Valve, 2 Spool for 580N with mechanical controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Drawing Loader Valve, 2 Spool for 580N with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Drawing Loader Valve, 3 Spool for 580N with mechanical backhoe controls . . . . . . . . . . . . . . . . . . . . . . . 41
Drawing Loader Valve, 3 Spool for 580N with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Drawing Loader valve, 3 Spool for 580SN, 580SN WT and 590SN with mechanical backhoe controls 43
Drawing Loader Valve, 3 Spool for 580SN, 580SN WT and 590SN with Pilot Controls . . . . . . . . . . . . . . 44
Drawing Backhoe Valve, 8 Spool foot swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Sectional view Stabilizer Section, 580N, 580SN, 580SN WT and 590SN machines with Pilot Controls 47
Sectional view Boom, Dipper, Bucket, Extendahoe Sections, 580N, 580SN, 580SN WT and 590SN ma-
chines with Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Exploded view - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Exploded view - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SERVICE

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassemble - Regulated manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assemble - Regulated manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Prepare - Machine Preparation, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Test Pressure Test, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Check - Flowmeter Check Sheet, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Prepare - Machine Preparation, 580N Mechanically Controlled machines . . . . . . . . . . . . . . . . . . . . . . . . . 76
Test Pressure Test, 580N Mechanically Controlled machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Check - Flowmeter Check Sheet, 580N Mechanically Controlled machines . . . . . . . . . . . . . . . . . . . . . . . 84
Prepare Machine Preparation, All 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . 87
Test Pressure Test, All 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Check Flowmeter Check Sheet, All 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . 100
Adjust Torque Control Adjustment, 580SN, 580SN WT and 590SN machines with Mechanical Controls
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Adjust Torque Control Adjustment, 580SN, 580SN WT and 590SN machines with Pilot Controls . . . . 107
Remote valve
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Remove - Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Install - Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Remove - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Install - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Remove - Clam control pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Install - Clam control pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Remove - Pilot controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Install - Pilot controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Remove - Mechanical controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Install - Mechanical controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Check - Pilot control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Relief valve
Adjust Main Relief Valve, 580N with mechanical controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Remove - Circuit relief valve, 580N, 580SN, 580SN WT and 590SN machines with Pilot Controls (Swing
and Bi-Directional relief valves only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Cleaning Relief Valve, Backhoe Main Relief Valve, 580N with Pilot Backhoe Controls . . . . . . . . . . . . . 142
Pressure test Loader and Backhoe Main Relief Valve for 580N mechanical machines only. Loader Main
Relief Valve for 580N machine with Pilot Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Pressure test - Load Sense Relief Valve for 580N Backhoe relief Pilot Controls only . . . . . . . . . . . . . . . 144
Adjust - 580N Backhoe relief Pilot Controls only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Adjust Dual Stage Relief Valve, 580N Pilot Controlled Backhoe Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Replace - Load Sense Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Hydraulic pump
Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Remove - 580SN, 580SN-WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Install - 580SN, 580SN-WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Disassemble - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Inspect - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Assemble - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Prepare Work Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Disassemble - Single Section Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Assemble - Single Section Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
580N, 580N NA, 580SN, 580SN WT, 590SN
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
580N, 580N NA, 580SN, 580SN WT, 590SN
Accumulator
Check - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Charging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Discharging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Disassemble - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Inspect - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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Pressure test Right Solenoid Valve for Ride Control (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Pressure test Checking the Nitrogen Charge in the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Charging - Charging the Accumulator With Dry Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Control valve
Cleaning 580N Pilot machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Cleaning - Swing, Bi-Dir Aux and Stabilizer sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Cleaning 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Disassemble - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Assemble - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Disassemble - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Inspect - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Assemble - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
DIAGNOSTIC

Testing - Problem in a loader circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Testing - Problem in the 4x1 Clam Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Testing 580N Machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Testing - Single function will not work independently from other functions . . . . . . . . . . . . . . . . . . . . . . . . 213
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Testing - Noise from the backhoe hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Testing - All pilot controls stop working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Testing - Pilot pattern change does not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Testing - Fault codes for pilot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Hydraulic pump
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Reservoir
Testing - Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Special tools
RCPH10TLB080AAM 1
DATAR
CAS10090 2
CAS-10090 Hand Pump
CAS10899 3
CAS-10899 Charging Kit
PRIMARY HYDRAULIC POWER SYSTEM - General specification

580N Single Gear Pump
Make and Model Parker P330 Single Section Gear Pump
Nominal Capacity of Hydraulic 115 l/min (30.5 US gpm)
Pump 580N @ 2200 RPM 108 l/min @ 231 bar ( 28.5 US gpm @ 3350 psi)
Steering Relief Pressure 162±10/-0 bar (2349.0±50 psi)
Pressure Settings
Main Relief Valve 231 bar (3350 psi) ± 3.5 bar (50 psi)
Accumulator for ride control 25 bar (362.5 psi) ± 1 bar (14.5 psi)
(Nitrogen charge)
Circuit relief valves (Hand pump setting only)
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580N Single Gear Pump

Backhoe bucket A (upper) port 296 bar (4293 psi) ± 3 bar (43.5 psi)
Backhoe bucket B (lower) port 283 bar (4105 psi) ± 3 bar (43.5 psi)
Swing A (upper) and B (lower) ports 207 bar (3000 psi) ± 3 bar (43.5 psi)
Loader bucket A (upper) and B 221 bar (3205 psi) ± 3 bar (43.5 psi)
(lower) ports
Boom A (upper) port with 221 bar (3205 psi) ± 3 bar (43.5 psi)
Mechanical Controls
Boom A (upper) port with Pilot 230 bar (3335 psi) ± 3 bar (43.5 psi)
Controls
Boom B (lower) port with Mechanical 340 bar (4930 psi) ± 3 bar (43.5 psi)
Controls
Boom B (lower) port with Pilot 360 bar (5220 psi) ± 3 bar (43.5 psi)
Controls
Dipper A (upper) port 283 bar (4103 psi) ± 3 bar (43.5 psi)
Dipper B (lower) port 250 bar (3625 psi) ± 3 bar (43.5 psi)
580SN Without Power Lift

Make and Model Bosch Rexroth Series 31 Variable Displacement Axial Piston Pump
Pump Controls Without Power Lift Option: High Pressure Cut-off (HPCO) control in pump
set to 238±3.5 bar (3450 ±50 psi)
Nominal Capacity @ 2200 RPM No Load: 156 l/min (41 US gpm)
Loader: 156 l/min @ 161 bar ( 41 US gpm @ 2335 psi)
103 l/min @ 238 bar ( 27 US gpm @ 3450 psi)
Backhoe: 156 l/min @ 214 bar ( 41 US gpm @ 3100 psi)
Pump Settings HPCO: 238±3.5 bar (3450±50 psi)
Steering relief pressure 162±10/-0 bar (2349.0±150-0 psi)
Standard Main Relief Pressure 238±3.5 bar (3450±50 psi)
Heavy Lift Main Relief Pressure 250±3.5 bar (3625.0±50 psi)
(lower) ports
Mechanical Controls
Controls
Controls
Controls
Swing Relief Pressure 207+7/3 bar (3001.5+100/-50 psi)at 53 l/min (14.0 US gpm)
580SN With Optional Power Lift

Make & Model Bosch Rexroth Series 31 Variable Displacement Axial Piston Pump
Pump Controls 1. LS Control with remote LS Relief Valve.
2. Primary remote LS relief in Power Lift valve for main relief pressure.
3. Secondary remote LS relief in Power Lift for "Power Lift" pressure
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580SN With Optional Power Lift

Power Lift capacity No load: 99.3 l/min (26.2 US gpm).
Max. Heavy lift capacity: 55 l/min (14.5 US gpm) 250 bar (3625.0 psi)@
1400 RPM.
(lower) ports
Mechanical Controls
Controls
Controls
Controls
580SN WT With Standard Power Lift

Power Lift capacity @ 1400 RPM No load: 99.3 l/min (26.2 US gpm).
Max. Power Lift capacity: 55 l/min (14.5 US gpm) 261 bar (3780 psi)@
1400 RPM.
(lower) ports
Mechanical Controls
Controls
Controls
Controls
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590SN With Standard Power Lift

Nominal capacity No Load: 162.6 l/min (43 US gpm)
Loader: 162.6 l/min @ 161 bar ( 43 US gpm @ 2335 psi)
107.8 l/min @ 238 bar ( 28.4 US gpm @ 3450 psi)
Backhoe: 162.6 l/min @ 214 bar ( 43 US gpm @ 3100 psi)
Power Lift capacity No load: 107 l/min (28.3 US gpm).
Max. Heavy lift capacity: 66 l/min (17.4 US gpm) 250 bar (3625.0 psi)@
1400 RPM.
(lower) ports
Mechanical Controls
Controls
Controls
Controls
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Accumulator - General specification - Ride control

Torque, accumulator charging valve cap 1.1 N·m (10 lb in)
Weight (approximate) 4.9 kg (10.8 lb)
Accumulator - Special tools - Ride control

Nitrogen charging kit with regulator 380001737
RCIL10TLB016BAF 1
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PRIMARY HYDRAULIC POWER SYSTEM - Exploded view
RCPH10TLB005GAM 1
1. Hoses swing control 5. Hydraulic filter 9. Left stabilizer hoses

2. Backhoe valve 6. Loader valve 10. Right stabilizer hoses
3. Left stabilizer load check valve 7. Pressure to backhoe valve 11. Right stabilizer load check valve
4. Return to filter 8. Swing cushion valve
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PRIMARY HYDRAULIC POWER SYSTEM - Exploded view -

Hydraulic gear pump, 580N only
RCPH10TLB007CAM 1
1. Input shaft 6. Quad ring 11. Front housing

2. Retaining ring 7. Pump gear 12. Vent
3. Shaft seal 8. Thrust plate (4) 13. Rear housing
4. Seal 9. Thrust plate seal 14. Cap screws
5. Bearing 10. Load sensing input
NOTE: Torque cap screws (14) to 339 N·m (250 lb ft).
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PRIMARY HYDRAULIC POWER SYSTEM - Exploded view Hydraulic

Pump 580SN, 580SN WT and 590SN
RCPH10TLB003HAM 1
1. Input shaft 6. Vent 11. Kidney plate

2. Retaining ring 7. Rear housing 12. Rotating group, housing
3. Dual shaft seal 8. Cap screws 13. On Stroke Piston Assembly
4. Bearing 9. Swash plate 14. Off Stroke Piston Assembly
5. Front Housing 10. Piston assembly
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Hydraulic gear pump seal, 580N only
RCPH10TLB005GAN 1
1.Input shaft 4. O-ring

2. Retaining ring 5. Seal
3. Seal retainer 6. Seal
NOTE: Seal (6) must be pressed flush with face of recess with lip toward gear as shown.
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PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema

Regulated manifold hydraulic schematic, Pilot Controls Only
RCPH10TLB056FAM 1
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. Extendahoe 11. Auxiliary hydraulics
6. Pattern control selection solenoids 12. Screen
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Regulated manifold, Pilot Controls only
RCIL10TLB001GAF 1
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. Pilot control on/off solenoid
5. 1.8 mm (0.071 in) orifice 10. Accumulator port
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PRIMARY HYDRAULIC POWER SYSTEM - Exploded view 580N

Pilot Machines only
RCPH10TLB006GAM 1
1. Cap for test port "M" (11/16-16 4. Control module 7. Load sense relief valve
ORFS)
2. Pilot manifold test port 5. Gas strut for Pilot Control Adjustment 8. Regulated LS Drain
3. Swing Dampening Valve 6. Regulated Manifold
NOTE: Connect a gauge capable of 344.8 bar (5000 psi) to "M" port (1) using adapter (PN 190119A1). Connect a
gauge capable of 69.0 bar (1000 psi) to the pilot manifold pressure test port (2).
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PRIMARY HYDRAULIC POWER SYSTEM - Exploded view 580SN,

580SN WT and 590SN machines with pilot controls
RCPH10TLB006GAM 1
1. Cap for test port "M" (11/16-16 4. Control module

ORFS)
2. Pilot manifold test port 5. Gas strut for Pilot Control Adjustment
3. Swing Dampening Valve 6. Regulated Manifold
NOTE: Connect a gauge capable of 344.8 bar (5000 psi) to "M" port (1) using adapter (PN 190119A1). Connect a
gauge capable of 69.0 bar (1000 psi) to the pilot manifold pressure test port (2).
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Remote valve - Component diagram - Pilot control color codes
RCPH10TBL001GAM 1
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Remote valve - Drawing Remote Clam Valve for 580SN, 580SN WT

and 590SN with Pilot Controlled Backhoe
RCPH10TLB040GAM 1
1. Pump pressure hose 4. Accumulator 7. Loader valve

2. Pressure hose to spool 5. Clam control block 8. Return to reservoir
3. Pressure to clam manifold 6. Pressure hose to spool
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Remote valve - Drawing 580N Mechanically Controlled Machines
RCPH10TLB039GAM 1
1. Return to reservoir 4. Clam control block 7. Pressure to clam manifold

2. Pressure hose to spool 5. Accumulator
3. Loader valve 6. Pressure hose to spool
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Remote valve - Drawing 580SN, 580SN WT and 590SN Mechanically

Controlled Machines
RCPH10TLB041GAM 1
1. Return to reservoir 4. Clam control block 7. Pressure to clam manifold

2. Pressure hose to spool 5. Accumulator
3. Loader valve 6. Pressure hose to spool
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Relief valve - Drawing Swing and Bi-Dir Aux section, Backhoe

Control Valves for 580N, 580SN, 580SN WT and 590SN Pilot
Controlled Machines.
RCPH10TLB042GAM 1
1. Circuit relief valve 4. Spool

2. Dampened compensator (Bi-Aux) 5. Centering spring
3. Solid compensator (Swing) 6. Check valve
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Relief valve - Drawing Relief Valve, Loader Dump, Backhoe Swing

on mechanically controlled Backhoes
RCPH10TLB006FAM 1
1. O-ring 4. Plunger 7. Cap

2. Poppet - Relief Valve 5. Back up Ring 8. Nut
3. Spring 6. Sleeve, Poppet
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Relief valve - Drawing Relief Valve, 4000 psi Spike Clipper for
Loader Valve on 580SN, 580SN WT and 590SN machines with
mechanical backhoe controls.
RCPH10TLB007FAM 1
1. O-ring 4. Back up Ring 7. Screw, Adjust

2. Poppet 5. Washer, Flat 8. Plug
3. Spring 6. Nut 9. Seal, Special
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Relief valve - Drawing Single Stage Relief Valve, 580 Main Relief
with mechanical backhoe controls
RCPH10TLB008FAM 1
1. O-ring 4. Piston 7. Screw, Adjust

2. Poppet 5. Back up Ring 8. Nut, Special
3. Spring 6. Plug
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Relief valve - Drawing Relief Valve, Main System Dual Stage for
580N with Pilot Controlled Backhoe
RCPH10TLB009FAM 1
1. O-ring 4. Piston 7. Screw, Adjust

2. Poppet 5. Back up Ring 8. Nut, Special
3. Spring 6. Plug 9. Special Fitting, ORFS
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Relief valve - Drawing Load Sense Relief Valve, 580N with Pilot
Controlled Backhoe
RCPH10TLB057FAM 1
1. O-ring 3. Spring 5. Adjustment screw

2. Poppet 4. Back up Ring 6. Jam Nut
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Hydraulic pump - Sectional view Hydraulic Pump, 580N only
RCPH10TLB011FAM 1
1. Inlet 3. CF Port 5. Priority Valve

2. EF Port 4. Load Sensing Port
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Hydraulic pump - Sectional view Hydraulic Pump, 580SN, 580SN

WT and 590SN with Power Lift
RCPH10TLB043GAM 1
1. Load Sense Spool 5. Inlet 8. Torque Control Variable Relief

2. Case Drain 1 6. Outlet 9. Case Drain 2
3. Load Sense Port (LS) 7. Gage Port 10. Torque Regulation Selection Solenoid
4. Torque Control Spool
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Hydraulic pump - Drawing - Output Test Hose Connections, 580SN,

580SN WT and 590SN
RCPH10TLB006GAM 1
1. Load sense hose 2. Return hose from loader valve 3. Pressure to backhoe valve
4. Attenuator hose to hydraulic pump 5. Back pressure check valve 6. To hydraulic filter
7. Attenuator hose 8. Test Adapter
NOTE: Connect flowmeter input hose to attenuator hose.

NOTE: Remove hydraulic tank filler cap and place flowmeter outlet hose (6) below oil level. Ensure hose is secured.
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Hydraulic pump - Drawing Power Lift Valve 580SN, 580SN WT and

590SN machines with Mechanical Controls
Power Lift Valve
RCPH10TLB063FAM 1
(1) Main relief valve (5) Return to tank

(2) Power Lift relief valve (6) Load sense gauge port
(3) Load sense port (Out to pump) (7) Power Lift solenoid
(4) Pressure Inlet (8) Orifice
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Hydraulic pump - Drawing Power Lift Valve 580SN, 580SN WT and

590SN machines with Pilot Controlled Backhoe
Power Lift Valve
RCPH10TLB012FAM 1
1. Low pressure relief valve 6. Filter screen

2. High pressure relief valve 7. Load sense gauge port
3. Load sense port (Out to pump) 8. Power lift solenoid
4.Load sense port (In) 9. Non adjustable LS drain (Pilot Controls Only)
5. Return to tank 10. Orifice
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Filter - Sectional view
RCPH10TLB004GAM 1
(1) Inlet (5) Filter

(2) To Reservoir (6) Filter Bypass Valve
(3) To Oil Cooler (7) Restriction Indicator
(4) From Ride Control Valve (8) Cooler Bypass Valve
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Accumulator - Exploded view - Ride control
RCPH10TLB015FAL 1
1. Tube 5. Quad ring 9. Guard

2. Gland with gas valve 6. O-ring 10. Gas valve assembly
3. Piston 7. Backup ring, if used 11. Gland without gas valve
4. Seal 8. Cap screw
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Accumulator - Detailed view - Ride control
RCIL10TLB005GAF 1
1. Tube 5. Quad ring 9. Guard

2. Gland with gas valve 6. O-ring 10. Gas valve assembly
3. Piston 7. Backup ring, if used 11. O-ring
4. Seal 8. Cap screw 12. Gland without gas valve
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Control valve - Drawing Backhoe Control Valve, 8 Spool,

Extendahoe with Pilot Controls, 580SN, 580SN WT and 590SN
machines
RCPH10TLB013GAM 1
1. Inlet 4. Left Stabilizer 7. Bucket

2. Swing 5. Right Stabilizer 8. Extendahoe
3. Boom 6. Dipper 9. Bi-Dir Aux
10 Outlet
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Control valve - Drawing Backhoe Control Valve, 8 Spool,

Extendahoe with Pilot Controls, 580N machines
RCPH11TLB004GAM 1
(1) Inlet (7) Bucket

(2) Swing (8) Extendahoe
(3) Boom (9) B-Dir Aux
(4) Left Stabilizer (10) Outlet
(5) Right Stabilizer (11) LS Relief
(6) Dipper (12) LS Drain
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Control valve - Drawing Loader Valve, 2 Spool for 580N with

mechanical controls
RCPH11TLB006FAM 1
(1) Power Beyond port (4) Gage Port

(2) Inlet port (5) Lift section
(3) Main Relief (6) Bucket section
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Control valve - Drawing Loader Valve, 2 Spool for 580N with pilot
controls
RCPH11TLB001FAL 1
(1) Power Beyond port (4) Lift section

(2) Inlet port (5) Bucket section
(3) Gage Port
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Control valve - Drawing Loader Valve, 3 Spool for 580N with

mechanical backhoe controls
RCPH11TLB007FAM 1
(1) Power Beyond port (5) Lift section

(3) Main Relief (7) Clam section
(4) LS Port (8) Outlet
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Control valve - Drawing Loader Valve, 3 Spool for 580N with pilot
controls
RCPH11TLB002FAL 1
(1) Power Beyond port (5) Bucket section

(2) Inlet port (6) Clam section
(3) LS Port (7) Outlet
(4) Lift section
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Control valve - Drawing Loader valve, 3 Spool for 580SN, 580SN WT

and 590SN with mechanical backhoe controls
RCPH11TLB005GAM 1

(2) Spike clipper (Internal component) (8) Clam section
(3) Priority spool (Internal component) (9) Power Beyond
(4) Steering pressure port (10) Outlet
(5) LS port (11) Main Relief Valve
(6) Lift section
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Control valve - Drawing Loader Valve, 3 Spool for 580SN, 580SN WT

and 590SN with Pilot Controls
RCPH11TLB003GAM 1
(1) Clam Section (6) Inlet Section

(2) Bucket Section (7) Steering Pressure Port
(3) Lift Section (8) Steering Load Sense Port (Bottom Face of
Inlet — Not Shown)
(4) Main LS Port (9) Tank
(5) Pressure Inlet
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Control valve - Drawing Backhoe Valve, 8 Spool foot swing
RCPH11TLB001HAM 1
(1) Inlet port (7) Stabilizer

(2) Outlet port (8) Stabilizer
(3) Auxiliary (9) Boom
(4) Extendahoe (10) Swing
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(5) Bucket (11) Boom low leak check

(6) Dipper (12) Bi-Aux lock solenoid
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Control valve - Sectional view Stabilizer Section, 580N, 580SN,

580SN WT and 590SN machines with Pilot Controls
RCPH10TLB062FAM 1
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Control valve - Sectional view Boom, Dipper, Bucket, Extendahoe

Sections, 580N, 580SN, 580SN WT and 590SN machines with Pilot
Controls
RCPH10TLB062FAM 1
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Control valve - Exploded view - Ride control solenoid valve
RCPH10TLB008CAM 1
(1) Ring Nut (3) Cartridge

(2) Coil (4) Control Block
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Control valve - Exploded view - Boom lock solenoid valve
RCPH10TLB002HAN 1
1. Relief valve body 5. Poppet 9. Piston 13. O-ring

2. Relief valve seat 6. O-ring 10. O-ring 14. Solenoid body
3. O-ring 7. Outer spring 11. Screw 15. Solenoid
4. Backup ring 8. Inner spring 12. Nut
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PRIMARY HYDRAULIC POWER SYSTEM - Cleaning

Special tools
CAS101162A, filter unit, portable.
RCPH10TLB306ABL 1
CAS10192, vacuum pump.
RCPH10TLB454ABL 2
CAS10508, fitting kit.
RCPH10TLB307ABL 3
General information
Contamination in the hydraulic system is a major cause of
the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil. Contamination
can enter the hydraulic system in several ways.
1. When you drain the oil or disconnect any line.
2. When you disassemble a component.
3. From normal wear of the hydraulic components.
4. From damaged or worn seals.
5. From a damaged component in the hydraulic system.
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All hydraulic systems operate with some contamination.

The design of the components in this hydraulic system per-
mits efficient operation with a small amount of contami-
nation. An increase in this amount of contamination can
cause problems in the hydraulic system. The following list
includes some of these problems.
1. Cylinder rod seals leak.
2. Control valve spools do not return to neutral.
3. Movement of control valve spools is difficult.
4. Hydraulic oil becomes too hot.
5. Pump gears, housing, and other parts wear rapidly.
6. Relief valves or check valves held open by dirt.
7. Quick failure of components that have been repaired.
8. Cycle times are slow; machine does not have
enough power.
If your machine has any of these problems, check the hy-
draulic oil for contamination. See types of contamination
below. If you find contamination, use the portable filter to
clean the hydraulic system.
Types of contamination
There are two types of contamination, microscopic and vis-
ible.
1. Microscopic contamination occurs when very fine
particles of foreign material are in suspension in the
hydraulic oil.
2. These particles are too small to see or feel. Micro-
scopic contamination can be found by identification
of the following problems or by testing in a laboratory.
Examples of the problems:
A. Cylinder rod seal leak.

B. Control valve spools do not return to neu-
tral.
C. The hydraulic system has a high operating
temperature.
3. Visible contamination is foreign material that can be
found by sight, touch, or odor. Visible contamination
can cause a sudden failure of components. Exam-
ples of visible contamination:
A. Particles of metal or dirt in the oil.

B. Air in the oil
C. The oil is dark and thick.
D. The oil has an odor of burned oil.
E. Water in the oil. See flushing water from
the hydraulic system, step 23.
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Cleaning the hydraulic system

1. Prepare the portable filter by doing the following
steps:
A. Remove all the hydraulic oil from the inlet
and outlet hoses for the portable filter.
B. Remove the filter element from the
portable filter.
C. Remove all hydraulic oil from the portable
filter.
D. Clean the inside of the housing for the filter
element.
2. You must know whether the contamination is micro-
scopic or visible. See types of contamination .
3. If the contamination is microscopic:
A. Check the maintenance schedule for the

machine to learn when the hydraulic oil
must be changed. If needed, change the
hydraulic oil.
B. Complete steps 6 through 35.
4. If the contamination is visible:
A. Change the hydraulic oil and hydraulic fil-

ter. Refer to the Operator's manual for
more details.
B. Complete steps 5 through 35.
5. Check the amount of contamination in the hydraulic
system by doing the following steps:
A. Disassemble one cylinder in two different

circuits. Check for damage to seals, scor-
ing of the cylinder wall, etc. Repair the
cylinders as necessary.
B. If, in your judgment, the damage to the
cylinders was caused by sever contamina-
tion and is not the result of normal wear, it
is necessary to remove, clean and repair
valves, pump, lines, cylinders, hydraulic
reservoir, etc. in the hydraulic system.
6. Remove the breather from the reservoir and connect
the vacuum pump to the opening. Start the vacuum
pump.
7. Loosen and remove the drain plug from the reservoir.
8. Using the fitting kit, install the valve in the hole for the
drain plug. Make sure that the valve is closed.
9. Stop the vacuum pump.
10. Connect the inlet hose for the portable filter to the
valve that is installed in the hole for the drain plug.
11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler cap.
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12. Install the outlet hose for the portable filter in the hy-
draulic reservoir filler neck.
13. Open the valve that is installed in the hole for the
drain plug.
14. Move the switch for the portable filter to the ON po-
sition. Start and run the engine at 1500 RPM.
15. Run the portable filter for 10 min.
16. Continue to run the portable filter. Increase the en-
gine speed to full throttle. Heat the oil to operating
temperature by doing the following steps:
Complete this procedure on variable pump machines
when the temperature is below 40 degrees F (4 de-
grees C) and the engine has been warmed up.
1. Leave the boom in the transport position
with the transport pin installed.
2. Activate the pilot control switch, if
equipped with pilot controls.
3. Raise the engine speed between 1600
and 1800 rpm.
4. Place and hold the boom control in the
down position.
5. Cycle the functions for approximately 30
seconds.
6. Release the controls for approximately 15
seconds.
7. Repeat steps until the desired oil temper-
ature of 120 degrees F (48 degrees C) is
reached.
17. Continue to run the engine at full throttle. Continue
to run the portable filter.
18. Operate each hydraulic circuit to completely extend
and retract the cylinders. Continue to operate each
hydraulic circuit two times, one after the other for 45
min.
19. Decrease the engine speed to low idle.
20. Continue to run the portable filter for 10 min.
21. Stop the portable filter.
22. Stop the engine.
23. Remove the hose from the hydraulic reservoir.
24. Close the valve that is installed in the hole for the
drain plug.
25. Disconnect the inlet hose for the portable filter from
the valve. Remove the outlet hose from the reservoir
filler neck and replace filler cap.
26. Connect a vacuum pump to the breather hose of the
hydraulic reservoir.
27. Start the vacuum pump.
28. Remove the valve from the hole for the drain plug.
29. Install the drain plug.
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30. Stop the vacuum pump. Disconnect the vacuum

pump from the opening in the reservoir and install
the breather.
31. Remove the hydraulic filter elements from the ma-
chine.
32. Install new hydraulic filter elements on the machine.
33. Start the engine. Check for oil leakage around the
new hydraulic filters.
35. Check the oil level in the hydraulic reservoir. Add oil
as required. See Section 1002 for specifications.
Flushing water from the hydraulic system

1. Start and run the engine at 1500 RPM.
2. Completely retract the cylinders of all attachments on
the machine. Swing the boom to the right, the right
cylinder will be fully retracted and the left will be fully
extended.
NOTE: If retracting the cylinder rods causes the attachments to be raised, block the attachments in place before
proceeding to the next step!
NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent
the attachment from falling.
3. Stop the engine.
4. Turn the key switch to the ON position.
5. Turn the Pilot Controls switch to the ON position.
6. Move each Pilot Control lever in each direction to
relieve pressure.
7. Loosen and remove the filler cap from the reservoir.
8. Drain the hydraulic oil from the reservoir.
A. See capacity specifications.

B. Have available acceptable equipment to
drain the hydraulic oil.
C. Remove the drain plug from the bottom of
the reservoir.
chine.
11. Install the drain plug in the bottom of the reservoir.
12. Fill the hydraulic reservoir with hydraulic fluid.
13. Disconnect the line from the open end and closed
end of each cylinder.
14. Be sure all control levers are in the neutral position.
15. Start and run the engine at low idle.
NOTICE: Check the oil level in the hydraulic reservoir frequently while doing step 16. Have another person hold a
container under the hydraulic lines while you do step 16.
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16. Slowly move each control lever in both directions un-

til oil begins to flow from the open line. Hold the con-
trol lever in place until clean oil flows from the open
line.
18. Connect the system line to the closed end of each
cylinder.
19. Connect a suitable drain line to the open end of each
cylinder and place the other end in an acceptable
container for contaminated oil.
20. Start the engine and run the engine at low idle.
21. Slowly and completely extend all cylinders. As the
piston rod comes in/out of the cylinder, oil will be
pushed out of the open end of the cylinders.
NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent
the attachment from falling.
22. Support any attachments that will be in the raised
position.
24. Disconnect the drain lines and connect the system
lines to the cylinders.
as required.
26. Install the filler cap on the reservoir.
chine.
29. Start and run the engine at 1500 RPM, operate each
hydraulic circuit to completely extend and retract the
cylinders.
30. Stop the engine and check for leaks. Check the oil
level in the hydraulic reservoir. Add oil as required.
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PRIMARY HYDRAULIC POWER SYSTEM - Disassemble - Regulated

manifold
1. Remove the pressure reducing valve.
RCPH10TLB371ABL 1
2. Remove the check valve and orifice.
RCPH10TLB443ABL 2
3. Remove the accumulator.
RCPH10TLB372ABL 3
4. Remove the nut and solenoid for the cutoff valve.
RCPH10TLB373ABL 4
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5. Loosen and remove the cutoff valve.
RCPH10TLB374ABL 5
6. Remove the nut and solenoid for the pattern control

selection valves.
RCPH10TLB376ABL 6
7. Loosen and remove the pattern control selection

valves.
RCPH10TLB378ABL 7
8. Remove the stabilizer solenoid mounting screws.
RCPH10TLB381ABL 8
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9. Remove the stabilizer solenoids.
RCPH10TLB382ABL 9
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PRIMARY HYDRAULIC POWER SYSTEM - Assemble - Regulated

manifold
1. Replace all O-rings and backup rings.
2. Lubricate all O-rings with hydraulic oil before in-
stalling.
RCPH10TLB383ABL 1
3. Install the stabilizer solenoids into the manifold.
RCPH10TLB382ABL 2
4. Install and torque the stabilizer mounting screws to

20 N·m (15 lb ft).
RCPH10TLB384ABL 3
5. Install the pattern control selection valves into the

manifold.
RCPH10TLB380ABL 4
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6. Torque the pattern control selection valves to 20 N·m

(15 lb ft).
RCPH10TLB385ABL 5
7. Install the solenoids on the pattern control selection

valves.
NOTE: Make sure the connectors are towards the bottom
of the manifold.
RCPH10TLB386ABL 6
8. Torque the pattern control selection solenoids to 1.7

- 2.2 N·m (15 - 19 lb in).
NOTICE: Overtorquing will cause the solenoid to bind and
stick.
RCPH10TLB387ABL 7
9. Install the orifice (1) into the manifold.

10. Install the O-ring (2) onto the check valve (3).
RCPH10TLB443ABL 8
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11. Install the check valve into the manifold with the small
holes facing away from the pressure reducing valve.
RCPH10TLB444ABL 9
12. Install the pressure reducing valve into the manifold.

13. Torque the pressure reducing valve to 20 N·m (15 lb
ft).
RCPH10TLB388ABL 10
14. Install the cutoff valve into the manifold.
RCPH10TLB375ABL 11
15. Torque the cutoff valve to 20 N·m (15 lb ft).
RCPH10TLB389ABL 12
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16. Torque the cutoff valve solenoid to 1.7 - 2.2 N·m (15
- 19 lb in).
NOTICE: Overtorquing will cause the solenoid to bind and
stick.
RCPH10TLB390ABL 13
17. Install and tighten the accumulator into the manifold.

Maximum applied torque 45 N·m (32 lb ft).
RCPH10TLB391ABL 14
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PRIMARY HYDRAULIC POWER SYSTEM - Prepare - Machine

Preparation, 580N Pilot machines
RCPH10TLB059FAM 1
Legend
(1) Pump (5) Tee Connector 84238739
(2) Loader Valve (6) Tube Assembly, Pump to Valve
(3) EF Pressure Port (7) Connector 3/8 ORFS-ORB 3/8
(4) Flow Meter Connection
NOTE: New ORFS flowmeter hoses will be required with this procedure.
NOTE: Remove hydraulic tank filler cap and place the flowmeter outlet hose (6) below oil level, SECURE HOSE.
NOTE: Make copies of the Flowmeter Check Sheet in rear of this section and use it to record the readings.
1. Park the machine on a level surface. Put the back-
hoe in the transport position. Lower the loader
bucket to the floor.
2. Stop the engine. Turn the key switch and the pilot
control switch to the ON position.
3. Operate the pilot controls and loader controls to re-
lieve any pressure in the system.
4. Connect a gauge capable of 69 bar (1000 psi) to the
pilot pressure test port.
5. Use an 11/16 - 16 ORFS fitting to connect a gauge
capable of measuring 345 bar (5000 psi) to the "M"
port on the backhoe valve. Use ORFS fitting part
number 190119A1.
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6. Remove pressure testing adapter from the pump EF

port (2), connect flowmeter input hose (3) to the fit-
ting.
7. Remove the screen from the reservoir and secure the
flowmeter return hose (6) below the oil level.
8. The oil must be at operating temperature. To heat
the oil:
A. With engine running at full throttle, close
the relief valve on the flowmeter to a least
103 bar (1500 psi).
B. Hold the loader control lever in the ROLL-
BACK position of 15 seconds.
C. Put the loader control lever in the NEU-
TRAL position for 15 seconds.
D. Repeat steps (B) and (C) until the temper-
ature of the oil is 52 °C (125 °F) or the side
of the reservoir is very warm.
Next operation:
PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, 580N Pilot machines (A.10.A).
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PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, 580N

Pilot machines
See PRIMARY HYDRAULIC POWER SYSTEM - Check - Flowmeter Check Sheet, 580N Pilot machines (A.10.A)
for form to record test results.
Prior operation:
PRIMARY HYDRAULIC POWER SYSTEM - Prepare - Machine Preparation, 580N Pilot machines (A.10.A).
Pilot Manifold Pressure Test
Test 1A
1. Run engine at high idle. Do not activate any backhoe
controls.
2. Monitor flowmeter. Record flow regulator pressure
on Flowmeter Check Sheet.
Test 1B
1. Enable backhoe pilot system switch.
2. Place any backhoe function on demand.
3. Monitor flowmeter. Record pilot pressure on
Flowmeter Check Sheet.
NOTE: A pressure reading of 24 - 34.5 bar (348.0 - 500.3 psi) is expected. If pressure is not to specification, replace
pressure reducing valve.
Backhoe Relief
4. Run engine at high idle. Retract Extendahoe if
equipped or hold Boom in raised position over relief.
5. Slowly open flowmeter load valve until pressure
reads zero.
Test 2A
1. Slowly close flowmeter load valve.
2. Monitor flowmeter. Record pressure when flow drops
by several l/min (gpm). Record results on Flowmeter
Check Sheet.
Test 2B
1. Continue to close load valve on flowmeter.
2. Monitor flowmeter. When flow reaches 0 l/min (gpm),
a pressure reading of 227 - 235 bar (3292 - 3408 psi)
is expected. Record results on Flowmeter Check
Sheet.
NOTE: If pressure is not in specification, adjust main relief valve. If readings from test 2A are not within 10 percent
of 2B reading, replace relief valve.
Pump Efficiency Test
Test 3A
3. Hold loader on demand and open the load valve. Ad-
just engine speed to 2000 RPM.
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4. Monitor flowmeter. Record results on Flowmeter

Check Sheet.
Test 3B
1. Continue to run engine at 2000 RPM. Slowly close
load valve until pressure is 138 bar (2001.0 psi).
Check Sheet.
3. Divide the flow reading at 138 bar (2001.0 psi) by
recorded flow reading at 0.0 bar (0 psi).
NOTE: Pump efficiency is calculated by multiplying result by 100. If pump efficiency is greater than 70 percent, pump
is good. Continue to next test. If pump efficiency is less than 70 percent, repair or replace pump before continuing to
next test.
4. Run engine at 2000 RPM. Increase pressure on
flowmeter to 138 bar (2001.0 psi).
Loader Control Valve Leak Test

flowmeter to 138 bar (2000 psi).
Test 4A
1. Raise loader. Hold loader in raised position.
2. Monitor flowmeter. Record l/min (gpm) on Flowmeter
Check Sheet.
Test 4B
1. Lower loader. Hold loader in lower position.
2. Monitor flowmeter. Record l/min (gpm) results on
Test 4C
1. Position loader approximately 45.7 cm (18 in) above
ground level. Hold bucket in rollback position.
Test 4D
1. Hold bucket in dump position.
Test 4E
1. Hold clam in open position.
Test 4F
1. Close clam and hold in closed position.
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NOTE: Compare test results from Test 3B and Tests 4A thru 4F. If results vary more than 3.8 l/min (1 US gpm), a
problem in circuit exists.
NOTE: If equipped with uni-directional valve, ensure valve is off.
Backhoe Control Valve Leak Test
Test 5A
1. Position backhoe to left side.
Test 5B
1. Position backhoe to right side.
Test 5C
1. If equipped with extend-a-hoe option, position out-
ward and hold in position.
Test 5D
1. If equipped with extend-a-hoe option, retract and
hold in position.
Test 5E
1. Raise left stabilizer. Hold in position.
Test 5F
3. Raise right stabilizer. Hold in position.
Test 5G
NOTE: When lowering stabilizers, lower evenly to full stroke, then raise.
1. Lower left stabilizer. Hold in position.
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Test 5H
1. Lower right stabilizer. Hold in position.
Test 5I
1. Roll backhoe bucket to dump position. Hold in posi-
tion.
Test 5J
1. Roll backhoe bucket to dig position. Hold in position.
Test 5K
1. Position dipper in full extended position. Hold in po-
sition.
Test 5L
1. Position dipper in full position. Hold in position.
Test 5M
1. Position boom in lower position. Hold in position.
Test 5N
1. Position boom in raised position. Hold in position.
Test 5O
1. If equipped with bi-directional auxiliary hydraulic, set
selector switch to Bi-Aux. Unhook the quick discon-
nect couplers or cap lines. Hold button in out posi-
tion.
Test 5P
1. Reverse direction on bi-directional valve.
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NOTE: Compare test results from Test 3B and Tests 5A thru 5P. If results vary more than 3.8 l/min (1 US gpm), a
Steering and Bucket Coupler Valve Flow Test

3. Install a "T" fitting a "CF" port on pump, see Hy-
draulic pump - Sectional view (A.10.A) for more
details. Connect flowmeter to "T" fitting.
Test 6A
1. Run engine at high idle. Close load valve on flowme-
ter.
2. Record bar (psi) results on Flowmeter Check Sheet.
Test 6B
1. Turn steering wheel to full right. Hold against stop.
2. Open flowmeter load valve to 69.0 bar (1000 psi).
3. With steering wheel held against stop, slowly close
load valve.
4. Monitor flowmeter. When flow begins to decrease
by several l/min (gpm), record bar (psi) results on
Test 6C
1. Continue to slowly close load valve.
2. Monitor flowmeter. When flow reaches 0.0 l/min
(0 US gpm), record bar (psi) results on Flowmeter
Check Sheet.
NOTE: A pressure reading of 162 - 172 bar (2349 - 2494 psi) is expected.
Test 6D
1. Open flowmeter load valve to fully open position.
2. If equipped with front or rear hydraulic coupler, en-
gage. Slowly close flowmeter load valve.
Test 6E
1. Continue to slowly close flowmeter load valve.
Check Sheet.
NOTE: A pressure reading of 162 - 193 bar (2349 - 2800 psi) is expected. If pressure is not to specification, adjust
quick coupler relief valve.
Steering and Bucket Lock Valve Leak Test

3. Turn steering wheel to full left. Hold against stop.
4. Close flowmeter load valve to 124.1 bar (1800 psi).
Adjust engine speed to 2000 RPM.
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Test 7A
Test 7B
3. Extend backhoe bucket fully to dump position. Place
loader and backhoe bucket on ground.
Test 7C
1. Retract loader lock pins.
Test 7D
1. Extend loader lock pins.
2. Record l/min (gpm) results on Flowmeter Check
Sheet.
Test 7E
1. Retract backhoe bucket lock pins.
Test 7F
1. Extend backhoe bucket lock pins.
NOTE: If flow readings of tests vary more than 3.8 l/min (1 US gpm), a problem in that circuit exists.
3. Open flowmeter valve. Stop engine. Inspect for re-
pairs and repair as necessary. Retest circuit.
4. Remove all test equipment. Connect all hydraulic
systems. Ensure hydraulic fluid level is to specifica-
tion. Add fluid as required.
Backhoe Valve Flow Regulator Test

5. Connect a gauge ( 69.0 bar (1000 psi) minimum) to
the M port on the Backhoe Control valve. Install test
point in the LS port on the Backhoe Valve.
6. Connect a gauge ( 69.0 bar (1000 psi) minimum) to
lead sense test port. Install a shut-off valve in hose.
7. Set engine speed to 1950 RPM. Do not activate any
controls.
Test 8A
1. Monitor M port pressure gauge. Record pressure on
Flowmeter Check List.
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Test 8B
1. Monitor load sense port pressure gauge. Record
pressure on Flowmeter Check List.
NOTE: Subtract Test 8B result from 8A result. Difference is backhoe flow regulating setting. Record result on Flowme-
ter Check List.
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PRIMARY HYDRAULIC POWER SYSTEM - Check - Flowmeter Check

Sheet, 580N Pilot machines
Provide the following information:
Owner:_______________ Model:_______________ Serial No.:_______________
Date:_______________ Hours:_______________
NOTE: Prior to testing, machine must be prepped and establish a minimum oil temperature of 51 °C (123.8 °F). See
PRIMARY HYDRAULIC POWER SYSTEM - Prepare - Machine Preparation, 580N Pilot machines (A.10.A) for
procedure.
Test 1- Pilot Manifold Pressure
Test 1A - flow regulator pressure __________bar __________psi
Test 1B - pilot pressure __________bar __________psi
Notes:
Test 2- Backhoe Relief
Test 2A - Relief opens @: __________bar __________psi
Test 2B __________bar __________psi
Notes:
Test 3- Pump Efficiency
Test 3A flow reading __________l/min __________gpm @ minimum
Test 3B flow reading __________l/min __________gpm @ 2000 psi
Test 3B divided by Test 3A = Flow resultant __________l/min __________gpm
Flow resultant multiplied by 100 = Pump efficiency __________%

Pump efficiency is calculated by multiplying result by 100. If pump efficiency is greater than 70 percent, pump is
good. If pump efficiency is less than 70 percent, repair or replace pump.
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Test 4- Loader Control Valve Leakage
Test 4A - Loader Raised __________l/min __________gpm
Test 4B - Loader Lowered __________l/min __________gpm
Test 4C - Bucket Rollback __________l/min __________gpm
Test 4D - Bucket Dump __________l/min __________gpm
Test 4E - Clam Open __________l/min __________gpm
Test 4F - Clam Closed __________l/min __________gpm
Notes:
Test 5- Backhoe Control Valve Leakage @ 2000 RPM
Test 5A - Swing Left __________l/min __________gpm
Test 5B - Swing Right __________l/min __________gpm
Test 5C - Extend-a-hoe extended __________l/min __________gpm
Test 5D - Extend-a-hoe retracted __________l/min __________gpm
Test 5E - Left stabilizer raised __________l/min __________gpm
Test 5F - Right stabilizer raised __________l/min __________gpm
Test 5G - Left stabilizer lowered __________l/min __________gpm
Test 5H - Right stabilizer lowered __________l/min __________gpm
Test 5I - Bucket in dump position __________l/min __________gpm
Test 5J - Bucket in curl position __________l/min __________gpm
Test 5K - Dipper extended __________l/min __________gpm
Test 5L - Dipper retracted __________l/min __________gpm
Test 5M - Boom lowered __________l/min __________gpm
Test 5N - Boom raised __________l/min __________gpm
Test 5O - Bi-directional auxillary forward __________l/min __________gpm
Test 5P - Bi-directional auxillary reversed __________l/min __________gpm
Notes:
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Test 6- Steering and Bucket Lock Valve Flow
Test 6A - Steering standby __________bar __________psi
Test 6B - Steering relief - Begins to open @ __________bar __________psi
Test 6C - Steering relief - Fully open @ __________bar __________psi
Test 6D - Coupler relief - Begins to open @ __________bar __________psi
Test 6E - Coupler relief - Fully open @ __________bar __________psi
Notes:
Test 7- Steering and Bucket Lock Valve Flow @ High Idle
Test 7A - Steering right __________l/min __________gpm
Test 7B - Steering left __________l/min __________gpm
Test 7C - Loader bucket retract __________l/min __________gpm
Test 7D - Loader bucket extend __________l/min __________gpm
Test 7E - Backhoe bucket retract __________l/min __________gpm
Test 7F - Backhoe bucket extend __________l/min __________gpm
Notes:
Test 8- Backhoe Valve Flow Regulator
Test 8A - __________bar __________psi
Test 8B - __________bar __________psi
Test 8A minus Test 8B = Valve flow regulator setting __________bar __________psi
Notes:
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PRIMARY HYDRAULIC POWER SYSTEM - Prepare - Machine

Preparation, 580N Mechanically Controlled machines
RCPH10TLB059FAM 1
Legend
(1) Pump (5) Tee Connector 84238739
(2) Loader Valve (6) Tube Assembly, Pump to Valve
(3) EF Pressure Port (7) Connector 3/8 ORFS-ORB 3/8
(4) Flow Meter Connection
NOTE: New ORFS flowmeter hoses will be required with this procedure.
NOTE: Remove hydraulic tank filler cap and place the flowmeter outlet hose (6) below oil level, SECURE HOSE.
NOTE: Make copies of the Flowmeter Check Sheet in rear of this section and use it to record the readings.
2. Stop the engine. Turn the key switch and the pilot
control switch to the ON position.
3. Operate the pilot controls and loader controls to re-
lieve any pressure in the system.
pilot pressure test port.
5. Use an 11/16 - 16 ORFS fitting to connect a gauge
capable of measuring 345 bar (5000 psi) to the "M"
port on the backhoe valve. Use ORFS fitting part
number 190119A1.
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6. Remove pressure testing adapter from the pump EF

port (2), connect flowmeter input hose (3) to the fit-
ting.
7. Remove the screen from the reservoir and secure the
flowmeter return hose (6) below the oil level.
the oil:
A. With engine running at full throttle, close
the relief valve on the flowmeter to a least
103 bar (1500 psi).
B. Hold the loader control lever in the ROLL-
BACK position of 15 seconds.
C. Put the loader control lever in the NEU-
D. Repeat steps (B) and (C) until the temper-
ature of the oil is 52 °C (125 °F) or the side
Next operation:
PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, 580N Mechanically Controlled machines
(A.10.A).
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PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, 580N

Mechanically Controlled machines
See PRIMARY HYDRAULIC POWER SYSTEM - Check - Flowmeter Check Sheet, 580N Mechanically Controlled
machines (A.10.A) for form to record test results.
Prior operation:
PRIMARY HYDRAULIC POWER SYSTEM - Prepare - Machine Preparation, 580N Mechanically Controlled ma-
chines (A.10.A).
Backhoe Relief
1. Run engine at high idle. Retract Extendahoe if
equipped or hold Boom in raised position over relief.
reads zero.
Test 1A
Check Sheet.
Test 1B
2. Monitor flowmeter. When flow reaches 0 l/min (gpm),
a pressure reading of 227 - 235 bar (3292 - 3408 psi)
is expected. Record results on Flowmeter Check
Sheet.
Pump Efficiency Test
Test 2A
Check Sheet.
Test 2B
load valve until pressure is 138 bar (2000 psi).
Check Sheet.
3. Divide the flow reading at 138 bar (2000 psi) by
recorded flow reading at 0.0 bar (0 psi).
next test.
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Loader Control Valve Leak Test
Test 3A
Check Sheet.
Test 3B
Test 3C
Test 3D
Test 3E
Test 3F
Backhoe Control Valve Leak Test
Test 4A
Test 4B
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Test 4C
Test 4D
hold in position.
Test 4E
Test 4F
Test 4G
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Test 4H
Test 4I
tion.
Test 4J
Test 4K
sition.
Test 4L
Test 4M
Test 4N
Test 4O
1. If equipped with bi-directional auxiliary hydraulics,
set the selector switch to Bi-Aux. Unhook the quick
disconnect couplers or cap lines. Hold button in the
out position.
Test 4P
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Steering and Bucket Coupler Valve Flow Test

3. Install a "T" fitting a "CF" port on pump, see Hy-
draulic pump - Sectional view (A.10.A) for more
details. Connect flowmeter to "T" fitting.
Test 5A
ter.
Test 5B
load valve.
Test 5C
Check Sheet.
Test 5D
Test 5E
Check Sheet.
Steering and Bucket Coupler Valve Leak Test

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Test 6A
Test 6B
Test 6C
Test 6D
Sheet.
Test 6E
Test 6F
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PRIMARY HYDRAULIC POWER SYSTEM - Check - Flowmeter Check

Sheet, 580N Mechanically Controlled machines
Date:_______________ Hours:_______________
NOTE: Prior to testing, machine must be prepped and establish a minimum oil temperature of 51 °C (123.8 °F).
See PRIMARY HYDRAULIC POWER SYSTEM - Prepare - Machine Preparation, 580N Mechanically Controlled
machines (A.10.A) for procedure.
Test 1B __________bar __________psi
Notes:

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Notes:
Notes:
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Notes:
Notes:
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PRIMARY HYDRAULIC POWER SYSTEM - Prepare Machine

Preparation, All 580SN, 580SN WT and 590SN machines
RCPH10TLB058FAM 1
Legend
(1) Pump (4) Tee Connector
(2) To System (5) Pressure Port
(3) Attenuator Hose (6) Flowmeter Hose
NOTICE: If the machine is equipped with pilot controls, the pure closed center plug kit must be installed in the back-
hoe valve inlet before running the following tests. THIS IS ONLY TRUE FOR SUPER N MACHINES. INSTALLING
A CLOSED CENTER PLUG IN A 580N COULD RESULT IN PUMP DAMAGE. The kit should be removed from the
machine after these tests, and the original components which provide the constant flow closed center feature, re-in-
stalled. The pure closed center plug kit is part number 87447426. The kit will include a new “spool,” a new o-ring,
and a different cap. All of these components must be installed together for proper operation. If the new spool is used
with the cap that came with the machine, improper operation will result.
1. Park machine on level, firm surface. Position back-
hoe in transport position. Lower bucket to ground.
2. Stop engine. Turn ignition switch and pilot control
switch ON. Operate pilot and loader controls to re-
lieve pressure in system.
3. Connect pressure gauge ( 69 bar (1000 psi) mini-
mum) to pilot pressure test port.
Machines with Mechanical Controls

4. Remove diagnostic couple fitting and install a tee fit-
ting. From attenuator hose, attach flowmeter input
to the end of attenuator hose. It may make access
easier if the attenuator hose is unclamped.
5. Remove screen from reservoir. Secure flowmeter
return hose below oil level.
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ting. From attenuator hose, attach flowmeter input to
the end of attenuator hose.
Machines with Mechanical Controls

ting. From attenuator hose, attach flowmeter input
to the end of attenuator hose. It may make access
easier if the attenuator hose is unclamped.
ting. From attenuator hose, attach flowmeter input to
the end of attenuator hose.
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PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, All

580SN, 580SN WT and 590SN machines
See PRIMARY HYDRAULIC POWER SYSTEM - Check Flowmeter Check Sheet, All 580SN, 580SN WT and
590SN machines (A.10.A) for form to record test results.
Prior operation:
PRIMARY HYDRAULIC POWER SYSTEM - Prepare Machine Preparation, All 580SN, 580SN WT and 590SN
machines (A.10.A).
Pilot Manifold Pressure Test - Pilot controlled machines only
Test 1A
1. Enable backhoe pilot system switch.
2. Place any backhoe function on demand.
3. Monitor flowmeter. Record pilot pressure on
NOTE: A pressure reading of 24 - 34.5 bar (348.0 - 500.3 psi) is expected. If pressure is not to specification, replace
pressure reducing valve.
Backhoe Relief - Machines without PowerLift

1. Run engine at high idle. Hold Extendahoe on retract
if equipped or hold Boom in raised position over re-
lief.
reads zero.
Test 2A
Check Sheet.
Test 2B
2. Monitor flowmeter. When flow reaches zero, a pres-
sure reading of 234 - 242 bar (3400 - 3500 psi) is ex-
pected. Record results on Flowmeter Check Sheet.
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RCPH11TLB002GAM 1
(1) Normal Relief (2) Power Lift Relief
Test 2C
Machines With Power Lift

1. Turn the seat toward the rear (Backhoe).
3. Monitor flowmeter. When flow reaches zero, a pres-
sure reading of 234 - 242 bar (3400 - 3500 psi) is ex-
pected. Record results on Flowmeter Check Sheet.
NOTE: If pressure is not in specification, adjust normal relief valve on Power Lift control valve.
4. Activate Power Lift.
580SN and 590 machines

1. Monitor flowmeter. When flow reaches zero , a pres-
sure reading of 246 - 253 bar (3575 - 3675 psi) is
expected.
Record results on Flowmeter Check Sheet.
NOTE: If pressure is not in specification, adjust Power Lift relief valve.
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580SN WT machines
1. Monitor flowmeter. When flow reaches zero , a pres-
sure reading of 257 - 264 bar (3730 - 3830 psi) is
expected.
Record results on Flowmeter Check Sheet.
NOTE: If pressure is not in specification, adjust Power Lift relief valve on the Power Lift control valve.
Pump Efficiency Test - All

1. Remove the torque control supply tube (1) and cap
574342 the torque control supply tube ports (2) and
(3) on pump.
NOTE: All Super N machines are equipped with a torque regulation feature to control engine loading from the hydraulic
systems. To properly test the variable displacement pump, this feature needs to be disabled. This feature can be
disabled without changing any settings by simply removing torque control supply tube and cap both of the open ports.
RCPH11TLB001GAM 2
Test 3A
Check Sheet.
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Test 3B
load valve until pressure is 138 bar (2000 psi).
Check Sheet.
3. Divide the flow reading at 138 bar (2000 psi) by
recorded flow reading at 0 bar (0 psi).
next test.
Loader Control Valve Leak Test - All
Test 4A
Check Sheet.
Test 4B
Test 4C
Test 4D
Test 4E
Test 4F
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Backhoe Control Valve Leak Test - All
Test 5A
Test 5B
Test 5C
Test 5D
hold in position.
Test 5E
Test 5F
Test 5G
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Test 5H
Test 5I
tion.
Test 5J
Test 5K
sition.
Test 5L
Test 5M
Test 5N
Test 5O
1. If equipped with bi-directional auxiliary hydraulic, un-
hook quick disconnect couplers or cap lines. Hold
button in out position.
Test 5P
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Steering and Bucket Coupler Valve Flow Test - All

3. Install a "T" fitting a "D" port on pump, see Hydraulic
pump - Sectional view (A.10.A) for more details.
Connect flowmeter to "T" fitting.
Test 6A
ter.
Test 6B
load valve.
Test 6C
Check Sheet.
Test 6D
Test 6E
Check Sheet.
Steering and Bucket Coupler Valve Leak Test - All

Test 7A
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Test 7B
Test 7C
Test 7D
Sheet.
Test 7E
Test 7F
NOTE: For Pilot Controlled machines, replace the closed center plug in the backhoe valve with the standard flushing
valve components removed earlier.
Low Pressure Standby Regulator- Single gauge method

All 580SN, 580SN-WT and 590SN with Power Lift.
1. Warm the machine to 50 °C (120 °F). To warm the
engine:
• Machines with mechanical controls, me-
ter the stabilizer functions to maximum en-
gine load.
• Pilot Controlled machines, stall the boom
down function or stall a single function
while moving a secong function.
2. After the oil has reached 50 °C (120 °F), stop the
engine.
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3. Connect a gauge capable of 500 psi to the end of

the attenuator hose.
4. Remove the hose from the end of the load sense
compensator at the back of the pump and plug the
open hose end. Leave the port on the pump com-
pensator open.
5. Place a bucket under the open load sense compen-
sator port or connect a hose to the open port and run
into the fill neck of the hydraulic reservoir.
6. Start the machine and stall a single function.
7. The pressure displayed on the gauge at the attenu-
ator hose is the pump margin pressure. Acceptable
pump margin is 19 - 21 bar (275 - 305 psi).
8. Reconnect the LS hose to the LS port on the pump
compensator.
Low Pressure Standby Regulator - Two gauge method

All 580SN, 580SN-WT and 590SN with mechanical con-
trols and Power Lift.
1. Connect a gauge capable of 500 psi to the end of
the attenuator hose and a second 500 psi gauge to
the diagnostic port on the Power Lift valve.
engine:
gine load.
while moving a secong function.
3. Stall the stabilizer function and record the pressure
on both gauges.
4. To find the pump margin, subtract the load sense
pressure from the attenuator hose pressure.
Low Pressure Standby Regulator - Two gauge method

All 580SN, 580SN-WT and 590SN with Pilot controls and
Power Lift.
1. Connect a gauge capable of 500 psi to the end of the
attenuator hose and a second 500 psi gauge to the
load sense diagnostic port on the Power Lift valve.
engine:
gine load.
while moving a second function.
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3. Set the engine to 2000 RPM. Do not operate any

functions. Record the pressures at the attenuator
hose gauge and the load sense gauge at Power Lift
valve.
4. To find the pump margin, subtract the load sense
pressure from the attenuator hose pressure.
Pump Margin Adjustment

5. If the load sense margin is not within specifications,
the setting can be adjusted by loosening the lock nut
at the top of the load sense (1)compensator and ad-
justing the set screw. Tightening the set screw in-
creases the margin and loosening the set screw de-
creases the pump margin.
RCPH11TLB001GAM 3
(1) Load Sense - Margin Control

(2) Torque Control Screw
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High Pressure Cutoff

(HPCO) - 580SN Mechanical without Power Lift
1. Connect a pressure gauge capable of 500 psi to the
end of the attenuator hose.
2. Warm the engine to 50 °C (120 °F). To warn the en-
gine, set the throttle to full speed and meter the sta-
bilizer control to maximum engine load.
3. Stall the stabilizer, extendahoe or loader lift and
record the pressure on the gauge. This is the HPCO
pressure (machine stall pressure). The acceptable
pressure range is 234 - 241 bar (3400 - 3500 psi).
If the HPCO is out of range, adjust the HPCO screw
on the pump compensator. This is the same location
as the LS adjustment for machines with Power Lift.
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PRIMARY HYDRAULIC POWER SYSTEM - Check Flowmeter Check

Sheet, All 580SN, 580SN WT and 590SN machines
Date:_______________ Hours:_______________
NOTE: Prior to testing, machine must be prepped and establish a minimum oil temperature of 51 °C (123.8 °F). See
machines (A.10.A) for procedure.
Test 1- Pilot Manifold Pressure
Test 1B - pilot pressure __________bar __________psi
Notes:
Test 2B __________bar __________psi
Notes:

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Notes:
Notes:
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Notes:
Notes:
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PRIMARY HYDRAULIC POWER SYSTEM - Adjust Torque Control

Adjustment, 580SN, 580SN WT and 590SN machines with
Mechanical Controls
NOTICE: This procedure should be followed carefully and should ONLY be performed as a last step in the trou-
bleshooting/repair process. Improper adjustment will damage the hydraulic system.
For this test the machine will see pressure of at least 221
bar (3200 psi). A 75 US gpm flowmeter (p/n CAS10280)
will be used. If the flowmeter is equipped with pipe thread
connections, these fittings will have to be removed and re-
placed with ORFS connections (p/n 87303844). Also, hose
with a minimum 275 bar (4000 psi) working pressure will
need to be used. It is recommended that the hoses be
made 8 ft to 12 ft long with #16 female ORFS (1 7/16-12)
ends.
1. Remove the tee from the pressure outlet at the rear
of the pump and install a plug 9847694 in the open
end of the tee and tighten.
2. Attach one end of a test hose to the adapter fitting at
the pressure outlet of the pump. Connect the other
end of the hose to the inlet port of the test flowmeter.
3. Remove the loader valve return hose from the tee at
the rear of the filter. Install a plug in the end of the
return hose and tighten.
4. Connect the end of the second test hose at the open
port and the other end to the outlet of the flowmeter.
5. Warn the machine to 49 °C (120 °F). To warm the
machine start the engine and set the throttle to 2000
RPM. Adjust the load valve at the service flowmeter
to 172 - 207 bar (2500 - 3000 psi). Allow the ma-
chine to run in this condition until the temperature is
reached.
6. Stop the engine.
7. Remove the torque controls supply tube from the
pump.
8. Cap the open adapter fitting at the variable relief
valve on the top of the pump using 574342.
9. Connect a hose from the open port at the torque con-
trol compensator and run into the fill neck of the hy-
draulic reservoir.
10. Connect a gauge capable of 34.5 bar (500 psi) to
the diagnostic fitting at the power lift valve.
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RCPH10TLB013FAM 1
(1) Torque Control Variable Relief (5) Pressure Compensator (580SN with Power
Lift) Load Sense Compensator (580SN with
Power Lift, 580SN WT, 590SN)
(2) Torque Control Supply Tube (6) Torque Control Compensator
(3) Gauge Port (7) Load Sense Port
(4) Mode Selection Solenoid
Checking Torque Control

11. Unscrew the load valve on the service flowmeter to
the lowest setting.
12. Start the engine and set engine speed to 2000 RPM.
13. Increase the load on the service flowmeter until the
flow has dropped to 19 l/min (5 US gpm) or less.
14. Read the pressure on the 5000 psi gauge. This is the
torque compensator margin setting. The acceptable
range for all models is 17 - 19 bar (246 - 275 psi).
15. If the pressure must be adjusted, loosen the lock-
nut on the torque control compensator and adjust the
set screw. Tightening the set screw will increase the
pressure setting and loosening the set screw will de-
crease the pressure setting.
17. After the torque control compensator pressure has
been adjusted correctly, remove the hose that con-
nects the compensator to the hydraulic reservoir. Re-
install the cap on the hydraulic reservoir.
18. Remove the cap that was installed at the torque con-
trol variable relief valve.
19. Reinstall the torque control supply tube.
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NOTICE: Remove the 34.5 bar (500 psi) gauge from the diagnostic fitting. The system will be tested at pressures
greater than 34.5 bar (500 psi) and the will be damaged or destroyed if it is not removed for the remainder of the test.
NOTICE: The hydraulic oil temperature should never be allowed to rise above 80 °C (175 °F). If at any time the oil rises
above this temperature, set the load valve in the service flowmeter to its lowest setting and allow the oil to circulate
and cool before continuing this test. This temperature should be checked every five minutes while preforming this
test.
21. Increase the load on the service flowmeter to read
165 bar (2400 psi) on the left gauge of the flowme-
ter. Record the flow rate on the flowmeter. For the
580SN and 580SN WT. the acceptable range is 125
- 128 l/min (33 - 33.7 US gpm). For the 590SN, the
acceptable range is 130 - 140 l/min (34.4 - 37 US
gpm).
22. If the correct flow rate is not shown on the flowmeter,
the torque control variable relief valve will need to be
adjusted.
1. Remove the plastic cap from the torque
control variable relief.
2. Ensure the SMALL lock nut is tight on the
relief.
3. Loosen the LARGE locknut on the vari-
able relief.
4. Tighten the set screw to increase the flow
on the flowmeter. Loosen the setscrew to
decrease the flow on the flowmeter.
5. Retighten the LARGE locknut on the vari-
able relief.
6. Check the flow on the flowmeter. Note
that adjusting the torque control variable
relief may slightly change the pressure at
the service flowmeter. Be sure to reset
the load to 165.5 bar (2400 psi) before
checking the flow.
23. Check the temperature of the hydraulic oil in the
reservoir. The oil should never be allowed to rise
above 80 °C (175 °F). If at any time the oil rises
above this temperature, set the load valve in the ser-
vice flowmeter to its lowest setting and allow the oil
to circulate and cool before continuing this test. This
temperature should be checked every five minutes
while preforming this test.
24. Once the flow at the 165.5 bar (2400 psi) load level
is checked, the flow must be set at a higher level.
Increase the load at the service flowmeter to 221 bar
(3200 psi). The flow on the flowmeter should be 95
- 105 l/min (25 - 28 US gpm) for the 580SN and
580SN WT. The flowmeter should read 95 - 105 l/min
(25 - 28 US gpm) for the 590SN.
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25. If the correct value is not shown on the flowmeter for

the higher load case, the torque control variable relief
valve will need to be adjusted.
2. Ensure the LARGE locknut is tight on the
relief.
3. Loosen the SMALL locknut on the variable
relief.
on the flowmeter. Loosen the set screw to
decrease the flow on the flowmeter,
5. Tighten the SMALL locknut on the variable
relief.
the service flowmeter. Be sure to reset
the load to 165.5 bar (2400 psi) before
checking the flow.
NOTE: Note that adjusting the set screw on the variable relief with either the large or small locknut will slightly change
the setting of the other. Repeat steps 21 to 25 making slight adjustments until the flow is correct at each load case.
26. Repeat the set up steps in reverse order to return the
machine to working condition.
NOTE: Any steps related to the torque control supply tube may be eliminated since the tube was reinstalled at an
earlier step.
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PRIMARY HYDRAULIC POWER SYSTEM - Adjust Torque Control

Adjustment, 580SN, 580SN WT and 590SN machines with Pilot
Controls
For this test the machine will see pressure of at least 221
bar (3200 psi). A 75 US gpm flowmeter ( CAS10280)
will be used. If the flowmeter is equipped with pipe thread
connections, these fittings will have to be removed and re-
placed with ORFS connections (p/n 87303844). A hose
with a minimum 275 bar (4000 psi) working pressure must
be used. It is recommended that the hoses be made 8 ft
to 12 ft long with #16 female ORFS (1 7/16-12) ends.
1. Remove the tee from the pressure outlet at the rear
of the pump and install a plug ( 9847694) in the open
end of the tee and tighten.
2. Attach one end of a test hose to the adapter fitting at
the pressure outlet of the pump. Connect the other
end of the hose to the inlet port of the test flowmeter.
3. Remove the #16 ORB internal hex plug from the rear
face of the backhoe valve.
4. Install a long #16 ORB to #16 ORFS adapter fitting (
87326799) in the open port of the backhoe valve.
5. Connect the end of the second test hose at the
adapter fitting on the backhoe valve. The opposite
end of the hose must be connected to the outlet of
the service flowmeter.
6. Remove the plug from the pressure gauge port at the
top rear of the pump.
7. Install a tee 84151565 in the gauge port at the top of
the pump.
8. Remove the hose that connects the load sense com-
pensator to the power lift valve. Cap the open con-
nection at the power lift valve.
9. Connect a hose from the tee at the gauge port of the
pump to the open port at the LS compensator. The
hose needs to have #6 ORFS female ends and be
rated to 275 bar (4000 psi).
10. Connect a diagnostic fitting 190119A1 at the avail-
able port on the gauge port tee.
machine, start the engine and set the throttle to 2000
RPM. Adjust the load valve at the service flowmeter
to 172 - 207 bar (2500 - 3000 psi). Allow the ma-
chine to run in this condition until the temperature is
reached.
diagnostic fitting installed at the tee in the gauge port
of the pump.
14. Remove the torque control supply tube from the
pump.
15. Cap the open adapter fitting 574342 at the variable
relief valve.
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16. Connect a hose from the open port at the torque con-
trol compensator and run into the fill neck of the hy-
draulic reservoir.
RCPH10TLB013FAM 1
(1) Torque Control Variable Relief

(2) Torque Control Supply Tube
(3) Gauge Port
(4) Mode Selection Solenoid
(5) Load Sense Compensator (580SN with Power Lift, 580SN WT, 590SN)
(6) Torque Control Compensator
(7) Load Sense Port
Checking Torque Control

17. Unscrew the load valve on the service flowmeter to
the lowest setting.
19. Increase the load on the service flowmeter until the
flow has dropped to 19 l/min (5 US gpm) or less.
20. Read the pressure on the 34.5 bar (500 psi). This is
the torque compensator margin setting. The accept-
able range for all models is 17 - 19 bar (246.5 - 275.5
psi).
21. If the pressure must be adjusted, loosen the lock-
nut on the torque control compensator and adjust the
set screw. Tightening the set screw will increase the
pressure setting and loosening the set screw will de-
crease the pressure setting.
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23. After the torque control compensator pressure has

been adjusted correctly, remove the hose that con-
nects the compensator to the hydraulic reservoir. Re-
install the cap on the hydraulic reservoir.
24. Remove the cap that was installed at the torque con-
trol variable relief valve.
25. Reinstall the torque control supply tube.
NOTICE: Remove the 500 psi gauge from the diagnostic fitting. The system will be tested at pressures greater than
500 psi and the will be damaged or destroyed if it is not removed for the remainder of the test.
NOTICE: The oil should never be allowed to rise above 80 °C (175 °F). If at any time the oil rises above this tem-
perature, set the load valve in the service flowmeter to its lowest setting and allow the oil to circulate and cool before
continuing this test. This temperature should be checked every five minutes while preforming this test.
27. Increase the load on the service flowmeter to read
165.5 bar (2400 psi) on the left gauge of the flow
meter. Record the flow rate on the flowmeter. For
the 580SN and 580SN WT. the acceptable range is
125 - 135 l/min (33 - 35.6 US gpm). For the 590SN,
the acceptable range is 130 - 140 l/min (34.4 - 37
US gpm).
28. If the correct flow rate is not shown on the flowmeter,
the torque control variable relief valve will need to be
adjusted.
2. Ensure the SMALL lock nut is tight on the
relief.
3. Loosen the LARGE locknut on the vari-
able relief.
on the flowmeter. Loosen the setscrew to
decrease the flow on the flowmeter.
5. Retighten the LARGE locknut on the vari-
able relief.
the service flowmeter. Be sure to reset the
load to 2400 psi before checking the flow.
29. Check the temperature of the hydraulic oil in the
reservoir. The oil should never be allowed to rise
above 80 °C (175 °F). If at any time the oil rises
above this temperature, set the load valve in the ser-
vice flowmeter to its lowest setting and allow the oil
to circulate and cool before continuing this test. This
temperature should be checked every five minutes
while preforming this test.
30. Once the flow at the 2400 psi load level is checked,
the flow must be set at a higher level. Increase the
load at the service flowmeter to 220 bar (3200 psi).
The flow on the flowmeter should be 90 - 100 l/min
(23.8 - 26.4 US gpm) for the 580SN and 580SN WT.
The flowmeter should read 95 - 105 l/min (25 - 27.7
US gpm) for the 590SN.
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31. If the correct value is not shown on the flowmeter for

the higher load case, the torque control variable relief
valve will need to be adjusted.
2. Ensure the LARGE locknut is tight on the
relief.
3. Loosen the SMALL locknut on the variable
relief.
on the flowmeter. Loosen the set screw ti
decrease the flow on the flowmeter,
5. Tighten the SMALL locknut on the variable
relief.
the service flowmeter. Be sure to reset the
load to 2400 psi before checking the flow.
NOTE: Note that adjusting the set screw on the variable relief with either the large or small locknut will slightly change
the setting of the other. Repeat steps 21 to 26 making slight adjustments until the flow is correct at each load case.
32. Repeat the set up steps in reverse order to return the
machine to working condition.
NOTE: Any steps related to the torque control supply tube may be eliminated since the tube was reinstalled at an
earlier step.
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Remote valve - Remove - Remote control valves

1. Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
NOTICE: Turn on the ignition switch and the pilot control
switch. Move the backhoe control lever back and forth sev-
eral times to release any hydraulic pressure in the pilot con-
trol circuit.
2. Place the pilot control switch and the ignition switch
in the OFF position.
3. Remove the wrist rest, pull the rubber boot up and
remove the two mounting screws and the retaining
plate.
RCPH10TLB334ABL 1
4. On the right tower (facing rear of machine) remove

the tilt levers.
RCPH10TLB335ABL 2
5. Remove the tilt adjusting knob from rear of tower.
RCPH10TLB336ABL 3
6. Remove the rear floor mat (if equipped) and floor

boards.
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7. Disconnect the electrical connector for the tower, re-

move the boot from the tower.
RCPH10TLB337ABL 4
8. Remove the heat shield from inside of the control

tower.
9. Remove the control mounting bolts, pivot adjusting
knob and pivot bolt from the tower.
RCPH10TLB338ABL 5
10. Disconnect electrical connector from control handle,

remove the upper housing for the tower.
RCPH10TLB332ABL 6
11. Check to ensure all hoses have the proper plastic

tie markers, see illustration Remote valve - Compo-
nent diagram (A.10.A), prior to removal. Disconnect
one at a time from the remote control valve. Install
plugs in the hoses and caps on the fittings.
12. Remove the remote control valve from the control
tower.
RCPH10TLB333ABL 7
Next operation:
Remote valve - Install (A.10.A)
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Remote valve - Install - Remote control valves

Prior operation:
Remote valve - Remove (A.10.A)
1. Install new O-rings on the adapters for the remote

control valve.
2. Remove the plugs from the hoses. Remove the caps
from the fittings. Connect the hydraulic hoses to the
fittings according to the identification tags.
3. Connect the electrical connectors for the remote con-
trol valve.
4. Place the upper housing around the control handle,
install the pivot bolt and pivot adjusting knob into
tower.
RCPH10TLB338ABL 1
5. Install the control mounting screws in the tower.

6. Stand cover up beside control tower, connect electri-
cal connector to chassis harness.
7. Start the machine and operate the hydraulics.
8. Make sure that the remote control valve operates the
backhoe correctly.
9. Check for leaks at the remote control valve.
10. Turn the machine off.
11. Install the heat shield in the tower.
RCPH10TLB339ABL 2
12. Install cover on tower, connect electrical connector.
RCPH10TLB337ABL 3
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13. On the right tower (facing rear of machine) install the

tilt levers.
RCPH10TLB335ABL 4
14. Install the retaining plate, two mounting screws and

washers. Pull the rubber boot down and secure it to
the retaining plate.
15. Install the wrist rest.
16. Install floor boards and floor mat (if equipped).
17. Start the machine and place the pilot control switch
in the on position.
18. Operate the remote control valves for ten minutes to
remove any air from the system.
19. Check the level of hydraulic oil in the reservoir and
add as required. RCPH10TLB334ABL 5
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Remote valve - Remove - Loader control valve
NOTE: Put identification tags on all disconnected hoses

and wires. Seal disconnected hoses and fittings with caps
and plugs.
1. Park the machine on a level surface and apply the
parking brake.
2. Lower the loader bucket to the floor and stop the
engine.
3. Move the loader control lever in all directions to re-
lease the pressure from the loader hydraulic circuits.
4. Remove the two screws from the right hand side of
the floor mat.
RCPH10TLB318ABL 1
5. Pull the floor mat away from the loader control cover.
RCPH10TLB076AAM 2
6. Remove the boot retaining screw.
RCPH10TLB447ABL 3
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7. Pull the cover off of the louver assembly.
RCPH10TLB314ABL 4
8. Push the four tabs inward while pulling the louver

assembly out.
RCPH10TLB312ABL 5
9. Pull the louver assembly (1) off of the hose (2) and
push the hose back into the cover.
RCPH10TLB313ABL 6
10. Pull the rubber boot upward turning it inside out. This
will allow the boot to slide through the hole in the
cover.
11. Remove the three bolts which fasten the loader con-
trol cover to the cab frame. Remove the cover.
RCPH10TLB075AAM 7
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12. Remove the bolts (1) from the loader control plate.
Remove the front plate (2) first then back plate (3).
NOTE: The back plate is sealed with silicone sealant.
RCPH10TLB309ABL 8
RCPH10TLB308ABL 9
13. Remove front cab floor plate (2).
RCPH10TLB001BAN 10
1. Cab floormat 3. Loader control lever split floor plate

2. Front cab floor plate
14. Disconnect the lever linkage rods from the valve.
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15. Remove the cap (1) from the hydraulic reservoir.

This will reduce the hydraulic oil loss as the hoses
and tubes are removed from the loader control valve.
RCPH10TLB428AAF 11
16. If machine is equipped with a pilot controlled clam

bucket, tag and disconnect hoses to clam controls
(1).
RCPH10TLB004GAN 12
17. Remove skid plate from machine.
RCPH10TLB077AAM 13
18. Disconnect the wiring for the magnetic detent located

on the bucket section of the loader control valve.
RCPH10TLB327ABL 14
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19. Disconnect and remove tubes (1), disconnect hoses

(2), and disconnect tubes (3) from the fittings on the
loader control valve. Install caps on the fittings and
plugs in the tubes and hoses.
580SN, 580SN-WT and 590SN will have steering
and coupler (if equipped) hoses connected to the
loader valve.
NOTE: Cab is removed for clarity only.
RCPH10TLB328ABL 15
20. Connect acceptable lifting equipment to the loader

control valve.
21. Loosen and remove the three bolts (1), washers (2)
and spacers (3) that fasten the loader control valve
to the chassis.
NOTE: Do not loose spacers that are behind loader valve.
580N 2 spool, does not have spacers.
22. Remove the loader control valve from the machine.
RCPH10TLB045GAM 16
Next operation:
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Remote valve - Install - Loader control valve

Prior operation:
Remote valve - Remove - Loader control valve (A.10.A)
1. Use acceptable lifting equipment to put the loader

control valve into position in the machine.
2. Install the three bolts (1), washers (2), and spacers
(3) to fasten the loader control valve to the chassis.
RCPH10TLB045GAM 1
NOTE: Do not loose spacers that are behind loader valve.

NOTE: 580N 2 spool, does not have spacers.
3. Remove the lifting equipment from the loader control
valve.
4. Remove caps from the fittings and plugs from the
tubes and hoses. Connect tubes (3), connect hoses
(2), install and connect tubes (1) to the fittings on the
loader control valve.
NOTE: Cab is removed for clarity only.
RCPH10TLB328ABL 2
5. Connect the wiring for the magnetic detent.
RCPH10TLB075AAM 3
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6. Install skid plate on machine.
RCPH10TLB326ABL 4
If machine is equipped with a pilot controlled clam bucket,

connect hoses to clam controls, remove tags install during
disassembly.
RCPH10TLB445ABL 5
7. Install the hydraulic reservoir cap.
RCPH10TLB428AAF 6
8. Connect the lever linkage rods to the valves.
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9. Install front cab floor plate (1).
RCPH10TLB001BAN 7
1. Front cab floor plate

2. Loader control lever split floor plate
3. Floor mat
10. Put a bead of RTV silicone sealant on the mating

surface of the back plate (3) and install. Install the
front plate (2) and tighten the bolts (1).
RCPH10TLB309ABL 8
RCPH10TLB308ABL 9
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11. Put the louver assembly (1) on the hose (2) and push
into the cover.
RCPH10TLB313ABL 10
12. Push the cover on the louver assembly.
RCPH10TLB314ABL 11
13. Install the boot and retaining screw.
RCPH10TLB447ABL 12
14. Put the floor mat back into place and install the two
screws.
NOTE: See Throttle command - Adjust - Throttle link-
age adjustment (B.20.A). Adjust the loader control linkage
as required.
15. Start the engine and let it run at low idle. Activate the
loader control lever for both the bucket and lift func-
tion. If equipped, activate the clam function. Hold in
each position for 15 - 20 s.
engine.
RCPH10TLB318ABL 13
17. Check for oil leakage at the loader control valve.
as required. See Capacities () for specifications.
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Remote valve - Remove - Clam control pilot valve

and wires. Close disconnected hoses and fittings with caps
and plugs.
parking brake.
engine.
3. Move the loader control lever in all directions to re-
lease the pressure from the loader hydraulic circuits.
4. Turn the ignition switch to the ON position and ac-
tivate the clam control several time to release any
pressure in the accumulator, turn the ignition switch
OFF.
5. Tag and disconnect hoses from the clam control
block.
RCPH10TLB004GAN 1
6. Tag and disconnect the electrical connectors from

the solenoids.
7. Remove the mounting bolts, remove the clam control
block from the loader valve guard.
Next operation:
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Remote valve - Install - Clam control pilot valve

Prior operation:
1. Install the control block on the loader valve guard.

2. Connect hoses and solenoid wires, remove tags in-
stalled during removal.
3. Start and operate clam control, open and close the
clam three times.
4. Stop the machine, check the valve for leaks.
5. Check oil level in the reservoir, add oil as required.
RCPH10TLB040GAM 1
(1) Pump pressure hose (5) Clam control block

(2) Pressure hose to spool (6) Pressure hose to spool
(3) Pressure to clam manifold (7) Loader valve
(4) Accumulator (8) Return to reservoir
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Remote valve - Remove - Pilot controls backhoe valve

WARNING
Pressurized system!
Before attempting any service procedure, it is your responsibility to know the number of accumulators
on the machine, and the correct procedure for releasing the pressure of each accumulator.
W0136A
1. Park the machine on a level surface, lower stabilizers

and loader bucket to the floor.
2. Turn off the engine, turn the ignition switch to the on
position and the pilot control switch to the on position.
3. Move the pilot controls in all directions several times
to release the accumulator pressure, move the
loader controls in all directions to release pressure
on the loader.
4. Turn pilot control switch and ignition switch off.
5. Remove the ROPS Cab/Canopy from the machine,
see ROPS - Remove (E.34.A).
6. Disconnect the hydraulic hoses at the swing cylin-
ders that come from the swing cushioning valve, cap
the fittings and plug the hoses.
7. Tag and disconnect all hydraulic hoses from the con-
trol valve, cap and plug all hoses and fittings.
8. Disconnect the electrical connectors for the pilot unit.
RCPH10TLB331ABL 1
9. Disconnect the backup alarm.
RCPH10TLB329ABL 2
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RCPH10TLB330ABL 3
10. Attach suitable lifting equipment to the pilot control,

remove the mounting bolts from the pilot control.
NOTICE: Do not attach lifting equipment to any hydraulic
tubes.
11. Loosen and remove the mounting bolts from the pilot
control mounting bracket.
12. Slowly raise the control unit from the machine, make
sure control unit does not become entangled on the
frame.
13. Place the control unit on a bench, block unit to ensure
that no tubing is bent.
Next operation:
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Remote valve - Install - Pilot controls backhoe valve

Prior operation:
1. Attach suitable lifting equipment to the pilot control.

NOTICE: Do not attach lifting equipment to any hydraulic
tubes.
2. Slowly lower the control unit into the machine, make
sure control unit does not become entangled on the
frame.
3. Install and tighten the mounting bolts for the pilot con-
trol bracket.
4. Connect the backup alarm.
RCPH10TLB330ABL 1
RCPH10TLB329ABL 2
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5. Connect the electrical connectors for the pilot unit.

6. Remove caps and plugs, connect all hydraulic hoses
to the control valve.
7. Connect the hydraulic hoses to the swing cylinders.
8. Install the ROPS Cab/Canopy on the machine, refer
to section ROPS - Install (E.34.A).
9. Start the machine and place the pilot control switch
in the on position.
10. Operate the pilot control valves for ten minutes to
remove any air from the system.
RCPH10TLB331ABL 3
NOTE: It may take several temperature cycles of the ma-
chine and several hours of operation to fully remove all of
the air.
11. Check the level of hydraulic oil in the reservoir and
add oil as required.
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Remote valve - Remove - Mechanical controls backhoe valve

and tubes. Close disconnected hoses, tubes and fittings
with caps and plugs.
1. Park the machine on a level surface and lower the
loader bucket to the floor.
2. If the backhoe is equipped with an Extendahoe, in-
stall the Extendahoe lock pin.
3. Lower the stabilizers until the stabilizer pads just
touch the floor.
4. Extend the backhoe straight behind the machine with
the backhoe bucket resting on the ground.
5. Stop the engine and apply the parking brake.
6. Move the backhoe control levers in all directions until
all hydraulic pressure has been removed from the
backhoe hydraulic circuits.
7. Remove the four retaining screws.
RCPH10TLB316ABL 1
8. Remove the bolts (1) which fasten the backhoe con-

trol tower covers.
RCPH10TLB317ABL 2
1. Bolt 2. Front cover 3. Rear cover
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9. Pull the rubber boot (1) up and remove the rear cover
(3) and front cover (2).
RCPH10TLB315ABL 3
10. Remove the backhoe control tower covers (2) and

(3).
11. If equipped, remove the cab floor mat (1). Remove
the rear cab floor plate (2).
12. Attach identification tags to the linkage for the back-
hoe control valve.
13. Disconnect the linkage rods from the spools on the
backhoe control valve.
14. Remove the bolts which fasten the backhoe control
tower assembly to the valve mounting brackets.
15. Remove the backhoe control tower assembly from
the machine.
RCPH10TLB078GAL 4
16. Remove the cap from the hydraulic reservoir. This

will reduce the hydraulic oil loss as the hoses and
tubes are removed from the valve.
17. Disconnect the hoses and tubes from the backhoe
control valve. Install caps on the fittings and plugs in
the hoses and tubes.
18. Connect acceptable lifting equipment to the backhoe
control valve.
19. Remove the bolts that fasten the backhoe control
valve right and left mounting brackets to the chas-
sis.
RCPH10TLB428AAF 5
20. Remove the backhoe control valve from the ma-
chine.
Next operation:
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Remote valve - Install - Mechanical controls backhoe valve
Prior operation:
1. Using acceptable lifting equipment, place the back-

hoe control valve in the machine.
2. Align the left and right valve mounting brackets with
the chassis mounting holes. Install the bolts.
3. Remove the lifting equipment.
4. Connect all hoses and tubes.
5. Install the hydraulic reservoir cap.
6. Install the backhoe control tower assembly. Use the
bolts to fasten the backhoe control tower to the valve
mounting brackets.
7. Connect the linkage rods to the spools on the back-
hoe control valve.
8. Install the rear cab floor plate (1). If equipped, install
the cab floor mat (2).
RCPH10TLB078GAL 1
9. If the machine is equipped with auxiliary hydraulics,

connect the control cables to the backhoe control
tower.
10. Install the backhoe control tower assembly covers (2)
and (3).
RCPH10TLB317ABL 2
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11. Install the four retaining screws.
RCPH10TLB316ABL 3
12. Start the engine and activate each of the backhoe

control levers. Hold each lever over relief in each
direction for 15 - 20 s.
13. Stop the engine. Check for oil leaks at the backhoe
control valve.
as required.
RCPH10TLB453ABL 4
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Remote valve - Check - Pilot control unit

NOTE: Remove control unit from machine, see Remote valve - Remove (A.10.A).
1. Loosen the handle jam nut, unscrew handle from
control unit.
NOTE: During assembly torque jam nut to 40 N·m +/- 4
(29.5 lb ft +/- 3).
RCPH10TLB452ABL 1
2. Place the control handle in a soft jawed vise.
RCPH10TLB428ABL 2
3. Loosen the cardan.
RCPH10TLB429ABL 3
4. Remove the cardan from the control unit.
RCPH10TLB430ABL 4
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5. Keep all shims for the cardan together for use during
assembly.
NOTE: During assembly use LOCTITE® 262 on threads and
torque cardan bolt to 40 N·m +/- 4 (29.5 lb ft +/- 3).
RCPH10TLB431ABL 5
6. Remove the retaining plate from the control unit.
RCPH10TLB432ABL 6
7. Mark the guides and the body so components will be

placed into the same position.
RCPH10TLB433ABL 7
8. Insert the end of a thin screwdriver between the guide

and the body, carefully lift the guide to remove it from
the body.
RCPH10TLB434ABL 8
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9. Mark the retainer cups.
RCPH10TLB435ABL 9
10. Remove the regulation units.
RCPH10TLB436ABL 10
11. Push down on the retainer cup and twist the plunger
out of the cup.
RCPH10TLB440ABL 11
12. Remove the spring and shims from the plunger.
RCPH10TLB441ABL 12
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13. Inspect the regulation units, repair or replace as nec-

essary.
RCPH10TLB442ABL 13
1. Dust boot 5. Retainer cup

2. Plunger 6. Spring
3. Spring 7. Plunger
4. Plunger 8. Spring
14. Turn control unit over in the vise and remove the
lower body.
RCPH10TLB437ABL 14
15. Remove and replace the “O” rings.
RCPH10TLB439ABL 15
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16. Install bolt and torque to 50 N·m +/- 5 (37 lb ft +/-

3.5).
NOTICE: Make sure notches are aligned during assembly.
RCPH10TLB438ABL 16
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Relief valve - Adjust Main Relief Valve, 580N with mechanical

controls
1. The main relief valve is in the inlet section of the
loader control valve. Loosen the locknut (1) on the
main relief valve. Turn the adjusting screw (2) clock-
wise to increase the pressure and counterclockwise
to decrease the pressure.
2. Check the pressure again.
3. If the main relief valve pressure is very low and the
steering relief pressure is normal, repeat test, Relief
valve - Pressure test (A.10.A) with the bucket bot-
tomed out.
4. When the pressure is correct, tighten the lock nut (1).
RCPH10TLB001CAM 1
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Relief valve - Remove - Circuit relief valve, 580N, 580SN, 580SN WT

and 590SN machines with Pilot Controls (Swing and Bi-Directional
relief valves only)
Prior operation:
Control valve - Cleaning (A.10.A)
NOTE: This procedure is for the Swing and Bi-Dir relief valves only. The Boom, Dipper, Bucket and Loader bucket
use a different design that cannot be disassembled.
NOTE: The following procedures are for reference only, the relief valves are replaced as an assembly and are not
repairable.
1. Loosen the jam nut on relief valve.
RCPH10TLB418ABL 1
2. Remove the adjusting screw and jam nut.
RCPH10TLB419ABL 2
3. Remove the spring and poppet.
RCPH10TLB420ABL 3
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4. Loosen the plug.
RCPH10TLB421ABL 4
5. Remove the plug from the body.
RCPH10TLB422ABL 5
6. Remove the spring and poppet from the body.
RCPH10TLB423ABL 6
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Relief valve - Cleaning Relief Valve, Backhoe Main Relief Valve,

580N with Pilot Backhoe Controls
1. Loosen the locking nut for the adjusting screw. See
Relief valve - Drawing (A.10.A) for details.
RCPH10TLB424ABL 1
2. Loosen the adjusting screw.

NOTE: The adjusting screw will not come out completely.
RCPH10TLB425ABL 2
3. Loosen the adjusting screw retaining nut.
RCPH10TLB426ABL 3
4. Remove the locking nut from the adjusting screw,

remove the retaining nut from the adjusting screw,
remove the spring and poppet from the body.
RCPH10TLB427ABL 4
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Relief valve - Pressure test Loader and Backhoe Main Relief Valve
for 580N mechanical machines only. Loader Main Relief Valve for
580N machine with Pilot Controls.
2. The hydraulic oil temperature must be 51 °C (124 °F).
To heat the hydraulic oil, do the following steps:
3. A. With the engine running at full throttle,
hold the loader control lever in the ROLL-
BACK position for 15 seconds.
B. Put the loader control lever in the NEU-
C. Repeat steps A and B until the tempera-
ture of the oil is 51 °C (124 °F) or the side
4. Connect DATAR. Connect TA092 pressure trans-
ducer to the quick disconnect fitting at the EF port
on the pump. Set the transducer to 600 Bar.
NOTE: If DATAR is not available, use a pressure gauge of
27580 kPa (4000 psi) or greater. Connect the pressure
gauge to the quick disconnect fitting.
5. Run the engine at full throttle. Hold the loader con-
trol lever in the RAISE position until the loader stops
moving.
6. Hold the loader control lever in the RAISE position
and read the pressure. Then release the loader con-
trol lever and decrease the engine speed to low idle.
Stop the engine.
7. Compare the reading with specifications, PRIMARY
HYDRAULIC POWER SYSTEM - General specifi-
cation (A.10.A). If the readings are not correct, ad-
just the main relief valve.
For 580N with mechanical controls see Relief valve
- Adjust Main Relief Valve, 580N with mechanical
controls (A.10.A).
For 580N with pilot backhoe controls see Relief
valve - Adjust Dual Stage Relief Valve, 580N Pilot
Controlled Backhoe Valves (A.10.A).
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Relief valve - Pressure test - Load Sense Relief Valve for 580N
Backhoe relief Pilot Controls only
Prior operation:
Relief valve - Pressure test Loader and Backhoe Main Relief Valve for 580N mechanical machines only. Loader
Main Relief Valve for 580N machine with Pilot Controls. (A.10.A)
1. Park machine on level and firm surface.

2. Put backhoe in transport position. Lower loader
bucket to ground.
3. Stop engine. Turn ignition and pilot switch to ON
position. Operate pilot and loader controls to relieve
pressure in system.
4. Ensure oil temperature is at operating temperature.
Do the following:
1. Start engine. Run engine at full throttle
and position boom in travel lock position.
Hold boom control lever in the lower posi-
tion for 15 seconds.
2. Put boom control lever in NEUTRAL posi-
tion for 15 seconds.
3. Repeat steps A and B until oil temperature
reaches minimum of 51 °C (123.8 °F).
5. Use adapter 190119A1 to connect DATAR. Connect
TA092 pressure transducer to "M" port. Set trans-
ducer to 600 bar on backhoe valve.
NOTE: If DATAR is not available, use pressure gauge capable of minimum 344.8 bar (5000 psi) Connect to "M" port.
Use adapter 190119A1 on backhoe valve.
6. Run engine at high idle. Hold a stabilizer over relief.
Record pressure result.
7. Compare to specification. See PRIMARY HY-
DRAULIC POWER SYSTEM - General specifica-
tion (A.10.A).
8. If pressure setting is not in specification, adjust load
sense relief valve. See Relief valve - Adjust - 580N
Backhoe relief Pilot Controls only (A.10.A)
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Relief valve - Adjust - 580N Backhoe relief Pilot Controls only

Prior operation:
Relief valve - Pressure test - Load Sense Relief Valve for 580N Backhoe relief Pilot Controls only (A.10.A).
The Load Sense Relief for the 580N Pilot is located in the
inlet section of the backhoe valve under the rear floor plate
of the cab.
1. Remove locking cover from load sense relief valve.
2. Loosen lock nut (1) located on adjustment screw (2).
RCIL10TLB001CAN 1
3. Turn adjustment screw clockwise to increase pres-

sure or counterclockwise to decrease pressure.
4. Check pressure. When pressure is in specification,
tighten adjustment screw lock nut. Install locking
cover.
Next operation:
Relief valve - Replace - Load Sense Relief Valve (A.10.A).
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Relief valve - Adjust Dual Stage Relief Valve, 580N Pilot Controlled
Backhoe Valves
The Dual Stage Relief valve is in the inlet section of the
loader control valve.
1. Loosen lock nut (1) located on adjustment flats(2).
RCPH10TLB010BAM 1
2. Turn adjustment screw clockwise to increase pres-

sure or counterclockwise to decrease pressure.
3. Check pressure. When pressure is in specification,
tighten adjustment screw lock nut. Install locking
cover.
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Relief valve - Replace - Load Sense Relief Valve

Prior operation:
Relief valve - Adjust - 580N Backhoe relief Pilot Controls only (A.10.A).
1. Loosen and remove load sense relief valve.

2. Lubricate load sense relief valve O-rings with clean
oil.
3. Install load sense relief valve in section bore.
4. Torque valve to 41 - 50 N·m (30.2 - 36.9 lb ft).
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Hydraulic pump - Remove - 580N only

and wires. Close disconnected hoses and fittings with caps
and plugs.
parking brake.
engine.
3. Move the loader and backhoe control levers in all
directions to release the pressure from the hydraulic
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 pres-
sure.
tubes are removed from the hydraulic pump.
5. Remove the drive shaft from the transmission to the
rear axle.
6. Remove floor mat (if equipped), remove front center
floor plate.
RCPH10TLB428AAF 1
7. Remove the Allen head screw and loosen the hose

clamp on the inlet hose to the pump.
RCPH10TLB320ABL 2
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8. Remove the two lower mounting nuts, (powershift

transmissions), or bolts (manual transmissions).
RCPH10TLB323ABL 3
9. Attach suitable lifting equipment to the pump.

10. Remove the two upper Allen screws from the pump
inlet, disconnect hoses from fittings (2), (3) and (4).
RCPH11TLB006GAM 4
11. Remove the two upper mounting nuts, (powershift

transmissions), or bolts (manual transmissions).
12. Slide the pump to the rear off of the drive splines,
remove the pump from the machine.
RCPH10TLB325ABL 5
Next operation:
Hydraulic pump - Install (A.10.A)
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Hydraulic pump - Install - 580N only

Prior operation:
Hydraulic pump - Remove (A.10.A)
1. Use a new O-ring on pump mounting flange, slide the

pump onto the drive splines.
2. Install but do not tighten the two upper mounting nuts
(powershift transmissions) or bolts (manual trans-
missions).
RCPH10TLB325ABL 1
3. Install and tighten the two lower mounting nuts

(powershift transmissions) or bolts (manual trans-
missions). Tighten the upper mounting nuts/bolts.
RCPH10TLB323ABL 2
4. Remove lifting equipment to the pump.

5. Install but do not tighten the two upper Allen screws
in the pump inlet. Connect and tighten hoses to fit-
tings (2), (3) and (4).
RCPH11TLB006GAM 3
6. Ensure O-ring is installed in the suction flange.
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7. Install the Allen screw. Tighten all three Allen screws

with equal pressure. Tighten the hose clamp on the
inlet hose to the pump.
RCPH10TLB320ABL 4
8. Install the drive shaft to the rear axle.

9. Complete the following procedure to fill the hydraulic
pump with oil.
A. Fill the hydraulic reservoir. Verify the oil

level in the hydraulic reservoir is correct.
B. Remove the cap from the hydraulic reser-
voir.
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.
D. Have another person start and run the en-
gine at low idle while shop air is being ap-
plied to the hydraulic reservoir.
NOTE: 34.5 - 69.0 kPa (5.0 - 10.0 psi) is all that is required
to move the oil. Pressure above 69.0 kPa (10.0 psi) can
damage the hydraulic reservoir.
10. Operate all hydraulic circuits. Stop the engine and
check for leaks. Fill the hydraulic reservoir as re-
quired.
11. Install floor plate, (if equipped) install floor mat.
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Hydraulic pump - Remove - 580SN, 580SN-WT and 590SN

and wires. Seal disconnected hoses and fittings with caps
and plugs.
parking brake.
engine.
3. Move the loader and backhoe control levers in all
directions to release the pressure from the hydraulic
circuits.
NOTE: Turn on ignition switch and pilot control switch.
Move pilot handles in all directions several times to release
hydraulic and accumulator pressure. If equipped with clam
bucket operate clam controls.
tubes are removed from the hydraulic pump.
5. Remove the drive shaft from the transmission to the
rear axle.
6. Remove floor mat (if equipped), remove front center
floor plate.
RCPH10TLB428AAF 1
7. Disconnect electrical connector from solenoid at rear

of pump.
8. Disconnect the electrical connector from the power
lift solenoid (if equipped).
9. Remove the 2 bolts connecting the power lift valve to
its mounting bracket (if equipped).
10. Disconnect the load sense and pressure lines for the
power lift valve at the ends connected to the pump.
Move the power lift valve over to give more working
room.
11. Disconnect the case drain (1) and output hose (2).
RCPH10TLB013FAM 2
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12. Remove the 2 screws holding the suction line and

power lift bracket.
13. Remove the two lower mounting bolts.
14. Attach suitable lifting equipment to the pump.
15. Remove the two upper mounting bolts.
16. Slide the pump to the rear, off of the drive splines.
Remove the pump from the machine.
NOTICE: Do not use either of the thin tubes on the pump to lift, carry or hold the pump. This will damage the tubes.
Next operation:
Hydraulic pump - Install (A.10.A)
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Hydraulic pump - Install - 580SN, 580SN-WT and 590SN

Prior operation:
Hydraulic pump - Remove (A.10.A)
1. Use a new O-ring on pump mounting flange. Slide

the pump onto the drive splines.
2. Install but do not tighten the two upper mounting
bolts.
3. Install and tighten the two lower mounting bolts.
Tighten the upper mounting nuts/bolts.
4. Remove lifting equipment from the pump.
5. Verify that the suction flange has the O-ring installed.
6. Connect the inlet hose. If equipped with Power Lift,
connect the Power Lift bracket at the same time.
7. Connect the output hose (1) and load sense hose
(2) (if equipped). and Power Lift pressure hose (if
equipped).
RCPH10TLB013FAM 1
8. Reconnect the Power Lift valve to the bracket using

existing hardware.
9. Reconnect all electrical connectors.
10. Use a hand pump filled with MS1209 and connect
it to the quick coupler on the side of the pump, fill
the pump with approximately 1 l (1 US qt) of oil. If
a hand pump is not available, use a funnel with a
flexible neck to pour oil into the open case drain port
on the pump. If using the funnel method, oil must be
added to the pump until it runs out of the open case
drain port.
RCPH10TLB012BAM 2
11. Connect the case drain hose.

12. Install the drive shaft to the rear axle.
13. Fill the hydraulic reservoir. Verify the oil is at the
correct level.
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14. Disconnect the two top connectors from the engine

controller.
RCPH10TLB032AAL 3
15. Crank the engine over for 5 s. Turn the ignition switch
off. Crank the engine again for 5 s.
16. Turn the ignition switch off and connect the connector
to the engine controller.
17. Recheck the hydraulic oil level in the reservoir. Fill if
needed.
18. Connect a quick coupler and hose to the fitting on the
attenuator hose located at the left side of the backhoe
valve.
19. Attached a needle valve to the hose.
20. Start and operate the machine at low idle for a mini-
mum of 5 min . Use an assistant to monitor the hy-
draulic oil level in the reservoir. Stop the machine
and add oil as needed to maintain the oil level in the
sight glass.
NOTE: The system will have noise until all of the air is
purged.
21. Using the needle valve, slowly open and allow oil to
flow from the valve until there are no noticeable air
bubbles in the stream and the stream is a solid color.
22. Close the needle valve, stop the engine, remove the
hose and quick coupler from the attenuator hose.
23. Start the engine and advance the throttle to mid po-
sition.
24. Wait for a minimum of 15 s before cycling hydraulic
circuits.
NOTE: Oil level will drop in the reservoir, refill reservoir as
necessary to maintain oil level in the sight gauge.
25. Cycle any functions that were disconnected or
drained of hydraulic fluid three complete cycles.
Bottom the cylinder out in each cycle.
NOTE: If no function was disconnected, cycle two of the
following for three complete cycles: backhoe dipper, ex-
tend-a-hoe, backhoe bucket, or loader bucket.
26. Stop the engine and check for leaks. Fill the hy-
draulic reservoir as required.
27. Install floor plate, (if equipped) install floor mat.
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Hydraulic pump - Disassemble - Priority Valve, 580N only

Hydraulic pumps are precision machined components
and must be handled appropriately. Before beginning
any pump disassembly or repair procedures, clean the
work area thoroughly of all contaminates. It is advised
that clean towels, paper towels or cardboard be placed
on the workbench to provide a clean work surface. The
work are should be free of blowing dust, welding sparks
or anything that could contaminate the pump components.
If any pump component must be cleaned, use a clean
solvent from a can such as brake or carburetor cleaner.
Use of typical shop parts washers is not advised due to
containments in the cleaning fluid.
1. Loosen and remove load sensor fitting from hydraulic
pump.
RCPH10TLB341ABL 1
2. Remove the springs from the pump.
RCPH10TLB342ABL 2
3. Use a magnet and pull the spool from the pump.
RCPH10TLB344ABL 3
Next operation:
Hydraulic pump - Inspect (A.10.A)
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Hydraulic pump - Inspect - Priority Valve, 580N only

Prior operation:
Hydraulic pump - Disassemble (A.10.A)
1. Inspect the springs for damaged or broken coils,

check spool and bore for scaring. Replace compo-
nents as needed.
RCPH10TLB345ABL 1
Next operation:
Hydraulic pump - Assemble (A.10.A)
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Hydraulic pump - Assemble - Priority Valve, 580N only

1. Lubricate spool with clean hydraulic oil and carefully
install into bore.
RCPH10TLB343ABL 1
2. Place springs into spool and push spool into pump

body.
RCPH10TLB342ABL 2
3. Tighten the Priority Valve fitting.
RCPH10TLB341ABL 3
Next operation:
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Hydraulic pump - Prepare Work Surface

Hydraulic pumps are precision machined components
and must be handled appropriately. Before beginning
any pump disassembly or repair procedures, clean the
work area thoroughly of all contaminates. It is advised
that clean towels, paper towels or cardboard be placed
on the workbench to provide a clean work surface. The
work are should be free of blowing dust, welding sparks
or anything that could contaminate the pump components.
If any pump component must be cleaned, use a clean
solvent from a can such as brake or carburetor cleaner.
Use of typical shop parts washers is not advised due to
containments in the cleaning fluid.
Next operation:
Pump Disassembly
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Hydraulic pump - Disassemble - Single Section Gear Pump

Prior operation:
Hydraulic pump - Prepare Work Surface (A.10.A)
1. Clean the outside of the hydraulic pump. Fasten the

hydraulic pump in a vise with soft jaws. Make align-
ment marks on each section of the hydraulic pump.
RCPH11TLB001BAL 1
2. Loosen and remove the bolts and the flat washers

that fasten the closed end cover.
RCPH11TLB002BAL 2
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3. Remove the closed end cover.
RCPH11TLB003BAL 3
4. Remove the quad ring.
RCPH11TLB004BAL 4
5. Remove the thrust plate.
RCPH10TLB349ABL 5
6. Remove the driven and drive gear.
RCPH10TLB350ABL 6
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7. Remove the shaft end gear housing.
RCPH11TLB005BAL 7
8. If the thrust plate stayed with the end housing, re-

move the thrust plate.
9. Remove the quad ring from the bottom of the shaft
end gear housing or shaft end cover.
RCPH11TLB006BAL 8
10. Remove the snap ring from the shaft end cover.
RCPH10TLB363ABL 9
11. Remove the outer seal and carrier from the shaft end
cover.
RCPH10TLB362ABL 10
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12. Remove the inner seal from the shaft end cover.
RCPH10TLB359ABL 11
13. Remove the seals from the thrust plates.
RCPH10TLB364ABL 12
Next operation:
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Hydraulic pump - Inspect

Prior operation:
Discard all seals and quad rings. Clean all parts in cleaning
solvent. Check all machined surfaces for damage or wear.
1. 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
in), use a new gear housing.
RCPH10TLB448ABL 1
2. Inspect the thrust plates for scoring, pitting, or other

damage.
RCPH10TLB450ABL 2
3. 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 in) 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.
RCPH10TLB449ABL 3
Next operation:
Hydraulic pump - Assemble (A.10.A)
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Hydraulic pump - Assemble - Single Section Gear Pump

Prior operation:
1. Install new quad rings in the grooves in the gear

housings. Use petroleum jelly to hold the quad rings
in position.
2. 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.
RCPH10TLB360ABL 1
3. Install a new seal into the carrier, replace O-ring on

carrier.
RCPH10TLB361ABL 2
4. Press the carrier into the end cover until the snap ring
can be installed in the groove.
RCPH10TLB358ABL 3
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5. Install the snap ring.
RCPH10TLB363ABL 4
6. Install new seals in the thrust plates.
RCPH10TLB365ABL 5
7. Fasten the shaft end cover in a vise with soft jaws.

Install the thrust plate so that the seal is down and
the open ends of the rectangular relief groove on the
face of the thrust plate are toward the outlet side of
the hydraulic pump.
RCPH11TLB007BAL 6
8. Install the shaft end gear housing.
RCPH10TLB370ABL 7
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9. Install the drive and the driven gear.
RCPH11TLB009BAL 8
10. Install the thrust plate so that the seal is up. The seal
must be toward the outlet side of the hydraulic pump.
RCPH11TLB010BAL 9
11. Install the quad ring.
RCPH11TLB011BAL 10
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12. Install the closed end cover.
RCPH11TLB012BAL 11
13. Install the bolts and the flat washers. Tighten the
bolts evenly to a torque of 339 N·m (250 lb ft).
RCPH11TLB013BAL 12
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Hydraulic pump - Assemble

580N, 580N NA, 580SN, 580SN WT, 590SN
1. Insert the piston and shoe assemblies into the re-

tainer plate.
RCPH10CCH700BAO 1
2. Install the pivot ring (1) on the cylinder block assem-

bly.
RCPH10CCH699BAO 2
3. Install the pistons and retaining plate into the cylinder

block.
4. Place the swash plate on the rotation group.
5. Using a press, install the tapered roller bearing cone.
RCPH10CCH702BAO 3
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6. Install the seal on the pump housing.
RCPH10TLB029BAM 4
7. Insert the shaft into the swash plate and rotation

group.
RCPH10TLB030BAM 5
8. Install the swash plate trunnion bearings (1) in the

pump housing.
RCPH10CCH698BAO 6
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9. Insert the shaft assembly into the pump housing.
RCPH10CCH703BAO 7
Measuring the shaft bearing spacer

10. Install the pump housing o-ring.
RCPH10TLB024BAM 8
11. Install the port block o-rings.
RCPH10TLB023BAM 9
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12. Install the port block on the pump housing. Torque

the bolts to 50 - 54 N·m (37 - 40 lb ft).
RCPH10TLB021BAM 10
13. Install a dial indicator, as shown, with the indicator in

contact with the end of the shaft and set at zero.
RCPH10CCH704BAO 11
14. Pry up on the shaft and record the measurement of

the indicator. Be sure the indicator returns to zero
when the shaft moves downwards. If the indicator
does not return to zero, reset the indicator and repeat
the procedure.
RCPH10CCH705BAO 12
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15. Remove the dial indicator and the port block from
the pump housing. Remove the bearing from the
shaft. Select a bearing spacer that is 0.00 to 0.05 mm
(0.000 to 0.002 inch) thicker than the dial indicator
recorded measurement.
RCPH10CCH706BAO 13
16. Install the bearing adjustment shim.
RCPH10CCH697BAO 14
17. Install the tapered roller bearing cone.
RCPH10CCH696BAO 15
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18. Install the control valve follower. Torque the bolt to

15 - 20 N·m (11 - 15 lb ft).
RCPH10TLB027BAM 16
19. Install the control plate.
RCPH10TLB026BAM 17
20. Install the counter piston spring and counter piston.
RCPH10TLB025BAM 18
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21. Install the control piston guide.
RCPH10TLB022BAM 19
22. Install the port block. Torque the bolts to 50 - 54 N·m

(37 - 40 lb ft).
RCPH10TLB021BAM 20
23. Install the control valve. Torque the bolts to 15 - 16

N·m (10 - 12 lb ft).
NOTE: Verify proper placement of o-rings.
RCPH10TLB020BAM 21
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24. Install the flange cover and gasket. Torque the bolts
to 52 - 61 N·m (38 - 45 lb ft).
RCPH10TLB019BAM 22
25. Install the compensator and gasket. Torque the bolts

to 15 - 16 N·m (10 - 12 lb ft).
RCPH10TLB018BAM 23
26. Install the solenoid.
RCPH10TLB017BAM 24
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27. Install the solenoid line.
RCPH10TLB016BAM 25
28. Install the compensator valve line.
RCPH10TLB015BAM 26
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Hydraulic pump - Disassemble

580N, 580N NA, 580SN, 580SN WT, 590SN
Prior operation:
Hydraulic pump - Prepare Work Surface (A.10.A)
RCPH10TLB043GAM 1
(1) Load Sense Spool (6) Outlet

(2) Case Drain 1 (7) Gage Port
(3) Load Sense Port (LS) (8) Torque Control Variable Relief
(4) Torque Control Spool (9) Case Drain 2
(5) Inlet (10) Torque Regulation Selection Solenoid
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1. Remove the torque tubes from the pump.
RCPH10TLB015BAM 2
2. Remove the solenoid retention nut, o-ring and sole-

noid coil from the pump. The solenoid cartridge can
remain installed .
3. Remove the 4 screws holding the pump compen-
sator. Remove the compensator and gasket.
RCPH10TLB018BAM 3
4. Clamp the pump in a vise with the shaft pointing

down. The vise jaws must be on the side of the pump
mounting flange and NOT on the machined surface
of the machined alignment boss.
5. Remove the 4 large screws that secure the rear cover
on the pump.
RCPH10TLB021BAM 4
6. Remove the rear cover of the pump and valve plate.

Also remove the control pistons and springs.
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7. There is one large and four small o-rings that seal

the rear cover of the pump. Remove these and set
aside.
8. Remove the rear bearing and spacer underneath
from the pump shaft.
9. With a helper, remove the pump from the vise.
10. While holding the rotating group into the pump, tilt
the pump and pour the oil from the pump case into a
bucket or drain pan.
11. Set the pump on a workbench with the shaft horizon-
tal and remove the rotating group from the pump. It
is best to reach in past the cylinder and separate the
piston shoes from the swash plate.
12. Remove the two screws holding the torque control
variable relief onto the to of the pump. Remove the
variable relief.
13. Remove the single screw holding the relief valve cam
onto the swash plate. Note the orientation of the
cam, then pull if free of the swash plate. The cam
is pressed onto a pin, so a pair of pliers may be used
to pull the cam loose.
14. Remove the swash plate and shaft from the pump.
15. Remove the swash plate trunnion bearings (1) from
the pump housing.
RCPH10CCH698BAO 5
16. Remove the seal from the pump housing.

17. Remove the shaft from the swash plate and rotation
group.
18. Using a press, remove the tapered roller bearing
cone.
RCPH10CCH701BAO 6
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19. Mark the pistons and retaining plate with their posi-
tion in the cylinder. Remove the pistons and retaining
plate.
20. Remove the pivot ring (1) from the cylinder block as-
sembly.
RCPH10CCH699BAO 7
21. remove the piston and shoe assemblies from the re-
tainer plate.
RCPH10CCH700BAO 8
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Accumulator - Check - Ride control

1. Ensure that the oil side of the accumulator is com-
pletely discharged.
1. Put the ride control switch in the ON posi-
tion.
2. Lower the loader to the floor.
3. Put the loader control lever in the FLOAT
position.
5. Put the key switch in the ON position.
6. Move the loader control lever in all direc-
tions to release any pressure in the hy-
draulic circuits.
7. Put the loader control lever in the FLOAT
position.
NOTICE: Ensure you leave the ride control switch and the
key switch in the ON position and the loader control lever
in the FLOAT position.
2. Close valve (B) and valve (C) on the nitrogen charge
with regulator kit 380001737.
RCIL10TLB016BAF 1
3. Turn the stem out of valve (F) until the stem stops.
4. If you have not already done so, remove the cap
screws and guard from the accumulator.
5. Connect valve (F) to the valve stem.
6. Make sure that valve (D) is open.
7. Turn the stem into valve (F) and read the pressure on
gauge (E). The pressure must be 24 - 26 bar (350 -
375 psi).
8. If the pressure is too low, charge the accumulator
with dry nitrogen. Refer to Accumulator - Charging
- Ride control (A.10.A).
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Accumulator - Charging - Ride control

Prior operation:
Accumulator - Check - Ride control (A.10.A)
Prior operation:
Keep the nitrogen charge with regulator kit 380001737 attached to the machine.
1. Slowly turn valve (A) counter-clockwise to lower the

pressure.
2. Open valve (B).
3. Close valve (C) and valve (D).
4. Turn the stem out of valve (F) until the stem stops
moving.
RCIL10TLB016BAF 1
5. Disconnect valve (F) from the valve stem on the ac-

cumulator.
6. Connect the nitrogen charge with regulator kit to a
dry nitrogen tank.
7. Slowly turn valve (A) clockwise and read gauge (E).
8. When the pressure is 24 - 26 bar (350 - 375 psi),
stop turning valve (A).
9. If the pressure increases above 26 bar (375 psi),
quickly open and close valve (D) and read gauge
(E). The pressure shown on gauge (E) is the charge
pressure.
10. Check gauge (E) again.
11. If the pressure is still too high, turn valve (A) coun-
terclockwise a small amount and quickly open and
close valve (D).
12. Repeat steps 10 and 11 until the pressure is within
specification.
13. Connect valve (F) to the valve stem on the accumu-
lator.
14. Turn the stem into valve (F) until the stem stops mov-
ing.
15. Open valve (D) to charge the accumulator.
16. After the accumulator stops charging, turn the stem
out of valve (F) until the stem stops moving.
17. Close valve (B).
18. Disconnect the nitrogen charge with regulator kit
from the valve stem in the accumulator
19. Install the cap on the valve stem.
20. Install the guard and cap screws.
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Accumulator - Discharging - Ride control

NOTICE: Always discharge the nitrogen in the accumulator before disassembling the accumulator.
1. Use the nitrogen charging with regulator kit
380001737 to discharge the accumulator. The tool
must be disconnected from the nitrogen tank (7).
2. Close valve (B), valve (C) and valve (D).
NOTICE: To help prevent equipment damage, the low
pressure gauge (valve (C)) must be shut off during high
pressure applications of 10 bar (150 psi) and above.
3. Turn the knob counter-clockwise on valve (A) to ad-
just the regulator to the minimum pressure setting.
4. Turn the T-handle on valve (F) until it is fully out.
5. Remove the guard and cap from the accumulator
charging stem (8). RCIL10TLB016BAF 1
6. Connect valve (F) to the stem on the accumulator.

7. Turn the T-handle inward on valve (F) to engage the
pin in the valve stem.
8. Open valve (D) and check the charge pressure on
gauge (E).
9. Partially open valve (B) to discharge the accumula-
tor. The accumulator charge will bleed down through
the regulator.
10. Once the accumulator is fully discharged, disconnect
valve (F) from the accumulator stem.
Next operation:
Accumulator - Disassemble - Ride control (A.10.A)
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Accumulator - Disassemble - Ride control

1. Fasten the accumulator tube (1) in a vise with soft
jaws. Be careful not to damage the tube.
2. Loosen and remove the gland with the gas valve (2)
from the tube end.
NOTICE: The gland with the gas valve must be removed
first.
3. Loose and remove the glad without the gas valve (12)
from the other end of the tube.
4. Use a rod and push out the piston (3).
NOTE: This piston is at the same end of the tube that you
removed the gland with the gas valve.
5. Remove and discard the seals (4) and the quad ring
(5) from the piston.
6. Remove and discard the O-rings (6) and the backup
rings (7), if used, from the glands.
7. Loosen and remove the cap screws (8) and the guard
RCIL10TLB018BAF 1
(9).
8. Loosen and remove the gas valve assembly (10)
from the gland.
9. Remove and discard the O-ring (11) from the gas
valve assembly.
10. Remove the cap, the body, and the valve core from
the gas valve assembly.
Next operation:
Accumulator - Inspect (A.10.A)
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Accumulator - Inspect - Ride control

Prior operation:
Accumulator - Disassemble (A.10.A)
1. Discard parts removed from the gland (2) and (4) and
piston (3).
2. Clean all parts in cleaning solvent free of dirt and
contaminates.
3. Inspect the inside of the tube (1) for deep grooves
and other damage. If there is any damage, a new
accumulator must be used.
4. Remove small scratches on the piston (3), gland (2)
and (14) or tube (1) with an emery cloth of 400 or finer
grit. Rotate the emery cloth with a circular motion
when trying to removing the scratches. Inspect the
gland ends of the tube for sharp edges that will cause
damage to the seals, quad ring, or O-rings. Remove
any sharp edges as needed.
5. Inspect the gland (9) for rust. Clean and remove the
rust as required.
6. Inspect the piston (3) for damage or wear. If the
piston (3) is damaged or worn, a new accumulator
must be used.
7. Inspect the gland ends of the tube (1) for sharp
edges that will damage the seals (4), quad ring (5) or
O-rings (6). Remove any sharp edges as required.
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RCPH11TLB007GAM 1
(1) Tube (8) Cap Screw

(2) Gland with Gas Valve (9) Guard
(3) Piston (10) Gas Valve Assembly
(4) Seal (11) Cap
(5) Quad Ring (12) Valve Core
(6) O-ring (13) Body
(7) Backup Ring, if used (14) Gland without Gas Valve
Next operation:
Accumulator - Assemble (A.10.A)
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Accumulator - Assemble
Prior operation:
Accumulator - Inspect (A.10.A)
1. Install a new quad ring (6) on the piston (3).
RCIL10TLB018BAF 1
(1) Tube (8) Cap Screw

(2) Gland with Gas Valve (9) Guard
(3) Piston (10) Gas Valve Assembly
(4) Seal (11) Cap
(5) Quad Ring (12) Valve Core
(6) O-ring (13) Body
(7) Backup Ring, if used (14) Gland without Gas Valve
2. Install a new seals (4) on each end of the piston (3).

3. Lubricate the bore of the tube (1) and the piston (3)
with clean oil.
NOTE: The piston must be installed slowly to prevent dam-
age to the quad ring on the threads in the tube.
4. Start the piston (3) into the gas valve end of the tube
(1). A soft hammer and wood block may be used to
drive the piston (3) into the tube (1). See the illustra-
tion below of the correct piston installation. Carefully
drive the piston (3) at least 51 mm (2 in) into the
tube (1). Keep pressure against the piston (3) when
driving the piston (3) into the tube (1). This will help
prevent damage to the quad ring (5).
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5. If used, install a new backup ring (6) on the gland (2).

Make sure the backup ring (6) is installed as shown
in the illustration below.
RCPH11TLB001BAM 2
(6) O-ring (7) Backup ring

(A) To thread end of gland
6. Install the O-ring (6) next to the backup ring (7) as

shown in the illustration above. If a backup ring (7) is
not used, install an O-ring in the grove on the piston.
7. Lubricate the o-ring (6) and backup ring (7) with clean
oil and start the gland (2) into the tube (1).
RCIL10TLB018BAF 3
8. Fasten the tube (1) in the vise and tighten the gland.
9. repeat steps 5 through 8 for the other end of the tube
(1).
10. Install a new o-ring (6) on the body (13) of the gas
valve assembly (10).
11. Install the valve core (12) in the body (13).
12. Lubricate the O-ring (6) with clean oil and install and
tighten the gas valve assembly (10) in the gland.
13. Install the cap (11).
14. Charge the accumulator with dry nitrogen. Refer to
Accumulator - Charging - Ride control (A.10.A).
15. Install the guard (9) and cap screws (8).
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RCPH11TLB007GAM 4
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Accumulator - Pressure test Right Solenoid Valve for Ride Control

(Accumulator)
RCPH10TLB008GAM 1
(1) Ride Control Valve (4) Tube, Ride Control to P2 Port

(2) Accumulator (5) Tube, Ride Control to P1 Port
(3) Tube, Ride Control to Accumulator (6) Tube, Ride Control T Port
1. Verify that the oil side of the accumulator is com-

pletely discharged by doing the following:
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A. Put the ride control switch in the ON posi-

tion.
B. Lower the loader to the floor. Put the
loader control lever in the float position.
C. Stop the engine. Put the key switch in the
ON position.
D. Move the loader control lever in all di-
rections to release any pressure in the
hydraulic circuits. Put the loader control
lever in the float position.
2. Put the ride control switch and key switch in the OFF
position.
3. Put the loader control lever in the NEUTRAL position.
4. Disconnect the tube (3) between the right solenoid
valve (1) and the accumulator (2) at the right solenoid
valve.
5. Remove the adjustable elbow fitting in the right sole-
noid valve. Install an adjustable tee in that location.
6. Connect the tube from the accumulator to the ad-
justable tee fitting in the right solenoid valve.
7. Connect DATAR to the fitting on the right solenoid
valve. Connect TA092 pressure transducer to the
fitting. Set the transducer to 60 Bar.
NOTE: If DATAR is not available, a pressure gauge of 27580 kPa (4000 psi) or greater can be used.
8. Put the ride control switch in the OFF position. Start
and Run the engine at low idle.
9. Move the loader control lever to the RAISE position
while monitoring the pressure value. The pressure
should be approximately 0 kPa (0 psi). If the pres-
sure reading indicates more than 172 kPa (25 psi)
repair or replace the right solenoid valve for ride con-
trol.
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Accumulator - Pressure test Checking the Nitrogen Charge in the

Accumulator
CAS10899 1
1. Make sure that the oil side of the accumulator is com-

pletely discharged by doing the following.
A. Put the ride control switch in the ON posi-
tion.
B. Lower the loader to the floor. Put the
loader control lever in the float position.
C. Stop the engine. Put the key switch in the
ON position.
D. Move the loader control lever in all di-
rections to release and pressure in the
hydraulic circuits. Put the loader control
lever in the FLOAT position.
E. Leave the ride control switch and key
switch in the ON position.
F. Leave the loader control lever in the
FLOAT position.
2. Close valves (B) and (C) on the nitrogen charging kit.
3. Turn the stem out of valve (F) until the stem stops.
4. Remove the cap screws and guard from the accumu-
lator.
5. Remove the cap from the valve stem on the accumu-
lator.
6. Connect valve (F) to the valve stem.
7. Verify that valve (D) is open.
8. Turn the stem into valve (F) and read the pressure
on gauge (E). The pressure must be between 2413 -
2585 kPa (350 - 375 psi). If the pressure is too low,
charge the accumulator with dry nitrogen.
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Accumulator - Charging - Charging the Accumulator With Dry

Nitrogen
NOTE: Verify the pressure in the accumulator according to the instructions in Accumulator - Pressure test (A.10.A).
CAS10899 1
1. Slowly turn the valve (A) counterclockwise to lower

the pressure.
2. Open valve (B). Close valves (C) and (D).
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.
5. Slowly turn valve (A) clockwise and read gauge (E)
until the pressure is 2413 - 2585 kPa (350 - 375 psi).
6. If the pressure increases above 2585 kPa (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 quickly open
and close valve (D). The pressure shown on gauge
(E) is the charging pressure.
7. Connect valve (F) to the stem on the accumulator.
Turn the stem into valve (F) until the stem stops mov-
ing and open valve (D) to charge the accumulator.
8. After the accumulator stops charging, turn the stem
out of valve (F) until the stem stops moving.
9. Close valve (B) and disconnect the nitrogen charging
kit from the valve stem on the accumulator.
10. Install the cap on the valve stem. Install the guard
and cap screws.
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Control valve - Cleaning 580N Pilot machines only

1. Remove valve from machine, see Remote valve -
Remove (A.10.A)
2. Clean the valve.
3. Loosen the plug.
NOTE: During assembly torque to 90 - 110 N·m (66 - 81 lb
ft).
RCPH10TLB392ABL 1
4. Remove the plug.
RCPH10TLB393ABL 2
5. Remove the springs.
RCPH10TLB394ABL 3
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6. Remove the spool.
RCPH10TLB395ABL 4
7. Loosen the load sense relief valve.

ft).
RCPH10TLB396ABL 5
8. Remove the load sense relief valve.
RCPH10TLB397ABL 6
9. Loosen load sense drain orifice.

ft).
RCPH10TLB398ABL 7
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10. Remove the load sense drain orifice.
RCPH10TLB399ABL 8
11. Number the sections for correct assembly.
RCPH10TLB400ABL 9
12. Remove the nuts securing the sections.

NOTE: During assembly use new O-rings in all sections
and torque nuts to 42 N·m +/- 4.2 (31 lb ft +/- 3).
RCPH10TLB401ABL 10
13. Remove the end cover.
RCPH10TLB402ABL 11
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14. Continue to separate the working sections from inlet

section.
RCPH10TLB403ABL 12
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Control valve - Cleaning - Swing, Bi-Dir Aux and Stabilizer sections

For Stabilizer Sections, begin at step 8.
1. Unscrew the check valve plug.
RCPH10TLB404ABL 1
2. Remove the check valve. Clean and inspect check

valve, replace as an assembly as needed.
NOTE: During assembly use new O-ring and torque to 30
N·m +/- 3 (22 lb ft +/- 2).
RCPH10TLB405ABL 2
3. Repeat steps 1 and 2 for the other check valve.

4. Remove the cap from the relief valve.
RCPH10TLB406ABL 3
5. Loosen the relief valve.

ft).
RCPH10TLB407ABL 4
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6. Remove the relief valve from the section.
RCPH10TLB408ABL 5
7. Repeat steps 4 through 6 and remove the other pres-

sure relief valve.
8. Loosen and remove the end cap mounting screws.
NOTE: During assembly torque to 9 - 11 N·m (7 - 8 lb ft).
RCPH10TLB409ABL 6
9. Remove the end cap.
RCPH10TLB410ABL 7
10. Remove the spring.
RCPH10TLB411ABL 8
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11. Remove the spool guide.
RCPH10TLB412ABL 9
12. Repeat steps 8 through 11 and remove the other end

cap.
13. Remove the spool from the section.
NOTICE: Record spool grove orientation in relation to the
A or B ports. Labels A and B are cast into the valve section.
RCPH10TLB413ABL 10
14. Unscrew the compensator plug.

NOTE: During assembly use new O-ring and torque to 54
- 66 N·m (40 - 49 lb ft).
RCPH10TLB414ABL 11
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15. Remove the compensator piston. Clean and inspect

the piston and bore, use new parts as required.
(1) Solid compensator
RCPH10TLB415ABL 12
(2) Dampened compensator (Stabilizer sections use a load

check)
RCPH10TLB416ABL 13
16. Separate and inspect the dampened compensator or

load check.
RCPH10TLB417ABL 14
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Control valve - Cleaning 580SN, 580SN WT and 590SN machines

1. Remove valve from machine, see Remote valve -
Remove (A.10.A)
2. Clean the valve.
3. Loosen the plug.
ft).
RCPH10TLB392ABL 1
4. Remove the plug.
RCPH10TLB393ABL 2
RCPH10TLB394ABL 3
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RCPH10TLB395ABL 4
7. Loosen and remove the plug installed in the load

sense relief valve location. .
RCPH10TLB396ABL 5
8. Loosen and remove plug installed in the load sense

drain orifice.
RCPH10TLB398ABL 6
9. Number the sections for correct assembly.
RCPH10TLB400ABL 7
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10. Remove the nuts securing the sections.

NOTE: During assembly use new O-rings in all sections
and torque nuts to 42 N·m +/- 4.2 (31 lb ft +/- 3).
RCPH10TLB401ABL 8
11. Remove the end cover.
RCPH10TLB402ABL 9
12. Continue to separate the working sections from inlet

section.
RCPH10TLB403ABL 10
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Control valve - Disassemble - Ride control solenoid valve

1. Remove the ring nut (1) from the solenoid.
2. Remove the coil (2).
3. Remove the cartridge (3) from the ride control valve
block.
4. Remove and discard the O-rings from the cartridge.
RCPH10TLB008CAM 1
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Control valve - Assemble - Ride control solenoid valve

1. Install new O-rings on the cartridge (3).
2. Lubricate the O-rings on the cartridge with clean hy-
draulic oil.
3. Install and tighten the cartridge in the ride control
valve block.
4. Install the coil (2).
5. Install and tighten the ring nut (1).
RCPH10TLB008CAM 1
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Control valve - Disassemble - Boom lock solenoid valve

1. Fasten the body of the boom lock solenoid valve in a
vise with soft jaws.
2. Loosen and remove the relief valve body (1).
3. Remove the piston (9), outer spring (7), inner spring
(8), poppet (5), relief valve seat (2), backup ring (4),
and O-ring (3) from the solenoid body.
4. Discard the backup ring and the O-ring.
5. Remove and discard O-ring (13) from the relief valve
body.
6. Remove and discard the O-ring (10) from the piston.
7. Remove the and discard O-ring (6) from the poppet.
RCIL10TLB017BAF 1
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Control valve - Inspect - Boom lock solenoid valve

Prior operation:
Control valve - Disassemble (A.10.A)
1. Clean the relief body, the piston, the poppet, and the
relief valve seat in cleaning solvent.
2. Inspect all the disassembled parts for damage or
wear.
3. Replace as needed.
4. Inspect the solenoid in the solenoid valve for dam-
age.
5. If damage is found, replace the solenoid. DO NOT
repair the solenoid.
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Control valve - Assemble - Boom lock solenoid valve

Prior operation:
Control valve - Inspect (A.10.A)
1. Install a new O-ring (3), a new backup ring (4), the

relief valve seat (2), a new O-ring (6), the poppet (5),
the inner spring (8), the outer spring (7), a new O-ring
(10), and the piston (9) into the solenoid body.
2. Install a new O-ring (13) onto the relief valve body
(1).
3. Install the relief valve body onto the solenoid body.
4. Adjust the pressure setting of the relief valve. Refer
to the instructions provided with the relief valve.
RCIL10TLB017BAF 1
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PRIMARY HYDRAULIC POWER SYSTEM - Testing - Problem in a

loader circuit
N° Test Point Expected Result Other Result (Possible Cause)
1 Condition Result Action
Check the machine for missing or Yes, check the O-ring on the end of No, check the operation of the spool
damaged parts. If equipped with ride the circuit relieve valve or plug. in both directions. Is the spool oper-
control, make sure the ride control ation correct? If no, remove and in-
button is in the OFF position. spect the spool and loader valve for
Check damage. Repair or replace the spool
Check the operation of the problem or valve, as necessary.
circuit, Do the cylinder(s) move in
both directions.
2 Check Result Action
Is the circuit relief valve or plug Yes, check the setting of the circuit No, replace the O-ring.
O-ring within acceptable limits? relief valve, if used, for the problem
circuit. Is the setting correct?
Is the circuit relief valve setting cor- Yes, check the cylinder piston pack- No, adjust circuit reliefs.
rect? ing. Is the cylinder piston packing
acceptable?
Is the cylinder piston packing accept- Yes, the control valve has internal No, replace or repair the cylinder, as
able? wear or damage. Repair or replace necessary.
the individual section or control valve
as necessary.
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Problem in the

4x1 Clam Circuit
Check for power at controller, Is Yes, disconnect solenoids, activate No, check fuse, check wring to con-
power present at controller? circuit. troller.
Is power present at solenoids? Yes, take an Ohm reading on the No, check wiring to solenoids.
solenoids, a reading of 5.4 Ohms at
20 °C (68.0 °F) should be obtained.
Are the Ohm readings correct? Yes, check pilot pressure at pilot No, replace solenoids.
manifold, a reading of 24 - 34.5 bar
(348.0 - 500 psi)should be obtained.
Is the pilot pressure correct? Yes, Does the accumulator hold a No, replace pressure reducing
charge. To check the accumulator, catridge.
open the clam so the weight of the
clam is on the cylinders, raise the
loader and hold under pressure for
30 seconds. Stop the engine, turn
the ignition switch to accessory, acti-
vate the clam switch to the close po-
sition.
Does the clam drop? Yes, check for operation of spool in No, replace the accumulator.
both directions.
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Is the spool operation correct? Yes, check whether the cylinder No, remove and inspect the spool
packing is within acceptable limits. and loader valve for damage. Repair
or replace the spool or valve as nec-
essary.
Is the cylinder piston packing within Yes, troubleshooting complete. No, repair the cylinder, as necessary.
acceptable limits?
PRIMARY HYDRAULIC POWER SYSTEM - Testing 580N Machines

only
Check the machine for missing or Yes, does the pilot accumulator hold No, replace the pressure reducing
damaged parts. If equipped with ride a charge. To check the accumula- cartridge. If still no, remove and in-
control, make sure the ride control tor, extend the dipper out from the spect the check valve orifice.
button is in the OFF position. machine so the weight of the dip-
Check per is on the cylinder, curl the bucket
Operations slow or not working cor- and hold under pressure for 30 sec-
rectly. Check the pilot pressure at pi- onds. Stop the engine, turn the igni-
lot control manifold. Reading should tion switch to accessory, activate the
be 24 - 34.5 bar (348.0 - 500.3 psi) pilot controls, pull the dipper control
Is pilot pressure correct? lever.
Does the dipper drop? Yes, is the minimum displacement No, replace the accumulator.
bypass valve stuck open?
Does the valve move freely? Yes, load sensing relief not set cor- No, remove and examine for con-
rectly or contaminated. Take pres- tamination jamming the valve open.
sure reading at "M" port on backhoe If contaminated, replace valve.
valve by operating a stabilizer over Clean hydraulics, refer to section
relief. PRIMARY HYDRAULIC POWER
SYSTEM - Cleaning (A.10.A)
Is the pressure setting correct, 207 - Yes, check the setting of the circuit No, adjust the LS relief setting. If re-
214 bar (3001.5 - 3103.0 psi) relief valve, if used, for the problem lief cannot be achieved, replace the
circuit. LS relief valve.
Is the circuit relief valve setting cor- Yes, low pilot pressure at backhoe No, replace of adjust the circuit relief
rect? valve pilot port for the specific func- valve.
tion. Reading should be 24 - 34.5
bar (348.0 - 500.3 psi)
Is the pilot pressure correct? Yes, remove the end cap of the pilot No, Is the function controlled by the
spool chamber and check that the hydraulic joystick or by an electrically
spool moves freely. controlled solenoid? Hydraulic: If
pressure is less than 24 bar (348.0
psi) and pilot pressure at the point
manifold pressure is OK, replace the
joystick control valve. If the prob-
lem is not fixed replace the pres-
sure reduction manifold. Electrical:
Check the electronic controller for er-
ror codes, repair faults. If the prob-
lem is not fixed replace the pressure
reduction manifold.
84516378 05/07/2011
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Does the spool move freely? Yes, check the boom section regen- No, replace the valve section. See
erative spool. To check extend the section Control valve - Remove -
boom out behind the machine about Mechanical linkage backhoe ma-
3 foot from the ground, with the en- chines only (J.50.C)
gine at high idle raise the boom.
Does the boom go down slightly be- Yes, replace the boom section in the No, go to next test.
fore raising? backhoe valve.
Is engine load excessive when a hy- Yes, adjust the pump compensator No, check the cylinder piston pack-
draulic function is stalled? (Pump to 20 bar (290 psi)and minimum dis- ing.
does not destroke). placement bypass to 26 bar (377.0
psi). NOTE: Oil that is cold, below
4 °C (39.2 °F) will have the same af-
fect, heat they hydraulic oil accord-
ing to instructions in the operator's
manual.
Is the cylinder piston packing good? No, NOTE: Boom cylinder only. A Yes, troubleshooting complete.
cushion relief valve is installed in the
piston. The problem in the boom cir-
cuit can be the cushion relief valve
instead of the cylinder piston pack-
ing. Repair the cylinder, as neces-
sary.
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Single function

will not work independently from other functions
Sectional pressure check Sectional pressure compensator Replace sectional compensator or
plugged or jammed. valve section. See section Con-
trol valve - Remove - Mechanical
linkage backhoe machines only
(J.50.C)
PRIMARY HYDRAULIC POWER SYSTEM - Testing

Intermittent stabilizer operation. Is Yes, check the connectors at the No, make sure the electronic con-
operator waiting 1 to 2 seconds be- proportional control solenoids and trols are in the neutral position when
fore operating the stabilizers after switches for good contacts. placing the pilot system switch to the
power up the system? "ON" position.
Are the contacts good? Yes, check proportional valves for No, repair connectors.
sticking. Remove the solenoid,
attach a 12V system to the sole-
noid connectors. Connect and dis-
connect power while watching for
plunger movement.
Does the plunger move? Yes, troubleshooting complete. No, replace the solenoid. NOTE:
Check for operation within the 6
small holes in the stem. There is only
a slight movement of the plunger.
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PRIMARY HYDRAULIC POWER SYSTEM - Testing

Examine swivel mechanism. Yes, See next test. No, if shafts are bent or knuckles are
Check distorted, replace swivel assembly.
Are the swivel shafts or the knuckle
joints undamaged?
Do electrically controlled compo- Yes, go to next test. No, if solenoids have power but are
nent operations stop after release not returning to neutral, replace con-
of switch, stabilizer, extend-a-ahoe, trol solenoids, if solenoids do not
auxiliary hydraulics? have power, replace the switch.
Pull up the boot on the handle, ex- Yes, go to next test. No, disassemble pilot control han-
amine valves for free movement. dles, See section Remote valve -
Check with machine off then check Remove - Pilot controls backhoe
with machine on and pilot controls valve (A.10.A) and check for defects
energized. Do spool return to neu- or contamination. If contaminated,
tral freely. clean, reassemble and test, if de-
fects found, replace handle assem-
bly.
Connect a tee into the pilot circuit Yes, go to next test. No, if pressure does not drop to 0 -
that is not returning to neutral, attach 0.4 bar (0.000 - 5.8 psi)replace the
a 70 bar (1015.0 psi) gauge. Full control handle.
stroke the function and record pres-
sure, release the function. Does the
pressure drop instantaneously.
Remove pilot spool end cap. Does Yes, go to next test. No, remove spool and check for con-
the spool move freely? tamination, clean the components,
reassemble and test. If defects
are found replace defective compo-
nents.
Remove pilot spool end cap. Are Yes, troubleshooting complete. No, if defects are found replace de-
spool centering rings free of defects? fective components.
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Noise from the

backhoe hydraulic system
Does the system operate normally Yes, troubleshooting complete. No, air in the pilot system or system
without noise. pressure is low. 1. Crack open the
pilot lines on the pilot end caps at the
backhoe valve, operate each func-
tion until no air spits or bubbles out of
the lines. 2. Start the machine and
operate the backhoe, fully stroking
each function back and forth. Con-
tinuously operate the systems until
the oil is at operating temperature. If
noise persists, shut down and allow
to cool and repeat the procedure.
Low pilot pressure will not fully shift Yes, troubleshooting complete. No, replace the pressure reducing
the spool. Reading should be 24 - cartridge.
34.5 bar (348.0 - 500.3 psi). Is the
pilot pressure correct?
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PRIMARY HYDRAULIC POWER SYSTEM - Testing - All pilot controls

stop working
Yes, check the relay for proper con-
Check the fuse. Is the fuse service- No, replace fuse.
able? nection.
Is the relay properly connected? Yes, check enable switch for proper No, reconnect relay.
connection.
Is the enable switch properly con- Yes, troubleshooting complete. No, reconnect enable switch.
nected?
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Pilot pattern

change does not function
NOTE: Overtorquing will cause the solenoid to bind and stick.
NOTE: Pattern change problems will only affect boom and dipper functions.
Change the switch from #1 setting to Yes, disconnect the pattern changeNo, check for power to the switch, if
#2 setting. Does pattern change light solenoids and check for power. power is present change the switch,
illuminate? if no power see electrical trou-
bleshooting.
Is there power at both of the pattern Yes, remove and check O-rings on No, check wiring and connectors.
change solenoids? solenoids.
Are O-rings serviceable? Yes, swap the solenoids and check No, replace O-rings.
operation.
Did bad operation reverse? Yes, replace the solenoids. Check the torque on the solenoid coil
mounting nuts, torque should be 1.7
- 2.2 N·m (15.0 - 19.5 lb in)
PRIMARY HYDRAULIC POWER SYSTEM - Testing - 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- No, troubleshooting complete. Yes, test solenoids, 5.5 Ohms at 20
hoe or auxiliary control shorted to °C (68 °F), replace as needed.
ground or open circuit. Check wiring
from stabilizer, extend-a-hoe or aux-
iliary control to module, is there still
a problem?
Is there still a problem? No, troubleshooting complete. Yes, replace control module.
Fault code2: Stabilizer, ex- No, troubleshooting complete. Yes, check wiring from stabilizer,
tend-a-hoe or auxiliary hydraulics extend-a-hoe or auxiliary control to
control shorted to Vbat. module.
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Is there still a problem? No, troubleshooting complete. Replace control module.
Fault code 3: Interlock for stabilizer, No, troubleshooting complete. Yes, check that all function switches
extend-a-hoe or auxiliary hydraulics are in the off position or are not de-
controls. pressed, turn the pilot power off and
back on.
Is there still a problem? No, troubleshooting complete. Yes, test, if problem persists, replace
control module.
Fault code4: Driver fault. Check No, troubleshooting complete. Yes, test solenoids, 5.5 Ohms at 20
wiring from stabilizer, extend-a-hoe °C (68.0 °F), replace as needed.
or auxiliary control to module, is
there still a problem?
Is there still a problem? No, troubleshooting complete. Replace control module.
Fault light on with no blink. Replace No, troubleshooting complete. Yes, call technical support.
control module, is there still a prob-
lem?
Fault light off. No power to module No, troubleshooting complete. Yes, replace control module.
or faulty control module. Check fuse
and pilot control relay, is there still a
problem?
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Hydraulic pump - Testing

Do a pump test. Is the pump good? Yes, do a stall test according to the No, Repair or replace the hydraulic
instructions in Section ENGINE - pump.
Speeds stall test normal (all mod-
els) (B.10.A)
Do a stall test, Is there still a prob- No, troubleshooting complete. Yes, See section PRIMARY HY-
lem? DRAULIC POWER SYSTEM -
Cleaning (A.10.A). Is the oil con-
taminated?
Is the hydraulic oil contaminated? No, check the remaining circuits. Yes, clean or replace the hydraulic
oil. See Section PRIMARY HY-
DRAULIC POWER SYSTEM -
Cleaning (A.10.A)
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Reservoir - Testing - Hydraulic oil reservoir

Visually check the machine for oil Yes, verify correct movement of the Fill the hydraulic reservoir with the oil
leakage and damaged or missing pilot controls. Check the operation specified in Capacities ()
parts. Repair or replace any dam- of the machine, does the machine
aged or missing parts. operate correctly.
Check
Check the oil level in the hydraulic
reservoir. Is the oil level correct?
Does the machine operate correctly? Yes, troubleshooting complete. Heat the oil in the hydraulic system to
operating temperature. Operate the
machine to find which circuits have
problems.
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Index

SYSTEMS - A

Accumulator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Accumulator - Charging - Charging the Accumulator With Dry Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Accumulator - Charging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Accumulator - Check - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Accumulator - Detailed view - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Accumulator - Disassemble - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Accumulator - Discharging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Accumulator - Exploded view - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Accumulator - General specification - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accumulator - Inspect - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Accumulator - Pressure test Checking the Nitrogen Charge in the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Accumulator - Pressure test Right Solenoid Valve for Ride Control (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . . 191
Accumulator - Special tools - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control valve - Assemble - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Control valve - Assemble - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Control valve - Cleaning - Swing, Bi-Dir Aux and Stabilizer sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Control valve - Cleaning 580N Pilot machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Control valve - Cleaning 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Control valve - Disassemble - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Control valve - Disassemble - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Control valve - Drawing Backhoe Control Valve, 8 Spool, Extendahoe with Pilot Controls, 580N machines . . . . 38
Control valve - Drawing Backhoe Control Valve, 8 Spool, Extendahoe with Pilot Controls, 580SN, 580SN WT and
590SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Control valve - Drawing Backhoe Valve, 8 Spool foot swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control valve - Drawing Loader Valve, 2 Spool for 580N with mechanical controls . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control valve - Drawing Loader Valve, 2 Spool for 580N with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Control valve - Drawing Loader Valve, 3 Spool for 580N with mechanical backhoe controls . . . . . . . . . . . . . . . . . 41
Control valve - Drawing Loader Valve, 3 Spool for 580N with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Control valve - Drawing Loader Valve, 3 Spool for 580SN, 580SN WT and 590SN with Pilot Controls . . . . . . . . . 44
Control valve - Drawing Loader valve, 3 Spool for 580SN, 580SN WT and 590SN with mechanical backhoe controls
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Control valve - Exploded view - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Control valve - Exploded view - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Control valve - Inspect - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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Control valve - Sectional view Boom, Dipper, Bucket, Extendahoe Sections, 580N, 580SN, 580SN WT and 590SN
machines with Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control valve - Sectional view Stabilizer Section, 580N, 580SN, 580SN WT and 590SN machines with Pilot Controls
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Filter - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hydraulic pump - Assemble - Single Section Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Hydraulic pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
580N, 580N NA, 580SN, 580SN WT, 590SN
Hydraulic pump - Assemble - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Hydraulic pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
580N, 580N NA, 580SN, 580SN WT, 590SN
Hydraulic pump - Disassemble - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Hydraulic pump - Disassemble - Single Section Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Hydraulic pump - Drawing - Output Test Hose Connections, 580SN, 580SN WT and 590SN . . . . . . . . . . . . . . . . 31
Hydraulic pump - Drawing Power Lift Valve 580SN, 580SN WT and 590SN machines with Mechanical Controls 32
Hydraulic pump - Drawing Power Lift Valve 580SN, 580SN WT and 590SN machines with Pilot Controlled Backhoe
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hydraulic pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Hydraulic pump - Inspect - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Hydraulic pump - Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Hydraulic pump - Install - 580SN, 580SN-WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Hydraulic pump - Prepare Work Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Hydraulic pump - Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Hydraulic pump - Remove - 580SN, 580SN-WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Hydraulic pump - Sectional view Hydraulic Pump, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic pump - Sectional view Hydraulic Pump, 580SN, 580SN WT and 590SN with Power Lift . . . . . . . . . . . . 30
Hydraulic pump - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
PRIMARY HYDRAULIC POWER SYSTEM - Adjust Torque Control Adjustment, 580SN, 580SN WT and 590SN
machines with Mechanical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
PRIMARY HYDRAULIC POWER SYSTEM - Adjust Torque Control Adjustment, 580SN, 580SN WT and 590SN
machines with Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
PRIMARY HYDRAULIC POWER SYSTEM - Assemble - Regulated manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PRIMARY HYDRAULIC POWER SYSTEM - Check - Flowmeter Check Sheet, 580N Mechanically Controlled ma-
chines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PRIMARY HYDRAULIC POWER SYSTEM - Check - Flowmeter Check Sheet, 580N Pilot machines . . . . . . . . . 73
PRIMARY HYDRAULIC POWER SYSTEM - Check Flowmeter Check Sheet, All 580SN, 580SN WT and 590SN
machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
PRIMARY HYDRAULIC POWER SYSTEM - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
PRIMARY HYDRAULIC POWER SYSTEM - Disassemble - Regulated manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
PRIMARY HYDRAULIC POWER SYSTEM - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PRIMARY HYDRAULIC POWER SYSTEM - Exploded view - Hydraulic gear pump seal, 580N only . . . . . . . . . . 14
PRIMARY HYDRAULIC POWER SYSTEM - Exploded view - Hydraulic gear pump, 580N only . . . . . . . . . . . . . . 12
PRIMARY HYDRAULIC POWER SYSTEM - Exploded view - Regulated manifold, Pilot Controls only . . . . . . . . 16
PRIMARY HYDRAULIC POWER SYSTEM - Exploded view 580N Pilot Machines only . . . . . . . . . . . . . . . . . . . . . 17
PRIMARY HYDRAULIC POWER SYSTEM - Exploded view 580SN, 580SN WT and 590SN machines with pilot
controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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PRIMARY HYDRAULIC POWER SYSTEM - Exploded view Hydraulic Pump 580SN, 580SN WT and 590SN . 13
PRIMARY HYDRAULIC POWER SYSTEM - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema Regulated manifold hydraulic schematic, Pilot Con-
trols Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PRIMARY HYDRAULIC POWER SYSTEM - Prepare - Machine Preparation, 580N Mechanically Controlled ma-
chines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
PRIMARY HYDRAULIC POWER SYSTEM - Prepare - Machine Preparation, 580N Pilot machines . . . . . . . . . . 64
machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
PRIMARY HYDRAULIC POWER SYSTEM - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, 580N Mechanically Controlled machines . . . . 78
PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . 66
PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, All 580SN, 580SN WT and 590SN machines 89
PRIMARY HYDRAULIC POWER SYSTEM - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
PRIMARY HYDRAULIC POWER SYSTEM - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
PRIMARY HYDRAULIC POWER SYSTEM - Testing - All pilot controls stop working . . . . . . . . . . . . . . . . . . . . . . 215
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Fault codes for pilot controller . . . . . . . . . . . . . . . . . . . . . . 215
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Noise from the backhoe hydraulic system . . . . . . . . . . . 214
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Pilot pattern change does not function . . . . . . . . . . . . . . 215
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Problem in a loader circuit . . . . . . . . . . . . . . . . . . . . . . . . . 211
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Problem in the 4x1 Clam Circuit . . . . . . . . . . . . . . . . . . . . 211
PRIMARY HYDRAULIC POWER SYSTEM - Testing - Single function will not work independently from other func-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
PRIMARY HYDRAULIC POWER SYSTEM - Testing 580N Machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Relief valve - Adjust - 580N Backhoe relief Pilot Controls only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Relief valve - Adjust Dual Stage Relief Valve, 580N Pilot Controlled Backhoe Valves . . . . . . . . . . . . . . . . . . . . . . 146
Relief valve - Adjust Main Relief Valve, 580N with mechanical controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Relief valve - Cleaning Relief Valve, Backhoe Main Relief Valve, 580N with Pilot Backhoe Controls . . . . . . . . . 142
Relief valve - Drawing Load Sense Relief Valve, 580N with Pilot Controlled Backhoe . . . . . . . . . . . . . . . . . . . . . . . 28
Relief valve - Drawing Relief Valve, 4000 psi Spike Clipper for Loader Valve on 580SN, 580SN WT and 590SN
machines with mechanical backhoe controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Relief valve - Drawing Relief Valve, Loader Dump, Backhoe Swing on mechanically controlled Backhoes . . . . . 24
Relief valve - Drawing Relief Valve, Main System Dual Stage for 580N with Pilot Controlled Backhoe . . . . . . . . . 27
Relief valve - Drawing Single Stage Relief Valve, 580 Main Relief with mechanical backhoe controls . . . . . . . . . 26
Relief valve - Drawing Swing and Bi-Dir Aux section, Backhoe Control Valves for 580N, 580SN, 580SN WT and
590SN Pilot Controlled Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Relief valve - Pressure test - Load Sense Relief Valve for 580N Backhoe relief Pilot Controls only . . . . . . . . . . 144
Relief valve - Pressure test Loader and Backhoe Main Relief Valve for 580N mechanical machines only. Loader
Main Relief Valve for 580N machine with Pilot Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Relief valve - Remove - Circuit relief valve, 580N, 580SN, 580SN WT and 590SN machines with Pilot Controls
(Swing and Bi-Directional relief valves only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Relief valve - Replace - Load Sense Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Remote valve - Check - Pilot control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Remote valve - Component diagram - Pilot control color codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Remote valve - Drawing 580N Mechanically Controlled Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Remote valve - Drawing 580SN, 580SN WT and 590SN Mechanically Controlled Machines . . . . . . . . . . . . . . . . . 22
Remote valve - Drawing Remote Clam Valve for 580SN, 580SN WT and 590SN with Pilot Controlled Backhoe 20
Remote valve - Install - Clam control pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Remote valve - Install - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Remote valve - Install - Mechanical controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Remote valve - Install - Pilot controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Remote valve - Install - Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Remote valve - Remove - Clam control pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Remote valve - Remove - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Remote valve - Remove - Mechanical controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Remote valve - Remove - Pilot controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Remote valve - Remove - Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Reservoir - Testing - Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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SECONDARY HYDRAULIC POWER SYSTEM - 12.A
580N
580SN WT
580SN
590SN
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Contents

SYSTEMS - A
TECHNICAL DATA
Coupler
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Coupler
Exploded view - Extendahoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Extendahoe hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Coupler hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - Coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sectional view Backhoe and Loader Quick Coupler Single Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sectional view Backhoe and Loader Quick Coupler Dual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE
Coupler
Remove - Hydraulic backhoe quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install - Hydraulic backhoe quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspect - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remote valve
Disassemble - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inspect - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check - Swing Cushion Valve (Swing Drift Troubleshooting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - SECONDARY HYDRAULIC POWER
SYSTEM
Coupler - Special tools

Tool kit 380100096
RCPH10TLB001AAL 1
Tool kit 380100096
RCPH10TLB017AAL 2
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SYSTEM
Coupler - Exploded view - Extendahoe
RCPH10TLB004FAL 1
RCPH10TLB005FAL 2
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SYSTEM
RCPH10TLB021AAL 3
(1) Retaining ring (15) Coupler

(2) Groove pin (16) Step pin seal orientation
(3) Step pin (17) Flat socket head screw (2)
(4) Outer coupler set screws (2) (18) Cover
(5) Outer coupler set screws (2) (19) Bolt
(6) Hose guard (20) Washer
(7) Hoses (21) 580SN Hose routing (top view)
(8) 90° Elbow (22) 590SN Hose routing (top view)
(9) Adapter (23) Sleeve
(10) Cylinder tube (24) Dipper ears
(11) Sleeve (25) Clamp
(12) 3/8 inch — 24 UNF hydraulic port (26) Cordura sleeve
(13) 7/16 inch — 20 UNF hydraulic port (27) Clamp
(14) Step pin seal
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SYSTEM
Coupler - Exploded view - Extendahoe hose routing
RCPH10TLB012GAM 1
580SN, 590SN WT and 590 SN Extendahoe hose routing
(1) Cylinder Assembly, bucket (7) Clamp

(2) Cylinder Extendahoe (8) Elbow, 45° adjustable
(3) Tube, Bucket Cylinder Rod (9) Elbow, 90° adjustable
(4) Tube, Bucket Cylinder Head (10) Connector 5/8 ORFS-ORB 5/8
(5) Tube, Extendahoe Cylinder Rod (11) Support
(6) Tube, Bucket Cylinder Rod
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SYSTEM
Coupler - Exploded view - Coupler hose routing

(1) 5 mm (0.20 in) Clearance (minimum) (3) 90 ° Elbows
(2) Hoses (4) Coupler
RCPH10TLB002AAL 1
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SYSTEM
Coupler - Exploded view

(1) Coupler
(2) Fitting access hole
RCPH10TLB018AAL 1
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SYSTEM
Coupler - Exploded view - Coupler cylinder
RCPH10TLB006FAL 1
(1) Cylinder tube (5) Internal retaining ring

(2) Retaining ring (6) Spacer
(3) Rod (7) External retaining ring
(4) Gland
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SYSTEM
Coupler - Exploded view - Quick coupler cylinder
RCPH10TLB006FAL 1
Quick coupler cylinder
(1) Tube (4) Snap ring

(2) Snap ring (5) Gland
(3) Spacer
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SYSTEM
RCPH10TLB003FAL 2
Coupler cylinder piston
(6) Piston rod (9) Ring

(7) Seal (10) O-ring
(8) Ring
RCPH10TLB020AAL 3
Coupler cylinder gland
(11) Wiper seal (14) O-ring

(12) Bushing (15) Backup ring
(13) Seal
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SYSTEM
Coupler - Exploded view - Swing dampening valve
RCPH10TLB002FAL 1
(1) Swing cushion valve (7) Plug

(2) Inline check valve (8) Bi-directional check valve
(3) Orifice check valve (9) Crossover spool assembly
(4) Bi-directional check valve (10) Plug
(5) Internal inline check valve (11) Spring
(6) Orifice plug (12) Crossover spool
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SYSTEM
Coupler - Sectional view Backhoe and Loader Quick Coupler Single

Valve
RCPH10TLB006CAM 1
(1) A Port - To RETRACT side of cylinder (6) Load Sensing Port

(2) B Port - To EXTEND side of cylinder (7) Two position - 2 way solenoid valve to
control pilot pressure
(3) Pressure Relief Valve (8) Two position - 4 way solenoid valve to
control cylinder
(4) To Tank (9) Orifice and check valve
(5) Pressure Port
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SYSTEM
Coupler - Sectional view Backhoe and Loader Quick Coupler Dual

Valve
RCPH10TLB002HAM 1
(1) A Port - To RETRACT side of cylinder (6) Load sensing port

(2) B Port - To EXTEND side of cylinder (7) Two position - 2 way solenoid valve to
control pilot pressure
(3) Pressure relief valve (8) Two position - 4 way solenoid to control
cylinder
(4) To tank (9) Orifice and check valve
(5) Pressure Port
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SYSTEM
Coupler - Remove - Hydraulic backhoe quick coupler

NOTE: Refer to Coupler - Exploded view (A.12.A)
1. Remove the bucket from the backhoe.
2. Remove the retaining rings (1) from the sleeves (11)
and (23).
3. Extend the piston rods out.
4. Remove the groove pins (2) from the step pins (3).
5. Remove the step pins (3).
NOTE: Step pins can be difficult to remove, due to the fit
of the step pin seal (14).
NOTE: If the cylinder (10) needs to be removed or the tube
is damaged follow steps 6 through 12. If only the piston
seals are to be replaced go to Coupler - Disassemble
(A.12.A).
6. Remove the two bolts (19) and two washers (20)
which fasten the cover (18) to the hose guard (6).
7. Remove and discard the two countersunk head
socket screws (17) that fasten the hose guard (6) to
the coupler (15) and retain the cylinder (10) in place.
8. Remove and discard the two outer set screws (4) and
two outer set screws (5) that fasten the sleeves (11)
and (23) in place.
9. Disconnect the hoses (7) from the 90 ° elbows (8)
and plug the hoses.
10. Remove the 90 ° elbows (8) and the adapters (9)
from the cylinder (10).
NOTE: Adapters (9) are sealed in place with silicone sealant.

11. Use an acceptable driver being capable of 178 - 222
kN (40016 - 49908 lb) and drive the cylinder tube
(10) and the sleeve (11) out of the coupler (15).
12. Drive the other sleeve (23) out of the coupler (15).
Next operation:
Coupler - Install (A.12.A)
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SYSTEM
Coupler - Install - Hydraulic backhoe quick coupler

Prior operation:
Coupler - Remove (A.12.A)
1. Center the coupler (15) between the dipper ears (24).

2. Install the sleeve (23) with the groove for the outer
coupler set screws (4) and (5) towards the center of
the coupler (15).
kN (40000 - 50000 lb) and drive the sleeve (23) into
the coupler (15) until the groove is in the center of
the set screw (4) and (5) holes.
4. Align the two slots in the cylinder tube (10) with the
two tapped holes in the center of the coupler (15).
Make sure the hydraulic ports (12) and (13) in the
cylinder tube (10) line up with the openings in the
coupler (15). The smaller hydraulic port (12) should
be towards the top of the coupler (15).
5. Install the cylinder (10), as indicated on illustration
Coupler - Exploded view (A.12.A), so that the
smaller hydraulic port (12) is towards the top of the
coupler (15) and the cylinder (10) it is up against the
sleeve (23). Drive the sleeve (23) in or out, so that
the hydraulic ports (12) and (13) are in the center of
the opening in the coupler (15).
6. Use new screws, install two outer coupler set screws
(4) and (5) to hold the sleeve (23) in place. Tighten
the outer coupler set screws to a torque of 14 - 20
N·m (124 - 177 lb in).
7. Install the other sleeve (11) with the grooves for the
outer coupler set screws (4) and (5) towards the cen-
ter of the coupler (15).
kN (40000 - 50000 lb) and drive the other sleeve (11)
into place until it contacts the cylinder (10).
9. Use new screws, install two outer coupler set screws
(4) and (5) to hold the sleeve (11) in place. Tighten
the outer coupler set screws to a torque of 14 - 20
N·m (124 - 177 lb in).
10. Place the step pin seal (14) in the groove on the
outside of each of the step pins (3). See step pin seal
orientation (16) for proper step pin seal installation.
11. Lubricate the outside diameters of both step pins (3)
with Lubriplate prior to installation.
12. With the piston rods extended out, install the step
pins (3) and push the step pins (3) into place.
13. Align the hole for the groove pin (2) in the step pins
(3) with the hole in the piston rod and install the
groove pins (2). The groove pins (2) should be in-
stalled at least 2 mm (0.08 in) below the surface of
the step pins (3) on each side.
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SYSTEM
14. Push the step pins (3) inward enough to allow the re-
taining rings (1) to be installed on the inside retaining
ring groove of the sleeves (11) and (23). Install the
retaining rings (1) in the sleeves (11) and (23).
15. Install the hoses (7) for the 580SN with the standard
dipper so that the hex on the fittings nearest to the
bucket pivot touches the clamp (27). Tighten the
clamp (27).
16. For the hose (7) installation on the 580SN and 590SN
machines equipped with the Extendahoe option, see
Coupler - Exploded view (A.12.A). Install the 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).
17. 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).
18. Install the hoses (7) around the coupler (15) as
shown on Coupler - Exploded view (A.12.A).
19. Refer to Coupler - Exploded view (A.12.A) and con-
nect the hoses (7) to the 90 ° elbows (8) so that the
hoses (7) are staggered to run on each side of the
coupler (15). Tighten the 90 ° elbows (8) so that
there is a minimum of 5 mm (0.20 in) of clearance
between the hoses (7) and each side of the coupler
(15). Tighten the hose connections on the 90 ° el-
bows (8).
20. Place a 6 mm (0.24 in) fillet bead of RTV silicone
sealant around the inside of the coupler (15) fitting
access slot and area around the adapters (9). The
RTV silicone sealant should not prevent access to
the fittings in the coupler (15). Fill the ends of the set
screw holes (4) and (5) with RTV silicone sealant.
21. See the Coupler - Exploded view (A.12.A) and
route the hoses (7) for the proper machine applica-
tion (21) and (22) under the clamp (25).
22. Place 25 mm +/- 10 mm (0.98 in +/- 0.40 in) of the
cordura sleeve (26) under the clamp (25).
23. Install the hose guard (6) and cover (18) on the
coupler (15). Install and tighten the bolt (19) and
washer (20). Install two new countersunk head
socket screws (17) which fasten the hose guard
(6) to the coupler (15). The two countersunk head
socket screws (17) protrude into the grooves on the
cylinder tube (10) to hold the cylinder tube (10) in
place within the coupler (15). Tighten the two flat
head socket screws (17).
24. Start the engine and check for hydraulic leaks. Ro-
tate the coupler (15) at slow speed all the way back
to the bucket dump position. Stop the engine. Make
sure all the slack in the hoses (7) is taken up towards
the clamp (25). Tighten the clamp (25).
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SYSTEM
Coupler - Disassemble - Quick coupler cylinder

NOTE: Refer to illustrations in Coupler - Exploded view (A.12.A).
1. Remove the bucket from the backhoe.
2. Remove the retaining rings (1) from the sleeves (11)
and (23).
3. Extend the piston rods out.
4. Remove the groove pins (2) from the step pins (3).
5. Remove the step pins (3).
NOTE: Step pins can be difficult to remove, due to the fit
of the step pin seal (14).
6. Remove the snap ring (2) from the gland (5). Then
push the gland (5) slightly into the cylinder.
7. Remove the spacer (3).
8. Remove the snap ring (4) from the tube (1).
9. Install the plastic service ring into the snap ring
groove in the tube (1).
RCPH10TLB019AAL 1
10. Pull the rod assembly (6) out of the tube (1).
11. Remove the plastic service ring from the tube (1).
12. Remove the gland (5) from the rod (6).
13. Fasten the rod (6) in a vise with soft jaws.
14. Remove the seal (7), ring (8), ring (9), and O-ring
15. Remove the wiper seal (11), bushing (12), seal (13),
O-ring (14), and backup ring (15) from the gland (5).
NOTE: Repeat steps 6 through 15 for the other side.
Next operation:
Coupler - Inspect (A.12.A)
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SYSTEM
Coupler - Inspect - Quick coupler cylinder

Prior operation:
Coupler - Disassemble (A.12.A)
1. Clean the glands (5), piston rods (6) and tube (1) in
cleaning solvent.
2. Discard the parts that were removed from the pistons
and the glands (5).
3. Illuminate the inside of the tube (1). Inspect the in-
side of the tube (1) for deep grooves and other dam-
age. If there is damage to the tube (1), a new tube
(1) must be used. See Coupler - Remove (A.12.A)
for removal of cylinder tube.
4. Remove small scratches on the inside of the tube (1)
with emery cloth of medium grit. Use the emery cloth
with a rotary motion.
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).
Plastic service ring orientation.
RCPH10TLB019AAL 1
Next operation:
Coupler - Assemble (A.12.A)
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SYSTEM
Coupler - Assemble - Quick coupler cylinder

1. Install a new O-ring (10), ring (9), ring (8), and seal
(7) on the piston.
RCPH10TLB003FAL 1
2. Lubricate the bore of the gland (5) with clean oil and
push the gland assembly onto the piston rod (6). The
wide end of the gland (5) should contact the piston.
NOTE: Repeat steps 1 and 2 for the other gland (5) and piston rod (6).
3. Lubricate the seals of the piston rod (6) and the gland
(5) with clean oil. Push the piston rod and gland sub-
assembly into the bore of the tube (1) far enough to
allow the installation of the snap ring (4). If neces-
sary, use a soft hammer to drive the piston rod (6)
and gland (5) into the tube (1).
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SYSTEM
RCPH10TLB006FAL 2
4. Install the snap ring (4) in the tube (1).

5. Pull the rod (6) outwards until the gland (5) is seated
against the snap ring (4).
6. Install the spacer (3) on the gland (5).
7. Install the snap ring (2) on the gland (5).
NOTE: Repeat steps 3 through 7 for the other side.
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SYSTEM
Remote valve - Disassemble - Swing dampening valve

NOTE: Your valve may appear different than that of the following photos, the procedures are the same.
1. Fasten the swing cushion valve in the vise with soft
jaws. Loosen the plug for the crossover spool as-
sembly.
RCPH10TLB003AAL 1
2. Remove the plug.
RCPH10TLB004AAL 2
RCPH10TLB005AAL 3
4. Remove the crossover spool.
RCPH10TLB006AAL 4
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SYSTEM
5. Loosen and remove the inline check valve.
RCPH10TLB007AAL 5
6. Loosen and remove the internal inline check valve.
RCPH10TLB008AAL 6
7. Loosen and remove the orifice check valve.
RCPH10TLB009AAL 7
8. Loosen and remove the orifice plug.
RCPH10TLB010AAL 8
9. Repeat steps 5 through 8 for the opposite end of the

swing cushion valve.
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SYSTEM
10. Loosen and remove the plug for the bi-directional

check valve.
RCPH10TLB011AAL 9
11. Loosen and remove the bi-directional check valve.
RCPH10TLB012AAL 10
Next operation:
Remote valve - Inspect (A.12.A)
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SYSTEM
Remote valve - Inspect - Swing dampening valve

Prior operation:
Remote valve - Disassemble (A.12.A)
1. Inspect the parts of the crossover spool assembly.

Replace the O-ring (2) on the plug. Replace parts as
required.
RCPH10TLB016AAL 1
1. Plug 3. Spring
2. O-ring 4. Crossover spool
2. Inspect the parts of the inline check valve (1) and

internal inline check valve (4). Replace the O-rings
(2) and backup ring (3). Use new parts as required.
RCPH10TLB014AAL 2
3. Inspect the parts of the orifice check valve (1) and

orifice plug (4). Replace the O-rings (2) and backup
ring (3). Use new parts as required.
RCPH10TLB015AAL 3
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SYSTEM
4. Inspect the parts of the bi-directional check valve (1)

and plug (4). Replace the O-rings (2) and backup
rings (3). Use new parts as required.
RCPH10TLB013AAL 4
Next operation:
Remote valve - Assemble (A.12.A)
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SYSTEM
Remote valve - Assemble - Swing dampening valve

Prior operation:
Remote valve - Inspect (A.12.A)
1. Use clean oil to lubricate the O-rings (2) and backup

rings (3) on the bi-directional check valve (1) and plug
(4).
RCPH10TLB013AAL 1
2. Install the bi-directional check valve. Tighten the

bi-directional check valve to a torque of 5.4 - 6.7 N·m
(48 - 59 lb in).
RCPH10TLB012AAL 2
3. Install the plug for the bi-directional check valve.

Tighten the plug to a torque of 15 - 20 N·m (133 -
177 lb in).
RCPH10TLB011AAL 3

rings (3) on the orifice check valve (1) and orifice plug
(4).
RCPH10TLB015AAL 4
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SYSTEM
5. Install the orifice plug. Tighten the orifice plug to a

torque of 8 - 11 N·m (71 - 97 lb in).
RCPH10TLB010AAL 5
6. Install the orifice plug. Tighten the orifice plug to a

torque of 29 - 33 N·m (257 - 292 lb in).
RCPH10TLB009AAL 6

rings (3) on the inline check valve (1) and internal
inline check valve (4).
RCPH10TLB014AAL 7
8. Install the internal inline check valve. Tighten the

internal inline check valve to a torque of 10 - 13 N·m
(89 - 115 lb in).
RCPH10TLB008AAL 8
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SYSTEM
9. Install the inline check valve. Tighten the inline check

valve to a torque of 29 - 33 N·m (257 - 292 lb in).
RCPH10TLB009AAL 9

section.
11. Use clean oil to lubricate the O-ring (2) on the plug
(1), the spring (3), and the crossover spool (4).
RCPH10TLB016AAL 10
12. Install the crossover spool.
RCPH10TLB006AAL 11
13. Install the spring.
RCPH10TLB005AAL 12
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SYSTEM
14. Start the plug into the valve.
RCPH10TLB004AAL 13
15. Tighten the plug to a torque of 25 - 30 N·m (221 - 266

lb in).
RCPH10TLB003AAL 14
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SYSTEM
Remote valve - Check - Swing Cushion Valve (Swing Drift

Troubleshooting)
1. Park machine on firm and level surface.
2. Ensure hydraulic oil is at operating temperature of 52
°C (125.6 °F).
3. Position loader bucket flat on ground. Lower stabi-
lizers to position rear tires 152.4 mm (6 in) above
ground.
4. Move backhoe from transport position. Fully extend
dipper and bucket. Lower boom until backhoe bucket
is 304.8 mm (12 in) above ground.
NOTE: If equipped with extend-a-hoe option, ensure feature is completely retracted.

5. Use a stabilizer to lower one side of machine. Lower
until rear tire achieves minimal contact to ground.
6. Measure angle of backhoe frame. Raise or lower sta-
bilizers to ensure machine is positioned at 10 degree
angle from level side to lowered side.
7. Lower boom and position backhoe bucket on ground.
Mark ground location of backhoe bucket.
8. Raise boom and position backhoe bucket 1.8 m (6
ft) above ground.
9. Turn engine OFF. Wait five minutes.
10. Start engine. Lower boom and establish minimal
ground contact with backhoe bucket.
11. Measure distance between current location and
marked location as determined in step 7. Record
result.
NOTE: Result should not exceed 203.2 mm (8 in).
12. Repeat previous steps to measure swing drift for
other side of machine.
13. Do the following for measured results:
• If swing drift exceeds 203.2 mm (8 in) for
both sides, see Swing Drift Measured in
Two Directions for procedures.
• If swing drift exceeds 203.2 mm (8 in) on
one side only, see Swing Drift Measured
in One Direction for procedures.
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SYSTEM
Swing Drift Measured in Two Directions

1. Remove hoses from swing cushion valve fittings. In-
stall caps and plugs for open hoses and fittings.
2. Repeat steps 1 through 12.
• If swing drift is noted, swing cylinders are
suspect. Repair swing cylinders as re-
quired. See Cylinder - Disassemble -
Swing cylinders (all models) (H.20.D)
for procedure.
• If swing drift is not present, continue to the
next step.
3. Remove swing cushion valve.
4. Connect swing hoses to swing sections located in
backhoe control valve.
• If swing drift is noted, swing section of
backhoe control valve is suspect. Inspect
and repair as required.
• If swing drift is not present, swing cush-
ion valve is suspect. Replace swing cush-
ion valve. See Remote valve - Inspect
- Swing dampening valve (A.12.A) for
procedure.
Swing Drift Measured in One Direction

1. Disconnect swing cushion valve from swing section
in backhoe control valve.
2. Connect hoses to swing section in backhoe control
valve.
• If swing drift is not present, swing cush-
ion valve is suspect. Replace swing cush-
ion valve. See Remote valve - Inspect
- Swing dampening valve (A.12.A) for
procedure.
• If swing drift is noted, continue to the next
step.
4. Inspect anti-cavitation check valve located in swing
valve. Replace as required.
5. Inspect swing circuit relief valve O-ring, located in
swing valve section. Replace as required.
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Index

SYSTEMS - A

Coupler - Assemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Coupler - Disassemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Coupler - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Coupler - Exploded view - Coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Coupler - Exploded view - Coupler hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Coupler - Exploded view - Extendahoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coupler - Exploded view - Extendahoe hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coupler - Exploded view - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Coupler - Exploded view - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Coupler - Inspect - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Coupler - Install - Hydraulic backhoe quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Coupler - Remove - Hydraulic backhoe quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Coupler - Sectional view Backhoe and Loader Quick Coupler Dual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Coupler - Sectional view Backhoe and Loader Quick Coupler Single Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Coupler - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remote valve - Assemble - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remote valve - Check - Swing Cushion Valve (Swing Drift Troubleshooting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remote valve - Disassemble - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remote valve - Inspect - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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ELECTRICAL POWER SYSTEM - 30.A
580N
580SN WT
580SN
590SN
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Contents

SYSTEMS - A
TECHNICAL DATA
Wiring harness
General specification - Electrical wire circuits - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Connector
Component diagram 01 Side Console Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component diagram 02 Front Console Harness. SPS/PWR Trans, Mech W/ Opt . . . . . . . . . . . . . . . . . . 23
Component diagram 03 Chassis Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Component diagram 04 Cab Rear Lights Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Component diagram 05 Front Lights Canopy Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Component diagram 06 Hydraulic Filter Restriction Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Component diagram 07 Cab B-Post Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Component diagram 08 C-Post Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Component diagram 09 Combo Aux, Mech Control, Hammer or BiDir Valve Harness . . . . . . . . . . . . . . . 60
Component diagram 10 Combo Aux, Pilot Control, Hammer or Bi-Dir Valve Harness . . . . . . . . . . . . . . . 62
Component diagram 11 Combo Aux, Mech Control Hammer Valve Only Harness . . . . . . . . . . . . . . . . . . 64
Component diagram 12 Combo Aux, Pilot Control, Hammer Valve Only . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Component diagram 13 A-Post Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Component diagram 14 A-Post, Canopy, Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Component diagram 15 Rear Lights, Canopy, Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Component diagram 16 Rear Lights, Canopy, Harness (6 lights) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Component diagram 17 Pilot Controls Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Component diagram 18 Front Lights, Cab Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Component diagram 19 Front Lights Canopy Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Component diagram 20 Power shift jumper harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Component diagram 21 Side console, SPS/PWR Trans, HPCR, W/opt harness . . . . . . . . . . . . . . . . . . 100
Wiring harness
Electrical schematic frame 01 Power Distribution/ Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electrical schematic frame 02 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Electrical schematic frame 03 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Electrical schematic frame 04 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
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Electrical schematic frame 05 Powershift Transmission Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Electrical schematic frame 06 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Electrical schematic frame 07 Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Electrical schematic frame 08 Front Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Electrical schematic frame 09 Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Electrical schematic frame 10 Windshield Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Electrical schematic frame 11 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Electrical schematic frame 12 Power Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Electrical schematic frame 13 SAHR Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Electrical schematic frame 14 HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Electrical schematic frame 15 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Electrical schematic frame 16 Rear Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Electrical schematic frame 17 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Electrical schematic frame 18 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Electrical schematic frame 19 Comfort Steer/ Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Electrical schematic frame 20 Canopy Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Electrical schematic frame 21 Powershift Transmission Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . 162
Electrical schematic frame 22 Trax SPS/ PS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Electrical schematic frame 23 Hydraulic Heavy Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Electrical schematic frame 24 Combo Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Electrical schematic frame 25 Pilot Controls Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Electrical schematic frame 26 DIA Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Battery
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Inspect and clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM
Wiring harness - General specification - Electrical wire circuits -

580N only
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Connector - Component diagram 01 Side Console Harness

Connectors
X 2 connector
RCPH10TLB027AAM 1
Cavity Wire ID Circuit Cavity Wire ID Circuit

1 4063 YE 3 25S1 YE
2 23215 YE 4 19E5 OG
X 6 connector
RCPH10TLB023AAM 2

1 AP73 OG Heavy lift key on 3 G071 BK
2 36R1 BL Seat position switch 4 AP71 WH Torque control key on
X 9 Data link Connector
RCPH10TLB025AAM 3
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A G076 BK F N/C
B 1019 RD ECU B+ G N/C
C E353 YE CAN High H N/C
D E343 GN CAN Low J N/C
E E892 YE K Line
X 12 connector
RCPH10TLB073AAM 4

1 42C4 VT Rear work lights 25 AP02 OG
2 AP59 OG Rear lights key on 26 N/C
3 19E1 OG Transmission key on 27 AP03 OG
power
4 AP17 OG 28 P029 RD
5 N/C 29 63R1 Rear wiper/ washer key on
6 N/C 30 N/C
7 19E2 OG Transmission key on 31 AP38 4WD/ Ride control key on
power
8 AP58 OG Rear lights key on 32 64A1 RD Horn B+
9 42C8 VT Rear work light 33 AAP07 OG
10 G213 BK 34 8502 BN A/C Compressor solenoid
power
11 N/C 35 AP42 OG
12 19N1 RD Air suspension seat 36 P015 RD
B+
13 N/C 37 0901 OG Comfort steer key on
14 N/C 38 8501 BN A/C Compressor solenoid
power
15 N/C 39 AP43 OG Pilot controls key on
16 P016 RD 40 0491 RD Dome light B+
17 5701 OG Couplers/ EH Clam/ 41 AP04 OG
Boom lock/ Radio key
on
18 5303 OG Return to dig 42 P014 RD
19 41FB VT 43 AP46 OG
20 P022 RD 44 8403 RD Cigarette lighter B+
21 AP06 OG 45 AP08 OG HVAC Key on
22 AP05 OG 46 P023 RD B+
23 41R7 OG Tail light 47 AP47 OG Side lights key on
24 9302 RD Radio B+ 48 P017 RD
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X 13 connector
RCPH10TLB073AAM 5

1 4043 OG Park brake key on 25 N/C
2 2P01 RD Trax B+ 26 N/C
3 P013 RD 27 60A3 BN A/C High pressure switch fault
4 P011 RD 28 60A4 BN A/C High pressure switch fault
5 4041 OG 29 N/C
6 P018 RD 30 N/C
7 1P03 RD Instrument cluster B+ 31 N/C
8 1010 RD ECU B+ 32 N/C
9 0717 WH Heavy lift output 33 AP48 OG
10 N/C 34 5045 YE Backhoe quick coupler retract
11 P018 RD B+ 35 AP52 OG
12 3P01 OG 36 P027 RD B+
13 AP72 WH Torque control key on 37 AP49 OG Heavy lift key on
14 N/C 38 G019 BK
15 P012 RD 39 AP53 OG Customer key on
16 3P0X OG Instrument cluster key 40 P028 RD B+
on
17 N/C 41 5026 YE Loader quick coupler retract
18 N/C 42 5015 YE Quick coupler load sense
output
19 G051 BK 43 5013 YE Quick coupler load sense
output
20 6003 BN A/C High pressure 44 5014 YE Quick coupler load sense
switch output
21 N/C 45 G017 BK
22 N/C 46 G018 BK
23 60B2 BN A/C Low pressure 47 5044 YE Backhoe quick coupler retract
switch signal
24 N/C 48 5025 YE Loader quick coupler retract
X 14 connector
RCPH10TLB073AAM 6

1 G079 BK 25 4053 YE Park brake declutch
2 4061 YE Park brake declutch 26 4042 OG Park brake key on
3 21C2 YE 27 E172 YE Crank enable from ECU
4 21A3 YE Crank signal 28 P023 RD B+
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5 19E4 OG 29 N/C
6 N/C 30 N/C
7 N/C 31 N/C
8 N/C 32 N/C
9 N/C 33 4052 Park brake logic
10 4034 WH Park brake solenoid 34 G081 BK
output
11 0221 YE Neutral signal to 35 21B1 WH Crank output
interlock relay
12 G077 BK 36 E372 YE Crank enable from ECU
13 0221 YE Neutral signal to 37 N/C
interlock relay
14 E291 YE Crank request to ECU 38 N/C
15 0715 WH 39 N/C
16 3P0X OG Heavy lift key on 40 N/C
17 N/C 41 N/C
18 N/C 42 N/C
19 N/C 43 N/C
20 N/C 44 N/C
21 E321 YE Crank request to ECU 45 N/C
22 G078 BK 46 N/C
23 0716 WH Heavy lift output 47 N/C
24 G111 BK 48 N/C
X 16 connector
RCPH10TLB002BAM 7

1 G074 BK Ground 4 N/C
2 4002 OG Accessory 5 AP01 OG Power relay 1 key on
3 P005 RD B+
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X 17 connector
RCPH10TLB002BAM 8

1 G073 BK Ground 4 N/C
2 4003 OG Accessory 5 AP15 OG Power relay 2 key on
3 P008 RD B+
X 20 connector
RCPH10TLB033AAM 9

A1 42C7 VT Rear work light B5 4804 VT Rotating beacon
A2 63R4 OG Rear wiper/ washer B6 0431 VT Side work lights
key on
A3 45RB VT B7 63R9 OG Rear wiper/ washer key on
A4 4400 VT Brake light B8 8802 BN Blower motor low
A5 45LA VT C1 8702 BN Blower motor medium
A6 60C2 BN A/C Compressor C2 8202 TN Rear wiper high
output
A7 G059 BK C3 8902 TN Rear wiper park
A8 N/C C4 5707 OG
B1 8602 BN Blower motor high C5 9302 RD Radio B+
B2 8102 TN Rear wiper low C6 60B2 BN A/C Low pressure switch
signal
B3 N/C C7 0491 RD Dome light B+
B4 41R5 VT Tail light C8 N/C
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X 21 connector
RCPH10TLB035AAM 10

1 P018 RD B+ 4 4001 OG
2 21A2 YE Crank signal 5 N/C
3 3001 OG Ignition- 6 N/C
X 22 connector
RCPH10TLB036AAM 11

1 8702 BN Blower motor medium 4 AP08 OG HVAC key on
2 8602 BN Blower motor high 5 8501 BN A/C compressor solenoid
power
3 8802 BN Blower motor low
X 23 connector
RCPH10TLB002AAM 12
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1 N/C 6 N/C
2 AP40 OG 4WD key on 7 N/C
3 25C2 YE 8 N/C
4 N/C 9 G072 BK
5 N/C 10 N/C
X 24 connector
RCPH10TLB002AAM 13

1 N/C 6 N/C
2 AP39 OG 7 N/C
3 4011 WH Ride control solenoid 8 N/C
output
4 N/C 9 G092 BK
5 N/C 10 N/C
X 26 connector
RCPH10TLB002AAM 14

1 1121 RD Enter signal 6 N/C
3 1111 RD Display signal 8 N/C
4 N/C 9 N/C
5 N/C 10 N/C
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X 27 connector
RCPH10TLB002AAM 15

1 1141 RD Down signal 6 N/C
3 1131 RD Up signal 8 N/C
4 N/C 9 N/C
5 N/C 10 N/C
X 28 connector
RCPH10TLB032AAM 16

1 N/C 14 1141 RD Down signal
2 3P0X OG Instrument cluster key 15 21A1 YE
on
3 21C4 YE 16 3802 BL Air filter restriction switch
4 41R6 VT 17 36H2 BL Hydraulic filter restriction
switch
5 42FA VT 18 4022 BL
6 42C9 VT 19 36R1 BL Seat position switch
7 0715 WH 20 1202 BL Foot throttle idle validation
8 N/C 21 1211 BL One touch decel signal
9 0711 YE 22 N/C
10 60A5 BN 23 N/C
11 1111 RD Display signal 24 N/C
12 1121 RD Enter signal 25 N/C
13 1131 RD Up signal 26 N/C
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X 29 connector
RCPH10TLB031AAM 17

1 1P04 RD Instrument cluster B+ 14 32T2 YE Transmission temperature
sender signal
2 N/C 15 N/C
3 E344 GN 16 2162 YE Foot throttle signal
4 E354 YE 17 2171 YE Hand throttle signal
5 N/C 18 2182 PK Foot throttle 5V
6 2601 WH Audible alarm output 19 2191 PK Hand throttle 5V
7 0715 WH 20 2202 BL Foot throttle ground
8 N/C 21 2211 GN Hand throttle ground
9 N/C 22 N/C
10 N/C 23 N/C
11 N/C 24 3402 YE
12 N/C 25 N/C
13 36F2 YE Fuel level sender 26 G066 BK
X 30 connector
RCPH10TLB058AAM 18

A 2601 WH Audible alarm output B G058 BK Ground
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X 33 connector
RCPH10TLB030AAM 19

A 2191 PK Hand throttle 5V C 2211 GN Hand throttle ground
B 2171 YE Hand throttle signal
X 34 connector
RCPH10TLB028AAM 20

A N/C D 5018 YE Backhoe quick coupler
extend
B N/C E 5708 OG Couplers/ EH Clam/
Boom lock/ Radio key on
C N/C F 504A YE Backhoe quick coupler
retract
X 35 connector
RCPH10TLB028AAM 21
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A N/C D N/C
B N/C E 504A YE Backhoe quick coupler
retract
C N/C F 5043 YE Backhoe quick coupler
retract
X 37 connector
RCPH10TLB002AAM 22

1 N/C 6 N/C
2 63R3 OG Rear wiper/ washer key 7 N/C
on
3 6502 WH Rear windshield wasjer 8 N/C
pump output
4 N/C 9 N/C
5 N/C 10 N/C
X 39 connector
RCPH10TLB018AAM 23

A 5072 OG Couplers/ EH Clam/ Boom B G179 BK
lock/ Radio key on
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X 51 connector
RCPH10TLB026AAM 24

1 21B1 WH Crank output 25 AP43 OG Pilot controls key on
2 1507 OG 26 E342 GN CAN Low
3 0738 WH Hammer valve power 27 AP70 WH Torque control key on
4 1018 RD ECU B+ 28 5016 YE Quick coupler load sense
output
5 N/C 29 9403 YE
6 N/C 30 0976 WH Comfort steer output
7 64B4 WH Horn output 31 4011 WH Ride control solenoid
output
8 36H2 BL Hydraulic filter 32 19EF OG Transmission key on
restriction switch power
9 36F2 YE Fuel level sensor 33 25B7 LB Reverse signal
10 0713 WH Heavy lift output 34 G150 BK Combo switch ground
11 E372 YE Crank enable from ECU 34 64A2 RD Horn B+
12 0732 WH Aux forward from ECU 36 6002 BN
13 E321 YE Crank request to ECU 37 5303 OG Return to dig
14 0729 BL Combo hydraulics 38 N/C
signal
15 0737 YE Aux forward or hammer 39 E172 YE Crank enable from ECU
valve output
16 4032 WH Park brake solenoid 40 N/C
output
17 1211 BL One touch decel signal 41 E352 YE CAN High
18 4022 BL 42 N/C
19 5024 YE Loader quick coupler 43 N/C
retract
20 5042 YE Backhoe quick coupler 44 3402 YE
retract
21 E291 YE Crank request to ECU 45 32T2 YE Transmission
temperature sender
signal
22 3802 BL Air filter restriction 46 60A2 BN
switch
23 E892 YE K Line 47 31S2 YE
24 60C2 BN A/C Compressor output
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X 98 connector
RCPH10TLB002AAM 25

1 4035 WH Park brake solenoid 6 N/C
output
2 4051 YE Park brake logic 7 N/C
3 4044 OG Park brake key on 8 N/C
4 N/C 9 N/C
5 N/C 10 N/C
X 112 connector
RCPH10TLB002AAM 26

1 N/C 6 42CA VT Rear work light
2 AP47 OG Side lights key on 7 N/C
3 0431 VT Side work lights 8 N/C
4 N/C 9 G099 BK
5 AP60 OG Rear lights key on 10 N/C
X 123 connector
RCPH10TLB074AAM 27
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1 P010 - RD B+ 1 P006 - RD B+
1 P027 - RD B+ 1 P008 - RD B+
1 P005 - RD B+ 1 P009 - RD B+
X 143 connector
RCPH10TLB002AAM 28

1 8102 TN Rear wiper low 6 N/C
2 63R9 OG Rear wiper/ washer key 7 N/C
on
3 8202 TN Rear wiper high 8 N/C
4 8902 TN Rear wiper park 9 N/C
5 N/C 10 N/C
X 181 connector
RCPH10TLB029AAM 29

A 8401 RD B G068 BK
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X 182 connector
RCPH10TLB029AAM 30

A 8402 RD B G070 BK
X 184 Connector
RCPH10TLB058AAM 31

A 19N1 RD B G067 BK
X 186 connector
RCPH10TLB002AAM 32

1 N/C 6 N/C
2 AP51 OG 7 N/C
3 0711 YE 8 N/C
4 N/C 9 N/C
5 N/C 10 N/C
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X 221 connector
RCPH10TLB034AAM 33

1 8502 BN
X 222 connector
RCPH10TLB034AAM 34

1 6004 BN
X 274 connector
RCPH10TLB002AAM 35

1 G150 BK 6 0732 WH
2 0729 BL 7 N/C
3 N/C 8 N/C
4 0738 WH 9 N/C
5 0737 YE 10 N/C
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X 300 connector
RCPH10TLB001BAM 36

1 2P01 RD Rear Wiper Motor 29 G101 BK Rear Wiper Motor (Brake)
(Low)
2 5207 YE Rear Wiper 30 N/C
disconnect Switch
3 3053 WH Rear Wiper Motor 31 N/C
(High)
(Low)
5 19ED OG Rear Wiper 33 N/C
disconnect Switch
6 3043 WH Rear Wiper Motor 34 19EB OG Not Used
(High)
(Low)
8 19EC OG Rear Wiper 36 N/C
disconnect Switch
(High)
10 N/C 38 3023 WH Rear Wiper Motor (Brake)
11 3573 WH Rear Wiper 39 25X3 WH Not Used
disconnect Switch
12 3073 GY Rear Wiper Motor 40 3083 GY Not Used
(High)
13 3033 GY Rear Wiper Motor 41 3603 GY Rear Wiper Motor (Brake)
(Low)
14 N/C 42 N/C
15 3151 PK Rear Wiper Motor 43 3431 YE Not Used
(High)
16 21C7 YE Rear Wiper Motor 44 3441 YE Rear Wiper Motor (Brake)
(Low)
17 0401 BL Rear Wiper 45 3451 YE Not Used
disconnect Switch
18 25A5 LB Rear Wiper Motor 46 25B6 LB Not Used
(High)
19 1902 YE Rear Wiper Motor 47 3223 YE Rear Wiper Motor (Brake)
(Low)
20 N/C 48 N/C
21 4062 YE 49 3214 YE Not Used
22 25C2 YE Rear Wiper Motor 50 9403 YE Rear Wiper Motor (Brake)
(Low)
23 3584 YE Rear Wiper 51 25S1 YE Not Used
disconnect Switch
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24 N/C 52 N/C
25 3301 BL 53 31S2 Rear Wiper Motor (Brake)
26 N/C 54 3541 YE Not Used
27 E356 YE Rear Wiper Motor 55 E346 GN Not Used
(High)
28 N/R 56 N/C
X 345 connector
RCPH10TLB022AAM 37

A1 G108 BK B5 3573 WH
A2 3053 WH B6 19EE OG
A3 3063 WH B7 3301 BL
A4 3013 WH B8 3451 YE
A5 N/C C1 N/C
A6 N/C C2 3043 WH
A7 3023 WH C3 3033 GY
A8 3151 PK C4 3593 WH
B1 3541 YE C5 3603 GY
B2 3073 GY C6 3431 YE
B3 3083 GY C7 3441 YE
B4 25X3 WH C8 0401 BL
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Connector - Component diagram 02 Front Console Harness.

SPS/PWR Trans, Mech W/ Opt
Connector 10
RCPH10TLB072AAM 1

1 4601 - VT Hazard light switch 5 45L9 - VT Left indicator light
2 AP27 - OG Hazards key on 6 47L1 - VT Left turn signal indicator
3 47R1 - VT Right turn signal 7 45R9 - VT Right indicator light
indicator
4 G100 - BK
Connector 38
RCPH10TLB002AAM 2

1 6602 - TN Front wiper low 6 N/C
2 63F2 - OG Front wiper/washer key 7 N/C
on
3 6702 - TN Front wiper high 8 N/C
4 6902 - TN Front wiper park 9 N/C
5 N/C 10 N/C
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Connector 40
RCPH10TLB003AAM 3

1 P024 - RD B+ 25 21C5 - YE Neutral signal
2 64A4 - RD Horn B+ 26 4009 - OG Accessory
3 45RA - VT Right indicator light 27 2181 - PK Foot throttle 5V
4 P026 - RD 28 6501 - WH Rear windshield washer
pump output
5 P021 - RD B+ 29 1201 - BL Foot throttle idle validation
6 P030 - RD B+ 30 3224 - YE Gear command 2
7 4407 - VT Brake light 31 N/C
8 25B3 - LB Reverse signal 32 N/C
9 42F1 - VT Front work light 33 0902 - OG Comfort steer key on
10 41FD - VT Front driving light 34 N/C
11 45L8 - VT Left indicator light 35 N/C
12 N/C 36 N/C
13 5205 - YE In gear signal 37 N/C
14 25A4 - LB Froward signal 38 3583 - YE Auto signal
15 5011 - YE Loader quick coupler 39 1901 - YE Gear command 1
extend
16 63F3 - OG Front wiper/washer key 40 0972 - YE Comfort steer output
on
17 5021 - YE Loader quick coupler 41 4803 - VT Rotating beacon
retract
18 2161 - YE Foot throttle signal 42 6702 - TN Front wiper high
19 4008 - OG Accessory 43 N/C
20 2201 - BL Foot throttle ground 44 6902 - TN Front wiper park
21 19E3 - OG 45 6602 - TN Front wiper low
22 5705 - OG Couplers/ EH clam/ 46 42F5 Front work light
on
23 64B1 - WH Horn output 47 41FC - VT Front driving light
24 3211 - YE Kickdown signal
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Connector 118
RCPH10TLB002AAM 4

1 N/C 6 N/C
2 AP37 - OG Beacon key on 7 N/C
3 4803 - VT Rotating beacon 8 N/C
4 N/C 9 G087 - BK Ground
5 N/C 10 N/C
Connector 132
RCPH10TLB002AAM 5

1 N/C 6 N/C
2 AP28 - OG Hazards key on 7 N/C
3 4601 - VT Hazards light switch 8 N/C
5 N/C 10 N/C
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Connector 133
RCPH10TLB005AAM 6

A 6501 - WH Rear windshield B G095 - BK Ground
washer pump output
Connector 134
RCPH10TLB005AAM 7

A 6501 - WH Front windshield B G095 - BK Ground
washer pump output
Connector 137
RCPH10TLB002AAM 8

1 N/C 6 N/C
2 AP24 - OG Front work light key on 7 N/C
3 42F7 - VT Front work light 8 N/C
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5 N/C 10 N/C
Connector 138
RCPH10TLB006AAM 9

A G089 - BK Ground C 47L1 - VT Left turn signal indicator
B 47R1 - VT Right turn signal
indicator
Connector 139
RCPH10TLB037AAM 10

31 64B1 - WH Horn output 56C N/C
31B 64A4 - RD B+ 56D N/C
49A AP29 - OG Signal lights key on 56E N/C
56 AP30 - OG Front driving lights key L 45R8 - VT Right indicator light
on
56A 41F7 - VT Front driving light R 45LB - VT Left indicator light
56B N/C
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Connector 140
RCPH10TLB038AAM 11

1 N/C 3 AP33 - OG Brake lights key on
Connector 141
RCPH10TLB038AAM 12

1 N/C 3 AP34 - OG Brake lights key on
Connector 142
RCPH10TLB002AAM 13

1 0963 - YE Comfort steer enable 6 N/C
2 0974 - WH Comfort steer output 7 N/C
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4 0962 - YE Comfort steer enable 9 N/C
5 0953 - YE Comfort steer logic 10 0975 - YE Comfort steer output
circuit
Connector 144
RCPH10TLB002AAM 14

1 N/C 6 N/C
2 63F4 - OG Front wiper/ washer 7 N/C
key on
3 6201 - WH Front windshield 8 N/C
washer pump output
4 N/C 9 N/C
5 N/C 10 N/C
Connector 145
RCPH10TLB002AAM 15

1 5011 - YE Loader quick coupler 6 N/C
extend
2 5705 - OG Couplers/ EH clam/ 7 N/C
on
retract
4 N/C 9 N/C
5 N/C 10 N/C
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Connector 146
RCPH10TLB001AAM 16

1 N/C 5 25B2 -LB Reverse signal
2 1901 - YE Gear command 1 6 21C5 - YE Neutral signal
3 3221 - YE 7 25A2 - LB Forward signal
4 3211 -YE Kickdown signal 8 19E10 - OG Transmission key on power
Connector 147
RCPH10TLB073AAM 17

2 P025 - RD B+ 26 N/C
3 4009 - OG Accessory 27 5204 - YE In gear signal
4 P031 - RD B+ 28 5203 - YE In gear signal
5 N/C 29 N/C
6 N/C 30 N/C
7 N/C 31 25B5 - LB Reverse signal
8 N/C 32 25A3 - LB Forward signal
9 AP13 - OG Power relay 4, key on 33 N/C
10 G082 - BK 34 N/C
11 AP20 - OG Power relay 3, key on 35 AP36 - OG
12 G075 - BK 36 AP31 - OG
13 3221 - YE 37 N/C
14 0902 - OG Comfort steer key on 38 N/C
15 0961 - YE Comfort steer enable 39 AP37 - OG Beacon key on
16 0952 - YE Comfort steer logic 40 AP35 - OG Brake lights key on
circuit
17 0951 - YE Comfort steer logic 41 AP21 - OG
circuit
18 N/C 42 AP23 - OG
19 N/C 43 AP22 - OG
20 N/C 44 AP32 - OG
21 3224 - YE Gear command 2 45 63F1 - OG Front wiper/ washer key on
22 G084 - BK 46 AP26 - OG Signal lights key on
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23 0971 - WH Comfort steer output 47 AP24 - OG Front work lights key on
24 G080 - BK 48 AP30 - OG Front driving lights key on
Connector 155
RCPH10TLB004AAM 18

A 2161 - YE Foot throttle signal D N/C
B 2201 - BL Foot throttle ground E 1201 - BL Foot throttle idle validation
C 2181 - PK Foot throttle 5V F N/C
Connector 342
RCPH10TLB002AAM 19

1 3581 - YE Auto signal 6 N/C
2 19E9 - OG Transmission key on 7 N/C
power
4 N/C 9 N/C
5 N/C 10 3582 - YE Auto signal
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Connector G208 Ground M10 Ring Terminal
RCPH10TLB062AAM 20

1 G095 - BK 1 G043 - BK
1 G096 - BK 1 G156 - BK Front console harness
ground
1 G085 - BK 1 G159 - BK Front console harness
ground
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Connector - Component diagram 03 Chassis Harness

X 1 connector
RCPH10TLB003AAM 1

1 21B3 WH 25 AP44 OG
2 1502 OG 26 E348 GN
3 0739 WH 27 0902 OG
4 1016 RD 28 5017 WH
5 N/C 29 7024 YE
6 N/C 30 7015 WH
7 64B6 WH 31 4012 WH
8 36H1 BL 32 25E2 WH
9 36F1 YE 33 25S2 WH
10 0714 WH 34 G149 BK
11 E371 YE 35 64A5 RD
12 073A WH 36 6001 BN
13 E322 YE 37 5302 OG
14 0725 BL 38 N/C
15 0736 YE 39 E171 YE
16 4031 WH 40 2603 LB
17 1212 BL 41 E358 YE
18 4021 BL 42 2703 LB
19 5023 WH 43 N/C
20 5041 WH 44 3401 YE
21 E292 YE 45 32T1 YE
22 3801 BL 46 60A1 BN
23 E891 YE 47 AP74 WH
24 60C3 BN
X 52 connector
RCPH10TLB018AAM 2
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A 4014 WH B G091 BK
X 53 connector
RCPH10TLB010AAM 3

1 5302 OG 2 5301 BL
X 54 connector
RCPH10TLB015AAM 4

A 64A5 RD F G149 BK
B 64B5 WH G 0725 BL
C AP44 OG H 0736 YE
D G116 BK J 073A WH
E 1212 BL K 0739 WH
X 55 connector
RCPH10TLB011AAM 5
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A 2707 LB B G030 BK
X 56 connector
RCPH10TLB018AAM 6

A 4013 WH B G090 BK
X 57 connector
RCPH10TLB010AAM 7

1 4031 WH 2 G020 BK
X 58connector
RCPH10TLB018AAM 8

1 7015 WH 2 G083 BK
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X 59 connector
RCPH10TLB019AAM 9

A 5041 WH B G025 BK
X 60connector
RCPH10TLB019AAM 10

A 5023 WH B G024 BK
X 61 connector
RCPH10TLB019AAM 11

A 5017 WH B G023 BK
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X 63 connector
RCPH10TLB009AAM 12

1 36F1 YE 2 G021 BK
X 65 connector
RCPH10TLB020AAM 13

1 E121 YE 2 E751 YE
X 68 connector
RCPH10TLB008AAM 14

1 E421 YE 3 1506 OG
2 G016 BK
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X 70 Engine Controller Connector
RCPH10TLB007AAM 15

1 46
2 1011 RD 47
3 1012 RD 48
4 49
5 G012 BK 50
6 G013 BK 51
7 52
8 1013 RD 53
9 1014 RD 54
10 G014 BK 55
11 G015 BK 56
12 E121 YE 57
13 58
14 59
15 60
16 61
17 E171 YE 62
18 63
19 64
20 65
21 66
22 67
23 68
24 69
25 70
26 71
27 72
28 73
29 E292 YE 74
30 75 E751 YE
31 76
32 E322 YE 77
33 78
34 E348 GN 79
35 E358 YE 80
36 81
37 E371 YE 82
38 83
39 84
40 1505 OG 85
41 86
42 E421 YE 87
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43 88
44 89 E891 YE
45
X 76 connector
RCPH10TLB010AAM 16

1 0902 OG 2 7024 YE
X 77 connector
RCPH10TLB010AAM 17

1 25S2 WH 2 G028 BK
X 78 connector
RCPH10TLB010AAM 18

1 25E2 WH 2 G029 BK
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X 79 connector
RCPH10TLB010AAM 19

1 2603 LB 2 G045 BK
X 80 connector
RCPH10TLB010AAM 20

1 2701 LB 2 G044 BK
X 82 connector
RCPH10TLB014AAM 21

A 21B3 WH
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X 83 connector
RCPH10TLB017AAM 22

A 6001 BN B 60A1 BN
X 86 connector
RCPH10TLB016AAM 23

1 3401 YE 3 N/C
2 1501 OG
X 93 connector
RCPH10TLB010AAM 24

1 AP74 WH 2 G310 BK
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X 99 connector
RCPH10TLB013AAM 25

1 4021 BL
X 122 connector
RCPH10TLB021AAM 26

1 P002 RD
X 220 connector
RCPH10TLB012AAM 27

1 36H1 BL
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X 275 connector
RCPH10TLB010AAM 28

1 0714 WH 2 G110 BK
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Connector - Component diagram 04 Cab Rear Lights Harness

X 115 connector
RCPH10TLB040AAM 1

1 41R3 - VT Tail light 7 0433 - VT Side work lights
2 4801 - VT Rotating beacon 8 45L6 - VT Left indicator light
3 45R6 - VT Right indicator light 9 N/C
4 42C5 - VT Rear work light 10 G053 - BK Rear work light ground
5 42CJ - VT Rear work light 11 G049 - BK Blower motor ground
6 4403 - VT Brake light 12 G098 - BK Dome light ground
X 162 connector
RCPH10TLB010AAM 2

X 163 connector
RCPH10TLB010AAM 3

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X 164 connector
RCPH10TLB010AAM 4

X 165 connector
RCPH10TLB010AAM 5

X 166 connector
RCPH10TLB010AAM 6

1 4801 - VT Rotating beacon 2 G052 - BK Rotating beacon ground
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X 169 connector
RCPH10TLB020AAM 7

1 45L6 - VT Left indicator light 2 G050 - BK Left rear turn signal ground
X 170 connector
RCPH10TLB011AAM 8

A 4402 - VT Left brake light B 41R2 - VT Tail light
X 171 connector
RCPH10TLB011AAM 9

A 4401 - VT Right brake light B 41R1 - VT Tail light
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X 173 connector
RCPH10TLB020AAM 10

1 45R6 - VT Right indicator light 2 G046 - BK Rear right turn signal ground
X 174 connector
RCPH10TLB055AAM 11

1 G048 - BK Left tail light ground
X 176 connector
RCPH10TLB055AAM 12

1 G047 - BK Right tail light ground
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X 450 connector
RCPH10TLB010AAM 13

1 0435 - VT Left side work lights 2 G211 - BK Left side work lights ground
X 451 connector
RCPH10TLB010AAM 14

1 0434 - VT Right side work lights 2 G212 - BK Right side work lights ground
G206 Rear Light Harness, Ground M10 Ring Terminal
RCPH10TLB056AAM 15

1 G050 - BK Left rear turn signal 1 G211 - BK Left side work lights ground
ground
1 G052 - BK Rotating beacon 1 G057 - BK Rear work light ground
ground
1 G053 - BK Rear work light ground 1 G046 - BK Rear right turn signal ground
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1 G098 - BK Dome light ground 1 G212 - BK Right side work lights ground
1 G054 - BK Rear work light ground 1 G047 - BK Right tail light ground
1 G055 - BK Rear work light ground 1 G048 - BK Left tail light ground
1 G056 - BK Rear work ground 1 G049 - BK Blower motor ground
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Connector - Component diagram 05 Front Lights Canopy Harness

Connector 177
RCPH10TLB010AAM 1

1 41FF - VT Front driving light 2 G174 - BK Front driving light ground
Connector 178
RCPH10TLB010AAM 2

1 41FE - VT Front driving light 2 G173 - BK Front driving light ground
Connector 179
RCPH10TLB052AAM 3

1 G172 - BK Front right turn signal
ground
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Connector 180
RCPH10TLB052AAM 4

1 45RE - VT Right indicator light
Connector 188
RCPH10TLB052AAM 5

1 45LE - VT Left indicator light
Connector 189
RCPH10TLB052AAM 6

1 G175 - BK Front left turn signal
ground
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Connector 505
RCPH10TLB051AAM 7

1 41FE - VT Front driving light 5
2 41FF - VT Front driving light 6
3 45RE - VT Right indicator light 7
4 G176 - BK Front wiper motor 8 45LE - VT Left indicator light
ground canopy
RCPH10TLB056AAM 8

1 G172 - BK Front right turn signal 1 G175 - BK Front left turn signal ground
ground
1 G173 - BK Front driving light 1 G176 - BK Front wiper motor ground
ground canopy
1 G174 - BK Front driving light
ground
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Connector - Component diagram 06 Hydraulic Filter Restriction

Jumper Harness
X 62 connector
RCPH10TLB013AAM 1

1 36H3 - BL
X 223 connector
RCPH10TLB056AAM 2

1 36H3 - BL
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Connector - Component diagram 07 Cab B-Post Harness

Connector 101
RCPH10TLB022AAM 1

A1 42C6 - VT B5 4802 - VT
A2 63R5 - OG B6 0432 - VT
A3 45R7 - VT B7 63R7 - OG
A4 4404 - VT B8 8801 - BN
A5 45L7 - VT C1 8701 - BN
A6 60C1 - BN C2 8201 - TN
A7 G061 - BK C3 8901 - TN
A8 N/C C4 900 - OG
B1 8601 - BN C5 9301 - RD
B2 8101 - TN C6 60B1 - BN
B3 N/C C7 0492 - RD
B4 41R4 - VT C8 N/C
Connector 102
RCPH10TLB044AAM 2

A 3C01 - BK C 5E01 - BK
B 4D01 - GY 6F01 - GY
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Connector 103
RCPH10TLB011AAM 3

A 60C1 - BN B 60B1 - BN
Connector 104
RCPH10TLB041AAM 4

A 8801 - BN C 8601 - BN
B 8701 - BN G097 - BK
Connector 105
RCPH10TLB043AAM 5

A 0493 - RD B 61B1 - VT
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Connector 109
RCPH10TLB042AAM 6

1 N/C 6 4D01 - GY
5E01 - BK 7 900 - OG
3 N/C 8 9301 - RD
4 6F01 - GY 9 G061 - BK
5 3C01 - BK
Connector 110
RCPH10TLB045AAM 7

A G062 - BK C 61B1 - VT
B 0494 - RD
Connector 111
RCPH10TLB048AAM 8

1 63R7- OG
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Connector 116
RCPH10TLB046AAM 9

A 8201 - TN C 63R0 - OG
B 8101 - TN D 8901 - TN
Connector 117
RCPH10TLB047AAM 10

1 G060 - BK
Connector 129
RCPH10TLB048AAM 11

1 63R8 - OG
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Connector 161
RCPH10TLB049AAM 12

1 41R4 - VT 7 0432 - VT
2 4802 - VT 8 45L7 - VT
3 45R7 - VT 9 N/C
4 42CB - VT 10 G060 - BK
5 42CC - VT 11 G097 - BK
6 4404 - VT 12 G062 - BK
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Connector - Component diagram 08 C-Post Harness

Connector 500
RCPH10TLB022AAM 1

A1 042C - VT Rear work light canopy B5 5480 - VT Rotating beacon canopy
A2 N/C B6 0439 - VT Side work lights canopy
A3 545R - VT Right turn indicator B7 N/C
canopy
A4 5440 - VT Brake lights canopy B8 N/C
A5 545L - VT Left turn indicator C1 N/C
canopy
A6 N/C C2 N/C
A7 N/C C3 N/C
A8 N/C C4 N/C
B1 N/C C5 N/C
B2 N/C C6 N/C
B3 N/C C7 N/C
B4 541R - VT Tail light canopy C8 N/C
Connector 501
RCPH10TLB049AAM 2

1 541R - VT Tail light canopy 7 0439 - VT Side work lights canopy
2 5480 - VT Rotating beacon 8 545L - VT Left turn indicator canopy
canopy
3 545R - VT Right turn indicator 9 N/C
canopy
4 42CL - VT Rear work lights 10 N/C
5 542C - VT Rear work lights 11 N/C
canopy
6 5440 - VT Brake lights canopy 12 N/C
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Connector - Component diagram 09 Combo Aux, Mech Control,

Hammer or BiDir Valve Harness
Connector 87
RCPH10TLB057AAM 1

A N/C F N/C
B N/C G N/C
C 0747 - YE H 0747 - YE
D G200 - BK J 0742 - YE
E N/C K 0741 - YE
Connector 91
RCPH10TLB058AAM 2

A 0743 - YE B 0741 - YE
Connector 432
RCPH10TLB018AAM 3

A 0742 - YE B G201 - BK
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Connector 433
RCPH10TLB018AAM 4

A 0743 - YE B G202 - BK
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Connector - Component diagram 10 Combo Aux, Pilot Control,

Hammer or Bi-Dir Valve Harness
Connector 434
RCPH10TLB054AAM 1

A 0772 - WH B G205 - BK
Connector 435
RCPH10TLB018AAM 2

A 0771 - WH B G206 - BK
Connector 446
RCPH10TLB015AAM 3

A 64A8 - RD F G131 - BK
B 64B9 - WH G 0726 - BL
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C AP4A - OG H 0735 - YE
D G225 - BK J N/C
E 1214 - BL K N/C
Connector 447
RCPH10TLB057AAM 4

A 64A8 - RD F G131 - BK
B 64B9 - WH G 0726 - BL
C AP4A - OG H 0735 - YE
D G207 - BK J 0772 - WH
E 1214 - BL K 0771 - WH
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Connector - Component diagram 11 Combo Aux, Mech Control

Hammer Valve Only Harness
Connector 90
RCPH10TLB058AAM 1

A 0761 - YE B 0762 - WH
Connector 436
RCPH10TLB018AAM 2

A 0762 - WH B G210 - BK
Connector 442
RCPH10TLB057AAM 3

A N/C F N/C
B G N/C
C 0761 - YE H N/C
D G210 - BK J N/C
E N/C K N/C
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Connector - Component diagram 12 Combo Aux, Pilot Control,

Hammer Valve Only
Connector 439
RCPH10TLB018AAM 1

A 0781 - OG B 0782 - BK
Connector 443
RCPH10TLB059AAM 2

A 0781 - OG B 0782 - BK
Connector 441
RCPH10TLB010AAM 3

A 0781 - OG B 0783 - WH
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Connector - Component diagram 13 A-Post Harness

Connector 191
RCPH10TLB060AAM 1

1 41F4 - VT Front driving light 5 42FE - VT
2 41F1 - VT Front driving light 6 42F4 - VT
4 G033 - BK Front wiper motor 8 45L4 - VT
connector 216
Connector 211
RCPH10TLB015AAM 2

A 41F4 - VT Front driving light G 6901 - TN Front wiper park
B 63FS - OG Front wiper/washer key H 45L4 - VT Left indicator light
on
C 45R4 - VT Right indicator light J 42FE - VT Front work light
D 6701 - TN Front wiper high K 41F1 - VT Front driving light
E 6601 - TN Front wiper low L N/C
F 42F4 - VT Front work light M N/C
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Connector 215
RCPH10TLB046AAM 3

A 6701 - TN Front wiper high C 63F5 - OG Front wiper/ Washer key On
B 6601 - TN Front wiper low D 6901 - TN Front wiper park
Connector 216
RCPH10TLB047AAM 4

A 6033 - BK Front wiper motor
ground connection
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Connector - Component diagram 14 A-Post, Canopy, Harness

Connector 191
RCPH10TLB060AAM 1

1 41F4 - VT Front driving light 5 42FE - VT Front work light
2 41F1 - VT Front driving light 6 42F4 - VT Front work light
4 N/C 8 45L4 - VT Left indicator light
Connector 211
RCPH10TLB015AAM 2

A 41F4 - VT Front driving light G N/C
B N/C H 45L4 - VT Left indicator light
C 45R4 - VT Right indicator light J 42FE - VT Front work light
D N/C K 41F1 - VT Front driving light
E N/C L N/C
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Connector - Component diagram 15 Rear Lights, Canopy, Harness

Connector 452
RCPH10TLB010AAM 1

1 0438 - VT Right side work light 2 G215 - BK Right side work light ground
canopy
Connector 453
RCPH10TLB010AAM 2

1 0437 - VT Left side work light 2 G216 - BK Left side work light
canopy
Connector 504
RCPH10TLB063AAM 3

1 41R8 - VT Tail light 7 0436 - VT Side work lights canopy
2 4805 - VT Rotating beacon 8 45LD - VT Left indicator light
3 45RC - VT Right indicator light 9 N/C
4 42CG - VT Rear work light 10 N/C
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5 42CD - VT Rear work light 11 N/C
Connector 512
RCPH10TLB010AAM 4

1 42CD - VT Rear work light 2 G165 - BK Rear work lights ground
Connector 515
RCPH10TLB010AAM 5

1 42CG - VT Rear work light 2 G168 - BK Rear work lights ground
Connector 520
RCPH10TLB061AAM 6

1 45RC - VT Right indicator light
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Connector 521
RCPH10TLB053AAM 7

1 G163 - BK Rear right turn signal
ground
Connector 522
RCPH10TLB061AAM 8

1 41RA - VT Right tail light
Connector 523
RCPH10TLB061AAM 9

1 440A - VT Brake light
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Connector 524
RCPH10TLB061AAM 10

1 440B - VT Brake light
Connector 525
RCPH10TLB061AAM 11

1 45LD - VT Left indicator light
Connector 526
RCPH10TLB053AAM 12

1 G169 - BK Rear left turn signal
ground
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Connector 527
RCPH10TLB010AAM 13

Connector 528
RCPH10TLB061AAM 14

1 41RC - VT Left tail light
RCPH10TLB062AAM 15

1 G215 - BK Right side work light 1 G165 - BK Rear work lights ground
ground
1 G216 - BK Left side work light 1 G168 - BK Rear work lights ground
ground
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1 G171 - BK Rotating beacon 1 G169 - BK Rear left turn signal ground
ground
1 G163 - BK Rear right turn signal
ground
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Connector - Component diagram 16 Rear Lights, Canopy, Harness

(6 lights)
Connector 452
RCPH10TLB010AAM 1

1 0438 - VT Right side work light 2 G215 - BK Right side work light ground
canopy
Connector 453
RCPH10TLB010AAM 2

1 0437 - VT Left side work light 2 G216 - BK Left side work light
canopy
Connector 504
RCPH10TLB063AAM 3

1 41R8 - VT Tail light 7 0436 - VT Side work lights canopy
2 4805 - VT Rotating beacon 8 45LD - VT Left indicator light
3 45RC - VT Right indicator light 9 N/C
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4 42CG - VT Rear work light 10 N/C
5 42CD - VT Rear work light 11 N/C
Connector 512
RCPH10TLB010AAM 4

1 42CE - VT Rear work light 2 G165 - BK Rear work lights ground
Connector 513
RCPH10TLB010AAM 5

1 42CF - VT Rear work light 2 G166 - BK Rear work lights ground
Connector 514
RCPH10TLB010AAM 6
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1 42CH - VT Rear work light 2 G167 - BK Rear work lights ground
Connector 151
RCPH10TLB010AAM 7

1 42CK - VT Rear work light 2 G168 - BK Rear work lights ground
Connector 520
RCPH10TLB061AAM 8

1 45RC - VT Right indicator light
Connector 521
RCPH10TLB053AAM 9

1 G163 - BK Rear right indicator turn
signal ground
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Connector 522
RCPH10TLB061AAM 10

1 41RA - VT Right tail light
Connector 523
RCPH10TLB061AAM 11

1 440A - VT Brake light
Connector 524
RCPH10TLB061AAM 12

1 440B - VT Brake light
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Connector 525
RCPH10TLB061AAM 13

1 45LD - VT Left indicator light
Connector 526
RCPH10TLB053AAM 14

1 G169 - BK Rear left turn signal
ground
Connector 527
RCPH10TLB010AAM 15

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Connector 528
RCPH10TLB061AAM 16

1 41RC - VT Left tail light
RCPH10TLB062AAM 17

1 G215 - BK Right side work light 1 G166 - BK Rear work lights ground
ground
1 G216 - BK Left side work light 1 G167 - BK Rear work lights ground
ground
1 G171 - BK Rotating beacon 1 G168 - BK Rear work lights ground
ground
1 G163 - BK Rear right turn signal 1 G169 - BK Rear left turn signal ground
ground
1 G165 - BK Rear work lights ground
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Connector - Component diagram 17 Pilot Controls Harness

Connector 400
RCPH10TLB069AAM 1

1 6013 - OG Pilot controls on/off 13 6130 - BL
2 G153 - BK 14 6140 - BL
3 6030 - WH Left stabilizer up 15 0731 - YE Aux forward or hammer valve
solenoid output output
4 6040 - WH Left stabilizer down 16 6161 - PK
solenoid output
5 6050 - WH Right stabilizer up 17 6170 - YE
solenoid output
6 6060 - WH Right stabilizer down 18 6180 - YE
output
7 6070 - WH E'hoe extend solenoid 19 N/C
output
8 6080 - WH E'hoe retract solenoid 20 N/C
output
9 6090 - YE 21 0738 - BL Combo hydraulics signal to
pilot controls module
10 6100 - YE 22 0727 - BL Combo hydraulics signal to
11 6110 - YE 23 6230 - WH Aux reverse solenoid output
12 6120 - YE
Connector 401
RCPH10TLB064AAM 2

1 6060 - WH Right stabilizer down 2 G135 - BK Right stabilizer down
solenoid output solenoid ground
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Connector 402
RCPH10TLB064AAM 3

1 6050 - WH Right stabilizer up 2 G134 - BK Right stabilizer up solenoid
solenoid output ground
Connector 403
RCPH10TLB064AAM 4

1 6040 - WH Left stabilizer down 2 G133 - BK Left stabilizer down solenoid
Connector 404
RCPH10TLB064AAM 5

1 6030 - WH Left stabilizer up 2 G132 - BK Left stabilizer up solenoid
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Connector 405
RCPH10TLB064AAM 6

1 6230 - WH Aux reverse solenoid 2 G139 - BK Aux reverse solenoid ground
output
Connector 407
RCPH10TLB064AAM 7

1 6080 - WH E'hoe retract solenoid 2 G137 - BK E'hoe retract solenoid ground
output
Connector 408
RCPH10TLB064AAM 8

1 6070 - WH E'hoe extend solenoid 2 G136 - BK E'hoe extend solenoid
output ground
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Connector 409
RCPH10TLB067AAM 9

A G128 - BK Pilot controls ground B 6140 - BL
Connector 410
RCPH10TLB010AAM 10

1 6242 - WH Pattern change switch 2 G144 - BK Pattern change 1 valve diode
output ground
Connector 411
RCPH10TLB010AAM 11

1 6028 - WH Pressure reducing 2 G140 - BK Pressure reducing valve
valve output ground
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Connector 412
RCPH10TLB010AAM 12

1 6243 - WH Pattern change switch 2 G142 - BK Pattern change 2 valve
output ground
Connector 413
RCPH10TLB010AAM 13

1 6027 - YE Pressure reducing 2 G141 - BK Pattern change 1 valve
valve output ground
Connector 414
RCPH10TLB010AAM 14

1 6244 - WH Pattern change switch 2 G143 - BK Pattern change valve diode
output ground
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Connector 417
RCPH10TLB066AAM 15

1 N/C 6 6021 - YE Pilot controls power
2 AP57 - OG Pilot controls key on 7 G115 - BK Pilot controls on/ off switch
ground
3 6010 - OG 8 6020 - YE Pilot controls power
4 N/C 9 N/C
5 AP45 - OG Pilot controls key on 10 N/C
Connector 418
RCPH10TLB066AAM 16

1 N/C 6 N/C
2 6024 - BK Pilot controls power 7 G117 - BK Pattern change switch
ground
3 6240 - WH 8 N/C
4 N/C 9 N/C
5 N/C 10 N/C
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Connector 419
RCPH10TLB068AAM 17

30 6012 - OG Pilot controls on/ off 87 6025 - YE Pilot controls power
85 6026 - YE Pilot controls power 87A N/C
86 G145 - BK Pilot controls on/ off
relay coil ground
Connector 420
RCPH10TLB010AAM 18

1 G127 - BK Pilot controls ground 2 1213 - BL One-touch decel signal
Connector 421
RCPH10TLB010AAM 19

1 64A7 - RD Horn B+ 2 64B8 - WH Horn output
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Connector 422
RCPH10TLB065AAM 20

1 6169 - PK Pilot controls module 4 G122 - BK E'hoe retract switch ground
5V output
2 6168 - PK Pilot controls module 5 6120 - YE
5V output
3 G124 - BK E'hoe extend switch 6 6110 - YE
ground
Connector 423
RCPH10TLB065AAM 21

1 6164 - PK Pilot controls module 4 G121 - BK Aux reverse switch ground
5V output
2 6165 - PK Pilot controls module 5 6170 - YE
5V output
3 G123 - BK Aux forward switch 6 6180 - YE
ground
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Connector 424
RCPH10TLB030AAM 22

A 6166 - PK Pilot controls module C G120 - BK Right stabilizer switch ground
5V output
B 6100 - YE
Connector 425
RCPH10TLB030AAM 23

A 6167 - PK Pilot controls module C G119 - BK Left stabilizer ground
5V output
B 6090 - YE
Connector 426
RCPH10TLB067AAM 24

A G129 - BK Pilot controls ground B 6130 - BL
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Connector 430
RCPH10TLB018AAM 25

A 6023 - OG Pilot controls power B G155 - BK
Connector 455
RCPH10TLB057AAM 26

A 64A7 - RD Horn B+ F G130 - BK Pilot controls ground
B 64B8 - WH Horn output G 0721 - BL Combo hydraulics signal to
C AP56 - OG Pilot controls key on H 0731 - YE Aux forward or hammer valve
output
D G301 - BK Pilot controls ground J N/C
E 1213 - BL One-touch decel signal K N/C
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Connector - Component diagram 18 Front Lights, Cab Harness

Connector 192
RCPH10TLB010AAM 1

1 42F3 - VT Front work light 2 G035 - BK Front work light ground
Connector 193
RCPH10TLB010AAM 2

1 41F3 - VT Front driving light 2 G036 - BK Front driving light ground
Connector 194
RCPH10TLB010AAM 3

1 41F2 - VT Front driving light 2 G037 - BK Front driving light ground
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Connector 195
RCPH10TLB010AAM 4

1 42F2 - VT Front work light 2 G038 - BK Front work light ground
Connector 196
RCPH10TLB020AAM 5

1 45L1 - VT Left indicator light 2 G041 - BK Front left indicator ground
Connector 201
RCPH10TLB020AAM 6

1 45R1 - VT Right indicator light 2 G039 - BK Front right indicator ground
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Connector 213
RCPH10TLB051AAM 7

4 G034 - BK Front wiper motor 8 45L1 - VT Left indicator light
ground
Connector G207
RCPH10TLB062AAM 8

1 G034 - BK Front right indicator 1 G036 - BK Front driving light ground
ground
1 G041 - BK Front indicator ground 1 G037 - BK Front driving light ground
1 G034 - BK Front wiper motor 1 G038 - BK Front work light ground
ground
1 G035 - BK Front work light ground
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Connector - Component diagram 19 Front Lights Canopy Harness

Connector 177
RCPH10TLB010AAM 1

1 41FF - VT Front driving light 2 G174 - BK Front driving light ground
Connector 178
RCPH10TLB010AAM 2

1 41FE - VT Front driving light 2 G173 - BK Front driving light ground
Connector 179
RCPH10TLB061AAM 3

1 G172 - BK Front right turn signal
ground
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Connector 180
RCPH10TLB061AAM 4

1 45RE - VT Right indicator light
Connector 188
RCPH10TLB061AAM 5

1 45LE - VT Left indicator light
Connector 189
RCPH10TLB061AAM 6

ground
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Connector 505
RCPH10TLB051AAM 7

1 41FE - VT Front driving light 5 42FG - VT Front work light
2 41FF - FF Front driving light 6 42FF - VT Front work light
3 45RE - VT Right indicator light 7 N/C
4 G176 - BK Front wiper motor 8 45LE - VT Left indicator light
ground canopy
Connector 530
RCPH10TLB010AAM 8

1 42FF - VT Front work light 2 G320 - BK Front right work light ground
Connector 531
RCPH10TLB010AAM 9

1 42FG - VT Front work light 2 G321 - BK Front left work light ground
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RCPH10TLB062AAM 10

1 G172 - BK Front right turn signal 1 G176 - BK Front wiper motor ground
ground canopy
1 G173 - BK Front driving light 1 G320 - BK Front right work light ground
ground
1 G174 - BK Front driving light 1 G321 - BK Front left work light ground
ground
ground
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Connector - Component diagram 20 Power shift jumper harness

Connector 355
RCPH10TLB070AAM 1

1 3054 - WH Forward solenoid 5 3044 - WH PWM 1/3 solenoid output
output
2 3074 - GY Forward solenoid 6 3034 - GY PWM 1/3 solenoid return
return
3 3064 - WH Reverse solenoid 7 3594 - WH S3 solenoid output
output
4 3084 - GY Reverse solenoid 8 3604 - GY PWM 2/4 solenoid return
return
Connector 357
RCPH10TLB071AAM 2

1 G221 - BK Trax controller power 7 3304 - YE Transmission speed sensor
ground signal
2 3014 - WH S13 solenoid output 8 19EJ - OG Transmission key on power
3 3024 - WH 9 3434 YE Transmission temperature
signal to trax
4 G222 - BK Trax controller power 10 N/C
ground
5 25X4 4WD output 11 3444 - BL Transmission charge
pressure signal
6 3574 - WH Diff lock solenoid 12 0406 - BL Trax signal ground
output
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Connector 374
RCPH10TLB033AAM 3

A1 G220 - BK Trax controller power B5 3574 - WH Diff lock solenoid output
ground
A2 3054 - WH Forward solenoid B6 19EJ - OG Transmission key on power
output
A3 3064 - WH Reverse solenoid B7 3304 YE Transmission speed signal
output
A4 3014 - WH S13 solenoid output B8 N/C
A5 N/C C1 N/C
A6 N/C C2 3044 - WH PWM 1/3 solenoid output
A7 3024 - WH C3 3034 - GY PWM 1/3 solenoid output
A8 N/C C4 3594 - WH S3 solenoid
B1 N/C C5 3604 - GY PWM 2/4 solenoid return
B2 3074 - GY Forward solenoid C6 3434 - YE Transmission temperature
return signal to trax
B3 3084 - GY Reverse solenoid C7 3444 - BL Transmission charge
return pressure signal
B4 25X4 - WH 4WD output C8 0406 - BL Trax signal ground
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Connector - Component diagram 21 Side console, SPS/PWR Trans,

HPCR, W/opt harness
Connector 2
RCPH10TLB027AAM 1

1 4063 - YE 3 25S1 - YE
2 3215 - YE 4 19E5 - OG
Connector 3
RCPH10TLB056AAM 2

1 AP53 - OG Customer key on
Connector 5
RCPH10TLB056AAM 3

1 P028 - RD B+
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Connector 6
RCPH10TLB023AAM 4

1 AP37 - OG Heavy lift key on 3 G071 - BK
2 36R1 - BL Seat position switch 4 AP71 - WH Torque control key on
Connector 7
RCPH10TLB056AAM 5

1 5709 - OG Couplers/ EH Clam/
Boom lock/ Radio, key
on
Connector 9
RCPH10TLB025AAM 6

A G076 - BK Ground F N/C
B 1019 - RD ECU B+ G N/C
C E353 - YE CAN High H N/C
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D E343 - GN CAN Low J N/C
E E892 - YE K line
Connector 12
RCPH10TLB073AAM 7

1 42CA - VT Rear work light 25 AP02 - OG
2 AP59 - OG Rear lights key on 26 N/C
3 19E1 - OG Transmission key on 27 AP03 - OG
4 AP17 - OG 28 P029 - RD
5 29 63R1 - OG Rear wiper/ washer key on
6 30
7 19E2 - OG Transmission key on 31 AP38 - OG 4WD/ Ride control key on
power
8 AP58 - OG Rear lights on 32 64A1 - RD Horn B+
9 42C8 - VT Rear work lights 33 AP07 - OG
10 G213 - BK Ground 34 8502 - BN A/C compressor solenoid
power
11 35 AP42 - OG
12 19N1 - RD Air suspension seat B+ 36 P015 - RD
13 37 0901 - OG Comfort steer key on
14 38 8501 - BN A/C compressor solenoid
power
15 39 AP43 - OG Pilot controls key on
16 P016 - RD 40 0491 - RD Dome light B+
17 5701 - OG Couplers/EH Clam/ 41 AP04 - OG
on
18 5303 - OG Return to dig 42 P014 - RD
19 41FB - VT 43 AP46 - OG
20 P022 - RD 44 8403 - RD Cigarette lighter B+
21 AP06 - OG 45 AP08 - OG HVAC key on
22 AP05 - OG 46 P023 - RD B+
23 41R7 - VT Tail lights 47 AP47 - OG Side lights key on
24 9302 - RD Radio B+ 48 P017 - RD
Connector 13
RCPH10TLB073AAM 8
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1 4043 - OG Park brake key on 25 N/C
2 4043 - OG Trax B+ 26 N/C
3 P013 - RD 27 60A3 - BN A/C High pressure switch
fault
4 P011 - RD 28 60A4 - BN A/C High pressure switch
fault
5 4041 - OG 29 N/C
6 P018 - RD B+ 30 N/C
7 1P03 - RD Instrument cluster B+ 31 N/C
8 1010 - RD ECU B+ 32 N/C
9 0717 - WH Heavy lift output 33 AP48 - OG
10 N/C 34 5045 - YE Backhoe quick coupler
retract
11 P018 - RD B+ 35 AP52 - OG
12 3P01 - OG 36 P027 - RD B+
13 AP72 - WH Torque control key on 37 AP49 - OG Heavy lift key on
14 N/C 38 G019 - BK r
15 P012 - RD 39 AP35 - OG Customer key on
16 3P0X - OG Instrument cluster key 40 P028 - RD B+
on
17 N/C 41 5026 - YE Loader quick coupler retract
18 N/C 42 5015 - YE Quick coupler load sense
output
19 G051 - BK 43 5013 - YE Quick coupler load sense
output
20 6003 - BN A/C High pressure 44 5014 - YE Quick coupler load sense
switch
21 N/C 45 G017 - BK
22 N/C 46 G018 - BK
23 60B2 - BN A/C Low pressure 47 5044 - YE Backhoe quick coupler
switch signal retract
24 N/C 48 5025 9 YE Loader quick coupler retract
Connector 14
RCPH10TLB073AAM 9

1 G079 - BK 25 4053 - YE Park brake declutch
2 4061 - YE Park brake declutch 26 4042 - OG Park brake key on
3 21C2 27 E172 - YE Crank enable from ECU
4 21A3 Crank signal 28 P023 - RD B+
5 19E4 - OG 29 N/C
6 N/C 30 N/C
7 N/C 31 N/C
8 N/C 32 N/C
9 N/C 33 4052 - YE Park brake logic
10 4034 - WH Park brake solenoid 34 G081 - BK
output
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11 0221 - YE Neutral signal to 35 21B1 - WH Crank output
interlock relay
12 G077 - BK 36 N/C
13 0221 - YE Neutral signal to 37 N/C
interlock relay
14 E291 - YE Crank request to ECU 38 N/C
15 0715 - WH 39 N/C
16 AP50 - OG Heavy lift key on 40 N/C
17 N/C 41 N/C
18 N/C 42 N/C
19 N/C 43 N/C
20 N/C 44 N/C
21 E321 - YE Crank request to ECU 45 N/C
22 G078 - YE 46 N/C
23 0716 - WH Heavy lift output 47 N/C
24 G111 - BK 48 N/C
Connector 16
RCPH10TLB002BAM 10

1 G074 - BK Ground 4 N/C
2 4002 - OG Accessory 5 AP01 - OG Power relay 1 key on
3 P005 - RD B+
Connector 17
RCPH10TLB002BAM 11

1 G073 - BK Ground 4 N/C
2 4003 - OG Accessory 5 AP15 - OG Power relay 2 key on
3 P008 - RD B+
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Connector 20
RCPH10TLB033AAM 12

A1 42C7 - VT Rear work light B5 4804 - VT Rotating beacon
A2 63R4 - OG Rear wiper/ washer B6 0431 - VT Side work lights
key on
A3 45RB - VT B7 63R9 - OG Rear wiper/ washer key on
A4 4400 - VT Brake light B8 8802 - BN Blower motor low
A5 45LA - VT C1 8702 - BN Blower motor medium
A6 60C2 - BN A/C Compressor output C2 8202 - TN Rear wiper high
A7 G059 - BK C3 8902 - TN Rear wiper park
A8 N/C C4 5707 - OG
B1 8602 - BN Blower motor high C5 9302 - RD Radio B+
B2 8102 - TN Rear wiper low C6 60B2 - BN A/C Low pressure switch
signal
B3 N/C C7 0491 - RD Dome light B+
B4 41R5 - VT Tail light C8 N/C
Connector 21
RCPH10TLB035AAM 13

1 P018 - RD B+ 4 4001 - OG
2 21A2 - YE Crank signal 5 N/C
3 3001 - OG Ignition
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Connector 22
RCPH10TLB035AAM 14

1 8702 - BN Blower motor medium 4 AP08 - OG HVAC key on
2 8602 - BN Blower motor high 5 8501 - BN A/C compressor solenoid
power
3 8802 - BN Blower motor low
Connector 23
RCPH10TLB002AAM 15

1 N/C 6 N/C
2 AP40 - OG 4 WD key on 7 N/C
3 25C2 - YE 8 N/C
4 N/C 9 G072 - BK
5 N/C 10 N/C
Connector 24
RCPH10TLB002AAM 16
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1 N/C 6 N/C
2 AP39 - OG 7 N/C
3 4011 - WH Ride control solenoid 8 N/C
output
4 N/C 9 G092 - BK
5 N/C 10 N/C
Connector 26
RCPH10TLB002AAM 17

1 1121 - RD Enter signal 6 N/C
3 1111 - RD Display signal 8 N/C
4 N/C 9 N/C
5 N/C 10 N/C
Connector 27
RCPH10TLB002AAM 18

1 1141 - RD Down signal 6 N/C
3 1131 - RD Up signal 8 N/C
4 N/C 9 N/C
5 N/C 10 N/C
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Connector 28
RCPH10TLB032AAM 19

1 N/C 14 1141 - RD Down signal
2 3P0X - OG Instrument cluster key 15 21A1 - YE
on
3 21C4 - OG 16 3802 - BL Air filter restriction switch
4 41R6 - VT 17 36H2 - BL Hydraulic filter restriction
switch
5 42FA - VT 18 4022 - BL
6 42C9 - VT 19 36R1 - BL Seat position
7 4409 - VT 20 1202 - BL Foot throttle validation
8 N/C 21 1211 - BL One touch signal
9 0711 - YE 22 N/C
10 60A5 - BN 23 N/C
11 1111 - RD Display signal 24 N/C
12 1121 - RD Enter signal 25 N/C
13 1131 - RD Up signal 26 N/C
Connector 29
RCPH10TLB031AAM 20

1 1P04 - RD Instrument cluster B+ 14 32T2 - YE Transmission temperature
sender signal
2 N/C 15 N/C
3 E344 - GN 16 2162 - YE Foot throttle signal
4 E354 - YE 17 2171 - YE Hand throttle signal
5 N/C 18 2182 - PK Foot throttle 5V
6 2601 - WH Audible alarm output 19 2191 - PK Hand throttle 5V
7 0715 - WH 20 2202 - BL Foot throttle ground
8 N/C 21 2211 - GN Hand throttle ground
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9 N/C 22 N/C
10 N/C 23 N/C
11 N/C 24 3402 - YE
12 N/C 25 N/C
13 36F2 - YE Fuel level sender 26 G066 - BK
Connector 30
RCPH10TLB058AAM 21

A 2601 - WH Audible alarm output B G058 - BK Ground
Connector 33
RCPH10TLB030AAM 22

A 2191 - PK Hand throttle 5V C 2211 - GN Hand throttle ground
B 2171 - YE Hand throttle signal
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Connector 34
RCPH10TLB028AAM 23

A N/C D 5018 - YE Backhoe quick coupler
extend
B N/C E 5706 - OG Couplers/ EH Clam/ Boom
lock/ Radio, key on
C N/C F 504A - YE Backhoe quick coupler
retract
Connector 35
RCPH10TLB028AAM 24

A N/C D N/C
B N/C E 504A - YE Couplers/ EH Clam/ Boom
lock/ Radio, key on
C N/C F 504A - YE Backhoe quick coupler
retract
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Connector 37
RCPH10TLB037AAM 25

1 N/C D N/C
2 63R3 - OG Rear wiper/ washer E N/C
key on
3 6502 - WH Rear windshield F N/C
washer pump output
N/C N/C
N/C N/C
Connector 39
RCPH10TLB018AAM 26

A 5702 - OG Couplers/ EH Clam/ B G179 - BK Ground
on
Connector 51
RCPH10TLB026AAM 27
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1 21B1 - WH Crank output 25 AP43 - OG Pilot controls key on
2 1507 - OG 26 E342 - GN CAN Low
3 0738 - WH Hammer valve power 27 AP70 - WH Torque control key on
4 1018 - RD ECU B+ 28 5016 - YE Quick coupler load sense
output
5 N/C 29 9403 - YE
6 N/C 30 0976 - WH Comfort steer output
7 64B4 - WH Horn output 31 4011 - WH Ride control solenoid output
8 36H2 - WH Hydraulic filter 32 19EF - OG Transmission key on power
restriction switch
9 36F2 - YE Fuel level sensor 33 25B7 - LB Reverse signal
10 0713 - WH Heavy lift output 34 G150 - BK Combo hyd switch ground
11 E372 - YE Crank enable from 35 64A2 - RD Horn B+
ECU
12 0732 - WH Aux forward output 36 6002 - BN
13 E321 - YE Crank request to ECU 37 5303 - OG Return to dig
14 0729 - BL Combo hydraulics 38 N/C
signal
15 0737 - YE Aux forward or hammer 39 E172 - YE Crank enable from ECU
valve output
16 4032 - WH Park brake solenoid 40 N/C
output
17 1211 - BL One touch decel signal 41 E352 - YE CAN High
18 4022 - Bl 42 N/C
retract
20 5042 - YE Backhoe quick coupler 44 3402 - YE
retract
21 E291 - YE Crank request to ECU 45 32T2 - YE Transmission temperature
sender signal
22 3802 - BL Air filter restriction 46 60A2 - BN
switch
23 E892 - YE K line 47 31S2 - YE
24 60C2 - BN A/C compressor output
Connector 72
RCPH10TLB056AAM 28

A 64A6 - RD Horn B+
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Connector 73
RCPH10TLB056AAM 29

A 64B3 - WH Horn output
Connector 98
RCPH10TLB002AAM 30

1 4035 - WH park brake solenoid 6 N/C
output
2 4051 - YE Park brake logic 7 N/C
3 4044 - OG Park brake key on 8 N/C
4 N/C 9 N/C
5 N/C 10 N/C
Connector 112
RCPH10TLB002AAM 31
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1 N/C 6 42CA - VT Rear work lights
2 AP47 - OG Side lights key on 7 N/C
3 0431 - VT Side work lights 8 N/C
5 AP60 - OG Rear lights key on 10 N/C
Connector 123
RCPH10TLB021AAM 32

1 P010 - RD B+ 1 P006 - RD B+
1 P027 - RD B+ 1 P008 - RD B+
1 P005 - RD B+ 1 P009 - RD B+
Connector 143
RCPH10TLB002AAM 33

1 8102 - TN Rear wiper low 6 N/C
2 63R9 - OG Rear wiper/ washer 7 N/C
key on
3 8202 - TN Rear wiper high 8 N/C
4 8902 - TN Rear wiper park 9 N/C
5 N/C 10 N/C
Connector 149
RCPH10TLB024AAM 34
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A 41F9 - VT Front driving light G 6903 - TN Front wiper park
B 63F6 - OG Front wiper/ washer H 45LC - VT Left indicator light
key on
C 45RD - VT Right indicator light J 42F6 - VT Front work light
D 6703 - TN Front wiper high K 41F6 - VT Front driving light
E 6603 - TN Front wiper low L N/C
Connector 150
RCPH10TLB026AAM 35

1 P007 - RD B+ 25 21C6 - YE Neutral signal
2 64A3 - RD Horn B+ 26 4006 - OG Accessory
3 45R5 - VT Right indicator light 27 2182 - PK Foot throttle 5V
4 P019 - RD B+ 28 6502 - WH Rear windshield washer
pump output
5 P003 - RD B+ 29 1202 - BL Foot throttle idle validation
6 P004 - RD B+ 30 3223 - YE
8 25B4 - LB Reverse signal 32 N/C
9 42F8 - VT Front work light 33 0901 - OG Comfort steer key on
10 41F8 - VT Front driving light 34 N/C
11 45L5 - VT Left indicator light 35 N/C
12 N/C 36 N/C
13 5207 - YE 37 N/C
14 25A5 - LB 38 3584 - YE
15 5012 - YE Quick coupler load 39 1902 - YE
sense output
16 63F6 - OG Front wiper/ washer 40 0976 - WH Comfort steer output
key on
17 5022 - YE Loader quick coupler 41 4804 - VT Rotating beacon
retract
18 2162 - YE Foot throttle signal 42 6703 - TN Front wiper high
20 2202 - BL Foot throttle ground 44 6903 - TN Front wiper park
21 19E7 - OG Transmission key on 45 6603 - TN Front wiper low
power
22 5704 - OG Couplers/ EH Clam/ 46 42F6 - VT Front work light
on
23 64B2 - WH Horn output 47 41F6 - VT Front driving light
24 3212 - YE Kickdown signal
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Connector 181
RCPH10TLB029AAM 36

A 8401 - RD Cigarette lighter B+ B G068 - BK Ground
Connector 182
RCPH10TLB029AAM 37

A 8402 - RD Cigarette lighter B+ B G070 - BK Ground
Connector 184
RCPH10TLB058AAM 38

A 19N1 - RD Air suspension seat B+ B G067 - BK Ground
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Connector 186
RCPH10TLB002AAM 39

1 N/C 6 N/C
2 AP51 - OG Heavy lift key on 7 N/C
3 0711 - YE 8 N/C
4 N/C 9 N/C
5 N/C 10 N/C
Connector 221
RCPH10TLB034AAM 40

1 8502 - BN A/C Compressor
solenoid power
Connector 222
RCPH10TLB034AAM 41

1 6004 - BN A/C High pressure
switch
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Connector 274
RCPH10TLB002AAM 42

1 G150 - BK 6 N/C Aux forward output
2 0729 - BL Combo hydraulic signal 7 N/C
3 N/C 8 N/C
4 0738 - WH Hammer valve power 9 N/C
5 N/C Aux forward or hammer 10 N/C
valve output
Connector 300
RCPH10TLB001BAM 43

1 2P01 - RD Trax B+ 29 G101 - BK Aux forward output
2 5207 - YE 30 N/C
3 3053 - WH Forward solenoid 31 N/C
output
4 3063 - WH Reverse solenoid 32 N/C
output
5 19ED - OG 33 N/C
6 3043 - WH S2 solenoid output 34 19EB - OG
7 3593 - WH S3 solenoid output 35 N/C
8 19EC - OG 36 N/C
9 3013 - WH S1 solenoid output 37 N/C
10 N/C 38 3023 - WH S4 solenoid output
11 3573 - WH Diff lock solenoid 39 25X3 - WH 4WD output
output
12 3073 - GY Forward solenoid 40 3083 - GY Reverse solenoid return
return
13 3033 - GY PWM 1/3 solenoid 41 3603 - GY PWM 2/4 solenoid return
return
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14 N/C 42 N/C
15 3151 - PK Trax 5V output 43 3431 - YE Transmission temperature
signal to Trax
16 21C7 - YE 44 3441 - YE Transmission charge
pressure signal
17 0401 - BL Trax signal ground 45 3451 - YE Gear switch 3/4
18 25A5 - LB 46 35B6 - LB
19 1902 - YE 47 3223 - YE
20 N/C 48 N/C
21 4062 - YE 49 3214 - YE
22 25C2 - YE 50 9403 - YE
23 3584 - YE 51 25S1 - YE
24 N/C 52 N/C
25 3301 - BL Transmission speed 53 31S2 - YE
sensor signal
26 N/C 54 3541 - YE Gear switch 1/2
27 E356 - YE 55 E346 - GN
28 N/C 56 N/C
Connector 345
RCPH10TLB022AAM 44

A1 G108 - BK Trax controller power B5 3573 - WH Diff lock solenoid output
ground
A2 3053 - WH Forward solenoid B6 19EE - OG
output
A3 3063 - WH Reverse solenoid B7 3301 - BL Transmission speed sensor
output signal
A4 3013 - WH S1 solenoid output B7 3451 - YE Gear switch 3/4
A5 N/C C1 N/C
A6 N/C C2 3043 - WH S2 solenoid output
A7 3023 - WH S4 solenoid output C3 3033 - GY PWM 1/3 solenoid return
A8 3151 - PK Trax 5V output C4 3593 - WH S3 solenoid output
B1 3541 - YE Gear switch 1/2 C5 3603 - GY PWM 2/4 solenoid return
B2 3073 - GY Forward solenoid C6 3431 - YE Transmission temperature
return signal to Trax
B3 3083 - GY Reverse solenoid C7 3441 - YE Transmission charge
return pressure signal
B4 25X3 - WH 4 WD output C8 0401 - BL Trax signal ground
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Connector G203 Ground Ring Terminal
RCPH10TLB062AAM 45

1 G081 - BK 1 G076 - BK
1 G160 - BK Side console harness 1 G154 - BK
ground
ground
ground
Connector G203 Ground Ring Terminal
RCPH10TLB062AAM 46

1 G190 - BK Side console harness
ground
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Wiring harness - Electrical schematic frame 01 Power Distribution/

Charging System
Connector ID
X 1 connector
X 5 connector
X 12 connector
X 13 connector
X 40 connector
X 51 connector
X 83 connector
X 122 connector
X 123 connector
X 147 connector Power Relay 3 & 4
X 150 connector
G205 connector
G209 connector
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RCIL10TLB001JAM 1
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Wiring harness - Electrical schematic frame 02 Starting System

Connector ID
X 1 connector
X 12 connector
X 13 connector
X 14 connector
X 40 connector
X 51 connector
X 82 connector
X 150 connector
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RCIL10TLB002JAM 1
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Wiring harness - Electrical schematic frame 03 Grounding

Connector ID
XG200 connector Cab Ground Side Console on Loader Control
XG201 connector Chassis Ground on Upright
G203 connector Cab Ground Side Console Harness
G204 connector Cab Ground Side Console Harness
G208 connector Cab Ground Fire Wall
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RCIL10TLB003JAM 1
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Wiring harness - Electrical schematic frame 04 Engine Control

Connector ID
X 1 connector
X 9 connector Diagnostic Port
X 13 connector
X 51 connector
X 65 connector Grid Heater Relay Ciol
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RCIL10TLB004JAM 1
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Wiring harness - Electrical schematic frame 05 Powershift Transmission

Inputs
Connector ID
X 1 connector
X 12 connector
X 40 connector
X 51 connector
X 147 connector Forward and Reverse Diodes
X 150 connector
X 349 connector Left Brake Pressure Switch
X 350 connector RightBrake Pressure Switch
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RCIL10TLB005JAM 1
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Wiring harness - Electrical schematic frame 06 Hydraulics

Connector ID
X 1 connector
X 7 connector Boom Lock
X 12 connector
X 13 connector
X 39 connector
X 40 connector
X 50 connector
X 51 connector
X 53 connector Return To Dig Solenoid
X 59 connector Backhoe Quick Coupler Retract Solenoid
X 60 connector Loader Quick coupler Retract Solenoid
X 61 connector Load Sense Solenoid
X 150 connector
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RCIL10TLB006JAM 1
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Wiring harness - Electrical schematic frame 07 Pilot Controls

Connector ID
X 401 connector RH Stabilizer Down Solenoid
X 402 connector RH Stabilizer Up Solenoid
X 403 connector LH Stabilizer Down Solenoid
X 404 connector LH Stabilizer Up Solenoid
X 405 connector Aux Reverse Solenoid
X 407 connector Extendahoe Retract Solenoid
X 408 connector Extendahoe Extend Solenoid
X 410 connector Pattern Change Solenoid 1
X 411 connector Pressure Reducing Valve
X 412 connector Pattern Change Solenoid 2
X 413 connector Pressure Reducing Valve Diode
X 414 connector Pattern Change Valve Diode
X 419 connector
X 430 connector Hammer Valve Option Harness
X 455 connector
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RCIL10TLB007JAM 1
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Wiring harness - Electrical schematic frame 08 Front Exterior Lights

Connector ID
X 40 connector
X 147 connector
X 149 connector
X 150 connector
X 191 connector
X 192 connector Front Work Light
X 193 connector Front Driving Light
X 194 connector Front Driving Light
X 194 connector Front Work Light
X 196 connector Left Indicator Light
X 198 Left Indicator Light
X 199 Left Indicator Light
X 201 connector Right Indicator Light
X 211 connector
X 213 connector
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RCIL10TLB008JAM 1
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Wiring harness - Electrical schematic frame 09 Interior Lighting

Connector ID
X 12 connector
X 20 connector
X 101 connector
X 105 connector Dome Light Switch
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RCIL10TLB009JAM 1
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Wiring harness - Electrical schematic frame 10 Windshield Wipers

Connector ID
X 12 connector
X 20 connector
X 40 connector
X 101 connector
X 111 connector Rear Wiper Cutout Switch
X 113
X 114
X 116 connector
X 117 connector
X 129 connector Rear Wiper Cutout Switch
X 147 connector
X 149 connector
X 150 connector
X 211 connector
X 214
X 215 connector
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RCIL10TLB010JAM 1
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Wiring harness - Electrical schematic frame 11 Instrument Cluster

Connector ID
X 1 connector
X 6 connector Seat Position Switch
X 13 connector
X 40 connector
X 51 connector
X 54 connector
X 62 connector Hydraulic Filter Restriction Switch
X 63 connector
X 66 connector Air Filter Restriction Switch Ground
X 67 connector Air Filter Restriction Switch
X 71 connector Transmission Temperature Sender
X 150 connector
X 220 connector
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RCIL10TLB011JAM 1
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Wiring harness - Electrical schematic frame 12 Power Points

Connector ID
X 12 connector
X 181 connector Cigarette Lighter Plug I
X 182 connector Cigarette Lighter Plug II
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RCIL10TLB012JAM 1
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Wiring harness - Electrical schematic frame 13 SAHR Park Brake

Connector ID
X 1 connector
X 13 connector
X 14 connector
X 51 connector
X 57 connector Park Brake Solenoid
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RCIL10TLB013JAM 1
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Wiring harness - Electrical schematic frame 14 HVAC

Connector ID
X 1 connector
X 12 connector
X 22 connector Blower Switch
X 51 connector
X 69 Connector A/C Compressor
X 221 connector Thermostat Switch
X 222 connector Thermostat Switch
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RCIL10TLB014JAM 1
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Wiring harness - Electrical schematic frame 15 Radio

Connector ID
X 12 connector
X 20 connector
X 101 connector
X 102 connector Speaker connector from radio
X 210 connector Antenna Ground
X 255 connector Left and Right Speaker
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RCIL10TLB015JAM 1
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Wiring harness - Electrical schematic frame 16 Rear Exterior Lights

Connector ID
X 12 connector
X 20 connector
X 40 connector
X 101 connector
X 115 connector
X 147 connector
X 150 connector
X 161 connector
X 162 connector Rear Work Light R1
X 163 connector Rear Work Light L1
X 166 connector Rotating Beacon
X 169 connector Left Turn Signal/ Hazard Light
X 170 connector Left Tail Light Brake Light
X 171 connector Right Tail Light Brake Light
X 173 connector Right Turn Signal/ Hazard Light
X 174 connector Left Tail Light Brake Light
X 176 connector Right Tail Light Brake Light
X 450 connector Left Side Work Lights
X 451 connector Right Side Work Light
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RCIL10TLB016JAM 1
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Wiring harness - Electrical schematic frame 17 Options

Connector ID
X 2 connector
X 12 connector
X 45 connector
X 135 connector Clam Controller
X 136 connector Clam Controller
X 184 connector Air Suspension Seat
X 250 connector
X 276 connector
X 277 connector
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RCIL10TLB017JAM 1
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Wiring harness - Electrical schematic frame 18 Horn

Connector ID
X 1 connector
X 12 connector
X 40 connector
X 51 connector
X 150 connector
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RCIL10TLB018JAM 1
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Wiring harness - Electrical schematic frame 19 Comfort Steer/ Ride

Control
Connector ID
X 1 connector
X 12 connector
X 40 connector
X 51 connector
X 52 connector Ride Control Tank Solenoid
X 56 connector Ride Control Accumulator Solenoid
X 58 connector Comfort Steer Solenoid
X 147 connector
X 150 connector
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RCIL10TLB019JAM 1
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Wiring harness - Electrical schematic frame 20 Canopy Exterior Lights

Connector ID
X 177 connector Left Front Driving Light
X 178 connector Right Front Driving Light
X 179 connector Right Indicator Light Ground
X 180 connector Right Indicator Light
X 188 connector Left Indicator Light
X 189 connector Left Indicator light Ground
X 452 connector Right Side Light
X 453 connector Left Side Light
X 500 connector C-Post Lighting Harness
X 501 connector C-Post Lighting Harness
X 504 connector Rear Lighting Harness Canopy
X 505 connector Front Lighting Harness Canopy
X 512 connector Rear Work Light R1
X 514 connector Rear Work light R2
X 520 connector Right Turn Signal/ Hazard Light
X 521 connector Right Turn Signal/ Hazard Light Ground
X 522 connector Right Tail Light
X 523 connector Brake Light
X 524 connector Brake Light
X 525 connector Left Turn Signal/ Hazard Light
X 526 connector Left Turn Signal/ Hazard Light Ground
X 527 connector Rotating Beacon
X 528 connector Left Tail Light
X 530 connector Right Front Work Light
X 531 connector Left Front Work Light
G218 connector Ground Connection
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RCIL10TLB020JAM 1
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Wiring harness - Electrical schematic frame 21 Powershift Transmission

Jumper Harness
Connector ID
X 354 connector
X 355 connector
X 356 connector
X 357 connector
X 374 connector
X 380 connector Forward Solenoid
X 381 connectorReverse Solenoid
X 382 connectorPWM 1/3 Solenoid
X 383 connectorPWM 2/4 Solenoid
X 384 connectorS13 Solenoid
X 385 connectorS24 Solenoid
X 386 connector4WD Solenoid
X 387 connector Differential Lock Solenoid
X 388 connectorTransmission Speed Sensor
X 389 connectorTransmission Temperature Sensor
X 390 connectorTransmission Pressure Switch
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RCIL10TLB021JAM 1
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Wiring harness - Electrical schematic frame 22 Trax SPS/ PS Controller

Connector ID
X 300 connector Trax Controller
X 320 connector Forward Solenoid
X 321 connector Reverse Solenoid
X 322 connector S2 Solenoid
X 326 connector 4WD Solenoid
X 327 connector Differential Lock Solenoid
X 328 connector Transmission Pressure Switch
X 329 connector Transmission Temperature Switch
X 330 connector Transmission Speed Sensor
X 344 connector
X 345 connector
X 360 connector Gear Switch 2
X 361 connectorGear Switch 1
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RCIL10TLB022JAM 1
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Wiring harness - Electrical schematic frame 23 Hydraulic Heavy Lift

Connector ID
X 1 connector
X 6 connector Torque Control Seat Switch
X 13 connector
X 14 connector
X 51 connector
X 93 connector Torque Control Solenoid
X 186 connector Hydraulic Heavy Lift Switch
X 275 connector Heavy Lift Solenoid
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RCIL10TLB023JAM 1
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Wiring harness - Electrical schematic frame 24 Combo Hydraulics

Connector ID
X 1 connector
X 51 connector
X 54 connector
X 87 connector Mechanical Controls Combo
X 90 connector Hammer Valve Foot Switch (Mechanical Controls Hammer Valve)
X 91 connector Hammer Valve Foot Switch (Mechanical Controls Combo)
X 274 connector Combo Hydraulics Switch
X 441 connector Hammer Valve LH Joystick Switch
X 442 connector Hammer Valve Options Harness
X 432 connector Spool Lock Solenoid
X 433 connector Hammer Valve Solenoid (Mechanical Controls Combo)
X 434 connector Aux Forward Solenoid
X 435 connector
X 436 connector Hammer Valve Solenoid (Mechanical Controls Hammer Valve)
X 439 connector Hammer Valve Solenoid
X 443 connector Hammer Valve Option Harness
X 446 connector
X 447 connector
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RCIL10TLB024JAM 1
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Wiring harness - Electrical schematic frame 25 Pilot Controls Input

Connector ID
X 1 connector
X 12 connector
X 51 connector
X 54 connector
X 409 connector Right Hand Stabilizer Pressure Switch
X 420 connector Pilot Control One-Touch Decel
X 421 connector Pilot Control Horn Switch
X 422 connector Extendahoe Extend/Retract Push Button
X 423 connector Bi-Directional Aux Hydraulics Forward/ Reverse
X 424 connector Right Hand Stabilizer Switch
X 425 connector Left Hand Stabilizer Switch
X 426 connector Left Hand Stabilizer Pressure Switch
X 455 connector
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RCIL10TLB025JAM 1
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Wiring harness - Electrical schematic frame 26 DIA Kits

Connector ID
X 700 connectorRotating Beacon Jumper
X 702 connector Boom Lock Harness
X 705 connector
X 706 connector
X 707 connector
X 708 connector
X 709 connector
X 710 connector
X 711 connector
X 712 connector
X 713 connector
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RCIL10TLB026JAM 1
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Alternator - Remove
NOTE: The alternator is located behind the fan on the en-

gine housing.
parking brake.
2. Remove the pin that fastens the support strut to the
loader frame.
3. Raise the loader frame until the support strut is
against the end of the lift cylinder.
4. Stop the engine and install the pin in the support
strut.
RCPH10TLB227AAF 1
5. Remove the bolts and washers that fasten the battery

cover to the right side of the machine by the step.
RCPH11TLB001AAM 2
RCPH11TLB002AAM 3
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7. Remove the negative cable (2) from the battery post.

Move the cable away from the battery terminals.
8. Remove the positive cable (1) from the battery. Move
the cable away from the battery terminals.
RCPH10TLB429AAF 4
9. Open the hood.
RCPH10TLB356AAF 5
10. Install a breaker bar in the bracket for the tension

pulley.
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.
12. Tag and disconnect all wires and cable from the al-
ternator. Remove the bolt that fastens the alternator
to the brace. Hold the alternator and remove the bolt
from the top of the alternator.
13. Remove the alternator from the mounting bracket.
RCPH10TLB231ABL 6
(1) Wires (3) Bolt

(2) Bolt (4) Spacer
Next operation:
Alternator - Install (A.30.A)
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Alternator - Install
Prior operation:
Alternator - Remove (A.30.A)
1. Hold the alternator in alignment with the mounting

bracket and install the bolt at the top of the alternator.
Do not tighten the bolt. Install the bolt that fastens
the alternator to the brace. Tighten both of the bolts.
Install the wires and cables on the alternator.
RCPH10TLB231ABL 1
(1) Wires (3) Bolt

(2) Bolt (4) Spacer
2. Use the breaker bar to move the tension pulley just

far enough to install the drive belt. Install the drive
belt on the alternator.
3. Remove the breaker bar.
4. Close the hood.
5. Connect the positive battery cable (1) to the positive
post on the battery.
6. Connect the negative battery cable (2) to the nega-
tive post on the battery.
RCPH10TLB429AAF 2
7. Install the battery cover.

8. Install the washers and bolts that fasten the battery
cover to the machine.
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Battery - Service instruction

Electrolyte Level
If the battery is a maintenance free battery, check the
level of the electrolyte every 1000 hours of operation or
six months, whichever occurs first. For all other batter-
ies, check the level of the electrolyte every 250 hours of
operation.
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 for access to
the battery caps, it is possible that the words Maintenance
Free have been removed from the decal.
RCPH10TLB291AAF 1
Check the level of the electrolyte more often during hot

weather. The use of a large amount of water by the battery
can be caused by high battery temperature or a voltage
regulator setting that is too high. Keep the electrolyte level
above the top of the plates in the battery at all times to
prevent damage to the battery.
NOTE: On maintenance free batteries it is necessary to
remove the center part of the decal for 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.
RCPH11TLB080AAL 2
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 needed. Too much
water can cause bad performance, a short service life, and
corrosion around the battery.
NOTE: Add water only. DO NOT add electrolyte.
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Battery - Inspect and clean

If damage causes an electrolyte leak, replace the battery.
Inspect the battery at regular intervals for dirt, corrosion,
and damage. Electrolyte and dirt on the top of the battery
can cause the battery to discharge by making a passage
for the current to flow.
If the battery must be cleaned, remove the battery from
the battery carrier and clean the battery, cable terminals,
and the battery carrier. When available, use Case Battery
Saver and Cleaner according to the instructions on the con-
tainer. Case Battery Saver and Cleaner also helps prevent
corrosion. If Case Battery Saver and Cleaner is not avail-
able, use baking soda and water as a cleaner. Do not per-
mit any type of cleaner to enter the cells of the battery.
Install the battery in the machine and make sure the fas-
teners are tight. Apply Case Battery Saver and Cleaner or
Urethane Seal Coat to the cable terminals to prevent corro-
sion. See the Parts Counter Catalog. Do not apply grease.
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Battery - Test
Visual Checks
1. Verify the cable connections are clean and tight. Ver-
ify the cables and connections are free of corrosion,
abrasion, damage and incorrect attachment. 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. Refer to Battery - Ser-
vice instruction (A.30.A) for details.
4. If you added water to the battery, the battery must be
charged for 15 minutes at 15 - 25 A to mix the water
with the electrolyte.
Specific Gravity Check

A hydrometer is used to check the specific gravity (weight)
of the electrolyte. The specific gravity is an indication of
the level of charge for each cell.
Hydrometers are made to show the correct specific gravity
when the temperature of the electrolyte is 26.7 °C (80 °F).
When you check the specific gravity, you must know the
temperature of the electrolyte. If your hydrometer does not
have a thermometer, get a thermometer to check the tem-
perature of the electrolyte. The thermometer must indicate
a high temperature of at least 52 °C (126 °F).
1. Remove enough electrolyte from a cell so that the
float is free in the tube.
NOTE: If the specific gravity cannot be checked without
first adding water to the cell, the battery must be charged
for 15 minutes at 15 - 25 A to mix the water with the elec-
trolyte. Then check the specific gravity.
2. Read the float.
3. Read the thermometer. If the reading is above 26.7
°C (80 °F) add specific gravity points to the reading
for specific gravity. If the reading is below 26.5 °C (80
°F) subtract specific gravity points from the reading
for specific gravity. See the following illustration and
add or subtract specific gravity points as needed.
4. Make a record of the corrected specific gravity read-
ing for each cell.
5. If the difference between the high reading and the
low reading is 0.050 or more, charge the battery and
check the specific gravity again. If after charging, the
difference is still 0.050 or more, install a new battery.
6. The corrected specific gravity reading shows the
level of charge for the cell. The level of charge must
be at least 75% in each of the cells. In maintenance
free batteries the level of charge is at least 75%
if the corrected specific gravity reading is 1.240 or
higher. In all other batteries the level of charge is at
least 75% if the corrected specific gravity reading is
1.230 or higher.
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7. If the difference between the high reading and the low

reading is less than 0.050, and the level of charge is
at least 75% in all of the cells, perform the Capacity
(Load) Test in this section.
8. If the difference between the high reading and the low
reading is less than 0.050, but the level of charge is
less than 75% in any of the cells, charge the battery
and check the specific gravity again. If after charg-
ing:
A. The level of charge is less than 75% in any
of the cells, replace the battery.
B. The level of charge is at least 75% in all
of the cells, perform the Capacity (Load)
Test.
Capacity (Load) Test

This test can be done using a variable load tester such as
the CAS10147. Other test equipment can be used. Con-
nect the test equipment according to the instructions of the
manufacturer of the equipment.
1. The level of charge of the battery must be at least
75%. Perform the Specific Gravity Check in this sec-
tion.
2. Prepare the CAS10147 tester for the test.
A. Select the voltmeter range that will mea-
sure 1 - 18 V.
B. Make sure the load control knob is in the
OFF position.
C. Select the ammeter range that will mea-
sure 0 - 1000 A.
D. Move the volt lead switch to the NT posi-
tion.
3. Connect the tester to the battery.
NOTE: Never apply a load for longer than 15 seconds. Af-
ter each 15 seconds, turn the load control knob to OFF for
at least one minute.
4. Apply a 15 A load to the battery for 15 seconds. Wait
at least three minutes before applying the load again.
5. Check and make a record of the temperature of the
electrolyte.
6. Find the correct load for this test in Specifications in
Section 4002.
NOTE: The correct load is half of the cold cranking am-
peres at -17 °C (1 °F).
7. Turn the load control knob until the ammeter indi-
cates the specified load. Keep the load for 15 sec-
onds and read the voltmeter. Turn the load control
knob to OFF.
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8. Compare the test reading and the temperature of the

electrolyte to the chart below.
A. If the test result is equal to or more than
the voltage shown, the battery is in good
condition.
B. If the test result is less than the voltage
shown, replace the battery.
Temperature of Minimum
electrolyte Voltage
21 °C (70 °F) or higher 9.6
16 °C (61 °F) 9.5
10 °C (50 °F) 9.4
4 °C (39 °F) 9.3
-1 °C (30 °F) 9.1
-7 °C (19 °F) 8.9
-12 °C (10 °F) 8.7
-18 °C (0 °F) 8.5
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Battery - Charging
WARNING
Explosive gas!
battery.
W0005A
Before you charge the battery, check the level of the electrolyte.
It is difficult to give an exact charging rate because of the following variable conditions: (1) temperature of the elec-
trolyte, (2) level of charge, and (3) condition of the battery. Use the charging guide for the correct charging rate and
time.
Charging Guide For Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity Slow Charge Fast Charge
10 Hours at 5 A 2.5 Hours at 20 A
80 Minutes or Less
80 to 125 Minutes
7.5 Hours at 10 A 1.5 Hours at 50 A
20 Hours at 5 A 5 Hours at 20 A
125 to 170 Minutes
170 to 250 Minutes
* Initial rate for a 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.
Charging Guide For Batteries Other Than Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity Slow Charge Fast Charge
80 Minutes or Less
80 to 125 Minutes
7.5 Hours at 10 A 1.5 Hours at 50 A
125 to 170 Minutes
170 to 250 Minutes
6 Hours at 40 A
Above 250 Minutes 24 Hours at 10 A
4 Hours at 60 A
* Initial rate for a standard taper charger.
The charging rate must be decreased if:

1. Too much gas causes the electrolyte to
flow from the cells.
2. The temperature of the electrolyte rises
above 52 °C (126 °F).
NOTE: For the best charge, use the slow charging rates.
The battery is fully charged when, over a three hour period
at a low charging rate, no cell is giving too much gas, and
the specific gravity does not change.
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Preparing a dry charged battery for use

1. Remove the caps from the battery.
RCPH10TLB291AAF 1
2. Fill each cell to the top of the separators with elec-

trolyte. This will permit the volume of electrolyte to
increase when heated by charging the battery.
RCPH11TLB080AAL 2
3. Install the caps on the battery.

4. Connect a battery charger to the battery.
5. Charge the battery at 30 A until the specific gravity is
1.250 or more and the temperature of the electrolyte
is at least 15.5 °C (60 °F).
6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of the
cell opening.
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Battery - Disconnect
WARNING
Explosive gas!
battery.
W0005A
WARNING
W0006A
Battery - Basic instructions (A.30.A)
1. Remove the battery cover hardware.
RCPH11TLB001AAM 1
RCPH11TLB002AAM 2
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3. Disconnect the negative battery cable from the neg-

ative battery terminal.
RCPH11TLB003AAM 3
Next operation:
Battery - Connect (A.30.A)
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Battery - Connect
WARNING
Explosive gas!
battery.
W0005A
WARNING
W0006A
1. Connect the negative battery cable to the negative

battery terminal.
RCPH11TLB003AAM 1
RCPH11TLB002AAM 2
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3. Install the battery cover hardware.
RCPH11TLB001AAM 3
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Index

SYSTEMS - A

Wiring harness - Electrical schematic frame 02 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Wiring harness - Electrical schematic frame 03 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Wiring harness - Electrical schematic frame 04 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Wiring harness - Electrical schematic frame 05 Powershift Transmission Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Wiring harness - Electrical schematic frame 06 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Wiring harness - Electrical schematic frame 07 Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Wiring harness - Electrical schematic frame 08 Front Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Wiring harness - Electrical schematic frame 09 Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Wiring harness - Electrical schematic frame 10 Windshield Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Wiring harness - Electrical schematic frame 11 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Wiring harness - Electrical schematic frame 12 Power Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Wiring harness - Electrical schematic frame 13 SAHR Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Wiring harness - Electrical schematic frame 14 HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Wiring harness - Electrical schematic frame 15 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Wiring harness - Electrical schematic frame 16 Rear Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Wiring harness - Electrical schematic frame 17 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Wiring harness - Electrical schematic frame 18 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Wiring harness - Electrical schematic frame 19 Comfort Steer/ Ride Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Wiring harness - Electrical schematic frame 20 Canopy Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Wiring harness - Electrical schematic frame 21 Powershift Transmission Jumper Harness . . . . . . . . . . . . . . . . . 162
Wiring harness - Electrical schematic frame 22 Trax SPS/ PS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Wiring harness - Electrical schematic frame 23 Hydraulic Heavy Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Wiring harness - Electrical schematic frame 24 Combo Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Wiring harness - Electrical schematic frame 25 Pilot Controls Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Wiring harness - Electrical schematic frame 26 DIA Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Battery - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Battery - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Battery - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Battery - Inspect and clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Battery - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Battery - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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Connector - Component diagram 01 Side Console Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connector - Component diagram 02 Front Console Harness. SPS/PWR Trans, Mech W/ Opt . . . . . . . . . . . . . . . 23
Connector - Component diagram 03 Chassis Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connector - Component diagram 04 Cab Rear Lights Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Connector - Component diagram 05 Front Lights Canopy Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Connector - Component diagram 06 Hydraulic Filter Restriction Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Connector - Component diagram 07 Cab B-Post Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Connector - Component diagram 08 C-Post Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connector - Component diagram 09 Combo Aux, Mech Control, Hammer or BiDir Valve Harness . . . . . . . . . . . . 60
Connector - Component diagram 10 Combo Aux, Pilot Control, Hammer or Bi-Dir Valve Harness . . . . . . . . . . . . 62
Connector - Component diagram 11 Combo Aux, Mech Control Hammer Valve Only Harness . . . . . . . . . . . . . . . 64
Connector - Component diagram 12 Combo Aux, Pilot Control, Hammer Valve Only . . . . . . . . . . . . . . . . . . . . . . . 65
Connector - Component diagram 13 A-Post Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connector - Component diagram 14 A-Post, Canopy, Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Connector - Component diagram 15 Rear Lights, Canopy, Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Connector - Component diagram 16 Rear Lights, Canopy, Harness (6 lights) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connector - Component diagram 17 Pilot Controls Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connector - Component diagram 18 Front Lights, Cab Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Connector - Component diagram 19 Front Lights Canopy Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connector - Component diagram 20 Power shift jumper harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Connector - Component diagram 21 Side console, SPS/PWR Trans, HPCR, W/opt harness . . . . . . . . . . . . . . . 100
Wiring harness - Electrical schematic frame 01 Power Distribution/ Charging System . . . . . . . . . . . . . . . . . . . . . 122
Wiring harness - General specification - Electrical wire circuits - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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FAULT CODES - 50.A
580N
580SN WT
580SN
590SN
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Contents

SYSTEMS - A
FAULT CODES - 50.A
DIAGNOSTIC
ELECTRONIC SYSTEM
0000-Retrieving fault codes, Backhoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1001-Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1002-Engine coolant temperature too high, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1003-Air conditioning pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1004-Hydraulic filter blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1009-Transmission oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1010-Foot throttle signal out of range, IVS not changing state in 300 ms . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1011-Foot throttle signal out of range, throttle above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . 32
1012-Foot throttle signal out of range, throttle below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . 35
1013-Foot throttle signal out of range, signal unusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1014-Battery charge voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1015-Battery charge voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1018-Boost air temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1019-Engine coolant temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1020-Transmission oil temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1021-Fuel temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1022-Water in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1023-Foot throttle supply voltage too high, over 5.2 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1024-Foot throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1025-Foot throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1026-Foot throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1032-Hand throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . 60
1033-Hand throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1034-Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1035-Hand throttle sensor signal above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1036-Hand throttle sensor signal below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1037-Hand throttle sensor out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1039-Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1040-Engine RPM over 2750 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1041-Engine RPM over 3000 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1045-Fuel level sensor open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1047-Transmission temperature sensor below 3.0 ohms for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1050-Alternator L+ terminal under 1.5 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1051-Timeout of CAN message EEC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1052-Timeout of CAN message, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1053-Timeout of CAN message CNFBAM, 25 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . 115
1054-Timeout of CAN message engine temperature, 5 seconds without message . . . . . . . . . . . . . . . . 119
1055-Timeout of CAN message inlet/exhaust, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . 123
1056-Timeout of CAN message engine fluid, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . 127
1057-Timeout of CAN message vehicle electrical, 5 seconds without message . . . . . . . . . . . . . . . . . . . 131
1058-Timeout of CAN message EDC2BC, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1059-Timeout of CAN message DM1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3006-Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3007-Coolant temperature signal - signal above range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3010-Air intake temperature sensor signal above maximum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3011-Air intake temperature sensor signal below minimum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3015-Fuel Temperature Sensor - Signal Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3019-Boost Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3022-Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3023-Atmospheric pressure sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3025-Atmospheric pressure sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3028-Oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3029-Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3030-Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3031-Oil pressure sensor - hardware error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3032-Oil Pressure Sensor - Value Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3033-Oil Temperature Sensor - Signal Not Plausible (Compared With Coolant Temperature) . . . . . . . 179
3034-Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3035-Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3047-Main Relay Failure - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3048-Main Relay Failure - Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3059-ECM afterrun was interrupted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3060-Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3062-Cylinder 1 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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3088-Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3090-Phase defect of camshaft speed sensor signal detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3091-Camshaft sensor phase synchronization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3095-Operating With Camshaft Sensor Only - Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3104-Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3107-Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3108-Fuel Metering Unit - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3110-Rail Pressure Sensor Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . 260
3111-Rail Pressure Sensor Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3113-Grid heater battery switch relay short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3114-Grid heater battery switch relay short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3118-ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3119-ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3131-Grid Heater Always Switched On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3138-Metering Unit - Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . 275
3142-High Pressure Test - Test Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3145-Terminal 15 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3147-Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3154-Grid Heater Relay - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3155-Grid Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3156-Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3171-Fuel rail system pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3172-Fuel rail system pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
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3173-Rail Pressure Governor Deviation Below Min. Limit for Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3174-Rail Pressure Governor Deviation Exceeded Max. Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3175-Fuel system leak detected - large leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3176-Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3177-Engine Overspeed Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3188-Cylinder 1 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3192-Cylinder 2 warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3211-Bank 1 - Injector cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3213-Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3221-Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . 331
3228-Injection Processor Error - Unlocked/Initialization Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3229-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
3239-Engine Controller EEPROM - Read Operation Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3240-Engine Controller EEPROM - Write Operation Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3241-Engine Controller EEPROM - Default Value Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3244-Engine Controller Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
3246-Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
3247-Shutoff Paths Failed During Initialization - Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . 348
3248-Shutoff Paths During Initialization - Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
3249-TPU Monitoring - Time Deviation Between TPU And System Not Plausible . . . . . . . . . . . . . . . . . 350
3250-Dataset - Variant Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3251-Dataset - Requested Variant Could Not Be Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3252-Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3253-ADC Monitoring - Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
3254-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
3258-HS power stage hardware reports 'short circuit to battery' longer than 500 ms. . . . . . . . . . . . . . . 358
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3259-HS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . 361
3260-LS power stage hardware reports 'open load' longer than 100 ms . . . . . . . . . . . . . . . . . . . . . . . . . 364
3261-LS power stage hardware reports 'short circuit to battery' or 'excess temperature' longer than 100
ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
3262-LS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . 370
3263-Busoff in CAN C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
3265-Energizing time exceeds limit of over run monitoring, injection time too long . . . . . . . . . . . . . . . . 374
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
3278-Engine Controller Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
3279-Engine Controller Internal Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
3280-Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
3281-Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
3316-Minimum Number Of Injections Not Reached - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3334-Timeout of CAN Message TSC1 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
3339-Timeout of CAN Message TSC1 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3350-Terminal 50 - always on, starting circuit signal is active for an excessive time period . . . . . . . . . 399
3361-ECM EEPROM - General Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3363-Atmospheric Pressure Sensor - Processed via ADC, not plausible . . . . . . . . . . . . . . . . . . . . . . . . . 403
3856-Coolant temperature signal test failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3998-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3999-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
4000-Power supply (pin 2), forward FWD drive (pin 3), or RVS drive (pin 4) drive shorted to ground . 410
4001-Power supply (pin 5), PWM 1 drive (pin 6), or PWM 2 drive (pin 7) drive shorted to ground . . . . 416
4002-Power supply for digital outputs (pin 8) does not have power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
4004-Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 rpm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
4005-Downshift delayed due to possible engine overspeed condition S-Type Transmission Only . . . . 428
4006-FWD input (Pin 12) feedback circuit is reading current with command . . . . . . . . . . . . . . . . . . . . . . 429
4007-FWD input (Pin 12) current is too low with command present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
4008-FWD solenoid is drawing more current than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
4009-FWD solenoid is drawing less current than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
4011-RVS input (pin 40) feedback circuit is reading current with command . . . . . . . . . . . . . . . . . . . . . . . 441
4012-RVS input (pin 40) current is too low with command present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
4013-RVS solenoid is drawing more current than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
4014-RVS solenoid is drawing less current than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
4016-First and third shift modulation solenoid input (pin 13) feedback circuit is reading current without
command - H-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
4017-First and third shift modulation solenoid input (pin 13) current is too low with command present 456
4018-First and third shift modulation solenoid is drawing more current than commanded H-Type Trans-
mission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
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4019-First and third shift modulation solenoid is drawing less current than commanded H-Type Transmis-
sion Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
4021-Second and fourth shift modulation solenoid input (pin 41) feedback circuit is reading current with
command - H-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
4022-Second and fourth shift modulation solenoid input (pin 41) current is too low with command present
- H-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
4023-Second and fourth shift modulation solenoid is drawing more current than commanded - H-Type
Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
4024-Second and fourth shift modulation solenoid is drawing less current than commanded - H-Type Trans-
mission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
4026-First / Third shift solenoid shorted to ground - H-Type Transmission Only . . . . . . . . . . . . . . . . . . . 477
4027-Second / Fourth shift solenoid shorted to ground - H-Type Transmission Only . . . . . . . . . . . . . . . 480
4028-Differential lock or 4 wheel drive solenoid shorted to ground - H-Type and S-Type Transmissions 483
4029-Shifter Lever improperly connected, no power to pin 16, pin 18, or pin 46 for more than 3 seconds -
H-Type and S-Type Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
4030-Shifter Lever malfunction: transmission in neutral receives forward and neutral together - H-Type
and S-Type Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
4031-Shifter Lever malfunction: transmission in neutral receives reverse and neutral together . . . . . . 495
4032-Shifter Lever malfunction: transmission in forward receives forward and reverse together . . . . . 500
4033-Shifter Lever malfunction: transmission in reverse receives forward and reverse together . . . . . 505
4034-Shifter Lever malfunction: transmission in forward receives neutral and forward together - H-Type
4035-Shifter Lever malfunction: transmission in reverse receives neutral and reverse together . . . . . 515
4036-During transition from second to third gear, and Gear CMD_01 signal erratic or incorrect - H-Type
4037-During transition from first to second gear, and Gear CMD_02 signal erratic or incorrect . . . . . . 525
4038-During transition from third to fourth gear, and Gear CMD_02 signal erratic or incorrect . . . . . . . 530
4040-Transmission Controller Driveline Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
4041-Transmission output shaft frequency above 3000 Hz detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
4042-Temperature signal erratic or incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
4043-Temperature sensor input (Pin 43) is shorted to a ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
4044-Temperature sensor input (Pin 43) is open circuit or shorted to a voltage above 5 volts . . . . . . . 545
4045-Charge pressure is not detected when engine speed is above 700 rpm for 10 seconds . . . . . . . 548
4046-Charge pressure is not detected and vehicle speed is over 10 kph (6 mph) . . . . . . . . . . . . . . . . . 551
4047-Charge pressure switch is closed with no frequency input to the TRAX controller . . . . . . . . . . . . 554
4054-Unknown vehicle model value from VCM S-type transmission only . . . . . . . . . . . . . . . . . . . . . . . . 557
4100-Missing EEC 1 message on CAN - H-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
4101-Internal TRAX failure, hardware measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
4102-Internal TRAX failure, software timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
4103-Internal TRAX failure, software not running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
4105-Internal TRAX failure, redundant flash memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
4106-Internal TRAX failure, sensor supply high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
4107-Internal TRAX failure, sensor supply low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
4200-First shift solenoid shorted to ground S-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
4203-Fourth shift solenoid shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
4204-System detects different gear than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
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4205-System can not engage required gear. (Engaged gear is different than requested gear) . . . . . . 585
4206-Gear engagement failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
4207-1ST/2ND gear shift rail position reporting first gear at startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
4208-1ST/2ND gear shift rail position reporting second gear at startup . . . . . . . . . . . . . . . . . . . . . . . . . . 591
4209-3RD/4TH gear shift rail position reporting third gear at startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
4210-3RD/4TH gear shift rail position reporting forth gear at startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
4211-First and second gear sensor input shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
4212-First and second gear sensor input voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
4213-Third and forth gear sensor input shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4214-Third and forth gear sensor input voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
4825-Loss of TC1 message after 15 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
4850-Possible detection wrong transmission type for installed software . . . . . . . . . . . . . . . . . . . . . . . . . . 610
4995-Incorrect VCM configuration of transmission type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
4996-Electronic transmission offline or incorrect VCM configuration of transmission type . . . . . . . . . . . 612
4997-Loss of messaging from Trax controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
4998-Unknown transmission error code with amber lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
4999-Unknown transmission error code with red lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
9001-Hour meter plausibility, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
9002-Hour meter RAM checksum failure, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
9003-J1939 receive buffer overflow, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
9004-EEPROM checksum failure, hour meter location 1, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . 624
9007-Abnormal reset watchdog time-out, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
9008-A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628
9009-A/D fault foot throttle power, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
9010-A/D fault hand throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
9011-A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
9012-A/D fault, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
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HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - FAULT CODES
0000-Retrieving fault codes, Backhoes

NOTE: The Electronic Service Tool must be used to remove faults from memory.
Context:
General fault code identification and response.
Cause:
General fault code description.
Possible failure modes:
1. List of possible failure modes.
Solution:
1. Press the enter key once.
BD08E038-01 1
(A) Escape key (C) Up key

(B) Enter key (D) Down key
2. Press the down arrow until a warning icon is displayed.
BD08E036-01 2
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3. Press ENTER to view faults.
BD08E037-01 3
(A) Fault Number (D) Number of occurrences of this fault

(B) Number of faults (E) The hour reading on the machine of the last
occurrence
(C) Fault code
4. The screen will automatically scroll to the next fault.

5. Press the ESCAPE key to return.
6. Fault Code Grouping
(1) 1000 to 1999 vehicle errors.

(2) 2000 to 2999 not used.
(3) 3000 to 3999 engine errors.
(4) 4000 to 4999 transmission errors.
(5) 5000 to 5999 not used.
(6) 6000 to 6999 not used.
(7) 7000 to 7999 not used.
(8) 8000 to 8999 not used.
(9) 9000 to 9999 internal AIC errors.
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1001-Engine Air Filter Blocked

Context:
The Instrument Cluster detects a signal to ground on pin 16 indicating that the Air Filter Restriction Switch has been
tripped. The Instrument Cluster will illuminate Air Filter Restriction Lamp while this fault is active.
Cause:
The Instrument Cluster detects a signal to ground indicating that the Air Filter Restriction Switch has been tripped.
1. Clogged air filter.

2. Faulty air filter restriction switch.
3. Signal wire short circuit.
4. Faulty Instrument Cluster.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occur-
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for Active fault codes: Start and operate machine.
A. OK – Fault is not recorded again. OK to return the machine to service.
B. NOT OK – Fault code 1001 is recorded again. Go to Step 2.

2. Inspect the engine air filter.
(1) Inspect the engine air filter. Replace the filter if needed.
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RCPH10TLB036AAF 3
A. OK – The filter is OK and does not need to be replaced. Go to 3.
B. NOT OK – The filter is in poor condition or is clogged. Replace the filter. Go to Step 3 to confirm elimination
of the fault.
3. Verify that the wiring and connectors are free of damage.
RCPH10TLB054FAM 4
Schematic legend
(1) Air Filter Restriction Switch (3) GND005 Chassis Ground On Upright
(2) Instrument Cluster
(1) Inspect the Instrument Cluster and the Air Filter Restriction Switch connections. All connections should be
secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster and the Air Filter Restriction Switch. Verify that the harness
is free of damage, corrosion, abrasion and incorrect attachment.
A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or the harness has damage. Repair or replace the harness or connectors as
required. Return to Step 1 to confirm elimination of fault.
4. Check Air Filter Restriction Circuit
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BD08D002-01 5
(1) Air filter restriction switch

(2) Connector air filter restriction switch
(1) Disconnect 3801-BL from air filter restriction switch.
(2) Turn the key switch on. Engine off. The Air Filter Restriction fault code should no longer be Active.
A. OK – The fault code is no longer active. Go to Step 4.
B. NOT OK – Fault code 1001 is still active. Go to step 5.

5. Check air filter restriction switch
(1) Remove the air filter restriction switch from the air filter housing.
(2) Measure the resistance across the switch. The resistance should be greater than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. Inspect the wiring around the sensor. Go to Step 5.
B. NOT OK – The resistance is less than 20,000 ohms. Replace the air filter restriction switch. Return to
Step 1 to confirm elimination of fault.
6. Measure the resistance of the signal wire.
BD08E042-01 6
(1) Instrument cluster connector 1

(1) Measure the resistance from X-28 pin 16 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The resistance is greater than 20,000 ohms. Temporarily repalce the tRax Control and retest. Go
to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short to chassis gound in the signal wire.
Repair or repalce the wire as required. Return to Step 1 to confirm elimination of fault.
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Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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1002-Engine coolant temperature too high, critical

NOTICE: Check coolant level before proceeding.
Context:
The Instrument Cluster has detected a coolant temperature above 111 °C (232 °F) for a period greater than 5 seconds.
The Instrument Cluster will illuminate the Coolant Temperature Icon and the Danger Icon . The audible alarm
will sound continuously while this fault is active.
Cause:
The coolant temperature signal is above normal. The Instrument Cluster has detected a coolant temperature above
111 °C (232 °F) for a period greater than 5 seconds.
1. Low coolant level.

2. Wiring or circuits shorted to ground.
3. Faulty reading from component.
Solution:
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(2) To check for fault code: Start and operate machine.
A. OK – Fault code is not recorded again. OK to return the machine to service.
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2. Visually inspect cooling system.
(1) Run engine at 1500 RPM.
(2) Check fan operation.
(3) Check cooling core for clogs.
A. OK – The fan is operating properly and there are no clogs in the system. Go to Step 3.
B. NOT OK – The fan is not operating properly or the radiator is clogged. Repair as required. Return to Step
1 to confirm elimination of fault.
3. Check engine coolant temperature sensor.
RCPH10TLB087AAM 3
(1) Coolant Temperature Sensor connected to the Instrument Cluster

(2) Coolant Temperature Sensor connected to the ECU
RCPH10TLB046FAM 4
Schematic legend
(1) Coolant Temperature Sensor (3) Chassis Ground, (sensor is internally
grounded to chassis ground)
(1) Disconnect the terminal from the coolant temperature sender.
(2) Measure the resistance of the temperature sender to chassis ground.
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Temperature Open circuit resistance in ohms

110 °C (230.0 °F) 130 Ω
100 °C (212.0 °F) 175 Ω
92 °C (197.6 °F) 223 Ω
85 °C (185.0 °F) 280 Ω
78 °C (172.4 °F) 358 Ω
68 °C (154.4 °F) 511 Ω
A. OK – The resistance measurement was within the values stated in the table above. Go to Step 4.
B. NOT OK – Resistance reading is not acceptable. Replace the transmission temperature sender. Return
to Step 1 to confirm elimination of fault.
4. Check wiring to Instrument Cluster
BD08E042-01 5

(1) Disconnect Instrument Cluster connector X 29.
(2) Measure the resistance from Coolant Temperature sender connector pin 1 to chassis ground. The resis-
tance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
A. NOT OK – Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
B. OK – Go to Step 5.
5. Replace the instrument cluster.
(1) Remove and replace the instrument cluster.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance
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1003-Air conditioning pressure too high

Context:
The Instrument Cluster measures 12 volts on connector X-28 pin 10. The Instrument Cluster will illuminate the Air
Conditioning Icon while the fault is active and will sound the alarm for one second on the next system power up
following the event.
Cause:
The Instrument Cluster has detected the air conditioning pressure to be greater than 27.6 bar (400 psi).
1. Air conditioning pressure greater than 27.6 bar (400 psi).

2. Faulty reading from pressure switch.
3. Wiring or circuit shorted to positive battery.
4. Connectors not mated fully, pins not seated properly in connector, bent pin or broken wires at rear of connector.
5. Faulty A/C Relay (K-008).
Solution:
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(2) To check for fault code: Start the engine. Turn the A/C (air conditioner) temperature switch to the cold
position and the blower switch to the high position.
A. OK – Fault 1003 is not recorded again. OK to return the machine to service.
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2. Verify the harness is not damaged.
(1) Inspect the Instrument Cluster and A/C High Pressure switch and the A/C Relay (K-008) connections. All
connections should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the A/C High Pressure switch and the A/C Relay (K-008).
Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment.
RCPH10TLB055FAM 3
Schematic legend
(1) Signal from Blower Motor (Routed from (5) A/C Compressor
F-023 10A Fuse)
(2) A/C Relay Coil Ground (GND004 Cab (6) A/C Relay
Ground Side Console on Loader Control)
(3) A/C Fault Signal to Cluster (X-028 pin 10) (7) A/C Low Pressure Switch (Switch is closed
in a fault position)
(4) A/C High Pressure Switch (Switch is
closed in a fault position)
A. OK - The wiring is free of corrosion, damage, abrasion and incorrect attachment. Go to Step 3.
B. NOT OK - The wiring is not free of corrosion, damage, abrasion and incorrect attachment. Repair or
replace the harness as required. Go to Step 1 to confirm elimination of the fault.
3. Check air conditioning system pressure.
(1) Install a gauge capable of measuring a minimum of 27.6 bar (400 psi) on the A/C High Side test port.
(2) Turn the key switch ON. Turn the A/C (air conditioner) temperature switch to the cold position and the blower
switch to the high position.
(3) Measure the pressure at the high side test port. The pressure should be less than 27.6 bar (400 psi).
BD08F240-01 4
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(1) Connector A/C High Pressure Switch

(Connector is located behind grill on front of machine)
(2) Cooling pack
(3) A/C Highside Test Port
A. OK – The pressure is below 27.6 bar (400 psi) Go to Step .4.
B. NOT OK – The pressure is above 27.6 bar (400 psi). Repair or replace air conditioning system. Return
4. (1) Start the engine. Turn the A/C (air conditioner) temperature switch to the cold position and the blower switch
to the high position.
(2) Disconnect the high pressure switch (S-027). The fault code should no longer be active.
A. OK - The fault code in not active when the pressure switch is disconnected and the fault code is active
when the switch is reconnected. Replace the switch. Go to Step 1 to confirm elimination of the fault.
B. NOT OK - The fault code is active while the switch is disconnected. Go to Step 5.
5. Check Instrument Cluster signal pin.
(1) Disconnect the A/C High Pressure Switch input pin to the Instrument Cluster. Remove pin 10 (60A5 BN A/C
Fault Signal) on connector X-28.
(2) Turn the ignition switch to the ON position, turn the A/C (air conditioner) temperature switch to the cold
position and the blower switch to the high position.
A. OK – The fault code 1003 is not active when the pin is removed and the key switch is ON. Reinstall wire
60A5 BN A/C Fault Signal into instrument cluster connector X-28, pin 10. Go to Step 6.
B. NOT OK – Fault code 1003 is still active. Temporarily replace the instrument cluster and retest. Return to
6. Check the A/C Relay
(1) Turn ignition switch to the OFF position.
(2) Remove the A/C Relay K-008. Inspect the pins and wiring to the relay.
RCPH10TLB302AAF 5
(1) Fuse block

(2) Diagnostic port
(3) Turn the key switch ON. Turn the A/C (air conditioner) temperature switch to the cold position and the blower
switch to the high position. Fault code 1003 should not be active.
A. OK – The fault code is not active when relay K-008 removed. Replace the relay. Go to Step 1 to confirm
elimination of the fault code.
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B. NOT OK – The fault code 1103 is active with relay K-008 removed. There is a short circuit to positive
battery in the wiring harness. Repair or replace the harness as needed. Go to Step 1 to confirm elimination
of the fault code. .
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1004-Hydraulic filter blocked

Context:
The Instrument Cluster measures 0 volts on connector X-28 pin 17. The Instrument Cluster will illuminate the Hy-
draulic Filter Restriction Icon while the fault is active and will sound the alarm for one second on the next system
power up following the event.
Cause:
The Instrument Cluster measures 0 volts on connector X-28 pin 17.
1. Clogged hydraulic filter

2. Faulty reading from switch
3. Signal wire short to ground
Solution:
Prior to clearing fault codes, write down all fault codes, number of occurrences and engine hours at last occur-
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2

2. Inspect Hydraulic Filter.
(1) Inspect the hydraulic filter. Replace the filter if needed.
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RCPH10TLB045AAF 3
A. OK – The filter is OK and does not need to be replaced. Go to 3.
B. NOT OK – The filter is in poor condition or is clogged. Replace the filter. Go to Step 3 to confirm elimination
of the fault.
3. Verify the harness and connectors are not damaged.
(1) Inspect the Instrument Cluster and Hydraulic Filter Restriction Switch connections. All connections should
be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Hydraulic Filter Restriction Switch. Verify that the
harness is free of damage, corrosion, abrasion or incorrect attachment.
RCPH10TLB047FAM 4
Schematic legend
(1) Hydraulic Filter Restriction Switch (3) Chassis Ground
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RCPH10TLB016GAM 5
(1) Hydraulic oil filter restriction switch

(2) Filter head
A. OK - The wiring is free of corrosion, damage, abrasion and incorrect attachment. Go to Step 3.
B. Not OK - The wiring is not free of corrosion, damage, abrasion and incorrect attachment. Repair or replace
the harness as required. Go to Step 1 to confirm elimination of the fault.
4. Measure the resistance of the Filter Restriction Switch.
(1) Measure the resistance between the filter bypass switch housing and filter head. The resistance should be
greater than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. Go to Step 5.
B. NOT OK – The resistance is less than 20,000 ohms. Replace hydraulic filter bypass switch and retest.
Return to Step 1 to confirm elimination of fault.
5. Check hydraulic filter bypass switch.
(1) Disconnect connector 223-1 (circuit 36H3) from filter bypass switch.
(2) Measure the resistance from the Filter Bypass Switch terminal 1 to chassis ground. Wiggle the harness
during measurement to reveal an intermittent condition. The resistance should be greater than 20,000 ohms.
B. NOT OK – The resistance is less than 20,000 ohms. Replace hydraulic filter bypass switch and retest.
6. Check circuit 36H for short to chassis ground.
BD08E042-01 6

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(1) Disconnect Instrument Cluster Connector X 28. Measure the resistance between pin 17 and chassis ground.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent short condition.
(2) Measure the resistance from 36H3 to ground. The resistance should be greater than 20,000 ohms. Wiggle
the harness during measurement to reveal an intermittent short circuit condition.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the Instrument Cluster and retest.
Go to Step 6 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground. Repair or
replace the signal wire as required. Return to Step 1 to confirm elimination of fault.
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1009-Transmission oil temperature too high

Context:
The Instrument Cluster monitored a Transmission Oil Temperature greater than 115 °C (239 °F) for a period greater
than 5 seconds.
Cause:
The Transmission Oil Temperature is above 115 °C (239 °F) for a period greater than 5 seconds.
1. Low transmission oil level

2. Faulty fan operation
3. Clogged cooling core
4. Faulty reading from sensor
5. Faulty instrument cluster
Solution:
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
A. OK – Fault is not recorded again. OK for return to service.

2. Verify transmission oil level.
(1) Check transmission oil level, add oil as required. Refer to Operator's Manual for more details.
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A. OK – The oil level is correct and the fault is not recorded again. OK for return to service.
B. NOT OK – The oil level is correct but the fault is recorded again, go to Step 3
3. Stop machine operations.
A. OK – The cooling system is operating properly. Go to Step 4.
B. NOT OK – The cooling system is not operating properly or the cooling core is clogged. Repair fan or clear
clogs from cooling core. Repair as required. Return to Step 1 to confirm elimination of fault.
4. Check temperature sender.
BD00M233-01 3
NOTE: Standard transmission. Top view of transmission looking down through the floor plate.
(1) Shift lever

(2) Transmission temperature sender
BD08E063-01 4
NOTE: Power shift transmission. Bottom view of sensor look up.
(1) Transmission temperature sender

(2) Trax controller temperature sender
(1) Disconnect terminal connector from the transmission temperature sender.
(2) Measure the resistance from the Transmission Temperature sender ground connection to chassis ground.
The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
(3) Measure the resistance across the temperature sender.
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Temperature Open circuit resistance in ohms

110 °C (230.0 °F) 130 Ω
100 °C (212.0 °F) 175 Ω
92 °C (197.6 °F) 223 Ω
85 °C (185.0 °F) 280 Ω
78 °C (172.4 °F) 358 Ω
68 °C (154.4 °F) 511 Ω
A. OK – The resistance measurements were within range, go to Step 5.
B. NOT OK – Resistance reading is not acceptable for a room temperature sender. Replace the transmission
temperature sender. Return to Step 1 to confirm elimination of fault.
5. Check wiring to Instrument Cluster
BD08E042-01 5

(1) Disconnect Instrument Cluster connector X 29.
(2) Measure the resistance from Transmission Temperature sender connector (X 29) pin 1 (signal wire) to chas-
sis ground. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to
reveal an intermittent condition.
A. OK – The resistance measurement is greater than 20,000 ohms. Temporarily replace the Instrument Clus-
ter and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the wire.
Repair or replace the wire as required. Return to Step 1 to confirm elimination of fault.
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1010-Foot throttle signal out of range, IVS not changing state in

300 ms
Context:
The IVS (idle validation signal) did not change from a high state (+12 volts) to a low state (0 volts) when the throttle
moved off of low idle. The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one
second, on the next system power up following the event.
Cause:
The IVS did not change state in 0.3 sec after the throttle was moved off of low idle.
1. Faulty wiring or connections.

2. Faulty reading from foot throttle sensor.
3. Faulty Instrument Cluster
Solution:
Prior to clearing fault codes, write down all fault codes, the number of occurrences and engine hours of last
occurrence.
(2) To check for fault code: Start the engine and actuate the throttle.
A. OK – Fault is not recorded again. OK for return the machine to service.

2. Measure the voltage at throttle sensor.
BD08E027-01 1
(1) Throttle position sensor connector

(2) Foot throttle assembly
(3) Throttle position sensor
(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins and wiring for damage,
corrosion, abrasion or incorrect attachment.
(2) Turn the ignition switch to the ON position.
(3) Measure the voltage from pin B to pin C. The voltage should be between 4.8 volts and 5.2 volts. Wiggle the
harness during measurement to reveal an intermittent condition.
A. OK — The voltage is correct. Go to Step 3.
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B. NOT OK — The voltage is greater than 5.2 volts go to procedure 1023-Foot throttle supply voltage
too high, over 5.2 volts for 5 seconds (B.20.A) OR the voltage is less than 4.8 volts, go to procedure
1024-Foot throttle supply voltage too low, under 4.8 volts for 5 seconds (B.20.A).
3. Check idle validation circuit
RCPH10TLB018GAM 2
Throttle Signal Legend

(1) Idle Validation Signal (3) Throttle movement in degrees of travel. 0
degrees equals low idle. 20 degrees equals
WOT (Wide Open Throttle).
(2) Throttle Signal Voltage
This step is used to monitor the throttle validation signal. The sensor must be connected and active in order to
continue. The dealer must provide a breakout Tee or connector back probes in order to complete this procedure.
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RCPH10TLB048FAM 3
Schematic legend
(1) Foot Throttle (3) Dealer supplied breakout T
(1) Turn the key switch ON, engine OFF. Measure the voltage from pin E to pin B. The voltage should be ap-
proximately 12 volts.
(2) Move the throttle approximately 3 degrees. The idle validation signal should change from 12 volts to 0 volts.
A. OK — The signal changed from 12 volts to 0 volts. Go to Step 4.
B. NOT OK — The voltage was not correct or the voltage did not change from 12 volts to 0 volts as the throttle
moved off of low idle. Replace the sensor and retest. Return to step 1 to confirm elimination of fault.
4. Check the wire harness from the sensor to the Instrument Cluster.
(1) Turn the key switch OFF.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(3) Remove pin 20 from connector X-28.
(4) Turn the key switch ON, engine OFF.
(5) Measure the voltage from the removed wire, pin 20 to X-29 pin 20 (Ground). Move the throttle approximately
3 degrees. The idle validation signal should change from 12 volts to 0 volts. The signal should stay at 0 volts
as the throttle is moved to WOT (wide open throttle).
A. OK — The voltage changed from 12 volts to 0 volts when the throttle was moved. Temporarily replace the
Instrument Cluster and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK — The voltage was not correct or voltage did not change from 12 volts to 0 volts as the throttle
moved off of low idle. There is a problem with the idle validation signal wire from the sensor to the Instru-
ment Cluster. Replace the wire. Return to step 1 to confirm elimination of fault.
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1011-Foot throttle signal out of range, throttle above 95% of input

for 5 seconds
Context:
The Instrument Cluster measured a foot throttle signal greater than 4.75 Volts. The Instrument Cluster will illuminate
the Warning Lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The Instrument Cluster monitored a throttle signal greater than 4.75 volts (95%) for a period greater than 5 seconds.

Solution:
occurrence.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.

2. Check voltage at throttle sensor.
BD08E027-01 1

(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins.
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3. Check the throttle signal from the sensor.
RCPH10TLB017GAM 2

(1) Idle Validation Signal
(3) Throttle movement in degrees of travel. 0 degrees equals low idle. 20 de-
grees equals WOT (Wide Open Throttle).
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RCPH10TLB048FAM 3
Schematic legend
(1) Foot Throttle (3) Breakout Tee
(1) Connect the break out Tee and measure the voltage from pin A to pin B (or slide Back Probes into pin A and
B).
(3) Measure the voltage from pin A to pin B. Move the throttle from low idle to WOT (wide open throttle). The
voltage should change from approximately 0.55 volts at low idle to 4.2 volts at WOT.
A. OK — The voltage measurement is correct. Go to Step 4.
B. NOT OK — The voltage did not change from 0.55 volts to 4.2 volts as the throttle moved from low idle to
WOT or the voltage was greater than 4.75 volts at WOT. Replace the sensor. Return to step 1 to confirm
elimination of fault.
4. Measure the throttle signal from the sensor to the Instrument Cluster.
(4) Turn the key switch ON, engine OFF. Measure the voltage from removed wire, pin 16 to X-29 pin 20 (Ground).
Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approximately 0.55
volts at low idle to 4.2 volts at WOT.
A. OK — The voltage changed from approximately 0.5 volts to 4.2 volts. Temporarily replace the Instrument
Cluster and retest. Go to Step 1 to confirm elimination of the fault.
WOT or the voltage was greater than 4.75 volts at WOT. There is a problem in the throttle signal wire from
the sensor to the Instrument Cluster. Replace the wire. Return to step 1 to confirm elimination of fault.
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1012-Foot throttle signal out of range, throttle below 5% of input

for 5 seconds
Context:
The Instrument Cluster measures a foot throttle signal less than 0.5 Volts. The Instrument Cluster will illuminate the
Warning Lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The Instrument Cluster monitored a throttle signal less than 0.5 volts (5%) for a period greater than 5 seconds.
1. Faulty wiring or connections shorted to ground.

Solution:
occurrence.

BD08E027-01 1

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RCPH10TLB017GAM 2

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RCPH10TLB048FAM 3
Schematic legend
B).
WOT or the voltage was less than 0.5 volts at low idle. Replace the sensor and retest. Return to step 1 to
confirm elimination of fault.
WOT or the voltage was less than 0.5 volts at low idle. There is a problem in the throttle signal wire from
the sensor to the Instrument Cluster. Repair or replace the wire as required. Return to step 1 to confirm
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1013-Foot throttle signal out of range, signal unusable

Context:
The Instrument Cluster measures a foot throttle signal that is unstable. The Instrument Cluster will illuminate the
Warning Lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The Instrument Cluster monitors a fluctuation in the throttle signal that is not possible.

Solution:
occurrence.

BD08E027-01 1

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3. Measure the throttle signal from the sensor.
RCPH10TLB017GAM 2
Idle Validation, Throttle Signal Legend

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RCPH10TLB048FAM 3
Schematic legend
(1) Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pin A and
B).
voltage should change from approximately 0.55 volts at low idle to 4.2 volts at WOT. Wiggle the sensor harness
to reveal an intermittent condition.
WOT or there were voltage fluctuations or spikes as the throttle was moved. Replace the sensor. Return
to step 1 to confirm elimination of fault.
A. OK — The throttle signal voltage changed from 0.55 volts to 4.2 volts. Temporarily replace the Instrument
WOT or there were voltage fluctuations or spikes as the throttle was moved. There is a problem in the
throttle signal wire from the sensor to the Instrument Cluster. Replace the wire. Return to step 1 to confirm
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1014-Battery charge voltage too high

Context:
The Instrument Cluster measured an alternator voltage greater than 16 volts for a period greater than 5 seconds.
The Instrument Cluster will illuminate the battery warning symbol indicating that it has detected a problem in the
battery charging system.
Cause:
The alternator output is greater than 16 volts.
1. Faulty alternator, alternator output greater than 16 volts.

Solution:
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(2) To check for Active fault code: Start and operate machine.

2. Measure the alternator output.
(1) Start the engine. Set engine speed to low idle and measure the voltage at the Alternator. The voltage should
be approximately 14.2 volts.
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A. OK – The voltage is approximately 14.2 volts. Go to Step 3.
B. NOT OK – The voltage is greater than 14.6 volts. Replace the alternator. Go to test Step 1 to confirm
3. Measure the voltage at instrument cluster.
RCPH10TLB049FAM 3
Schematic Legend
(1) Alternator (5) ECU Key ON signal
(2) Instrument Cluster connection, X-29 pin (6) Battery connection to Alternator
24
(3) Trax Controller connection, X-300 pin 53 (7) F-002, 5 Amp
(4) Key switch
Alternator Connections
ALT1 RD 4GA Battery Connection
1 3401 YE 20GA Alternator Charge Signal
2 1501 OG 20GA Key switch (Switched battery to alternator)
3 31S1 YE 20GA Alt Tach signal
(1) Disconnect the Instrument Cluster Connector 2 (X 29). Inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment. Measure the voltage on pin X-29 pin 24 to X-29 pin 26. The voltage
should be approximately 14.2 V. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage is approximately 14.2 volts. Temporarily replace the Instrument Cluster and retest. Go
to Step 1 to confirm elimination of the fault code.
B. NOT OK – The voltage is greater than 14.6 volts. Replace the alternator. Return to Step 1 to confirm
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1015-Battery charge voltage too low

NOTICE:
Context:
The Instrument Cluster measured an alternator voltage less than 11 volts for a period greater than 5 seconds. The
Instrument Cluster will illuminate the battery warning symbol indicating that it has detected a problem in the
battery charging system.
Cause:
The alternator output is less than 11 volts.
1. Instrument Cluster signal wire shorted to chassis ground.

2. Faulty alternator, alternator output less than 11 volts.
Solution:
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2

2. Measure the alternator output.
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(1) Start the engine. Set engine speed to low idle and measure the voltage at the Alternator. The voltage should
be approximately 14.2 volts.
A. OK – The voltage is approximately 14.2 volts. Go to Step 3.
B. NOT OK – The voltage is less than 11 volts. Replace the alternator.1 to confirm elimination of fault.
RCPH10TLB049FAM 3
Schematic legend
24
(4) Key switch
Alternator Connections
ALT1 RD 4GA Battery Connection
1 3401 YE 20GA Alternator Charge Signal
2 1501 OG 20GA Key switch (Switched battery to alternator)
3 31S1 YE 20GA Alt Tach signal
abrasion, corrosion or incorrect attachment. Measure the voltage on pin X-29 pin 24 to X-29 pin 26. The voltage
should be approximately 14.2 V. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage measurement is correct. Temporarily replace the Instrument Cluster and retest. Go to
Step 1 to confirm elimination of the fault code.
B. NOT OK – The voltage is less than 11 volts. Replace the alternator and retest. Return to Step 1 to confirm
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1018-Boost air temperature too high

NOTE: See engine repair manual for electrical schematic information.
Cause:
The engine inlet air temperature is greater than 95 °C (203 °F) for a period greater than 5 seconds. The Instrument
Cluster will illuminate the amber warning light while the fault is active.
Solution:
1. Fault Code 1018 is a CAN Data Link message from the ECU to the Instrument Cluster. This fault code is dis-
played on the Instrument Cluster to warn the operator of a high boost temperature warning. Refer to the engine
troubleshooting guide for more information.
RCPH10TLB138AAF 1
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1019-Engine coolant temperature too high

Cause:
The coolant temperature is greater than 107 °C (224 °F) for a period greater than 5 seconds. The Instrument Cluster
will illuminate the amber warning light while the fault is active.
Solution:
1. This is an information fault code only. The fault code is logged and indicates that the coolant temperature is
approaching the fault code trigger point.
2. Verify proper coolant level.
played on the Instrument Cluster to warn the operator of a high coolant temperature warning. Refer to the engine
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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1020-Transmission oil temperature above normal

Cause:
The transmission oil temperature is greater than 105 °C (221 °F) for a period greater than 5 seconds. The Instrument
Cluster will illuminate the amber warning light while the fault is active.
Solution:
1. This is an information fault code only. The fault code is logged and indicates that the transmission oil temperature
is approaching the fault code trigger point.
2. Verify proper transmission oil level.
played on the Instrument Cluster to warn the operator of a high transmission oil temperature warning. Refer to
the engine troubleshooting guide for more information.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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1021-Fuel temperature above normal

Context:
Fuel temperature is greater than 82 °C (180 °F) for a period greater than 5 seconds. The Instrument Cluster will
illuminate the amber warning light while the is active fault.
Cause:
Fuel temperature is greater than 82 °C (180 °F) for a period greater than 5 seconds.
Solution:
played on the Instrument Cluster to warn the operator of a high fuel temperature warning. Refer to the engine
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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1022-Water in fuel
Context:
The Instrument Cluster has detected excess water in the fuel system. The Instrument Cluster will illuminate the amber
warning light while the is active fault.
Cause:
Fault Code 1022 is a CAN Data Link message from the ECU to the Instrument Cluster. This fault code is displayed
on the Instrument Cluster to warn the operator that the ECU has detected excess water in the fuel system. Refer to
the engine troubleshooting guide for more information.
Solution:
1. Drain the fuel filter of excess water.
RCPH10TLB278AAF 1
RCPH10TLB027AAF 2
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1023-Foot throttle supply voltage too high, over 5.2 volts for 5
seconds
Context:
The Instrument Cluster detects a voltage greater than 5.2 volts on the throttle 5 volt supply line (connector X-29, pin
18).The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the next
system power up following the event.
Cause:
The Instrument Cluster detects a voltage greater than 5.2 volts on the throttle 5 volt supply line (connector X-29, pin
18).
1. Throttle supply wire shorted to battery.

2. Wiring open circuit.
3. Failed Instrument Cluster.
Solution:
1. Verify that the fault code is still active. Cycle the key switch power. Refer to 0000 - Retrieving fault codes,
Backhoes.
A. OK – Fault code 1023 is not recorded again. OK to return the machine to service.
B. NOT OK – Fault is recorded again. Go to 2.

2. Check wiring to sensor
RCPH10TLB048FAM 1
Schematic legend
(1) Inspect the wiring from the Instrument Cluster to the foot throttle. The wires should be free of damage,
abrasion, corrosion and incorrect attachment.
A. OK — The wiring is free of damage, abrasion, corrosion and incorrect attachment. Go to Step 3.
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B. NOT OK — The wiring is damaged or corroded. Repair as required. Go to Step 3 to confirm elimination
of fault code.
3. Measure the voltage at the foot throttle connector.
BD08E027-01 2
(1) Foot Throttle connector

(2) Foot Throttle sensor
(1) Disconnect the foot throttle sensor. Turn the key switch "On". Measure the voltage from pin C to pin B. The
voltage should be approximately 5 volts.
A. OK — The voltage is between 4.8 and 5.2 volts. There is an intermittent condition in the wiring to the
Instrument Cluster. Inspect the wiring and connectors for damage. Repair as required. Go to 1 to confirm
B. NOT OK — The voltage is greater than 5.2 volts. Go to 4.

4. Measure the voltage at the instrument cluster.
BD08E042-01 3

(1) Turn the key switch "Off." Remove wire 18 from connector X-29. Insert a test wire into pin 18.
(2) Turn the key switch "On" and measure the voltage at pin 18. The voltage should be approximately 5 volts.
A. OK — The voltage is 5 volts. There is a problem in the wiring harness from the Instrument Cluster to the
foot throttle. Repair or replace the harness as required. Go to 1 to confirm elimination of fault.
B. NOT OK — The voltage is greater than 5.2 volts. There is a problem in the Instrument Cluster. Temporarily
replace the Instrument Cluster and retest. Go to 1 to confirm elimination of fault.
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1024-Foot throttle supply voltage too low, under 4.8 volts for 5
seconds
Context:
The Instrument Cluster detects a voltage less than 4.8 volts on the throttle 5 volt supply line (connector X-29, pin 18).
The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the next
Cause:
The Instrument Cluster detects a voltage less than 4.8 volts on the throttle 5 volt supply line (connector X-29, pin 18).
1. Throttle supply wire shorted to minus battery or chassis ground.

2. Failed Throttle Sensor
3. Failed Instrument Cluster
Solution:
Backhoes.
A. OK – Fault code 1024 is not recorded again. OK to return the machine to service.
B. NOT OK – Fault is recorded again. Go to Step 2.

2. Inspect wiring to sensor
RCPH10TLB048FAM 1
Schematic legend
(1) Inspect the wiring from the Instrument Cluster to the foot throttle. The wires should be free of damage,
abrasion, corrosion and incorrect attachment.
A. OK — The wiring is free of damage, abrasion, corrosion and incorrect attachment. Go to Step 3.
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B. NOT OK — The wiring is damaged or corroded. Repair as required. If the fault code is active after the
repair, go to Step 3.
3. Measure the voltage at the foot throttle connector.
BD08E027-01 2
(1) Foot Throttle connector

(2) Foot Throttle sensor
(1) Disconnect the foot throttle sensor. Turn the key switch "On". Measure the voltage from pin C to pin B. The
A. OK — The voltage is between 4.8 and 5.2 volts. There is an intermittent condition in the wiring to the
Instrument Cluster. Inspect the wiring and connectors for damage. Repair as required. Go to 1 to confirm
B. NOT OK — The voltage is less than 4.8 volts. Go to Step 4.

BD08E042-01 3

(1) Turn the key switch "Off." Remove wire 18 from connector X-29. Insert a test wire into pin 18.
(2) Turn the key switch "On" and measure the voltage from pin 18 to X-29 pin 26 (Ground or chassis ground).
The voltage should be approximately 5 volts.
A. OK — The voltage is 5 volts. There is a problem in the wiring harness from the Instrument Cluster to the
foot throttle. Replace or repair the harness. Go to 1 to confirm elimination of fault.
B. NOT OK — The voltage is less than 4.8 volts. There is a problem in the Instrument Cluster. Replace the
Instrument Cluster. Go to 1 to confirm elimination of fault.
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1025-Foot throttle sensor voltage over 5.3 volts for 5 seconds

Context:
The Instrument Cluster measures a foot throttle signal greater than 5.3 volts for a period greater than 5 seconds. The
Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the next system
power up following the event.
Cause:
The Instrument Cluster measures a foot throttle signal greater than 5.3 volts for a period greater than 5 seconds.
1. Faulty wiring harness. Wiring or circuits shorted to positive battery.

2. Faulty reading from sensor.
Solution:
occurrence.

BD08E027-01 1

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too high, over 5.2 volts for 5 seconds (B.20.A). OR the voltage is less than 4.8 volts, go to procedure
RCPH10TLB017GAM 2

This step is used to monitor the foot throttle signal. The sensor must be connected and active in order to con-
tinue. The dealer must build a breakout harness as shown below.
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RCPH10TLB048FAM 3
Schematic legend
B).
A. OK — The voltage changed from approximately 0.5 volts to 4.2 volts. Go to Step 4.
B. NOT OK — The voltage did not change from 0.55 volts to 4.2 volts as the throttle moved from low idle
to WOT or the voltage was greater than 4.75 volts at WOT. Temporarily replace the sensor and retest.
Return to step 1 to confirm elimination of fault.
WOT or the voltage was greater than 4.75 volts at WOT. There is a problem in the throttle signal wire from
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1026-Foot throttle sensor voltage under 200 mV for 5 seconds

Context:
The Instrument Cluster measures a foot throttle signal less than 200mV (0.2 volts). The Instrument Cluster will illu-
minate the Warning Lamp and will sound the alarm for one second on the next system power up following the
event.
Cause:
The Instrument Cluster measures a foot throttle signal less than 200mV (0.2 volts).
1. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.
Connector pins corroded or dirty.
2. Faulty wiring harness. Wiring or circuits shorted to negative battery
Solution:
occurrence.

BD08E027-01 1

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too high, over 5.2 volts for 5 seconds (B.20.A). OR the voltage is less than 4.8 volts, go to procedure
RCPH10TLB017GAM 2

This step is used to monitor the foot throttle signal. The sensor must be connected and active in order to con-
tinue. The dealer must build a breakout harness as shown below.
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RCPH10TLB048FAM 3
Schematic legend
(1) Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pin A and
B).
WOT or the voltage was less than 0.5 volts at low idle. Temporarily replace the sensor and retest. Return
the sensor to the Instrument Cluster. Repair or replace the wire as required. Return to step 1 to confirm
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1032-Hand throttle supply voltage too low, under 4.8 volts for 5
seconds
Context:
The Instrument Cluster detects a voltage less than 4.8 volts on the hand throttle 5 volt supply line (connector X-29,
pin 19). The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the
next system power up following the event.
Cause:
The Instrument Cluster detects a voltage less than 4.8 volts on the hand throttle 5 volt supply line (connector X-29,
pin 19).
1. Throttle supply wire shorted to minus battery or chassis ground.

2. Failed Throttle sensor.
Solution:
Backhoes.

BD08E041-01 1
(1) Location of hand throttle

(2) Hand throttle connector
(1) Inspect the Instrument Cluster and the Hand Throttle connections. All connections should be secure and
tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Hand Throttle. Verify that the harness is free of
damage, corrosion, abrasion and incorrect attachment.
3. Measure the voltage at the hand throttle connector.
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RCPH10TLB050FAM 2
Instrument Cluster Description Wire ID

X-029 connector
17 Throttle Signal 2171 YE 20GA
19 +5V Supply to throttle 2191 PK 20GA
21 Sensor Ground 2211 GN 20GA
Schematic legend
(1) Hand Throttle (3) Dealer supplied breakout T
(1) Disconnect the hand throttle sensor.
(2) Turn the key switch ON.
(3) Measure the voltage from pin A to pin C. The voltage should be approximately 5 volts.
A. OK — The voltage is between 4.8 and 5.2 volts. Replace the hand throttle and retest. Go to Step 1 to
B. NOT OK — The voltage is less than 4.8 volts. Go to Step 4.

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BD08E042-01 3

(1) Turn the key switch OFF. Remove wire 19 from connector X-29. Insert a test wire into pin 19.
RCPH10TLB036GAM 4
Schematic legend
(1) Hand Throttle (5) Remove existing wire from the Instrument
Cluster connector.
(2) Instrument Cluster (6) Insert a jumper wire.
(3) Breakout Harness (7) Existing Wire Harness
(4) Digital Voltmeter
(3) Measure the voltage from X-29 pin 19 to X-29 pin 21 (Ground or chassis ground). The voltage should be
approximately 5 volts.
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A. OK — The voltage is between 4.8 and 5.2 volts. There is a problem in the wiring harness from the Instru-
ment Cluster to the foot throttle. Replace or repair the harness as required. Go to 1 to confirm elimination
of fault.
B. NOT OK — The voltage is less than 4.8 volts. There is a problem in the Instrument Cluster. Temporarily
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1033-Hand throttle sensor voltage over 5.3 volts for 5 seconds

Context:
The Instrument Cluster detects a voltage greater than 5.3 volts on the hand throttle 5 volt supply line (connector X-29,
pin 19).The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the
Cause:
The Instrument Cluster detects a voltage greater than 5.3 volts on the hand throttle 5 volt supply line (connector X-29,
pin 19).
1. Throttle supply wire has an open circuit or is shorted to battery supply or another voltage source.
Solution:
Backhoes.

BD08E041-01 1

(1) Inspect the Instrument Cluster and the Hand Throttle connections. All connections should be secure and
damage, corrosion, abrasion or incorrect attachment.
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RCPH10TLB050FAM 2

X-029 connector
Schematic legend
A. OK — The voltage is between 4.8 and 5.2 volts. Temporarily replace the hand throttle and retest. Go to
B. NOT OK — The voltage is greater than 5.2 volts. Go to Step 4.

4. Measure the voltage from X-29
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BD08E042-01 3

(1) Turn the key switch OFF. Remove wire 19 from connector X-29. Insert a test wire into pin 19.
RCPH10TLB036GAM 4
Schematic legend
(1) Hand Throttle (5) Remove existing wire from the Instrument
Cluster connector.
(2) Instrument Cluster (6) Insert a jumper wire.
(3) Dealer Supplied Breakout Harness (7) Existing Wire Harness
(4) Digital Voltmeter
(3) Measure the voltage from X-29 pin 19 to X-29 pin 21 (Ground or chassis ground). The voltage should be
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A. OK — The voltage is between 4.8 and 5.2 volts. There is a problem in the wiring harness from the Instru-
ment Cluster to the foot throttle. Replace or repair the harness as required. Go to 1 to confirm elimination
of fault.
B. NOT OK — The voltage is less than 4.8 volts. There is a problem in the Instrument Cluster. Temporarily
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1034-Hand throttle sensor voltage under 200 mV for 5 seconds

Context:
The Instrument Cluster detects a throttle signal less than 0.2 volts on the hand throttle signal line (connector X-29,
Cause:
pin 17).
1. Hand throttle signal wire is shorted to chassis ground.

Solution:
Backhoes.

BD08E041-01 1

(1) Inspect the Instrument Cluster and the Hand Throttle connections. All connections should be secure, tight,
free of corrosion, abrasion and damage.
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RCPH10TLB050FAM 2

X-029 connector
Schematic legend
(2) Disconnect the throttle sensor from the harness. Disconnect connector X-029 from the Instrument Cluster.
(4) Measure the resistance from X-029 pin 17 to pin B of the throttle connector. The resistance should be less
than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance measurement from step 3 is greater than 20,000 ohms and the resistance measure-
ment from step 4 is less than 10 ohms. Go to Step 3.
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B. NOT OK — The resistance measurement from step (3) is less than 20,000 ohms. There is a short circuit
to chassis ground. Repair or replace the harness as required. Go to Step 3 to confirm elimination of the
fault.
C. NOT OK — The resistance measurement from step (4) is greater than 10 ohms. There is an open circuit
in the throttle signal wire. Repair or replace the harness as required. Go to Step 3 to confirm elimination
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
(1) Hand Throttle (3) Breakout Tee
(1) Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pins A and
B).
A. OK — The voltage changed from 0.5 volts to 4.2 volts. Go to Step 4.
WOT or the voltage was less than 0.5 volts at low idle. Replace the sensor. Return to step 1 to confirm
A. OK — The voltage changed from 0.5 volts to 4.2 volts. Temporarily replace the Instrument Cluster. Go to
Step 1 to confirm elimination of the fault.
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1035-Hand throttle sensor signal above 95% of input for 5 seconds

Context:
The Instrument Cluster detects a throttle signal greater than 4.75 volts on the hand throttle signal line (connector X-29,
Cause:
The Instrument Cluster detects a throttle signal greater than 4.75 volts on the hand throttle signal line (connector X-29,
pin 17).
1. Hand throttle signal wire is shorted to another voltage source or there is an open circuit in the wire or connec-
tions.
Solution:
Backhoes.

BD08E041-01 1

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RCPH10TLB050FAM 2

X-029 connector
Schematic legend
(3) Measure the resistance from X-029 pin 17 to battery supply. The resistance should be greater than 20,000
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to battery supply. Repair or replace the harness as required. Go to Step 3 to confirm elimination of the
fault.
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
(1) Connect the break out Tee and measure the voltage from pin A to pin B (or slide Back Probes into pins A
and B).
WOT or the voltage was less than 0.5 volts at low idle. Temporarily replace the sensor and retest. Return
(4) Turn the key switch ON, engine OFF. Measure the voltage from the removed wire, pin 17 to X-29 pin 21
(Ground). Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approx-
imately 0.55 volts at low idle to 4.2 volts at WOT.
A. OK — The voltage changed from 0.5 volts to 4.2 volts. Temporarily replace the Instrument Cluster and
retest. Go to Step 1 to confirm elimination of the fault.
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1036-Hand throttle sensor signal below 5% of input for 5 seconds

Context:
pin 17).The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the
Cause:
pin 17).

Solution:
Backhoes.

BD08E041-01 1

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RCPH10TLB050FAM 2

X-029 connector
Schematic legend
(1) Hand Throttle (3) Breakout T
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fault.
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
B).
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1037-Hand throttle sensor out of range

Context:
Cause:
pin 17).

2. Hand throttle signal wire is shorted to battery supply or another voltage source.
3. Open circuit in the Hand throttle signal wire.
Solution:
Backhoes.

BD08E041-01 1

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RCPH10TLB050FAM 2

X-029 connector
Schematic legend
(4) Measure the resistance from X-029 pin 17 to battery. The resistance should be greater than 20,000 ohms.
Wiggle the harness during measurement to reveal an intermittent condition.
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B. NOT OK — The resistance measurements from step (3) or (4) is less than 20,000 ohms. There is a short
circuit in the harness. Repair or replace the harness as required. Go to Step 3 to confirm elimination of
the fault.
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
(1) Connect the break out Tee and measure the voltage from pin A to pin B (or slide Back Probes into pins A
and B).
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1039-Hand throttle sensor voltage under 200 mV for 5 seconds

Context:
Cause:
pin 17).

Solution:
Backhoes.

BD08E041-01 1

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RCPH10TLB050FAM 2

X-029 connector
Schematic legend
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fault.
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
B).
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1040-Engine RPM over 2750 for 5 seconds

Cause:
The Instrument Cluster has detected an engine speed greater than 2750 RPM for a period greater than 5 seconds.
The Warning Lamp will illuminate Amber and the LCD backlight will change from the normal backlight to Amber.
The Instrument Cluster will sound the alarm for one second upon activation per key cycle.
Solution:
1. Fault Code 1040 is displayed on the Instrument Cluster to warn the operator that the engine speed has exceeded
2750 RPM.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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1041-Engine RPM over 3000 for 5 seconds

NOTICE: Always stop the machine and shut down the engine whenever the Danger lamp illuminates.
Cause:
The Instrument Cluster has detected an engine speed greater than 3000 RPM for a period greater than 5 seconds.
The Danger Lamp will illuminate Red and the LCD backlight will change from the normal backlight to Red. The
Instrument Cluster will sound the alarm continuously.
Solution:
1. Stop the engine.

2. Fault Code 1041 is displayed on the Instrument Cluster to warn the operator that the engine speed has exceeded
3000 RPM. Stop the engine.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low
WARNING
Fire hazard!
When handling diesel fuel, observe the following precautions:
1. Do not smoke.
2. Never fill the tank when the engine is running.
3. Wipe up spilled fuel immediately.
W0099A
Context:
The Instrument Cluster has detected the fuel sender resistance below 2 ohms for a period greater than 2 seconds.
The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the next
Cause:
The Instrument Cluster has detected the fuel sender resistance below 2 ohms for a period greater than 2 seconds.
1. Wiring or circuits shorted to minus battery or chassis ground.

2. Faulty fuel level sensor.
Solution:
rence.

RCPH10TLB081AAM 1
(1) Fuel level sensor

(2) Fuel level sensor connector - X-063
(3) Connector X-001/X-051
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(1) Inspect the Instrument Cluster and the Fuel Level Sender connections. All connections should be secure,
tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Fuel Level Sender. Verify that the harness is free of
3. Measure the resistance of the fuel level signal to chassis ground.
(1) Disconnect connector X-63.
RCPH10TLB051FAM 2
Schematic legend
(1) Hand Throttle (3) 22 ohm in-line resistor
(2) Instrument Cluster (4) GND005 Chassis Ground on upright
(2) Measure the resistance from X-63, pin A (Sensor side) to chassis ground. Refer to the fuel tank level. The
resistance reading should approximately equal the value from the table.
Level Length Resistance

1º Full 0.0 to 55.2 27.25 Ω ± 1.75 Ω
2º 55.2 to 141.0 47.5 Ω ± 2.0 Ω
3º 141.0 to 200.0 74.25 Ω ± 2.25 Ω
4º 200.0 to 228.0 84.5 Ω ± 2.5 Ω
5º 228.0 to 255.0 94.5 Ω ± 2.5 Ω
6º 255.0 to 282.0 104.5 Ω ± 2.5 Ω
7º 282.0 to 305.5 112.75 Ω ± 2.75 Ω
8º 1/2 tank 305.5 to 325.5 121.0 Ω ± 3.0 Ω
9º 325.5 to 346.0 129.25 Ω ± 2.75 Ω
10º 346.0 to 365.5 139.25 Ω ± 3.25 Ω
11º 365.5 to 385.0 149.25 Ω ± 3.25 Ω
12º 385.0 to 395.0 169.25 Ω ± 3.25 Ω
13º 395.0 to 405.0 189.25 Ω ± 3.75 Ω
14º 405.0 to 416.0 216.25 Ω ± 3.75 Ω
15º Empty 416.0 to 442.0 249.25 Ω ± 4.25 Ω
Resistance values are measured from the fuel level sensor connector X-063, pins A and B. If resistance mea-
surements are taken from connector X-051 and X-001 or from the Instrument Cluster, add 22 ohms to the
value.
A. OK - The resistance measurements were within tolerances. Go to Step 4.
B. NOT OK - The resistance values did not match the values from the table or the resistance was less than
25 ohms. Replace the sensor. Go to Step 1 to confirm elimination of the fault code.
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4. Measure the resistance at the fuel level sensor.
(1). Tilt the cab and remove the fuel level sender from the tank.
(2). Disconnect the harness from the sender.
(3). Move the fuel level float from the low to high position while measuring the resistance of the sender. The
resistance should change linearly from approximately 27 Ω at the full tank position to approximately 250 Ω at
the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower
resistance.
A. OK - The resistance measurements from the sensor are within specifications. Go to Step 5.
B. NOT OK - The resistance readings from the sensor are not steady or the values are not accurate. Tem-
porarily replace sensor and retest. Return to Step 1 to confirm elimination of fault.
5. Check fuel level wiring.
(1). Measure the resistance from G021-BK (X 63 pin B) to ground. The resistance should be less than 10 ohms.
(2). Measure the resistance from 36F1-YE (X-063 pin A) to Instrument Cluster connector X-29, pin 13. The
resistance should be approximately 22 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
A. OK - The resistance measurements from the sensor were within specifications. Temporarily replace the
B. NOT OK - The resistance readings were not with the limits defined in the step. Repair or replace the
harness as required. Return to Step 1 to confirm elimination of fault.
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1045-Fuel level sensor open circuit

WARNING
Fire hazard!
1. Do not smoke.
W0099A
Context:
The Instrument Cluster has detected an open circuit in the fuel sender signal. The Instrument Cluster will illuminate
the Warning Lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The Instrument Cluster has detected an open circuit in the fuel sender signal.
1. Open circuit in the fuel level sender signal wire.

2. Faulty fuel level sensor.
Solution:
rence.

RCPH10TLB081AAM 1
(1) Fuel level sensor

(2) Fuel level sensor connector - X-063
(3) Connector X-001/X-051
(1) Inspect the Instrument Cluster and the Fuel Level Sender connections. All connections should be secure,
tight, free of corrosion, abrasion and damage.
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(2) Inspect the harness from the Instrument Cluster to the Fuel Level Sender. Verify that the harness is free of
3. Measure the resistance of the fuel level signal wire to chassis ground.
(1) Disconnect connector X-63.
RCPH10TLB051FAM 2
Schematic legend
(1) Hand Throttle (3) 22 ohm inline resistor
(2) Instrument Cluster (4) GND005 Chassis Ground on upright
(2) Measure the resistance from X-63, pin A (Sensor side) to chassis ground. Refer to the fuel tank level. The
resistance reading should approximately equal the value from the table.
Level Length Resistance

1º Full 0.0 to 55.2 27.25 Ω ± 1.75 Ω
2º 55.2 to 141.0 47.5 Ω ± 2.0 Ω
3º 141.0 to 200.0 74.25 Ω ± 2.25 Ω
4º 200.0 to 228.0 84.5 Ω ± 2.5 Ω
5º 228.0 to 255.0 94.5 Ω ± 2.5 Ω
6º 255.0 to 282.0 104.5 Ω ± 2.5 Ω
7º 282.0 to 305.5 112.75 Ω ± 2.75 Ω
8º 1/2 tank 305.5 to 325.5 121.0 Ω ± 3.0 Ω
9º 325.5 to 346.0 129.25 Ω ± 2.75 Ω
10º 346.0 to 365.5 139.25 Ω ± 3.25 Ω
11º 365.5 to 385.0 149.25 Ω ± 3.25 Ω
12º 385.0 to 395.0 169.25 Ω ± 3.25 Ω
13º 395.0 to 405.0 189.25 Ω ± 3.75 Ω
14º 405.0 to 416.0 216.25 Ω ± 3.75 Ω
15º Empty 416.0 to 442.0 249.25 Ω ± 4.25 Ω
Resistance values are measured from the fuel level sensor connector X-063, pins A and B. If resistance mea-
surements are taken from connector X-051 and X-001 or from the Instrument Cluster, add 22 ohms to the
value.
A. OK - The resistance measurements were within tolerances. Go to Step 4.
B. NOT OK - The resistance values did not match the values from the table or the resistance was less than
25 ohms. Temporarily replace the sensor and retest. Go to Step 1 to confirm elimination of the fault code.
4. Measure the resistance at the fuel level sensor.
(1). Tilt the cab and remove the fuel level sender from the tank.
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(2). Disconnect the harness from the sender.
(3). Move the fuel level float from the low to high position while measuring the resistance across the sender.
The resistance should change linearly from approximately 27 Ω at the full tank position to approximately 250 Ω
at the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower
resistance.
A. OK - The resistance measurements from the sensor were within specifications. Go to Step 5.
B. NOT OK - The resistance readings from the sensor were not steady or the values were not accurate.
Temporarily replace sensor and retest. Return to Step 1 to confirm elimination of fault.
5. Check fuel level wiring.
(1). Measure the resistance from G021-BK (X 63 pin B) to ground. The resistance should be less than 10 ohms.
(2). Measure the resistance from 36F1-YE (X-063 pin A) to Instrument Cluster connector X-29, pin 13. The
resistance should be approximately 22 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
(3). Measure the resistance from 36F1-YE (X 63 pin A) to ground (engine block). The resistance should be
greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance measurements from the sensor were within specifications. Temporarily replace the
B. NOT OK - The resistance readings were not with the limits defined in the step. Repair or replace the
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1047-Transmission temperature sensor below 3.0 ohms for 5

seconds
Context:
The Instrument Cluster measures a resistance less than 3 ohms for a period greater than 5 seconds. The Instrument
Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the next system power up
following the event.
Cause:
The Instrument Cluster measures a resistance less than 3 ohms for a period greater than 5 seconds.
1. Wiring or circuits shorted to minus battery or chassis ground.

3. Faulty reading from Instrument Cluster.
Solution:
rence.

RCPH10TLB082AAM 1
(1) Transmission temperature sensor, connected to Instrument Cluster

(2) Transmission temperature sensor, connected to ECU
(1) Inspect the Instrument Cluster and the Transmission Temperature Sensor connections. All connections
should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Transmission Temperature Sensor. Verify that the
harness is free of damage, corrosion, abrasion or incorrect attachment.
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3. Measure the sensor open circuit resistance.
RCPH10TLB052FAM 2

X-029 connector
14 Transmission Temperature Signal 32T2 YE 20GA
Schematic legend
(1) Transmission Temperature Sensor (2) Instrument Cluster
(1) Disconnect the terminal connector from the transmission temperature sender.
(2) Measure the resistance from the Transmission Temp Sensor to chassis ground.
Temperature Resistance in ohms. Measured from the sensor connection to chassis

ground
110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
A. OK – The resistance measurements are within the specifications in the table. Go to Step 4.
B. NOT OK – The resistance measurements are not within range or the measurement is less than 3 ohms.
Replace transmission temperature sender. Return to Step 1 to confirm elimination of fault.
4. (1) Measure the resistance of the signal wire to chassis ground.
(2) Disconnect connector from transmission temperature sender.
(3) Disconnect the Instrument Cluster connector X-29.
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BD08E042-01 3

(4) Measure the resistance from X-29, pin 14 to X-29 pin 26. Wiggle the harness during measurement to reveal
an intermittent condition. The resistance should be greater than 20,000 ohms.
(5) Measure the resistance from X-29, pin 14 to chassis ground. Wiggle the harness during measurement to
reveal an intermittent condition. The resistance should be greater than 20,000 ohms.
A. OK – The resistance measurements are greater than 20,000 ohms. Temporarily replace the Instrument
Cluster and retest. Return to Step 1 to confirm elimination of fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit in the signal wire. Repair or
replace the wire as required. Go to Step 1 to confirm elimination of fault.
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1050-Alternator L+ terminal under 1.5 volts for 5 seconds

NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical
system.
Context:
The Instrument Cluster measured a voltage less than 1.5 volts for a period greater than 5 seconds on connector
X-29, pin 24. The Instrument Cluster will illuminate the battery warning symbol when it detects a problem in the
battery charging system. The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for
one second on the next system power up following the event.
Cause:
The Instrument Cluster measured a voltage less than 1.5 volts for a period greater than 5 seconds.
2. Wiring or circuits open.
3. Connector pins corroded or dirty.
4. Alternator output voltage is less than 11 volts.
5. Faulty reading from Instrument Cluster.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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2. Test the alternator output
(1) Start the engine. Set engine speed to low idle.
(2) Measure the voltage at the Alternator output. The voltage should be approximately 14.2 volts.
RCPH10TLB083AAM 3
(1) Alternator
(2) Connector X-083
A. NOT OK – The voltage is less than 11 volts. Replace the alternator.1 to confirm elimination of fault.
B. OK – The voltage is approximately 14.2 volts. Go to Step 3.

RCPH10TLB049FAM 4
Schematic legend
24
(4) Key switch
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abrasion, corrosion or incorrect attachment.
(2) Measure the voltage on pin X-29 pin 24 to X-29 pin 26. The voltage should be approximately 14.2 V. Wiggle
the harness during measurement to reveal an intermittent condition.
A. OK – The measured voltage was approximately 14.2 volts. Temporarily replace the Instrument Cluster
and retest. Go to Step 1 to confirm elimination of the fault code.
B. NOT OK – The voltage is less than 11 volts. Replace the alternator. Return to Step 1 to confirm elimination
of fault.
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1051-Timeout of CAN message EEC1, 5 seconds without message

Context:
CAN Data Link communications between the Instrument Cluster and the ECU have been lost. The Instrument Cluster
did not receive the EEC1 message from the ECU. This fault code may be displayed with other CAN Data Link fault
messages. The Instrument Cluster will illuminate the Danger Lamp and will continually sound the audible
alarm. The Low Oil Pressure lamp will also turn on.
Cause:
The Instrument Cluster did not receive the EEC1 message from the ECU. CAN Data Link communications between
the Instrument Cluster and the ECU have been lost.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
3. Wiring or circuits shorted.
5. Faulty ECU
Solution:
Prior to clearing fault codes, write down all existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
A. OK – Fault is not recorded again. OK to return the machine service.
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2. Verify the harness is not damaged
(2) Verify the connections to the ECU, Instrument Cluster, TRAX Controller and Diagnostic Connector are tight
and secure.
(3) Verify the harness is free of damage, abrasion, corrosion and incorrect attachment.
A. OK - The harness is not damaged and the connections are secure. Go to Step 3.
B. NOT OK - The harness is damaged or the connectors are loose or damaged. Repair as required. Go to
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(1) ECU Connector (5) Internal termination resistor, 120 ohms

(2) Instrument Cluster connector, X-29 (6) CAN Data Link LOW (Green Wire)
(3) Diagnostic Connector, X-009 (7) CAN Data Link HIGH (Yellow Wire)
(4) TRAX Controller, X-300
(2) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
chassis ground. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
(3) Measure the resistance from pin 4 on connector X-29 to chassis ground. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
(5) Measure the resistance from pin 4 on connector X-29 to positive battery. The resistance should be greater
A. OK - All resistance measurements are greater than 20,000 ohms. Go to Step 4.
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B. NOT OK - The resistance is less than 20,000 ohms. There is a short circuit in the CAN Data Link. Tem-
porarily replace the CAN Data Link wires and retest. Go to Step 1 to confirm elimination of the fault code.
4. Measure the resistance through the CAN Data Link circuit.
(1) Turn the key switch OFF. Disconnect Instrument Cluster connector X-029.
(2) Measure the resistance between pin 3 and pin 4 on connector X-029. The resistance should be between
108 and 132 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance is between 108 and 132 ohms. Temporarily replace the Instrument Cluster. Go to
Step 1.
B. NOT OK - The resistance is less than 108 ohms, go to test Step 5.
C. NOT OK - The resistance is greater than 132 ohms, go to test step 7.

5. Measure the resistance through the ECU harness to connector X-001
(1) Disconnect connector X-001/X-051.
(2) Measure the resistance between pin 26 and 41 on connector X-001. The resistance should be between 108
and 132 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-051
and the Instrument Cluster. Repair as required. Go to Step 1 to confirm elimination of the fault.
B. NOT OK - The resistance is greater than 132 ohms. Go to step 6.

6. Measure the resistance at the ECU.
(1) Disconnect the ECU connector.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
and the ECU. Repair as required. Go to Step 1 to confirm elimination of the fault.
B. NOT OK - The resistance is greater than 132 ohms. Temporarily replace the ECM and retest. Go to step
1 to confirm elimination of the fault.
7. Measure the resistance through the CAN circuit.
(1) Disconnect the ECU. Disconnect the TRAX Controller.
RCPH10TLB085AAM 4
(2) Measure the resistance between pins 3 and 4 on connector X-029. The resistance should be greater than
20,000 ohms. Wiggle the harness during the measurement to reveal an intermittent condition. The resistance
should be less than 10 ohms.
A. OK - The resistance is greater than 20,000 ohms. Temporarily replace the ECU and retest. Go to Step 1.
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B. NOT OK - The resistance is less than 20,000 ohms. There is a short circuit between the CAN Data Link
wires. Repair or replace the harness as required. Go to step 1 to confirm elimination of fault.
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1052-Timeout of CAN message, 5 seconds without message

Context:
did not receive the a message from the ECU for a period of 5 seconds. This fault code may be displayed with other
CAN Data Link fault messages. The Instrument Cluster will illuminate the Danger Icon and will continually
sound the audible alarm.
Cause:
The Instrument Cluster did not receive a message from the ECU for 5 seconds. CAN Data Link communications
between the Instrument Cluster and the ECU have been lost.
5. Faulty ECU
Solution:
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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B. NOT OK – The fault code is recorded again. Go to Step. 2.

and secure.
RCPH10TLB030FAM 3

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A. OK - The resistance is between 108 and 132 ohms. Temporarily replace the Instrument Cluster and retest.
Go to Step 1.


and the ECU. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
RCPH10TLB085AAM 4
20,000 ohms. Wiggle the harness during the measurement to reveal an intermittent condition.
A. OK - The resistance is greater than 20,000 ohms. Temporarily replace the ECU and retest. Go to Step 1
to confirm elimination of the fault.
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1053-Timeout of CAN message CNFBAM, 25 seconds without

message
Context:
did not receive the CNFBAM message from the ECU for a period of 25 seconds. This fault code may be displayed
with other CAN Data Link fault messages. The Instrument Cluster will illuminate the Danger Lamp and will
continually sound the audible alarm while this fault is active.
Cause:
The Instrument Cluster did not receive the CNFBAM message from the ECU for 25 seconds. CAN Data Link com-
munications between the Instrument Cluster and the ECU have been lost.
5. Faulty ECU
Solution:
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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B. NOT OK – The fault code is recorded again. Go to Step 2.

2. Verify the harness is not damaged.
and secure.
RCPH10TLB030FAM 3

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Step 1.


RCPH10TLB085AAM 4
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1054-Timeout of CAN message engine temperature, 5 seconds

without message
Context:
did not receive the engine temperature message from the ECU for a period of 5 seconds. This fault code may be
displayed with other CAN Data Link fault messages. The Instrument Cluster will illuminate the Danger Lamp
and will continually sound the audible alarm while this code is active.
Cause:
The Instrument Cluster did not receive the engine temperature message from the ECU for 5 seconds. CAN Data Link
communications between the Instrument Cluster and the ECU have been lost.
5. Faulty ECU
Solution:
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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and secure.
RCPH10TLB030FAM 3

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(1) Turn the key switch OFF. Disconnect the Instrument Cluster connector X-029.
Go to Step 1.

5. Measure the resistance through the ECU harness to connector X-001.

RCPH10TLB085AAM 4
to confirm elimination of the fault..
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1055-Timeout of CAN message inlet/exhaust, 5 seconds without

message
Context:
did not receive the inlet/exhaust message from the ECU for a period of 5 seconds. This fault code may be displayed
continually sound the audible alarm while this code is active.
Cause:
did not receive an inlet/exhaust temperature message from the ECU for 5 seconds. This fault code may be displayed
with other CAN Data Link fault messages.
5. Faulty ECU
Solution:
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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and secure.
RCPH10TLB030FAM 3

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Go to Step 1.


RCPH10TLB085AAM 4
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1056-Timeout of CAN message engine fluid, 5 seconds without

message
Context:
did not receive the engine fluid message from the ECU for a period of 5 seconds. This fault code may be displayed
continually sound the audible alarm.
Cause:
did not receive an engine fluid message from the ECU for 5 seconds. This fault code may be displayed with other
CAN Data Link fault messages.
5. Faulty ECU
Solution:
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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and secure.
RCPH10TLB030FAM 3

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(2) Measure the resistance between pin 34 and pin 35 on the ECU. (Connector B). The resistance should be
between 108 and 132 ohms.
RCPH10TLB085AAM 4
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1057-Timeout of CAN message vehicle electrical, 5 seconds without

message
Context:
did not receive the vehicle electrical message from the ECU for a period of 5 seconds. This fault code may be dis-
played with other CAN Data Link fault messages. The Instrument Cluster will illuminate the Danger Lamp
and will continually sound the audible alarm while this fault is active.
Cause:
did not receive a vehicle electrical message from the ECU for 5 seconds. This fault code will be displayed with other
CAN Data Link fault messages.
5. Faulty ECU
Solution:
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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and secure.
RCPH10TLB030FAM 3

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(2) Measure the resistance between pin 34 and pin 35 on the ECU. (Connector B). The resistance should be
between 108 and 132 ohms.
RCPH10TLB085AAM 4
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1058-Timeout of CAN message EDC2BC, 5 seconds without

message
Context:
did not receive the EDC2BC message from the ECU for a period of 5 seconds. This fault code may be displayed
continually sound the audible alarm while the fault is active.
Cause:
did not receive a EDC2BC message from the ECU for 5 seconds. This fault code will be displayed with other CAN
Data Link fault messages.
5. Faulty ECU
Solution:
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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and secure.
RCPH10TLB030FAM 3

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RCPH10TLB085AAM 4
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wires. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault.
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1059-Timeout of CAN message DM1, 5 seconds without message

Context:
did not receive the DM1 diagnostic message from the ECU for a period of 5 seconds. This fault code may be displayed
continually sound the audible alarm while the fault is active.
Cause:
did not receive a the DM1 diagnostic message from the ECU for 5 seconds. This fault code will be displayed with
other CAN Data Link fault messages.
5. Faulty ECU
Solution:
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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and secure.
RCPH10TLB030FAM 3

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(2) Measure the resistance between X-029 pin 3 and pin 4. The resistance should be between 108 and 132


RCPH10TLB085AAM 4
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3006-Coolant Temperature Sensor - Signal Not Plausible

Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant temp sensor. This error
could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines
that the Coolant temp sensor temperature value is not valid, it will substitute another value to be used. In case of a
defective Coolant temp sensor during engine warm-up, a default coolant temperature value is derived from the ramp
of the currently logged sensor data. If an error would occur during normal engine operation, the oil temperature is
used as the default value. If the Oil temp / press sensor is defective, 85 °C (185 °F) is substituted as the default value.
Cause:
The Coolant temp sensor signal to the ECU is either erratic or intermittent.
1. Faulty Coolant temp sensor.

2. Faulty electrical wiring or intermittent connection between Coolant temp sensor and ECU.
3. Faulty ECU, supply voltages or grounds.
Solution:
1. Operation: Electrical Inspection.

Vehicle Status: Key Off Engine Off.
Remove Coolant temp sensor connector WTF and inspect housing body/latch, pins and wiring harness for dam-
age. Also, inspect connector portion of the Coolant temp sensor.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection.
B. If no damage is determined, proceed to step 2.

2. Operation: Check Open Circuit Supply Voltage for Coolant temp sensor.
Vehicle Status: Key On Engine Off.
Remove connector WTF from Coolant temp sensor and check for (DC) voltage outlined in the table below. Use
the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to
access the pins on the connector.
Test Type From To Expected Results

1. Voltage WTF (Pin 1) (+) WTF (Pin 2) (-) Approx. 5 volts (DC)
A. If 5 volts (DC) is present, proceed to step 4.
B. If 5 volts (DC) is not present, proceed to step 3.

3. Operation: Check for Faulty Wiring.
Vehicle status: Key Off Engine Off.
Remove and perform continuity tests between connectors WTF and 2 on engine sensor harness. Flex harness
during test to check for any intermittent operation. Use the test lead labeled "Coolant/Fuel Temp Sensor" from
the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector WTF.
Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multi-
meter (DMM) to the 2 connector. Make sure the DMM's test lead resistance is taken into account when making
continuity measurements. See test table below.
Important Note:
Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main
ECU connectors if this is not followed.
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1. Continuity WTF (Pin: 1) 2, (Pin: 15) Approx. 0 - 0.10 ohms
2. Continuity WTF, (Pin: 2) 2, (Pin: 26) Approx. 0 - 0.10 ohms
3. Short Circuit 2, (Pin: 15) 2, (Pin: 32) Open Circuit
A. If continuity/shorts test is successful, go to step 4.
B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. Operation: Coolant temp sensor Test
Remove WTF connector and test resistance of Coolant temp sensor using the table of resistance vs. temp.
below. Approximate the temperature when performing test. Coolant temp sensor failures are typically at the
extreme ends of the table or off the table entirely. Use the test lead labeled "Coolant/Fuel Temp Sensor" from
the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor.
Coolant Temperature Resistance Value

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
A. If the resistance measurement does not approximately match the table, replace the sensor.
B. If the resistance measurement does approximately match the table, proceed to step 5.
5. Operation: Check for ECU Voltages and Ground Continuity.
Vehicle Status (when removing connector 1): Key Off Engine Off.
Vehicle Status (when performing test): Key On Engine Off.
Vehicle Status (when replacing connector 1): Key Off Engine Off.
Use product schematic for a reference, remove connector 1 from the ECU and check for 12 volts and continuity
at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the
Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the connector 1. Make sure the
DMM's test lead resistance is taken into account when making any continuity measurements.
Important Note:
Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when
removing and replacing main ECU connectors if this is not followed.

1. Voltage 1, (Pin 2, 3, 8, 9, 40) Ground (engine block) Approx. 12 volts
2. Continuity 1, (Pin 5, 6, 10, 11) Ground (engine block) Approx. 0 - 0.10 ohms
A. If the voltages and ground paths are correct and the Coolant temp sensor was not replaced on a prior
diagnostic of this type, replace the sensor.
B. If the voltages and ground paths are correct and the Coolant temp sensor was replaced on a prior diag-
nostic of this type, re-initialize the ECU as if it was blank (new) and load the appropriate data-set.
C. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this
type, replace the ECU.
D. If the voltages and ground paths are not correct, refer to schematic and determine root cause of power or
continuity problem(s).
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3007-Coolant temperature signal - signal above range

Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant temperature sensor. This
error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines
that the Coolant tempurature sensor temperature value is not valid, it will substitute another value to be used. In case
of a defective Coolant temperature sensor during engine warm-up, a default coolant temperature value is derived
from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil
temperature is used as the default value. If the Oil temperature / pressure sensor is defective, 85 °C (185 °F) is
substituted as the default value.
Cause:
The Coolant temperature sensor signal to the ECU is out of range of the upper threshold limit.
1. Faulty Coolant temperature sensor.

2. Faulty electrical wiring, short to high source or open circuit condition.
Solution:
1. Verify the fault code is present and active.
A. If fault code is present and active, continue with 2.
B. If fault code is no longer present, continue with step 6.

2. Verify complete voltage supply circuit for the Coolant temperature sensor. Remove the connector WTF from
Coolant temperature sensor and check for voltage outlined in the table below. Use the test lead labeled "Coolant/
Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector.

1. Voltage Coolant temperature sen- Coolant temperature sen- Approx. 5 volts
sor connector WTF (Pin 1) sor connector WTF (Pin 2)
(+) (-)
A. If 5 volts is present, continue with step 4.
B. If 5 volts is not present, continue with step 3.

3. Check for faulty wiring. Remove and perform continuity tests between the Coolant temperature sensor and the
ECU engine connectors on the engine sensor harness. Flex harness during test to check for any intermittent
operation. Use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit
380040185 to be able to access the pins on the Coolant temperature sensor connector. Also, use the 0.4 mm
(0.017 in) diameter test probes from the repair kit when connecting the digital multi-meter (DMM) to the ECU
engine connector. See test table below.

1. Continuity Coolant temperature sen- ECU engine connector 2 Approx. 0 - 0.10 ohms
sor connector WTF (Pin: (Pin: 15)
1)
2. Continuity Coolant temperature sen- ECU engine connector 2 Approx. 0 - 0.10 ohms
sor connector WTF (Pin: (Pin: 26)
2)
3. Short Circuit ECU engine connector 2 ECU engine connector 2 Open Circuit
(Pin: 15) (Pin: 32)
4. Short Circuit ECU engine connector ECU engine connector 2 Open Circuit
2(Pin: 15) (Pin: 33)
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5. Short Circuit ECU engine connector 2 ECU engine connector 2 Open Circuit
(Pin: 15) (Pin: 26)
A. If continuity/short tests are successful, continue with step 4.
B. If continuity/short test are unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. Verify proper Coolant temperature sensor operation. Remove Coolant temperature sensor connector WTF and
test resistance of Coolant temperature sensor using the table of resistance vs. temp. below. Approximate the
temperature when performing test. Coolant temperature sensor failures are typically at the extreme ends of
the table or off the table entirely. Use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF)
Diagnostic Repair Kit 380040185 to access the pins on the sensor.

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
B. If the resistance measurement does approximately match the table, continue with step 5.
5. Verify ECU ground and voltage supply. Use the product schematic for a reference, with the ignition switch OFF
remove ECU vehicle connector 1 from the ECU. Check for 12 volts with the ignition switch in the ON position,
and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter
test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the ECU
vehicle connector. Make sure the DMM's test lead resistance is taken into account when making any continuity
measurements.

1. Voltage ECU vehicle connector 1 Ground (engine block) Approx. 12 volts
(Pin 2, 3, 8, 9, 40)
2. Continuity ECU vehicle connector 1 Ground (engine block) Approx. 0 - 0.10 ohms
(Pin 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this
B. If the voltages and ground paths are not correct locate and repair the damaged section(s) of the wiring
harness.
6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals
or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent
breaks or shorts in the wiring concerned. Operate the machine while monitoring the Display.
A. If damage is found or other than normal display readings are indicated, repair the damage discovered
during the inspection or locate and repair the other than normal display condition and verify that the error
has been resolved.
B. If no damage or other than normal display readings are indicated, erase the fault code and continue oper-
ation.
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3008-Coolant Temperature Signal - Signal Below Range Minimum

Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant temperature sensor. This
error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines
that the Coolant temperature sensor temperature value is not valid, it will substitute another value to be used. In case
of a defective Coolant temperature sensor during engine warm-up, a default coolant temperature value is derived
from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil
temperature is used as the default value. If the Oil temperature / pressure sensor is defective, 85 °C (185 °F) is
substituted as the default value.
Cause:
The Coolant temperature sensor signal to the ECU is out of range of the lower threshold limit.
1. Faulty Coolant temperature sensor.

2. Faulty electrical wiring, short to low source condition.
3. Faulty ECU, supply voltages.
Solution:
A. If fault code is present and active, continue with step 3.

2. Verify Coolant temperature sensor is working properly. Disconnect the Coolant temperature sensor, connector
WTF, and test resistance of Coolant temperature sensor using the table of resistance vs. temperature below.
Approximate the temperature when performing test. Coolant temperature sensor failures are typically at the
extreme ends of the table or off the table entirely. Use the test lead labeled "Coolant/Fuel Temp Sensor" from
the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor.

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
B. If the resistance measurement does approximately match the table, continue with step 4.
3. Check for supply voltage from the ECU in the Coolant temperature sensor supply wiring. Remove the connector
from Coolant temperature sensor WTF and check for voltage between Coolant temperature sensor connector
WTF, pin 1 and ground. If necessary, use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II
(NEF) Diagnostic Repair Kit 380040185 to access the pins on the connector. There should be 5 volts.
A. If 5 volts is present, continue with step 5.
B. If 5 volts is not present, continue with step 2.

4. Check the ECU output to the Coolant temperature sensor. With the ignition switch in the OFF position, remove
the Coolant temperature sensor connector WTF and the ECU engine connector 2 on engine sensor harness.
Turn the ignition switch to the ON position and check for voltage between ECU engine connector WTF, pin 15
and ground. If necessary, use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic
Repair Kit 380040185 to access the pins on the Coolant temperature sensor, connector WTF. Also, use the 0.4
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mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter to the ECU engine
connector 2. There should be 5 volts.
A. If 5 volts is present, locate a repair the open circuit condition between the ECU engine connector 2, pin
15 and the Coolant temperature sensor connector WTF, pin 1.
B. If 5 volts is not present, replace the ECU.

5. Verify the Coolant temperature sensor ground path. With the ignition switch in the OFF position, disconnect
ECU engine connector, 2, and check for continuity to ground from pin 26 of the ECU. Use the 0.4 mm (0.017 in)
diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the multi-meter
to the ECU engine connector, 2.
A. If there is continuity, locate and repair short to ground in Engine sensor harness between the ECU engine
connector 2 and the Coolant temperature sensor connector, WTF.
B. If there is not continuity, replace the ECU.

has been resolved.
B. If no damage or no other than normal display readings are indicated, erase the fault code and continue
operation.
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3010-Air intake temperature sensor signal above maximum range

Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost
Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related
to the temperature sensing function of the device. This error could result from a signal out of range or a signal that
is either erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will
substitute a default value of 29.96 °C (86 °F).
Cause:
The Boost Pressure sensor signal to the ECU is out of range of the upper threshold limit.
1. Faulty sensor.
2. Faulty electrical wiring or connection.
Solution:

Remove Boost Pressure sensor connector LDFT and inspect housing body/latch, pins and wiring harness for
damage. Also, inspect connector portion of the Boost Pressure sensor.
good and sound electrical connection. Replace Boost Pressure sensor if damaged.

2. Operation: Check Open Circuit Voltages for Boost Pressure sensor.
Remove connector LDFT from Boost Pressure sensor and check for voltages (DC) between connector pins
outlined in the table below. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic
Repair Kit 380040185 to access the pins on the connector.

1. Voltage LDFT (Pin 3) LDFT (Pin 1) Approx. 5 volts
3. Voltage LDFT (Pin 4) LDFT (Pin 1) Approx. 5.4 volts
A. If the voltage test sequence is successful, proceed to step 4.
B. If the voltage test sequence is not successful, proceed to step 3.

Remove and perform continuity/shorts tests between connectors LDFT and 2 on engine wiring harness. Flex
harness during test to check for any intermittent operation. Use the test lead labeled "Air Press/Temp Sensor"
from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector
LDFT. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital
multi-meter (DMM) to connector 2. Make sure the DMM's test lead resistance is taken into account when making
Important Note:
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Test Type From: To: Expected Results

1. Continuity LDFT (Pin: 1) 2 (Pin: 25) Approx. 0 - 0.10 ohms
5. Shorts 2 (Pin: 36) 2 (Pin: 25, 34, 33) Open Circuit
6. Shorts 2 (Pin: 25) 2 (Pin: 34, 33) Open Circuit
7. Shorts 2 (Pin: 34) 2 (Pin: 33) Open Circuit
4. Operation: Boost Pressure sensor Test
Remove the Boost Pressure sensor connector LDFT and remove the sensor from the engine intake manifold.
Allow the sensor to cool to ambient temperature for several minutes, and then test sensor resistance across
pins 2 and 3, using the table of resistance vs. temperature below. Approximate the ambient air temperature
when performing the test. Boost Pressure sensor failures are typically at the extreme ends of the table or off
the table entirely. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair
Kit 380040185 to access the contacts on the Boost Pressure sensor (pins 2 and 3).
Temperature Resistance Nominal Value Resistance Min/Max. Range

-40 °C (-40 °F) 48153 ohms 45301 - 51006 ohms
-35 °C (-31 °F) 35763 ohms 33703 - 37823 ohms
-30 °C (-22 °F) 26854 ohms 25350 - 28359 ohms
-25 °C (-13 °F) 20376 ohms 19265 - 21487 ohms
-20 °C (-4 °F) 15614 ohms 14785 - 16443 ohms
-15 °C (5 °F) 12078 ohms 11453 - 12702 ohms
-10 °C (14 °F) 9426 ohms 8951 - 9901 ohms
-5 °C (23 °F) 7419 ohms 7055 - 7783 ohms
0 °C (32 °F) 5887 ohms 5605 - 6168 ohms
5 °C (41 °F) 4707 ohms 4487 - 4926 ohms
10 °C (50 °F) 3791 ohms 3618 - 3964 ohms
15 °C (59 °F) 3075 ohms 2939 - 3211 ohms
20 °C (68 °F) 2511 ohms 2402 - 2619 ohms
25 °C (77 °F) 2063 ohms 1976 - 2150 ohms
30 °C (86 °F) 1715 ohms 1645 - 1786 ohms
35 °C (95 °F) 1432 ohms 1374 - 1490 ohms
40 °C (104 °F) 1199 ohms 1152 - 1247 ohms
45 °C (113 °F) 1009 ohms 970 - 1047 ohms
50 °C (122 °F) 851 ohms 819 - 883 ohms
55 °C (131 °F) 721 ohms 694 - 747 ohms
60 °C (140 °F) 612 ohms 590 - 634 ohms
65 °C (149 °F) 522 ohms 503 - 540 ohms
70 °C (158 °F) 446 ohms 431 - 462 ohms
75 °C (167 °F) 383 ohms 370 - 396 ohms
80 °C (176 °F) 329 ohms 319 - 340 ohms
85 °C (185 °F) 284 ohms 275 - 293 ohms
90 °C (194 °F) 246 ohms 238 - 254 ohms
95 °C (203 °F) 214 ohms 207 - 220 ohms
100 °C (212 °F) 186 ohms 180 - 192 ohms
105 °C (221 °F) 162 ohms 157 - 167 ohms
110 °C (230 °F) 142 ohms 138 - 147 ohms
115 °C (239 °F) 125 ohms 121 - 129 ohms
120 °C (248 °F) 110 ohms 106 - 113 ohms
125 °C (257 °F) 97 ohms 93 - 100 ohms
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130 °C (266 °F) 85 ohms 83 - 88 ohms
Use product schematic for a reference, remove connector 1 from the ECU and check for voltage and continuity
Important Note:

1. Voltage 1 (Pin 2, 3, 8, 9, 40) Ground (engine block) Approx. 12 volts
2. Continuity 1 (Pin 5, 6, 10, 11) Ground (engine block) Approx. 0 - 0.10 ohms
A. If the voltages and ground paths are correct and the Boost Pressure sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Boost Pressure sensor was replaced on a prior diag-
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3011-Air intake temperature sensor signal below minimum range

Context:
Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related
to the temperature sensing function of the device. This error could result from a signal out of range or a signal that
is either erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will
substitute a default value of 29.96 °C (86 °F).
Cause:
The Boost Pressure sensor signal to the ECU is out of range of the lower threshold limit.
1. Faulty sensor.
Solution:


Remove LDFT connector from Boost Pressure sensor and check for voltages (DC) between connector pins


Remove and perform continuity/shorts tests between connectors LDFT and 2 on engine wiring harness. Flex
harness during test to check for any intermittent operation. Use the test lead labeled "Air Press/Temp Sensor"
from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector
LDFT. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital
multi-meter (DMM) to the 2 connector. Make sure the DMM's test lead resistance is taken into account when
making continuity measurements. See test table below.
Important Note:
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1. Continuity LDFT 2 (Pin: 25) Approx. 0 - 0.10 ohms
4. Operation: Boost Pressure sensor Test
Remove the Boost Pressure sensor connector LDFT and remove the sensor from the engine intake manifold.
Allow the sensor to cool to ambient temperature for several minutes, and then test sensor resistance across
pins 2 and 3, using the table of resistance vs. temperature below. Approximate the ambient air temperature
when performing the test. Boost Pressure sensor failures are typically at the extreme ends of the table or off
the table entirely. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair
Kit 380040185 to access the contacts on the Boost Pressure sensor (pins 2 and 3).

-40 °C (-40 °F) 48153 ohms 45301 - 51006 ohms
-35 °C (-31 °F) 35763 ohms 33703 - 37823 ohms
-30 °C (-22 °F) 26854 ohms 25350 - 28359 ohms
-25 °C (-13 °F) 20376 ohms 19265 - 21487 ohms
-20 °C (-4 °F) 15614 ohms 14785 - 16443 ohms
-15 °C (5 °F) 12078 ohms 11453 - 12702 ohms
-10 °C (14 °F) 9426 ohms 8951 - 9901 ohms
-5 °C (23 °F) 7419 ohms 7055 - 7783 ohms
0 °C (32 °F) 5887 ohms 5605 - 6168 ohms
5 °C (41 °F) 4707 ohms 4487 - 4926 ohms
10 °C (50 °F) 3791 ohms 3618 - 3964 ohms
15 °C (59 °F) 3075 ohms 2939 - 3211 ohms
20 °C (68 °F) 2511 ohms 2402 - 2619 ohms
25 °C (77 °F) 2063 ohms 1976 - 2150 ohms
30 °C (86 °F) 1715 ohms 1645 - 1786 ohms
35 °C (95 °F) 1432 ohms 1374 - 1490 ohms
40 °C (104 °F) 1199 ohms 1152 - 1247 ohms
45 °C (113 °F) 1009 ohms 970 - 1047 ohms
50 °C (122 °F) 851 ohms 819 - 883 ohms
55 °C (131 °F) 721 ohms 694 - 747 ohms
60 °C (140 °F) 612 ohms 590 - 634 ohms
65 °C (149 °F) 522 ohms 503 - 540 ohms
70 °C (158 °F) 446 ohms 431 - 462 ohms
75 °C (167 °F) 383 ohms 370 - 396 ohms
80 °C (176 °F) 329 ohms 319 - 340 ohms
85 °C (185 °F) 284 ohms 275 - 293 ohms
90 °C (194 °F) 246 ohms 238 - 254 ohms
95 °C (203 °F) 214 ohms 207 - 220 ohms
100 °C (212 °F) 186 ohms 180 - 192 ohms
105 °C (221 °F) 162 ohms 157 - 167 ohms
110 °C (230 °F) 142 ohms 138 - 147 ohms
115 °C (239 °F) 125 ohms 121 - 129 ohms
120 °C (248 °F) 110 ohms 106 - 113 ohms
125 °C (257 °F) 97 ohms 93 - 100 ohms
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130 °C (266 °F) 85 ohms 83 - 88 ohms
Use product schematic for a reference, remove 1 connector from the ECU and check for voltage and continuity
Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to the 1 connector. Make sure the
Important Note:

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3015-Fuel Temperature Sensor - Signal Above Maximum

Context:
The Engine Control Unit (ECU) has detected a fault associated with Fuel temperature sensor. This error typically
results from a signal that is out of range. When the ECU determines that the Fuel temperature sensor temperature
value is invalid, it will substitute the current coolant temperature value, or in the case of a defective Coolant tempera-
ture sensor , the value 19.96 ° C (67.9 °F) will be substituted.
Cause:
The Fuel temperature sensor signal to the ECU is out of the range of the upper threshold limit.
1. Faulty Fuel temperature sensor.

2. Faulty electrical wiring or short to high source or open circuit condition.
Solution:
1. Verify this error code is still present and in an active state.
A. If the error is still present and active, continue with step 2.
B. If the error is no longer present or is in an inactive state, continue with step 6.

2. Ensure electrical integrity of the Fuel temperature sensor. Remove connector KTF from the Fuel temperature
sensor and use a multi-meter to check the resistance of the sensor. Use the table below to ensure proper sensor
resistance.
Fuel Temperature Resistance Value

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
A. If sensor resistance is within range leave connector KTF disconnected and continue with step 3.
B. If the sensor is out of range, replace the sensor.

3. Verify proper supply voltage to the sensor from the ECU. Measure voltage between connector KTF, pin 2 and
ground. There should be 5 V.
A. If there is 5 V, continue with step 5.
B. If there is greater than 5 V, continue with step 4.

4. Verify voltage output from ECU. Disconnect ECU engine connector, connector 3. Measure voltage between pin
24 on the ECU and ground. There should be 5 V.
A. If there is 5 V, there is a short to high source between ECU engine connector, connector 2, and the Fuel
temperature sensor connector, connector KTF. Locate and repair the shorted condition.
B. If there is greater than 5 V, there is a short to high source internal to the ECU, replace the ECU.
5. Check signal wire from Fuel temperature sensor to ECU. Measure voltage between the ECU engine connector,
connector 3, pin 35 and ground.
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has been resolved.
ation.
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3016-Fuel Temperature Sensor - Signal Below Range Minimum

Context:
The Engine Control Unit (ECU) has generated a fault associated with Fuel temperature sensor . This error typically
results from a signal that is out of range. When the ECU determines that the fuel temperature sensor temperature
value is invalid, it will substitute the current "Coolant Temperature" value, or in the case of a defective Coolant tem-
perature sensor , the value 19.96 °C (67.9 °F) will be substituted.
Cause:
The Fuel temperature sensor signal to the ECU is out of the range of the lower threshold limit.
1. Faulty Fuel temperature sensor .

2. Faulty electrical wiring or short to low source (ground).
Solution:

Remove Fuel temp sensor connector KTF and inspect housing body/latch, pins and wiring harness for damage
or corrosion. Also, inspect connector portion of the Fuel temp sensor.
A. If a problem is determined after careful inspection, repair wiring and/or replace connector parts to ensure
a good and sound electrical connection. Replace Fuel temp sensor if damaged.
B. If no problems are determined, proceed to step 3.

3. Operation: Check Supply Voltage for Fuel temp sensor.
Remove connector from Fuel temp sensor and check for voltage outlined in the table below. Use the test lead
labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins
on the connector.

1. Voltage KTF (Pin 1) KTF (Pin 2) Approx. 5 volts
A. If the voltage test is successful, proceed to step 5.
B. If the voltage test is not successful, proceed to step 4.

Remove and perform continuity tests between connector KTF and connector 2 on engine sensor harness. Flex
harness during test to check for any intermittent operation. Use the test lead labeled "Coolant/Fuel Temp Sensor"
from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connec-
tor KTF. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital
multi-meter (DMM) to connector 2. Make sure the DMM's test lead resistance is taken into account when taking
Important Note:
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1. Continuity KTF (Pin: 1) 2 (Pin: 35) Approx. 0 - 0.10 ohms
2. Continuity KTF (Pin: 2) 2 (Pin: 17) Approx. 0 - 0.10 ohms
3. Short Circuit KTF (Pin: 35) 2 (Pin: 32) Open Circuit
4. Short Circuit 2 (Pin: 35) 2 (Pin: 33) Open Circuit
5. Operation: Fuel temp sensor Test
Remove Fuel temp sensor connector KTF and test resistance of Fuel temp sensor using the table of resistance
vs. temp. below. Approximate the fuel temperature when performing test. Fuel temp sensor failures are typically
at the extreme ends of the table or off the table entirely. Use the test lead labeled "Coolant/Fuel Temp Sensor"
from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the pins on the sensor.
Fuel Temperature Resistance Value

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
Use product schematic, remove connector 1 from the ECU and check for voltage and continuity at the appropri-
ate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from the Tier II (NEF)
Diagnostic Repair Kit 380040185 when connecting the DMM to connector 1. Make sure the DMM's test lead
resistance is taken into account when making any continuity measurements.
Important Note:

1. Voltage Connector 1 (Pin 2, 3, 8, 9, Ground (engine block) Approx. 12 volts
40)
2. Continuity Connector 1 (Pin 5, 6, 10, Ground (engine block) Approx. 0 - 0.10 ohms
11)
A. If the voltages and ground paths are correct and the Fuel temp sensor was not replaced on a prior diag-
nostic of this type, replace the sensor.
B. If the voltages and ground paths are correct and the Fuel temp sensor (FTS) was replaced on a prior
diagnostic of this type, re-initialize the ECU as if it was blank (new) and load the appropriate data-set.
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has been resolved.
ation.
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3019-Boost Pressure Sensor - Signal Above Range Maximum

Context:
Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to
the pressure sensing function of the device. This error could result from a signal out of range or a signal that is either
erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will substitute a
default value of 270 kPa (39 psi).
Cause:
The Boost Pressure sensor signal to the ECU is out of range of the upper threshold limit.
1. Faulty sensor.
Solution:


2. Operation: Check Open Circuit Voltages for Boost Press sensor.
Remove LDFT connector from Boost Pressure sensor and check for voltages (DC) between connector pins


Remove and perform continuity/shorts tests between connectors LDFT and connector 2 on engine wiring har-
ness. Flex harness during test to check for any intermittent operation. Use the test lead labeled "Air Press/Temp
Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor
connector LDFT. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the
digital multi-meter (DMM) to connector 2. Make sure the DMM's test lead resistance is taken into account when
Important Note:
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2. Continuity LDFT (Pin: 2) LDFT (Pin: 36) Approx. 0 - 0.10 ohms
Important Note:

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3022-Boost Pressure Sensor - Signal Not Plausible

Context:
Cause:
The Boost Pressure sensor signal to the ECU and the Atmospheric Pressure Sensor (APS) internal to the ECU do
not agree on engine startup.
1. Faulty sensor.
3. Faulty ECU with integrated APS, supply voltages or grounds.
Solution:


2. Operation: Check Open Circuit Voltages for Boost Press sensor.
Remove LDFT connector from Boost Press sensor and check for voltages (DC) between connector pins outlined
in the table below. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair
Kit 380040185 to access the pins on the connector.


Important Note:
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Important Note:

A. If the voltages and ground paths are correct and the Boost Press sensor was not replaced on a prior
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3023-Atmospheric pressure sensor - signal not plausible

NOTE: Atmospheric pressure sensor is inside the engine control module, replace ECU. (Not necessary if never run-
ning in high altitude and if turbocharger is without VGT).
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3024-Atmospheric Pressure Sensor - Signal Above Range Maximum

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3025-Atmospheric pressure sensor - signal below range minimum

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3028-Oil pressure too low

Context:
The Engine Control Unit (ECU) generated a fault associated with the Oil temp / press sensor. The Oil temp / press
sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the
pressure sensing function of the device. This fault is a result of a plausibility check of the engine running extremely
low oil pressure. All subsequent engine error states are frozen in case there is a sensor power supply ( 5 volts dc)
error. The ECU only starts the plausibility check if there are no sensor power supply ( 5 volts dc) or Analog to Digital
Converter (ADC) signal or CAN message processing errors detected.
Cause:
The Oil temp / press sensor pressure signal to the ECU is operating at the extreme low end of the signal range.
1. Low engine oil level.

2. Faulty electrical wiring.
3. Faulty engine lubrication system.
4. Faulty Oil temp / press sensor.
Solution:
1. Operation: Inspect Electrical Components and Check Engine Oil Level.

Electrical:
Remove Oil temp / press sensor connector ODFT and inspect housing body/latch, pins and wiring harness for
damage or corrosion. Also, inspect connector portion of the Oil temp / press sensor.
Oil Level:
Check oil level on dipstick.
A. If the engine oil level is low, top off the oil level with the recommended grade of oil specified in the appro-
priate Engine Maintenance and Repair Manual.
B. If electrical damage has been determined after careful inspection, repair wiring and/or replace connector
parts to ensure a good and sound electrical connection. Replace Oil temp / press sensor if damaged.
C. If oil level is proper and no electrical damage has been determined, proceed to step 2.
2. Operation: Check Engine Oil Pressure
Vehicle Status: Key Off Engine Off (test preparation)
Vehicle Status: Key On Engine On (during test)
Use the procedure established in the appropriate Engine Maintenance and Repair Manual to test the pressure
of the engine oil lubrication system.
A. If the oil pressure test is successful, proceed to step 3.
B. If the oil pressure test is not successful, refer to the appropriate Engine Maintenance and Repair Manual
to diagnose, troubleshoot and repair the low oil pressure fault condition.
3. Operation: Check Open Circuit Voltages for Oil temp / press sensor.
Remove ODFT connector from the Oil temp / press sensor and check for voltages (DC) between connector pins
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1. Voltage ODFT (Pin 3) ODFT (Pin 1) Approx. 5 volts
3. Voltage ODFT (Pin 4) ODFT (Pin 1) Approx. 5.4 volts

Remove and perform continuity tests between connectors ODFT and 2 on engine wiring harness. Flex harness
during test to check for any intermittent operation. Use the test lead labeled "Air Press/Temp Sensor" from the
Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector ODFT .
Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the digital multi-meter
(DMM) to connector 2. Make sure the DMM's test lead resistance is taken into account when taking continuity
measurements. See test table below.
Important Note: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when
removing main ECU connectors if this is not followed.

1. Continuity ODFT (Pin: 1) 2 (Pin: 24) Approx. 0 - 0.10 ohms
5. Short Circuit 2 (Pin: 28) 2 (Pin: 24, 27, 32) Open Circuit
6. Short Circuit 2 (Pin: 24) 2 (Pin: 27, 32) Open Circuit
at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes from
the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to connector 1 . Make sure the
Important Note:

A. If the voltages and ground paths are correct and the Oil temp / press sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Oil temp / press sensor was replaced on a prior
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3029-Oil Pressure Sensor - Short Circuit To Battery

Context:
pressure sensing function of the device. This error could result from a signal out of range or a plausibility check (oil
pressure too high). The plausibility check is only started if there are no sensor power supply ( 5 volts dc) or Analog
to Digital Converter (ADC) signal errors detected.
Cause:
The Oil temp / press sensor signal to the ECU is out of range of the upper threshold limit.

2. Faulty electrical wiring, signal short to high source or open circuit condition.
Solution:

good and sound electrical connection. Replace OPS sensor if damaged.



Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector ODFT.
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Important Note:

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3030-Oil Pressure Sensor - Short Circuit To Ground

Context:
Cause:
The Oil temp / press sensor signal to the ECU is either erratic or intermittent.
1. Faulty electrical wiring or intermittent connection between Oil temp / press sensor and ECU.
Solution:




(DMM) to the connector 2. Make sure the DMM's test lead resistance is taken into account when taking continuity
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5. Short Circuit ODFT (Pin: 28) 2 (Pin: 24, 27, 32) Open Circuit
6. Short Circuit ODFT (Pin: 24) 2 (Pin: 27, 32) Open Circuit
7. Short Circuit ODFT (Pin: 27) 2 (Pin: 32) Open Circuit
the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the DMM to connector 1. Make sure the
Important Note:

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3031-Oil pressure sensor - hardware error

Context:
Cause:
The Oil temp / press sensor signal to the ECU is either erratic or intermittent.

2. Faulty electrical wiring or intermittent connection between Oil temp / press sensor and ECU.
Solution:




(DMM) to the connector 2. Make sure the DMM's test lead resistance is taken into account when taking continuity
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Important Note:

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3032-Oil Pressure Sensor - Value Too High

Context:
Cause:
The Oil temp / press sensor signals to the ECU are both operating in the extreme upper portion of signal range.

2. Faulty electrical wiring.
4. Faulty engine lubrication system.
5. Low engine oil level.
Solution:
1. Operation: Inspect Electrical Components and Check Engine Oil Level.

Electrical:
Oil Level:
Check oil level on dipstick.
A. If the engine oil level is low, top off the oil level with the recommended grade of oil specified in the appro-
priate Engine Maintenance and Repair Manual.
B. If electrical damage has been determined after careful inspection, repair wiring and/or replace connector
parts to ensure a good and sound electrical connection. Replace Oil temp / press sensor if damaged.
C. If oil level is proper and no electrical damage has been determined, proceed to step 2.
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Important Note:

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3033-Oil Temperature Sensor - Signal Not Plausible (Compared

With Coolant Temperature)
Context:
temperature sensing function of the device. This error could result from a signal out of range or a plausibility check
against the Coolant temp sensor or CAN message processing. The ECU prohibits any plausibility check if there are
any Analog to Digital Converter (ADC) signal errors detected on the Oil temp / press or the Coolant temp sensor.
Cause:
The Oil temp / press and Coolant temp sensor signals to the ECU are out of range with respect to each other.
1. Faulty Oil temp / press sensor (inaccurate).

2. Faulty Coolant temp sensor (inaccurate).
3. Faulty electrical wiring, high resistance connections.
5. Faulty oil lubrication or coolant system.
Solution:
1. Operation: Check for Coolant System Faults.
Use EST to check for errors associated with coolant temperature.
A. If any of the errors exist, resolve the existing error. Then determine if this error has also been resolved.
B. If none of the errors exist, continue with step 2.

good and sound electrical connection. Replace Oil temp / press sensor if damaged.



4. Operation: Oil temp / press sensor Test
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Remove ODT connector and test resistance of Oil temp / press sensor using the table of resistance vs. temp.
below. Approximate the engine oil temperature when performing test. Oil temp / press sensor failures are
typically at the extreme ends of the table or off the table entirely. Use the test lead labeled "Air Press/Temp
Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor.
Use a multi-meter between pins 1 and 2.
Engine Oil Temperature Resistance Value (between pins 1 and 2)

-40 °C (-40 °F) 70 kOhm
-20 °C (-4 °F) 25 kOhm
0 °C (32 °F) 7.5 kOhm
20 °C (68 °F) 4.5 kOhm
40 °C (104 °F) 1.5 kOhm
60 °C (140 °F) 750 ohms
80 °C (176 °F) 550 ohms
100 °C (212 °F) 320 ohms
120 °C (248 °F) 130 ohms

Important Note:
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3034-Oil Temperature Sensor - Signal Above Range Maximum

Context:
Cause:
The Oil temp / press sensor signal to the ECU is out of range of the upper threshold limit.

2. Faulty electrical wiring, signal short to high source or open circuit condition.
Solution:




Remove and perform continuity tests between connectors ODT and 2 on engine wiring harness. Flex harness
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4. Continuity ODFT (Pin: 4) (Pin: 27) Approx. 0 - 0.10 ohms
5. Short Circuit 2 (Pin: 28) 2 2 (Pin: 24, 27, 32) Open Circuit
Important Note:

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3035-Oil Temperature Sensor - Signal Below Range Minimum

Context:
Cause:
The Oil temp / press sensor signal to the ECU is out of range of the lower threshold limit.

2. Faulty electrical wiring, signal short to low source condition.
Solution:




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Important Note:

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3037-Boost Pressure Sensor - Signal Low

Context:
Cause:
The Boost Pressure sensor signal to the ECU is out of range of the lower threshold limit.
1. Faulty sensor.
Solution:


Remove connector from Boost Pressure sensor and check for voltages (DC) between connector pins outlined
in the table below. Use the test lead labeled "Air Press/Temp Sensor" from the Tier II (NEF) Diagnostic Repair
Kit 380040185 to access the pins on the connector.


Important Note:
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Important Note:

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3047-Main Relay Failure - Short Circuit To Battery

Cause:

5. Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean female pins by
installing and removing.
Solution:
rence.
A. NOT OK – Fault code 3047 is recorded again. Go to Step 2.
B. OK – Fault is not recorded again. OK for return to service.

3. Check Power Relay No. 2 fuse.
RCPH10TLB301AAF 1
(1) Fuse block

(2) Diagnostic Connector
A. NOT OK – Replace fuse. Return to Step 1 to confirm elimination of fault. If fuse blows again, go to Step 4
4. Check ground circuit.
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RCPH10TLB301AAF 2
(1) Power Relay #2
(1) Disconnect Power Relay number 2 connector. Inspect connector and wiring for corrosion, abrasion or incor-
rect attachment.
(2) Measure the resistance from pin 86 (pin 1) to ground. The resistance should be less than 10 ohms. Wiggle
A. NOT OK – Determine the break between connector and ground. Return to Step 1 to confirm elimination
of fault.
5. (1) Turn the key switch ON. Engine OFF.
(2) Take a voltage reading at pin 85 of the Power Relay 2 connector to pin E of the Ignition Switch connector.
The voltage should be approximately 12 V .
of fault.
6. Check circuit to Fuse Block.
RCPH10TLB302AAF 3
(1) Fuse block

(1) Take reading from pin 87 of Power Relay 2 connector to the Power Relay No. 2 fuse.
A. NOT OK – Determine the break between connector and fuse block. Return to Step 1 to confirm elimination
of fault.
B. OK – Replace Power Relay No. 2. If fault is recorded again contact Technical Services Group for assis-
tance.
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3048-Main Relay Failure - Short Circuit to Ground

Cause:

Solution:
rence.

3. Check Power Relay No. 2 fuse.
BD08E024-01 1
(1) Fuse block

A. NOT OK – Replace fuse. Return to Step 1 to confirm elimination of fault. If fuse blows again, go to Step 4
4. Check ground circuit.
BD08F241-01 2
(1) Power Relay #2
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(1) Disconnect Power Relay number 2 connector. Inspect connector and wiring for corrosion, abrasion or incor-
rect attachment.
(2) Measure the resistance from pin 86 (pin 1) to ground. The resistance should be less than 10 ohms. Wiggle
A. NOT OK – Determine the break between connector and ground. Return to Step 1 to confirm elimination
of fault.
5. (1) Turn the key switch ON. Engine OFF.
(2) Take a voltage reading at pin 85 of the Power Relay 2 connector to pin E of the Ignition Switch connector.
The voltage should be approximately 12 V .
of fault.
6. Check circuit to Fuse Block.
BD08E024-01 3
(1) Fuse block

(1) Take reading from pin 87 of Power Relay 2 connector to the Power Relay No. 2 fuse.
A. NOT OK – Determine the break between connector and fuse block. Return to Step 1 to confirm elimination
of fault.
B. OK – Replace Power Relay No. 2. If fault is recorded again contact Technical Services Group for assis-
tance.
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3051-Battery Voltage To Engine Controller - Voltage Too High

NOTICE: Check alternator output voltage, if above 18 V troubleshoot the charging system before proceeding.
Context:
Besides the 3 independent 5V voltage supplies, the ECU also provides a 12V supply for the sensors. This 12V supply
is monitored to ensure it remains within a certain range. This is done by using an analog input of the ECU. The lower
and upper thresholds depend on the battery voltage.
Cause:

4. Connector pins corroded or dirty. When removing connectors, inspect and clean contacts. Clean female pins
by inserting and removing a mating male pin.
Solution:
rence.
(1) Turn ignition switch to ON position.
(2) Clear all fault codes.

2. Measure the ECU unswitched input voltage
BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
(1) Turn ignition OFF. Disconnect Engine Control Unit (ECU) connector B from engine controller.
(2) Inspect pins on Engine Control Unit (ECU) connector and on engine controller. Clean connections.
(3) Turn the ignition ON.
(4) Measure the voltage from pins 2, 3, 8, and 9 on ECU connector B to ground (ECU connector B pins 5, 6, 10
and 11). The voltage should be between 11.5 V and . 13 V.
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A. NOT OK – Check fuse F-001 and wiring to ECU. Return to Step 1 to confirm elimination of fault.
3. Replace the engine control module.
(1) Remove and replace engine control module.
for assistance.
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3052-Battery Voltage To Engine Controller - Voltage Too Low

NOTICE: Check the battery output voltage, if below 10 V charge the battery before proceeding.
Cause:
1. Low battery voltage.

installing and removing mating male pin.
Solution:
1. Verify that fault code 3052 is still active, refer to 0000 - Retrieving fault codes, Backhoes.
rence.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
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3. Test alternator. Refer to Alternator - Malfunction (A.30.A).
A. NOT OK – Replace alternator. Return to Step 1 to confirm elimination of fault.
for assistance.
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3059-ECM afterrun was interrupted

NOTICE: Fault Code 3059 is stored in historical information. For multiple occurrences of this fault proceed with the
following tests.
Cause:

Solution:
rence.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
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3. Test alternator, refer to Alternator - Malfunction (A.30.A).
A. NOT OK – Replace alternator. Return to Step 1 to confirm elimination of fault.
for assistance.
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3060-Cylinder 1 - Unclassifiable Error In Injector

Context:
The engine control unit (ECU) has determined that an unclassifiable failure exists in the Cylinder #1 injector circuit.
A power stage component energizes the injection system transistors and simultaneously observes the current flow
in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current
flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so
it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder
specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match
the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect
is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of
a failure in the Cylinder #1 injector circuit that is unclassifiable over 8 camshaft revolutions. As a result of this error an
individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently
applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect
is still present). and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the injector output power driver
stage.
1. Faulty injection valve.

2. Faulty electrical wiring (damaged connector or conductor).
3. Faulty ECU, hardware or software.
Solution:

2. Visually check the electrical integrity of the injector circuit (Inspect connector housing body/latch, pins and wiring
harness for damage or corrosion).
B. If no damage is determined, the ECU or injector may have failed. Try reloading the ECU software. If the
fault reoccurs, try replacing the injector. If the fault reoccurs, replace the ECU.
has been resolved.
ation.
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3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery)

NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to be able to take accurate resis-
tance measurements. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements
required to be taken, could be as low as 0.4 ohms and any inaccuracies in the DMM could cause a technician to take
the wrong diagnostic path.
Context:
The Engine Control Unit (ECU) generated an error associated with the injector power driver stage. The power stage
component of the ECU energizes the injection system transistors and simultaneously observes the current flow (sense
resistors) in the high-side and low-side switching branches. If there is a deviation from the expected current flow, the
driver circuitry detects the specific error and reports it back to the ECU. The ECU will process the error message so
that it records information on performed injections, cylinder bank specific errors and cylinder specific errors. The error
message is then compared to applicable error patterns and if there is a match, a fault code is generated. If an error
message doesn't match any pattern, the error is treated as unclassifiable. This monitoring function is performed once
per camshaft revolution.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the
injector output power driver stage.
1. Faulty injection valve or shorted solenoid windings.

2. Faulty electrical wiring, short to high source or damaged wiring harness.
Solution:

Remove the following connector for electrical inspection:

1. ECU injector connector 3.
2. Valve cover connector VC1.
Inspect connector housing body/latch, pins and wiring harness for damage or corrosion.

2. Operation: Injector Resistance Test Cylinder #1/2 injector connector VC1 to Cylinder #1/2 injector.
Remove connector VC1 and perform an injector resistance test on the Cylinder #1/2 injector connector VC1.
Use the standard multi-meter test leads to access the connector pins. Make sure that the multi-meter's test
lead resistance is taken into account when resistance measurements are taken. Record the multi-meter's test
lead resistance by touching the leads together on the lowest Ohms scale and mentally recording the resistance
value. Subtract this value from the actual resistance measurement taken. See test table below.

1. Resistance Cylinder #1/2 injector con- Cylinder #1/2 injector con- Approx. 0.4 - 0.5 ohms
nector VC1. connector nectorVC1 connector pin:
pin: 3 4
A. If resistance test was not successful, proceed to step 4
B. If resistance test was successful, reconnect connector VC1. Proceed to step 3.

3. Operation: Injector Resistance Test ECU harness side of connector 3 to Cylinder #1 injector.
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Remove ECU connector 3 and perform an injector resistance test. Use the spade style test leads from the
from the Tier II (NEF) Diagnostic Repair Kit # 380040185 when probing the ECU harness side of connector 3.
Make sure that the multi-meter's test lead resistance is taken into account when resistance measurements are
taken. Record the multi-meter's test lead resistance by touching the leads together on the lowest Ohms scale
and mentally recording the resistance value. Subtract this value from the actual resistance measurement taken.
See test table below.

1. Resistance ECU harness connector 3, ECU harness connector 3, Approx. 0.4 - 0.5 ohms
pin: 4 pin: 13
A. If resistance test was not successful, repair wiring harness between ECU harness connector 3 and con-
nector VC1.
B. If resistance test was successful, proceed to step 5.

4. Operation: Standalone Injector Resistance Test.
Remove valve cover from the top of the head to allow access to the internal injector wiring harness. Remove the
Cylinder #1 injector connector (two flying leads with ring terminals). Perform a resistance test on the terminals
located on top of the solenoid portion of the injector. Make sure that the multi-meter's test lead resistance is taken
into consideration when resistance measurements are taken. Record the multi-meter's test lead resistance by
touching the leads together on the lowest Ohms scale and mentally recording the resistance value. Subtract
this value from the actual resistance measurement taken. See test table below.

1. Resistance Cylinder #1 injector, con- Cylinder #1 injector, con- Approx. 0.4 - 0.5 ohms
nector INJ1, terminal #1 nector INJ1, terminal #2
A. If resistance test was successful, repair the internal harness between the Cylinder #1 injector and the
connector INJ1.
B. If resistance test was not successful, replace the Cylinder #1 injector.

Vehicle Status (when removing ECU connector 1) Key Off Engine Off.
Vehicle Status (when performing test) Key On Engine Off.
Vehicle Status (when replacing ECU connector 1) Key Off Engine Off.
Remove connector 1 from the ECU and check for voltage and continuity at the appropriate pins defined in the
test table below. Use the 0.43 mm (0.017 in) diameter test probes from the Tier II (NEF) Diagnostic Repair Kit
# 380040185 when connecting the DMM to the ECU connector 1. Make sure the DMM's test lead resistance is
taken into account when making any continuity measurements.
Important Note: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage
could result when removing and replacing main ECU connectors if this is not followed.

1. Voltage ECU connector 1, pin 2, 3, Ground (engine block) Approx. 12.0 volts (DC)
8, 9, 40
2. Continuity ECU connector 1, pin 5, 6, Ground (engine block) Approx. 0.0 - 0.1 ohms
10, 11
A. If the voltages and ground paths are correct, proceed to step 6.
B. If the voltages and ground paths are not correct, refer to product schematic and determine root cause of
power and/or continuity problem(s).
6. Operation: Re-initialize the ECU.
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Using the EST service tool, re-initialize the ECU and load the appropriate data-set for this engine type. A call
will have to be made to CNH TSS to get an authorization code for the ECU initialization download. Check to
see if the fault code has cleared.
A. If the fault code did not clear, Replace the ECU.
B. If fault code cleared, continue with operation of machine.
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3062-Cylinder 1 - Electronic injector , Low signal

WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
NOTICE: When available use special tool 380040185 harness diagnostic/repair kit and 380040188 electro injector
test fixture.
NOTICE: Always turn ignition switch and master disconnect switch to the OFF position before removing or installing
connections to the engine controller.
Cause:

Solution:
rence.
(1) Turn ignition switch to RUN position to power instrument cluster.
(2) Clear all fault codes from the cluster.

2. Check circuits from engine controller to injector connector.
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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector B
(1) Disconnect Engine Control Module (ECU) connector A and inspect pins, wiring and connectors for damage,
(2) Disconnect injector connectors for cylinders 1 and 2. Inspect pins, wiring and connectors for damage, abra-
sion, corrosion or incorrect attachment.
BD08J015-01 2
(1) Rail pressure sensor

(2) Connector injectors (for cylinders 1 and 2)
(3) High pressure common rail
(3) Measure the resistance from ECU connector A, pin 4, to injector connector pin 1. The resistance should be
less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK— Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
B. OK— Go to Step 3.
3. Check circuits from rocker housing connector to injector 1.
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BD08J013-01 3
(1) Injector cylinder 1 (4) Injector cylinder 4

(2) Injector cylinder 2 (5) Rocker housing connector for cylinders 3 and 4
(1) Remove engine valve cover.
NOTE: During installation of valve cover, tighten mounting nuts to a torque of 20 - 30 Nm (15 - 22 lb ft).
(2) Disconnect leads from number 1 injector.
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(3) Check for open circuit from injector 1 leads to pins 1 and 2 of connector in rocker housing, a reading of
continuity should be obtained.
(4) Check for short circuit between pins 1 and 2 of connector in rocker housing, an open circuit should be ob-
tained.
(5) Check for short circuit between pins 1 and 2 of connector in rocker housing and ground, an open circuit
should be obtained.
A. NOT OK— Determine the break or short between connectors and repair. Return to Step 1 to confirm
4. Check injector.
(2) Take an Ohm reading between terminals on number 1 injector, a reading of 0.5 - 1.0 Ω at 20 °C (68.0 °F)
should be obtained.
A. NOT OK— Replace injector as needed. Return to Step 1 to confirm elimination of fault.
Prior to changing the engine control module contact Technical Services Group for further assistance.
(2) Write symptom on failed engine control module.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again contact Technical Services Group
for assistance.
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3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground)

NOTE: This diagnostic procedure requires a good quality multi-meter to be able to take accurate resistance measure-
ments. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements required to
be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 Ω) and any inaccuracies
in the DMM could cause a technician to take the wrong diagnostic path.
NOTE: Make sure that the multi-meter's test lead resistance is taken into account when resistance measurements
are taken. Record the multi-meter's test lead resistance by touching the leads together on the lowest Ohms scale and
mentally recording the resistance value. Subtract this value from the actual resistance measurement taken.
Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 1. A
power stage component energizes the unit injection system transistors and simultaneously observes the current flow
flow the component detects specific errors and reports them to the ECU . This error message is then rearranged so
is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result
of a short circuit of the high side to the low side or ground over 3 camshaft revolutions. As a result of this error an
individual cylinder or bank is shut off, based on parameters established in the ECU . Certain parameters, as currently
Cause:
1. Faulty cylinder 1 solenoid windings.

2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness).
3. Faulty ECU, ECU hardware or software.
Solution:

2. Carefully disconnect the engine cylinder harness from the ECU at ECU cylinder harness connector 3. Use a
multi-meter to check the resistance, on the cylinder harness side of connector 3, between pins 4 and 13. There
should be 0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU cylinder connector 3 disconnected and continue with step 3
B. If the resistance was lower than range minimum, continue with step 6.
3. Use a multi-meter to check for continuity, on the ECU cylinder harness side of connector 3, from pin 4 to chassis
ground and pin 13 to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, continue with step 4
B. If there was no continuity on either pin to chassis ground, the ECU may have failed. Try reloading the ECU
software and if the fault reoccurs, replace the ECU .
4. Disconnect the engine cylinder harness from the injector (valve) cover at connector VC1. Use a multi-meter to
check for continuity, on the injector (valve) cover side of connector VC1 from pin A to chassis ground and pin B
to chassis ground. There should not be continuity.
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A. If there was continuity on either or both pins to chassis ground, leave connector VC1 disconnected and
continue with step 5
B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine
cylinder harness between Valve cover connector VC1 and ECU to cylinder harness connector 3. Locate
and repair the grounded conductor.
5. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 1 injector at connector INJ1
terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the injector, from terminal 1 to
chassis ground. There should not be continuity.
A. If there is continuity, Cylinder 1 injector's solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in Cylinder 1 injector circuit, between connector
INJ1 and connector VC1. Locate and repair the grounded conductor.
6. Disconnect the engine injector harness from the injector cover at Cylinder 1 /2 valve cover connector VC1 and
use a multi-meter to check the resistance on the injector cover side of Cylinder 1 /2 valve cover connector VC1
between pins A and B. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the engine injector harness between
the Cylinder 1 / 2 valve cover connector VC1 and ECU cylinder harness connector 3, locate and repair the
short circuit.
B. If the resistance was lower than range minimum, continue with step7
7. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 1 injector at connector
INJ1 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder 1 injector, from
terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the injector harness, between Cylinder
1 injector connector INJ1 and connector VC1. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder 1 injector solenoid coil has failed. Replace
the injector.
has been resolved.
ation.
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Context:
Cause:
stage.

Solution:

has been resolved.
ation.
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Context:
Cause:

Solution:




nector VC2 connector pin: nector VC2 connector pin:
3 4

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pin: 12 pin: 5
nector VC2.


nector INJ3 terminal #1 nector INJ3 terminal #2
connector INJ3.


8, 9, 40
10, 11
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WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
test fixture.
Cause:
1. Engine misfires, runs erratic.

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector B
BD08J014-01 2

(3) Check for open circuit from ECU connector A, pin 16 to injector connector pin 1. The resistance should be
(4) Check for open circuit from ECU connector A, pin 1 to injector connector pin 2. The resistance should be
(5) Measure the resistance between pins 1 and 16 on ECU connector A. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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BD08J013-01 3

(3) Check for open circuit from injector 3 leads to pins 1 and 2 of connector in rocker housing, a reading of
continuity should be obtained.
(4) Check for short circuit between pins 1 and 2 of connector in rocker housing, an open circuit should be ob-
tained.
(5) Check for short circuit between pins 1 and 2 of connector in rocker housing and ground, an open circuit
should be obtained.
4. Check injector.
(2) Take an Ohm reading between terminals on number 3 injector, a reading of 0.5 - 1.0 Ω at 20 °C (68.0 °F)
should be obtained.
for assistance.
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required to be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 Ω) and any
inaccuracies in the DMM could cause a technician to take the wrong diagnostic path.
Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 3.
the failure corresponding to the matched pattern is output. If an error message does not match any pattern the defect
is still present) and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:

Solution:
1. Carefully disconnect the engine injector harness from the ECU at connector 3. Use a multi-meter to check the
resistance, on the ECU engine injector harness side of connector 3, between pins 12 and 5. There should be
0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU harness connector 3 disconnected, and continue with step
2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 12
to chassis ground and pin 5 to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, continue with step 3.
software and if the fault reoccurs, replace the ECU.
3. Disconnect the engine injector harness from the injector (valve) cover at connector VC2. Use a multi-meter to
check for continuity, on the injector (valve) cover side of connector VC2 from pin 3 to chassis ground and pin 4
continue with step 4.
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injector harness between connector VC2 and ECU harness connector 3. Locate and repair the grounded
conductor.
4. Remove the injector (valve) cover and disconnect the injector harness from Cylinder #3 injector at connector
INJ3 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder #3 injector,
from terminal 1 to chassis ground. There should not be continuity.
A. If there is continuity, the Cylinder #3 injector solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in the Cylinder #3 injector circuit, between
connector INJ3 and connector VC2. Locate and repair the grounded conductor.
5. Disconnect the engine injector harness from the injector cover at connector VC2 and use a multi-meter to check
the resistance on the injector cover side of connector VC2 between pins 3 and 4. There should be 0.4 - 0.5 Ω.
connector VC2 and ECU harness connector 3, locate and repair the short circuit.
6. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder #3 injector at connector
from terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the injector harness, between con-
nector INJ3 and connector VC2. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder #3 injector solenoid coil has failed. Replace
the injector.
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Context:
Cause:
stage.

Solution:

has been resolved.
ation.
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Context:
Cause:

Solution:




1 2

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pin: 11 pin: 6
nector VC1.


connector INJ2 .


8, 9, 40
10, 11
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WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
test fixture.
Cause:

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector B
BD08J015-01 2
(1) Rail pressure sensor

(3) Measure the resistance from ECU connector A, pin 2 to injector connector pin 2. The resistance should be
(4) Measure the resistance from ECU connector A, pin 15 to injector connector pin 4. The resistance should be
(5) Measure the resistance between ECU connector A pins 15 and 2. The resistance should be greater than
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BD08J013-01 3

(3) Measure the resistance from injector 2 leads to pins 3 and 4 of connector in rocker housing. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance between pins 3 and 4 of connector in rocker housing. The resistance should be
(5) Measure the resistance between pins 3 and 4 of connector in rocker housing and ground (engine block).
intermittent condition.
4. Check injector.
(2) Measure the resistance between terminals on number 2 injector. The resistance should be between 0.5 -
1.0 Ω at 20 °C (68.0 °F).
for assistance.
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Context:
Cause:

Solution:
0.4 - 0.5 Ω.
2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 11
to chassis ground and pin 6 to chassis ground. There should not be continuity.
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injector harness between connector VC1 and ECU harness connector 3. Locate and repair the grounded
conductor.
connector VC1 and connector VC1. Locate and repair the grounded conductor.
the injector.
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Context:
Cause:
stage.

Solution:

has been resolved.
ation.
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Context:
Cause:

Solution:




1 2

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pin: 3 pin: 14
nector VC2.


connector INJ4.


8, 9, 40
10, 11
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WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
test fixture.
Cause:

Solution:
rence.

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BD07F080-01 1
(1) Connector C
(2) Connector A
(3) Connector B
BD08J014-01 2

(3) Measure the resistance from ECU connector A, pin 12, to injector connector pin 3. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance between pins 5 and 12 on ECU connector A. The resistance should be greater than
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BD08J013-01 3

(3) Measure the resistance from injector 4 leads to pins 3 and 4 of connector in rocker housing. The resistance
(4) Measure the resistance between pins 3 and 4 of connector in rocker housing. The resistance should be
(5) Measure the resistance between pins 3 and 4 of connector in rocker housing and ground (engine block).
4. Check injector.
(2) Measure the resistance between terminals on number 4 injector, a reading of 0.5 - 1.0 Ω at 20 °C (68.0 °F) .
for assistance.
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Context:
Cause:

Solution:
0.4 - 0.5 Ω.
2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 3 to
chassis ground and pin 14 to chassis ground. There should not be continuity.
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injector harness between connector VC2 and ECU harness connector 3.Locate and repair the grounded
conductor.
connector INJ4 and connector VC2. Locate and repair the grounded conductor.
the injector.
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3088-Crankshaft sensor lost synchronization

Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Increment speed (Crankshaft speed)
sensor. If the engine has a defective Crankshaft speed sensor it can run off the Segment speed (Camshaft speed)
sensor. This is referred to as BACKUP mode. Diagnostics of the SIG failure is only active if voltage is present at
terminal 15 (Ignition ON) and no errors are active for the sensor supply voltage.
Cause:
The ECU has determined that there is no signal from the Crankshaft speed sensor. The engine is now operating in
BACKUP mode.
1. Faulty Crankshaft speed sensor.

2. Faulty electrical wiring and/or connections.
3. Faulty ECU, or ECU supply voltages or grounds.
Solution:

2. Remove Crankshaft speed sensor connector DG6 Incr and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Crankshaft speed sensor.
good and sound electrical connection. Replace Crankshaft speed sensor if damaged.
B. If no damage is determined, leave connector disconnected and proceed to step 3.

3. Operation: Resistance Check for Faulty CKP, Engine flywheel RPM, sensor.
Vehicle Status: Key Off Engine Off
Connect the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit
380040185 to access the sensor side of the terminals. See test table below.
Test Type From To Results (Min) Results (Max)

1. Resistance Crankshaft speed Crankshaft speed 750 ohms 1000 ohms
sensor connector sensor connector
DG6 Incr, (Pin 1) DG6 Incr, (Pin 2)
A. If the resistance test does not fall in the specified range, replace Crankshaft speed sensor.
B. If the resistance test does fall in the specified range, leave connector disconnected and proceed to step 4.
4. Operation: Check Output of Crankshaft speed sensor.
Vehicle Status: Key Off Engine Off (test setup)
Make the following electrical tests in the table below. There will be (2) types of tests (in-line and single ended)
that will need to be performed which use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF)
Diagnostic Repair Kit 380040185. Reference the descriptions below to make the proper electrical connections
for each test type.
Single Ended Test Lead Connection Test (Standalone Crankshaft speed sensor Test)
Remove Crankshaft speed sensor connector and connect the above mentioned special test lead to the Crank-
shaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the test leads. Use the test table below to determine the measurement results.
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In-Line Test Lead Connection Test:

Remove Crankshaft speed sensor connector and connect the above mentioned special test lead in-line with the
sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection
process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips
from the test leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Camshaft speed sensor during the single ended test, if it isn't already (based
on the fault code type). The engine can also be very hard to start when running exclusively off the Camshaft
speed sensor. The ECU needs to see a few revolutions of the camshaft to be able to use this information to
start the engine.
The Crankshaft speed sensor and the Camshaft speed sensor are exactly the same. These sensors may be
swapped in this diagnostic procedure to determine the functionality of the Crankshaft speed sensor. A new set
of error codes may be generated by the ECU if the sensors are swapped.

1. Voltage (AC) - Single Crankshaft speed sensor Crankshaft speed sensor Approx. 16 - 18 volts (AC)
ended connection at low connector DG6 Incr, (Pin connector DG6 Incr, (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Incr, (Pin connector DG6 Incr, (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
3. Voltage (AC) - In-line Crankshaft speed sensor Crankshaft speed sensor Approx. 10 - 12 volts (AC)
connection at low RPM ( connector DG6 Incr, (Pin connector DG6 Incr, (Pin
1000 - 1100 RPM) 1) 2)
connection at high RPM ( connector DG6 Incr, (Pin connector DG6 Incr, (Pin
2000 - 2200 RPM) 1) 2)
A. If the voltage test was successful, proceed to step 6.
B. If the voltage test was not successful for any of the single ended connections, replace the sensor.
C. If the voltages encountered during testing are low and the sensor was replaced on a prior diagnostic pro-
cedure of this type, ensure the Crankshaft speed sensor is installed properly.
D. If the voltage test was successful for the single ended connections and not for any of the in-line connec-
tions, leave the connector disconnected and proceed to step 5.
Perform continuity tests between connector DG6 Incr and connector 2 on ECU engine harness. Flex harness
the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor connector DG6
Incr. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter
to connector 2. Make sure the multi-meter's test lead resistance is taken into account when taking continuity

1. Continuity Crankshaft speed sensor ECU engine harness con- Approx. 0 - 0.10 ohms
connector DG6 Incr, (Pin: nector 2, (Pin: 23)
1)
2)
3. Short Circuit ECU engine harness con- ECU engine harness con- Open Circuit
nector 2, (Pin: 23) nector 2, (Pin: 19)
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Using the product schematics for a reference, remove connector 1 from the ECU A-01 and check for voltage and
continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in) diameter test probes
from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the multi-meter to connector 1. Make
sure the multi-meter's test lead resistance is taken into account when making any continuity measurements.

1. Voltage ECU vehicle harness con- Ground (engine block) Approx. 12 volts (DC)
nector 1, (Pin: 2, 3, 8, 9,
40)
2. Continuity ECU vehicle harness con- Ground (engine block) Approx. 0 - 0.10 ohms
nector 1, (Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Crankshaft speed sensor was not replaced on a prior
diagnostic procedure of this type, replace the sensor.
B. If the voltages and ground paths are correct and the Crankshaft speed sensor was replaced on a prior
diagnostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-ini-
tialize the ECU as if it was blank (new) and load the appropriate data-set.
type, replace the ECU .
D. If the voltages and ground paths are not correct, refer to product schematics and determine root cause of
has been resolved.
ation.
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3089-Crankshaft Sensor - Invalid Signal

Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Crankshaft speed sensor. If the engine
has a defective Crankshaft speed sensor it can run off the Camshaft speed sensor. This is referred to as BACKUP
mode. Diagnostics of the FMI=3 failures is only active if terminal 40 is on (KEY ON) and no errors are reported in the
sensor supply voltage. For the FMI=4 failures, additional conditions for active diagnostics are included, such as the
engine must be in startup mode and the engine speed must be above 450 RPM.
Cause:
The ECU has determined that there are errors in the signal from the Crankshaft speed sensor.

3. Faulty ECU, supply voltages or ground paths.
Solution:
A. If fault code is present and active, continue with step 2.

2. Inspect the Crankshaft speed sensor. Remove the Crankshaft speed sensor connector DG6 Incr, and inspect
housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect the connector portion of the
Crankshaft speed sensor.

3. Check internal resistance of Crankshaft speed sensor. Remove Crankshaft speed sensor connector, DG6 Incr,
and connect the test lead labeled "Cam/Crankshaft Sensor Interface Harness" from the Tier II (NEF) Diagnostic
Repair Kit 380040185 to the Crankshaft speed sensor to access the sensor terminals. Use a multi-meter to
measure the resistance between pins 1 (yellow) and 2 (red) of the Crankshaft speed sensor. There should be
between 825 - 975 Ω at 20 °C (68 °F).
A. If the resistance is not within the specified range, replace the Crankshaft speed sensor.
B. If the resistance is within the specified range, proceed to step 4.

4. Check the Crankshaft speed sensor output. With the "Cam/Crankshaft Sensor Interface Harness" from the Tier
II (NEF) Diagnostic Repair Kit 380040185 connected to the Crankshaft speed sensor, use a multi-meter to check
for voltage (AC), while starting the engine, between pins 1 (yellow) and 2 (red) of the Crankshaft speed sensor
connector, DG6 Incr. here should be a minimum of .50 V (AC) while cranking and a higher reading once the
engine starts.
A. If the voltage is less than .50 V (AC), replace the sensor.
B. If the voltage is above .50 V (AC), proceed to step 5.

5. Check for faulty wiring between the Crankshaft speed sensor and the ECU. Measure resistance between the
Crankshaft speed sensor, DG6 Incr, pin 2, and the ECU engine connector 2, pin 23.
A. If there is continuity, go to step 6.
B. If there is no continuity, find and repair the damaged wiring between connector DG6 Incr, pin 2 and 2 , pin
23.
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6. Check voltage and ground supply to ECU. Disconnect ECU vehicle connector 1 and use a multi-meter to verify
the ECU has sufficient supply voltage and ground paths. Use the table below as a reference.

1. Voltage ECU vehicle connector 1, Ground (engine block) Approx. 12 volts (DC)
(Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle connector 1, Ground (engine block) Approx. 0 - 0.10 ohms
(Pin: 5, 6, 10, 11)
A. If the voltage supply and ground paths are sufficient, continue with step 7.
B. If the voltage supply and ground paths are not present, use the vehicle schematics to find and repair the
cause.
7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals
breaks or shorts in the wiring concerned. Operate the machine while monitoring the display.
has been resolved.
ation.
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3090-Phase defect of camshaft speed sensor signal detected

Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Segment speed sensor (Camshaft
speed sensor). If the engine has a defective Camshaft speed sensor it can run off the Increment speed sensor (Crank-
shaft speed sensor). Diagnostics is active if voltage is present at terminal 15 (Ignition On),, the current engine speed
is above 50 RPM, no error in the Crankshaft speed sensor is present and the sensor supply voltage ( 5 volts DC) is
not defective.
Cause:
The ECU has determined that there is no signal from the Camshaft speed sensor.
1. Faulty Camshaft speed sensor.

2. Camshaft speed sensor is not mechanically installed correctly.
Solution:

2. Remove Camshaft speed sensor connector DG6 Segm and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Camshaft speed sensor.
good and sound electrical connection. Replace Camshaft speed sensor if damaged.

3. Operation: Resistance Check for Faulty Camshaft speed sensor.
380040185 to access the sensor terminals. See test table below.

1. Resistance Camshaft speed Camshaft speed 750 ohms 1000 ohms
DG6 Segm (Pin 1) DG6 Segm (Pin 2)
A. If the resistance test does not fall in the specified range, replace Camshaft speed sensor.
4. Operation: Check Output of Camshaft speed sensor.
for each test type.
Single Ended Test Lead Connection Test (Standalone Camshaft speed sensor Test).
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Remove Camshaft speed sensor connector DG6 Segm and connect the above mentioned special test lead to
the Camshaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the
breakout alligator clips from the test leads. Use the test table below to determine the measurement results.

Remove Camshaft speed sensor connector DG6 Segm and connect the special test lead in-line with the sensor
and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process.
Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips from the
test leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Crankshaft speed sensor during this test. The Camshaft speed sensor and the
Crankshaft speed sensor are exactly the same. These sensors may be swapped in this diagnostic procedure
to determine the functionality of the Camshaft speed sensor. A new set of error codes may be generated by the
ECU if sensors are swapped.

1. Voltage (AC) - Single Camshaft speed, sensor Camshaft speed, sensor Approx. 2 - 3 volts (AC)
ended connection at low connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
3. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 1.5 - 2.8 volts
connection at low RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin (AC)
1000 - 1100 RPM) 1) 2)
4. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 3 - 4.5 volts (AC)
connection at high RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin
2000 - 2200 RPM) 1) 2)
C. If the voltages encountered during testing are low and the sensor was replaced on a prior diagnostic of
this type, ensure the Camshaft speed sensor was properly installed.
tions, proceed to step 5.
Perform continuity tests between connector DG6 Segm and connector 2 on engine wiring harness. Flex harness
Segm. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter

1. Continuity Camshaft speed sensor ECU engine harness con- Approx. 0 - 0.10 ohms
connector DG6 Segm (Pin: nector 2 (Pin: 10)
1)
2)
nector 2 (Pin: 10) nector 2 (Pin: 9)
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Vehicle Status (when removing connector 1). Key Off Engine Off.
Vehicle Status (when performing test). Key On Engine Off.
Vehicle Status (when replacing connector 1). Key Off Engine Off.
Using the product schematics for a reference, remove connector 1 from the ECU and check for voltage and

1. Voltage ECU vehicle harness 1, Ground (engine block) Approx. 12 volts (DC)
(Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle harness 1, Ground (engine block) Approx. 0 - 0.10 ohms
(Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Camshaft speed sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Camshaft speed sensor was replaced on a prior diag-
nostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-initialize
the ECU as if it was blank (new) and load the appropriate data-set.
has been resolved.
ation.
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3091-Camshaft sensor phase synchronization failure

Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Segment speed sensor (Camshaft
speed sensor). If the engine has a defective Camshaft speed sensor it can run off the Increment speed sensor (Crank-
shaft speed sensor). Diagnostics is active if voltage is present at terminal 15 (Ignition On),, the current engine speed
is above 50 RPM, no error in the Crankshaft speed sensor is present and the sensor supply voltage ( 5 volts DC) is
not defective.
Cause:
The ECU has determined that there is no signal from the Camshaft speed sensor.
1. Faulty Camshaft speed sensor.

2. Camshaft speed sensor is not mechanically installed correctly.
Solution:

2. Remove Camshaft speed sensor connector DG6 Segm and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Camshaft speed sensor.
good and sound electrical connection. Replace Camshaft speed sensor if damaged.

3. Operation: Resistance Check for Faulty Camshaft speed sensor.

DG6 Segm (Pin 1) DG6 Segm (Pin 2)
4. Operation: Check Output of Camshaft speed sensor.
for each test type.
Single Ended Test Lead Connection Test (Standalone Camshaft speed sensor Test).
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Remove Camshaft speed sensor connector DG6 Segm and connect the above mentioned special test lead to
the Camshaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the

Remove Camshaft speed sensor connector DG6 Segm and connect the special test lead in-line with the sensor
and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process.
Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips from the
test leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Crankshaft speed sensor during this test. The Camshaft speed sensor and the
Crankshaft speed sensor are exactly the same. These sensors may be swapped in this diagnostic procedure
to determine the functionality of the Camshaft speed sensor. A new set of error codes may be generated by the
ECU if sensors are swapped.

ended connection at low connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
3. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 1.5 - 2.8 volts
connection at low RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin (AC)
1000 - 1100 RPM) 1) 2)
4. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 3 - 4.5 volts (AC)
connection at high RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin
2000 - 2200 RPM) 1) 2)
this type, ensure the Camshaft speed sensor was properly installed.
tions, proceed to step 5.
Perform continuity tests between connector DG6 Segm and connector 2 on engine wiring harness. Flex harness
Segm. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter

1)
2)
nector 2 (Pin: 10) nector 2 (Pin: 9)
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Vehicle Status (when removing connector 1). Key Off Engine Off.
Vehicle Status (when performing test). Key On Engine Off.
Vehicle Status (when replacing connector 1). Key Off Engine Off.

1. Voltage ECU vehicle harness 1, Ground (engine block) Approx. 12 volts (DC)
(Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle harness 1, Ground (engine block) Approx. 0 - 0.10 ohms
(Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Camshaft speed sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Camshaft speed sensor was replaced on a prior diag-
nostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-initialize
the ECU as if it was blank (new) and load the appropriate data-set.
has been resolved.
ation.
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3093-Offset Between Camshaft And Crankshaft - Outside

Boundaries
Context:
The Engine Control Unit (ECU) has reported an error with the phase relationship between the Increment speed sensor
(Crankshaft speed sensor) and the Segment speed sensor (Camshaft speed sensor). The engine will alternatively
use a redundant angular system which is based on the Crankshaft speed sensor. Diagnostics is active under these
conditions: 1) terminal 40 (Key On) is active, 2) current engine speed is above 50 RPM, 3) no error is reported for the
Crankshaft speed sensor and 4) sensor supply voltage ( 5 volts DC) is not defective .
Cause:
The ECU has determined that there is a phase relationship error between the Crankshaft speed sensor and the
Camshaft speed sensor.
1. Faulty Camshaft speed sensor or Crankshaft speed sensor.

2. Camshaft speed sensor or Crankshaft speed sensor are not mechanically installed correctly.
4. Faulty ECU, or ECU supply voltages or ground.
Solution:
2. Operation: Electrical and Sensor Mounting Inspection.
Remove Camshaft speed sensor connector DG6 Incr and Crankshaft speed sensor connector DG6 Incr and
inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect the connector portion
and mechanical mounting (seating) of the Camshaft speed sensor and Crankshaft speed sensor.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure
a good and sound electrical connection. Replace Camshaft speed sensor or Crankshaft speed sensor if
damaged.
B. If any of the sensors are not mounted correctly (loose, not seated properly, etc.), remount the sensors
taking special care to make sure it is properly seated (flush with sealing surface) and fastened.
C. If no damage is determined, proceed to step 3.

3. Operation: Resistance Test for Camshaft speed sensor.
Remove Camshaft speed sensor connector and connect the test lead labeled "Coolant/Fuel Temp Sensor" from
the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor terminals. See test table below.

DG6 Incr (Pin 1) DG6 Incr (Pin 2)
B. If the resistance test does fall in the specified range, proceed to step 4.
4. Operation: Resistance Test for Crankshaft speed sensor.
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Remove Crankshaft speed sensor connector DG6 Incr and connect the test lead labeled "Coolant/Fuel Temp
Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to access the sensor terminals. See test table
below.

DG6 Incr (Pin 1) DG6 Incr (Pin 2)
A. If the resistance test does not fall in the specified range, replace Crankshaft speed sensor.
B. If the resistance test does fall in the specified range, proceed to step 5.
5. Operation: Check Crankshaft speed sensor Output Voltage and Harness Wiring.
Perform both (2) electrical tests defined below:
1) AC output voltage test for Crankshaft speed sensor

NOTE: When performing this electrical test, use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier
II (NEF) Diagnostic Repair Kit 380040185.
Remove Crankshaft speed sensor connector DG6 Incr and connect the Coolant/Fuel Temp Sensor test lead
in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during
the connection process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the Coolant/Fuel Temp Sensor test lead. Use the table below to determine test parameters
and the measurement results.

connection at low RPM ( connector DG6 Incr (Pin 1) connector DG6 Incr (Pin 2)
1000 - 1100 RPM)
connection at high RPM ( connector DG6 Incr (Pin 1) connector DG6 Incr (Pin 2)
2000 - 2200 RPM)
2) Harness wiring continuity/shorts electrical test (Crankshaft speed sensor).

Remove and perform continuity tests between Crankshaft speed sensor connector DG6 Incr and ECU engine
harness connector 2 on engine wiring harness. Flex harness during test to check for any intermittent operation.
Use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185
to be able to access the pins on the Crankshaft speed sensor connector DG6 Incr. Also, use the 0.4 mm (0.017
in) diameter test probes from the repair kit when connecting the multi-meter to connector 2. Make sure the multi
meter's test lead resistance is taken into account when taking continuity measurements. See test table below.

1)
2)
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3. Shorts ECU engine harness con- ECU engine harness con- Open Circuit
A. If both electrical tests are successful, proceed to step 7.
B. If harness wiring continuity/shorts test was not successful, find and repair the damaged section(s) of the
wiring harness.
C. If the voltage test was not successful and the continuity/shorts test was successful, proceed to step 6.
6. Operation: Crankshaft speed sensor alignment.
Check proper mechanical alignment and tooth spacing of the Crankshaft speed sensor. The spacing between
the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly
(flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared.
A. If this fault code is still present and has not cleared, Replace Crankshaft speed sensor, being careful to
ensure the sensor's mechanical alignment and tooth spacing is correct and the sensor is seated properly.
B. If this fault code is still present and has not cleared, proceed to step 13.
7. Operation: Check Camshaft speed sensor Output Voltage and Harness Wiring.
Perform both (2) electrical tests defined below:
1) AC output voltage test for Camshaft speed sensor:

NOTE: When performing this electrical test, use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier
II (NEF) Diagnostic Repair Kit 380040185.
Remove Camshaft speed sensor connector DG6 Segm and connect the Coolant/Fuel Temp Sensor test lead
in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during
the connection process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the Coolant/Fuel Temp Sensor test lead. Use the table below to determine test parameters
and the measurement results.

1. Voltage (AC) - In-line Camshaft speed sensor Camshaft speed sensor Approx. - 1.5 - 2.8 volts
connection at low RPM ( connector DG6 Segm, connector DG6 Segm, (AC)
1000 - 1100 RPM) (Pin 1) (Pin 2)
2. Voltage (AC) - In-line Camshaft speed sensor Camshaft speed sensor Approx. - 3 - 4.5 volts
connection at high RPM ( connector DG6 Segm, connector DG6 Segm, (AC)
2000 - 2200 RPM) (Pin 1) (Pin 2)
2) Harness wiring continuity/shorts electrical test (Camshaft speed sensor).

Remove and perform continuity tests between Camshaft speed sensor connector DG6 Segm and ECU engine
harness connector 2. Flex harness during test to check for any intermittent operation. Use the test lead labeled
"Coolant/Fuel Temp Sensor" from the Tier II (NEF) Diagnostic Repair Kit # 380040185 to be able to access the
pins on the sensor connector DG6 Segm.. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair
kit when connecting the multi-meter to the ECU engine harness connector 2. Make sure the multi-meter's test
lead resistance is taken into account when taking continuity measurements. See test table below.
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connector DG6 Segm (Pin: nector 2, (Pin: 10)
1)
connector DG6 Segm (Pin: nector 2, (Pin: 9)
2)
nector 2 (Pin: 10) nector 2, (Pin: 9)
A. If both electrical tests are successful, proceed to step 10.
B. If harness wiring continuity/shorts test was not unsuccessful, find and repair the damaged section(s) of
the wiring harness.
C. If the voltage test was not successful and the continuity/shorts test was successful, proceed to step 8.
8. Operation: Camshaft Position (CMP), Engine camshaft RPM B-07, sensor Alignment.
Check proper mechanical alignment and tooth spacing of the Camshaft speed sensor. The spacing between
the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly
(flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared.
A. If this fault code is still present and has not cleared, proceed to step 9.
9. Operation: Replace Camshaft speed sensor.
Replace the Camshaft speed sensor. Make sure that the proper mechanical alignment and tooth spacing is
correct. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure
that the sensor is seated properly (flush with mounting flange). After the sensor alignment is complete, check
to see if this fault code has cleared.
10. Operation: Replace Crankshaft speed sensor.
Replace the Crankshaft speed sensor. Make sure that the proper mechanical alignment and tooth spacing is
11. Operation: Swap the New Crankshaft speed sensor with the Old Camshaft speed sensor.
Replace the new Crankshaft speed sensor with the old Camshaft speed sensor. Make sure that the proper
mechanical alignment and tooth spacing is correct for both sensors. The spacing between the trigger teeth
and the sensor is critical for proper voltage output. Make sure that the sensors are seated properly (flush with
mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared.
A. If this fault code still exists, proceed to step 12.

12. Operation: Replace Old Camshaft speed sensor.
Replace the old Camshaft speed sensor. When this is complete, both Crankshaft speed sensor and Camshaft
speed sensor will have been replaced. Make sure that the proper mechanical alignment and tooth spacing is
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A. If this fault code still exists, proceed to step 13.

Vehicle Status (when removing the ECU vehicle harness connector 1): Key Off Engine Off.
Vehicle Status (when replacing ECU vehicle harness connector 1): Key Off Engine Off.
Using the product schematics for a reference, remove the ECU vehicle connector 1 from the ECU and check
for voltage and continuity at the appropriate pins defined in the test table below. Use the 0.4 mm (0.017 in)
diameter test probes from the Tier II (NEF) Diagnostic Repair Kit 380040185 when connecting the multi-meter
to the ECU vehicle connector 1. Make sure the multi-meter's test lead resistance is taken into account when
making any continuity measurements.

nector 1, (Pin: 2, 3, 8, 9,
40)
nector 1, (Pin: 5, 6, 10, 11)
B. If the voltages and ground paths are not correct, refer to schematics and determine root cause of power
and/or continuity problem(s).
14. Operation: Re-Initialize the ECU .
A. If the fault code did not clear, replace the ECU.

has been resolved.
ation.
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3095-Operating With Camshaft Sensor Only - Backup Mode

Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Increment speed sensor (Crankshaft
speed sensor). In the case of a defective Crankshaft speed, sensor the engine can also be run alone with the Segment
speed sensor (Camshaft speed sensor) in a BACKUP mode. This operation, however, imposes a lot of restrictions
on the system since the precise position of the crankshaft can only be roughly estimated by the camshaft information.
In case the engine enters this BACKUP operation due to a crankshaft sensor error the fault path at hand is set.
Cause:
The ECU has determined that there are errors in the signal from the Crankshaft speed sensor and is currently oper-
ating in BACKUP mode. The engine is operating with input from only the Camshaft speed sensor.

Solution:

2. Remove Crankshaft speed sensor connector DG6 Incr and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Crankshaft speed sensor.

3. Operation: Resistance Check for Faulty Crankshaft speed sensor.

DG6 Incr, (Pin 1) DG6 Incr, (Pin 2)
A. If the resistance test does not fall in the specified range, replace the Crankshaft speed sensor .
4. Operation: Check Output of Crankshaft speed sensor.
for each test type.
Single Ended Test Lead Connection Test (Standalone Crankshaft speed sensor test):
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Remove Crankshaft speed sensor connector DG6 Incr and connect the above mentioned special test lead to
the Crankshaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the

Remove Crankshaft speed sensor connector DG6 Incr and connect the above mentioned special test lead in-line
with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the
connection process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the test leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Camshaft speed sensor during this test. The engine can also be very hard
to start when the Crankshaft speed sensor is disconnected. The ECU needs to see a few revolutions of the
camshaft to be able to use this information to start the engine. Another starting technique would be to have the
Crankshaft speed sensor connected in-line with the engine wiring harness with the special test lead (Tier II NEF
Diagnostic Repair Kit), start the engine and then disconnect the test lead from the wiring harness.
The Crankshaft speed sensor and the Camshaft speed sensor are exactly the same. These sensors may be
swapped in this diagnostic procedure to determine the functionality of the Crankshaft speed sensor. A new set
of error codes may be generated by the ECU if sensors are swapped.

ended connection at low connector DG6 Incr, (Pin connector DG6 Incr, (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Incr, (Pin connector DG6 Incr, (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
connection at low RPM ( connector DG6 Incr, (Pin connector DG6 Incr, (Pin
1000 - 1100 RPM) 1) 2)
connection at high RPM ( connector DG6 Incr, (Pin connector DG6 Incr, (Pin
2000 - 2200 RPM) 1) 2)
this type, ensure the sensor is installed properly.
tions, leave the connector disconnected and proceed to step 5.
Perform continuity tests between connector DG6 Incr and connector 2 on engine wiring harness. Flex harness
Incr. Also, use the 0.4 mm (0.017 in) diameter test probes from the repair kit when connecting the multi-meter
to the connector 2. Make sure the multi-meter's test lead resistance is taken into account when taking continuity
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1)
2)
3. Shorts ECU engine harness con- ECU engine harness con- Open Circuit

nector 1, (Pin: 2, 3, 8, 9,
40)
nector 1, (Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Crankshaft speed sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Crankshaft speed sensor was replaced on a prior
diagnostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-ini-
tialize the ECU as if it was blank (new) and load the appropriate data-set.
C. If the voltages and ground paths are correct and the ECU was re initialized on a prior diagnostic of this
has been resolved.
ation.
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3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum

Context:
The engine control unit (ECU) has sensed that the Fuel Pressure sensor signal is too low. The test frequency of the
sensor is every 10 ms and if the signal is below 0.25 V for over 200 ms, the error is set. Once set the ECU will,
instead of using the peak rail pressure value of the last 10 ms and the current rail pressure, output a substitute value
from a curve (MAP) in the ECU depending on engine speed and injection quantity.
Cause:
The Rail Pressure sensor signal is too low.
1. Faulty Rail Pressure sensor.

2. Faulty circuit wiring, shorted to low source.
Solution:
1. Disconnect the engine sensor harness from the ECU at ECU engine connector 2 and place the Key switch in
the "On" position. Use a multi-meter check the voltage on the ECU from pin 13 to pin 12. There should be 5 V.
A. If there is 5 V reconnect ECU engine connector and continue with step 2
B. If there is less than 5 V, there is a failure inside the ECU, replace the ECU.
2. Disconnect the engine sensor harness from the Fuel Pressure sensor and place the Key switch in the "On"
position. Use a multi-meter check the voltage on the engine harness side of Fuel pressure sensor connector
RDS4 from pin 3 to pin 2. There should be 5 V.
A. If there is 5 V leave the Fuel pressure sensor connector disconnected and continue with step 3
B. If there is less than 5 V, there is a short to low source in the sensor circuit wiring, leave the Fuel pressure
sensor connector disconnected and continue with step 4
3. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter to test for
continuity between the engine sensor harness side of ECU engine connector 2, pin 14 and ground and also
between Fuel pressure sensor connector RDS4 pin 1 and ground. There should be no continuity.
A. If there is continuity on either or both tests, there is a short to low source in the sensor signal wire, locate
and repair the short to low source.
B. If there is no continuity, either the sensor has failed or the ECU is faulty. Replace the common rail pressure
sensor and if the fault reoccurs reload the ECU software. If the fault reoccurs after replacing the sensor
and reloading software, replace the ECU.
4. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter to test for
continuity between the engine sensor harness side of ECU engine connector 2, pin 13 and ground and also
between Fuel pressure sensor connector RDS4 pin 3 and ground. There should be no continuity.
A. If there is continuity, on either or both tests, there is a short to low source in the sensor source wire. Locate
and repair the short to low source.
B. If there is no continuity, on either or both tests, there is a short to low source in the sensor ground reference
wire. Locate and repair the short to low source.
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3104-Rail Pressure Relief Valve - Open

Context:
The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) is open. Normally the fuel pressure
in the rail is regulated by the metering unit of the high pressure pump. However, if this component is malfunctioning
the rail pressure can rise to critical levels. For this reason the common rail has a Pressure Relief Valve (PRV) which is
a mechanical safety valve (no electrical connectors) that opens at a certain pressure level. An opening of the PRV is
detected by evaluating the gradient of the rail pressure (calculated by the ECU). If the PRV does not open on its own
after exceeding the pressure threshold it can also be forced open by a so-called 'kickoff' or pressure shock when the
metering valve of the high pressure fuel pump is set to maximum possible quantity. Once the PRV has been opened
it will remain open as long as the engine is running. A defective common rail pressure sensor, as judged by the ECU,
which evokes a kickoff (pressure shock) or a defect in an injection relevant component (small leak) can cause this
error to occur. This fault will only be cleared after an ECU reset.
1. Faulty Rail Pressure sensor, signal not plausible.

2. Faulty common rail fuel system, small leak.
Solution:
1. Use EST to check for other Rail Pressure sensor and injector (cylinder or bank) errors.
A. If Rail Pressure sensor or injector errors exist, follow troubleshooting procedure for existing Rail Pressure
sensor or injector error.
B. If no Rail Pressure sensor or injector errors exist, continue with step 2

2. Check common rail fuel system for leaks.
A. If common rail fuel system leak is found, repair as required.
B. If no common rail fuel system leak is found, continue with step 3

3. Visually inspect connector RDS4 and connector 2 for electrical integrity.
A. If damage or connectivity issues are discovered, repair, clean or replace as required.
B. If no damage or connectivity issues are discovered, replace Rail Pressure sensor and restart engine. If
error reoccurs continue with step 4
4. Visually inspect connector 2 for electrical integrity.
B. If no damage or connectivity issues are discovered, continue with step 5

5. Visually inspect injector connectors INJ1, INJ2, INJ3, INJ4, INJ5 AND INJ6 for electrical integrity.
B. If no damage or connectivity issues are discovered, continue with step 6

6. Reload ECU software.
A. If error reoccurs after trying to reload software, replace ECU.
B. If error has been resolved, continue with normal operation of machine.
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3105-Rail Pressure Relief Valve - Pressure Shock Requested

Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high and the Pressure Relief
Valve (PRV) did not open. Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure
pump. However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the
common rail has a Pressure Relief Valve (PRV) which is a mechanical safety valve (no electrical connectors) that
opens at a certain pressure level. An opening of the PRV is detected by evaluating the gradient of the rail pressure
(calculated by the ECU). If the PRV does not open on its own after exceeding the pressure threshold it can also be
forced open by a so-called 'kickoff' or pressure shock when the metering valve of the high pressure fuel pump is set to
maximum possible quantity. Rail pressure in excess of 148500 kPa (21538.1 psi) for 1 s evokes a kickoff (pressure
shock) request by the ECU. If the pressure shock (kickoff) does not immediately open the PRV, this error will occur.
This fault will only be cleared after an ECU reset.
1. Faulty ECU, improper data set.

2. Faulty PRV, mechanical valve does not function.
Solution:
1. Use the EST to flash the ECU with the appropriate data set.
A. If the error reoccurs, replace the PRV.
B. If the error does not reoccur, return the combine to service.
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3106-Rail Pressure Relief Valve - Did Not Open After Pressure

Shock
Context:
The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) did not open after a pressure
shock (kickoff). Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure pump.
However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the common
rail has a Pressure Relief Valve (PRV) which is a mechanical safety valve (no electrical connectors) that opens at a
certain pressure level. An opening of the PRV is detected by evaluating the gradient of the rail pressure (calculated
by the ECU). If the PRV does not open on its own after exceeding the pressure threshold it can also be forced open
by a so-called 'kickoff' or pressure shock when the metering valve of the high pressure fuel pump is set to maximum
possible quantity. Rail pressure in excess of 148500 kPa (21538.1 psi) for 1 s evokes a kickoff (pressure shock)
request by the ECU. If the pressure shock (kickoff) request is present longer than 2 s and did not immediately open
the PRV, this error will occur. This fault will only be cleared after an ECU reset.
1. Faulty ECU, improper data set.

2. Faulty PRV, mechanical valve does not function.
Solution:
1. Use the EST to flash the ECU with the appropriate data set.
A. If the error reoccurs, replace the PRV.
B. If the error does not reoccur, return the combine to service.
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3107-Metering unit output short circuit to battery on low side

Context:
The engine control unit (ECU) has determined that a short to high source circuit condition exists in the fuel high pres-
sure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common
rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (Main
Relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The
low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the
circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it
is switched off for some reason. Failure detection of is only possible if the low side power stage is switched on. With
the current settings, the monitoring is shut off during after-run. This error is the result of the power stage hardware
report of 'short circuit to battery' (on the low side of the metering unit) longer than 0.0 (zero) milliseconds and once
the permanent error is detected the power stage is switched off.
Cause:
Fuel high pressure pump circuit is shorted to a high source.
1. Faulty fuel high pressure pump control circuit, shorted to a high source.
Solution:

2. Disconnect the Engine Injector harness from the ECU at connector 3 and place the Key switch in the "On"
position. Use a multi-meter to test for voltage from the Engine Injector harness side of connector 3, pin 10 to
chassis ground. There should be no voltage.
A. If there is voltage, locate and repair the short to the voltage source.
B. If there is no voltage, continue with step 3

3. Disconnect the Engine Injector harness from the fuel high pressure pump at connector ZME and use a multi-
meter to check the resistance of the fuel high pressure pump solenoid coil. There should be a small amount of
resistance.
A. If there is a small amount of resistance, try reloading the ECU software and if the error reoccurs, replace
the ECU.
B. If there is no resistance, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
has been resolved.
ation.
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3108-Fuel Metering Unit - Short Circuit To Ground

Context:
The engine control unit (ECU) has determined that a short to low source circuit condition exists in the fuel high pres-
sure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common
rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (Main
Relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The
low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the
circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it
is switched off for some reason. Failure detection of is only possible if the low side power stage is switched off. With
report of 'short circuit to ground' (on the low side of the metering unit) longer than 0.28 seconds and the power stage
has most likely switched off.
Cause:
Fuel high pressure pump circuit is shorted to a low source.
1. Faulty fuel high pressure pump control circuit, shorted to a low source.
Solution:

2. Disconnect the Engine Injector harness from the ECU at connector 3. Use a multi-meter to test for continuity
from the Engine Injector harness side of connector 3, pin 10 to ground. There should be no continuity.
A. If there is continuity, continue with step 3
B. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
3. Disconnect the Engine Injector harness from the Fuel high pressure pump at connector ZME and use a multi-
meter to check for continuity on the fuel high pressure pump side of connector ZME, pins 1 and 2 to chassis
ground. There should be no continuity on either pin to ground.
A. If there is continuity on either pin, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
B. If there is no continuity on either pin, there is a short to low source in the Engine Injector harness, locate
and repair the short to ground.
has been resolved.
ation.
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3110-Rail Pressure Sensor Monitoring - Signal Above Range

Maximum
Context:
The engine control unit (ECU) has sensed that the Rail Pressure sensor offset signal is too high. This test is performed
during after-run and is aborted if the Key switch is switched "On" during after-run. During after-run the measured raw
value of the Rail Pressure sensor is compared to the atmospheric pressure sensor within the ECU. To ensure that the
rail pressure has depressurized sufficiently to atmospheric levels after engine shutoff, the monitoring is released only
if the delay time determined by the rail pressure dependent curve (ECU pre-programmed data) has elapsed and the
fuel temperature is above -0.04 °C (31.93 °F). If the raw value of the rail pressure sensor exceeds 0.65 V over 100
milliseconds during after-run, this error is set and will reset if the value goes below the limit for over 100 milliseconds.
Cause:
The Rail Pressure sensor after-run signal is too high.
1. Faulty circuit wiring or electrical connection.

2. Faulty sensor.
Solution:
1. Use EST to check for other Rail Pressure sensor errors.
A. If Rail Pressure sensor errors exist, follow troubleshooting procedure for existing Rail Pressure sensor
error.
B. If no Rail Pressure sensor errors exist, continue with step 2

2. Disconnect the Engine Sensor harness from the ECU at connector 2 and from the Rail Pressure sensor at
connector RDS4. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector
2, pin 13 to the Engine Sensor harness side of connector RDS4, pin 3. There should be continuity.
A. If there is continuity, leave the connectors disconnected and continue with step 3
B. If there is no continuity, there is an open circuit condition in the sensor source wire. Locate and repair the
open circuit condition.
3. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector 2, pin 14 to the
Engine Sensor harness side of connector RDS4, pin 2. There should be continuity.
B. If there is no continuity, there is an open circuit condition in the sensor ground reference wire. Locate and
repair the open circuit condition.
B. If there is no continuity, there is an open circuit condition in the sensor signal wire. Locate and repair the
5. Visually inspect both connectors for electrical integrity.
B. If no damage or connectivity issues are discovered, replace the sensor.
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3111-Rail Pressure Sensor Monitoring - Signal Below Range

Minimum
Context:
The engine control unit (ECU) has sensed that the Rail Pressure sensor offset signal is too low. This test is performed
during after-run and is aborted if the Key switch is switched "On" during after-run. During after-run the measured raw
value of the Rail Pressure sensor is compared to the atmospheric pressure sensor within the ECU. To ensure that the
rail pressure has depressurized sufficiently to atmospheric levels after engine shutoff, the monitoring is released only
if the delay time determined by the rail pressure dependent curve (ECU pre-programmed data) has elapsed and the
fuel temperature is above -0.04 °C (31.93 °F). If the raw value of the rail pressure sensor is below 0.35 V over 100
milliseconds during after-run, this error is set and will reset if the value goes above the limit for over 100 milliseconds.
Cause:
The Rail Pressure sensor after-run signal is too low.
1. Faulty circuit wiring or electrical connection.

2. Faulty sensor.
Solution:
1. Use EST to check for other Rail Pressure sensor errors.
A. If Rail Pressure sensor errors exist, follow troubleshooting procedure for existing Rail Pressure sensor
error.
B. If no Rail Pressure sensor errors exist, continue with step 2

2. Disconnect the Engine Sensor harness from the ECU at connector 2 and from the Rail Pressure sensor at
connector RDS4. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector
2, pin 13 to the Engine Sensor harness side of connector RDS4, pin 3. There should be continuity.
B. If there is no continuity, there is an open circuit condition in the sensor source wire. Locate and repair the
B. If there is no continuity, there is an open circuit condition in the sensor ground reference wire. Locate and
repair the open circuit condition.
B. If there is no continuity, there is an open circuit condition in the sensor signal wire. Locate and repair the
5. Visually inspect both connectors for electrical integrity.
B. If no damage or connectivity issues are discovered, replace the sensor.
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3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range

Context:
The engine control unit (ECU) has sensed that the Fuel Pressure sensor signal is too high. The test frequency of the
sensor is every 10 ms and if the signal is in excess of 4.86 V for over 200 ms, the error is set. Once set the ECU will,
instead of using the peak rail pressure value of the last 10 ms and the current rail pressure, output a substitute value
from a curve (MAP) in the ECU depending on engine speed and injection quantity.
Cause:
The Fuel Pressure sensor signal is too high.
1. Faulty Fuel Pressure sensor.

2. Faulty circuit wiring, shorted to high source.
Solution:
1. Disconnect the engine sensor harness from the ECU at ECU engine connector 2 and place the Key switch in
the "On" position. Using a multi-meter check the voltage on the ECU engine connector from pin 13 to pin 12.
There should be 5 V.
A. If there is 5 V reconnect ECU engine connector and continue with step 2
B. If there is greater than 5 V, there is a failure inside the ECU, replace the ECU.
2. Disconnect the engine sensor harness from the Rail Pressure sensor and place the Key switch in the "On"
position. Use a multi-meter check the voltage on the engine harness side of Rail pressure sensor connector
RDS4 from pin 3 to pin 2. There should be 5 V.
A. If there is 5 V leave the Rail pressure sensor connector disconnected and continue with step 3
B. If there is greater than 5 V, there is a short to high source in the sensor circuit wiring, leave the Rail pressure
sensor connector RDS4 disconnected and continue with step 4
3. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter test for
voltage between the engine sensor harness side of ECU engine connector 2, pin 14 and ground and also be-
tween Rail pressure sensor connector RDS4, pin 1 and ground. There should be no voltage.
A. If there is voltage on either or both tests, there is a short to high source in the sensor signal wire, locate
and repair the short to high source.
B. If there is no voltage, either the sensor has failed or the ECU is faulty. Replace the Rail Pressure sensor
and if the fault reoccurs reload the ECU software. If the fault reoccurs after replacing the sensor and
reloading software, replace the ECU.
4. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter test for
voltage between the engine sensor harness side of ECU engine connector 2, pin 13 and ground and also be-
tween Rail pressure sensor connector RDS4, pin 3 and ground. There should be no voltage.
A. If there is voltage, on either or both tests, there is a short to high source in the sensor source wire. Locate
and repair the short to high source.
B. If there is no voltage, on both tests, there is a short to high source in the sensor ground reference wire.
Locate and repair the short to high source.
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3113-Grid heater battery switch relay short circuit to battery

NOTICE: When available use special tool 380040185 harness diagnostic/repair kit.
Cause:

Solution:
rence.

2. Check grid heater relay.
BD08F244-01 1
(1) Grid heater relay

(2) Connector grid heater relay
(3) Battery terminal
(4) Grid heater terminal
(1) Disconnect the grid heater relay connector. Inspect pins, wiring and connectors for damage, abrasion, cor-
rosion or incorrect attachment.
(2) Measure the resistance from pin 1 on the grid heater relay to battery terminal and heater terminal studs.
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(4) Measure the resistance between pin 1 and pin 2 on grid heater relay. The resistance should be approximately
15 - 40 Ω.
A. NOT OK – Replace relay. Return to Step 1 to confirm elimination of fault.
3. Check circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
(1) Disconnect ECU connector B and the grid heater relay connector. Inspect pins, wiring and connectors for
damage, abrasion, corrosion or incorrect attachment.
(2) Measure the resistance between ECU connector B pin 12 and pin 75. The resistance should be greater than
(3) Measure the resistance from grid heater relay connector 1 to ECU connector B pin 12. The resistance should
(4) Measure the resistance from grid heater relay connector pin 2 to ECU connector B pin 75. The resistance
A. NOT OK – Determine the short circuit or break between connectors and repair. Return to Step 1 to confirm
4. Replace the engine control unit.
(1) Remove and replace engine control unit.
for assistance.
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3114-Grid heater battery switch relay short circuit to ground

Cause:

Solution:
rence.

BD08F244-01 1

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15 - 40 Ω.
3. Check circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
for assistance.
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3118-ECM 12V sensor supply voltage high

NOTICE: Check alternator output voltage, if above 14 V, troubleshoot charging system before proceeding.
NOTE: Besides the 3 independent 5V voltage supplies the ECU also provides a 12V supply for the sensors. This 12V
supply is monitored to ensure it remains within a certain range. This is done by using an analog input of the ECU.
The lower and upper thresholds depend on the battery voltage.
Cause:

Solution:
rence.

2. Check input voltage.
BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
(1) Turn ignition OFF. Disconnect ECU connector B. Inspect pins, wiring and connectors for damage, abrasion,
corrosion or incorrect attachment.
(3) Measure the voltage between pins 2, 3, 8, and 9 of ECU Connector B and ground (pins 5, 6, 10 and 11).
The voltage should be approximately 12 V.
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A. NOT OK – Check fuses, replace as needed. Return to Step 1 to confirm elimination of fault. If fuses check
good go to Step 3.
3. Check circuit 1016-RD.
RCPH10TLB302AAF 2
(1) Fuse block

(2) Diagnostic port
(1) Inspect fuse block connections and wiring for damage, abrasion, corrosion or incorrect attachment.
(2) Measure the resistance from ECU connector B, pins 2, 3, 8, and 9 to fuse F-001. The resistance should be
A. NOT OK – If circuit is open, check circuit SP-021 splice on front console harness. Repair or repalce the
for assistance.
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3119-ECM 12V sensor supply voltage low

NOTICE: Check alternator output voltage. Troubleshoot charging system before proceeding.
Cause:

Solution:
rence.

2. Check input voltage.
BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
(1) Turn ignition OFF. Disconnect ECU connector B. Inspect pins, wiring and connectors for damage, abrasion,
corrosion or incorrect attachment.
(3) Measure the voltage between pins 2, 3, 8, and 9 of ECU Connector B and ground (pins 5, 6, 10 and 11).
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good go to Step 3.
RCPH10TLB302AAF 2
(1) Fuse block

(2) Diagnostic port
(1) Inspect fuse block connections and wiring for damage, abrasion, corrosion or incorrect attachment.
(2) Measure the resistance from ECU connector B, pins 2, 3, 8, and 9 to fuse F-001. The resistance should be
A. NOT OK – If circuit is open, check circuit SP-021 splice on front console harness. Repair or repalce the
for assistance.
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3131-Grid Heater Always Switched On

Cause:

Solution:
rence.

BD08F244-01 1

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15 - 40 Ω.
3. Check circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
for assistance.
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3137-Metering Unit - Open Load

Context:
The engine control unit (ECU) has determined that an open circuit condition exists in the Pump control valve (Metering
Unit - High Pressure Pump Regulator solenoid/valve) circuit. The metering unit of the fuel high pressure pump regu-
lates the pressure in the common rail. The metering unit is controlled by both main relay 1 high side and a low side
power stages (Main Relay 1 is an electronic control circuit within the ECU used to provide fixed and variable control
signals to devices external to the ECU). The monitoring at low side is stopped if a short circuit to ground at the high
side (main relay 1) is detected or it is switched off for some reason. Failure detection of an over current condition is
only possible if the low side power stage is switched on and the open circuit condition only if it is switched off. With
report of an 'open load' in the metering unit longer than 200 milliseconds.
Cause:
Pump control valve circuit is open.
1. Faulty Pump control valve, open solenoid coil.

2. Faulty circuit, open conductor.
Solution:
1. Disconnect the ECU cylinder connector from the ECU at connector 3. Use a multi-meter to check the resistance
on the Engine Injector harness side of connector 3, from pin 9 to pin 10. There should be approximately 3.2 Ω.
A. If there is approximately 3.2 Ω, check for other ECU errors that could inhibit operation of the ECU main
relay 1 circuit and follow those troubleshooting procedures.
B. If there is a high resistance reading, leave connector 3 disconnected and continue with step 2
2. Disconnect the Engine Injector harness from the Pump control valve at connector ZME. Use a multi-meter to
check the resistance of the Pump control valve solenoid coil. There should be approximately 3.2 Ω.
A. If there is approximately 3.2 Ω, leave connector ZME disconnected and continue with step 3
B. If there is a high resistance reading, replace the Pump control valve solenoid.
3. Use a multi-meter to check for continuity from the Engine Injector harness side of connector ZME, pin 1 to the
Engine Injector harness side of connector 3, pin 10. There should be continuity.
B. If there is no continuity, locate and repair the break in the wire.

Engine Injector harness side of connector 3, pin 9. There should be continuity.
A. If there is continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
B. If there is no continuity, locate and repair the break in the wire.
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3138-Metering Unit - Temperature Too High

Context:
The engine control unit has determined that a short circuit condition exists in the fuel high pressure pump circuit. The
metering unit of the fuel high pressure pump regulates the pressure in the common rail. The metering unit is controlled
by both main relay 1 high side and a low side power stages (Main Relay 1 is an electronic control circuit within the
ECU used to provide fixed and variable control signals to devices external to the ECU. The monitoring at low side is
stopped if a short circuit to ground at the high side (main relay 1) is detected or it is switched off for some reason.
Failure detection of an over current condition is only possible if the low side power stage is switched on and the open
circuit condition only if it is switched off. With the current settings, the monitoring is shut off during after-run. This
error is the result of the power stage hardware report of 'excess temperature' (high current) in the metering unit circuit
longer than 200 milliseconds.
Cause:
Fuel high pressure pump circuit is shorted.
1. Faulty fuel high pressure pump, shorted solenoid coil.

2. Faulty control circuit, short circuit.
Solution:
1. Disconnect the Engine Injector harness from the ECU at connector 3. Use a multi-meter to check the resistance
on the Engine Injector harness side of connector 3, from pin 9 to pin 10. There should be approximately 3.2 Ω.
A. If there is approximately 3.2 Ω, use EST to check for other ECU errors that could inhibit operation of the
ECU main relay 1 circuit and follow those troubleshooting procedures.
B. If there is significantly less than 3.2 Ω, leave connector 3 disconnected and continue with step 2.
2. Disconnect the Engine Injector harness from the fuel high pressure pump at connector ZME. Use a multi-meter
to check the resistance of the fuel high pressure pump solenoid coil. There should be approximately 3.2 Ω.
A. If there is approximately 3.2 Ω, leave connector ZME disconnected and continue with step 3.
B. If there is significantly less than 3.2 Ω, replace the fuel high pressure pump solenoid coil.
Engine Injector harness side of connector 3, pin 9. There should not be continuity.
A. If there is no continuity, leave the connectors disconnected and continue with step 4.
B. If there is continuity, the fuel high pressure pump control circuit wires have been shorted together, locate
and repair the shorted wires.
Engine Injector harness side of connector 3, pin 10. There should not be continuity.
A. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
B. If there is continuity, the fuel high pressure pump control circuit wires have been shorted together, locate
and repair the shorted wires.
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3141-Set point of fuel volume flow through metering unit is lower

than calculated limit
Context:
The engine control unit (ECU) has determined that there is either Fuel System Leakage or the Metering Unit (High
Pressure Pump Regulator solenoid/valve) is jammed in closed position. The rail pressure is monitored by various fault
paths during active pressure control by the metering unit. The fault path at hand detects a leakage of fuel by monitoring
the set-point current used to control the metering unit. The monitoring is only active if the high pressure governor (High
Pressure Pump Regulator solenoid/valve) is operating in closed loop control, the rail pressure governor deviation is
within the range +/- 5000 kPa (725.2 psi) and the monitoring has not been inhibited by other faults. If the metering
unit current control set-point current is below a calculated minimum limit over 2.5 seconds this error will occur. [This
limit is calculated from various curves, maps and correction factors established by the ECU]. This error is the result
of an inaccurate Rail pressure sensor or defective high pressure pump in the high pressure system or Metering unit
reflux too low, fuel system leakage, or metering unit jammed in the closed position in the low pressure system.
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3142-High Pressure Test - Test Active

Context:
The engine control unit (ECU) has acknowledged that the 'High Pressure Test' is running. The 'High Pressure Test' is
a test procedure used to evaluate the performance of the fuel high pressure unit (pump, rail pressure control valve,
etc.) and is executed via a diagnostic tester request. If this test is running the rail pressure monitoring has to be
deactivated, which is done by setting this fault path. Therefore, this failure path is used more for information purposes
and inhibit handling than as an actual error status.
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3145-Terminal 15 - No Signal
WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
NOTICE: Fault Code 3145 is stored historical information. For multiple occurrences of this fault proceed with the
following tests.
NOTE: See engine repair manual for electrical schematic information. When available use special tool 380040185
harness diagnostic/repair kit.
Cause:

5. Connector pins corroded or dirty.
Solution:
rence.

2. Check voltage at ECU (Engine Control Unit).
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BD08E032-01 1
(1) ECU (Engine Control Unit)

(2) Connector B Engine Controller
(1) Disconnect ECU connector B. Inspect pins, wiring and connectors for damage, abrasion, corrosion or incor-
rect attachment.
(2) Turn ignition switch to the ON position. measure the voltage from ECU connector B, pin 40 to chassis ground.
good go to Step 3.
3. Check supply voltage to ignition switch.
(1) Turn ignition switch to the OFF position. Disconnect the ignition switch connector. Inspect pins, wiring and
connectors for damage, abrasion, corrosion or incorrect attachment.
(2) Measure the voltage from pin 1 of the ignition switch connector to ground. The voltage should be approxi-
mately 12 V. If no voltage is present check circuit 1D from ignition switch pin 1 to power junction.
A. NOT OK – Determine break in circuit 1D and repair. Return to Step 1 to confirm elimination of fault.
4. Check ignition switch.
(1) Measure the resistance from ignition switch pin 1 to pin 4. The resistance should greater than 20,000 ohms.
Wiggle the harness during measurement to revel an intermittent condition.
(2) Turn ignition switch to the ON position (with the ignition switch connector removed). Measure the resistance
between ignition switch from pin 1 to pin 4 on switch. The resistance should be less than 10 ohms.
A. NOT OK – Replace ignition switch. Return to Step 1.
5. Check circuit 3.
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RCPH10TLB302AAF 2
(1) Fuse block

(2) Diagnostic connector
(1) Disconnect fuse block and inspect connections (F-025) and wiring for damage, abrasion, corrosion or incor-
rect attachment.
A. NOT OK – Circuit is open. Repair or replace harness as required. Go to Step 1.
6. Replace ECU (Engine Control Unit).
(1) Remove and replace ECU.
for assistance.
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3147-Oil Temperature Too High

Context:
temperature sensing function of the device. This error resulted from a plausibility check against the oil temperature
being too high. The ECU will prohibit the any plausibility check when there are Analog to Digital Converter (ADC)
signal errors detected on the Oil temp / press sensor.
Cause:
The Oil temp / press sensor is reporting an abnormally high oil temperature to the ECU.

2. Faulty electrical wiring and / or connections.
4. Faulty oil lubrication or coolant system.
Solution:
1. Operation: Check for Coolant System Faults.
Use EST to check for errors associated with coolant temperature.

Also, check the coolant level. A faulty coolant system that is operating above normal temperatures could cause
a high oil temperature since the engine has an integrated oil / coolant heat exchanger.
A. If the coolant level is low, add the appropriate amount and type of coolant.
B. If any of the errors exist, resolve the existing error. Then determine if this error has also been resolved.
C. If none of the errors exist, continue with step 2.

2. Operation: Check for Oil Pressure Faults.
Use EST to check for errors associated with oil pressure.

Also, check the engine oil level on the sump dipstick. A low pressure oil delivery system, could result in high oil
temperatures.
A. If the oil level is low, add the appropriate amount and type of oil.
B. If any of the errors exist, resolve the existing error. Then determine if this error has also been resolved.
C. If none of the errors exist, continue with step 3.


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5. Operation: Oil temp / press sensor Test
Remove ODFT connector and test resistance of Oil temp / press sensor using the table of resistance vs. temp.
below. Approximate the engine oil temperature when performing test. Oil temp / press sensor failures are
typically at the extreme ends of the table or off the table entirely. Use the test lead labeled "Air Press/Temp
Sensor" from the Tier II (NEF) Diagnostic Repair Kit 380040185 to be able to access the pins on the sensor.
Use a multi-meter between pins 1 and 2.
Engine Oil Temperature Resistance Value (between pins 1 and 2)

-40 °C (-40 °F) 70 kOhm
-20 °C (-4 °F) 25 kOhm
0 °C (32 °F) 7.5 kOhm
20 °C (68 °F) 4.5 kOhm
40 °C (104 °F) 1.5 kOhm
60 °C (140 °F) 750 ohms
80 °C (176 °F) 550 ohms
100 °C (212 °F) 320 ohms
120 °C (248 °F) 130 ohms

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Important Note:

1. Voltage 1, (Pin 2, 3, 8, 9, 40) Ground (engine block) Approx. 12 volts
2. Continuity 1, (Pin 5, 6, 10, 11) Ground (engine block) Approx. 0 - 0.10 ohms
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3154-Grid Heater Relay - Short Circuit To Battery

Cause:

Solution:
rence.

BD08F244-01 1

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15 - 40 Ω.
3. Check circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
for assistance.
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3155-Grid Heater Relay - Short Circuit To Ground

Cause:

Solution:
rence.

BD08F244-01 1

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15 - 40 Ω.
3. Check circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
for assistance.
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3156-Grid Heater Relay - No Load

Cause:

5. Connector pins corroded or dirty. .
Solution:
rence.

BD08F244-01 1

15 - 40 Ω.
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3. Check circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
for assistance.
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3171-Fuel rail system pressure too low

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
Cause:

Solution:
rence.

2. Check fuel delivery system.
(1) Refer to the Engine Repair Manual for the following: Check and repair leaks in the high and low pressure
sides of the fuel system. Check for clogged fuel filter, worn or stuck injectors, and defective low and high pres-
sure pumps.
A. OK - Go to Step 3.
B. NOT OK - Repair fuel system leaks and/or repair worn or defective components. Return to Step 1 to
3. Check rail pressure sensor.
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BD08E030-01 1
(1) Connector fuel pressure sensor

(2) Common rail pressure sensor
(3) Common rail
(1) Disconnect the fuel pressure sensor. Inspect pins, wiring and connectors for damage, abrasion, corrosion
or incorrect attachment.
(1). Disconnect fuel pressure sensor connector. Turn the key switch ON. The Fuel Pressure sensor fault code
should change to an Open Circuit fault while the sensor is disconnected.
(2) Fabricate a 6 inch jumper wire. Short the fuel pressure signal wire to sensor common wire (Ground). The
fault code should change from an open circuit to a short circuit while the jumper is installed.
A. OK - Replace sensor. Go to Step 1 to confirm elimination of fault.
B. NOT OK - Go to step 4.
4. Check voltage at fuel pressure sensor.
(1) Disconnect the Fuel Pressure Connector.
(2) Turn the ignition switch ON to power the system.
(3) Measure the voltage on the fuel pressure sensor connector pin 3 to pin 1 (ground). The voltage should be
approximately 5 V.
A. NOT OK - Go to Step 5.
B. OK - Replace sensor. Return to Step 1 to confirm elimination of fault.

5. Check fuel pressure circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
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(1) Disconnect ECU connector C. Inspect pins, wiring and connectors for damage, abrasion, corrosion or incor-
rect attachment.
(2) Measure the resistance from fuel pressure sensor connector pin 1 to ECU connector C, pin 12. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
B. NOT OK - Determine the break between connectors and repair. Return to Step 1 to confirm elimination of
fault.
6. Check fuel high pressure regulator.
BD08F245-01 3
(1) Connector high pressure regulator

(2) High pressure pump
(1). Disconnect connector from fuel high pressure regulator. Inspect pins, wiring and connectors for damage,
(2). Measure the resistance between pins 1 and 2 on the high pressure regulator. The resistance should be
approximately 3.2 Ω.
A. NOT OK – Replace fuel high pressure regulator. Return to Step 1 to confirm elimination of fault.
7. Check high pressure regulator circuit.
BD08E032-01 4
(1) Connector C
(2) Connector A
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(3) Connector B
(1). Disconnect ECU connector A. Inspect pins, wiring and connectors for damage, abrasion, corrosion or in-
correct attachment.
(2). Measure the resistance between pin 9 to pin 10 on ECU connector A. The resistance should be greater
(3). Measure the resistance from high pressure regulator pin 1 to ECU connector A pin 9. The resistance should
(4). Measure the resistance from high pressure regulator pin 2 to ECU connector A pin 10. The resistance
A. NOT OK - Determine the break or short between connectors or wiring and repair as required. Return to
B. OK - Go to Step 8.
for assistance.
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3172-Fuel rail system pressure too high

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
Cause:

Solution:
rence.

sure pumps.
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BD08E030-01 1

(3) Common rail
(1) Disconnect the fuel pressure sensor. Inspect pins, wiring and connectors for damage, abrasion, corrosion
or incorrect attachment.
(1). Disconnect fuel pressure sensor connector. Turn the key switch ON. The Fuel Pressure sensor fault code
(2) Fabricate a 6 inch jumper wire. Short the fuel pressure signal wire to sensor common wire (Ground). The
4. Check voltage at fuel pressure sensor.
(1) Disconnect the Fuel Pressure Connector.
(3) Measure the voltage on the fuel pressure sensor connector pin 3 to pin 1 (ground). The voltage should be
approximately 5 V.

5. Check fuel pressure circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
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(1) Disconnect ECU connector C. Inspect pins, wiring and connectors for damage, abrasion, corrosion or incor-
rect attachment.
fault.
BD08F245-01 3

BD08E032-01 4
(1) Connector C
(2) Connector A
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(3) Connector B
correct attachment.
for assistance.
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3173-Rail Pressure Governor Deviation Below Min. Limit for Speed

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
Cause:

Solution:
rence.

sure pumps.
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BD08E030-01 1

(3) Common rail
(1) Disconnect rail pressure sensor connector. Inspect pins, wiring and connectors for damage, abrasion, cor-
(1). Disconnect rail pressure sensor connector. Turn the key switch ON. The rail Pressure sensor fault code
(2) Fabricate a 6 inch jumper wire. Short the Rail pressure signal wire to sensor common wire (Ground). The
4. Check voltage at rail pressure sensor.
(1) Disconnect the Rail Pressure sensor connector.
(3) Measure the voltage between Fuel Pressure connector pin 3 to pin 1 (ground). The voltage should be ap-
proximately 5 V.

5. Check rail pressure circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
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(1) Disconnect Electronic Control Unit (ECU) connector C. Inspect pins, wiring and connectors for damage,
(2) Measure the resistance from Rail Pressure sensor connector pin 1 to ECU connector C pin 12. The resis-
fault.
BD08F245-01 3

BD08E032-01 4
(1) Connector C
(2) Connector A
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(3) Connector B
correct attachment.
for assistance.
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3174-Rail Pressure Governor Deviation Exceeded Max. Limit

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
Cause:

Solution:
rence.

sure pumps.
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BD08E030-01 1

(3) Common rail
proximately 5 V.

BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
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fault.
BD08F245-01 3

BD08E032-01 4
(1) Connector C
(2) Connector A
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(3) Connector B
correct attachment.
for assistance.
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3175-Fuel system leak detected - large leak

WARNING
Escaping fluid!
doctor immediately.
W0178A
WARNING
Fire hazard!
1. Do not smoke.
W0099A
Cause:

Solution:
rence.

sure pumps.
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BD08E030-01 1

(3) Common rail
proximately 5 V.

BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
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fault.
BD08F245-01 3

BD08E032-01 4
(1) Connector C
(2) Connector A
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(3) Connector B
correct attachment.
for assistance.
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3176-Fuel delivery exceeded threshold for pressure in overrun

mode
Context:
The engine control unit (ECU) has determined that the Metering Unit (High Pressure Pump Regulator solenoid/valve)
has excessively opened to reach the desired Rail pressure. The rail pressure is monitored by various fault paths
during active pressure control by the metering unit. The fault path at hand detects an excessive leakage of fuel by
monitoring the set-point value of the fuel volume flow through the metering unit during overrun. The monitoring is
only active if the high pressure governor (High Pressure Pump Regulator solenoid/valve) is operating in closed loop
control, the engine is in overrun condition, the fuel injection quantity is zero and the monitoring has not been inhibited
by other faults. If the set-point value of the rail pressure governor for the fuel volume flow through the metering unit
exceeds an upper limit over 2.5 seconds this error will occur. [This limit is interpolated from the rail pressure dependent
curve, established by the ECU]. This error is the result of leakage in the high pressure section; injection nozzle stuck
in open position, worn or defective high pressure pump, worn injector, leaking pressure relief valve. or leakage in the
low pressure system; 'Zero delivery' is not active in metering unit (excessive leakage in metering unit).
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3177-Engine Overspeed Detected

Context:
The Engine Control Unit (ECU) has detected an engine over-speed condition. An engine over-speed can occur both
during certain engine operating conditions without any defect in a component, for example downhill driving, or as a
result of, for example another ECU error. This error is for information purposes and is initiated by engine speed in
excess of 2800 RPM for over 5 seconds and is reset once the engine speed is below the threshold for over 2 seconds.
Though this error by itself does not require any action, the over-speed state can cause an injection shutoff request
within the ECU. If this error reoccurs frequently, check driving conditions of the vehicle, engine speed acquisition and
injection system for quantity set-point and actual value during fault recognition, check also for other ECU errors.
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3188-Cylinder 1 Warning - Open Load

Context:
The Engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 1 injector circuit. A
the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is
treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of an
open circuit failure being present for over 3 camshaft revolutions. As a result of this error an individual cylinder or bank
is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent
(without a healing possibility, once tested by switching on the component to see if the defect is still present) and others
evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
The Engine control unit (ECU) has determined that there is a fault associated with the current monitoring of the Cylin-
der 1 injector output power driver stage.
1. Faulty Cylinder 1 injector solenoid windings.

2. Faulty electrical wiring, open circuit (damaged wiring).
Solution:

2. Carefully disconnect the engine harness from the ECU at the cylinder connector 3. Use a multi-meter to check
the resistance, on the engine harness side of the cylinder connector 3, between pins 4 and 13. There should
be 0.4 - 0.5 Ω.
A. If the resistance is within range, the ECU may have failed. Try reloading the ECU software and if the fault
reoccurs, replace the ECU .
B. If the resistance was significantly greater than maximum range, continue with step 3
3. Disconnect the engine cylinder harness from the injector (valve) cover at connector VC1. Use a multi-meter to
check resistance on the injector (valve) cover side of connector from pin 3 to pin 4. There should be 0.4 - 0.5 Ω.
A. If a small amount of resistance exists, there is open circuit condition in the engine cylinder harness between
the ECU cylinder harness connector 3 and the Cylinder 1 /2 valve cover connector VC1. Locate and repair
the broken conductor.
INJ1. Use a multi-meter to check resistance, on the Cylinder 1 injector, from terminal 1 to terminal 2. There
should be 0.4 - 0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between injector
connector and ECU cylinder connector . Locate and repair the broken conductor.
B. If the resistance was significantly greater than maximum range, the Cylinder 1 injector solenoid coil has
failed. Replace the injector.
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has been resolved.
ation.
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3192-Cylinder 2 warning - Open Load

Context:
The engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 2 injector circuit. A
(without a healing possibility, once tested by switching on the component to see if the defect is still present). and
others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
Cylinder 2 injector output power driver stage.
1. Faulty injection valve or open solenoid windings.

Solution:

resistance, on the engine injector harness side of connector 3, between pins 6 and 11. There should be 0.4 -
0.5 Ω.
reoccurs, replace the ECU.
check resistance on the injector (valve) cover side of connector VC1 from pin 1 to pin 2. There should be 0.4 -
0.5 Ω.
A. If a small amount of resistance exists, there is open circuit condition in the engine injector harness between
connector 3 and connector VC1. Locate and repair the broken conductor.
terminal 1 (high side ring terminal) Use a multi-meter to check resistance, on the Cylinder 2 injector, from terminal
1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between con-
nector VC1 and connector INJ2. Locate and repair the broken conductor.
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has been resolved.
ation.
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Context:
Cause:

Solution:

0.5 Ω.
0.5 Ω.
nector 3 and connector VC2. Locate and repair the broken conductor.
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has been resolved.
ation.
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Context:
Cause:

Solution:

0.5 Ω.
0.5 Ω.
nector VC2 and connector INJ4. Locate and repair the broken conductor.
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has been resolved.
ation.
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3210-Bank 1 - General Short Circuit To Injector Cable

NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to accurately measure resistance
. The DMM must measure to a resolution of 0.1 ohms. The required measurements are as low as 0.4 ohms (typical
injector solenoid coil resistance is 0.4 - 0.5 Ω) and any DMM inaccuracies will cause the technician to inaccurately
troubleshoot.
NOTE: Ensure the DMM's test lead resistance is considered when measuring resistance. Touch the leads together
on the lowest Ohms scale and record the resistance measurement. Subtract this value from all future resistance
measurements.
Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 1 (Group A, Cylinders
1, 2, & 3). A power stage component energizes the injection system transistors while observing the current flow
in the high-side and low-side switching branch by sensing resistors. Deviations from the expected current flow are
detected as specific errors by the component and reported to the ECU. Error messages are configured to contain
information on performed injections, same bank cylinder errors, bank specific errors and cylinder specific errors. The
configured error message is compared to applicable error patterns, and the failure matching the pattern is output. If an
error message doesn't match a pattern the defect becomes an unclassifiable error. Monitoring is performed once per
camshaft revolution. This error is a result of a general short circuit of the high side to battery or ground over 4 camshaft
revolutions. This error shuts off an individual cylinder or bank, based on ECU parameters. Certain parameters, as
currently applied, are permanent; there is no healing possibility after testing: switching on the component to ascertain
the defect's presence. Others evoke an irreversible or reversible engine shut off.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of an injector
output power driver stage in Bank 1.

2. Faulty electrical wiring, short high side to high source, low side or ground (damaged wiring harness).
Solution:

2. Disconnect the engine injector harness from the ECU at connector 3. Use a DMM to check the resistance on
the engine injector harness side of connector 3.
From:
1. Pin 4 to pin 13
2. Pin 11 to pin 6
3. Pin 5 to pin 12
There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU connector 3 disconnected and continue to step 8.
B. If the resistance was below range, record the pin numbers and continue to step 3.
3. Use a DMM to check for continuity on the engine injector harness side of connector 3, from pins 4, 11, and 5 to
A. If there was continuity, record the pin number and continue to step 4.
B. If there was no continuity, continue to step 6.
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4. Disconnect the engine injector harness from the injector (valve) cover at connector VC1 and connector VC2.
Use a DMM to check for continuity on the injector (valve) cover side of connector :
From:
1. Connector VC1 pin 4, if recorded pin in Step 3 was pin 4, to chassis ground
3. Connector VC2 pin 4, if recorded pin in Step 3 was pin 5, to chassis ground.
There should not be continuity.
A. If there was continuity, leave connector VC1 and connector VC2 disconnected. Continue to step 5.
B. If there was no continuity, there is a short to ground condition in the engine injector harness between
connector VC1 pin 4 or 1, and ECU connector 3 pin 4, or 11
or between connector VC2 pin 4 and ECU connector 3, pin 5. Locate and repair the grounded conductor.
5. Remove the injector (valve) cover and disconnect the injector harness from the injector:
For:
1. Cylinder #1 injector at connector INJ1 terminal 1 (high side ring terminal) if recorded pin in Step 3
was pin 4
2. Cylinder #2 injector at connector INJ2 if recorded pin in Step 3 was pin 11
Use a DMM to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be
continuity.
A. If there is continuity, the injector solenoid coil has failed: replace the injector.
B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ1
(if recorded pin in Step 3 was pin 4), or connector INJ2 (if recorded pin in Step 3 was pin 11), and connector
VC1, pin 4, or 1 and ECU connector 3, pin 4, or 11
or connector VC2 and connector INJ3 (if recorded pin in Step 3 was pin 5) and ECU connector 3, pin 5.
Locate and repair the grounded conductor.
6. Disconnect the engine injector harness from the injector cover at connector VC1 and VC2. Use a DMM to
measure the resistance on the injector cover side of connector :
From:
1. VC1, pin 4 to 3, if recorded pins in Step 2 were pins 4 and 13
2. VC1, pin 2 to 1, if recorded pins in Step 2 were pins 11 and 6
3. VC2, Pin 3 to 4, if recorded pins in Step 2 were pins 5 and 12
connector VC1, pin 4, or 1, and ECU connector 3, pin 13, or 6
or connector VC2, pin 4 and ECU connector 3 pin 12. Locate and repair the short circuit.
B. If the resistance was below range, continue to step 7

For:
1. Cylinder #1 injector at connector INJ1, terminal 1 (high side ring terminal), if recorded pins in Step
2 were pins 4 and 13
2. Cylinder #2 injector at connector INJ2, if recorded pins in Step 2 were pin 11 and 6
3. Cylinder #3 injector at connector INJ3, if recorded pins in Step 2 were pins 5 and 12
Use a DMM to check for continuity, on the injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
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nector INJ1 or INJ2 and connector VC1 pin 3, or 2, ECU connector 3 pin 13, or 6
or connector INJ3 and connector VC2 pin 3, ECU connector 3, pin 12. Locate and repair the shorted
conductors.
B. If the resistance was below range, the injector solenoid coil has failed. Replace the injector.
8. Use a DMM to check for continuity, on the engine injector harness side of ECU connector 3, from pins 4, 11,
and 5 to all other populated pins in connector 3. There should not be continuity.
A. If there is continuity, record the pin numbers and use to locate and repair the shorted conductors.
B. If there is no continuity, the ECU may have failed. Attempt reloading the ECU software. If the fault reoc-
curs, replace the ECU.
has been resolved.
ation.
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3211-Bank 1 - Injector cable Short Circuit Low Side To Ground

Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 1 (Group A, Cylinders
Cause:
injector output power driver stage in Bank 1.
1. Faulty injection valve (solenoid coil shorted to ground).

2. Faulty electrical wiring, short low side to ground (damaged wiring).
Solution:

2. Carefully disconnect the engine injector harness from the ECU at connector 3. Use a multi-meter to check for
continuity, on the engine injector harness side of ECU connector 3 from pins 13, 6 and 12 to chassis ground.
A. If there is continuity on any of the pins to chassis ground, record the pin number and continue with step 3.
B. If there is no continuity, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs,
replace the ECU.
3. Disconnect the engine injector harness from the injector (valve) cover at connector VC1 and VC2. Use a multi-
meter to check for continuity, on the injector (valve) cover side of connector VC1 from pin 3, if recorded pin in
Step 2 was pin 13, or pin 2, if recorded pin in Step 2 was pin 6
or connector VC2 pin 3, if recorded pin in Step 2 was pin 12, to chassis ground. There should not be continuity.
A. If there was continuity to chassis ground, leave connector VC1 and VC2 disconnected, and continue with
step 4
B. If there was no continuity to chassis ground, there is a short to ground condition in the engine injector
harness between connector VC1 pin 3 or 2 and ECU connector 3 pin 13 or 6
or between connector VC2, pin 3 and ECU connector 3, pin 12. Locate and repair the grounded conductor.
INJ1 terminal 2 (low side ring terminal), if recorded pin in Step 2 was pin 13, or disconnect the injector harness
from the Cylinder #2 injector at connector INJ2, if recorded pin in Step 2 was pin 6 or disconnect the injector
harness from the Cylinder #3 injector at connector INJ3, if recorded pin in Step 2 was pin 12. Use a multi-meter
to check for continuity, on the injector, from terminal 2 to chassis ground. There should not be continuity.
A. If there is continuity, the injector solenoid coil has failed, replace the injector.
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B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ1,
if recorded pin in Step 2 was pin 13, or connector INJ2 if recorded pin in Step 2 was pin 6 and connector
VC1 pin 2 or 3 and ECU connector 3 pin 6 or 13
or connector INJ3, if recorded pin in Step 2 was pin 12. and connector VC2, pin 3 and ECU connector 3,
pin 12. Locate and repair the grounded conductor.
has been resolved.
ation.
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3213-Bank 1 - Unclassifiable Error

Context:
The engine control unit (ECU) has determined that an unclassified error exists in an injector cable in Bank 1 (Group
A, Cylinders 1, 2, & 3). A power stage component energizes the injection system transistors and simultaneously
observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation
from the expected current flow the component detects specific errors and reports them to the ECU. This error message
is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific
errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and
if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match
any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution.
This error is the result of an unclassified error being present over 9 camshaft revolutions. As a result of this error an
is still present), and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
stage in Bank 1.

Solution:

2. Visually check the electrical integrity of the injector circuits in Bank 1 (Inspect connector housing body/latch,
pins and wiring harness for damage or corrosion).
B. If no damage is determined, the ECU may have failed. Try reloading the ECU software and if the fault
has been resolved.
ation.
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3218-Bank 2 - General Short Circuit On Injector Cable

NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to accurately measure resistance
. The DMM must measure to a resolution of 0.1 ohms. The required measurements are as low as 0.4 ohms (typical
injector solenoid coil resistance is 0.4 - 0.5 Ω) and any DMM inaccuracies will cause the technician to inaccurately
troubleshoot.
NOTE: Ensure the DMM's test lead resistance is considered when measuring resistance. Touch the leads together
on the lowest Ohms scale and record the resistance measurement. Subtract this value from all future resistance
measurements.
Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 2 (Group B, Cylinders
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of an injector
output power driver stage in Bank 2.

2. Faulty electrical wiring, short high side to high source, low side or ground (damaged wiring harness).
Solution:

2. Disconnect the engine injector harness from the ECU at connector 3. Use a DMM to check the resistance on
the engine injector harness side of connector 3.
From:
1. Pin 14 to pin 3
2. Pin 16 to pin 1
3. Pin 15 to pin 2
A. If the resistance was within range, leave connector 3 disconnected and continue to step 8.
B. If the resistance was below range, record the pin numbers and continue to step 3.
3. Use a DMM to check for continuity on the engine injector harness side of connector 3, from pins 3, 1, and 2 to
A. If there was continuity, record the pin number and continue to step 4.
B. If there was no continuity, continue to step 6.
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4. Disconnect the engine injector harness from the injector (valve) cover at connector VC3 and connector VC2.
Use a DMM to check for continuity on the injector (valve) cover side of connector :
From:
3. Connector VC2 pin 2, if recorded pin in Step 3 was pin 3, to chassis ground.
A. If there was continuity, leave connector VC3 and connector VC2 disconnected. Continue to step 5.
B. If there was no continuity, there is a short to ground condition in the engine injector harness between
connector VC3 pin 2 or 3, and ECU connector 3, pin 1 or 2
or between connector VC2 pin 2 and ECU connector 3 pin 3. Locate and repair the grounded conductor.
For:
1. Cylinder #4 injector at connector INJ4 terminal 1 (high side ring terminal) if recorded pin in Step 3
was pin 3
Use a DMM to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be
continuity.
A. If there is continuity, the injector solenoid coil has failed: replace the injector.
B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ5
(if recorded pin in Step 3 was pin 1), or connector INJ6 (if recorded pin in Step 3 was pin 2), and connector
or connector VC2 pin 2 and connector INJ4 (if recorded pin in Step 3 was pin 3) and ECU connector 3 pin
3. Locate and repair the grounded conductor.
6. Disconnect the engine injector harness from the injector cover at connector VC3 and VC2. Use a DMM to
measure the resistance on the injector cover side of connector :
From:
1. VC3 pin 1 to 2, if recorded pins in Step 2 were pins 2 and 15
2. VC3 pin 3 to 4, if recorded pins in Step 2 were pins 1 and 16
3. VC2 Pin 1 to 2, if recorded pins in Step 2 were pins 3 and 14
connector VC3 pin 2 or 3, and ECU connector 3 pin 16 or 15
or connector VC2 pin 2 and ECU connector 3 pin 14. Locate and repair the short circuit.
B. If the resistance was below range, continue to step 7.

For:
1. Cylinder #4 injector at connector INJ4 terminal 1 (high side ring terminal), if recorded pins in Step
2 were pins 3 and 14
2. Cylinder #5 injector at connector INJ5, if recorded pins in Step 2 were pin 1 and 16
3. Cylinder #6 injector at connector INJ6, if recorded pins in Step 2 were pins 2 and 15
Use a DMM to check for continuity, on the injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
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nector INJ5, or INJ6 and connector VC3 pin 4 or 1, ECU connector 3 pin 16 or 15
or connector INJ4 and connector VC2 pin 1 and, ECU connector 3 pin 14. Locate and repair the shorted
conductors.
B. If the resistance was below range, the injector solenoid coil has failed. Replace the injector.
8. Use a DMM to check for continuity, on the engine injector harness side of connector 3, from pins 3, 1, and 2 to
all other populated pins in ECU connector 3. There should not be continuity.
A. If there is continuity, record the pin numbers and use to locate and repair the shorted conductors.
B. If there is no continuity, the ECU may have failed. Attempt reloading the ECU software. If the fault reoc-
curs, replace the ECU.
has been resolved.
ation.
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3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground

Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 2 (Group B, Cylinders
Cause:
injector output power driver stage in Bank 2.
1. Faulty injection valve (solenoid coil shorted to ground).

2. Faulty electrical wiring, short low side to ground (damaged wiring).
Solution:

2. Carefully disconnect the engine injector harness from the ECU at connector 3. Use a multi-meter to check for
continuity, on the engine injector harness side of ECU connector 3 from pins 16, 15 and 14 to chassis ground.
A. If there is continuity on any of the pins to chassis ground, record the pin number and continue with step 3.
B. If there is no continuity, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs,
replace the ECU.
3. Disconnect the engine injector harness from the injector (valve) cover at connector VC3 and VC2. Use a multi-
meter to check for continuity, on the injector (valve) cover side of connector VC3 from pin 4, if recorded pin in
Step 2 was pin 16, or pin 1, if recorded pin in Step 2 was pin 15
or connector VC2 pin 1, if recorded pin in Step 2 was pin 14, to chassis ground. There should not be continuity.
A. If there was continuity to chassis ground, leave connector VC3 and VC2 disconnected, and continue with
step 4
B. If there was no continuity to chassis ground, there is a short to ground condition in the engine injector
harness between connector vc3 pin 4 or 1 and ECU connector 3 pin 16 or 15
or between connector VC2 pin 1 and ECU connector 3 pin 14. Locate and repair the grounded conductor.
INJ4 terminal 2 (low side ring terminal), if recorded pin in Step 2 was pin 14, or disconnect the injector harness
from the Cylinder #5 injector at connector INJ5, if recorded pin in Step 2 was pin 16 or disconnect the injector
harness from the Cylinder #3 injector at connector INJ6, if recorded pin in Step 2 was pin 15. Use a multi-meter
to check for continuity, on the injector, from terminal 2 to chassis ground. There should not be continuity.
A. If there is continuity, the injector solenoid coil has failed, replace the injector.
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B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ5,
if recorded pin in Step 2 was pin 16, or connector INJ6 if recorded pin in Step 2 was pin 15 and connector
or connector INJ4, if recorded pin in Step 2 was pin 14. and connector VC2 pin 1 and ECU connector 3
pin 14. Locate and repair the grounded conductor.
has been resolved.
ation.
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3221-Bank 2 - Unclassifiable Error

Context:
The engine control unit (ECU) has determined that an unclassified error exists in an injector cable in Bank 2 (Group
B, Cylinders 4, 5, & 6). A power stage component energizes the injection system transistors and simultaneously
observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation
from the expected current flow the component detects specific errors and reports them to the ECU. This error message
is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific
errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and
if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match
any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution.
This error is the result of an unclassified error being present over 9 camshaft revolutions. As a result of this error an
Cause:
stage in Bank 2.

Solution:

2. Visually check the electrical integrity of the injector circuits in Bank 2 (Inspect connector housing body/latch,
pins and wiring harness for damage or corrosion).
B. If no damage is determined, the ECU may have failed. Try reloading the ECU software and if the fault
has been resolved.
ation.
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3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage

Too Low
Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “A”, the
fault path for errors in the power stage component of the unit injection system. The power stage monitors itself and
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If an internal reset or parity
error is present longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder
or bank is shut off. This shut off is currently applied to be permanent without a healing possibility by switching on the
component to see if the defect is still present. With either an irreversible or reversible shut off of the engine being
executed. The reason for this failure is a defective ECU. If the fault doesn't reset or reoccurs, replace the ECU.
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3228-Injection Processor Error - Unlocked/Initialization Error

Context:
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If an internal program flow
error exists for longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder
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3229-Injection processor error - stop engine

Context:
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the YSEL signal is not
inverted as requested during injection for longer than 3 camshaft revolutions , this error will occur. As a result of this
error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without a healing
possibility by switching on the component to see if the defect is still present. With either an irreversible or reversible
shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't reset or
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Context:
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the power stage compo-
nent On Time-out is present for at least one cylinder for longer than 3 camshaft revolutions , this error will occur. As a
result of this error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without
a healing possibility by switching on the component to see if the defect is still present. With either an irreversible or
reversible shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't
reset or reoccurs, replace the ECU.
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Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “B”, the
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. An internal reset or parity
error present longer than 3 camshaft revolutions, will produce this error. As a result of this error an individual cylinder
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Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “B”, the
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If an internal program flow
error exists for longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder
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Context:
The engine control unit (ECU) has sensed a problem with the internal supply for Fuel Injector Group “B”, the fault
path for errors in the power stage component of the unit injection system. The power stage monitors itself and reports
detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the power stage component
On Time-out is present for at least one cylinder for longer than 3 camshaft revolutions , this error will occur. As a
result of this error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without
a healing possibility by switching on the component to see if the defect is still present. With either an irreversible or
reversible shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't
reset or reoccurs, replace the ECU.
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Context:
The engine control unit (ECU) has detected that injection time is too long. The sum of all torque-forming energizing
times of an individual cylinder exceeds the limit, calculated from the map (depending on the engine speed and the
time since the overrun monitoring is active) for more than 100 test events (test frequency every 10 ms). When the
engine is in overrun operation the monitoring becomes active and the current injection energizing time is compared
with a maximum permissible time limit. If the limit is exceeded an ECU recovery (reset ) is triggered and if the error
reoccurs in the same driving cycle, the torque-determining power stages are irreversibly shut off. The basic idea is
that the operator reacts to an unintentional torque increase, caused by a malfunction of the ECU, by releasing the
accelerator pedal (reducing engine speed) which causes the engine to enter the overrun operation mode. Overrun
monitoring is only released if various conditions are met, such as no accelerator pedal activation, no activated cruise
control, no intervention of the vehicle dynamic control or gearbox control is present, etc. This failure could be the
result of electronic disturbances, a requested torque increase via tester, the wrong application of injection relevant
parameters, or a defective ECU. If this failure persists, the ECU may need to be replaced.
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3238-Communication error of CJ940 processor

Context:
The engine control unit (ECU) has detected an internal communications error. Internal communications between
the micro-controller and each CJ940 module (peripheral integrated circuit) via the SPI bus is monitored cyclically
every 20 milliseconds by evaluating the corresponding communication error flag which is provided by the hardware
encapsulation. For every test an error counter is increased or decreased in steps of one. If the error counter for
defective SPI buss communications reaches or exceeds a value of 5 this error becomes active and will reset once the
error counter is equal to or below the value of 0 (zero). This error is caused by electrical disturbances or an internal
defect of the ECU. If failure remains present, replace the ECU.
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3239-Engine Controller EEPROM - Read Operation Error

Context:
The engine control unit (ECU) has detected an error during the last EEPROM read operation. The hardware encap-
sulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found
or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and
depending on their value a failure or no failure is detected. If a failure is detected this error sets and should reset
immediately if the EEPROM operates correctly. This failure can be the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the
ECU.
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3240-Engine Controller EEPROM - Write Operation Failure

Context:
The engine control unit (ECU) has detected an error during the last EEPROM write operation. The hardware encap-
sulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found
or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and
depending on their value a failure or no failure is detected. If a failure is detected this error sets and should reset
immediately if the EEPROM operates correctly. This failure can be the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the
ECU.
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3241-Engine Controller EEPROM - Default Value Used

Context:
The engine control unit (ECU) has detected that substitute values for the EEPROM values are used. This happens if a
checksum error (CRC) is registered during reading. The hardware encapsulation of the ECU checks each data block
of the EEPROM and sets a status flag depending on if an error is found or not found. These flags are processed every
20 milliseconds by the Diagnostic System Management (DSM) and depending on their value a failure or no failure
is detected. If a failure is detected this error sets and should reset immediately if the EEPROM operates correctly.
This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU
correctly with the proper data set. If the error persists, replace the ECU.
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3242-Engine Controller (Locked) Recovery Occurred

Context:
The engine control unit (ECU) has detected, during system start up, a hardware or configuration problem. This triggers
an ECU recovery (reset of the CPU - Central Processing Unit) that is stored as protected. During a fresh ECU start
up different hardware tests are performed. If the error remains present even after reset, the software remains in the
boot-block and the driving software is not processed. If three recoveries are triggered within 4 seconds an irreversible
shut off of the system is carried out and the ECU is classified as permanently defective. In this case no error entry is
possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed to start up,
one of three recovery errors becomes active depending on the visibility of the recovery. This error can be the result
of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs
repeatedly, reprogram the ECU and if the error remains, replace the ECU.
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3243-Engine Controller Recovery (Suppressed) - Recovery

Occurred
Context:
an ECU recovery (reset of the CPU - Central Processing Unit) that is not stored. During a fresh ECU start up different
hardware tests are performed. If the error remains present even after reset, the software remains in the boot-block
and the driving software is not processed. If three recoveries are triggered within 4 seconds an irreversible shut
off of the system is carried out and the ECU is classified as permanently defective. In this case no error entry is
possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed to start up,
one of three recovery errors becomes active depending on the visibility of the recovery. This error can be the result
of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs
repeatedly, reprogram the ECU and if the error remains, replace the ECU.
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3244-Engine Controller Recovery (Visible) - Recovery Occurred

Context:
an ECU recovery (reset of the CPU - Central Processing Unit) that is visible in the error memory. During a fresh ECU
start up different hardware tests are performed. If the error remains present even after reset, the software remains
in the boot-block and the driving software is not processed. If three recoveries are triggered within 4 seconds an
irreversible shut off of the system is carried out and the ECU is classified as permanently defective. In this case no
error entry is possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed
to start up, one of three recovery errors becomes active depending on the visibility of the recovery. This error can be
the result of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error
occurs repeatedly, reprogram the ECU and if the error remains, replace the ECU.
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3245-Engine Controller - Watchdog Not Plausible

Context:
The engine control unit (ECU) has detected a fault in the internal monitoring circuitry. The ECU contains a CPU (central
processing unit) and other microprocessor based circuitry one of which serves as a monitoring module (watchdog).
These two components communicate via the internal communications network (SPI-Bus). Both devices mutually
monitor one another for correct functioning. The watchdog initiates a query / response communication with the CPU,
which responds by starting a "command test" (test of the correct functioning of important processor commands) and
"program flow control" (monitors the correct execution of code segments of the monitoring). From the results of these
two procedures the response to the watchdog is composed. If this response does not correspond to the expected
value, an error counter is incremented. The CPU periodically sends incorrect responses (regarding response time
and value, respectively) as result of the watchdog query / response. The CPU then monitors if the above mentioned
counter is incremented or decremented in accordance with the incorrect or correct response. If the behavior of the
counter is implausible, a second counter is incremented. This monitoring process is executed every 80 ms. This error
is the result of one of the counters exceeding a count of 5 and will reset if both counters contain a value less than 5.
If the error exists only temporarily, it can be ignored and deleted in the fault memory. If the error is permanent, engine
injection will not be allowed and the ECU must be replaced.
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3246-Shutoff Paths During Initialization - Watchdog

Context:
The engine control unit (ECU) has detected an internal watchdog error. The ECU comprises redundant shutoff paths
(SOP) which deactivate all power stages relevant to injection if certain internal ECU errors are detected. The defects
which trigger SOP are the watchdog, over voltage and under voltage errors. In order to test the correct functioning
of the SOP procedure, every path is activated during ECU initialization and followed by activation of the fuel injection
power stage. Since the SOP is active, no injection should occur as it is blocked if the SOP procedure functions
properly. During a successful redundant SOP test an open circuit (no current flow) should be detected. The SOP test
can only be carried out if no errors, such as short circuits of the injection power stage, have been detected previously.
This fault is detected if injection occurred although internal SOP of the watchdog was active. If the failure remains
after ECU initialization, replace the ECU.
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3247-Shutoff Paths Failed During Initialization - Supply Voltage

Too High
Context:
The engine control unit (ECU) has detected that the internal supply voltage is too high. The ECU comprises redundant
shut-off paths (SOP) which deactivate all power stages relevant to injection if certain internal ECU errors are detected.
The defects which trigger SOP are the watchdog, over voltage and under voltage errors. In order to test the correct
functioning of the SOP procedure, every path is activated during ECU initialization and followed by activation of the
fuel injection power stage. Since the SOP is active, no injection should occur as it is blocked if the SOP procedure
functions properly. During a successful redundant SOP test an open circuit (no current flow) should be detected. The
SOP test can only be carried out if no errors, such as short circuits of the injection power stage, have been detected
previously. This fault is detected if injection occurred although internal SOP of the over-voltage was active. If the
failure remains after ECU initialization, replace the ECU.
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3248-Shutoff Paths During Initialization - Supply Voltage Too Low

Context:
The engine control unit (ECU) has detected that the internal supply voltage is too low. The ECU comprises redundant
shutoff paths (SOP) which deactivate all power stages relevant to injection if certain internal ECU errors are detected.
The defects which trigger SOP are the watchdog, over voltage and under voltage errors. In order to test the correct
functioning of the SOP procedure, every path is activated during ECU initialization and followed by activation of the
fuel injection power stage. Since the SOP is active, no injection should occur as it is blocked if the SOP procedure
functions properly. During a successful redundant SOP test an open circuit (no current flow) should be detected. The
SOP test can only be carried out if no errors, such as short circuits of the injection power stage, have been detected
previously. This fault is detected if injection occurred although internal SOP of the under-voltage was active. If the
failure remains after ECU initialization, replace the ECU.
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3249-TPU Monitoring - Time Deviation Between TPU And System

Not Plausible
Context:
The engine control unit (ECU) has detected that the TPU (time processing unit) and CPU (central processing unit)
have operated outside the established parameters more than 4 times since last ECU recovery (initialization). As
the time base of the CPU is checked according to a query / response communication with the monitoring module
(watchdog) it should be correct if no error has been detected and therefore can be used to check the time base of the
TPU. For this purpose the time basis of the TPU and CPU are compared every 10 ms. After 100 ms the maximum and
the minimum value together with the absolute value of the sum of the time differences are evaluated. If the maximum
time difference between the TPU and CPU time base exceeds the threshold of 81 ms or the minimum time difference
is below the limit of 81 ms or the absolute value of the sum of the time differences is above 81 msan error counter
is incremented. If this counter exceeds the value of 4, this fault is set and initiates an ECU recovery (reset). If this
failure persists, the ECU will need to be replaced.
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3250-Dataset - Variant Defect

Cause:
1. Internal ECU error
Solution:
rence.
(1). Use the Electronic Service Tool to clear all fault codes.
(2). To check for fault code: Start and operate machine.

2. Reset Engine Control Unit (ECU).
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
A. Return to Step 1 to confirm elimination of fault.
B. NOT OK - Go to Step 3.
(1). Remove and replace ECU (Engine Control Unit).
for assistance.
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3251-Dataset - Requested Variant Could Not Be Set

Cause:
Solution:
rence.

for assistance.
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3252-Controller Watchdog - SPI Communication Failure

Context:
The engine control unit (ECU) has detected an internal (SPI Bus) communication failure. The central processing
unit (CPU) and monitoring module (watchdog) contained with in the ECU, communicate with each other via the SPI
bus. Both devices mutually monitor each other for correct functioning. If, however, the SPI communication between
them fails this monitoring is impaired and an error counter is incremented. If the error counter exceeds 2 over two
20 ms (two tests) checks, this fault is activated. Communication status is checked autonomously by the SPI driver
component every 20 ms and reports a detected error to the ECU. This error initiates ECU recovery (reset). If the ECU
functions correctly after recovery, the SPI error is temporary and can be ignored and deleted from fault memory. If
the SPI error is permanent and the ECU does not leave boot-block, the ECU needs to be replaced.
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3253-ADC Monitoring - Reference Voltage Too Low

Cause:
Solution:
rence.

for assistance.
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3254-ADC Monitoring - Reference Voltage Too High

Cause:
Solution:
rence.

for assistance.
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3255-ADC Monitoring Test Impulse Error

Cause:
Solution:
rence.

for assistance.
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3256-ADC Monitoring Queue Error

Cause:
Solution:
rence.

for assistance.
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3258-HS power stage hardware reports 'short circuit to battery'

longer than 500 ms.
NOTICE: Replace Starter Relay and test system before proceeding.
Cause:

Solution:
rence.

2. Checking power circuit. (NOTE: Replace starter relay and test system before proceeding).
RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(1) Starter relay
(1). Measure the voltage from the power junction post to Ground. The voltage should be approximately 12 V.
(2). Remove starter relay connector. Inspect pins, wiring and connectors for damage, abrasion, corrosion or
incorrect attachment.
(3). Measure the voltage from the starter relay connector pin 30 to ground. The voltage should be 12 V.
A. NOT OK - Determine the break between the connectors and repair. Return to Step 1 to confirm elimination
of fault.
3. Circuit E172-YE and E372-YE.
(1). Remove starter relay.
BD08E032-01 3
(1) Connector C
(2) Connector A
(3) Connector B
(2). Remove ECU connector B. Inspect pins, wiring and connectors for damage, abrasion, corrosion or incorrect
attachment.
(3). Measure the resistance from starter connector relay pin 85 to ECU connector B pin 17. The resistance
A. NOT OK - Repair or replace the harness as required. Go to Step 1 to confirm elimination of fault.
4. Checking circuit 21B1-WH (starter solenoid)
(1). Measure the resistance from the Starter relay connector pin 87 to the starter solenoid connector pin A
(21B4-WH). The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal
an intermittent condition.
A. NOT OK - Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
for assistance.
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3259-HS power stage hardware reports 'short circuit to ground'

longer than 100 ms.
Cause:

Solution:
rence.

RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(1) Starter relay
of fault.
BD08E032-01 3
(1) Connector C
(2) Connector A
(3) Connector B
attachment.
for assistance.
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3260-LS power stage hardware reports 'open load' longer than

100 ms
Cause:

Solution:
rence.

RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(1) Starter relay
of fault.
BD08E032-01 3
(1) Connector C
(2) Connector A
(3) Connector B
attachment.
for assistance.
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3261-LS power stage hardware reports 'short circuit to battery' or

'excess temperature' longer than 100 ms.
Cause:

Solution:
rence.

RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(1) Starter relay
of fault.
BD08E032-01 3
(1) Connector C
(2) Connector A
(3) Connector B
attachment.
for assistance.
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3262-LS power stage hardware reports 'short circuit to ground'

longer than 100 ms.
Cause:

Solution:
rence.

RCPH10TLB013BAM 1
(1) Power junction post

(2) Back side of front console (engine compartment)
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BD08F241-01 2
(1) Starter relay
of fault.
BD08E032-01 3
(1) Connector C
(2) Connector A
(3) Connector B
attachment.
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for assistance.
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3263-Busoff in CAN C
Cause:
Solution:
rence.

for assistance.
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3265-Energizing time exceeds limit of over run monitoring, injection

time too long
Context:
The engine control unit (ECU) has detected that injection time is too long. The sum of all torque-forming energizing
times of an individual cylinder exceeds the limit, calculated from the map (depending on the engine speed and the
time since the overrun monitoring is active) for more than 100 test events (test frequency every 10 ms). When the
engine is in overrun operation the monitoring becomes active and the current injection energizing time is compared
with a maximum permissible time limit. If the limit is exceeded an ECU recovery (reset ) is triggered and if the error
reoccurs in the same driving cycle, the torque-determining power stages are irreversibly shut off. The basic idea is
that the operator reacts to an unintentional torque increase, caused by a malfunction of the ECU, by releasing the
accelerator pedal (reducing engine speed) which causes the engine to enter the overrun operation mode. Overrun
monitoring is only released if various conditions are met, such as no accelerator pedal activation, no activated cruise
control, no intervention of the vehicle dynamic control or gearbox control is present, etc. This failure could be the
result of electronic disturbances, a requested torque increase via tester, the wrong application of injection relevant
parameters, or a defective ECU. If this failure persists, the ECU may need to be replaced.
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3266-Error in engine speed check, speed signal not plausible

Context:
The engine control unit (ECU) has determined that the speed signal is not plausible. In order to execute an overrun
monitoring, which checks if the injection energizing time is below a certain limit during overrun, the information of the
current engine speed is required. As the overrun monitoring is executed in layer 2 of the ECU monitoring concept (i.e.
function monitoring) in order to monitor the safety-relevant signal paths of the operational layer (layer 1, application
software) a redundant engine speed is additionally calculated in layer 2, independent of the engine speed information
of layer 1. If the absolute value of the deviation between engine speed (layer 1) and redundant segment speed (layer
2) exceeds 320 RPM over 800 ms (test frequency is every 40 ms), while the redundant segment speed is above 1000
RPM this error is activated, which triggers an ECU recovery (reset). If this failure persists after ECU re-initialization,
replace the ECU.
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3278-Engine Controller Supply Voltage Too High

NOTE: Check alternator output voltage, if above 16 volts refer to electrical trouble shooting section before proceeding.
See engine repair manual for electrical schematic information.
Cause:

Solution:
rence.

BD08E032-01 1
RCPH10TLB084AAM 2
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(1) Connector C
(2) Connector A
(3) Connector B
(4) Fuse block
(5) Side console
for assistance.
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3279-Engine Controller Internal Supply Voltage Too Low

NOTICE: Check the battery output voltage, if below 10 V charge the battery before proceeding.
Cause:

Solution:
rence.

BD08E032-01 1
RCPH10TLB084AAM 2
(1) Connector C
(2) Connector A
(3) Connector B
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(4) Fuse block

(5) Side console
for assistance.
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3280-Sensor Supply Voltage 1 - High

Cause:

Solution:
rence.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
(4) Measure the voltage from pins 2, 3, 8, and 9 on ECU connector B to ground (ECU connector B, pins 5, 6, 10
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A. NOT OK – Voltage is too high. Troubleshoot the charging system. Return to Step 1 to confirm elimination
of fault.
B. NOT OK – Voltage is to low. Verify battery voltage. Check fuse F-001 and wiring to ECU. Return to Step
C. OK – Go to Step 3.
for assistance.
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3281-Sensor Supply Voltage 1 - Low

Cause:

Solution:
rence.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
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of fault.
RCPH10TLB302AAF 2
(1) Fuse block

(2) Diagnostic port
(1) Disconnect fuse block connector and inspect pins.
(2) Measure the resistance from pins 2, 3, 8, and 9 on ECU connector B to fuse F-001. Wiggle the harness
during measurement to reveal an intermittent condition. The resistance should be less than 10 ohms.
A. NOT OK – Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
for assistance.
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Cause:

Solution:
rence.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
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of fault.
for assistance.
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Cause:

Solution:
rence.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
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of fault.
RCPH10TLB302AAF 2
(1) Fuse block

(2) Diagnostic port
for assistance.
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Cause:

Solution:
rence.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
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of fault.
for assistance.
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Cause:

Solution:
rence.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
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of fault.
RCPH10TLB302AAF 2
(1) Fuse block

(2) Diagnostic port
for assistance.
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3316-Minimum Number Of Injections Not Reached - Stop Engine

Context:
The engine control unit (ECU) has determined that the minimum number of injections was not reached. The injector
shutoff function (within the ECU) can switch off a single injector valve or an entire injection bank if a defect has been
detected in a component (monitoring is performed in other fault paths). The shutoff procedure is performed either for
an individual cylinder or for an entire bank. However, if too many cylinders are shut down by the shutoff function it is
no longer possible to run the engine securely and it has to be shut down entirely. In this case the fault path at hand
is set. It is possible for the engine to continue running on two cylinders. The test frequency is once per injection.
If this error occurs, see individual injector and injection-bank errors which have triggered the shutoff or error in the
component.
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3334-Timeout of CAN Message TSC1 Speed

Context:
CAN Data Link communications from the ECU have been lost.
Cause:
CAN Data Link communications from the ECU have been lost. This fault code will be displayed with other CAN Data
Link fault messages. The engine may go into Limp Home Mode and engine speed will be set to 1500 RPM.
5. Faulty ECU
Solution:
last occurrence.

and secure.
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RCPH10TLB030FAM 1

Step 1.

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RCPH10TLB085AAM 2
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3339-Timeout of CAN Message TSC1 Torque

Context:
CAN Data Link communications from the ECU have been lost.
Cause:
CAN Data Link communications from the ECU have been lost. This fault code will be displayed with other CAN Data
Link fault messages. The engine may go into Limp Home Mode and engine speed will be set to 1500 RPM.
5. Faulty ECU
Solution:
last occurrence.

and secure.
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RCPH10TLB030FAM 1

Step 1.

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RCPH10TLB085AAM 2
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3350-Terminal 50 - always on, starting circuit signal is active for

an excessive time period
Cause:

Solution:
rence.

RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(1) Starter relay
of fault.
BD08E032-01 3
(1) Connector C
(2) Connector A
(3) Connector B
attachment.
for assistance.
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3361-ECM EEPROM - General Error

Cause:
1. Internal ECU error.
Solution:
rence.

(1) Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again go to Step 3.

3. Program the ECU (Engine Control Unit).
(1) Program the ECU using correct version of EST (Electronic Service Tool).
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again go to Step 4

(1) Remove and replace ECU (Engine Control Unit).
for assistance.
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3363-Atmospheric Pressure Sensor - Processed via ADC, not

plausible
Cause:
1. ECU internal error
Solution:
rence.

(1) Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again go to Step 3.

3. Program the ECU (Engine Control Unit).
(1) Program the ECU using correct version of EST (Electronic Service Tool).
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again go to Step 4

(1) Remove and replace ECU (Engine Control Unit).
for assistance.
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3856-Coolant temperature signal test failure

NOTICE: Check coolant level before proceeding.
NOTE: When available use special tool 380040185 harness diagnostic/repair kit.
Cause:

Solution:
rence.

A. NOT OK – Repair fan or clear clogs from radiator. Return to Step 1 to confirm elimination of fault.
3. Check engine coolant temperature sensor.
BD08E033-01 1
(1) Connector coolant temperature sensor

(2) Upper radiator hose
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(1) Disconnect the coolant temperature sensor. Inspect pins, wiring and connectors for damage, abrasion, cor-
(2) Measure the resistance of the coolant temperature sensor. The resistance should be between 304 - 342 Ω
at 80 °C (176.0 °F), 2262 - 2760 Ω at 20 °C (68.0 °F), 8244 - 10661 Ω at -10 °C (14.0 °F) should be obtained.
A. NOT OK – Replace sensor. Return to Step 1 to confirm elimination of fault.
4. Check circuit.
BD08E032-01 2
(1) Connector C
(2) Connector A
(3) Connector B
(1) Measure the resistance from coolant temperature sensor pin 2 to ECU connector C, pin 26. The resistance
(2) Measure the resistance from coolant temperature sensor pin 1 to ECU connector C, pin 15. The resistance
of fault.
for assistance.
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3998-Unknown error
Cause:
1. CAN communication interrupted during normal operation.

Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes .
rence.
(1) Turn ignition switch to RUN position.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
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3. (1) Use the "EASY" program in the EST tool to bring up the fault.
(2) The fault number will be unique for the engine controller.
(3) Use the fault description to analyze the error, contact Technical Services Group for assistance.
(4) If no text or unique engine controller fault is found but the fault still appears on the AIC, contact Technical
Services Group for assistance.
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3999-Unknown error
Cause:

Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes .
rence.

BD08E032-01 1
(1) Connector C
(2) Connector A
(3) Connector B
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3. (1) Use the "EASY" program in the EST tool to bring up the fault.
(2) The fault number will be unique for the engine controller.
(3) Use the fault description to analyze the error, contact Technical Services Group for assistance.
(4) If no text or unique engine controller fault is found but the fault still appears on the AIC, contact Technical
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4000-Power supply (pin 2), forward FWD drive (pin 3), or RVS drive
(pin 4) drive shorted to ground
Context:
The FNR (Forward-Neutral-Reverse) Switch provides the "In Gear" signal to the Trax control. The Trax control will
turn on the forward solenoid or the reverse solenoid based on the "In Gear" input and the "Forward" or the "Reverse"
input signals. While this fault is active, the transmission will shift into Neutral and the Instrument Cluster will illuminate
the Danger Lamp .
Cause:
The Trax control does not see 12 VDC on X-300 pin 2 or the forward solenoid, X-300 pin 3 or reverse solenoid, X-300
pin 4 outputs are shorted to ground.
1. Faulty wiring or connectors.

2. The "In Gear" signal is not present on Trax connector X-300, pin 2. "In Gear" signal wiring or circuit is open.
3. The Forward Solenoid signal wire, (X-300 pin 3) is shorted to chassis ground.
4. The Reverse Solenoid signal wire, (X-300 pin 4) is shorted to chassis ground.
5. Faulty Trax control
Solution:
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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BD08E025-01 3
RCPH10TLB086AAM 4
(1) Transmission controller

(2) Windshield washer reservoir
TRAX Controller Description Wire ID

X-300 connector
2 In Gear Signal 5207 YE 20GA
3 Forward solenoid signal/supply 3053 WH 20GA
4 Reverse solenoid signal/supply 3063 WH 20GA
12 Forward solenoid return 3073 GY 20GA
16 Neutral Signal 21C7 YE 20GA
18 Forward Signal 25A5 LB 20GA
40 Reverse solenoid return 3083 GY 20GA
46 Reverse Signal 25B6 LB 20GA
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RCPH10TLB037GAM 5
Schematic legend
(1) FNR Switch (4) TRAX Controller
(2) Forward Solenoid (5) S-Type Transmission
(3) Reverse Solenoid (6) H-Tyoe Transmission
(1) Inspect the connections to the FNR Switch, Connector X147 and Connector X-040/X-150 and X-300 on the
Trax control. All connections should be secure and tight.
(2) Inspect the harness from the FNR switch to the Trax Control. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
A. OK – Go to Step 3.
B. NOT OK – Repair or replace harness or connectors as needed. Return to Step 1 to confirm elimination of
fault.
3. Measure at voltage at the Trax Control.
(1) Lift the floor board to expose the Trax control.
(3) Place the FNR Switch in the Forward position.
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(4) Measure the voltage from X-300 pin 2 to X-300 pin 29 (chassis ground). The voltage should be between 12
and 14 volts. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage is correct, go to Step 4.
B. NOT OK – Go to Step 7
4. Measure the resistance of the Forward and Reverse solenoid circuits.
(2) Disconnect X-345/X-374.
A. OK – The resistance measurement was greater then 20,000 ohms. Go to Step 5.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the
harness. Repair or replace the faulty wire as needed. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance of the Forward and Reverse solenoid circuits.
(1) Measure the resistance from X-374 A2 to chassis ground. The resistance should be greater than 20,000
A. OK – The resistance measurement was greater then 20,000 ohms. Go to Step 6.
harness. Repair or replace the faulty wire as needed. Return to Step 1 to confirm elimination of fault.
6. Measure the resistance through the solenoid drive circuit.
(1) Measure the resistance between X-374 A2 and X-374 A3. The resistance should be approximately 7.25
oms. Wiggle the harness during measurement to reveal an intermittent condition.
(2) Measure the resistance between X-374 B2 and X-374 B3. The resistance should be approximately 7.25
A. OK – The resistance is between 6.5 and 8 ohms. Temporarily replace the Trax Control. Return to Step 1
to confirm elimination of fault.
B. NOT OK – The resistance is less than 6.5 ohms. Temporarily replace the solenoid and retest. Return to
7. Measure the voltage at the FNR Switch.
Use backprobes or a breakout harness to measure the voltage at the FNR switch.
FNR Connector Description Wire ID

1 No Connect
2 Gear Command 1 1901 YE 20GA
3 Gear Command 2 to comfort steer 3221 YE 20GA
4 Kick Down to Trax 3211 YE 20GA
5 Reverse Signal to Trax Control 25B2 LB 20GA
6 Neutral Signal to Trax Control 21C5 YE 20GA
7 Forward Signal to Trax Control 25A2 LB 20GA
8 Battery from X-040/X-150 pin 21 - F-009 19E10 OG 20GA
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RCPH10TLB020GAM 6
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
vided
(1) Measure the voltage from FNR connector pin 7 to ground. The voltage should be approximately 12 volts.
A. OK – The voltage is approximately 12 volts. Go to Step 9.
B. NOT OK – The voltage is not correct or less than 12 volts. Go to Step 8.

8. Measure the voltage to the FNR switch.
(1) Measure the voltage from the FNR connector, pin 8 to ground (chassis ground). The voltage should be
A. OK – The voltage is approximately 12 volts. Temporarily replace the FNR switch. Go to Step 1 to confirm
elimination of the fault.
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B. NOT OK – The voltage is not correct or less than 12 volts. Check the +B circuit to the switch. Verify fuse
F-009 is not blown. Repair as required.
9. Measure the voltage at X147.
(1) Measure the voltage at X147 pin 32 (diode side). The voltage should be approximately 12 volts.
B. NOT OK – The voltage is not correct or less than 12 volts. There is a problem in the signal wire from the
FNR switch to X-147 pin 32. Repair or replace the wire as required.
10. Measure the voltage at X 147
(1) Measure the voltage at X 147 pin 28. The voltage should be approximately 12 volts.
B. NOT OK – Replace the wire/diode from X147 pin 32 to X147 pin 28.
11. Measure the voltage at connector X-040
(1) Measure the voltage at X-040 pin 13. The voltage should be approximately 12 volts.
B. NOT OK – The voltage was not correct. There is a problem in circuit 5203 YE/ 5205 YE. Verify splice
SP-104 is in good condition.
12. Measure the resistance of the TRAX Key On signal
(1) Turn key switch OFF.
(2) Measure the resistance from X-150 pin 13 to X-300 pin 2. The resistance should be less than 10 ohms.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Control and retest. the voltage is
approximately 12 volts. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is greater than 10 ohms. Replace the wire from X-150 pin 13 to X-300 pin 2.
Go to test Step1 to confirm elimination of the fault.
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4001-Power supply (pin 5), PWM 1 drive (pin 6), or PWM 2 drive
(pin 7) drive shorted to ground
Context:
The Key Switch provides the "TRAX Key ON" signal to the Trax control. The Trax control will turn on the S2 Solenoid/
(PWM 1/3 Solenoid) based or the S3 Solenoid/ (PWM 2/4 Solenoid) based on the inputs to the control. While this
fault is active, the transmission will shift into Neutral and the Instrument Cluster will illuminate the Danger Lamp .
Cause:
The Trax control does not see 12 VDC on X-300 pin 5 or the S2 Solenoid/ (PWM 1/3 Solenoid), X-300 pin 6 or S3
Solenoid/ (PWM 2/4 Solenoid), X-300 pin 7 outputs are shorted to ground.

2. The "Trax Key On" signal is not present on Trax connector X-300, pin 5. "Trax Key On" signal wiring or circuit
is open.
3. The S2 Solenoid signal wire, (X-300 pin 6) is shorted to chassis ground.
4. The S3 Solenoid signal wire, (X-300 pin 7) is shorted to chassis ground.
5. The PWM 1/3 Solenoid signal wire, (X-300 pin 6) is shorted to chassis ground.
6. The PWM 2/4 Solenoid signal wire, (X-300 pin 7) is shorted to chassis ground.
Solution:
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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B. NOT OK – Fault code is recorded again. Go to Step 2.

BD08E025-01 3
RCPH10TLB086AAM 4
(1) Transmission controller

(2) Windshield washer reservoir

X-300 connector
5 TRAX Key ON 19ED OG 20GA
6 S2 Solenoid or PWM 1/3 Solenoid drive 3043 WH 20GA
signal
7 S3 Solenoid or PWM 2/4 Solenoid drive 3593 WH 20GA
signal
8 TRAX Key ON 19EC OG 20GA
13 PWM 1/3 Solenoid ground/return 3033 GY 20GA
34 TRAX Key ON 19EB OG 20GA
41 PWM 2/4 Solenoid ground/return 3603 GY 20GA
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RCPH10TLB021GAM 5
Schematic legend
(1) Key Switch (5) H-Type Transmission with Powershift
Jumper Harness
(2) S-Type Transmission (6) PWM 1/3 Solenoid (Powershift Transmis-
sion Only)
(3) S2 Solenoid (7) PWM 2/4 Solenoid (Powershift Transmis-
sion Only)
(4) S3 Solenoid (8) TRAX Control
(9) GND004 Cab Ground Side Console on
Loader Control
(1) Inspect the connections to the Key Switch, Connector X-012 and X-300 on the Trax control. All connections
should be secure and tight.
(2) Inspect the harness from the Key Switch to the Trax Control. Verify that the harness is free of damage,
B. NOT OK – The connectors or harness is damaged. Repair or replace harness or connectors as needed.
and 14.5 volts. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK TYPE 1 – The voltage is correct. go to Step 4 .
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B. OK TYPE 2 – The voltage is correct. go to Step 7 .
C. NOT OK – Go to Step 10
4. Measure the resistance of the S2 Solenoid and S3 Solenoid circuit to chassis ground.
(2) Disconnect X-300.
(3) Measure the resistance from X-300 pin 6 to chassis ground. The resistance should be approximately 7.25
(4) Measure the resistance from X-300 pin 7 to chassis ground. The resistance should be approximately 7.25
A. OK – The resistance measurement was approximately 7.5 ohms. Go to Step 6.
B. NOT OK – The resistance was less than 6.5 ohms. Go to Step 5.

5. Measure the resistance through the S2 Solenoid and S3 Solenoid.
(1) Disconnect solenoid connection 322-1 and 323-1.
(2) Measure the resistance from the solenoid to chassis ground. The resistance should be approximately 7.25
A. OK – The measured resistance was between 6.5 ohms and 8 ohms. The solenoid is OK. There is a short
to chassis ground in the solenoid drive wire. Repair or replace the wire as needed. Go to Step 1 to confirm
B. NOT OK – The resistance is less than 6.5 ohms. There is a short circuit to chassis ground in the solenoid.
Replace the solenoid. Return to Step 1 to confirm elimination of fault.
6. Measure the resistance of the PWM 1/3 Solenoid and PWM 2/4 Solenoid circuit to chassis ground.
(1) Disconnect solenoid connections 322-1 and 323-1. Disconnect the TRAX Control X-300.
(2) Measure the resistance X-300 pin 6 to chassis ground. The resistance should be greater than 20,000 ohms.
(3) Measure the resistance X-300 pin 7 to chassis ground. The resistance should be greater than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the Trax Control. Return to Step
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit in the solenoid drive wire from
the Trax Control to the solenoid. Replace the wire. Return to Step 1 to confirm elimination of fault.
7. Measure the resistance through the solenoid wires.
(2) Disconnect the TRAX X-300 connector.
(3) Measure the resistance between X-300 pin 6 and X-300 pin 13. The resistance should be approximately
7.25 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
7.25 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The resistance is between 6.5 ohms and 8 ohms. Go to Step 8.
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B. NOT OK – The resistance is less than 6.5 ohms. Go to Step 9.

8. Measure the resistance of the solenoid drive wires to chassis ground.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the TRAX Control. Go to Step 1
B. NOT OK – The resistance is less than 20,000 ohms. The signal wire has a short circuit to chassis ground.
Replace or repair the signal wire. Go to Step 1 to confirm elimination of the fault.
9. Measure the voltage at X147.
(1) Disconnect solenoid connection 322-1 and 323-1.
(2) Measure the between X-300 pin 6 and X-300 pin 13. The resistance should be greeter than 20,000 ohms.
(3) Measure the between X-300 pin 7 and X-300 pin 41. The resistance should be greeter than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. The solenoid in the circuit has a short circuit. Replace
the solenoid. Go to Step 1 to confirm elimination of the fault code.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit in the solenoid signal line and
solenoid return line. Repair as required. 1 to confirm elimination of the fault code.
(1) Measure the voltage at X-012 pin 3 to chassis ground. The voltage should be approximately 12 volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem between X-12 pin 3 and X-300 pin 5.
Inspect fuse F-009. Inspect splice SP-67. Repair as required. Go to Step 1 to confirm elimination of the
fault.
B. NOT OK – The voltage is less than 12 volts. Go to Step 11.

11. Measure the voltage at the key switch.
(1) Measure the voltage at the key switch pin 3 (Ignition). The voltage should be approximately 12 volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem between the key switch and X-012 pin
3. Inspect splice SP-012. Repair as required. Go to Step 1 to confirm elimination of the fault.

12. Measure the voltage input to the key switch.
(1) Measure the voltage at key switch connector pin 1 (Battery). The voltage should be approximately 12 volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem with the key switch. Replace the key
switch. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The voltage is less than 12 volts. There is a problem with the 12 volt supply to the key switch.
Inspect fuse F-025. Repair as required. Go to Step 1.
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4002-Power supply for digital outputs (pin 8) does not have power
Context:
The power supply for the digital outputs on the Trax Control is not functioning. The transmission will shift into Limp
Home mode in 2nd gear, without modulation. While this fault is active, the Instrument Cluster will illuminate the Warn-
ing Lamp .
Cause:
The power supply for the digital outputs on the Trax Control is not functioning.
1. Open circuit to the Trax Control

2. Faulty Fuse F-009
3. Faulty Trax Control
Solution:
rence.

BD08E025-01 1
RCPH10TLB086AAM 2
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X-300 connector
Key switch Description Wire ID

1 Battery P018 RD 16GA
2 Start 21A2 YE 20GA
3 Ignition 3001 OG 16GA
4 Accessory 4001 OG 20GA
RCPH10TLB032FAM 3
Schematic legend
(1) Key Switch (3) Battery supply to key switch from fuse
F-025
(2) Trax Control
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and 14.5 volts. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage is correct. Temporarily replace the Trax Control and retest. Go to Step 1 to confirm
B. NOT OK – The voltage is not correct. Go to Step 4.

fault.


(1) Measure the voltage at key switch connector pin 1 (Battery). The voltage should be between 12 and 14.2
volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem with the key switch. Replace the key
switch. Go to Step 1 to confirm elimination of the fault.
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4004-Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds
with engine speed above 900 rpm
Context:
Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 RPM. While this fault is
active, the Instrument Cluster will illuminate the Warning Lamp .
Cause:
Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 RPM.
1. Open circuit to the Trax Control

2. Faulty Fuse F-009
Solution:
rence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2

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BD08E025-01 3
RCPH10TLB086AAM 4

X-300 connector
Key switch Description Wire ID

1 Battery P018 RD 16GA
2 Start 21A2 YE 20GA
3 Ignition 3001 OG 16GA
4 Accessory 4001 OG 20GA
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RCPH10TLB032FAM 5
Schematic legend
(1) Key Switch (3) Battery to key switch from fuse F-025
(2) Trax Control
(3) Measure the voltage from X-300 pin 34 to X-300 pin 29 (chassis ground). The voltage should be between
12 and 14.5 volts. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage is correct. Temporarily replace the Trax Control and retest. Go to Step 1 to confirm
B. NOT OK – Go to Step 4
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fault.


(1) Measure the voltage at key switch connector pin 1 (Battery). The voltage should be approximately 12 volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem with the key switch. Temporarily
replace the key switch and retest. Go to Step 1 to confirm elimination of the fault.
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4005-Downshift delayed due to possible engine overspeed

condition S-Type Transmission Only
NOTE: Informational code only for the S-Type transmission.
Cause:
Downshift delayed due to possible engine overspeed condition. Downshift was not accomplished because vehicle
speed is too high. This is an informational fault code and no further troubleshooting is required.
Solution:
1. Fault Code 4005 is displayed on the Instrument Cluster to warn the operator that the downshift was not accom-
plished due to excessive engine speed.
RCPH10TLB138AAF 1
The Warning Lamp will illuminate Amber and the LCD backlight will change from the normal
backlight to Amber.
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4006-FWD input (Pin 12) feedback circuit is reading current with

command
Context:
input signals.
Cause:
The Trax Control is measuring an excessive current in the FWD input (Pin 12) feedback circuit when the Forward
Solenoid is ON. The current on X-300 pin 12 is greater than 1.1 Amp.

2. Short circuit in the Forward Solenoid.
3. The Forward Solenoid return wire, (X-300 pin 12) shorted to a voltage source.
Solution:
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
A. OK – The fault is not recorded again. Return the machine to service.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB034FAM 3
Schematic legend
(1) S-Type Transmission (4) H-Type Transmission with Powershift
Jumper Harness
(2) Forward Solenoid (5) Trax Control
(3) Reverse Solenoid (6) Forward signal (input) to the Trax Control
(1) Inspect Trax connector X-300 and the Forward Solenoid connections. All connections should be secure,
tight, free of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Trax Control to the Forward Solenoid. Verify that the harness is free of damage,
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B. NOT OK – The connectors or harness has damage. Repair or replace harness or connectors as required.
3. Measure the voltage on the solenoid return wire.
(2) Disconnect Trax connector X-300 and the Forward Solenoid connector X-320.
(4) Measure the voltage from X-300 pin 12 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
A. OK – The voltage measurement is less than 0.5 volts. Go to Step 4.
B. NOT OK – The voltage is greater than 0.5 volts. There is a short circuit to another voltage source. Replace
the wire from X-300 pin 12 to the Forward Solenoid. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the Forward Solenoid.
(2) Disconnect connector X-320 from the Forward Solenoid.
(3) Measure the resistance of the solenoid. The resistance should be approximately 7.25 ohms.
A. OK – The resistance is between 6.5 ohms and 8 ohms. Temporarily replace the Trax. Control and retest.
B. NOT OK – The resistance is less than 6.5 ohms. The Forward Solenoid has an internal short circuit.
Replace the Forward Solenoid and retest. Return to Step 1 to confirm elimination of fault.
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4007-FWD input (Pin 12) current is too low with command present
Context:
input signals.
Cause:
The Trax Control is measuring current in the FWD input (Pin 12) feedback circuit that is too low when the Forward
Solenoid is ON. The current on X-300 pin 12 is less than 0.05 Amp.

2. The Forward Solenoid drive or return wire has an open circuit.
3. Forward Solenoid has an internal open circuit.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB034FAM 3
Schematic legend
Jumper Harness
(1) Inspect Trax connector X-300 and the Forward Solenoid connections. All connections should be secure and
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3. Measure the resistance through the wire.
(2) Disconnect Trax connector X-300.
(3) Measure the resistance from X-300 pin 3 to X-300 pin 12. The resistance should be approximately 7.25
A. OK – The resistance is between 6.5 ohms and 8 ohms. Temporarily replace the Trax Control and retest.
Go to Step 1 to confirm the elimination of the fault. .
B. NOT OK – The resistance is greater than 8 ohms. There is a problem in the solenoid circuit. Go to Step 4.
B. NOT OK – The resistance is greater than 8 ohms. The Forward Solenoid has an internal open circuit.
(1) Disconnect X-300 and the Forward Solenoid connector, X-320.
(2) Fabricate a 5 inch jumper wire with pins on each end. Insert the jumper in connector X-320 pin 1 and X-320
pin 2.
(3) Measure the resistance between X300 pin 3 and X-300 pin 12. The resistance should be less than 10 ohms.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Control and retest. Go to Step 1
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Forward
solenoid. Verify all connections are tight and secure and free of damage. Repair or replace the wires as
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4008-FWD solenoid is drawing more current than commanded

Context:
input signals.
Cause:
The Trax Control is measuring an excessive current in the FWD input (Pin 12) feedback circuit when the Forward
Solenoid is ON.

2. Short circuit in the Forward Solenoid.
3. The Forward Solenoid return wire, (X-300 pin 12) is shorted to a voltage source.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB034FAM 3
Schematic legend
Jumper Harness
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(2) Disconnect Trax connector X-300 and the Forward Solenoid connector X-320.
B. NOT OK – The resistance was less than 6.5 ohms. The Forward Solenoid has an internal short circuit.
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4009-FWD solenoid is drawing less current than commanded

Context:
input signals.
Cause:
The Trax Control is measuring current in the FWD input (Pin 12) feedback circuit that is too low when the Forward
Solenoid is ON. The machine will go into Limp Home mode (without modulation) in gear 2 only.

2. The Forward Solenoid drive or return wire has an open circuit.
3. Forward Solenoid has an internal open circuit.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB034FAM 3
Schematic legend
Jumper Harness
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B. NOT OK – The resistance is greater than 8 ohms. The Forward Solenoid has an internal open circuit.
(1) Disconnect X-300 and the Forward Solenoid connector, X-320.
(2) Fabricate a 5 inch jumper wire with Deutsch pins on each end. Insert the jumper in connector X-320 pin 1
and X-320 pin 2.
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Forward
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4011-RVS input (pin 40) feedback circuit is reading current with

command
Context:
input signals.
Cause:
The Trax Control is measuring an excessive current in the REV input (Pin 40) feedback circuit when the Reverse
Solenoid is ON. The current on X-300 pin 40 is greater than 1.1 Amp.

2. Short circuit in the Reverse Solenoid.
3. The Reverse Solenoid return wire, (X-300 pin 40) is shorted to a voltage source.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
46 Reverse Signal 25A6 LB 20GA
RCPH10TLB036FAM 3
Schematic legend
Jumper Harness
(3) Reverse Solenoid (6) Reverse signal (input) to the Trax Control
(1) Inspect Trax connector X-300 and the Reverse Solenoid connections. All connections should be secure and
(2) Inspect the harness from the Trax Control to the Reverse Solenoid. Verify that the harness is free of damage,
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(2) Disconnect Trax connector X-300 and the Reverse Solenoid connector X-321.
the wire from X-300 pin 40 to the Reverse Solenoid. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the Reverse Solenoid.
(2) Disconnect connector X-321 from the Reverse Solenoid.
B. NOT OK – The resistance was less than 6.5 ohms. The Reverse Solenoid has an internal short circuit.
Replace the Reverse Solenoid and retest. Return to Step 1 to confirm elimination of fault.
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4012-RVS input (pin 40) current is too low with command present
Context:
input signals.
Cause:
The Trax Control is measuring current in the REV input (Pin 40) feedback circuit that is too low when the Reverse
Solenoid is ON. The current on X-300 pin 40 is less than 0.05 Amp.

2. The Reverse Solenoid drive or return wire has an open circuit.
3. Reverse Solenoid has an internal open circuit.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB036FAM 3
Schematic legend
Jumper Harness
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B. NOT OK – The resistance is greater than 8 ohms. The Reverse Solenoid has an internal open circuit.
(1) Disconnect X-300 and the Reverse Solenoid connector, X-321.
and X-321 pin 2.
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Reverse
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4013-RVS solenoid is drawing more current than commanded

Context:
input signals.
Cause:
The Trax Control is measuring an excessive current in the REV input (Pin 40) feedback circuit when the Reverse
Solenoid is ON.

2. Short circuit in the Reverse Solenoid.
3. The Reverse Solenoid return wire, (X-300 pin 40) is shorted to a voltage source.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB036FAM 3
Schematic legend
Jumper Harness
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B. NOT OK – The connectors or the harness is damaged. Repair or replace the harness or connectors as
needed. Return to Step 1 to confirm elimination of fault.
(2) Disconnect Trax connector X-300 and the Reverse Solenoid connector X-321.
the wire from X-300 pin 12 to the Reverse Solenoid. Return to Step 1 to confirm elimination of fault.
B. NOT OK – The resistance was less than 6.5 ohms. The Reverse Solenoid has an internal short circuit.
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4014-RVS solenoid is drawing less current than commanded

Context:
input signals.
Cause:
The Trax Control is measuring current in the REV input (Pin 40) feedback circuit that is too low when the Reverse
Solenoid is ON. The machine will go into Limp Home mode (without modulation) in gear 2 only.

2. The Reverse Solenoid signal or return wire has an open circuit.
3. Reverse Solenoid has an internal open circuit.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB036FAM 3
Schematic legend
Jumper Harness
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needed. Return to Step 1 to confirm elimination of fault.
(3) Measure the resistance of the solenoid through connector X-321 pin 1 and pin 2. The resistance should be
approximately 7.25 ohms.
B. NOT OK – The resistance is greater than 8 ohms. The Reverse Solenoid has an internal open circuit.
(1) Disconnect X-300 and the Reverse Solenoid connector, X-321.
and X-320 pin 2.
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Reverse
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4016-First and third shift modulation solenoid input (pin 13)

feedback circuit is reading current without command - H-Type
Transmission Only
Context:
First and third shift modulation solenoid input (pin 13) feedback circuit is reading too much current with command.
The machine will shift into Neutral while this fault is active.
Cause:
H-Type transmission only. First and third shift modulation solenoid input (pin 13) feedback circuit is reading too much
current with command.

2. Short circuit in the 1/3 Solenoid.
3. The 1/3 Solenoid return wire, (X-300 pin 13) is shorted to a voltage source.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
6 1/3 solenoid signal/supply 3043 WH 20GA
13 1/3 solenoid return 3033 GY 20GA
RCPH10TLB037FAM 3
Schematic legend
(1) 1/3 Solenoid (3) H-Type Transmission with Powershift
Jumper Harness
(2) 2/4 Solenoid (4) Trax Control
(1) Inspect Trax connector X-300 and the 1/3 Solenoid connections. All connections should be secure and tight
and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the 1/3 Solenoid. Verify that the harness is free of damage,
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(2) Disconnect Trax connector X-300 and the 1/3 Solenoid connector X-382.
the wire from X-300 pin 13 to the 1/3 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the 1/3 Solenoid.
(2) Disconnect connector X-382 from the 1/3 Solenoid.
B. NOT OK – The resistance was less than 6.5 ohms. The 1/3 Solenoid has an internal short circuit. Replace
the 1/3 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
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4017-First and third shift modulation solenoid input (pin 13) current
is too low with command present
Context:
First and third shift modulation solenoid input (pin 13) feedback circuit, current feedback is too low with command.
The machine will shift into Neutral while this fault is active.
Cause:
H-Type transmission only. First and third shift modulation solenoid input (pin 13) feedback circuit, current feedback is
too low with command.

2. Open circuit in the 1/3 Solenoid.
3. The 1/3 Solenoid signal or return wire has an open circuit.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB037FAM 3
Schematic legend
Jumper Harness
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B. NOT OK – The resistance is greater than 8 ohms. The 1/3 Solenoid has an internal open circuit. Replace
(1) Disconnect X-300 and the 1/3 Solenoid connector, X-382.
pin 2.
B. NOT OK – The resistance is greater than 10 ohms, there is an open circuit in the harness. Inspect con-
nectors from the Trax Control to the 1/3 solenoid. Verify all connections are tight and secure and free of
damage. Repair or replace the wires as required. Return to Step 1 to confirm elimination of fault.
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4018-First and third shift modulation solenoid is drawing more

current than commanded H-Type Transmission Only
Context:
First and third shift modulation solenoid input feedback circuit, current feedback is too high with command. The ma-
chine will shift into Neutral while this fault is active.
Cause:
too high with command.

3. The 1/3 Solenoid return wire, (X-300 pin 13) shorted to a voltage source.
Solution:

BD08E025-01 1
RCPH10TLB086AAM 2
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X-300 connector
RCPH10TLB037FAM 3
Schematic legend
Jumper Harness
(1) Inspect Trax connector X-300 and the 1/3 Solenoid connections. All connections should be secure, tight,
free of corrosion, abrasion and/or damage.
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B. NOT OK – The resistance is less than 6.5 ohms. The 1/3 Solenoid has an internal short circuit. Replace
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4019-First and third shift modulation solenoid is drawing less

current than commanded H-Type Transmission Only
Context:
First and third shift modulation solenoid input feedback circuit, current feedback is too low with command. The ma-
chine will shift into Neutral while this fault is active.
Cause:
too low with the solenoid commanded to the On position.

2. The 1/3 Solenoid wiring has an open circuit.
4. Faulty Trax control.
Solution:

BD08E025-01 1
RCPH10TLB086AAM 2
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X-300 connector
RCPH10TLB037FAM 3
Schematic legend
Jumper Harness
(3) Measure the resistance from X-300 pin 6to X-300 pin 13. The resistance should be approximately 7.25
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and X-382 pin 2.
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the harness. Inspect
connectors from the Trax Control to the 1/3 solenoid. Verify all connections are tight and secure and free
of damage. Repair or replace the wires as required. Return to Step 1 to confirm elimination of fault.
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4021-Second and fourth shift modulation solenoid input (pin

41) feedback circuit is reading current with command - H-Type
Transmission Only
Context:
Second and fourth shift modulation solenoid input, (pin 41) feedback circuit is reading too much current with command
Cause:
H-Type transmission only. Second and fourth shift modulation solenoid input (pin 41) feedback circuit is reading too
much current when the solenoid is commanded ON..

3. The 2/4 Solenoid return wire, (X-300 pin 41) is shorted to a voltage source.
Solution:

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB037FAM 3
Schematic legend
Jumper Harness
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the wire from X-300 pin 41 to the 2/4 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
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4022-Second and fourth shift modulation solenoid input (pin 41)

current is too low with command present - H-Type Transmission
Only
Context:
Second and fourth shift modulation solenoid input (pin 41) current is less than 0.05 A with more than 0.1 A commanded
for more than 250 ms.
Cause:
H-Type transmission only. Second and forth shift modulation solenoid input (pin 41) feedback circuit, current feedback
is too low with command. The transmission will go into Limp Home mode in first gear, without modulation.

2. The 2/4 Solenoid signal wire or return wire has an open circuit.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH10TLB037FAM 3
Schematic legend
Jumper Harness
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and X-383 pin 2.
B. NOT OK – The resistance is greater than 10 ohms, there is an open circuit in the harness. Inspect con-
nectors from the Trax Control to the 2/4 solenoid. Verify all connections are tight and secure and free of
damage. Repair or replace the wires as required. Return to Step 1 to confirm elimination of fault.
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4023-Second and fourth shift modulation solenoid is drawing more

current than commanded - H-Type Transmission Only
Context:
Second and fourth shift modulation solenoid input feedback circuit, current feedback is too high with command. The
machine will shift into Neutral.
Cause:
H-Type transmission only. Second and fourth shift modulation solenoid input (pin 41) feedback circuit, current feed-
back is too high with command.

3. The 2/4 Solenoid return wire, (X-300 pin 41) shorted to a voltage source.
Solution:

BD08E025-01 1
RCPH10TLB086AAM 2
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X-300 connector
RCPH10TLB037FAM 3
Schematic legend
Jumper Harness
the wire from X-300 pin 41 to the 2/4 Solenoid. Return to Step 1 to confirm elimination of fault.
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4024-Second and fourth shift modulation solenoid is drawing less

current than commanded - H-Type Transmission Only
Context:
Second and fourth shift modulation solenoid input feedback circuit, current feedback is too low with command. The
machine will shift into Neutral.
Cause:
H-Type transmission only. Second and fourth shift modulation solenoid input (pin 41) feedback circuit, current feed-
back is too low with the solenoid commanded to the On position.

2. The 2/4 Solenoid wiring has an open circuit.
Solution:

BD08E025-01 1
RCPH10TLB086AAM 2
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X-300 connector
RCPH10TLB037FAM 3
Schematic legend
Jumper Harness
B. NOT OK – The connectors or harness has damage. Repair or replace the harness or connectors as
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pin 2.
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the harness. Inspect
connectors from the Trax Control to the 2/4 solenoid. Verify all connections are tight and secure and free
of damage. Repair or replace the wires as required. Return to Step 1 to confirm elimination of fault.
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4026-First / Third shift solenoid shorted to ground - H-Type

Transmission Only
Context:
The 1/3 solenoid driver (output) is shorted to ground (chassis ground).
Cause:
H-Type Transmission Only - The 1/3 solenoid driver (output) is shorted to ground (chassis ground). The machine will
go into Limp Home Mode in second gear (without modulation).

2. The 1/3 Solenoid drive circuit shorted to ground (chassis ground).
3. 1/3 Solenoid has an internal short circuit.
Solution:

BD08E025-01 1

X-300 connector
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RCPH10TLB037FAM 2
Schematic legend
Jumper Harness
3. Measure the resistance to chassis ground.
BC08A418 3
(1) 2/4 PWM solenoid (5) 4 wheel drive solenoid

(2) Reverse solenoid (6) 2nd/4th solenoid
(3) Forward solenoid (7) Differential lock solenoid
(4) 1/3 PWM solenoid (8) 1st/3rd solenoid
(1) Disconnect Trax connector X-300 and 1/3 solenoid connector 382.
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B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the 1/3
solenoid drive circuit. Verify harness is free of abrasion and the connectors are not damaged. Repair or
replace the harness as required. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance across the solenoid.
(1) Measure the resistance from solenoid connector 382 pin 1 to chassis ground. The resistance should be
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the Trax control and retest. Go to
B. NOT OK – The resistance is less than 20,000 ohms. Replace the 1/3 solenoid and retest. Return to Step
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4027-Second / Fourth shift solenoid shorted to ground - H-Type

Transmission Only
Context:
The 2/4 solenoid driver (output) is shorted to ground (chassis ground).
Cause:
H-Type Transmission Only - The 2/4 solenoid driver (output) is shorted to ground (chassis ground). The machine will

2. The 2/4 Solenoid drive circuit shorted to ground (chassis ground).
3. 2/4 Solenoid has an internal short circuit.
Solution:

BD08E025-01 1

X-300 connector
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RCPH10TLB037FAM 2
Schematic legend
Jumper Harness
BC08A418 3

(1) Disconnect Trax connector X-300 and 2/4 solenoid connector 383.
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B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the 2/4
B. NOT OK – The resistance is less than 20,000 ohms. Replace the 2/4 solenoid and retest. Return to Step
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4028-Differential lock or 4 wheel drive solenoid shorted to ground -

H-Type and S-Type Transmissions
Context:
The Differential Lock solenoid driver (output) or the 4WD solenoid driver (output) is shorted to ground (chassis ground).
Cause:
The Differential Lock solenoid driver (output) or the 4WD solenoid driver (output) is shorted to ground (chassis ground).

2. The Differential Lock solenoid driver (output) or the 4WD solenoid driver (output) circuit is shorted to ground
(chassis ground).
3. Differential Lock solenoid or the 4WD solenoid has an internal short circuit.
Solution:

BD08E025-01 1

X-300 connector
39 4WD solenoid signal/supply 25X3 WH 20GA
11 Differential Lock signal/supply 3573 WH 20GA
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RCPH10TLB022GAM 2
Schematic legend
(1) S-Type Transmission Harness (4) Trax Control
(2) 4WD Solenoid (5) GND004 Cab Ground Side Console on
Loader Control
(3) Differential Lock Solenoid (6) H-Type Transmission with Powershift
Jumper Harness
(1) Inspect Trax connector X-300, 4WD Solenoid connector and Differential Lock solenoid connector. All con-
nections should be secure, tight, free of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Trax Control to the 4WD and Differential Lock Solenoids. Verify that the harness
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BC08A418 3

(1) Disconnect Trax connector X-300 and 4WD solenoid connector 326 (H-Type harness connector 386) and
Differential Lock solenoid connector 327 (H-Type harness connector 387).
solenoid drive circuit. Verify that the harness is free of abrasion and the connectors are not damaged.
Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
(1) Measure the resistance from 4WD solenoid connector 326 (H-Type harness connector 386) pin 1 to chassis
ground. The resistance should be greater than 20,000 ohms.
(2) Measure the resistance from Differential Lock solenoid connector 327 (H-Type harness connector 387) pin
1 to chassis ground. The resistance should be greater than 20,000 ohms.
B. NOT OK – The resistance is less than 20,000 ohms. Replace the solenoid and retest. Return to Step 1 to
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4029-Shifter Lever improperly connected, no power to pin 16,

pin 18, or pin 46 for more than 3 seconds - H-Type and S-Type
Transmissions
Context:
Shift lever improperly connected, no power to pin 16, pin 18, or pin 46 for more than 3 seconds.
Cause:
The Trax Control is powered ON but is not receiving a signal on X-300 pin 16, pin 18, or pin 46. If the Trax Control
does not receive a signal on either of these pins for more than 3 seconds, the Trax Control will log the fault code and
shift the transmission into Neutral.
1. Faulty wiring or connectors to the FNR Shift Lever.

2. Faulty wiring or connectors from the FNR Shift Lever to the Trax Control.
3. 12 volt supply to the FNR Shift Lever.
4. Faulty FNR Shift Lever.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH10TLB038FAM 2
Schematic legend
(1) Inspect Trax connector X-300 and the FNR Shift Lever connections. All connections should be secure and
(2) Inspect the harness from the Trax Control to the FNR Shift Lever. Verify that the harness is free of damage,
3. Measure the voltage at the FNR Shift Lever.
Use backprobes or a breakout harness (as shown below) to measure the voltage at the FNR switch.
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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(2) Measure the voltage from FNR connector pin 8 to chassis ground. The voltage should be approximately 12
volts.
A. OK – The voltage is between 12 and 14.2 volts. Go to Step 4.
B. NOT OK – The voltage is less than 12 volts. There is a problem with the voltage supply to the FNR Switch.
Verify that splices SP-062 and SP-067 are OK. Verify that the connections at X-040/150 and X-012 are
secure and free of damage. Verify that fuse F-009 is not blown. Repair or replace as required. Go to
Replace FNR selector. Return to Step 1 to confirm elimination of fault.
4. Measure the voltage of the switch output.
(2) Place the FNR switch in the Neutral position. Measure the voltage from pin 6 to chassis ground. The voltage
should be approximately 12 volts.
(3) Place the FNR switch in the Forward position. Measure the voltage from pin 7 to chassis ground. The voltage
should be approximately 12 volts.
(4) Place the FNR switch in the Reverse position. Measure the voltage from pin 5 to chassis ground. The
B. NOT OK – One or more voltage reading was less than 12 volts. There is a problem in the FNR Shift Lever.
Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the voltage at the Trax Control connector.
(2) Place the FNR switch in the Neutral position. Measure the voltage from X300 pin 16 to chassis ground
(X300-29). The voltage should be approximately 12 volts.
(3) Place the FNR switch in the Forward position. Measure the voltage from X300 pin 18 to chassis ground
(4) Place the FNR switch in the Reverse position. Measure the voltage from X300 pin 46 to chassis ground
A. OK – The voltage is between 12 and 14.2 volts for all three readings. Temporarily repalce the Trax Control
and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – One or more voltage reading was less than 12 volts. There is a problem in the harness from
the FNR Shift Lever to the Trax Control. Repair or replace the harness as required. Return to Step 1 to
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4030-Shifter Lever malfunction: transmission in neutral receives

forward and neutral together - H-Type and S-Type Transmissions
Context:
Shift lever malfunction; transmission in neutral position and receives a forward and neutral signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the neutral position and receives a forward signal and a neutral signal to-
gether more than 5 seconds. The Trax Control will log the fault code and keep the transmission in the neutral position
while the fault is active.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. The Neutral and Forward signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH10TLB038FAM 2
Schematic legend
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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(2) Use a wire removal tool and remove wire pin 6 and pin 7 from the FNR connector.
RCPH10TLB025GAM 5
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (4) Remove wires from pin 6 and pin 7.
Switch
(2) Breakout Harness - Dealer pro- (5) Digital Volt Meter
vided
(3) Engine Harness (6) Chassis ground
(4) Place the FNR switch in the Forward position.
(5) Measure the voltage from pin 6 to chassis ground. The voltage should be less than 0.5 volts.
(6) Measure the voltage from pin 7 to chassis ground. The voltage should be approximately 12 volts.
A. OK – The voltage on pin 6 is less than 0.5 volts and the voltage on pin 7 is between 12 and 14.2 volts. Go
to Step 4.
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B. NOT OK – The voltage on pin 6 is between 12 and 14.2 volts and the voltage on pin 7 is between 12 and
14.2 volts. Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of
fault.
4. Measure the resistance through the harness.
(2) Disconnect X-300 from the Trax Control.
(3) Measure the resistance between X-300 pin 16 and X-300 pin 18. The resistance should be greater than
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit between X-300 pin 16 and
X-300 pin 18. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
(1) Remove the breakout tee from the harness and FNR switch.
(2) Reinstall pin 6 and an pin 7 in the FNR connector. Reconnect the FNR harness connector to the FRN switch.
(4) Place the FNR Switch in the Neutral position.
(6) Measure the voltage from X-300 pin 16 to chassis ground. The voltage should be approximately 12 volts.
A. OK – The voltage on pin 18 is less than 0.5 volts and the voltage on pin 16 is between 12 and 14.2 volts.
Temporarily replace the Trax Control and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The voltage on pin 18 is between 12 and 14.2 volts and the voltage on pin 16 is between 12
and 14.2 volts. There is a short circuit between X-300 pin 18 and X-300 pin 16. Repair or replace the
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4031-Shifter Lever malfunction: transmission in neutral receives

reverse and neutral together
Context:
Shift lever malfunction; transmission in neutral position and receives a reverse and neutral signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the neutral position and receives a reverse signal and a neutral signal to-
gether more than 5 seconds. The Trax Control will log the fault code and keep the transmission in the neutral position
while the fault is active.
2. The Neutral and Reverse signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH10TLB038FAM 2
Schematic legend
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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RCPH10TLB026GAM 5
Schematic Legend
Switch
vided
(4) Place the FNR switch in the Reverse position.
to Step 4.
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fault.
(2) Reinstall pin 5 and an pin 6 in the FNR connector. Reconnect the FNR harness connector to the FRN switch.
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4032-Shifter Lever malfunction: transmission in forward receives

forward and reverse together
Context:
Shift lever malfunction; transmission in forward position and receives a forward and reverse signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the forward position and receives a forward signal and a reverse signal
together for a period greater than 5 seconds. The Trax Control will log the fault code and keep the transmission in the
neutral position while the fault is active.
2. The Forward and Reverse signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH10TLB038FAM 2
Schematic legend
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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RCPH10TLB027GAM 5
Schematic Legend
Switch
vided
A. OK – The voltage on pin 7 is between 12 and 14.2 volts and the voltage on pin 5 is less than 0.5 volts. Go
to Step 4.
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fault.
(2) Reinstall pin 5 and an pin 7 in the FNR connector. Reconnect the FNR harness connector to the FNR switch.
(4) Place the FNR Switch in the Reverse position.
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4033-Shifter Lever malfunction: transmission in reverse receives

forward and reverse together
Context:
Shift lever malfunction; transmission in reverse position and receives a forward and reverse signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the reverse position and receives a forward signal and a reverse signal
together for a period greater than 5 seconds. The Trax Control will log the fault code and keep the transmission in the
neutral position while the fault is active.
2. The Forward and Reverse signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH10TLB038FAM 2
Schematic legend
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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RCPH10TLB027GAM 5
Schematic Legend
Switch
vided
to Step 4.
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fault.
(4) Place the FNR Switch in the Forward position.
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4034-Shifter Lever malfunction: transmission in forward receives

neutral and forward together - H-Type and S-Type Transmissions
Context:
Shift lever malfunction; transmission in forward position and receives a forward and neutral signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the forward position and receives a forward signal and a neutral signal
together more than 5 seconds. The Trax Control will log the fault code and keep the transmission in the neutral
position while the fault is active.
2. The Neutral and Forward signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH10TLB038FAM 2
Schematic legend
(1) Inspect Trax connector X-300 and the FNR Shift Lever connections. All connections should be secure, free
of corrosion, abrasion and damage.
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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RCPH10TLB025GAM 5
Schematic Legend
Switch
vided
to Step 4.
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fault.
(2) Reinstall pin 6 and pin 7 in the FNR connector. Reconnect the FNR harness connector to the FNR switch.
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4035-Shifter Lever malfunction: transmission in reverse receives

neutral and reverse together
Context:
Shift lever malfunction; transmission is in the reverse position and receives a reverse and neutral signal together for
more than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the reverse position and receives a reverse signal and a neutral signal
together more than 5 seconds. The Trax Control will log the fault code and keep the transmission in the neutral
position while the fault is active.
2. The Neutral and Reverse signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH10TLB038FAM 2
Schematic legend
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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RCPH10TLB026GAM 5
Schematic Legend
Switch
vided
to Step 4.
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fault.
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4036-During transition from second to third gear, and Gear CMD_01

signal erratic or incorrect - H-Type and S-Type Transmissions
Context:
The Trax Control measured 12 volts on Gear Command 1 (X-300 pin 19) when the shifting from 2nd gear to 3rd gear.
Cause:
During the shift from 2nd gear to 3rd gear, the Trax Control measured 12 volts on Gear Command 1 (X-300 pin 19)
when it should have measured 0 volts. The Trax Control will log the fault code and go into Limp Home Mode (2nd
gear) while the fault is active.
2. Gear Command 1 and Gear Command 2 signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
47 3/4 Gear Command (Gear Command 2) 3223 YE 20GA
RCPH10TLB040FAM 2
Schematic legend
(1) FNR Switch (4) 12 volt supply from fuse F-009
(2) Relay K-014 Comfort Steer Cutout Relay (5) Gear Command 1
(3) TRAX Controller (6) Gear Command 2
Commanded Gear Gear Command 1 - FNR switch pin 2 Gear Command 2 - FNR switch pin 3 -
- Output Output
1st 12 volts 0 volts
2nd 0 volts 0 volts
3rd 0 volts 12 volts
4th 12 volts 12 volts
3. Measure the voltage at the FNR Shift Lever in second gear.
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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(2) Use a wire removal tool to remove wire pin 2 and pin 3 from the FNR connector.
RCPH10TLB028GAM 5
Schematic Legend
Switch
vided
(4) Place the FNR switch into second gear.
A. OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is less than 0.5 volts. Go to Step
4.
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B. NOT OK – The voltage on pin 2 is between 12 and 14.2 volts or the voltage on pin 3 is between 12 and
fault.
4. Measure the voltage at the FNR Shift Lever in third gear.
(2) Place the FNR switch into third gear.
(4) Measure the voltage from pin 3 to chassis ground. The voltage should be approximately 12 volts
to Step 5.
fault.
5. Measure the resistance through the harness
(3) Measure the resistance between X-300 pin 47 and X-300 pin 19. Wiggle the harness during measurement
to reveal an intermittent condition. The resistance should be greater than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the Trax Controller and retest. Go
to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short between pin 47 and pin 19. Repair
or replace the harness as required. Return to Step 1 to confirm elimination of fault.
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4037-During transition from first to second gear, and Gear CMD_02

signal erratic or incorrect
Context:
The Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47) when the shifting from 1st gear to 2nd gear.
Cause:
During the shift from 1st gear to 2nd gear, the Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47)
2. Gear Command 2 signal wire shorted to a voltage source.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH10TLB040FAM 2
Schematic legend
- Output Output
2nd 0 volts 0 volts
3. Measure the voltage at the FNR Shift Lever in first gear.
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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RCPH10TLB028GAM 5
Schematic Legend
Switch
vided
(4) Place the FNR switch into first gear.
to Step 4.
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fault.
4. Measure the voltage at the FNR Shift Lever in second gear.
A. OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is less than 0.5 volts Go to Step 5.
B. NOT OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is between 12 and 14.2
volts. Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of fault.
to reveal an intermittent condition. The resistance should be greater than 20,000 ohms.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short between pin 47 and pin 19. Repair
6. Measure the voltage on X-300 pin 19.
(2) Disconnect X-300 and remove the breakout tee from the FNR connector.
(4) Measure the voltage from X-300 pin 19 to chassis ground. Wiggle the harness during measurement to reveal
an intermittent condition. The voltage should be less than 0.5 volts.
A. OK – The voltage is less than 0.5 volts. Temporarily replace the Trax Control and retest. Go to Step 1 to
confirm elimination of the fault.
B. NOT OK – The voltage is approximately 12 volts. The wire has a short circuit to another voltage source.
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4038-During transition from third to fourth gear, and Gear CMD_02

signal erratic or incorrect
Context:
The Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47) when the shifting from 3rd gear to 4th gear.
Cause:
During the shift from 3rd gear to 4th gear, the Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47)
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH10TLB040FAM 2
Schematic legend
- Output Output
2nd 0 volts 0 volts
3. Measure the voltage at the FNR Shift Lever in third gear.
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BD08E055-01 3
RCPH10TLB020GAM 4
Schematic Legend
Switch
vided
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RCPH10TLB028GAM 5
Schematic Legend
Switch
vided
A. OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is between 12 and 14.2 volts Go
to Step 4.
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B. NOT OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is less than 0.5 volts.
Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of fault.
4. Measure the voltage at the FNR Shift Lever in fourth gear.
(2) Place the FNR switch into fourth gear.
A. OK – The voltage on pin 2 is between 12 and 14.2 volts and the voltage on pin 3 is between 12 and 14.2
volts Go to Step 5.
B. NOT OK – The voltage on pin 2 is between 12 and 14.2 volts and the voltage on pin 3 is less than 0.5
volts. Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of fault.
(3) Fabricate a jumper wire to short FNR connector pin 2 to pin 3.
RCPH10TLB014BAM 6
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (3) Jumper wire between pin 2 and pin
Switch 3.
(2) Engine Harness
to reveal an intermittent condition. The resistance should be less than 10 ohms.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Controller and retest. Go to Step
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in Gear Command 1 or Gear
Command 2 circuit. Repair or replace the harness as required. Return to Step 1 to confirm elimination of
fault.
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4040-Transmission Controller Driveline Configuration

Cause:
One or more parameters in the Transmission Control are not programmed.
1. The Transmission Control is not configured. The machine will go into Limp Home mode in first gear.
Solution:
1. Connect the Electronic Service Tool and configure all programmable parameters in the Transmission Control.
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4041-Transmission output shaft frequency above 3000 Hz detected

Context:
The Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47) when the shifting from 3rd gear to 4th gear.
Cause:
During the shift from 3rd gear to 4th gear, the Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47)
Solution:
rence.


X-300 connector
17 Sensor Common 0401 BL 20GA
25 Transmission Speed Signal 3301 BL 20GA
43 Transmission Temperature Signal 3431 YE 20GA
44 Transmission Pressure Switch 3441 YE 20GA
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RCPH10TLB030GAM 1
Schematic legend
(1) TRAX Controller (5) Transmission Pressure Switch - switch
closes when charge pressure = 9.5 bar
(138 psi) ± 1.5 bar (22 psi)
(2) Battery supply from fuse F-009 (6) Transmission Temperature Sensor
(3) S-Type Transmission Harness (7) Transmission Speed Sensor
(4) H-Type Transmission Jumper Harness
(1) Inspect Trax connector X-300 and the Transmission Speed Sensor connections. All connections should be
secure and tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Speed Sensor. Verify that the harness is free
of damage, corrosion, abrasion and incorrect attachment.
3. Check sensor of damage.
(1) Remove the sensor. The sensor is submerged in oil, care should be taken when removing the sensor so
minimal fluid is lost. Inspect the sensor for damage Remove all metal shaving from the sensor.
A. OK – The sensor is free of damage. Reinstall the speed sensor. Go to Step 4.
B. NOT OK – The sensor is damaged. Replace the sensor. Return to Step 1 to confirm elimination of fault.
4. Measure the sensor supply voltage.
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(2) Measure the voltage from Transmission Speed Sensor connector X330 (X-388) pin 3 to X330 (X-388) pin 2.
The voltage should be approximately 12 volts. Wiggle the harness during measurement to reveal an intermittent
condition.
A. OK – The voltage is between 11.0 and 14.2 volts. Go to Step 7.
B. NOT OK – The voltage is less than 11.4 volts or greater than 12.6 volts. Go to Step 5.
5. Measure the resistance through the sensor supply wire.
(2) Measure the resistance from X330 (X-388) pin 2 to X-300 pin 17. The resistance should be less than 10
A. OK – The resistance is less than 10 ohms. Go to Step 6.
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the harness. Repair or
replace the harness as required. Go to Step 1 to confirm elimination of fault.
6. Measure the supply voltage at connector X-344.
(2) Measure the voltage at X-344 pin B6. The voltage should be approximately 12 volts. Wiggle the harness
during measurement to reveal an intermittent condition.
B. NOT OK – The voltage is less than 11 volts. There is an open circuit in the wire from B6 to the sensor.
Repair or replace the wire. Go to Step 1 to confirm elimination of the fault.
7. Measure the resistance through the signal wire.
(2) Measure the resistance from X330 (X-388) pin 1 to X-330 pin 25. The resistance should be less than 10
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the sensor signal wire.
Repair or replace the wire. Go to Step 1 to confirm elimination of the fault.
8. Replace the sensor
(1) Slide the new copper washer over the sensor. Always use a new washer when installing a new transmission
speed sensor.
(2) Remove the sensor. The sensor is submerged in oil, care should be taken when removing the sensor so
minimal fluid is lost. Inspect the sensor for damage Remove all metal shaving from the sensor.
(3) Install the new sensor into the housing. Tighten nut to 25 N·m (18.4 lb ft).
(4) Reinstall the sensor connector and retest.
A. OK – The sensor has been replaced. The fault is not longer active. Stop.
B. NOT OK – The fault is still active. Temporarily replace the Trax Control and retest. Go to Step 1 to confirm
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4042-Temperature signal erratic or incorrect

Context:
The transmission temperature changed more than 50 °C (122 °F) between samples.
Cause:
The transmission temperature changed more than 50 °C (122 °F) between samples. The RED telltale light will illumi-
nate while the fault is active.
1. Faulty wiring or connections from the Transmission Temperature Sensor to the Trax Control.
2. Faulty sensor
Solution:
rence.


X-300 connector
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RCPH10TLB030GAM 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
(1) Inspect Trax connector X-300 and the Transmission Temperature Sensor connections. All connections
should be secure and tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Termperature Sensor. Verify that the harness
3. Measure the resistance of the temperature signal wire.
(2) Measure the resistance from Transmission Temperature Sensor 329 (H-Type Transmission 389) pin 1 to
X-300 pin 43. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal
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B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the wire. Repair or replace
the harness as required. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the Temperature Sensor
(1) Measure the resistance of the temperature sensor.
Transmission Sensor Open Circuit Resistance Measurements

Temperature Resistance in ohms (± 10%)
110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
A. OK – The resistance is measurements are within the values from the table. Temporarily replace the Trax
Control and retest. Go to Step 1.
B. NOT OK – The resistance is measurements were not within range. Temporarily replace the temperature
sensor and retest. Go to Step 1 to confirm elimination of fault.
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4043-Temperature sensor input (Pin 43) is shorted to a ground

Context:
The transmission temperature signal input is shorted to ground.
Cause:
The transmission temperature signal input is shorted to ground.
2. Faulty sensor
Solution:
rence.


X-300 connector
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RCPH10TLB030GAM 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
should be secure and tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Temperature Sensor. Verify that the harness
3. Measure the resistance of the temperature signal wire to chassis ground.
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B. NOT OK – The resistance is less than 20,000 ohms. There is an short circuit to chassis ground. Repair

110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
Control and retest.. Go to Step 1.
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4044-Temperature sensor input (Pin 43) is open circuit or shorted

to a voltage above 5 volts
Context:
The transmission temperature signal input is voltage is above 5 volts.
Cause:
The transmission temperature signal input has an open circuit or the signal wire is shorted to another voltage source.
2. Faulty sensor
Solution:
rence.


X-300 connector
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RCPH10TLB030GAM 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Temperature Sensor. Verify that the harness
3. Measure the resistance of the temperature signal wire.
(1) Turn the key switch OFF. Disconnect Trax Controller connector X-300 and Transmission Temperature Sensor
connector 329 (389).
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4. Measure the resistance of the temperature signal wire to battery.
(2) Measure the resistance from X-300 pin 43 to chassis ground. The voltage should be less than 0.5 volts.
A. OK – The voltage is less than 0.5 volts. Go to Step 5.
B. NOT OK – The voltage is greater than 0.5 volts. There is a short circuit to another voltage source. Repair

110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
Control and retest. Go to Step 1.
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4045-Charge pressure is not detected when engine speed is above

700 rpm for 10 seconds
Context:
The Trax Control did not receive a Transmission Charge Pressure signal while engine speed is greater than 700 rpm
for a period greater than 10 seconds.
Cause:
The Trax Control did not receive a Transmission Charge Pressure signal when engine speed is greater than 700 rpm.
The transmission will shift into Neutral while this code is active.
2. Faulty Charge Pressure switch
Solution:
rence.


X-300 connector
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RCPH10TLB030GAM 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
(1) Inspect Trax connector X-300 and the Transmission Pressure Switch connections. All connections should
be secure and tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Pressure Sensor. Verify that the harness is
free of damage, corrosion, abrasion and incorrect attachment.
3. Measure the resistance of the transmission pressure signal wire.
(1) Turn the key switch OFF. Disconnect Trax Controller connector X-300 and Transmission Pressure Sensor
(2) Measure the resistance from Transmission Pressure Sensor 328 (H-Type Transmission 390) pin 1 to X-300
44. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an inter-
mittent condition.
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pin 17. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an
4. Test the pressure switch.
(2) Remove the pressure switch from the transmission housing. Apply a pressure of 10 bar (145 psi) ± 1.5 bar
(22 psi) to the switch.
(2) Measure the resistance from terminal 1 to terminal 2 on the switch. The resistance should be less than 10
ohms while the pressure is applied.
B. NOT OK – The resistance is greater than 10 ohms. The switch is faulty. Replace the pressure switch.
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4046-Charge pressure is not detected and vehicle speed is over

10 kph (6 mph)
Context:
The Trax Control did not receive a Transmission Charge Pressure signal while vehicle speed is greater than 10 km/h
(6 mph) for a period greater than 0.5 seconds.
Cause:
The Trax Control did not receive a Transmission Charge Pressure signal while vehicle speed is greater than 10 km/h
(6 mph) for a period greater than 0.5 seconds.
1. Problem within the transmission.

Solution:
rence.

2. Check Charge Pressure
(1) Remove the pressure switch from the transmission housing.
(2) Install a gauge or use DATAR to measure the charge pressure. Charge pressure switch will be active when
the pressure is greater than 9.5 bar (138 psi). The measuring device should be capable of measuring 10 bar
without being damaged.
(3) Install the gauge. Monitor gauge pressure while operating the engine. a
A. OK – Charge pressure should be greater than 9.5 bar (138 psi) and the pressure switch should close. Go
to Step 3.
B. NOT OK – There is a problem with the transmission. Refer to the transmission section for more details.

X-300 connector
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RCPH10TLB030GAM 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
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5. Test the pressure switch.
(2) Remove the pressure switch from the transmission housing. Apply a pressure of 10 bar (145 psi) ± 1.5 bar
(22 psi) to the switch.
(3) Measure the resistance from terminal 1 to terminal 2 on the switch. The resistance should be less than 10
ohms while the pressure is applied.
B. NOT OK – The resistance is greater than 10 ohms. The switch is faulty. Replace the pressure switch.
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4047-Charge pressure switch is closed with no frequency input to

the TRAX controller
Context:
The Trax Control received a Charge Pressure Signal while engine speed equals 0 rpm.
Cause:
The Trax Control received a Charge Pressure Signal while engine speed equals 0 rpm. The Charge Pressure switch
is closed with no frequency input from the Transmission Speed sensor.
Solution:
rence.


X-300 connector
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RCPH10TLB030GAM 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
3. Check Charge Pressure switch
(2) Disconnect the Charge Pressure Switch connector 328 (390).
(3) Measure the resistance between pin 1 and pin 2 on the Charge Pressure switch. The resistance should be
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B. NOT OK – The resistance is less than 20,000 Replace the Charge Pressure switch. Go to Step 1 to
confirm elimination of the fault.
(2) Measure the resistance from Trax Control connector X-300 pin 44 to chassis ground. The resistance should
be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Control and retest. Go to Step 1.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit in the wire to chassis ground.
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4054-Unknown vehicle model value from VCM S-type transmission

only
Cause:
The transmission control does not recognize the vehicle model from the VCM. The Warning Lamp will illuminate
Amber and the LCD backlight will change from the normal backlight to Amber. The Instrument Cluster will sound the
alarm for one second upon activation per key cycle.
Solution:
1. Fault Code 4054 is displayed on the Instrument Cluster to warn the operator that the vehicle model has not been
programmed in the VCM. Set the model type in the machine configuration screen using the EST.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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4100-Missing EEC 1 message on CAN - H-Type Transmission Only

Context:
CAN Data Link communications between the Trax Control and the ECU have been lost
Cause:
CAN Data Link communications between the Trax Control and the ECU have been lost. The Trax Control did not
receive the EEC1 message from the ECU. This fault code may be displayed with other Trax CAN Data Link fault
messages indicating a failure in the Trax CAN Data Link circuit.
1. Power supply to the Trax Control.

3. Faulty wiring or CAN Data Link connections from the ECU to the Trax Control.
Solution:
last occurrence.

and secure.
(3) Verify the CAN Data Link connections from the ECU to the TRAX Control are tight and secure.
B. NOT OK - The harness or connectors have damage. Repair as required. Go to Step 1 to confirm elimi-
nation of fault.
3. Measure battery voltage at the Trax Control.
(2) Measure the voltage at the Trax Connector X-300 pin 1 to X-300 pin 29. The voltage should be approximately
12 volts.
A. OK - The voltage is between 12 and 14.2 volts. Go to Step 4.
B. NOT OK - The voltage is less than 12 volts. There is a problem with the battery supply to the Trax Control.
Verify fuse F-024 is not blown. Repair as required. Go to Step 1 to confirm elimination of fault.
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RCPH10TLB030FAM 1
Schematic Legend
(2) Disconnect the Trax connector X-300. Measure the resistance from pin 55 on connector X-300 to chassis
ground. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal
(1) Turn the key switch OFF. Disconnect Trax Control connector X-300.
A. OK - The resistance is between 54 and 66 ohms. Temporarily replace the Trax Control and retest. Go to
B. NOT OK - The resistance is less than 54 ohms or the resistance is greater than 66 ohms, go to test Step 6.
6. Measure the resistance between CAN High and CAN Low wires.
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(2) Disconnect the ECU and Instrument Cluster Data Link connectors.
A. OK - The resistance is greater than 20,000 ohms. Go to Step 7.
B. NOT OK - The resistance is less than 20,000 ohms. There is a short circuit between the CAN High and
CAN Low wires. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
7. Measure the resistance of the CAN Circuit to the Instrument Cluster.
(1) Fabricate a jumper wire 15 cm (6 in) long.
(2) Use the jumper wire to short (connect) X-029 pin 4 to pin 3.
RCPH10TLB042FAM 2
Schematic Legend
(4) TRAX Controller, X-300 (8) Jumper wire to short pin 4 to pin 3
(3) Measure the resistance between Trax Connector X-300 pin 27 and 55. The resistance should be less than
10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance is less than 10 ohms. Go to Step 8.
B. NOT OK - The resistance is greater than 10 ohms. There is an open circuit in the CAN Data Link to the
Instrument Cluster. Repair or replace the harness as required. Go to step 1 to confirm elimination of the
fault.
8. Measure the resistance of the CAN Circuit to the engine ECU.
(1) Use the jumper wire to short (connect) ECM CAN Data Link connector pin 35 to pin 34.
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RCPH10TLB043FAM 3
Schematic Legend
A. OK - The resistance is less than 10 ohms. Temporarily replace the ECU and retest. Go to Step 1 to confirm
elimination of the fault code.
engine ECU. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault.
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4101-Internal TRAX failure, hardware measurement

Cause:
1. Internal error in Transmission Control.
Solution:
rence.

2. Replace transmission controller.
for assistance.
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4102-Internal TRAX failure, software timing

Cause:
1. Internal error in Transmission Control Module
Solution:
rence.

for assistance.
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4103-Internal TRAX failure, software not running

Cause:
1. Internal failure inside Transmission Control Module
Solution:
rence.

for assistance.
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4105-Internal TRAX failure, redundant flash memory

Cause:
1. Transmission Control Module internal error
Solution:
rence.

for assistance.
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4106-Internal TRAX failure, sensor supply high

Context:
Trax Control 5 volt sensor output voltage is high.
Cause:
The Trax Control 5 volt sensor output is shorted to another voltage source.

Solution:
A. OK – Fault is not recorded again. Return the machine to service.


X-300 connector
15 5 Volt Supply 3151 PK 20GA
17 Signal Ground 0401 BL 20GA
45 Gear Switch 3/4 3451 YE 20GA
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RCPH10TLB032GAM 1
Schematic legend
(1) Gear Switch 1 (5) 27k ohm resistor
(4) Gear Switch 4 (8) Trax Control
(1) Inspect Trax connector X-300 and the Gear switch connections. All connections should be secure, tight, free
of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Trax Control to the Gear switches. Verify that the harness is free of damage,
3. Measure the voltage from X-300 pin 15 to chassis ground.
(2) Disconnect Trax Connector X-300.
A. OK – The voltage is less than 0.5 volts. Go to Step 4.
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B. NOT OK – The voltage is greater than 0.5 volts. The wire is shorted to another voltage source. Repair or
4. Measure the resistance through the harness and resistor network
(2) Disconnect X-344/345.
(3) Disconnect Gear Switch connector 361.
(4) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 34.9k Ω
± 10%.
(5) Reconnect connector 361 and disconnect Gear Switch connector 360.
± 10%.
± 10%.
(10) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 11.0k
Ω ± 10%.
Resistance measured with the sub harness disconnected from the vehicle harness
Gear Sw 1 Gear Sw 2 Gear Sw 3 Gear Sw 4 Pins B8/A8 Pins B1/A8 Pins B8/C8
Neutral Closed Closed Closed Closed 10.1k Ω 10.1k Ω 17.7k Ω
1ST Gear Open Closed Closed Closed 34.9k Ω 11.0k Ω 21.9k Ω
2ND Gear Closed Open Closed Closed 12.0k Ω 12.0k Ω 51.0k Ω
3RD Gear Closed Closed Open Closed 11.0k Ω 34.9k Ω 21.9k Ω
4TH Gear Closed Closed Closed Open 12.0k Ω 12.0k Ω 27.1k Ω
A. OK – The resistance values were within the limits defined in the table. Temporarily Replace the Trax
Control and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance values were not limits defined in the table. Temporarily replace the harness and
retest. Go to Step 1 to confirm elimination of fault.
5. Verify harness after repairs.
(1) Reconnect all loose connectors.
(2) Turn the key switch ON
(3) Use back probes or fabricate a breakout Tee and measure the voltage from X-300 pin 54 to chassis ground.
Refer to the table below for the prober gear switch positions and voltage measurements.
Voltage measured at Trax Control connector X-300

Gear Sw 1 Gear Sw 2 Gear Sw 3 Gear Sw 4 Voltage measured on Voltage measured on pin
pin 54 45
Neutral Closed Closed Closed Closed 3V 3V
1ST Gear Open Closed Closed Closed 1V 3V
2ND Gear Closed Open Closed Closed 4V 3V
3RD Gear Closed Closed Open Closed 3V 1V
4TH Gear Closed Closed Closed Open 3V 4V
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4107-Internal TRAX failure, sensor supply low

Context:
Trax Control 5 volt sensor output voltage is shorted to ground.
Cause:
The Trax Control 5 volt sensor output is shorted to ground.

Solution:


X-300 connector
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RCPH10TLB032GAM 1
Schematic legend
3. Measure the resistance from X-300 pin 15 to chassis ground.
(2) Disconnect Trax Connector X-300.
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B. NOT OK – The resistance is less than 20,000 ohms. The wire is shorted to chassis ground. Repair or
4. Measure the resistance through the harness and resistor newtork
± 10%.
± 10%.
± 10%.
Ω ± 10%.
A. OK – The resistance values were within the limits defined in the table. Temporarily Replace the Trax
Control and retest. Go to Step 1 to confirm elimination of the fault.
Voltage measured at Trax Control connector X-300 with reference to chassis ground.
pin 54 45
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4200-First shift solenoid shorted to ground S-Type Transmission

Only
Context:
The S1 solenoid driver (output) is shorted to ground (chassis ground).
Cause:
S-Type Transmission Only - The S1 solenoid driver (output) is shorted to ground (chassis ground). The machine will

2. The S1 Solenoid drive circuit shorted to ground (chassis ground).
3. S1 Solenoid has an internal short circuit.
Solution:


X-300 connector
9 S1 solenoid signal/supply 3043 WH 20GA
38 S4 solenoid return 3033 GY 20GA
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RCPH11TLB004FAL 1
Schematic legend
(1) S1Solenoid (5) Connector X-344/ X-345
(2) S4 Solenoid (6) S2 Solenoid
(3) Trax Control (7) S3 Solenoid
(4) Cab Ground Side Console on Loader
Control
(1) Inspect Trax connector X-300 and the S1 Solenoid connections. All connections should be secure and tight
(2) Inspect the harness from the Trax Control to the S1 Solenoid. Verify that the harness is free of damage,
(1) Disconnect Trax connector X-300 and S1 solenoid connector 324.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the S1
4. Measure the resistance to chassis ground..
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B. NOT OK – The resistance is less than 20,000 ohms. Replace the S1 solenoid and retest. Return to Step
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4203-Fourth shift solenoid shorted to ground

Context:
The S4 solenoid driver (output) is shorted to ground (chassis ground).
Cause:
S-Type Transmission Only - The S4 solenoid driver (output) is shorted to ground (chassis ground). The machine will

2. The S4 Solenoid drive circuit shorted to ground (chassis ground).
3. S4 Solenoid has an internal short circuit.
Solution:


X-300 connector
9 S1 solenoid signal/supply 3043 WH 20GA
38 S4 solenoid return 3033 GY 20GA
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RCPH11TLB004FAL 1
Schematic legend
(1) S1Solenoid (5) Connector X-344/ X-345
(2) S4 Solenoid (6) S2 Solenoid
(3) Trax Control (7) S3 Solenoid
(4) Cab Ground Side Console on Loader
Control
(1) Inspect Trax connector X-300 and the S4 Solenoid connections. All connections should be secure and tight
(2) Inspect the harness from the Trax Control to the S4 Solenoid. Verify that the harness is free of damage,
(1) Disconnect Trax connector X-300 and S4 solenoid connector 325.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the S4
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B. NOT OK – The resistance is less than 20,000 ohms. Replace the S4 solenoid and retest. Return to Step
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4204-System detects different gear than commanded

Context:
Trax Control detects a different gear than commanded.
Cause:
The gear indicated by the shift rail position sensors is not consistent with the gear the Trax control is commanding.
1. Faulty wiring or connectors

2. Faulty gear switch
4. Mechanical problem inside transmission
Solution:


X-300 connector
6 S2 Solenoid 3043 WH 20GA
45 Gear Switch 3/4 signal 3451 YE 20GA
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RCPH11TLB006FAL 1
Schematic legend
(2) Gear Switch 2 (9) S1 Solenoid
(5) 27k ohm resistor (12) S4 Solenoid
(6) 62k ohm resistor (13) SP-G11, Cab Ground Side Console on
Loader Control
(7) 12k ohm resistor
3. Monitor EST
(1) Connect EST.
(2) Turn the key switch ON, engine OFF. place the transmission into neutral.
(3) Monitor the S-type parameters related to the gear position switches and controls.
A. OK – All parameters are displayed correctly on the EST. Go to Step 4.
B. NOT OK – A fault code is generated, go to the proper troubleshooting procedure. Go to step 1 or the
corresponding troubleshooting procedure.
4. (1) Turn the engine on while monitoring the EST. Place the transmission in 1st gear. Monitor the EST screen
and diagnostic codes.
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RCPH11TLB007FAL 2
RCPH11TLB008FAL 3
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RCPH11TLB009FAL 4
RCPH11TLB010FAL 5
(2) Place the transmission in 2nd gear. Monitor the EST screen and diagnostic codes.
(3) Place the transmission in 3rd gear. Monitor the EST screen and diagnostic codes.
(4) Place the transmission in 4th gear. Monitor the EST screen and diagnostic codes.
A. OK – All parameters are within specs. There is a mechanical problem in the transmission. Go to Step 8.
B. NOT OK – There is a problem in the gear switch circuit. Replace the faulty gear switch. Go to Step 5.
5. Measure the resistance through the gear switch.
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(2) Disconnect S1 solenoid connector 361. Measure the resistance through the switch. The resistance should
be less than 10 ohms.
A. OK – All resistance measurements were greater than 20,000 ohms. Go to Step 6.
B. NOT OK – One or more resistance measurements are less than 10 ohms. Replace the faulty gear switch.
6. Measure the resistance through the harness and resistor network
± 10%.
± 10%.
± 10%.
Ω ± 10%.
A. OK – The resistance values were within the limits defined in the table. Temporarily replace the Trax Control
and retest. Go to Step 1 to confirm elimination of the fault.
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Voltage measured at Trax Control connector X-300

pin 54 45
8. Measure shift rail position
(2) Remove the first and second shift rail plug (2) and the third and fourth shift rail plug (1) from the rear of the
transmission.
RCPH11TLB001GAL 6
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(3) Measure the depth of the end of the rail (1) in relation to the edge of the transmission housing.
RCPH11TLB011FAL 7
Measurement Diagnosis
18 mm (0.709 in) Rail is in 1st or 3rd gear position.
29 mm (1.142 in) Neutral rail position
40 mm (1.575 in) Rail is in 2nd or 3rd gear position.
A. OK – The measurements are correct and all resistance values are correct. Temporarily Replace the Trax
Control and retest. Go to Step 1 to confirm elimination of fault.
B. NOT OK – The rail is out of position. Perform a pressure test to determine which rail is out of position.
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4205-System can not engage required gear. (Engaged gear is

different than requested gear)
Context:
The TRAX cannot complete a commanded shift within 3 tries and goes back to the previously selected gear.
1. This code is seen when the SPS fails to make a shift and then returns to the gear that was previously selected.
For example, the customer shifts the FNR from 2ndto 3rd, but the SPS fails to make the shift and returns to 2nd.
2. If the gear position switches are malfunctioning the transmission may be making the shift, but the TRAX is
receiving false information from the switches, like in the case of the water in the connector.
3. Cold oil can cause the transmission to be unable to shift.
Solution:


X-300 connector
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RCPH11TLB006FAL 1
Schematic legend
Loader Control
3. Refer to:
Command - Overview S-Type Transmission (C.20.E)
Command - Service instruction Shift Rail Position Testing — S-type Transmission (C.20.E)
Command - Service instruction Shift Rail Position Physical Measurement — S-Type Transmission
(C.20.E).
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4206-Gear engagement failed

Context:
The TRAX will attempt to shift into a gear 3 times and then it will attempt to shift back into the previous gear. If it then
fails to get back to the previous gear, it will go to neutral and throw fault 4206.
1. The length of each shifting attempt is based on the temperature of the transmission, and can be up to 6 seconds.
2. 4206 is the same as 4205, but the transmission is unable to make it back to the previously selected gear.
Solution:


X-300 connector
RCPH11TLB006FAL 1
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Schematic legend
Loader Control
3. Refer to:
(C.20.E).
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4207-1ST/2ND gear shift rail position reporting first gear at startup

Context:
The shift rails should be in neutral when the unit first starts, all the gear position switches should be closed. These
fault codes indicate that the TRAX saw the transmission in gear upon startup, when it should be in neutral.
1. Verify that the gear position switch giving the fault is open. If the switch reads closed, then check for a harness/
resistor network issue.
2. If the switches and harness are functioning correctly, then the shift rail is out of position at start-up.
Solution:


X-300 connector
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RCPH11TLB006FAL 1
Schematic legend
Loader Control
3. Refer to:
(C.20.E).
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4208-1ST/2ND gear shift rail position reporting second gear at

startup
Context:
Solution:


X-300 connector
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RCPH11TLB006FAL 1
Schematic legend
Loader Control
3. Refer to:
(C.20.E).
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4209-3RD/4TH gear shift rail position reporting third gear at startup

Context:
Solution:


X-300 connector
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RCPH11TLB006FAL 1
Schematic legend
Loader Control
3. Refer to:
(C.20.E).
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4210-3RD/4TH gear shift rail position reporting forth gear at startup

Context:
Solution:


X-300 connector
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RCPH11TLB006FAL 1
Schematic legend
Loader Control
3. Refer to:
(C.20.E).
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4211-First and second gear sensor input shorted to ground

Cause:
First and second gear sensor input to the Trax Control is shorted to ground.

Solution:


X-300 connector
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RCPH10TLB032GAM 1
Schematic legend
(1) Inspect Trax connector X-300 and the gear switch connections. All connections should be secure, tight, free
(2) Inspect the harness from the Trax Control to the gear switches. Verify that the harness is free of damage,
3. Measure the resistance between the signal wire and ground.
(2) Disconnect the Trax Controller connector X-300.
(3) Measure the resistance between Trax Connector pin 54 and chassis ground. The resistance should be
greater than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is greater than 10 ohms. Go to Step 4.
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire to chassis ground.
Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
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(2) Use a suitable wire to short Gear Switch 2 connector, pin 1 to pin 2. Disconnect Gear Switch 1 connector
361 pin 1. Verify that the wire from pin 1 does not short to chassis ground or to Gear Switch connector pin 2.
(3) Disconnect the Trax Controller harness X-300.
A. OK — The resistance is 27,000 ohms ±10 percent. Temporarily replace the Trax Controller and retest. Go
B. Not OK — The resistance is less than 10 ohms. Go to Step 5.

(1) Disconnect the Trax Controller harness X-300 from the Sub Harness X-344/X-345.
(2) Measure the resistance between Sub Harness connector B1 and C8. The resistance should be approxi-
mately 27,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is 27,000 ohms ±10 percent. There is a short circuit in the harness between X-300
and X-344/X-345. Temporarily replace the harness and retest. Go to Step 1 to confirm elimination of fault.
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire, B1 to signal
ground. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
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4212-First and second gear sensor input voltage too high

Cause:
First and second gear sensor input to the Trax Control is shorted to a voltage source. The Trax Control is measuring
a voltage greater than 4 volts of connector X-300 pin 54.

Solution:


X-300 connector
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RCPH10TLB032GAM 1
Schematic legend
3. Measure the resistance between the signal wire and battery supply.
(3) Measure the resistance between Trax Connector pin 54 and battery supply. The resistance should be greater
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire to battery supply.
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(2) Measure the resistance between Sub Harness connector B1 and A8. The resistance should be approxi-
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire, B1 to the 5 volt
sensor supply. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
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4213-Third and forth gear sensor input shorted to ground

Cause:
Third and fourth gear sensor input to the Trax Control is shorted to ground.

Solution:


X-300 connector
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RCPH10TLB032GAM 1
Schematic legend
3. Measure the resistance between the signal wire and ground.
(3) Measure the resistance between Trax Connector pin 45 and chassis ground. The resistance should be
greater than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire to chassis ground.
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(2) Measure the resistance between Sub Harness connector B8 and C8. The resistance should be approxi-
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire, B1 to signal
ground. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
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4214-Third and forth gear sensor input voltage too high

Cause:
Third and fourth gear sensor input to the Trax Control is shorted to a voltage source. The Trax Control is measuring
a voltage greater than 4 volts of connector X-300 pin 45.

Solution:


X-300 connector
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RCPH10TLB032GAM 1
Schematic legend
3. Measure the resistance between the signal wire and battery supply.
(3) Measure the resistance between Trax Connector pin 45 and battery supply. The resistance should be greater
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire to battery supply.
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(2) Measure the resistance between Sub Harness connector B8 and A8. The resistance should be approxi-
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire, B8 to the 5 volt
sensor supply. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
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4825-Loss of TC1 message after 15 seconds

Cause:
Wrong software in the Instrument Cluster. The sensitivity setting for the Forward, Neutral and Reverse has not been
programmed. The Warning Lamp will illuminate Amber and the LCD backlight will change from the normal
backlight to Amber. The Instrument Cluster will sound the alarm for one second upon activation per key cycle.
Solution:
1. Fault Code 4825 is displayed on the Instrument Cluster to warn the operator that the Forward, Neutral and
Reverse setting has not been programmed.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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4850-Possible detection wrong transmission type for installed

software
Cause:
Wrong transmission type is programmed in the Trax Control. The Warning Lamp will illuminate Amber and the
LCD backlight will change from the normal backlight to Amber. The Instrument Cluster will sound the alarm for one
second upon activation per key cycle.
Solution:
1. Fault Code 4850 is displayed on the Instrument Cluster to warn the operator that the wrong transmission type
has been programmed. This fault code may be active with 4022 and 4017.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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4995-Incorrect VCM configuration of transmission type

Cause:
Incorrect VCM configuration of transmission type. Power Shuttle has been selected in the VCM.
Solution:
1.
Power Shuttle has been selected in the VCM. The Warning Lamp will illuminate Amber and the LCD back-
light will change from the normal backlight to Amber. The Instrument Cluster will sound the alarm for one second
upon activation per key cycle.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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4996-Electronic transmission offline or incorrect VCM configuration

of transmission type
Context:
CAN Data Link communications between the Instrument Cluster and the Trax Control have been lost. This fault code
is displayed on the Instrument Cluster indicating that the Instrument Cluster was communicating with the Trax Control
but communications have now been lost.
Cause:
CAN Data Link communications between the Instrument Cluster and the Trax Control have been lost. The Instrument
Cluster did not receive the CAN Data Link messages from the Trax Control. This fault code may be displayed with
other CAN Data Link fault messages indicating a failure in the CAN Data Link circuit.
1. Incorrect VCM configuration of transmission type. Power Shuttle has not been selected in the VCM.
4. Faulty wiring or CAN Data Link connections from the Instrument Cluster to the Trax Control.
Solution:
last occurrence.

2. Check VCM transmission parameter
(1) Verify the VCM is programmed to the correct transmission type.
A. OK – The VCM is programmed properly. Go to Step 3.
B. NOT OK – The VCM is not programmed properly. Reprogram the VCM. Go to Step 1 to confirm elimination
of fault.
and secure.
nation of fault.
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12 volts.
RCPH10TLB030FAM 1
Schematic Legend
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RCPH10TLB042FAM 2
Schematic Legend
A. OK - The resistance is less than 10 ohms. Temporarily replace the Instrument Cluster and retest. Go to
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fault.
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4997-Loss of messaging from Trax controller

Context:
CAN Data Link communications between the Instrument Cluster and the Trax Control have been lost. This fault code
is displayed on the Instrument Cluster indicating that the Instrument Cluster was communicating with the Trax Control
but communications have now been lost.
Cause:
CAN Data Link communications between the Instrument Cluster and the Trax Control have been lost. The Instrument
Cluster did not receive the CAN Data Link messages from the Trax Control. This fault code may be displayed with
other CAN Data Link fault messages indicating a failure in the CAN Data Link circuit.

3. Faulty wiring or CAN Data Link connections from the Instrument Cluster to the Trax Control.
Solution:
last occurrence.

and secure.
nation of fault.
12 volts.
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RCPH10TLB030FAM 1
Schematic Legend
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RCPH10TLB042FAM 2
Schematic Legend
A. OK - The resistance is less than 10 ohms. Temporarily replace the Instrument Cluster and retest. Go to
fault.
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4998-Unknown transmission error code with amber lamp

Context:
The Instrument Cluster received and error message that it did not recognize.
Cause:
The Instrument Cluster received and error message that it did not recognize. The Instrument Cluster will illuminate
the Amber warning lamp.
1. Incompatible software versions.
Solution:
rence.

2. Update Instrument Cluster software
(1) Verify that the Instrument Cluster and Trax Control have the latest versions of software. Contact Technical
for assistance.
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4999-Unknown transmission error code with red lamp

Context:
The Instrument Cluster received and error message that it did not recognize.
Cause:
The Instrument Cluster received and error message that it did not recognize. The Instrument Cluster will illuminate
the Red warning lamp.
1. Incompatible software versions.
Solution:
rence.

2. Update Instrument Cluster software
(1) Verify that the Instrument Cluster and Trax Control have the latest versions of software. Contact Technical
for assistance.
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9001-Hour meter plausibility, internal error

Cause:
1. Instrument Cluster internal failure
Solution:
rence.

2. Replace instrument cluster.
for assistance.
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9002-Hour meter RAM checksum failure, internal error

Cause:
Solution:
rence.

for assistance.
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9003-J1939 receive buffer overflow, internal error

Cause:
Solution:
rence.

for assistance.
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9004-EEPROM checksum failure, hour meter location 1, internal

error
Cause:
Solution:
rence.

for assistance.
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error
Cause:
Solution:
rence.

for assistance.
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error
Cause:
1. Instrument Cluster internal error
Solution:
rence.

for assistance.
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9007-Abnormal reset watchdog time-out, internal error

Cause:
Solution:
rence.

for assistance.
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9008-A/D fault foot throttle, internal error

Cause:
Solution:
rence.

for assistance.
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9009-A/D fault foot throttle power, internal error

Cause:
Solution:
rence.

for assistance.
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9010-A/D fault hand throttle, internal error

Cause:
Solution:
1. Verify that fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
rence.

for assistance.
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9011-A/D fault foot throttle, internal error

Cause:
Solution:
rence.

for assistance.
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9012-A/D fault, internal error

Cause:
Solution:
rence.

for assistance.
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Index

SYSTEMS - A
FAULT CODES - 50.A

0000-Retrieving fault codes, Backhoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1001-Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1002-Engine coolant temperature too high, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1003-Air conditioning pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1004-Hydraulic filter blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1009-Transmission oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1010-Foot throttle signal out of range, IVS not changing state in 300 ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1011-Foot throttle signal out of range, throttle above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1012-Foot throttle signal out of range, throttle below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1013-Foot throttle signal out of range, signal unusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1014-Battery charge voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1015-Battery charge voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1018-Boost air temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1019-Engine coolant temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1020-Transmission oil temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1021-Fuel temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1022-Water in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1023-Foot throttle supply voltage too high, over 5.2 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1024-Foot throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1025-Foot throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1026-Foot throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1032-Hand throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1033-Hand throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1034-Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1035-Hand throttle sensor signal above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1036-Hand throttle sensor signal below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1037-Hand throttle sensor out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1039-Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1040-Engine RPM over 2750 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1041-Engine RPM over 3000 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1045-Fuel level sensor open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1047-Transmission temperature sensor below 3.0 ohms for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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1050-Alternator L+ terminal under 1.5 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1051-Timeout of CAN message EEC1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1052-Timeout of CAN message, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1053-Timeout of CAN message CNFBAM, 25 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1054-Timeout of CAN message engine temperature, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . 119
1055-Timeout of CAN message inlet/exhaust, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1056-Timeout of CAN message engine fluid, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1057-Timeout of CAN message vehicle electrical, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1058-Timeout of CAN message EDC2BC, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1059-Timeout of CAN message DM1, 5 seconds without message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3006-Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3007-Coolant temperature signal - signal above range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3010-Air intake temperature sensor signal above maximum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3011-Air intake temperature sensor signal below minimum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3015-Fuel Temperature Sensor - Signal Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3019-Boost Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3022-Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3023-Atmospheric pressure sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3025-Atmospheric pressure sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3028-Oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3029-Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3030-Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3031-Oil pressure sensor - hardware error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3032-Oil Pressure Sensor - Value Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3033-Oil Temperature Sensor - Signal Not Plausible (Compared With Coolant Temperature) . . . . . . . . . . . . . . . 179
3034-Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3035-Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3047-Main Relay Failure - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3048-Main Relay Failure - Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3059-ECM afterrun was interrupted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3060-Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
3062-Cylinder 1 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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3088-Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3090-Phase defect of camshaft speed sensor signal detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3091-Camshaft sensor phase synchronization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
3095-Operating With Camshaft Sensor Only - Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3104-Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
3107-Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
3108-Fuel Metering Unit - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3110-Rail Pressure Sensor Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3111-Rail Pressure Sensor Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
3113-Grid heater battery switch relay short circuit to battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3114-Grid heater battery switch relay short circuit to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3118-ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
3119-ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3131-Grid Heater Always Switched On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
3138-Metering Unit - Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . . . . . . . . . 275
3142-High Pressure Test - Test Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
3145-Terminal 15 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3147-Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3154-Grid Heater Relay - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
3155-Grid Heater Relay - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3156-Grid Heater Relay - No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3171-Fuel rail system pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3172-Fuel rail system pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3173-Rail Pressure Governor Deviation Below Min. Limit for Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
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3174-Rail Pressure Governor Deviation Exceeded Max. Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3175-Fuel system leak detected - large leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3176-Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3177-Engine Overspeed Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3188-Cylinder 1 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
3192-Cylinder 2 warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3211-Bank 1 - Injector cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
3213-Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
3221-Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3228-Injection Processor Error - Unlocked/Initialization Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3229-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
3239-Engine Controller EEPROM - Read Operation Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
3240-Engine Controller EEPROM - Write Operation Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3241-Engine Controller EEPROM - Default Value Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
3244-Engine Controller Recovery (Visible) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
3246-Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
3247-Shutoff Paths Failed During Initialization - Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3248-Shutoff Paths During Initialization - Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
3249-TPU Monitoring - Time Deviation Between TPU And System Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . 350
3250-Dataset - Variant Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
3251-Dataset - Requested Variant Could Not Be Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
3252-Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3253-ADC Monitoring - Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
3254-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
3258-HS power stage hardware reports 'short circuit to battery' longer than 500 ms. . . . . . . . . . . . . . . . . . . . . . . 358
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3259-HS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . . . . . . . . . 361
3260-LS power stage hardware reports 'open load' longer than 100 ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3261-LS power stage hardware reports 'short circuit to battery' or 'excess temperature' longer than 100 ms. . 367
3262-LS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . . . . . . . . . 370
3263-Busoff in CAN C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
3265-Energizing time exceeds limit of over run monitoring, injection time too long . . . . . . . . . . . . . . . . . . . . . . . . 374
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
3278-Engine Controller Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
3279-Engine Controller Internal Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
3280-Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
3281-Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
3316-Minimum Number Of Injections Not Reached - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
3334-Timeout of CAN Message TSC1 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
3339-Timeout of CAN Message TSC1 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
3350-Terminal 50 - always on, starting circuit signal is active for an excessive time period . . . . . . . . . . . . . . . . . 399
3361-ECM EEPROM - General Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3363-Atmospheric Pressure Sensor - Processed via ADC, not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3856-Coolant temperature signal test failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3998-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3999-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
4000-Power supply (pin 2), forward FWD drive (pin 3), or RVS drive (pin 4) drive shorted to ground . . . . . . . . . 410
4001-Power supply (pin 5), PWM 1 drive (pin 6), or PWM 2 drive (pin 7) drive shorted to ground . . . . . . . . . . . . 416
4002-Power supply for digital outputs (pin 8) does not have power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
4004-Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 rpm . . . . . 424
4005-Downshift delayed due to possible engine overspeed condition S-Type Transmission Only . . . . . . . . . . . . 428
4006-FWD input (Pin 12) feedback circuit is reading current with command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
4007-FWD input (Pin 12) current is too low with command present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
4008-FWD solenoid is drawing more current than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
4009-FWD solenoid is drawing less current than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
4011-RVS input (pin 40) feedback circuit is reading current with command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
4012-RVS input (pin 40) current is too low with command present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
4013-RVS solenoid is drawing more current than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
4014-RVS solenoid is drawing less current than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
4016-First and third shift modulation solenoid input (pin 13) feedback circuit is reading current without command -
H-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
4017-First and third shift modulation solenoid input (pin 13) current is too low with command present . . . . . . . 456
4018-First and third shift modulation solenoid is drawing more current than commanded H-Type Transmission Only
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
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4019-First and third shift modulation solenoid is drawing less current than commanded H-Type Transmission Only
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
4021-Second and fourth shift modulation solenoid input (pin 41) feedback circuit is reading current with command
- H-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
4022-Second and fourth shift modulation solenoid input (pin 41) current is too low with command present - H-Type
Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
4023-Second and fourth shift modulation solenoid is drawing more current than commanded - H-Type Transmission
Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
4024-Second and fourth shift modulation solenoid is drawing less current than commanded - H-Type Transmission
Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
4026-First / Third shift solenoid shorted to ground - H-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
4027-Second / Fourth shift solenoid shorted to ground - H-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . 480
4028-Differential lock or 4 wheel drive solenoid shorted to ground - H-Type and S-Type Transmissions . . . . . . 483
4029-Shifter Lever improperly connected, no power to pin 16, pin 18, or pin 46 for more than 3 seconds - H-Type
and S-Type Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486
4030-Shifter Lever malfunction: transmission in neutral receives forward and neutral together - H-Type and S-Type
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
4031-Shifter Lever malfunction: transmission in neutral receives reverse and neutral together . . . . . . . . . . . . . . 495
4032-Shifter Lever malfunction: transmission in forward receives forward and reverse together . . . . . . . . . . . . . 500
4033-Shifter Lever malfunction: transmission in reverse receives forward and reverse together . . . . . . . . . . . . . 505
4034-Shifter Lever malfunction: transmission in forward receives neutral and forward together - H-Type and S-Type
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
4035-Shifter Lever malfunction: transmission in reverse receives neutral and reverse together . . . . . . . . . . . . . 515
4036-During transition from second to third gear, and Gear CMD_01 signal erratic or incorrect - H-Type and S-Type
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
4037-During transition from first to second gear, and Gear CMD_02 signal erratic or incorrect . . . . . . . . . . . . . . 525
4038-During transition from third to fourth gear, and Gear CMD_02 signal erratic or incorrect . . . . . . . . . . . . . . . 530
4040-Transmission Controller Driveline Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
4041-Transmission output shaft frequency above 3000 Hz detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
4042-Temperature signal erratic or incorrect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
4043-Temperature sensor input (Pin 43) is shorted to a ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
4044-Temperature sensor input (Pin 43) is open circuit or shorted to a voltage above 5 volts . . . . . . . . . . . . . . . 545
4045-Charge pressure is not detected when engine speed is above 700 rpm for 10 seconds . . . . . . . . . . . . . . . 548
4046-Charge pressure is not detected and vehicle speed is over 10 kph (6 mph) . . . . . . . . . . . . . . . . . . . . . . . . . 551
4047-Charge pressure switch is closed with no frequency input to the TRAX controller . . . . . . . . . . . . . . . . . . . . 554
4054-Unknown vehicle model value from VCM S-type transmission only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
4100-Missing EEC 1 message on CAN - H-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
4101-Internal TRAX failure, hardware measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
4102-Internal TRAX failure, software timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563
4103-Internal TRAX failure, software not running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
4105-Internal TRAX failure, redundant flash memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
4106-Internal TRAX failure, sensor supply high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
4107-Internal TRAX failure, sensor supply low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
4200-First shift solenoid shorted to ground S-Type Transmission Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 572
4203-Fourth shift solenoid shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
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4204-System detects different gear than commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
4205-System can not engage required gear. (Engaged gear is different than requested gear) . . . . . . . . . . . . . . 585
4206-Gear engagement failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587
4207-1ST/2ND gear shift rail position reporting first gear at startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589
4208-1ST/2ND gear shift rail position reporting second gear at startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
4209-3RD/4TH gear shift rail position reporting third gear at startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
4210-3RD/4TH gear shift rail position reporting forth gear at startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595
4211-First and second gear sensor input shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597
4212-First and second gear sensor input voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
4213-Third and forth gear sensor input shorted to ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
4214-Third and forth gear sensor input voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
4825-Loss of TC1 message after 15 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
4850-Possible detection wrong transmission type for installed software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
4995-Incorrect VCM configuration of transmission type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
4996-Electronic transmission offline or incorrect VCM configuration of transmission type . . . . . . . . . . . . . . . . . . . 612
4997-Loss of messaging from Trax controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
4998-Unknown transmission error code with amber lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
4999-Unknown transmission error code with red lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
9001-Hour meter plausibility, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
9002-Hour meter RAM checksum failure, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
9003-J1939 receive buffer overflow, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
9004-EEPROM checksum failure, hour meter location 1, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
9007-Abnormal reset watchdog time-out, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
9008-A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628
9009-A/D fault foot throttle power, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
9010-A/D fault hand throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
9011-A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
9012-A/D fault, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
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CNH - Main 700 State Street Racine, Wisconsin United States 53404
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2011 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification
or equipment at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASE CONSTRUCTION Dealer.
84516378 05/07/2011
EN
SERVICE MANUAL
ENGINE AND PTO IN
580N
580SN WT
580SN
590SN
84516378 05/07/2011
B
Contents
ENGINE AND PTO IN - B
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
580N , 580SN WT , 580SN , 590SN
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A

580N , 580SN WT , 580SN , 590SN
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A

580N , 580SN WT , 580SN , 590SN
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A

580N , 580SN WT , 580SN , 590SN
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A

580N , 580SN WT , 580SN , 590SN
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B
ENGINE - 10.A
580N
580SN WT
580SN
590SN
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Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE
Speeds stall test normal (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Speeds stall test check sheet (580N only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Speeds stall test check sheet (580SN only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Speeds stall test check sheet (590SN only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Speeds stall test check sheet (580SN WT only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA
ENGINE
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
ENGINE
Service instruction - Engine repair service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remove - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Prepare for stall tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Balancer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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ENGINE AND PTO IN - ENGINE
ENGINE - Speeds stall test normal (all models)

NOTE: The following specifications are for engines with more than 50 hours of operation.
NOTE: Engine RPM speed is based on the ISO14396 Cetane number of at least 51 and density between 820 - 845
kg/m³ (1382 - 1424 lb/yd³). Fuel inlet 38 °C (100 °F) ± 2 °C (36 °F)
Model 580N
Function Engine RPM speed
Rated speed – full load 2200 RPM
Idle speed 875 - 1025 RPM
High idle– no load 2300 - 2450 RPM
Torque converter stall 2180 - 2310 RPM
Backhoe hydraulic stall 2230 - 2330 RPM
Loader hydraulic stall 2230 - 2330 RPM
Combined stall 1610 - 1890 RPM
Model 580SN
Model 590SN
Model 580SN WT
NOTE: During the stall tests (580SN WT model only) if the following readings occur during the specified tests, the
pump is at maximum stroke. The pump may need to be replaced.
Model 580SN WT– with pump at maximum stroke

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ENGINE - Speeds stall test check sheet (580N only)

Results from stall test procedure (fill in values accordingly)
ID RPM test valve Stall test component (specified value)
1 Loader hydraulic stall speed ( 2230 - 2330 RPM)
2 Backhoe hydraulic stall speed ( 2230 - 2330 RPM)
3 Torque converter stall speed ( 2180 - 2310 RPM)
4 Combined - loader hydraulic and torque converter - stall speed ( 2230 - 2330 RPM)
Stall test reference chart

ID RPM Results
1 2230 to 2330
2 2230 to 2330
All systems operating within normal specified RPM values.
3 2180 to 2310
4 1610 to 1890
1 Above 2330
2 2230 to 2330 Engine problem. Check engine speeds according to instructions in NEED IU
3 Above 2310 REFERENCE for details. Refer to the engine service manual.
4 Above 1890
1 Below 2230
Engine problem. Check engine speeds according to instructions in NEED IU
2 2230 to 2330
REFERENCE for details.Replace the fuel and air filters NEED IU REFERENCE for
3 Below 2180
details. Refer to the engine service manual.
4 Below 1610
1 Below 2230
2 2230 to 2330 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2180 to 2310 output of the hydraulic pump.
4 Below 1610
1 Above 2330
3 2180 to 2310 output of the hydraulic pump. Check for leakage in the loader control valve.
4 Above 1890
1 2230 to 2330
2 Below 2230 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
4 1610 to 1890
1 2230 to 2330
4 1610 to 1890
1 2230 to 2330
2 2230 to 2330
Torque converter or transmission problems.
3 Above 2310
4 Above 1890
1 2230 to 2330
2 2230 to 2330
3 Below 2180
4 Below 1610
ENGINE - Speeds stall test check sheet (580SN only)

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ID RPM Results
1 2240 to 2335
2 2160 to 2300
3 2080 to 2260
4 1695 to 1930
1 Above 2335
2 2160 to 2300
Engine problem. Check engine speeds. Refer to the engine service manual.
3 Above 2260
4 Above 1930
1 Below 2240
2 2160 to 2300 Engine problem. Check engine speeds. Replace the fuel and air filters Refer
3 Below 2080 to the engine service manual.
4 Below 1695
1 Below 2240
4 Below 1695
1 Above 2335
4 Above 1930
1 2240 to 2335
4 1695 to 1930
1 2240 to 2335
4 1695 to 1930
1 2240 to 2335
2 2160 to 2300
3 Above 2260
4 Above 1930
1 2240 to 2335
2 2160 to 2300
3 Below 2080
4 Below 1695
ENGINE - Speeds stall test check sheet (590SN only)


ID RPM Results
1 2240 to 2335
2 2190 to 2300
3 2125 to 2290
4 1830 to 2010
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ID RPM Results
1 Above 2335
2 2190 to 2300 Engine problem. Check engine speeds according to instructions in the engine
3 Above 2290 service manual.
4 Above 2010
1 Below 2240
2 2190 to 2300 Engine problem. Check engine speeds according to instructions in Refer to the
3 Below 2125 engine service manual.
4 Below 1830
1 Below 2240
4 Below 1830
1 Above 2335
4 Above 2010
1 2240 to 2335
4 1830 to 2010
1 2240 to 2335
4 1830 to 2010
1 2240 to 2335
2 2190 to 2300 Torque converter or transmission problems. Refer to section NEED IU
3 Above 2290 REFERENCE and check the transmission and torque converter.
4 Above 2010
1 2240 to 2335
2 2190 to 2300
3 Below 2125
4 Below 1830
ENGINE - Speeds stall test check sheet (580SN WT only)


ID RPM Results
1 2330 to 2420
2 2330 to 2420
3 2150 to 2295
4 2090 to 2270
1 Above 2420
2 2330 to 2420
Engine problem. Check engine speeds according to the engine service manual.
3 Above 2295
4 Above 2270
1 Below 2330
2 2330 to 2420 Engine problem. Check engine speeds. Replace the fuel and air filters. Refer
3 Below 2150 to the engine service manual.
4 Below 2090
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ID RPM Results
1 Below 2330
4 Below 2090
1 Above 2420
4 Above 2270
1 2330 to 2420
4 2090 to 2270
1 2330 to 2420
4 2090 to 2270
1 2330 to 2420
2 2330 to 2420
3 Above 2295
4 Above 2270
1 2330 to 2420
2 2330 to 2420
3 Below 2150
4 Below 2090
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ENGINE - Exploded view

1. Engine mounting bracket bolt 4. Engine mounting bracket
2. Flat washer 5. Engine mounting stabilizer
3. Engine mounting bolts 6. Lock nut
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RCPH10TLB029GAL 1
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ENGINE - Service instruction - Engine repair service manual

1. For engine repair, see engine service manual
87630273.
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ENGINE - Remove - 580N only

Put identification tags on all disconnected hoses and wires.
Close disconnected hoses and fittings with caps and plugs.
NOTE: The photos in this procedure may be different from
your machine and are for reference only.
loader and lock the support strut to hold the loader.
RCPH10TLB022AAL 1
2. Remove the battery cover from the right step. If the

machine has only one battery, disconnect the nega-
tive battery cable from the battery.
3. If the machine has two batteries, remove the termi-
nal nut (1). Remove the negative battery cable (2)
from the terminal and move the negative battery ca-
ble away from the battery. Make sure the jumper ca-
ble (3) is installed on the terminal and start the termi-
nal nut (2) onto the terminal.
RCPH10TLB030AAL 2
4. If equipped with air conditioning, discharge the air

conditioning system.
5. Remove the radiator wrapper, fan shroud, radiator,
oil coolers and, if equipped with air conditioning, the
condenser assembly. See Radiator - Remove -
580N only (B.50.A) for procedures.
6. If equipped with air conditioning, disconnect the elec-
trical connector (1). Remove the tie strap (2). Dis-
connect the hoses from the compressor.
RCPH10TLB042AAL 3
84516378 05/07/2011
B.10.A / 11
7. Remove the tie strap. Disconnect the electrical con-

nectors for the air restriction indicator.
RCPH10TLB025AAL 4
8. Loosen the clamp on the air cleaner hose at the tur-

bocharger. Disconnect the air cleaner hose from the
turbocharger.
RCPH10TLB024AAL 5
9. Disconnect crankcase ventilation hose and the aspi-

ration hose.
RCPH10TLB031AAL 6
10. Remove the cap screws and flat washers that fasten
the fixed hood to the uprights. Remove the fixed
hood and air cleaner as an assembly.
RCPH10TLB023AAL 7
11. Remove muffler and brackets from engine.
84516378 05/07/2011
B.10.A / 12
12. If equipped, disconnect grid heater positive cable

and sensor wires.
RCPH10TLB036AAL 8
13. Disconnect the electrical connector for the fuel injec-

tion pump (1) and oil pressure sender (2).
RCPH10TLB040AAL 9
14. Disconnect the throttle cable from the mounting

bracket.
RCPH10TLB034AAL 10
15. Disconnect the throttle rod (1). If equipped, discon-

nect the heater hose (2).
RCPH10TLB035AAL 11
84516378 05/07/2011
B.10.A / 13
16. Disconnect the fuel return line (1) and the fuel input
line (2).
RCPH10TLB041AAL 12
17. Disconnect the coolant temperature sender (1) and

coolant temperature switch (2).
RCPH10TLB039AAL 13
18. Disconnect the wires from the alternator.
RCPH10TLB037AAL 14
19. Disconnect the heater hose, if equipped.
RCPH10TLB043AAL 15
84516378 05/07/2011
B.10.A / 14
20. Disconnect the ground strap (1). Disconnect the

wires (2) from the starter.
RCPH10TLB038AAL 16
21. Remove the starter from the engine. Remove the

access cover from the bell housing.
RCPH10TLB026AAL 17
22. Install the engine turning tool, 380000988, to turn the

flywheel for access to the cap screws.
RCPH10TLB005BAL 18
84516378 05/07/2011
B.10.A / 15
23. Remove four cap screws that fasten the flywheel to

the flex plate.
RCPH10TLB027AAL 19
24. Connect lifting equipment to the lifting eyes on the

engine to hold the engine in place.
25. Remove the bolts, flat washers, and nuts from the
front engine mount.
RCPH10TLB028AAL 20
26. Loosen and remove the 12 cap screws and flat wash-
ers that fasten the transmission to the engine. Move
the heater hose and clamps out of the way.
27. Move the engine forward and raise the engine. Re-
move the engine from the machine.
NOTICE: 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.
Next operation:
ENGINE - Install - 580SN, 580SN-WT, 590SN only (B.10.A).
84516378 05/07/2011
B.10.A / 16
ENGINE - Install - 580N only

Prior operation:
ENGINE - Remove - 580N only (B.10.A).
If applicable, remove caps and plugs from previously dis-

connected hoses and fittings. Remove identification tags
after making the hose and wire connections.
1. Position the engine in the machine.
NOTICE: Make sure that the flex plate/converter assembly
stays in place on the transmission.
2. Move the heater hose and clamps out of the way.
Install and tighten the 12 flat washers and cap screws
securing the transmission to the engine.
Tighten cap screws to a torque of 52 - 57 N·m (38 -
42 lb ft).
3. Install and tighten the front engine mounting bolts,
flat washers, and nuts.
Tighten the self locking nuts to a torque of 90 - 100
N·m (66 - 74 lb ft).
RCPH10TLB028AAL 1
4. Disconnect the lifting equipment from the lifting eyes

on the engine.
5. Tighten the four cap screws that fasten the flywheel
to the flex plate.
Tighten cap screws to a torque of 52 - 57 N·m (38 -
42 lb ft).
RCPH10TLB027AAL 2
84516378 05/07/2011
B.10.A / 17
6. Remove the engine turning tool, 380000988.
RCPH10TLB005BAL 3
7. Install the access cover to the bell housing. Install

the starter onto the engine.
RCPH10TLB026AAL 4
8. Connect the wires (2) from the starter. Attach the

ground strap (1).
RCPH10TLB038AAL 5
84516378 05/07/2011
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9. If equipped, connect the heater hose.
RCPH10TLB043AAL 6
10. Connect the wires from the alternator.
RCPH10TLB037AAL 7
11. Connect the coolant temperature sender (1) and

coolant temperature switch (2).
RCPH10TLB039AAL 8
12. Connect the fuel return line (1) and the fuel input line
(2).
RCPH10TLB041AAL 9
84516378 05/07/2011
B.10.A / 19
13. Connect the throttle rod (1). If equipped, connect the

heater hose (2).
RCPH10TLB035AAL 10
14. Connect the throttle cable from the mounting bracket.
RCPH10TLB034AAL 11
15. Connect the electrical connector for the fuel injection

pump (1) and oil pressure sender (2).
RCPH10TLB040AAL 12
16. If equipped, connect the grid heater positive cable

and sensor wires.
RCPH10TLB036AAL 13
17. Attach the muffler and brackets to the engine.
84516378 05/07/2011
B.10.A / 20
18. Install the fixed hood and air cleaner. Secure the
fixed hood to the uprights with flat washers and cap
screws.
RCPH10TLB023AAL 14
19. Attach the aspiration hose and the crank case venti-
lation hose.
RCPH10TLB031AAL 15
20. Connect the air cleaner hose from the turbocharger.

Tighten the clamp on the air cleaner hose at the tur-
bocharger.
RCPH10TLB024AAL 16
21. Connect the electrical connectors for the air restric-

tion indicator. Secure with a tie strap.
RCPH10TLB025AAL 17
84516378 05/07/2011
B.10.A / 21
22. If the machine is equipped with air conditioning, con-

nect the electrical connector (1). Connect the hoses
from the compressor. Secure with a tie strap (2).
RCPH10TLB042AAL 18
23. Install the radiator wrapper, fan shroud, radiator, oil

coolers and, if equipped with air conditioning, con-
denser assembly. See Radiator - Install - 580N only
(B.50.A) for removal procedures.
24. If equipped with air conditioning, see ENVIRON-
MENT CONTROL Air-conditioning system -
Charging - Air conditioner system evacuation
and recharging (E.40.C) to recharge air condition-
ing system.
25. If the machine has two batteries, remove the terminal
nut (1) from the jumper cable (3). Attach the nega-
tive battery cable (2) to the terminal and install the
terminal nut (1).
If the machine has only one battery, connect the neg-
ative battery cable to the battery.
RCPH10TLB030AAL 19
26. Install the battery cover on the right-hand step.

27. Release the support strut lock and lower the loader
bucket.
RCPH10TLB022AAL 20
28. Fill the engine and cooling system. See Capacities

() for specifications.
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B.10.A / 22
ENGINE - Remove - 580SN, 580SN-WT, 590SN only

Prior operation:
Prior operation:
Engine hood - Remove (E.20.A)
Prior operation:
Radiator - Remove - 580SN, 580SN-WT, 590SN only (B.50.A)
1. Remove and disconnect compressor electrical con-

nection.
RCPH11TLB033AAM 1
2. Identify, tag and disconnect the high pressure and

low pressure A/C lines.
RCPH11TLB034AAM 2
3. Disconnect the air restriction indicator.
RCPH11TLB035AAM 3
84516378 05/07/2011
B.10.A / 23
4. Remove the air cleaner to turbo tube.
RCPH11TLB036AAM 4
5. Remove the aspirator tube.
RCPH11TLB037AAM 5
6. Remove crank case vent.
RCPH11TLB038AAM 6
7. Remove fixed hood hardware.
RCPH11TLB039AAM 7
84516378 05/07/2011
B.10.A / 24
8. Lift fixed hood and remove window washer hose.
RCPH11TLB040AAM 8
9. Remove fixed hood with air cleaner together.
RCPH10TLB031AAL 9
10. Remove muffler to turbo clamp.
RCPH11TLB042AAM 10
11. Remove muffler front and rear mounting hardware.
RCPH11TLB043AAM 11
84516378 05/07/2011
B.10.A / 25
12. Remove the muffler.
RCPH11TLB044AAM 12
13. Disconnect the grid heater connection.
RCPH11TLB045AAM 13
14. Disconnect the Electronic Control Unit.
RCPH11TLB046AAM 14
15. Disconnect the return fuel line.
RCPH11TLB047AAM 15
84516378 05/07/2011
B.10.A / 26
16. Disconnect the fuel input line.
RCPH11TLB048AAM 16
17. Disconnect the water in fuel sensor.
RCPH11TLB047AAM 17
18. Disconnect the alternator connections.
RCPH11TLB050AAM 18
19. Disconnect the heater hose.
RCPH11TLB049AAM 19
84516378 05/07/2011
B.10.A / 27
20. Disconnect the starter ground and positive battery

connections.
RCPH11TLB051AAM 20
21. Remove the starter.
RCPH11TLB052AAM 21
22. Disconnect the ignition connection.
RCPH11TLB053AAM 22
23. Remove the flywheel access cover.
RCPH11TLB054AAM 23
84516378 05/07/2011
B.10.A / 28
24. Rotate the engine to access flywheel flexplate hard-

ware. Use hardware tool 380000988
RCPH11TLB062AAM 24
25. Remove flywheel to flex plate hardware.
RCPH11TLB055AAM 25
26. Attach a suitable lifting device.
RCPH11TLB056AAM 26
27. Remove motor mount hardware.
RCPH11TLB057AAM 27
84516378 05/07/2011
B.10.A / 29
28. Remove engine to transmission hardware.
RCPH11TLB058AAM 28
29. Remove starter wire clamp.
RCPH11TLB059AAM 29
30. Remove heater hose.
RCPH11TLB060AAM 30
31. Carefully remove the engine from the chassis.
RCPH11TLB061AAM 31
Next operation:
ENGINE - Install - 580SN, 580SN-WT, 590SN only (B.10.A).
84516378 05/07/2011
B.10.A / 30
ENGINE - Install - 580SN, 580SN-WT, 590SN only

1. Carefully lower the engine into the chassis.
RCPH11TLB061AAM 1
2. Connect heater hose.
RCPH11TLB060AAM 2
3. Connect the starter wire clamp.
RCPH11TLB059AAM 3
4. Install engine to transmission hardware.
RCPH11TLB058AAM 4
84516378 05/07/2011
B.10.A / 31
5. Install engine mount hardware.
RCPH11TLB057AAM 5
6. Remove the lifting device.
RCPH11TLB056AAM 6
7. Rotate the engine to access flywheel. Use hardware

tool 380000988.
RCPH11TLB062AAM 7
8. Reinstall the flywheel to flex plate hardware.
RCPH11TLB055AAM 8
84516378 05/07/2011
B.10.A / 32
9. Install the flywheel access cover.
RCPH11TLB054AAM 9
10. Reconnect the ignition connection on the starter.
RCPH11TLB053AAM 10
11. Install the starter.
RCPH11TLB052AAM 11
12. Connect the starter ground and positive battery con-

nections.
RCPH11TLB051AAM 12
84516378 05/07/2011
B.10.A / 33
13. Connect the heater hose.
RCPH11TLB049AAM 13
14. Connect the alternator connections.
RCPH11TLB050AAM 14
15. Connect the water in fuel sensor.
RCPH11TLB047AAM 15
16. Connect the fuel input line.
RCPH11TLB048AAM 16
84516378 05/07/2011
B.10.A / 34
17. Connect the return fuel line.
RCPH11TLB047AAM 17
18. Connect the Electronic Control Unit.
RCPH11TLB046AAM 18
19. Connect the grid heater connection.
RCPH11TLB045AAM 19
20. Install the muffler.
RCPH11TLB044AAM 20
84516378 05/07/2011
B.10.A / 35
21. Install the muffler front and rear mounting hardware.
RCPH11TLB043AAM 21
22. Install the muffler to turbo clamp.
RCPH11TLB042AAM 22
23. Install the fixed hood with the air cleaner.
RCPH10TLB031AAL 23
24. Reconnect the window washer hose.
RCPH11TLB040AAM 24
84516378 05/07/2011
B.10.A / 36
25. Install the fixed hood hardware.
RCPH11TLB039AAM 25
26. Connect crank case vent.
RCPH11TLB038AAM 26
27. Connect the aspirator tube.
RCPH11TLB037AAM 27
28. Install the air cleaner to turbo tube.
RCPH11TLB036AAM 28
84516378 05/07/2011
B.10.A / 37
29. Connect the air restriction indicator.
RCPH11TLB035AAM 29
30. Connect the high pressure and low pressure A/C

lines.
RCPH11TLB034AAM 30
31. Reconnect the electrical connection.
RCPH11TLB033AAM 31
Next operation:
Radiator - Install - 580SN, 580SN-WT, 590SN only (B.50.A)
Next operation:
Engine hood - Install (E.20.A)
Next operation:
84516378 05/07/2011
B.10.A / 38
ENGINE - Prepare for stall tests

Do the stall test to find the cause of poor performance.
The main relief valve must be set within specifications to achieve accurate readings when performing the following
stall tests.
The engine is run at full throttle and the transmission and hydraulic systems are engaged separately, and then to-
gether.
Comparing the engine speeds from the stall test with the check sheets starting on page 6 will help to find the cause
of the problem. It can be necessary to check a separate system to find the exact cause of the problem.
Use a photo tachometer or other tachometer of equal accuracy to get accurate results from the stall test.
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.
Machines with standard transmission

NOTE: For 580N machines only and check the throttle linkage adjustments.
1. Apply the parking brake.
2. Move the transmission gear selector into fourth gear.
3. Lock the brake pedals together. Put your foot on
the service brakes and hold the machine with service
brakes.
4. Release the parking brake.
5. With the engine running at low idle, move the direc-
tion control lever forward.
6. Slowly increase the engine speed to full throttle.
7. If the machine begins to move at any time, decrease
the engine speed to low idle and stop the engine.
Machines with H–Type transmission

2. Place the automatic/manual switch in the manual po-
sition.
3. Select 4th gear on the range selector.
brakes.
6. With the engine running at low idle, move the direc-
tion control lever forward.
7. Slowly increase the engine speed to full throttle.
8. If the machine begins to move at any time, decrease
the engine speed to low idle and stop the engine.
See section 6004 and repair the service brakes.
Procedure to heat torque converter and hydraulic oil

3. Run the engine at full throttle, hold the loader control
lever in the rollback position for 15 seconds.
84516378 05/07/2011
B.10.A / 39
4. Return the loader control lever to neutral for 15 sec-

onds.
5. Return the boom control lever to neutral for 15 sec-
onds.
6. Repeat steps 3 and 4 until the temperature of the oil
is 52 °C (126 °F). The side of the reservoir will be
very warm at this temperature.
7. With the engine running at low idle, move the trans-
mission control to fourth gear and the direction con-
trol lever to forward.
8. Run the engine at full throttle for 15 seconds.
9. Decrease the engine speed to low idle and move the
direction control lever to neutral for 15 seconds.
10. Repeat steps 6 through 8 until the pointer in the
gauge for transmission oil temperature is in the cen-
ter of the green zone of the gauge for transmission
oil temperature.
Stall test procedure

1. Prepare the machine for the stall test according to
instructions in this section.
2. Heat the oil according to instructions in this section.
3. Apply the parking brake and start the engine.
4. With the engine running at full throttle, hold the loader
control lever in the lift position and read the tachome-
ter. Record the reading on line 1 of the check sheet.
5. With the engine running at full throttle and boom in
travel lock, hold the dipper lever in the in position and
read the tachometer. Record the reading on line 2 of
the check sheet.
6. Decrease the engine speed to low idle.
7. Move the transmission control lever to fourth gear.
NOTE: For machines with H-Type transmissions, place the
automatic/manual switch in the manual position.
brakes.
10. Move the direction control lever to forward.
11. Slowly increase the engine speed to full throttle and
read the tachometer. Record the reading on line 3
on the check sheet.
12. With the transmission control lever in fourth gear, the
direction control lever in forward, and the engine run-
ning at full throttle, hold the loader control lever in
the lift position and read the tachometer. Record the
reading on line 4 on the check sheet.
13. Decrease the engine speed to low idle, move the
directional control lever to neutral.
14. Run the engine at low idle for two minutes and then
stop the engine.
84516378 05/07/2011
B.10.A / 40
15. See the check sheet to understand the results of the

stall test.
84516378 05/07/2011
B.10.A / 41
Balancer - Remove
1. Drain oil from engine.
2. Put a suitable floor jack under the engine oil pan,
remove engine oil pan.
3. Remove the oil sump from the engine.
4. Turn the engine while pressing in on the timing lock
pin until pin locks engine on number one TDC.
RCPH10TLB004BAL 1
5. Remove the balancer from the engine.
RCPH10TLB003BAL 2
84516378 05/07/2011
B.10.A / 42
Balancer - Timing adjust

Prior operation:
Balancer - Remove (B.10.A)
1. Align the timing marks on the balancer.

2. Install the balancer retaining bolt securing the bal-
ancer timing adjustment.
RCPH10TLB001BAL 1
Next operation:
Balancer - Install (B.10.A)
84516378 05/07/2011
B.10.A / 43
Index
ENGINE - 10.A
Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Balancer - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ENGINE - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE - Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ENGINE - Install - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
ENGINE - Prepare for stall tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ENGINE - Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE - Remove - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ENGINE - Service instruction - Engine repair service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE - Speeds stall test check sheet (580N only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE - Speeds stall test check sheet (580SN WT only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE - Speeds stall test check sheet (580SN only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE - Speeds stall test check sheet (590SN only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE - Speeds stall test normal (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84516378 05/07/2011
B.10.A / 44
FUEL AND INJECTION SYSTEM - 20.A
580N
580SN WT
580SN
590SN
84516378 05/07/2011
B.20.A / 1
Contents
TECHNICAL DATA
Fuel injection pump

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Throttle command
Exploded view - Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Throttle command
Adjust - Throttle linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjust - Throttle lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel injection pump
Timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel tank
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
84516378 05/07/2011
B.20.A / 2
ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
Fuel injection pump - Special tools

CAS 1691A Gear puller
RCPH10TLB720ABL 1
84516378 05/07/2011
B.20.A / 3
380000988 Engine turning tool
RCPH10TLB005BAL 2
380001435 Valve gauge tool
RCPH10TLB721ABL 3
84516378 05/07/2011
B.20.A / 4
Throttle command - Exploded view - Throttle linkage
RCPH10TLB044GAL 1
1. Ball joint 6. Lever - hand throttle 11. Injection pump lever

2. Throttle lever 7. Cable 12. Cable jam nuts
3. Clevis 8. Cable jam nuts 13. Cable
4. Cross shaft 9. Lever - foot throttle 14. Clevis
5. Throttle pedal 10. Jam nut 15. Lock nut
84516378 05/07/2011
B.20.A / 5
Throttle command - Adjust - Throttle linkage adjustment

1. Disconnect the ball joint (1) from the lever on the fuel
injection pump. See the illustration Throttle com-
mand - Exploded view - Throttle linkage (B.20.A).
2. Use a photo tachometer or other tachometer of equal
accuracy to check the engine speeds. If the engine
speeds are not equal to the specifications in this sec-
tion, adjust the engine speeds as required. See Spe-
cial Tools in this section.
NOTE: Adjustment of high idle must be done by an authorized Case dealer.

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.
4. Connect the ball joint (1) to the lever on the fuel in-
jection pump.
5. Move the throttle lever (2) to the high idle position.
The ball joint (1) must obtain 1 mm (0.039 in) over-
ride at the injection pump lever (11) on the fuel injec-
tion pump.
6. To obtain the required override, adjust the throttle
cable jam nuts (8) at the engine.
7. Check to see that the high and low idle engine
speeds are as specified.
84516378 05/07/2011
B.20.A / 6
Throttle command - Adjust - Throttle lever adjustment

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 - 6.2
N·m (50 - 55 lb in) then torque the outer jam nut (10) to 3.3
- 5.7 N·m (29 - 50 lb in).
84516378 05/07/2011
B.20.A / 7
Fuel injection pump - Timing check

Park the machine on a level surface, secure the front loader in a raised position, stop the engine, remove the ignition
key raise the engine hood. Remove the battery cover and disconnect the battery.
Establishing TDC (Top Dead Center)

1. Using Engine Turning Tool 380000988, manually
turn the engine over, rotating the tone-wheel (1)
until the non-slotted section is at the top. This will
position the No. 1 piston near TDC.
RCPH10TLB742ABL 1
2. Remove the valve cover and install the Valve Gauge

Tool (1) – 380001435 on engine.
RCPH10TLB743ABL 2
3. Use the Valve Gauge Tool (1) to open the No. 1

cylinder intake valve.
4. Turn the engine over in a clockwise direction (as
viewed from the front) until the No. 1 piston makes
contact with the intake valve.
NOTICE: Do not use excessive force with the tuning tool,
otherwise damage to the intake valve will occur.
5. Attach a metal reference rod (2) to the bracket (1)
near the AC belt pulley (3).
6. Use the metal rod as a reference (2) point and mark
the pulley (4).
RCPH10TLB744ABL 3
7. Remove tool 380001435 closing the intake valve.
84516378 05/07/2011
B.20.A / 8
8. Continue to turn the engine in a clockwise direction,

approximately 1/5 turn, until the piston is on a down
cycle.
9. Install tool 380001435 to open the No. 1 cylinder
intake valve.
10. Turn the engine in a counter–clockwise direction until
the piston makes contact with the valve.
NOTICE: Do not use excessive force with the tuning tool,
otherwise damage to the intake valve will occur.
11. Mark the AC belt pulley (1) using the rod as a refer-
ence.
RCPH10TLB745ABL 4
12. 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.
RCPH10TLB746ABL 5
Checking Static Timing

1. Remove tool 380001435 closing the intake valve.
2. Locate the timing plug at the center of the four injec-
tion lines and remove it with a 12 mm socket.
3. Install adapter (1) CAS 2458 and insert the indicator
gauge (2) CAS 1745-1 into the pump.
RCPH10TLB747ABL 6
4. Preload the gauge approximately 2.5 mm (0.1 in).
84516378 05/07/2011
B.20.A / 9
5. Turn the engine counter–clockwise until the gauge

needle stops moving.
6. Zero out the gauge.
7. Turn the engine clockwise until the TDC Mark (1)
lines up with the reference rod (2).
RCPH10TLB748ABL 7
8. Take note of the timing pre-lift shown on the gauge.

The specifications are as follows:
• Natural Aspirated – 1.10 - 1.25 mm (0.043
- 0.049 in)
• Turbo – 0.95 - 1.10 mm (0.037 - 0.043 in)
If timing pre-lift is one of the following:
• Within the specification range – Remove
tools and install the previously removed
components.
• Out of the specification range – Perform
the Static Timing Reset procedure.
RCPH10TLB747ABL 8
Static Timing Reset

1. 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 (minimum)
to loosen the back bolt so that the gauge reading will not
be altered.
RCPH10TLB749ABL 9
2. Use the slots in the injection pump mount to ro-

tate (fine-tune) the pump into the correct position.
For example: If the gauge reading is 0.90 mm
(0.035 in), advance the timing by rotating the pump
counter–clockwise until the correct specification
range is reached.
3. Tighten the pump mounting nuts.
84516378 05/07/2011
B.20.A / 10
4. If the pre-lift specification cannot be reached by ro-

tating the pump, do the following procedures:
A. Confirm the gear housing nuts are tight.
B. Turn the engine over until the pre-lift is:
• Natural Aspirated – 1.20 - 1.25
mm (0.047 - 0.049 in)
• Turbo – 1.00 - 1.10 mm (0.039
- 0.043 in)
5. Confirm the injection pump lock bolt is tight.
RCPH10TLB726ABL 10
6. Remove the protective air inlet grill from the side of

the frame.
RCPH10TLB738ABL 11
7. Loosen the hose clamp and remove air cleaner inlet

hose.
RCPH10TLB739ABL 12
84516378 05/07/2011
B.20.A / 11
8. Reach through the air inlet hole in the frame, remove

the three retaining bolts and cover plate.
RCPH10TLB733ABL 13
9. Loosen and remove nut and washer.

NOTICE: Use caution when removing nut and washer they
can be dropped inside of the engine, requiring the engine to
be disassembled in order to remove the hardware. Failure
to comply will result in engine damage.
RCPH10TLB734ABL 14
10. Install the Injection Pump Drive Gear Puller CAS

1691A, and loosen the pump gear.
RCPH10TLB735ABL 15
11. Turn engine back to TDC.

12. Remove the gear puller, install lock washer and nut.
Tighten to a torque of 90 - 95 N·m (66 - 70 lb ft)
RCPH10TLB734ABL 16
84516378 05/07/2011
B.20.A / 12
13. Apply Loctite 5205 to the surface of the cover plate,

install the cover plate and mounting bolts, tighten
bolts.
RCPH10TLB733ABL 17
14. Verify that the pump pre-lift is within specifications:

• Natural Aspirated – 1.10 - 1.25 mm (0.043
- 0.049 in)
• Turbo – 0.95 - 1.10 mm (0.037 - 0.043 in)
15. If the pump pre-lift is one of the following:
• Within the specification range – Remove
tools and install the previously removed
components.
• Out of the specification range – Replace
the pump. Refer to Fuel injection pump
- Remove (B.20.A) and repeat these in-
structions for setting the injection pump
timing.
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Fuel injection pump - Remove

Prior operation:
Prior operation:
1. Secure loader in raised position, stop engine.
RCPH11TLB001AAM 1
2. Disconnect the negative battery cable (2) from the

terminal and move the negative battery cable away
from the battery.
3. Disconnect the positive battery cable (1) from the ter-
minal and move the negative battery cable away from
the battery.
RCPH10TLB429AAF 2
4. Remove grill from side of frame.
RCPH10TLB738ABL 3
84516378 05/07/2011
B.20.A / 14
5. Loosen hose clamp and remove air cleaner inlet

hose.
RCPH10TLB739ABL 4
6. Loosen jam nut for throttle cable.
RCPH10TLB736ABL 5
7. Remove the two throttle arm mounting bolts, move

the throttle cable out of the mounting bracket.
RCPH10TLB035AAL 6
8. Disconnect the ground strap (1). Disconnect the

wires (2) from the starter.
RCPH10TLB038AAL 7
84516378 05/07/2011
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9. Remove the starter from the engine and install

380000988 engine turning tool.
RCPH11TLB062AAM 8
10. Remove the front rocker arm cover and injector line
retaining bracket mounting bolt. Using engine turn-
ing tool turn engine in direction of running rotation
until push rods can be turned freely.
RCPH10TLB741ABL 9
11. Have an assistant continue to turn the engine with

turning tool while pressing in on lock pin located just
below injector pump.
RCPH10TLB725ABL 10
12. Once the lock pin has engaged continue to turn with
light pressure on turning tool until engine has com-
pletely stopped rotating.
13. Loosen injector pump locking bolt and remove the
slotted plate, tighten the locking bolt to 27 - 33 N·m
(20 - 24 lb ft).
RCPH10TLB726ABL 11
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14. Remove the injector line retaining bracket mounting

bolts.
RCPH10TLB727ABL 12
15. Remove fuel filter and mounting bracket from engine.
RCPH10TLB724ABL 13
16. Disconnect the power lead to the injector pump.
RCPH10TLB040AAL 14
17. 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.
RCPH10TLB041AAL 15
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18. Remove the mechanical fuel pump and engine oil

filler tube from the engine.
NOTE: In the following photos the engine is shown re-
moved from the machine, this is for clarity only, it is not
required to remove the engine.
19. 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.
RCPH10TLB730ABL 16
20. Disconnect fuel feed line from injector pump. Cover

line and fitting to keep foreign material from entering
the fuel system.
RCPH10TLB731ABL 17
21. Disconnect temperature sensor.
RCPH10TLB732ABL 18
84516378 05/07/2011
B.20.A / 18
22. Reaching through the inlet hole in the frame, remove

the three plate retaining bolts, remove the plate.
RCPH10TLB733ABL 19
23. Loosen and remove nut and washer.

NOTICE: Use caution when removing nut and washer they
can be dropped inside of the engine, requiring the engine to
be disassembled in order to remove the hardware. Failure
to comply will result in engine damage.
RCPH10TLB734ABL 20
24. Install gear puller and tighten bolts until gear is loose.
RCPH10TLB735ABL 21
25. 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.
RCPH10TLB728ABL 22
Next operation:
Fuel injection pump - Install (B.20.A)
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B.20.A / 19
Fuel injection pump - Install

Prior operation:
Fuel injection pump - Remove (B.20.A)
1. Use a suitable solvent to remove oil from the injection

pump drive shaft and drive gear tapers.
NOTICE: Tapers should be dried completely before continuing with the installation procedure.
2. Replace gasket on pump mounting flange.
3. Install pump and tighten the three mounting nuts.
RCPH10TLB728ABL 1
4. Install lock washer and nut, torque nut to 90 - 95 N·m

(66 - 70 lb ft).
NOTICE: Use caution when installing nut and washer.
They can be dropped inside of the engine, requiring the
engine to be disassembled in order to remove the hard-
ware. Failure to comply will result in engine damage.
RCPH10TLB734ABL 2
5. Apply Loctite 5205 to the surface of the cover plate,

install cover plate and mounting bolts, tighten bolts.
RCPH10TLB733ABL 3
84516378 05/07/2011
B.20.A / 20
6. Connect wire to temperature sensor.
RCPH10TLB732ABL 4
7. Connect the fuel feed line to the injector pump.
RCPH10TLB731ABL 5
8. Remove covers from lines and fittings. Connect fuel

injector lines (1), connect fuel return line (2), and
boost line (3) to the pump.
RCPH10TLB730ABL 6
9. Install oil filler tube (3), mechanical fuel pump (2), and
fuel filter (1) on the engine.
RCPH10TLB737ABL 7
84516378 05/07/2011
B.20.A / 21
10. Install the injector line retaining bracket mounting

bolts.
RCPH10TLB729ABL 8
11. Loosen injector pump locking bolt and install the slot-
ted plate, tighten the locking bolt to 12 - 14 N·m (106
- 124 lb in).
RCPH10TLB726ABL 9
12. Make sure locking pin is disengaged from gear.
RCPH10TLB725ABL 10
13. Install the starter.

14. Connect the positive battery cable (1) to the positive
terminal.
15. Connect the negative battery cable (2) to the nega-
tive terminal.
RCPH10TLB722ABL 11
84516378 05/07/2011
B.20.A / 22
16. Install the front rocker arm cover and injector line
retaining bracket mounting bolt.
RCPH10TLB741ABL 12
17. Install the throttle cable into the bracket and tighten
the jam nut.
RCPH10TLB736ABL 13
18. Install and tighten both throttle arm mounting bolts.
RCPH10TLB035AAL 14
19. Connect the power lead to the injector pump.
RCPH10TLB040AAL 15
84516378 05/07/2011
B.20.A / 23
20. Install air cleaner inlet hose and tighten the hose
clamp.
RCPH10TLB739ABL 16
21. Install grill on side of frame.
RCPH10TLB738ABL 17
22. Actuate the lever on the mechanical fuel pump to

prime the fuel system.
23. Start the machine and check for fuel leaks, check and
adjust throttle linkage as needed.
84516378 05/07/2011
B.20.A / 24
Fuel tank - Remove

WARNING
Fuel vapors are explosive and flammable.
Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove
key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.
W0904A
1. Support the fuel tank.
RCPH11TLB148AAM 1
2. Remove hardware.
3. Lower tank slightly.
RCPH11TLB148AAM 2
4. Disconnect fuel lines. Cap all open connections.
RCPH11TLB149AAM 3
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B.20.A / 25
5. Disconnect fuel sending wire.
RCPH11TLB149AAM 4
6. Carefully remove the fuel tank.
RCPH11TLB150AAM 5
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Fuel tank - Install

WARNING
Fuel vapors are explosive and flammable.
Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove
key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.
W0904A
1. Carefully move the fuel tank into position.
RCPH11TLB150AAM 1
2. Remove caps and reconnect fuel lines.

3. Reconnect the fuel sending wire connection.
RCPH11TLB149AAM 2
4. Raise the tank slightly. Reinstall the mounting hard-

ware.
RCPH11TLB148AAM 3
84516378 05/07/2011
B.20.A / 27
Index

Fuel injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel injection pump - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel injection pump - Timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Throttle command - Adjust - Throttle lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Throttle command - Adjust - Throttle linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Throttle command - Exploded view - Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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EXHAUST SYSTEM - 40.A
580N
580SN WT
580SN
590SN
84516378 05/07/2011
B.40.A / 1
Contents
FUNCTIONAL DATA
Exhaust manifold
Exploded view - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Exhaust manifold
Remove - 580 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84516378 05/07/2011
B.40.A / 2
84516378 05/07/2011
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ENGINE AND PTO IN - EXHAUST SYSTEM
Exhaust manifold - Exploded view - 580N only

1. Muffler 4. Bolts (2), nuts (2), and washers 7. Bolt (1), spacer (1), and washer
(4) (1)
2. Bolts (2) and washers (2) 5. Bolts (2), nuts (2), and washers 8. Bolt (1), nut (1), and washers (2)
(4)
3. Clamp T bolt 6. Bolt (1), nut (1), and washers (2) 9. Aspiration hose
84516378 05/07/2011
B.40.A / 4
RCPH10TLB013FAL 1
84516378 05/07/2011
B.40.A / 5
Exhaust manifold - Exploded view - 580SN, 580SN-WT, 590SN only

1. Muffler 4. Bolts (2), nuts (2), and washers 7. Bolt (1), spacer (1), and washer
(4) (1)
2. Bolts (2) and washers (2) 5. Bolts (2), nuts (2), and washers 8. Bolt (1), nut (1), and washers (2)
(4)
3. Clamp T bolt 6. Bolt (1), nut (1), and washers (2)
84516378 05/07/2011
B.40.A / 6
RCPH10TLB014FAL 1
84516378 05/07/2011
B.40.A / 7
Exhaust manifold - Remove - 580 only

Put identification tags on all disconnected hoses and wires. Be prepared to cap or plug disconnected hoses and
fittings.

RCPH10TLB022AAL 1
2. Remove the battery cover from the right-hand step

and perform the following procedure based on the
number of batteries present, dual battery illustrated:
• Dual battery – remove the terminal nut
(1). Remove the negative battery cable
(2) from the terminal and move the neg-
ative battery cable away from the battery.
Make sure the jumper cable (3) is installed
on the terminal and start the terminal nut
(2) onto the terminal.
• Single battery – disconnect the negative
battery cable from the battery and move it
away from the battery terminal. RCPH10TLB030AAL 2
3. Loosen the air cleaner hose clamp on the tur-

bocharger. Detach the hose from the turbocharger.
4. Loosen the air cleaner inlet hose clamp on the air
cleaner. Detach the inlet hose form the air cleaner.
5. Disconnect crank case ventilation hose and the as-
piration hose.
RCPH10TLB031AAL 3
6. Disconnect the electrical connectors for the air re-

striction indicator.
84516378 05/07/2011
B.40.A / 8

hood and air cleaner as one assembly.
RCPH10TLB023AAL 4
8. Loosen the T – clamp and disconnect the muffler

flange hose from the turbo.
9. Remove the mounting hardware that secures the
rear and front of the muffler to the engine block.
10. Remove the muffler assembly.
Next operation:
Exhaust manifold - Install (B.40.A)
84516378 05/07/2011
B.40.A / 9
Exhaust manifold - Install - 580N only

Prior operation:
Exhaust manifold - Remove (B.40.A)
NOTICE: Prevent damage to the exhaust system do the

following procedures in sequence. All gaps between
mounting surfaces should be eliminated before torque
sequence is started.
1. Assemble the muffler to the engine and hand tighten
the bolt hardware for alignment purposes.
2. Align and secure the muffler flange with turbo and
tighten “T” bolt clamp (3) to 6.5 - 7.5 N·m (57.5 - 66.4
lb in).
3. Tighten lower bolts (2) on rear bracket to engine
block to a torque of 64 - 75 N·m (47 - 55 lb ft).
4. Tighten right hand bolt (6) to muffler to a torque of 64
- 75 N·m (47 - 55 lb ft).
5. Tighten front bracket to engine lifting bracket mount-
ing nuts (4) to a torque of 64 - 75 N·m (47 - 55 lb ft).
6. Tighten mounting bolts (5) to engine to a torque of 64
- 75 N·m (47 - 55 lb ft).
7. Tighten brace mounting bolt (7) to gear housing to a
torque of 32 - 40 N·m (24 - 30 lb ft).
8. Tighten rear brace left hand bolt (8) to muffler to a
torque of 64 - 75 N·m (47 - 55 lb ft).
9. When mounting aspiration hose, torque hose clamps
to 3.1 - 3.4 N·m (27.4 - 30.1 lb in).
84516378 05/07/2011
B.40.A / 10
Exhaust manifold - Remove - 580SN, 580SN-WT, 590SN only

Put identification tags on all disconnected hoses and wires. Be prepared to cap or plug disconnected hoses and
fittings.

RCPH10TLB022AAL 1
2. Remove the battery cover from the right-hand step

and perform the following procedure based on the
number of batteries present, dual battery illustrated:
• Dual battery – remove the terminal nut
(1). Remove the negative battery cable
(2) from the terminal and move the neg-
ative battery cable away from the battery.
Make sure the jumper cable (3) is installed
on the terminal and start the terminal nut
(2) onto the terminal.
• Single battery – disconnect the negative
battery cable from the battery and move it
away from the battery terminal. RCPH10TLB030AAL 2
3. Loosen the air cleaner hose clamp on the tur-

bocharger. Detach the hose from the turbocharger.
RCPH10TLB024AAL 3
4. Loosen the air cleaner inlet hose clamp on the air

cleaner. Detach the inlet hose form the air cleaner.
84516378 05/07/2011
B.40.A / 11
5. Disconnect crank case ventilation hose.
RCPH10TLB031AAL 4

striction indicator.
hood and air cleaner as one assembly.
RCPH10TLB023AAL 5
8. Loosen the T – clamp and disconnect the muffler

flange hose from the turbo.
9. Remove the mounting hardware that secures the
rear and front of the muffler to the engine block.
10. Remove the muffler assembly.
Next operation:
Exhaust manifold - Install (B.40.A)
84516378 05/07/2011
B.40.A / 12
Exhaust manifold - Install - 580SN, 580SN-WT, 590SN only

1. IMPORTANT: To prevent damage to the exhaust sys-
tem do the following procedures in sequence. 1. As-
semble muffler (1) to engine with bolts finger tight.
NOTE: All gaps between mounting surfaces should
be eliminated before torque sequence is started. 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). 3.
Tighten lower bolts (2) on rear bracket to engine
block to a torque of 64 to 75 Nm (47 to 55 pound feet).
4. Tighten right hand bolt (6) to muffler to a torque of
64 to 75 Nm (47 to 55 pound feet). 5. Tighten front
bracket to engine lifting bracket mounting nuts (4) to
a torque of 64 to 75 Nm (47 to 55 pound feet). 6.
Tighten mounting bolts (5) to engine to a torque of
64 to 75 Nm (47 to 55 pound feet). 7. Tighten brace
mounting bolt (7) to gear housing to a torque of 44 to
54 Nm (32 to 40 pound feet). 8. Tighten rear brace
left hand bolt (8) to muffler to a torque of 64 to 75 Nm
(47 to 55 pound feet).
84516378 05/07/2011
B.40.A / 13
Index

Exhaust manifold - Exploded view - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust manifold - Exploded view - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust manifold - Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exhaust manifold - Install - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust manifold - Remove - 580 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exhaust manifold - Remove - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
84516378 05/07/2011
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ENGINE COOLANT SYSTEM - 50.A
580N
580SN WT
580SN
590SN
84516378 05/07/2011
B.50.A / 1
Contents
FUNCTIONAL DATA
Radiator
Exploded view - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Radiator
Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassemble - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Radiator - Exploded view - 580N only

1. Deaeration tank 4. Mounting bolts
2. Radiator hose 5. Oil cooler connectors
3. Clamp 6. Condenser Pivot Bolt
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RCPH10TLB031GAL 1
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Radiator - Exploded view - 580SN, 580SN-WT, 590SN only

1. Radiator 8. Transmission cooler tubes
2. Hydraulic oil cooler 9. Condenser and fuel cooler pivot bolts
3. Change air cooler 10. Oil cooler tubes
4. Air conditioning condenser 11. Fan shroud mounting bolts
5. Fuel cooler 12. Clamp
6. Transmission oil cooler 13. Deaeration tank
7. Charge air support bracket 14. Radiator hoses and clamps
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RCPH10TLB030GAL 1
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Radiator - Remove - 580N only

NOTE: The photos in this procedure may be different from your machine and are for reference only.
1. Put identification tags on all disconnected hoses and
wires. Close disconnected hoses and fittings with
caps and plugs.
loader and lock the support strut (1) to hold the
loader. Stop the engine and apply the parking brake.
RCPH10TLB022AAL 1
3. Remove the cap screws, bumpers and the grill from

the front of the machine.
RCPH10TLB051AAL 2
4. Open the hood. Connect acceptable lifting equip-

ment to the hood.
RCPH10TLB356AAF 3
5. Do the following procedure to remove the hood:

A. Remove the retainers from the hood struts
and disconnect the hood struts from the
stud.
B. Disconnect the hood cable from the radi-
ator shroud.
C. Carefully lower the hood back to the
closed position.
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6. Remove the bolts, washers, and nuts from the pivot

point on the hood.
RCPH10TLB046AAL 4
7. Drive the pivot tubes out of the hood pivot point. Re-
move the hood from the machine.
RCPH10TLB044AAL 5
8. Slowly remove the radiator cap. Install a hose on

the drain valve and drain the radiator into a clean
container that holds approximately 18 l (5 US gal).
RCPH10TLB050AAL 6
9. Loosen the clamp and disconnect the upper radiator

hose.
RCPH10TLB046AAL 7
10. Loosen the clamp and disconnect the lower radiator

hose.
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11. If equipped with air conditioning, discharge air con-

ditioning system. Disconnect high pressure switch,
disconnect hoses from condenser and receiver drier.
Remove the receiver drier and horn from the ma-
chine.
RCPH10TLB408ACL 8
12. Disconnect all four oil cooler hoses, two on each side
of the machine, from the oil cooler.
RCPH10TLB047AAL 9
13. Remove the radiator wrapper mounting bolts, re-

move the radiator wrapper from the machine.
RCPH10TLB053AAL 10
14. Attach suitable lifting equipment to the radiator.

Raise the cooling pack just enough to move it for-
ward and clear the fan.
RCPH10TLB053AAL 11
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15. Make sure that you have cleared the fan from the
shroud, raise the cooling pack from the machine.
RCPH10TLB048AAL 12
16. If applicable, see Radiator - Disassemble 580N

only (B.50.A) for procedures to replace worn or
damaged components.
Next operation:
Radiator - Install - 580N only (B.50.A).
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Radiator - Disassemble 580N only

Prior operation:
Radiator - Remove (B.50.A)
1. Place cooling pack on a bench, if equipped remove

the condenser bracket mounting bolts, three per
side.
2. Remove the cooler line mounting clamps, remove
the oil cooler mounting bolts.
3. Remove the fan shroud mounting bolts, deaeration
tank , and radiator hoses from the radiator.
4. Replace worn or damaged components.
Next operation:
Radiator - Assemble (B.50.A)
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Radiator - Assemble 580N only

Prior operation:
Radiator - Disassemble (B.50.A)
NOTE: Refer to the Radiator - Exploded view (B.50.A) for more details.
1. Install fan shroud and torque bolts to 13 - 25 N·m (10
- 18 lb ft).
2. Install deaeration tank.
3. Install radiator hoses and clamps, torque clamps to
4.5 - 5.5 N·m (40 - 49 lb in).
4. If fittings were removed from the oil cooler, install
fittings and torque to 77 - 85 N·m (57 - 63 lb ft).
NOTICE: Use two wrenches to minimize the torque trans-
mitted onto the elbow brazed to the oil cooler.
5. Install the oil coolers and tighten the mounting bolts.
6. Install the clamps and torque to 3.1 - 3.4 N·m (27 -
30 lb in).
7. Install the mounting brackets and tighten the mount-
ing bolts.
8. If equipped, mount the condenser into the bracket
using the pivot bolt.
9. Tighten the condenser pivot bolt tight enough to
remove the gaps between the mounting brackets
but not tight enough to prevent the condenser from
swinging out for cleaning.
10. Swing the condenser into position, install and tighten
retaining bolts.
Next operation:
Radiator - Install (B.50.A)
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Radiator - Install - 580N only

NOTE: The photos in this procedure may be different from your machine and are for reference only.
1. Attach suitable lifting equipment to the radiator.
2. Lower the assembly just in front of the fan and slowly
guide the cooling pack backward clearing the fan.
NOTE: Adjust fan shroud to obtain 20 mm (0.8 in) around
the fan.
RCPH10TLB048AAL 1
3. Install the radiator wrapper and secure with mounting

bolts on both sides of the machine.
RCPH10TLB053AAL 2
4. Connect all four oil cooler hoses, two on each side of

the machine.
RCPH10TLB047AAL 3
5. Install the receiver drier and horn on the machine.

Connect high pressure switch, connect the hoses
from condenser and receiver drier. If equipped
with air conditioning, see ENVIRONMENT CON-
TROL Air-conditioning system - Charging - Air
conditioner system evacuation and recharging
(E.40.C) to charge the system.
RCPH10TLB408ACL 4
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6. Connect the lower radiator hose and tighten the

clamp.
7. Connect the upper radiator hose and tighten the
clamp.
RCPH10TLB054AAL 5
8. Position the hood on the machine and drive the pivot

tubes into the hood pivot point.
RCPH10TLB044AAL 6
9. Secure the hood to the pivot point with the bolts,

washers, and nuts.
RCPH10TLB046AAL 7
10. Do the following procedure to secure the hood:

A. Carefully place the hood in a raised posi-
tion.
B. Attach the hood cable to the radiator
shroud.
C. Attach the hood struts to the stud and se-
cure with the retainers .
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11. Disconnect the lifting equipment from the hood .
RCPH10TLB356AAF 8
12. Install the front grill, bumpers, and secure in place

with the cap screws (1).
RCPH10TLB051AAL 9
13. Fill the radiator and deaeration reservoir to the full

line. See Capacities () for specifications.
14. Connect the battery.
15. Start the engine and allow the coolant to reach op-
erating temperature. Stop the engine and check for
leaks. After the coolant cools check the level and fill
as needed.
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Radiator - Remove - 580SN, 580SN-WT, 590SN only

Prior operation:
Prior operation:
1. Remove grill hardware.
RCPH11TLB009AAM 1
2. Remove grill bumpers.
RCPH11TLB010AAM 2
3. Remove the grill.
RCPH11TLB032AAM 3
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4. Drain the coolant.
RCPH11TLB011AAM 4
RCPH11TLB012AAM 5
5. Remove the radiator purge hose.
RCPH11TLB013AAM 6
6. Remove the upper radiator hose.
RCPH11TLB014AAM 7
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7. Remove the charge air cooler hoses and pipes.
RCPH11TLB015AAM 8
8. Cap (seal) all open ports to keep contaminates from

entering the system.
RCPH11TLB016AAM 9
9. Remove the lower radiator hose.
RCPH11TLB017AAM 10
10. Discharge the A/C system.

NOTICE: Use appropriate reclaiming devices when recov-
ering A/C refrigerant.
RCPH11TLB018AAM 11
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11. Disconnect the high pressure switch.
RCPH11TLB019AAM 12
12. Remove the horn.
RCPH11TLB020AAM 13
13. Disconnect A/C receiver dryer lines and cap all open
ports.
RCPH11TLB021AAM 14
14. Remove the dryer.
RCPH11TLB022AAM 15
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15. Disconnect the upper condenser line and cap all

open ports.
RCPH11TLB023AAM 16
16. Disconnect fuel cooler lines and cap open ports.
RCPH11TLB024AAM 17
17. Tag and disconnect the four oil cooler lines and cap
all open ports.
Left hand oil cooler lines Right hand oil cooler lines
RCPH11TLB026AAM 18 RCPH11TLB025AAM 19
18. Remove the radiator wrapper mounting bolts.
RCPH11TLB027AAM 20
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19. Remove the radiator wrapper.
RCPH11TLB028AAM 21
20. Remove hood strut mounts.
RCPH11TLB029AAM 22
21. Remove hood hinge plates.
RCPH11TLB029AAM 23
RCPH11TLB030AAM 24
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23. Remove cooling package mounting hardware.
RCPH11TLB029AAM 25
24. Remove cooling package.
RCPH11TLB031AAM 26
Next operation:
Radiator - Install - 580SN, 580SN-WT, 590SN only (B.50.A).
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Radiator - Disassemble - 580SN, 580SN-WT, 590SN only

Prior operation:
Radiator - Remove (B.50.A)
1. Place cooling pack on a bench, remove the charge

air support bracket mounting bolts, three per side.
2. Remove the cooler line mounting clamps, remove
the oil cooler mounting bolts.
3. Remove the fan shroud mounting bolts, deaeration
tank, and radiator hoses from the radiator.
4. Replace worn or damaged components.
Next operation:
Radiator - Assemble (B.50.A)
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Radiator - Assemble - 580SN, 580SN-WT, 590SN only

Prior operation:
Radiator - Disassemble (B.50.A)
NOTE: Refer to the Radiator - Exploded view (B.50.A) for more details.
1. Install fan shroud and torque bolts to 13 - 25 N·m (10
- 18 lb ft).
2. Install deaeration tank.
3. Install radiator hoses and clamps, torque clamps to
4.5 - 5.5 N·m (40 - 49 lb in).
4. If fittings were removed from the oil cooler, install
fittings and torque to 77 - 85 N·m (57 - 63 lb ft).
NOTICE: Use two wrenches to minimize the torque trans-
mitted onto the elbow brazed to the oil cooler.
5. Install the oil coolers and tighten the mounting bolts.
6. Install the clamps and torque to 3.1 - 3.4 N·m (27 -
30 lb in).
7. Install the charge air cooler mounting brackets and
tighten the mounting bolts.
8. If equipped with fuel cooler and condenser, mount
the charge air cooler and the mounting brackets for
the condenser and fuel cooler, tighten the mounting
bolts.
9. Mount the condenser and fuel cooler onto the bracket
using the pivot bolt.
10. Tighten the condenser and fuel cooler pivot bolt tight
enough to remove the gaps between the mounting
brackets but not tight enough to prevent the compo-
nents from swinging out for cleaning.
11. Swing the condenser and fuel cooler into position,
install and tighten retaining bolts.
Next operation:
Radiator - Install (B.50.A)
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Radiator - Install - 580SN, 580SN-WT, 590SN only

1. Carefully lower the cooling package into place.
RCPH11TLB031AAM 1
2. Install the cooling package with the existing mounting

hardware.
RCPH11TLB029AAM 2
RCPH11TLB030AAM 3
4. Install hood hinge plates.
RCPH11TLB029AAM 4
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5. Install hood strut mounts.
RCPH11TLB029AAM 5
6. Install the radiator wrapper.
RCPH11TLB028AAM 6
7. Install the radiator wrapper mounting bolts.
RCPH11TLB027AAM 7
8. Remove the caps and install the four oil cooler lines.
Left hand oil cooler lines Right hand oil cooler lines
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9. Connect fuel cooler lines and remove the caps from

the open ports.
RCPH11TLB024AAM 10
10. Remove the cap and install the upper condenser line.
RCPH11TLB023AAM 11
11. Move the dryer into place and secure to the frame.
RCPH11TLB022AAM 12
12. Remove all caps and reconnect A/C receiver dryer

lines.
RCPH11TLB021AAM 13
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13. Install the horn.
RCPH11TLB020AAM 14
14. Connect the high pressure switch.
RCPH11TLB019AAM 15
15. Install the lower radiator hose.
RCPH11TLB017AAM 16
16. Remove the caps from the open ports.
RCPH11TLB016AAM 17
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17. Install the charge air cooler hoses and pipes.
RCPH11TLB015AAM 18
18. Install the upper radiator hose.
RCPH11TLB014AAM 19
19. Install the radiator purge hose.
RCPH11TLB013AAM 20
20. Install the grill.
RCPH11TLB032AAM 21
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21. Install the grill bumpers.
RCPH11TLB010AAM 22
22. Install all grill hardware.
RCPH11TLB009AAM 23
23. Refill the system with coolant.
RCPH10TLB032AAF 24
24. Recharge the A/C system.
RCPH11TLB018AAM 25
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Index

Radiator - Assemble - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Radiator - Assemble 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Radiator - Disassemble - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Radiator - Disassemble 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Radiator - Exploded view - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Radiator - Exploded view - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Radiator - Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Radiator - Install - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Radiator - Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Radiator - Remove - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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STARTING SYSTEM - 80.A
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
STARTING SYSTEM
FUNCTIONAL DATA
Engine starter
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
STARTING SYSTEM
Remove - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter solenoid
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Test - Field coil test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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ENGINE AND PTO IN - STARTING SYSTEM
STARTING SYSTEM - General specification

SPECIFICATIONS
Manufacturer Nippondenso
No-Load Test at 20 °C (68.0 °F)
Volts 11 V
Current draw 200 A maximum
Starter drive speed 3000 RPM 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
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Engine starter - Exploded view
RCPH10TLB062GAL 1
1. Bolt 9. Armature 17. Idler gear

2. Lock washer 10. Field frame 18. Roller (5)
3. Flat washer 11. Cover 19. Bearing cage
4. O-ring 12. Gasket 20. Spring
5. Screw 13. Plunger 21. Steel ball
6. Cover 14. Nut 22. Starter drive
7. Brush holder 15. Starter solenoid assembly 23. Starter drive housing
8. Bearing 16. Thrust washer
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STARTING SYSTEM - Remove - Starter

Prior operation:
NOTE: The starter is located on the engine flywheel hous-

ing.
parking brake.
2. Remove the pin that fastens the support strut to the
loader frame.
3. Raise the loader frame until the support strut is
against the end of the lift cylinder.
4. Stop the engine and install the pin in the support
strut.
RCPH11TLB001AAM 1

7. A. Remove the negative battery cable (2)
from the battery. Move the cable away
from the battery terminals.
B. Remove the positive battery cable (1) from
the battery. Move the cable away from the
battery terminals.
RCPH10TLB429AAF 2
8. Open the hood.
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9. Tag and disconnect the wires and cables from the

terminals on the starter.
NOTE: Starter wire is coated with RTV silicone sealant.
RCPH10TLB232ABL 3
10. Remove the two bolts (1) that fasten the starter to the
flywheel housing. Remove the starter.
RCPH10TLB230ABL 4
Next operation:
STARTING SYSTEM - Install (B.80.A)
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STARTING SYSTEM - Install - Starter

Prior operation:
STARTING SYSTEM - Remove (B.80.A)
1. Put the starter in place on the flywheel housing.

2. Install the bolts (1) that fasten the starter to the fly-
wheel housing. Make sure the ground cable (2) is
installed under the upper bolt. Torque bolts to 40 -
47 N·m (29.5 - 34.7 lb ft).
RCPH10TLB230ABL 1
3. Connect the wires and cables to the terminals on the

starter.
RCPH10TLB232ABL 2
4. Cover the starter wire terminal with 737 RTV silicone

sealant.
NOTICE: Use only 737 RTV silicone sealant. Other
sealants can corrode the terminal.
5. Close the hood.
6. Reconnect the positive battery cable (1) to the bat-
tery.
7. Reconnect the negative battery cable (2) to the bat-
tery.
RCPH10TLB429AAF 3
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B.80.A / 7
RCPH11TLB002AAM 4

RCPH11TLB001AAM 5
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STARTING SYSTEM - Test

General information
1. The No-Load Test is done with the starter
removed from the engine.
2. Check to see if you can pull the gear on the
starter drive out of the starter drive hous-
ing.
3. Check to see if the starter drive can be
turned. Pull the gear on the starter drive
out of the starter drive housing. Turn the
gear to turn the starter drive and the arma-
ture.
4. If the starter drive cannot be turned, dis-
assemble the starter and make repairs as
needed. Then do the No-Load Test.
Test equipment
The No-Load Test can be done using a Sun Electric
VAT-33 Tester, an equivalent tester, or separate pieces of
test equipment.
A hand held tachometer is needed to measure the speed
of the armature shaft.
A remote starter button is needed to actuate the starter.
A fully charged 12 volt battery is needed to supply the elec-
tricity to turn the starter.
Test procedure
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.
1. If the VAT-33 tester is being used:
A. Select the 0 - 100 A range.
B. Select the 18 - 40 V range.
C. Move the volt lead switch to the EXT. po-
sition.
D. Turn the load control to the OFF position.
RCPH10TLB220ABL 1
2. Fasten the starter in a vise or use another method to

prevent the starter from moving. This must be done
to prevent personal injury.
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B.80.A / 9
3. Connect the positive battery cable (1) to the battery

terminal (2) on the starter solenoid and the negative
battery cable (3) to the mounting flange of the starter.
RCPH10TLB221ABL 2
4. Connect the positive load cable (1) to the positive

post of the battery. Connect the negative load cable
(2) to the negative post.
RCPH10TLB222ABL 3
5. Connect the red voltmeter lead (1) to the motor ter-

minal (2) on the starter solenoid.
RCPH10TLB223ABL 4
84516378 05/07/2011
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6. Connect the black voltmeter lead (1) the mounting

flange on the starter.
RCPH10TLB224ABL 5
7. Fasten the ammeter clamp (1) around the positive

battery cable so that the tip of the arrow is toward
the starter.
RCPH10TLB225ABL 6
8. Connect the leads from the remote starter button (1)

to the battery (2) and switch terminals (3).
RCPH10TLB226ABL 7
84516378 05/07/2011
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NOTICE: Steps 9, 10, and 11 must be done rapidly. Do not load the battery for more than 15 s at one time. After the
battery has been loaded for 15 s let the starter cool for 60 s.
9. Actuate the remote starter button (1) and turn the
load control (2) until the voltmeter (3) indicates 11 V.
RCPH10TLB227ABL 8
10. Look at the ammeter (4) and make a record of the

ammeter indication.
11. Use the hand held tachometer (5) and check the ar-
mature shaft speed. Make a record of armature shaft
speed.
12. Release the remote starter button and turn the load
control to the OFF position.
Understanding no load test results

1. If the current draw and the armature shaft speed are
within the ranges under Specifications, the starter is
good.
2. Low armature shaft speed and high current draw are
indications of too much friction. Possible causes of
too much friction are:
A. Tight, dirty, or worn bearings.
B. A bent armature shaft.
C. Loose pole shoes (pole shoes make con-
tact with the armature).
D. A short circuit in the armature coil. Dis-
assemble the starter. Use an armature
tester to test the armature. Use the in-
structions included with the armature
tester.
E. Damaged field coil. Refer to Starter sole-
noid - Test (B.80.A).
84516378 05/07/2011
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3. If the armature does not rotate and the current draw

is high, possible causes are:
A. Field terminal making contact with the field
frame. Inspect the insulators for the field
terminal.
B. Damaged field coil. Refer to Starter sole-
noid - Test (B.80.A)
C. Damaged bearings.
4. If the armature does not rotate and the current draw
is zero, possible causes are:
A. An open field circuit. Disassemble the
starter and inspect the field coil connec-
tions.
B. An open armature coil. Disassemble the
starter and check for burned commutator
bars. Use an armature tester to test the
armature. Use the instructions included
with the armature tester.
C. Brushes not making good contact with the
commutator bars. Check for high insula-
tion between the commutator bars, broken
brush springs, or worn brushes.
5. Low armature shaft speed and low current draw are
indications of:
A. Dirt or corrosion on connections.
B. Damaged wiring.
C. Dirty commutator bars.
D. All causes in step 4.
6. High armature shaft speed and high current draw are
indications of a short circuit in the field coil. It is
difficult to find a short circuit in a field coil. Install a
new field coil. Do the No Load Test again to check
for improvement in the operation of the starter.
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Starter solenoid - Remove

1. Pull back the boot on the motor terminal and loosen
and remove the nut and lock washer.
RCPH10TLB185ABL 1
2. Loosen and remove the screws that mount and hold

the brush holder to the cover.
RCPH10TLB186ABL 2
3. Loosen and remove the bolts.
RCPH10TLB187ABL 3
4. Remove the cover.
RCPH10TLB188ABL 4
84516378 05/07/2011
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5. Hold the spring away from one of the brushes con-

nected to the field coil and remove the brush from
the brush holder. Repeat this step for the other brush
connected to the field coil.
RCPH10TLB189ABL 5
6. Remove the brush holder.
RCPH10TLB190ABL 6
7. Remove the field frame assembly.
RCPH10TLB191ABL 7
8. Remove the armature.
RCPH10TLB192ABL 8
84516378 05/07/2011
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9. Fasten the starter solenoid in a vise and loosen and

remove the screws that hold the starter drive hous-
ing.
RCPH10TLB193ABL 9
10. Remove the starter drive housing from the starter

solenoid.
RCPH10TLB194ABL 10
11. Push down the starter drive housing as shown to

loosen and remove the starter drive.
RCPH10TLB195ABL 11
12. Remove the steel ball from the starter drive. If nec-
essary, use a magnet.
RCPH10TLB196ABL 12
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13. Remove the O-ring from the groove in the starter

drive housing.
RCPH10TLB171ABL 13
RCPH10TLB172ABL 14
15. Remove the idler gear.
RCPH10TLB173ABL 15
16. Remove the bearing cage.
RCPH10TLB174ABL 16
84516378 05/07/2011
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17. Remove the thrust washer.
RCPH10TLB175ABL 17
18. Loosen and remove the screws that hold the cover.
RCPH10TLB176ABL 18
19. If necessary, use a hammer to loosen the cover.
RCPH10TLB177ABL 19
RCPH10TLB178ABL 20
84516378 05/07/2011
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21. Remove the plunger.
RCPH10TLB179ABL 21
22. If necessary, remove the gasket from the cover.
RCPH10TLB180ABL 22
Next operation:
Starter solenoid - Inspect (B.80.A)
84516378 05/07/2011
B.80.A / 19
Starter solenoid - Inspect

Prior operation:
Starter solenoid - Remove (B.80.A)
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 (0.433 in) 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 (0.433 in) a new field frame as-
sembly must be used when the starter is assembled.
3. Use a spring scale to check the tension of the brush
springs. Pull the brush spring up until the brush
spring is just above the brush holder. The scale indi-
cation must be between 1.8 - 4.1 kg (4.0 - 9.0 lb). If
a brush spring is not as specified, use a new brush
spring when the starter is assembled.
Brush holder
1. Hold the leads of an ohmmeter against the frame and
the brush holders that have insulation between the
brush holder and frame.
2. The needle of the ohmmeter must not move, if the
needle moves replace the brush holder.
RCPH10TLB170ABL 1
Armature
1. Test the armature on an armature tester. Use the
equipment manufacturer’s instructions.
2. Put the armature on vee-blocks as shown and check
the runout of the armature with a dial indicator. The
runout must not be more than 0.05 mm (0.002 in).
RCPH10TLB228ABL 2
84516378 05/07/2011
B.80.A / 20
3. If necessary, put the armature in a lathe and remove

enough material from the commutator to make the
runout less than 0.05 mm (0.002 in).
4. Measure the diameter of the commutator. If the di-
ameter is less than 35 mm (1.378 in) install a new
armature.
5. If the depth of the groove between the commutator
bars is less than 0.2 mm (0.008 in), cut the insulation
between the commutator bars to a depth of 0.4 - 0.8
mm (0.016 - 0.031 in). Use sandpaper to remove
the rough edges from the commutator bars.
RCPH10TLB169ABL 3
6. Check the bearings on the armature for free rotation,

rough balls, and damage to the inner race or outer
race. If a bearing is to be replaced, use a press and
acceptable tools to remove and install the bearings.
Next operation:
Starter solenoid - Install (B.80.A)
84516378 05/07/2011
B.80.A / 21
Starter solenoid - Test - Field coil test

1. Hold one of the leads of an ohmmeter against the
field frame. Hold the other lead of the ohmmeter
against one of the brushes and look at the ohmme-
ter. Move the lead that is on the brush to the other
brush and look at the ohmmeter. The needle of the
ohmmeter must not move when the lead is in either
position. If the needle of the ohmmeter moved, in-
stall a new field frame assembly.
RCPH10TLB218ABL 1
2. Hold one of the leads of the ohmmeter against the

end of the cable. Hold the other lead of the ohmme-
ter against one of the brushes and look at the ohm-
meter. Move the lead that is on the brush to the other
brush and look at the ohmmeter. The needle of the
ohmmeter must move when the lead is in both posi-
tions. If the needle of the ohmmeter did not move,
install a new field frame assembly.
RCPH10TLB219ABL 2
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Starter solenoid - Install

Prior operation:
Starter solenoid - Inspect (B.80.A)
1. Install the plunger in the starter solenoid.
RCPH10TLB179ABL 1
2. If necessary, install a new gasket in the cover.
RCPH10TLB181ABL 2
3. Install the cover.
RCPH10TLB178ABL 3
4. Install and tighten the screws.
RCPH10TLB182ABL 4
84516378 05/07/2011
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5. Install the bearings in the bearing cage.
RCPH10TLB183ABL 5
6. Lubricate the bearings and teeth of the idler gear with

the grease specified in STARTING SYSTEM - Gen-
eral specification (B.80.A).
RCPH10TLB184ABL 6
7. Install the thrust washer.
RCPH10TLB212ABL 7
8. Install the bearing cage as shown.
RCPH10TLB213ABL 8
84516378 05/07/2011
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9. Install the idler gear.
RCPH10TLB214ABL 9
RCPH10TLB215ABL 10
11. Install a new O-ring in the groove in the starter drive

housing. Lubricate the O-ring with the grease speci-
fied in STARTING SYSTEM - General specification
(B.80.A).
RCPH10TLB216ABL 11
12. Lubricate the open bearing on the starter drive with

the grease specified in STARTING SYSTEM - Gen-
eral specification (B.80.A).
RCPH10TLB217ABL 12
84516378 05/07/2011
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13. Start the starter drive into the starter drive housing.
RCPH10TLB197ABL 13
14. Push down the starter drive housing to push the

starter drive all the way into the starter drive housing.
RCPH10TLB198ABL 14
15. Put a small amount of grease in the hole in the starter

drive and install the steel ball in the hole.
RCPH10TLB199ABL 15
16. Assemble the starter drive housing and starter sole-

noid.
RCPH10TLB194ABL 16
84516378 05/07/2011
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17. Install a lock washer, flat washer, and O-ring on the

screws that hold the starter drive housing. Lubricate
the O-rings with the grease specified in STARTING
SYSTEM - General specification (B.80.A).
RCPH10TLB200ABL 17
18. Install the screws in the starter drive housing.
RCPH10TLB201ABL 18
19. Fasten the starter solenoid in the vise and tighten the
screws that hold the starter drive housing.
RCPH10TLB193ABL 19
20. Install the armature.
RCPH10TLB192ABL 20
84516378 05/07/2011
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21. Install the field frame assembly.
RCPH10TLB191ABL 21
22. Use the springs to hold the brushes in the brush

holder as shown.
RCPH10TLB202ABL 22
23. Install the brush holder.
RCPH10TLB203ABL 23
24. Put the springs on top of the brushes connected to

the brush holder.
RCPH10TLB204ABL 24
84516378 05/07/2011
B.80.A / 28
25. Install the brushes that are connected to the field coil.
RCPH10TLB205ABL 25
26. Use a bolt to align the brush holder with the field
frame assembly.
RCPH10TLB206ABL 26
27. Move the brush holder so that the brush holder is

even with the end of the armature.
RCPH10TLB207ABL 27
28. Install the cover and align the cover with the brush
holder.
RCPH10TLB208ABL 28
84516378 05/07/2011
B.80.A / 29
29. Install and tighten the screws that hold the brush
holder.
RCPH10TLB209ABL 29
30. Install a lock washer, flat washer, and O-ring on the

bolts. Lubricate the O-rings with the grease speci-
fied in STARTING SYSTEM - General specification
(B.80.A).
RCPH10TLB210ABL 30
31. Install and tighten the bolts.
RCPH10TLB211ABL 31
32. Install the cable, lock washer, and nut on the motor
terminal, and tighten the nut.
RCPH10TLB185ABL 32
33. Pull the boot over the motor terminal.
84516378 05/07/2011
B.80.A / 30
Starter solenoid - Test

This test will check the condition of the pull-in winding and
the hold-in winding in the starter solenoid.
The jumper cable connected to the starter mounting flange
and the motor terminal must have a common connection at
the negative battery post.
Starter solenoid test procedure

1. Remove the rubber boot from the motor terminal.
Remove the nut and lock washer from the motor ter-
minal. Then remove the wire from the motor terminal.
2. Connect a jumper cable to the positive battery post
of a fully charged 12 volt battery. Connect the other
end of the jumper cable to the battery terminal on the
starter solenoid housing.
RCPH10TLB229ABL 1
1. 12 Volt battery 4. Switch terminal

2. Starter 5. Motor terminal
3. Battery terminal
3. Connect a jumper wire to the battery terminal and the

switch terminal in the starter solenoid housing. The
jumper wire must be made from No. 10 or larger wire.
4. Connect the jumper cable with the common connec-
tion to the starter mounting flange and the motor ter-
minal in the starter solenoid housing.
NOTE: Steps 5 and 7 must be done in a maximum of 5 seconds to prevent damage to the pull-in winding and the
hold-in winding.
5. Connect the jumper cable with the common connec-
tion to the negative battery post. The pinion gear on
the starter drive must come all the way out rapidly
and with force.
6. If the pinion gear did not come out rapidly and with
force, the pull-in winding is damaged. The complete
starter solenoid housing assembly must be replaced.
7. Disconnect the jumper cable from the motor terminal
in the starter solenoid housing. The pinion gear on
the starter drive must not move toward the starter
drive housing.
8. If the pinion gear started to move toward the starter
drive housing, the hold-in winding is damaged. The
complete starter solenoid housing assembly must be
replaced.
84516378 05/07/2011
B.80.A / 31
Index

Engine starter - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STARTING SYSTEM - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STARTING SYSTEM - Install - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STARTING SYSTEM - Remove - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STARTING SYSTEM - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter solenoid - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Starter solenoid - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Starter solenoid - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Starter solenoid - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Starter solenoid - Test - Field coil test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
84516378 05/07/2011
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84516378 05/07/2011
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PRINTED IN U.S.A.
84516378 05/07/2011
EN
SERVICE MANUAL
TRANSMISSION, DRIVE AND PTO OUT
580N
580SN WT
580SN
590SN
84516378 05/07/2011
C
Contents
TRANSMISSION, DRIVE AND PTO OUT - C
TRANSMISSION Power Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.C

580N , 580SN WT , 580SN , 590SN
TRANSMISSION Powershift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.20.E

580N , 580SN WT , 580SN , 590SN
84516378 05/07/2011
C
TRANSMISSION Power Shuttle - 20.C
580N
580SN WT
580SN
590SN
84516378 05/07/2011
C.20.C / 1
Contents
TECHNICAL DATA
TRANSMISSION Power Shuttle

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view - Four wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exploded view - Two wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic schema - Two Wheel Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic schema - Four Wheel Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Control valve
Exploded view - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exploded view - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shaft
Exploded view - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Exploded view - Shift rod and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exploded view - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exploded view - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Check Checking Supply Pump Pressure (4WD Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Test - Checking Converter In Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Test - Checking Regulated Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Test Checking Supply Pump Flow and Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Test - Checking Converter Out Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Test Checking Lubrication Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Test - Checking Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Pressure test – 2 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm . . . . . . . . . . . . . . . . . . . . . . . . 54
84516378 05/07/2011
C.20.C / 2
Pressure test - 2 Wheel Drive, Test Two - Engine at 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Tool connection Two Wheel Drive Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Tool connection - Pressure Test Ports, Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Tool connection Pressure Test Ports 4 Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Tool connection Four Wheel Drive Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Pressure test – 4 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm . . . . . . . . . . . . . . . . . . . . . . . . 60
Pressure test - 4 Wheel Drive, Test Two - Engine at 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Control valve
Disassemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Disassemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Inspect - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Assemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Shaft
Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Inspect - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Disassemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Inspect - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Assemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Adjust - Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Disassemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Inspect - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Assemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Disassemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Inspect - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Assemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Disassemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Inspect - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Assemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Disassemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Inspect - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Assemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Housing
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Disassemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Disassemble - Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Assemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Assemble - Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
DIAGNOSTIC

Testing - Machine Will Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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Testing - Will Not Go Into 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Testing - Machine Hesitates When Shifting Between Forward and Reverse . . . . . . . . . . . . . . . . . . . . . . 211
Testing - Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Testing - Transmission Oil is Too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Testing Problem in the Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Power Shuttle
TRANSMISSION Power Shuttle - General specification

Type of transmission oil MS-1209, Hy-Tran™ Ultra
Clutch disc clearance 2.3 - 4.3 mm (0.1 - 0.2 in)
Capacity - Two wheel drive

Total system 18.5 l (19.5 US qt)
Refill capacity with or without filter change 16 l (16.9 US qt)
Capacity - Four wheel drive

Total system 21 l (22.2 US qt)
Refill capacity with or without filter change 18.5 l (19.5 US qt)
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 the temperature, instrument variables, engine hours, etc.
Parameter Operating Pressure / Temperature

Output of pump supply 32 - 68 l/min (8.5 - 18.0 US gpm) at 900 - 2200 RPM
Pump supply pressure (4WD) 1248 - 1551 kPa (181 - 225 psi) at 900 - 2200 RPM
Regulated clutch pressure 1103 - 1303 kPa (160 - 189 psi) at 900 - 2200 RPM
Torque pressure IN pressure 48 - 903 kPa (7 - 131 psi) at 900 - 2200 RPM
Torque converter OUT pressure 0 - 427 kPa (0 - 62 psi) at 900 - 2200 RPM
Lubrication pressure 40 - 303 kPa (6 - 44 psi) at 900 - 2200 RPM
Transmission oil operating temperature (normal) 78 - 82 °C (172 - 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 bar (0 psi)
With differential lock solenoid energized (4WD) 12.5 - 15.5 bar (181.3 - 224.8 psi)
With differential lock solenoid energized (2WD) and 11 - 13 bar (159.5 - 188.5 psi)
direction control lever in Forward or Reverse position
Park brake check port 13.5 - 15.5 bar (195.8 - 224.8 psi)
NOTICE: Vehicle may move during park brake pressure check. Check park brake pressure from inside of the cab by
removing the floor plate.
TRANSMISSION Power Shuttle - Torque

Pipe plug in end of four-wheel drive shaft 30 N·m (265.5 lb in)
Solenoid valve in four-wheel drive valve 22.0 N·m (194.7 lb in)
Nut for solenoid coils on transmission control valve 7 - 10 N·m (62.0 - 88.5 lb in)
Fittings for four-wheel drive clutch tube 30 N·m (265.5 lb in)
Allen head screws for valve plate on front housing 23 N·m (203.6 lb in)
Test port plugs 23 N·m (203.6 lb in)
Detent plugs 80 N·m (59.0 lb ft)
Bolts for rear cover 50 N·m (36.9 lb ft)
Bolt for output flange 139 N·m (102.5 lb ft)
Allen head screws for shifter assembly 23 N·m (203.6 lb in)
Hollow cap screws for tube on front housing 40 N·m (354.0 lb in)
Bolts to fasten front and rear housings 50 N·m (36.9 lb ft)
Bolts to fasten cover below four-wheel drive flange 23 N·m (203.6 lb in)
Bolt for four-wheel drive flange 139 N·m (102.5 lb ft)
Bolts for oil pump 23 N·m (203.6 lb in)
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Fitting for oil filter 50 N·m (36.9 lb ft)

Bolts to fasten four-wheel drive valve to front housing 23 N·m (203.6 lb in)
Bolts to fasten cover for oil screen 23 N·m (203.6 lb in)
Bolts for transmission control valve 23 N·m (203.6 lb in)
Drain plug 80 N·m (59.0 lb ft)
Allen head screws to fasten pump support to pump 10 N·m (88.5 lb in)
housing
Nut for four-wheel drive solenoid coil 8 N·m (70.8 lb in)
Allen head screws for modulation cover 11 N·m (97.4 lb in)
Solenoid plunger in transmission control valve 23 N·m (203.6 lb in)
Bolts to fasten pump mount to rear housing 50 N·m (36.9 lb ft)
TRANSMISSION Power Shuttle - Special tools

CAS-1804 Pressure Fitting Kit
RCPH11TLB020BAL 1
CAS-40033 Transmission Tool Kit
RCPH11TLB021BAL 2
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CAS-1808 Flowmeter Fitting Kit
RCPH11TLB022BAL 3
CAS-2011 Filter base adapter used with CAS-2383 filter

adapter tube from CAS-40033, Transmission Tool Kit
RCPH11TLB023BAL 4
CAS-10280 Flowmeter
RCPH11TLB024BAL 5
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380040161 - Teflon seal installation
RCPH10TLB828AAL 6
CAS-2379 Input shaft holder and spring compressor
RCPH10TLB043ABL 7
CAS-2381 Seal driver
RCPH10TLB045BL 8
CAS-2378 transmission leg set
RCPH10TLB044ABL 9
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CAS2771A - Teflon seal installation tool kit - 4 wheel drive

shaft
RCPH10TLB688AAL 10
1. CAS2771-2 Seal Expander/Protector

2. CAS2771-1 Seal Compressor
3. CAS2771-3 Spacer
4. CAS2327 Pusher
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TRANSMISSION Power Shuttle - Exploded view

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 - 50 in-lb)
7. Flex plate
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RCPH10TLB5GAL 1
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TRANSMISSION Power Shuttle - Exploded view - Four wheel drive

transmission
Four-wheel drive transmission
1. Tube 13. Breather
2. Hollow bolt 14. Breather pipe
3. Copper washer 15. PTO flange
4. Copper washer 16. O-ring
5. Plug 17. Bolt
6. Plug 18. Rear cover
7. Plug 19. Bolt
8. O-ring 20. Dowel pin
9. Fitting 21. Drain plug
10. Copper washer 22. Rear housing
11. Test port plug 23. Four-wheel drive clutch tube
12. Park brake pressure tube 24. Front housing
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RCPH10TLB020GAL 1
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TRANSMISSION Power Shuttle - Exploded view - Two wheel drive

transmission
Two-wheel drive transmission
1. Tube 11. Dowel pin
2. Hollow bolt 12. Park brake pressure tube
3. Copper washer 13. Rear cover
4. Plug 14. PTO flange
5. Copper washer 15. Bolt
6. O-ring 16. O-ring
7. Sealing washer 17. Bolt
8. Test port plug 18. Drain plug
9. Breather 19. Rear housing
10. Breather pipe 20. Front housing
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RCPH10TLB021GAL 1
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TRANSMISSION Power Shuttle - Hydraulic schema - Two Wheel

Drive Schematic
RCPH11TLB001HAL 1
(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)
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(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 (Full flow with by-pass, 15 micron)
(12) Forward/ Reverse Shuttle Spool (Directs (27) Cold Oil By-Pass
flow to forward/reverse clutches)
(13) Torque Converter Inlet Pressure (28) Supply Pump
(14) Modulator Circuit (Pressure modulation (29) Strainer
for Forward/Reverse)
(15) To Differential Lock (Rear axle)
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TRANSMISSION Power Shuttle - Hydraulic schema - Four Wheel

Drive Schematic
RCPH11TLB002HAL 1
(1) Park Brake Solenoid (18) Regulated Clutch Pressure

(2) SAHR Park Brake (19) Modulation Spool and Picton (Regulates
clutch pressure)
(3) Torque Converter Relief Valve (20) Lubrication To Bearings And Clutch Packs
(4) Torque Converter (21) Reverse Clutch
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(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 (Full flow 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)
(13) Torque Converter Inlet Pressure (30) Check Valve
(14) Modulation Circuit (Pressure modulation (31) Supply Pump Pressure For Four Wheel
for Forward/ Reverse) Drive
(15) To Differential Lock (Rear axle) (32) Four Wheel Drive Selector Valve
(16) Differential Lock Solenoid (33) Four Wheel Drive Clutch (Spring applied,
hydraulic release)
(17) Flow Divider
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Control valve - Exploded view - Four wheel drive valve (if equipped)
Four wheel drive valve (if equipped)
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
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RCPH10TLB026GAL 1
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Control valve - Exploded view - Transmission control valve

Transmission control valve
1. Nut 9. Gasket 17. Snap ring-not 25. Plug
removable
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
solenoid valve
8. Modulation cover 16. Inner modulation piston 24. Allen head plug 32. Snap ring
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RCPH10TLB027GAL 1
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Shaft - Exploded view - Input shaft

Input shaft
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
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RCPH10TLB022GAL 1
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Shaft - Exploded view - Shift rod and forks

Shift rod and forks
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
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RCPH10TLB024GAL 1
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Shaft - Exploded view - Secondary shaft

Secondary shaft
1. Bearing 8. Steel ring 15. Sleeve 22. Thrust washer
2. Lock ring 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
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RCPH10TLB023GAL 1
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Shaft - Exploded view - Four wheel drive shaft

Four wheel drive shaft
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
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RCPH10TLB025GAL 1
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TRANSMISSION Power Shuttle - Remove

Prior operation:
Prior operation:
Rear wheel - Remove (D.50.C)
Prior operation:
Fuel tank - Remove (B.20.A)
Prior operation:
Hydraulic Pump removal
1. Position machine on a flat surface high enough to

allow transmission removal.
2. Remove front drive shaft guard.
RCPH11TLB001AAL 3 RCPH11TLB002AAL 4
3. Remove front drive shaft hardware.
RCPH11TLB003AAL 5
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4. Remove shaft from yoke.
RCPH11TLB004AAL 6
5. Remove front drive shaft.
RCPH11TLB005AAL 7
6. Remove plug and drain transmission oil. Install plug

into transmission after all of the oil has drained.
RCPH11TLB006AAL 8
7. Identify, tag and disconnect the transmission cooler

lines.
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8. Disconnect the transmission control valve connec-

tion.
RCPH11TLB009AAL 11
9. Remove control valve connection bracket.
RCPH11TLB010AAL 12
10. Disconnect the brake return line.
RCPH11TLB011AAL 13
11. Disconnect brake supply line.
RCPH11TLB012AAL 14
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12. Remove oil level tube.
RCPH11TLB013AAL 15
13. Disconnect oil the temperature sensor.
RCPH11TLB014AAL 16
14. Disconnect blue wire at switch (left hand rear of

transmission).
RCPH11TLB015AAL 17
15. Disconnect black and white wire at switch (left hand

rear top of transmission).
RCPH11TLB016AAL 18
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16. Disconnect the differential lock line.
RCPH11TLB017AAL 19
17. Plug and cap all open ports.
RCPH11TLB018AAL 20
18. Disconnect starter ground and positive battery con-

nections.
RCPH11TLB051AAM 21
19. Remove the starter.
RCPH11TLB052AAM 22
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20. Disconnect the ignition connection.
RCPH11TLB053AAM 23
21. Remove the access cover.
RCPH11TLB019AAL 24
22. Rotate engine to access flywheel hardware. Use tool

380000988 to rotate the engine.
RCPH11TLB062AAM 25
23. Rotate the engine to remove the flywheel to flex plate

hardware.
RCPH11TLB055AAM 26
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24. Use an appropriate lifting device to support engine.
RCPH11TLB020AAL 27
25. Support the transmission.
RCPH11TLB021AAL 28
26. Remove the engine to transmission hardware.
RCPH11TLB058AAM 29
27. Remove the right hand and left hand transmission

mount hardware.
RCPH11TLB022AAL 30
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28. Disconnect hydraulic reservoir hoses.
RCPH11TLB023AAL 31
29. Carefully remove the transmission.
RCPH11TLB024AAL 32
Next operation:
TRANSMISSION Power Shuttle - Install (C.20.C)
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TRANSMISSION Power Shuttle - Install

1. Move the transmission under the machine and raise
it into place.
RCPH11TLB024AAL 1
2. Connect the hydraulic reservoir hoses.
RCPH11TLB023AAL 2
3. Install the right hand and left hand transmission

mount hardware.
RCPH11TLB022AAL 3
4. Remove the transmission support.
RCPH11TLB021AAL 4
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5. Remove engine supports.
RCPH11TLB020AAL 5
6. Remove the access cover.
RCPH11TLB019AAL 6
7. Rotate the engine to access the flywheel mounting

holes. Use the 380000988 Turning Tool to rotate the
engine.
RCPH11TLB062AAM 7
8. Install the flywheel flex plate hardware.
RCPH11TLB055AAM 8
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9. Reconnect the ignition connection on the starter.
RCPH11TLB053AAM 9
10. Reinstall starter.
RCPH11TLB052AAM 10
11. Connect the starter ground and positive battery con-

nections.
RCPH11TLB051AAM 11
12. Connect the differential lock line.
RCPH11TLB017AAL 12
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13. Connect the black and white wire at the switch (left
hand rear top of transmission).
RCPH11TLB016AAL 13
14. Connect the blue wire at the switch (left hand rear of
transmission).
RCPH11TLB015AAL 14
15. Connect the oil temperature sensor.
RCPH11TLB014AAL 15
16. Install the oil level tube.
RCPH11TLB013AAL 16
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17. Connect brake supply line.
RCPH11TLB012AAL 17
18. Connect the brake return line.
RCPH11TLB011AAL 18
19. Install control valve connection bracket.
RCPH11TLB010AAL 19
20. Reconnect the transmission control valve connec-

tion.
RCPH11TLB009AAL 20
21. Reconnect the transmission cooler lines.
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22. Install front drive shaft.
RCPH11TLB005AAL 23
23. Install shaft to the yoke.
RCPH11TLB004AAL 24
24. Install front drive shaft hardware.
RCPH11TLB003AAL 25
25. Install front drive shaft guard.
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C.20.C / 45
26. Install wheels. Remove supports and lower machine.
NOTICE: Before staring the engine do the following

27. Make sure the transmission drain plug has been in-
stalled and tightened.
28. Fill the transmission, see Capacities ()
NOTE: If removed, install the rear wheels.

29. Remove the stands from under the machine and
lower the machine to the floor.
30. 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.
84516378 05/07/2011
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TRANSMISSION Power Shuttle - Check Checking Supply Pump

Pressure (4WD Only)
NOTE: See TRANSMISSION Power Shuttle - Tool connection Two Wheel Drive Port Identification (C.20.C) for
port identification.
NOTE: Two wheel drive machines can only be tested by performing a flow meter test.
1. Engage the parking brake.
2. Start the engine. The oil should be at normal operat-
ing temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 10
(A), see TRANSMISSION Power Shuttle - Tool
connection Four Wheel Drive Port Identification
(C.20.C).
4. Monitor the gauge and record the values for low idle,
see TRANSMISSION Power Shuttle - Pressure
test – 4 Wheel Drive, Test One — Engine at Idle
900 to 1100 rpm (C.20.C).
5. Monitor the gauge and record the values for full throt-
tle, see TRANSMISSION Power Shuttle - Pressure
test — 4 Wheel Drive, Test Two — Engine at 2200
rpm (C.20.C).
RCPH11TLB014BAL 1
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TRANSMISSION Power Shuttle - Test - Checking Converter In

Pressure
NOTE: See TRANSMISSION Power Shuttle - Tool connection Two Wheel Drive Port Identification (C.20.C) or
TRANSMISSION Power Shuttle - Tool connection Four Wheel Drive Port Identification (C.20.C) for test port
locations.
ing temperatures.
3. Connect a 14 bar (200 psi) to test port 6 (A) for 2WD
or 4WD machines.
4. Place transmission controls in neutral.
5. Monitor the gauge and record the values for low
idle, see TRANSMISSION Power Shuttle - Pres-
sure test – 2 Wheel Drive, Test One — Engine
at Idle 900 to 1100 rpm (C.20.C) or TRANSMIS-
SION Power Shuttle - Pressure test – 4 Wheel
Drive, Test One — Engine at Idle 900 to 1100 rpm
(C.20.C).
rpm (C.20.C) or TRANSMISSION Power Shuttle -
Pressure test — 4 Wheel Drive, Test Two — En-
gine at 2200 rpm (C.20.C).
RCPH11TLB015BAL 1
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TRANSMISSION Power Shuttle - Test - Checking Regulated Clutch

Pressure
locations.
ing temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 3 (A).
4. Move the direction control lever to forward.
(C.20.C).
RCPH11TLB016BAL 1
7. Repeat steps 5 and 6 with the control lever in re-

verse.
NOTE: Forward and reverse clutch pressure can be recorded separately using test port 5 (C) for Forward and test
port 4 (B) for Reverse.
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TRANSMISSION Power Shuttle - Test Checking Supply Pump Flow

and Relief Pressure
CAS-40033 Transmission Tool Kit
CAS-2011 Adapter with CAS-2383 Adapter Tube
OEM-1239 (CAS-10280) Flowmeter
locations.
1. Verify that all test equipment is clean.
ing temperatures.
4. Connect flowmeter and adapter to the transmission
filter base at test port 1 (A) and test port 2 (B). Open
the load valve on the flowmeter.
5. Move the transmission control into neutral.
(C.20.C).
8. At full throttle, close the load valve until the flow
drops. Read and record the pressure at which the
flow dropped.
RCPH11TLB017BAL 1
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TRANSMISSION Power Shuttle - Test - Checking Converter Out

Pressure
locations.
ing temperatures.
3. Connect a 20 bar (200 psi) to the service tee on test
port 8 (A).
4. Place the transmission in the neutral position.
(C.20.C).
RCPH11TLB018BAL 1
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TRANSMISSION Power Shuttle - Test Checking Lubrication

Pressure
locations.
ing temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 9 (A).
4. Place the transmission in neutral.
(C.20.C).
RCPH11TLB019BAL 1
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TRANSMISSION Power Shuttle - Test - Checking Differential Lock

Valve
CAS-1804 Pressure Test Kit
locations.
2. Place the transmission in neutral.
ing temperatures.
4. Connect a pressure test fitting and a 42 bar (600 psi)
gauge to test port 7 (A).
5. With the transmission shift lever in Neutral, put the
directional control lever in Forward or Reverse.
6. Run the engine at 2200 RPM.
7. Press and hold the differential lock switch located in
the loader control valve.
(C.20.C).
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TRANSMISSION Power Shuttle - Pressure test – 2 Wheel Drive, Test

One - Engine at Idle 900 to 1100 rpm
NOTE: All specifications shown were taken from a sampling of new peoduction machines with less than 20 engine
hours, your figures may differ slightly.
Test Port Item Specifications — 4 wheel Actual

Drive
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 200psi at 120° F)
1 and 2 Cold Oil By-Pass 2875 kPa to 3137 kPa
29.3 bar to 32.0 bar at 49° C
(417 to 455 psi I at 120° F)
7 Differential Lock 1262 to 1317 kPa,
Pressure (FNR must 12.7 to 13.4 bar (183 to 191
be in forward or reverse psi)
Forward
10 Pump Supply Pressure 1393 to 1427 kPa
14.2 to 14.6 bar (202 to 207
kPa)
4 Regulated Clutch 1276 to 1317 kPa
Pressure 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 to 4.2 bar (57 to 60 psi)
9 Lubrication Pressure 269 to 283 kPa
2.7 to 2.9 bar (39 to 42 psi)
Neutral
7.0 to 17.7 bar (194 to 202 psi)
5.3 to 5.9 bar (75 to 84 psi)
4.2 to 4.4 bar (60 to 62 psi)
3.4 to 3.7 bar (51 to 53 psi)
Reverse
14.2 to 14.6 psi (203 to 208 psi)
psi)
6 Torque Converted IN 517 to 565 kPa
5.3 to 5.8 bar (75 to 82 psi)
3.4 to 3.5 bar (48 to 50 psi)
2.2 to 2.3 bar (31 to 33 psi)
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TRANSMISSION Power Shuttle - Pressure test - 2 Wheel Drive, Test

Two - Engine at 2200 rpm
Drive
1 and 2 Supply Pump Flow 62 to 70L/min at 1379 kPa
14 bar at 49° C (16.3 to 18.5
gpm at 200 psi at 120° F)
30.9 bar to 33.7 bar at 49° C
(440 to 480 psi I at 120° F)
Forward
16.2 to 16.9 bar (230 to 240
kPa)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.4 to 4.6 bar (63 to 65 psi)
3.0 to 3.1bar (42 to 44 psi)
Neutral
8.8 to 9.8 bar (125 to 140psi)
6 Torque Converter IN 724 to 862kPa
7.4 to 8.8 bar (105 to 125 psi)
4.9 to 5.3 bar (70 to 73 psi)
4.2 to 4.4 bar (60 to 63 psi)
Reverse
15.9 to 16.6 psi (226 to 236 psi)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.0 to 4.2 bar (57 to 60 psi)
2.5 to 2.6 bar (35 to 37 psi)
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TRANSMISSION Power Shuttle - Tool connection Two Wheel Drive

Port Identification
RCPH11TLB002GAL 1
1. Flow meter adapter from charge pump to flow meter (Use CAS-2011). Connect the CAS-1029 Flow
meter or equivalent. Pump supply pressure on 2 Wheel Drive units can only be taken with a flow
meter connected to ports 1 and 2.
2. Return from flow meter to transmission (CAS-2383).
3. Regulated clutch pressure, common to forward and 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 pressure. Use CAS-2745 and CAS-2746
7. Differential lock pressure. Use CAS-2744
8. Converter out to cooler. Use CAS-2747
9. Lubrication pressure, common to converter return. Use CAS-2745 and CAS-2746 or use CAS-2747
84516378 05/07/2011
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TRANSMISSION Power Shuttle - Tool connection - Pressure Test

Ports, Two Wheel Drive
RCPH11TLB004GAL 1
(1) Reverse Clutch Pressure (3) Regulated Clutch Pressure

(2) Forward Clutch Pressure (4) Torque Converter Pressure
84516378 05/07/2011
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TRANSMISSION Power Shuttle - Tool connection Pressure Test

Ports 4 Wheel Drive
RCPH11TLB005GAL 1
(1) Supply Pump Pressure, Four Wheel Drive (4) Regulated Clutch Pressure
Only
(2) Reverse Clutch Pressure (5) Torque Converter Pressure
(3) Forward Clutch Pressure
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TRANSMISSION Power Shuttle - Tool connection Four Wheel Drive

Port Identification
RCPH11TLB003GAL 1
1. Flow meter adapter from charge pump to flow meter (Use CAS-2011). Connect the CAS-1029 Flow
meter or equivalent.
2. Return from flow meter to transmission (CAS-2383).
3. Regulated clutch pressure, common to forward and 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 pressure. Use CAS-2745 and CAS-2746
7. Differential lock pressure. Use CAS-2744
8. Converter out to 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
84516378 05/07/2011
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TRANSMISSION Power Shuttle - Pressure test – 4 Wheel Drive, Test

One - Engine at Idle 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.

Drive
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 200psi at 120° F)
29.3 bar to 32.0 bar at 49° C
(417 to 455 psi I at 120° F)
Forward
14.2 to 14.6 bar (202 to 207
kPa)
psi)
5.6 to 6.2 bar (79 to 88 psi)
4.0 to 4.2 bar (57 to 60 psi)
2.7 to 2.9 bar (39 to 42 psi)
Neutral
7.0 to 17.7 bar (194 to 202 psi)
5.3 to 5.9 bar (75 to 84 psi)
4.2 to 4.4 bar (60 to 62 psi)
3.4 to 3.7 bar (51 to 53 psi)
Reverse
14.2 to 14.6 psi (203 to 208 psi)
psi)
5.3 to 5.8 bar (75 to 82 psi)
3.4 to 3.5 bar (48 to 50 psi)
2.2 to 2.3 bar (31 to 33 psi)
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TRANSMISSION Power Shuttle - Pressure test - 4 Wheel Drive, Test

Two - Engine at 2200 rpm
Drive
1 and 2 Supply Pump Flow 62 to 70L/min at 1379 kPa
14 bar at 49° C (16.3 to 18.5
gpm at 200 psi at 120° F)
30.9 bar to 33.7 bar at 49° C
(440 to 480 psi I at 120° F)
Forward
16.2 to 16.9 bar (230 to 240
kPa)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.4 to 4.6 bar (63 to 65 psi)
3.0 to 3.1bar (42 to 44 psi)
Neutral
14.4 to 14.9 bar (205 to 212
psi)
6 Torque Converter IN 724 to 862kPa
7.4 to 8.8 bar (105 to 125 psi)
4.9 to 5.3 bar (70 to 73 psi)
4.2 to 4.4 bar (60 to 63 psi)
Reverse
15.9 to 16.6 psi (226 to 236 psi)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.0 to 4.2 bar (57 to 60 psi)
2.5 to 2.6 bar (35 to 37 psi)
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Control valve - Disassemble - Four wheel drive valve (if equipped)

1. Remove the nut.
RCPH10TLB734AAL 1
2. Remove the solenoid coil.
RCPH10TLB737AAL 2
3. Remove the solenoid valve.
RCPH10TLB738AAL 3
4. Remove the check valve from the solenoid valve

body. DO NOT try to disassemble the check valve.
There are no serviceable parts. If there is a problem,
use a new check valve.
RCPH10TLB740AAL 4
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5. Remove the three O-rings from the solenoid valve.
RCPH10TLB741AAL 5
Next operation:
Control valve - Assemble (C.20.C)
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Control valve - Assemble - Four wheel drive valve (if equipped)

1. Install the three new O-rings on the solenoid valve.
Use clean transmission oil to lubricate the O-rings.
RCPH10TLB741AAL 1
2. Install the check valve in the valve body as shown.
RCPH10TLB740AAL 2
3. Install the solenoid valve in the solenoid valve body.

Tighten the solenoid valve to a torque of 22 Nm (195
pound-inches).
RCPH10TLB739AAL 3
4. Install the solenoid coil on the solenoid valve.
RCPH10TLB737AAL 4
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5. Install the nut.
RCPH10TLB736AAL 5
6. Tighten the nut to a torque of 8 Nm (71 pound-

inches).
RCPH10TLB735AAL 6
Next operation:
Control valve - Disassemble (C.20.C)
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Control valve - Disassemble - 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.
1. Remove the nut for the forward/reverse solenoid.
RCPH10TLB742AAL 1
2. Remove the seal.
RCPH10TLB744AAL 2
3. Remove the first solenoid coil.
RCPH10TLB747AAL 3
4. Remove the O-ring from the either the solenoid coil

or the solenoid plunger.
RCPH10TLB748AAL 4
84516378 05/07/2011
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5. Remove the second solenoid coil.
RCPH10TLB749AAL 5
6. Remove the O-ring from the second solenoid coil.
RCPH10TLB750AAL 6
7. The remaining O-ring can stay with either the sole-

noid coil or the solenoid plunger. Remove the re-
maining O-ring.
RCPH10TLB751AAL 7
NOTE: Step 8 to 10 are for early production N Series 2 machines, current production have a 2 wire connector per
solenoid.
8. Remove the retainer from the rear of the connector
for the solenoid coils.
RCPH10TLB005ABL 8
NOTE: Before removing any wires from the connector, you may want to record the locations of the wires for reference
during assembly.
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9. Use a small punch to release the locking tab on the

terminal.
RCPH10TLB006ABL 9
10. Pull the wire and the terminal from the connector.
RCPH10TLB007ABL 10
11. Repeat steps 8 and 10 for the remaining wires and

terminals.
12. Remove the nut for the differential lock solenoid.
RCPH10TLB752AAL 11
13. Remove the solenoid coil.
RCPH10TLB753AAL 12
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14. Loosen and remove the solenoid plunger.
RCPH10TLB754AAL 13
15. Remove the O-rings from the solenoid plunger.
RCPH10TLB755AAL 14
16. Loosen and remove the solenoid plunger with the

forward/reverse spool attached.
RCPH10TLB756AAL 15
17. Use a small screwdriver to push down the spring as

shown so that you can disengage the notched end of
the forward/reverse spool from the post on the end of
the solenoid plunger.
RCPH10TLB011ABL 16
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18. Separate the solenoid plunger (1) , the spring (2), the
spring spacer (3) , and the forward/reverse spool (4).
RCPH10TLB009ABL 17
19. Remove the O-ring from the solenoid plunger.
RCPH10TLB010ABL 18
20. Remove the four Allen head bolts that fasten the
modulation cover to the control valve body.
RCPH10TLB754AAL 19
21. Remove the outer modulation piston (1) from the

modulation cover (2). Remove the two cover gaskets
(3) and the spacer gasket (4). Remove the check ball
(5) and spring (6) . Remove the outer modulation pis-
ton spring (7) , the inner (8) and outer spring (9) , and
the inner modulation piston pin (10) and piston (11).
RCPH10TLB758AAL 20
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22. Loosen the plug at the opposite end of the bore.
RCPH10TLB759AAL 21
23. Remove the plug (1) , snap ring (2) , flow divider shaft
(3) , the spring (4) , and the flow divider piston (5)
from the bore.
RCPH10TLB764AAL 22
24. Remove the plug from the bore for the forward/re-
verse spool.
RCPH10TLB760AAL 23
25. Remove the spring from the bore for the forward/
reverse solenoid.
RCPH10TLB761AAL 24
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26. Remove the spring spacer.
RCPH10TLB762AAL 25
27. Remove the four hex head plugs (1) and the Allen
head plug (2) only if the plugs are damaged or leak-
ing. There are copper washers under the plugs.
RCPH10TLB763AAL 26
Next operation:
Control valve - Inspect (C.20.C)
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Control valve - Inspect - Transmission control valve

1. Use cleaning solvent to clean all metal parts.
2. Check the springs for wear, cracks, heat distortion,
and other damage. Replace as necessary.
3. Inspect the spool and the pistons for damage or wear.
Make sure that the orifice in the outer modulation
piston is open. Use new parts as necessary.
4. Inspect the control valve body for cracks, corrosion,
and wear. Inspect the bores for wear. Find the bore
from which the ball was removed. There is a very
small orifice in one side of this bore. Make sure that
this orifice is open. If the control valve body is bad,
you must use a new transmission control valve.
5. Find the plate that held the ball in position. Put the
ball on the hole in the plate so that the ball is in con-
tact with the edge that has the radius. Hold the plate
and the ball up to a bright light and look at the bot-
tom 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.
Next operation:
Control valve - Assemble (C.20.C)
84516378 05/07/2011
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Control valve - Assemble - 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.
1. If the four hex head plugs (1) and the Allen head plug
(2) were removed, install the copper washers and the
plugs.
RCPH10TLB763AAL 1
2. Use clean transmission oil to lubricate the flow di-

vider shaft (1) . Install the flow divider shaft (1) . The
closed end of the flow divider piston (1) must be to-
ward 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).
RCPH10TLB764AAL 2
3. Tighten the plug at the in the bore.
RCPH10TLB759AAL 3
4. 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 towards
the outside of the valve body. Install the spring (6)
into the small bore. Install one cover 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) In-
stall 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 modula-
tion piston (1) with clean transmission oil and install
the piston (1) into the modulation cover (2) with the RCPH10TLB758AAL 4
closed end towards the modulation cover.
84516378 05/07/2011
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5. Install the modulation cover onto the valve body. In-

stall the four Allen head bolts into the cover. Tighten
the four Allen head bolts to a torque of 11 Nm (97
pound-inches).
RCPH10TLB754AAL 5
6. Install a new O-ring on the solenoid plunger. Use

clean transmission oil to lubricate the O-ring.
RCPH10TLB010ABL 6
7. Assemble the solenoid plunger (1), the spring (2), the

spring spacer (3), and the forward/reverse spool (4)
as shown above. One side of the spring spacer (3)
has a chamfer in the bore. Install the spring spacer
(3) so that the chamfer is toward the forward/reverse
spool (4).
RCPH10TLB009ABL 7
8. Use a small screwdriver to push down the spring as

shown so that you can engage the notched end 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 spring to hold the
forward/reverse spool in position.
RCPH10TLB011ABL 8
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9. Install the solenoid plunger and the forward/reverse

spool in the control valve body.
RCPH10TLB757AAL 9
10. Tighten the solenoid plunger to a torque of 23 Nm

(204 pound-inches).
RCPH10TLB756AAL 10
NOTE: The following photos do not show the forward/reverse solenoid installed. The forward/reverse solenoid must
be installed before doing steps 11, 12 and 13.
11. Install the spring spacer in the bore as shown. One
side of the spring spacer has a chamfer in the bore.
Install the spring spacer so that the chamfer is toward
the inside of the control valve body. Make sure that
the end of the forward/reverse spool comes through
the hole in the spring spacer.
RCPH10TLB762AAL 11
RCPH10TLB761AAL 12
84516378 05/07/2011
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13. Install a new O-ring on the plug. Use clean transmis-

sion oil to lubricate the O-ring. Install the plug in the
bore.
RCPH10TLB760AAL 13
14. Install new O-rings on the differential lock solenoid

plunger. Use clean transmission oil to lubricate the
O-rings.
RCPH10TLB755AAL 14
15. Install and tighten the differential lock solenoid

plunger to a torque of 15 Nm (133 pound-inches).
RCPH10TLB754AAL 15
NOTE: Step 16 to 18 are for early production N Series 2 machines, late production have a 2 wire connector per
solenoid.
16. 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.
RCPH10TLB008ABL 16
84516378 05/07/2011
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17. Push each terminal into the connector until the lock-
ing tab and the plastic tab engage, locking the termi-
nal into the connector.
RCPH10TLB007ABL 17
18. After all the terminals are in the connector, install the
retainer on the rear of the connector.
RCPH10TLB005ABL 18
19. Install the differential lock solenoid coil on the sole-

noid plunger.
RCPH10TLB746AAL 19
20. Install the nut. Tighten the nut to a torque of 7 to 10

Nm (62 to 89 pound-inches).
RCPH10TLB745AAL 20
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21. Install a new O-ring on the solenoid plunger at the

control valve body. Use clean transmission oil to lu-
bricate the O-ring.
RCPH10TLB751AAL 21
22. Install a new O-ring in the solenoid coil. Use clean

transmission oil to lubricate the O-ring.
RCPH10TLB750AAL 22
23. Install the solenoid coil on the solenoid plunger.
RCPH10TLB749AAL 23
24. Install a new O-ring on the solenoid plunger. Use

clean transmission oil to lubricate the O-ring.
RCPH10TLB748AAL 24
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25. Install the remaining solenoid coil on the solenoid

plunger.
RCPH10TLB747AAL 25
26. Install the sealing washer.
RCPH10TLB744AAL 26
27. Install the nut. Tighten the nut to a torque of 7 to 10

Nm (62 to 89 pound-inches).
RCPH10TLB743AAL 27
Next operation:
Next operation:
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Shaft - Disassemble - Input shaft

NOTE: Do steps 1 and 2 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.
1. 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 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.
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
forward gear. The forward gear must turn freely on
inspect the parts closely during disassembly so that
you can find and correct the problem.
3. 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.
RCPH10TLB786AAL 1
4. Remove the sealing ring.
RCPH10TLB788AAL 2
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5. Remove the snap ring above the bearing.
RCPH10TLB787AAL 3
6. Install a bearing separator under the gear as shown.

DO NOT install the bearing separator between the
gear and the bearing. Install a puller on the bearing
separator. Use a shaft protector 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.
RCPH10TLB789AAL 4
7. Remove the bearing.
RCPH10TLB790AAL 5
8. Remove the spacer.
RCPH10TLB791AAL 6
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9. Remove the gear.
RCPH10TLB792AAL 7
10. Remove the needle bearing.
RCPH10TLB793AAL 8
RCPH10TLB794AAL 9
12. Remove the roll pin.
RCPH10TLB795AAL 10
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13. 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.
RCPH10TLB796AAL 11
14. Tap lightly on the thrust plate to move the thrust plate
ring and the thrust plate. Remove the snap ring.
RCPH10TLB797AAL 12
15. Install the top piece of the CAS-2379 special tool as

shown. Use the three threaded rods and nuts to fas-
ten the two pieces together.
RCPH10TLB798AAL 13
16. Tighten the nuts evenly to compress the spring.

Compress the spring just enough to get access to
the snap ring.
RCPH10TLB800AAL 14
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17. Remove the snap ring.
RCPH10TLB799AAL 15
18. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS-2379 special tool.
RCPH10TLB800AAL 16
19. Use pry bars to lift the thrust plate evenly.
RCPH10TLB922AAL 17
20. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
RCPH10TLB809AAL 18
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21. Place a mark below the groove on the housing.
RCPH10TLB878AAL 19
22. Place a mark on each steel and friction disc and the
thrust plate. These marks will be used for reference
during the reassembly procedure.
RCPH10TLB879AAL 20
23. Place a mark on top of the thrust plate and each steel
and friction disc as they are removed. These marks
will be used for reference during the reassembly pro-
cedure.
RCPH10TLB880AAL 21
24. Remove the pressure plate and spring.
RCPH10TLB881AAL 22
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25. Remove the sleeve.
RCPH10TLB807AAL 23
NOTICE: Use an air hose with a safety on/off control nozzle with 2.1 bar (30 psi) maximum at the nozzle. Wear face
protection.
26. Use compressed air in the port shown to remove the
piston.
RCPH10TLB801AAL 24
27. Remove the piston.
RCPH10TLB802AAL 25
28. Put the input shaft in the bottom piece of the CAS-
2379 special tool as shown so that the forward clutch
is up.
RCPH10TLB923AAL 26
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29. Remove the four sealing rings (1)
RCPH10TLB819AAL 27
RCPH10TLB924AAL 28

gear and the bearing. Install an acceptable puller on
the bearing separator. Use a shaft protector between
the puller and the end of the input shaft. Use moly-
disulfide 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 dam-
age the parts.
RCPH10TLB925AAL 29
RCPH10TLB926AAL 30
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RCPH10TLB927AAL 31
NOTE: It is possible that the gear moved partially out 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.
34. Remove the gear.
RCPH10TLB928AAL 32
RCPH10TLB929AAL 33
RCPH10TLB930AAL 34
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37. Tap lightly on the end plate to move the end plate
ring and the end plate.
RCPH10TLB932AAL 35
RCPH10TLB931AAL 36
39. Use pry bars to lift the end plate evenly. Remove the
end plate.
RCPH10TLB933AAL 37
RCPH10TLB934AAL 38
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41. Install the top piece of the CAS-2379 special tool as

shown. Use the three threaded rods and nuts to fas-
ten the two pieces together.
RCPH10TLB935AAL 39
42. Tighten the nuts evenly to compress the spring.

Compress the spring just enough to get access to
the snap ring.
RCPH10TLB936AAL 40
RCPH10TLB937AAL 41
CAS-2379 special tool.
RCPH10TLB938AAL 42
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45. Remove the retainer plate.
RCPH10TLB939AAL 43
RCPH10TLB940AAL 44
47. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
RCPH10TLB941AAL 45
48. Follow the same procedure as Step 21and Step 22for

marking the top of the thrust plate and the steel and
friction discs as they are removed from the housing.
RCPH10TLB806AAL 46
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protection.
50. Use compressed air in the port shown to remove the
piston.
RCPH10TLB803AAL 47
51. Remove the piston.
RCPH10TLB802AAL 48
52. Remove the sealing ring from the OD and the ID of

each piston.
RCPH10TLB805AAL 49
Next operation:
Shaft - Inspect (C.20.C)
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Shaft - Inspect - Input shaft

1. Check the springs for broken or cracked coils. Com-
pare the heights of the two springs. If the two springs
are not approximately the same height, use new
springs. The correct spring height is approximately
85.5 mm (3.4 inches). Use new parts as required.
2. Check the sealing ring grooves (large and small) for
wear and damage. Use new parts as required.
3. Check the teeth on the gears for wear and 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.
4. Check the splines on the output shaft for wear and
damage. Check the passages in the output shaft
to be sure that the passages are open and free of
foreign material. Use new parts as required.
5. Check the ball bearings and the needle bearings for
flat areas, pitting, and other damage. Use new parts
as required.
6. If the clutch discs are to be used again, keep the
clutch packs separate and record which clutch pack
goes with each clutch. Use new parts as required.
RCPH10TLB804AAL 1
RCPH10TLB942AAL 2
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7. 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 parts during assembly. If
you will be using new friction discs, soak the friction
discs in clean transmission oi l for at least an hour
before assembly. If you are using the old friction
discs, make sure that the friction surfaces are coated RCPH10TLB943AAL 3
with transmission oil before assembly.

8. Inspect the bore and the shaft in the input shaft hous-
ing 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 tangs
on the steel discs. Use new par ts as required during
assembly.
9. Inspect the end of the clutch pack housing line bore
holes, if a rivet is coming out of the housing (arrow),
replace the rivet.
RCPH10TLB818AAL 4
Next operation:
Shaft - Assemble (C.20.C)
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Shaft - Assemble
1. Use clean transmission oil to lubricate the sealing
rings. Install new sealing rings in each piston.
RCPH10TLB805AAL 1
2. Slide the 380001926 piston installation tool on the

input shaft.
RCPH10TLB820AAL 2
3. 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.
the bore of the piston. Install the piston.
RCPH10TLB806AAL 3
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RCPH10TLB940AAL 4
6. Install the retainer plate. The side that has a raised

area around the bore goes down.
RCPH10TLB939AAL 5
7. 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 com-
press 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.
RCPH10TLB961AAL 6
8. Install the pin.
RCPH10TLB962AAL 7
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9. 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 up.
RCPH10TLB963AAL 8
10. Use clean transmission oil to lubricate the needle

bearings. Install the needle bearing.
RCPH10TLB964AAL 9
11. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the refer-
ence mark on top of the plate made during disas-
sembly is facing towards the gear.
RCPH10TLB971AAL 10
12. Install one steel disc with reference mark on top of

the steel disc towards the gear followed by one fric-
tion disc with the reference mark on top towards the
gear.
RCPH10TLB972AAL 11
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.
84516378 05/07/2011
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the steel disc towards the gear.
RCPH10TLB048ABL 12
14. Repeat steps 12 and 13 until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
15. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs
are down. Put the clutch pack on the clutch housing
as shown so that the tabs with the reference marks
on the steel discs are almost ready to start into the
slot in the clutch housing with the reference mark.
RCPH10TLB965AAL 13
16. 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.
RCPH10TLB966AAL 14
17. 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.
RCPH10TLB967AAL 15
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RCPH10TLB968AAL 16
19. 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.
RCPH10TLB969AAL 17

side with the oil grooves is down.
RCPH10TLB927AAL 18
21. Use an acceptable driver to drive the bearing onto

the input shaft until the bearing makes contact with
the thrust washer.
RCPH10TLB970AAL 19
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RCPH10TLB924AAL 20
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 1 through 22 must be performed before in-
stalling the Teflon sealing ring on the input shaft.
23. Place the 380001929 spacer into the 380001933 ex-
pander/protector.
RCPH10TLB821AAL 21
24. 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.
RCPH10TLB831AAL 22
25. Install the 380001928 pusher over the expander/pro-

tector and slide the sealing ring until it reaches the
groove in the shaft. Remove the pusher, protector,
and spacer from the shaft.
RCPH10TLB838AAL 23
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26. 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 to
allow the seal compressor to slip over the top of the
sealing ring and seat the sealing ring into the 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.
RCPH10TLB839AAL 24
27. 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 cooled and is
properly sized and seated in the groove. After the
sealing ring has cooled, remove the seal compressor
from the shaft.
RCPH10TLB840AAL 25

pander/protector.
RCPH10TLB822AAL 26
29. 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.
RCPH10TLB832AAL 27
84516378 05/07/2011
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groove in the shaft. Remove the pusher, expander/
protector, and spacer from the shaft.
RCPH10TLB837AAL 28

RCPH10TLB839AAL 29
from the shaft.
RCPH10TLB840AAL 30

pander/protector.
RCPH10TLB823AAL 31
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RCPH10TLB833AAL 32

RCPH10TLB836AAL 33

RCPH10TLB839AAL 34
from the shaft.
RCPH10TLB840AAL 35
84516378 05/07/2011
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pander/protector.
RCPH10TLB824AAL 36

RCPH10TLB834AAL 37

RCPH10TLB835AAL 38

RCPH10TLB839AAL 39
84516378 05/07/2011
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from the shaft.
RCPH10TLB840AAL 40
43. Put the input shaft in the bottom piece of the

CAS2379 special tool so that the reverse clutch
housing is up. Slide the 380001926 piston installa-
tion tool on the input shaft.
RCPH10TLB825AAL 41

the bore of the piston. Install the piston. Remove the
piston installation tool.
45. Install the sleeve.
RCPH10TLB882AAL 42
46. Install the pressure plate and the spring. The raised
area around the bore of the pressure plate must go
down. The side that has the groove around the bore
should face up. The outer edge of the snap ring must
fit in the groove after the parts are assembled.
RCPH10TLB881AAL 43
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47. 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 com-
press 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.
RCPH10TLB973AAL 44
48. Install the pin.
RCPH10TLB974AAL 45

side with the oil grooves is up.
RCPH10TLB975AAL 46
50. Use clean transmission oil to lubricate the needle

bearing. Install the needle bearing.
RCPH10TLB793AAL 47
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51. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the refer-
ence mark on top of the plate made during disas-
sembly is facing towards the gear.
RCPH10TLB971AAL 48
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.
the steel disc towards the gear followed by one fric-
tion disc with the reference mark on top towards the
gear.
RCPH10TLB972AAL 49

the steel disc towards the gear.
RCPH10TLB048ABL 50
54. Repeat steps 52 and 53until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
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55. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs
are down. Put the clutch pack on the clutch housing
as shown so that the tabs with the reference marks
on the steel discs are almost ready to start into the
slot in the clutch housing with the reference mark.
RCPH10TLB976AAL 51
56. 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.
RCPH10TLB977AAL 52
57. 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.
RCPH10TLB978AAL 53
RCPH10TLB979AAL 54
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59. 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.
RCPH10TLB980AAL 55
60. Use clean transmission oil to lubricate the spacer (1)

and install the spacer (1) on the input shaft. Install the
bearing (2) onto the input shaft. Use an acceptable
driver (3) to drive the bearing onto the input shaft until
the bearing (2) makes contact with the spacer (1)
RCPH10TLB981AAL 56
RCPH10TLB919AAL 57
gear, spacer, bearing, and snap ring installed on the input shaft. Steps 43 through 61 must be performed before
installing the Teflon sealing ring on the input shaft.
pander/protector.
RCPH10TLB826AAL 58
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63. Slide the expander/protector and spacer onto the in-

put shaft. Heat the Teflon sealing ring to 80° to 100°
C (176° to 212° F). Install the Teflon sealing ring onto
the 380001428 expander/protector.
RCPH10TLB829AAL 59

RCPH10TLB830AAL 60

RCPH10TLB841AAL 61
from the shaft.
RCPH10TLB827AAL 62
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67. Measure the clutch disc clearance for each clutch

assembly. The end cover must be all the way up
against the snap ring. Use a feeler gauge to mea-
sure 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 specifica-
tion, the clutch is probably assembled wrong. Clutch
plate wear will not cause the distance to be outside
the specification.
RCPH10TLB982AAL 63
NOTE: The art shows a clutch pack without the PTO through shaft, the procedures for steps 68 and 69 are the same.
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
reverse gear. The reverse gear must turn freely on
the input shaft . If the clutches do not work correctly,
disassemble the clutches to find the problem.
RCPH10TLB054GAL 64
Clutch pack
1. Forward clutch passage 4. Forward clutch pack 7. Input shaft
2. Reverse clutch passage 5. Reverse clutch pack
3. Forward gear 6. Reverse gear

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
forward gear. The forward gear must turn freely on
disassemble the clutches to find the problem.
Next operation:
Shaft - Disassemble (C.20.C)
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Shaft - Disassemble - Secondary shaft

1. Support the secondary shaft on blocks on the bench
as shown.
RCPH10TLB765AAL 1

gear and the bearing. If the bearing 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. In-
stall an acceptable puller on the bearing 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 is free.
Pulling any farther can damage the parts .
RCPH10TLB766AAL 2
RCPH10TLB767AAL 3
RCPH10TLB768AAL 4
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5. Remove the third gear from the shaft.
RCPH10TLB769AAL 5
6. Remove the synchronizer assembly.
RCPH10TLB770AAL 6
7. Use a feeler gauge to measure the clearance be-

tween the clutch ring (1)and the edge of the tapered
friction ring (2). This clearance (3) should be approx-
imately 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 mea-
surement for the opposite side of the synchronizer
assembly before disassembly.
RCPH10TLB810AAL 7
8. Remove the clutch ring from each side of the syn-

chronizer assembly.
RCPH10TLB817AAL 8
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9. Remove the tapered friction ring from each side of

the synchronizer assembly.
RCPH10TLB816AAL 9
10. Inspect the clutch ring teeth for wear, wear in excess
of 0.5 mm (0.02 inch) the ring must be replaced.
RCPH10TLB815AAL 10
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.
11. 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.
RCPH10TLB893AAL 11
12. This photo shows the relationship of the balls (1) , the
spring plates (2) , the springs (3) , and the hub (4)
RCPH10TLB949AAL 12
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13. Remove fourth gear.
RCPH10TLB771AAL 13
14. Turn the secondary shaft over so that second gear is

at the top. You can use a vise with soft jaws to hold
the secondary shaft in position.
RCPH10TLB772AAL 14
15. Install a bearing separator under the bearing race as

shown. If the bearing separator has a beveled edge,
the beveled edge must be down. Do not tighten the
bearing separator so much that the bearing separa-
tor pushes the synchronizer down. Install an accept-
able puller on the bearing separator. Use a shaft
protector between the puller and the end of the sec-
ondary 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.
RCPH10TLB773AAL 15
16. Remove the bearing race from the shaft.
RCPH10TLB774AAL 16
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17. Remove the snap ring from the shaft.
RCPH10TLB775AAL 17
18. Remove the shim(s) and the thrust washer.
RCPH10TLB776AAL 18
19. Remove the pin.
RCPH10TLB777AAL 19
20. Remove second gear.
RCPH10TLB778AAL 20
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RCPH10TLB779AAL 21
22. Remove the synchronizer ring and the first-second

synchronizer as an assembly.
RCPH10TLB780AAL 22

tween 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 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 synchro-
nizer assembly before disassembly.
24. Remove the steel ring (1) and the bronze ring (2)to-
gether.
RCPH10TLB946AAL 23
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25. Remove the tapered friction ring.
RCPH10TLB947AAL 24
26. Turn the synchronizer assembly over and remove the

synchronizer ring from the other side.
RCPH10TLB945AAL 25
27. Remove the steel ring (1) and the bronze ring (2)to-
gether.
RCPH10TLB946AAL 26
28. Remove the tapered friction ring.
RCPH10TLB947AAL 27
NOTE: The parts will 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.
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29. Support the sleeve on blocks. Push down on the hub

while you use a punch to push the detent assemblies
out of the sleeve and hub. Remove the sleeve from
the hub.
RCPH10TLB948AAL 28
30. This photo shows the relationship of the balls (1), the
spring plates (2), the springs (3), and the hub (4).
RCPH10TLB949AAL 29
31. Remove first gear.
RCPH10TLB781AAL 30
32. If equipped with four wheel drive, remove the snap

ring from the four wheel drive gear.
RCPH10TLB782AAL 31
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33. Remove the four wheel drive gear, if equipped. On

two-wheel drive transmissions, there is a raised area
on the shaft.
RCPH10TLB783AAL 32
34. If equipped with four wheel drive, do not remove the

snap ring for the four wheel drive gear unless the
snap ring is damaged.
RCPH10TLB784AAL 33
Next operation:
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Shaft - Inspect - Secondary shaft

1. Check the teeth on the gears for wear and damage. If
a tooth is badly damaged, be sure to inspect the gear
or spline that is in mesh with the damaged gear.
2. Check the splines on the secondary shaft for wear
and damage. Check the passages in the secondary
shaft to be sure that the passages are open and free
of foreign material.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
4. Check the teeth in the synchronizer assemblies for
wear and damage. Replace as necessary.
5. Check for wear or damage to the steel rings and
the bronze rings from the synchronizer assemblies.
Check the springs in the synchronizer assemblies for
wear, cracks, heat distortion, and other damage. Re-
place as necessary.
Next operation:
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Shaft - Assemble - Secondary shaft

NOTE: Before each gear is installed on the secondary shaft, make sure that the bore of the gear and the outside
diameter of the secondary shaft are completely lubricated with clean transmission oil.
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 install a snap ring so that the ends extend into an axial slot on the secondary shaft.
1. If equipped with four wheel drive, if the snap ring
was removed from the shaft, install the snap ring as
shown.
RCPH10TLB784AAL 1
2. 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.
RCPH10TLB783AAL 2
3. If equipped with four wheel drive, install the snap ring

for the four wheel drive gear.
RCPH10TLB782AAL 3
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4. Install first gear.
RCPH10TLB781AAL 4
5. This photo shows the correct relationship between

the hub and the sleeve for assembly of the first-sec-
ond synchronizer. The tabs (1) in the inside diameter
of the sleeve fit into the small recesses (2) in the out-
side diameter of the hub. The large recesses (3) in
the hub are for the detent assemblies, that are not
yet installed.
RCPH10TLB950AAL 5
6. This photo shows the correct positions of the hub, the

sleeve, the springs, the blocks, and the balls 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.
RCPH10TLB951AAL 6
7. Use a punch or screwdriver to push the balls into the

blocks and to push the blocks down so that the balls
are on the flat faces of the teeth, but not into the de-
tent grooves. When all the balls are in position, push
the hub and the blocks down until the balls move into
the detent groove.
RCPH10TLB952AAL 7
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8. Install the tapered friction ring on the synchronizer

assembly.
RCPH10TLB947AAL 8
9. 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)as shown.
RCPH10TLB946AAL 9
10. Install the synchronizer ring as shown. The flat sides

of the teeth must be up.
RCPH10TLB945AAL 10
11. Turn the synchronizer assembly over and install the

tapered friction ring on the other side.
RCPH10TLB947AAL 11
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12. 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)as shown.
RCPH10TLB946AAL 12
13. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer 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 en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, 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
three positions, the synchronizer assembly has dam-
aged parts or was not assembled correctly. Disas-
semble the synchronizer assembly to find the prob-
lem.
14. Install the synchronizer ring and the first-second syn-
chronizer as an assembly. Make sure the top syn-
chronizer ring is installed so that the flat sides of the
teeth are up.
RCPH10TLB780AAL 13
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.
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15. Install the spacer.
RCPH10TLB779AAL 14
16. Install and second gear. The teeth in the inside diam-
eter of the spacer must engage the teeth on the bot-
tom of second gear before second gear is installed.
RCPH10TLB778AAL 15
RCPH10TLB777AAL 16
Next operation:
Shaft - Adjust (C.20.C)
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Shaft - Adjust - Backlash adjustment

1. Install the thrust washer and snap ring.
RCPH10TLB775AAL 1
2. Use a feeler gauge and measure the backlash be-

tween the gear and the thrust washer. Record this
measurement (a). Subtract the recorded measure-
ment (a) from 0.20 to 0.42 mm (0.0079 to 0.0165
inch) (b). Select the shim(s) required (c). Example:
Use 0.83 ± 0.11 mm (0.0327 ± 0.0043 inch) shim (s).
a. 1.14 mm 0.0449 inch

b. -0.31 mm 0.0122 inch
c. 0.83 mm 0.0327 inch
3. Remove the snap ring and thrust washer.
RCPH10TLB775AAL 2
4. Use clean transmission oil to lubricate the shim(s)

and the thrust washer. Install the shim(s). Install the
thrust washer on top of the shim(s). Make sure that
the side with the oil grooves is down.
RCPH10TLB776AAL 3
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5. Put the bearing race on the shaft.
RCPH10TLB774AAL 4
6. Use an acceptable driver to drive the bearing race

onto the secondary shaft until bearing race makes
contact with the snap ring.
RCPH10TLB785AAL 5
7. Turn the secondary shaft over so that second gear is

at the bottom. Use blocks to support the secondary
shaft. Install the fourth gear on the secondary shaft.
RCPH10TLB771AAL 6
8. This photo shows the correct relationship between

the hub and the sleeve for assembly of the third-
fourth synchronizer. The tabs (1) in the inside diam-
eter 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, shown in-
stalled.
RCPH10TLB811AAL 7
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9. Install the 3 sets of hub springs, hub pins, and spring

plates into the synchronizer hub. Use a punch or
screwdriver to push the spring plates as the synchro-
nizer hub is installed into the sleeve. Be sure that
the spring plates are aligned with the grooves in the
sleeve.
RCPH10TLB952AAL 8
10. Install the friction ring on each side the synchronizer

assembly.
RCPH10TLB892AAL 9
11. Use clean transmission oil to lubricate and install the

clutch ring on each side of the synchronizer assem-
bly.
RCPH10TLB891AAL 10
12. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer 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 en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, 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 RCPH10TLB810AAL 11
three positions, the synchronizer assembly has dam-

aged parts or was not assembled correctly. Disas-
semble the synchronizer assembly to find the prob-
lem.
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13. Install the synchronizer assembly onto the shaft.
RCPH10TLB770AAL 12
14. Install the third gear on the shaft.
RCPH10TLB769AAL 13

washer. Install the thrust washer onto the shaft.
RCPH10TLB768AAL 14
16. Put the bearing in position on the secondary shaft.

Make sure that the snap ring groove is at the top.
RCPH10TLB767AAL 15
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17. Use an acceptable driver to drive the bearing onto

the secondary shaft until the bearing makes contact
with the thrust washer.
RCPH10TLB953AAL 16
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.
18. Check for correct operation of both synchronizer as-
semblies. If they do not shift smoothly, with the teeth
on the synchronizer ring aligned with the splines on
the sleeve, the re is a problem. Disassemble as nec-
essary, and correct the problem.
Next operation:
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Shaft - Disassemble - Primary shaft

1. Put the primary shaft on the bench so that the end
with the bearing attached is up. Remove the snap
ring.
RCPH10TLB954AAL 1

gear and the bearing. Install an acceptable puller on
the bearing separator. Use a shaft protector between
the puller and the end of the primary shaft. Use moly-
the end of the puller. Pull the bearing from the pri-
mary shaft.
RCPH10TLB955AAL 2
RCPH10TLB956AAL 3
RCPH10TLB957AAL 4
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5. Install a bearing separator under the lip of the bear-

ing race as shown. Install an acceptable puller on the
bearing separator. Use a shaft protector between the
puller and the end of the primary shaft. Use moly-
the end of the puller. Pull the bearing race from the
primary shaft.
RCPH10TLB958AAL 5
Next operation:
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Shaft - Inspect - Primary shaft

1. Check the teeth on the gears for wear and damage. If
a tooth is badly damaged, be sure to inspect the gear
or spline that is in mesh with the damaged gear.
2. Check the splines on the primary shaft for wear and
damage.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
Next operation:
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Shaft - Assemble - Primary shaft

1. Use an acceptable driver to drive the bearing race all
the way onto the primary shaft.
RCPH10TLB959AAL 1

washer. Install the thrust washer so that the side
with the oil grooves is down.
RCPH10TLB957AAL 2
3. Put the bearing into position so that the snap ring

groove on the outside diameter of the bearing is at
the top.
RCPH10TLB956AAL 3
4. Use an acceptable driver to drive the bearing onto the

primary shaft until the bearing makes contact with the
thrust washer.
RCPH10TLB960AAL 4
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RCPH10TLB954AAL 5
Next operation:
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Shaft - Disassemble - Reverse shaft

1. The bearings are the only serviceable parts on the re-
verse shaft. If you remove the bearings, use a shaft
protector between the puller and the end of the re-
verse shaft. Use molydisulfide grease to lubricate the
shaft protector and the end of the puller. (1)Bearing,
(2) Reverse shaft
RCPH10TLB050ABL 1
Next operation:
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Shaft - Inspect - Reverse shaft

1. Check the teeth on the gears for wear and damage.
If a tooth is badly damaged, be sure to inspect the
gear that is in mesh with the damaged gear. Check
the bearings for flat areas, pitting, and other damage.
Replace as necessary.
Next operation:
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Shaft - Assemble - Reverse shaft

1. Use an acceptable driver to drive each bearing onto
the reverse shaft until the bearing makes contact with
the shoulder on the reverse shaft.
Next operation:
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Shaft - Disassemble - Oil pump

NOTE: Bolts (6), O-Rings, bushings and seals are the only serviceable components in the oil pump. Complete dis-
assembly of the oil pump is shown for reference only.
1. Remove the O-ring.
RCPH10TLB983AAL 1
2. Remove the two Allen head bolts that fasten the

pump support to the pump housing.
RCPH10TLB984AAL 2
3. Separate the pump support from the pump housing.
RCPH10TLB985AAL 3
4. Remove the large gear from the pump housing.
RCPH10TLB986AAL 4
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NOTE: Install a plastic plug in the bearings to keep the bearings from falling out when the small gear is removed from
the pump housing.
5. Remove the small gear from the pump housing.
RCPH10TLB987AAL 5
NOTE: Be careful when removing the plastic plug 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.
6. Remove the seal from the pump housing.
RCPH10TLB988AAL 6
7. Turn the pump housing over and use blocks to sup-

port the pump housing. Use an acceptable driver to
drive the bushing from the bore of the pump housing.
RCPH10TLB989AAL 7
8. Support the large gear on blocks as shown. Use a

punch and a hammer to drive the bushing from the
large gear.
RCPH10TLB994AAL 8
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9. Use an acceptable driver to push the needle bearing

out of the small gear.
RCPH10TLB996AAL 9
10. Remove the shaft for the small gear only if the shaft
is damaged. The shaft will probably be difficult to
remove.
RCPH10TLB993AAL 10
11. Use a blind hole puller and a slide hammer to pull the
bushing from the shaft of the pump support.
RCPH10TLB997AAL 11
12. Remove the roll pin for the torque converter relief
valve.
RCPH10TLB999AAL 12
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13. Remove the plug, the spring, and the ball for the
torque converter relief valve.
RCPH10TLB001ABL 13
14. Remove the roll pin for the oil pump relief valve. Be
very careful because the large amount of spring ten-
sion will force the parts out when the roll pin is re-
moved.
RCPH10TLB002ABL 14
15. Remove the plug, the spring, the pin, and the plunger
for the oil pump relief valve.
RCPH10TLB038ABL 15
Next operation:
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Shaft - Inspect - Oil pump

1. 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 con-
verter for similar damage. Replace the large gear
and the torque converter as necessary.
2. 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.
3. Inspect the splines on the shaft for wear and damage.
If you find damage, inspect the part that is installed
on the shaft.
4. Inspect all passages to be sure that the passages are
open and free of foreign material.
5. Check the needle bearing for wear, pitting, or other
damage.
6. Inspect the parts of the torque converter relief valve
and the oil pump relief valve for wear and damage.
Next operation:
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Shaft - Assemble - Oil pump

1. Install the plunger for the oil pump relief valve.
RCPH10TLB042ABL 1
2. Install the pin for the oil pump relief valve. The ma-
chined end of the pin must be toward the plunger.
Make sure that the pin goes into the bore of the
plunger.
RCPH10TLB041ABL 2
RCPH10TLB040ABL 3
4. Install the plug.
RCPH10TLB039ABL 4
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5. This step will be difficult because the spring will be

under heavy tension. Push the plug in until the plug
is to the inside of the hole for the roll pin. Install the
roll pin.
RCPH10TLB002ABL 5
6. Install the ball, the spring, and the plug for the torque
converter relief valve. Make sure that the hole in the
plug is aligned with the hole for the roll pin.
RCPH10TLB001ABL 6
7. Install the roll pin through the holes in the pump sup-
port and the hole in the plug.
RCPH10TLB003ABL 7
8. Use an acceptable driver to install a new bushing in

the shaft of the pump support.
RCPH10TLB998AAL 8
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9. Use an acceptable driver to install a new needle

bearing in the small gear. Push the needle bearing
until the needle bearing is approximately centered in
the bore of the gear.
RCPH10TLB996AAL 9
10. If the shaft for the small gear was removed, clean the
mating surfaces and apply either Loctite 640 (green)
or Loctite 642 (amber) before installation.
RCPH10TLB993AAL 10
11. Support the large gear on blocks so that the side with
the lugs is down. Use an acceptable driver to push
the new bushing to the end of the bore.
RCPH10TLB995AAL 11
12. Put a new bushing into position so that the recess (1)
in the bushing is aligned with the oil drain hole (2) in
the pump housing.
RCPH10TLB990AAL 12
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13. Use an acceptable driver to install the bushing.
RCPH10TLB992AAL 13
14. Use an acceptable driver to install a new seal in the

end of the pump housing.
RCPH10TLB991AAL 14
15. Use clean transmission oil to lubricate the small gear,

the needle bearing, and the bore in the pump hous-
ing. Install the small gear on the shaft in the pump
housing. Install the same number of needle bearings
that were removed between the small gear and the
shaft.
RCPH10TLB987AAL 15
16. Use clean transmission oil to lubricate the large gear,

the bushing in the large gear, and the bore in the
pump housing. Install the large gear so that the side
with the lugs is down.
RCPH10TLB986AAL 16
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17. Install the pump support on the pump housing. Make

sure that all the bolt holes are aligned.
RCPH10TLB985AAL 17
18. 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.
RCPH10TLB984AAL 18
19. 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 be-
tween the two parts and be in contact with both parts.
Tighten the clamp. Tap the housing with a soft ham-
mer. 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.
20. Put the oil pump on a clean work surface so that the
pump housing is up. Insert a small screwdriver or
punch through the hole in the torque converter hub
and rotate the large gear by pushing against 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.
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21. Install a new O-ring.
RCPH10TLB983AAL 19
Next operation:
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Shaft - Disassemble - Four wheel drive shaft

1. There is a pipe plug at the bottom of the hole in the
end of the shaft (see arrow). DO NOT remove the
pipe plug unless the pipe plug is damaged.
RCPH10TLB883AAL 1
2. Use an acceptable tool to press the spring retainer

down until you have access to the snap ring (see ar-
row). Remove the snap ring from the groove. Re-
lease the tension and remove the tool.
RCPH10TLB884AAL 2
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.
3. Remove the snap ring from the shaft.
RCPH10TLB885AAL 3
RCPH10TLB886AAL 4
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5. Remove the special washer.
RCPH10TLB887AAL 5
RCPH10TLB888AAL 6
RCPH10TLB889AAL 7
8. Remove the two O-rings from the shaft.
RCPH10TLB890AAL 8
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9. Remove the two Teflon sealing rings from the shaft.
RCPH10TLB890AAL 9
Next operation:
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Shaft - Inspect - Four wheel drive shaft

1. 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.
2. Check the splines on the shaft and inside the sleeve
for wear and damage.
3. Check the passages in the shaft to be sure that the
passages are open and free of foreign material.
4. Check the springs for wear, cracks, heat distortion,
and other damage. Replace as necessary.
Next operation:
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Shaft - Assemble - Four wheel drive shaft

NOTE: Special tools used up to step 6 are from the tool set CAS2771A, standard transmission without rear pump
drive.
1. Install new O-rings on the shaft. Use clean transmis-
sion oil to lubricate the O-rings.
RCPH10TLB890AAL 1
2. Install the CAS2771-2 expander/protector on the

shaft.
RCPH10TLB894AAL 2
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.
3. 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.
RCPH10TLB895AAL 3
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4. Install the CAS2327 pusher over the expander/pro-

groove in the shaft. Remove the pusher and ex-
pander/protector from the shaft.
RCPH10TLB896AAL 4
5. Install the end of the CAS2771-7 seal compressor

RCPH10TLB897AAL 5

from the shaft.
RCPH10TLB898AAL 6
7. Place the CAS2771-3 spacer against the end of the

shaft.
RCPH10TLB899AAL 7
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8. 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.
RCPH10TLB900AAL 8
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.
CAS2771-2 expander/protector.
RCPH10TLB900AAL 9
10. Install the CAS2327 pusher over the expander/pro-

RCPH10TLB902AAL 10
11. Install the end of the CAS2771-1 seal compressor

RCPH10TLB903AAL 11
84516378 05/07/2011
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from the shaft.
RCPH10TLB904AAL 12
13. Install the sleeve on the shaft. Be careful not to dam-

age the Teflon sealing rings and the O-rings while in-
stalling the sleeve.
RCPH10TLB889AAL 13
14. Install the springs.
RCPH10TLB888AAL 14
15. Install the special washer.
RCPH10TLB887AAL 15
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16. Install the spacer onto the shaft.
RCPH10TLB886AAL 16
17. Install the snap ring onto the shaft.
RCPH10TLB885AAL 17
18. Use an acceptable tool to press the spring retainer

down until you have access to the snap ring groove
(see arrow). Install the snap ring in the groove. Re-
lease the tension and remove the tool. Make sure
that the snap ring is seated in the recess in the spring
retainer.
RCPH10TLB884AAL 18
NOTE: The tool used in the photo above is a piece of round tubing with a rectangular access hole cut out.
19. If the pipe plug at the bottom of the hole in the end
of the shaft (see arrow) was removed, apply Loctite
242 or Loctite 262 to the threads of the new pipe plug
before installation. Tighten the pipe plug to a torque
of 30 Nm (266 pound-inches).
RCPH10TLB004ABL 19
Next operation:
Housing - Disassemble (C.20.C)
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Housing - Disassemble
NOTE: Some photos may not represent your transmission, the procedures are the same.
1. Fasten the rear housing to acceptable support equip-
ment . It is recommended that you use equipment
that will let you rotate the transmission.
RCPH10TLB689AAL 1
2. Remove the drain plug and drain the oil from the
transmission.
RCPH10TLB690AAL 2
NOTE: The four-wheel drive transmission is shown. On two-wheel drive transmissions, the drain plug is at the rear
of the transmission.
3. Remove the two cap screws that fasten the cover for
the oil screen. Remove the cover.
RCPH10TLB693AAL 3
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4. Remove the oil screen and the O-ring.
RCPH10TLB695AAL 4
NOTE: Steps 8 through 10 are for four-wheel drive transmissions only. If you are working on a two-wheel drive trans-
mission, go to step 11.
5. Remove the oil filter.
RCPH10TLB698AAL 5
6. 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 all oil from the threads and apply Loctite 542
or Loctite 262 (red) before installation.
RCPH10TLB703AAL 6
7. Remove the fitting for the oil filter.
RCPH10TLB699AAL 7
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RCPH10TLB701AAL 8
RCPH10TLB702AAL 9
10. Use a blind hole puller to remove the four-wheel drive

priority valve.
RCPH10TLB907AAL 10
NOTE: The four-wheel drive priority valve is 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.
11. Remove the dipstick.
RCPH10TLB908AAL 11
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12. Remove the dipstick tube.
RCPH10TLB909AAL 12
13. Remove the fitting for the dipstick tube.
RCPH10TLB808AAL 13
14. Remove the bolts that fasten the transmission control

valve to the front housing.
RCPH10TLB847AAL 14
15. Remove the transmission control valve and the gas-

ket.
16. Remove the three bolts that fasten the four-wheel
drive valve to the front housing.
RCPH10TLB848AAL 15
17. Remove the four-wheel drive valve and the gasket.
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18. Remove the seven bolts that fasten the pump mount
to the rear housing.
RCPH10TLB849AAL 16
19. Remove the pump mount housing.
RCPH10TLB850AAL 17
20. Use a plastic mallet and tap the through shaft out of
the transmission rear housing.
RCPH10TLB851AAL 18
21. Pull the shaft from the transmission.
RCPH10TLB852AAL 19
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22. Remove the seal from the shaft.
RCPH10TLB814AAL 20
23. Remove the snap ring from the pump shaft.
RCPH10TLB813AAL 21
24. Use a suitable driver and remove the bearing from

the pump drive shaft.
RCPH10TLB812AAL 22
25. Remove the pressure sensor switch from the brake

housing.
RCPH10TLB853AAL 23
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26. Remove the solenoid from the brake housing.
RCPH10TLB854AAL 24
27. Make sure the orifice remains in the brake housing.
RCPH10TLB855AAL 25
28. Remove the three Allen head bolts that fasten the
shifter housing to the rear cover. Remove the shifter
assembly and the O-ring.
RCPH10TLB856AAL 26
29. Remove the bolt and the output flange.
RCPH10TLB857AAL 27
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30. Remove the output flange.
RCPH10TLB858AAL 28
31. Remove three of the parking brake cover bolts.

Loosen the remaining three bolts evenly one turn
at a time to relieve spring pressure in the brake
housing.
RCPH10TLB859AAL 29
NOTE: Housing is under spring pressure, failure to follow instructions will result in serious injury and damage to
equipment.
32. Remove the brake discs from the brake housing.
RCPH10TLB859AAL 30
33. Remove the brake disc flange from the output shaft.
RCPH10TLB860AAL 31
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34. Remove the rear cover mounting bolts.
RCPH10TLB861AAL 32
35. At the three prying points, use pry bars and loosen
the rear cover from the transmission.
RCPH10TLB864AAL 33
36. Remove the rear cover from the transmission.
RCPH10TLB865AAL 34
37. Remove the seal from the rear cover.

38. Use a punch to remove the pins that fasten the shift
collars to the shift rods.
RCPH10TLB723AAL 35
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39. Remove the shift collars from the shift rods.
RCPH10TLB725AAL 36
40. Remove the two Allen head bolts that hold the plate
between the two shift rods.
RCPH10TLB726AAL 37
41. Remove the plate.
RCPH10TLB728AAL 38
42. Remove the two shift interlock balls from the groove
between the two shift rods.
RCPH10TLB729AAL 39
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43. Remove one of the detent plugs from the right-hand

side of the rear housing.
RCPH10TLB730AAL 40
44. Remove the detent spring.
RCPH10TLB731AAL 41
45. Remove the detent ball.
RCPH10TLB049ABL 42
46. Repeat steps 43 through 45 to remove the other de-

tent plug, spring, and ball.
NOTE: Rotate the transmission in the stand so the shafts will not fall out when the snap ring is removed.
47. Push the secondary shaft to the rear so that there is
clearance between the snap ring and the rear hous-
ing. Remove the snap ring.
RCPH10TLB732AAL 43
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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.
48. Remove all of the housing bolts that are fastened
from the rear housing to the front housing. There
are 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.
RCPH10TLB704AAL 44
49. Rotate the transmission so that the front housing is

up. On four-wheel drive transmissions only, there are
three bolts fastened from the front housing to the rear
housing. Remove these bolts.
RCPH10TLB717AAL 45
NOTE: Steps 50 through 57 are for four-wheel drive transmissions only. If you are working on a two-wheel drive
transmission, go to step 58.
50. 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.
RCPH10TLB906AAL 46
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51. Remove the washer.
RCPH10TLB705AAL 47
52. Remove the four-wheel drive flange.
RCPH10TLB706AAL 48
53. Remove the O-ring from the four-wheel drive flange.
RCPH10TLB707AAL 49
54. Remove the three bolts that fasten the cover to the
front housing.
RCPH10TLB708AAL 50
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RCPH10TLB710AAL 51
56. Remove the O-ring from the cover.
RCPH10TLB711AAL 52
57. Remove the seal from the cover.
RCPH10TLB020ABL 53
58. Make a mark across the joint between the oil pump
and the torque converter housing so that the oil pump
can be aligned the same way during installation.
RCPH10TLB866AAL 54
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59. Remove the six bolts that fasten the oil pump in po-
sition.
RCPH10TLB867AAL 55
60. Use two pry bars to lift the oil pump evenly until the
oil pump can be removed.
RCPH10TLB713AAL 56
61. Remove the oil pump.
RCPH10TLB714AAL 57
62. Pull up the input shaft to get clearance as you release

the snap ring.
RCPH10TLB715AAL 58
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RCPH10TLB716AAL 59
64. Fasten acceptable lifting equipment to the front hous-

ing as shown. Use pry bars at both ends of the hous-
ings to separate the front housing from the rear hous-
ing.
RCPH10TLB718AAL 60
65. As you lift the front housing, continue to use the pry
bar to make sure that the front housing comes up
evenly. Also, it will probably be necessary to hit the
end of the four-wheel drive shaft, if so equipped, and
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.
RCPH10TLB910AAL 61
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.
66. 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.
RCPH10TLB720AAL 62
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67. On machines with four-wheel drive, remove the four-

wheel drive shaft bearing from the front housing.
RCPH10TLB911AAL 63
68. Remove the tube from the front housing only if the
tube is damaged or leaking.
RCPH10TLB027ABL 64
69. Remove the three O-rings from the flange of the rear
housing.
RCPH10TLB920AAL 65
70. On machines with four-wheel drive, remove the four-

wheel drive shaft.
RCPH10TLB720AAL 66
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71. Remove the input shaft and the reverse shaft to-
gether.
RCPH10TLB921AAL 67
NOTE: Make a mark on the top end of the reverse shaft so that you can install the reverse shaft with the same end
up during assembly.
72. Rotate the rear housing so that the open side is up.
Connect acceptable lifting equipment to the top gear
on the secondary shaft.
RCPH10TLB912AAL 68
73. Use the lifting equipment to begin lifting the sec-

ondary shaft while you use your hands to lift the pri-
mary shaft. At the same time, move the primary
shaft back and forth to keep the primary shaft mov-
ing 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.
RCPH10TLB913AAL 69
74. Continue to lift the secondary shaft until you can

move the secondary shaft out of the shift forks. Then
remove the secondary shaft.
RCPH10TLB914AAL 70
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75. Remove the shift rod and fork assembly for first and
second gear from the rear housing.
RCPH10TLB915AAL 71
76. 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.
RCPH10TLB916AAL 72
NOTE: Steps 77 and 78 are for four-wheel drive transmissions only. If you are working on a two-wheel drive trans-
77. Remove the four-wheel drive clutch gear.
RCPH10TLB733AAL 73
RCPH10TLB917AAL 74
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79. It is not necessary to remove the test port plugs (1),

the breather (2), or the temperature sender (3) from
the rear housing unless these parts are leaking or
damaged.
RCPH10TLB918AAL 75
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 dis-
tribution holes.
81. 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.
RCPH10TLB023ABL 76
82. Remove the three Allen head bolts that fasten the
valve plate to the front housing.
RCPH10TLB025ABL 77
83. Remove the valve plate from the front housing.
RCPH10TLB024ABL 78
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84. Remove the gasket.
RCPH10TLB026ABL 79
Next operation:
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Housing - Disassemble - Shifter housing

1. Use side cutters as shown to release the catch on
the band that fastens the boot to the shifter housing.
Remove the band.
RCPH10TLB012ABL 1
2. Remove the boot from the shifter housing.
RCPH10TLB013ABL 2
3. Remove the two pins (one on either side of the shifter

housing). Use a screwdriver to lift each pin as shown
until you can reach the pin with your fingers. Then
pull the pin out.
RCPH10TLB013ABL 3
4. Remove the snap ring from the shift lever.
RCPH10TLB016ABL 4
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5. Remove the bushing from the shift lever.
RCPH10TLB019ABL 5
RCPH10TLB018ABL 6
7. Remove the shift lever from the shifter housing.
RCPH10TLB017ABL 7
Next operation:
Housing - Disassemble (C.20.C)
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Housing - Disassemble - Shift rods and shift forks

1. If disassembly is required, remove the roll pins and
separate the shift forks from the shift rods. Make sure
that you remember how the parts are assembled and
which parts go together. The forks are the only parts
that are not interchangeable. Inspect all parts for
burrs and excessive wear. Assembly is the reverse
of disassembly.
RCPH10TLB944AAL 1
Next operation:
Housing - Assemble (C.20.C)
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Housing - Assemble - Shifter housing

1. Apply lithium grease to the ball of the shift lever. In-
stall the shift lever in the shifter housing.
RCPH10TLB017ABL 1
2. 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.
RCPH10TLB021ABL 2
RCPH10TLB018ABL 3
4. Install the bushing.
RCPH10TLB019ABL 4
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5. Put the snap ring on the shift lever. Use a deep

well socket to push the snap ring into the snap ring
groove.
RCPH10TLB015ABL 5
6. Install the pins through the holes in the shifter hous-

ing so that the pins engage the slots in the shift lever.
RCPH10TLB013ABL 6
7. 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.
RCPH10TLB013ABL 7
8. Install the band or clamp on the boot. Use the side

cutters to engage the catch on the band.
RCPH10TLB012ABL 8
Next operation:
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Housing - Assemble - Transmission housing

1. If the four-wheel drive clutch tube (four-wheel drive
machine only) was removed from the front housing,
install the four-wheel drive clutch tube. Tighten the
fittings to a torque of 40 Nm (265 pound-inches).
RCPH10TLB023ABL 1
2. Install plugs (foam ear plugs work well) in the three oil
passages in the edge of the rear housing. Scrape all
sealing material from the sealing surface of the rear
housing. Prepare the sealing surface by rubbing with
a 3M Scotch-Brite fiber pad or equivalent. DO NOT
use steel wool or anything that can leave material
on the sealing surface. Flush the rear housing with
solvent.
RCPH10TLB028ABL 2
3. Install plugs (foam ear plugs work well) in the three

oil passages in the edge of the front housing. (The
plugs have not been installed in the picture above.)
Scrape all sealing material from the sealing surface
of the front housing. Prepare the sealing surface by
rubbing with a 3M Scotch-Brite fiber pad or equiv-
alent. DO NOT use steel wool or anything that can
leave material on the sealing surface. Flush the front
housing with solvent.
RCPH10TLB023ABL 3
4. Install the gasket for the valve plate on the front hous-
ing.
RCPH10TLB026ABL 4
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5. Put the valve plate into position.
RCPH10TLB024ABL 5
6. 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).
RCPH10TLB025ABL 6
7. If the test port plugs (1), the breather (2), and the
temperature sender (3) were removed from the rear
housing, install these parts. Tighten the test port
plugs (1) to a torque of 23 Nm (204 pound-inches).
RCPH10TLB918AAL 7
8. Put the bearing for the four-wheel drive shaft into
position in the rear housing.
RCPH10TLB917AAL 8
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9. Install the four-wheel drive clutch gear so that the

side with the lugs is up.
RCPH10TLB733AAL 9
10. 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 syn-
chronizers as shown. Begin to lower the assembly
into the rear housing.
RCPH10TLB029ABL 10
11. As you lower the assembly into the rear housing, also
begin to install the primary shaft so that the gears on
the primary shaft go into mesh with the 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
parts are in position, disconnect the lifting equipment.
RCPH10TLB913AAL 11
12. 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.
RCPH10TLB732AAL 12
NOTE: In steps 13 through 15, the photos show 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.
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13. Install the lower detent ball.
RCPH10TLB049ABL 13
14. Install the lower detent spring.
RCPH10TLB731AAL 14
15. 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).
RCPH10TLB730AAL 15
16. Repeat steps 13 through 15 to install the upper de-

tent ball, spring, copper washer, and plug.
17. Install the two detent balls in the groove between the
two shift rods.
RCPH10TLB729AAL 16
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18. Install the plate over the two detent balls.
RCPH10TLB728AAL 17
19. 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).
RCPH10TLB727AAL 18
20. Install the shift collars on the shift rods.
RCPH10TLB725AAL 19
21. Install the pins to fasten the shift collars to the shift
rods.
RCPH10TLB724AAL 20
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22. Scrape all sealing material from the sealing surface

of the rear cover. Prepare the sealing surface by
rubbing with a 3M Scotch-Brite fiber pad or equiv-
alent. DO NOT use steel wool or anything that can
leave material on the sealing surface. Wipe the seal-
ing surface with Loctite Safety Solvent or equivalent.
Apply a layer of Loctite 518 or Super bond 539 to the
sealing surface.
23. Put the rear cover in position. Make sure that the
dowel 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 50 Nm (37 pound-feet).
RCPH10TLB861AAL 21
NOTE: The above photo shows the shifter installed, the shifter should not be installed at this time.
24. Install a new O-ring on the shifter assembly. Use
clean oil to lubricate the O-ring. Put the shifter as-
sembly into position on the rear cover.
RCPH10TLB722AAL 22
25. Install the three Allen head bolts to fasten the shifter
assembly to the rear cover. Tighten the three Allen
head bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB721AAL 23
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26. If the tube was removed from the front housing, in-
stall the tube now. Tighten the hollow bolts to a
torque of 40 Nm (354 pound-inches).
RCPH10TLB027ABL 24
27. Install the input shaft and the reverse shaft together
as shown. If you are using the same reverse shaft,
make sure that you install it with the same end up as
when it was removed.
RCPH10TLB921AAL 25
28. On machines with four-wheel drive, install the four-

wheel drive shaft. Use clean transmission oil to lu-
bricate the bearing surfaces on the four-wheel drive
shaft. Make sure that the four-wheel drive shaft goes
through the four-wheel drive clutch gear, the thrust
washer, and the bearing.
RCPH10TLB719AAL 26
29. Wipe the sealing surface of the rear housing and the
front housing with Loctite Safety Solvent or equiva-
lent. Apply a layer of Loctite 518 or Super bond 529
to the sealing surface of the rear housing.
RCPH10TLB030ABL 27
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30. Remove the three plugs from the oil passages in the
rear housing (see arrows). Install three new O-rings
for the oil passages. Remove the three plugs from
the oil passages in the front housing.
RCPH10TLB920AAL 28
31. Use clean transmission oil to lubricate the bearing for

the primary shaft and the bearing for the secondary
shaft. Install the bearings.
RCPH10TLB720AAL 29
32. Install the front housing on the rear housing. Make

sure that the bearings on the shafts go straight into
the bores in the front housing. Push the front housing
all the way down on the rear housing.
RCPH10TLB718AAL 30
33. Install all of the housing bolts that fasten the rear
housing to the front housing. There are 13 of these
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
together, then tighten the bolts to a torque of 50 Nm
(37 pound-feet).
RCPH10TLB704AAL 31
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34. Install the three bolts that fasten from the front hous-
ing to the rear housing. Tighten the bolts to a torque
of 50 Nm (37 pound-feet).
RCPH10TLB033ABL 32
35. Use clean transmission oil to lubricate the bearing for

the four-wheel drive shaft. Install the bearing on the
four-wheel drive shaft.
RCPH10TLB034ABL 33
36. Use the CAS-2381 special tool to install a new seal in

the cover. Push just until the seal stops moving. DO
NOT use excessive force. Fill the cavity under the
lip of the seal with high temperature wheel bearing
grease.
RCPH10TLB022ABL 34
37. Install a new O-ring on the cover. Use clean trans-

mission oil to lubricate the O-ring.
RCPH10TLB711AAL 35
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38. Install the cover in the front housing.
RCPH10TLB710AAL 36
39. Install the three bolts that fasten the cover to the front
housing. Tighten the bolts to a torque of 23 Nm (204
pound-inches).
RCPH10TLB709AAL 37
40. Install a new O-ring in the four-wheel drive flange.

Use clean transmission oil to lubricate the O-ring.
RCPH10TLB707AAL 38
41. Install the four-wheel drive flange on the four-wheel

drive shaft.
RCPH10TLB706AAL 39
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42. Install the washer.
RCPH10TLB705AAL 40
43. Install and tighten the cap screw in the four-wheel

drive shaft to a torque of 139 Nm (103 pound-feet).
RCPH10TLB906AAL 41
44. Pull the input shaft toward the front of the transmis-
sion to get clearance for the snap ring.
RCPH10TLB031ABL 42
45. Install the snap ring on the bearing.
RCPH10TLB032ABL 43
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46. It will be easier to install the oil pump if you use a

guide stud as shown above. You can make a guide
stud by cutting the head from an M8 bolt.
RCPH10TLB036ABL 44
47. 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.
RCPH10TLB035ABL 45
48. If you used a guide stud, remove the guide stud. In-
stall the six bolts that fasten the oil pump in posi-
tion. Tighten the bolts to a torque of 23 Nm (204
pound-inches).
RCPH10TLB712AAL 46
49. Install the hub onto the output shaft as shown.
RCPH10TLB877AAL 47
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50. Install a reaction plate first.
RCPH10TLB876AAL 48
51. Install a friction plate and a wave spring, continue to

install a reaction plate, friction plate and wave spring
until all components are installed.
RCPH10TLB875AAL 49
52. Install the back plate as shown.
RCPH10TLB874AAL 50
RCPH10TLB873AAL 51
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54. Install the brake housing.
RCPH10TLB872AAL 52
55. Install the bolts, use an alternately tightening pattern

until the brake housing is tight against the transmis-
sion. Torque the bolts to 50 Nm (37 pound feet).
RCPH10TLB871AAL 53
56. Install the flange and a new O-ring.
RCPH10TLB869AAL 54
57. Install the bolt and washer.
RCPH10TLB868AAL 55
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58. Torque bolt to 139 Nm (103 pound feet).
RCPH10TLB870AAL 56
59. Make sure the orifice is in the brake housing, install

new O-rings.
RCPH10TLB855AAL 57
60. Install the brake solenoid, torque the solenoid to 20

Nm (15 pound feet).
RCPH10TLB854AAL 58
61. Install the pressure sensor switch into the brake

housing.
RCPH10TLB853AAL 59
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62. Slide the expander/protector onto the pump drive

shaft.
RCPH10TLB842AAL 60

380001428 expander/protector.
RCPH10TLB843AAL 61

RCPH10TLB844AAL 62

RCPH10TLB845AAL 63
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from the shaft.
RCPH10TLB846AAL 64
67. Install the bearing and snap ring on the pump drive
shaft, install the shaft in the rear housing.
68. Install the PTO shaft into the transmission.
RCPH10TLB850AAL 65

of the pump mount and rear cover. Prepare the sea
ling surface by rubbing with a 3M Scotch-Brite fiber
pad or equivalent. DO NOT use steel wool or any-
thing 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.
70. Install the pump mount on the rear housing, torque
bolts to 50 Nm (37 pound-feet).
RCPH10TLB849AAL 66
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71. Install the fitting for the dipstick tube.
RCPH10TLB808AAL 67
72. Install the dipstick tube.
RCPH10TLB909AAL 68
73. Install the dipstick.
RCPH10TLB908AAL 69
NOTE: The following photo shows the four-wheel drive priority valve installed and is for reference for the plug only.
74. 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).
RCPH10TLB703AAL 70
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75. Install the four-wheel drive priority valve in the oil filter
bore.
RCPH10TLB037ABL 71
RCPH10TLB702AAL 72
77. Install the spool.
RCPH10TLB701AAL 73
78. Install the fitting for the oil filter. Tighten the fitting to
a torque of 50 Nm (37 pound-feet).
RCPH10TLB700AAL 74
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79. Use clean transmission oil to lubricate the gasket on

the oil filter. Install the oil filter.
RCPH10TLB698AAL 75
80. Install the gasket for the four-wheel drive valve.
RCPH10TLB905AAL 76
81. Put the four-wheel drive valve in position on the gas-

ket.
RCPH10TLB697AAL 77
82. Install the three bolts that fasten the four-wheel drive
valve to the front housing. Tighten the bolts to a
torque of 23 Nm (204 pound-inches).
RCPH10TLB696AAL 78
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83. 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.
RCPH10TLB695AAL 79
84. Install the cover for the oil screen. Install the two
bolts that fasten the cover for the oil screen. Tighten
the bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB694AAL 80
85. Install the gasket for the transmission control valve.

Put the transmission control valve in position on the
gasket.
RCPH10TLB692AAL 81
86. Install the bolts that fasten the transmission control

valve to the front housing. Tighten the bolts in a
pattern alternating from front to back and side to side
until all the bolts are at a torque of 23 Nm (204 pound-
inches).
RCPH10TLB691AAL 82
NOTE: The following photo shows the drain plug for four wheel drive machines.
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87. Install a new O-ring on the drain plug. Lubricate the

O-ring with clean transmission oil. Install the drain
plug. Tighten the drain plug to a torque of 80 Nm (59
pound-feet).
RCPH10TLB690AAL 83
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TRANSMISSION Power Shuttle - Testing - Machine Will Not Move

Verify the transmission oil level. The oil level is correct. Go to next The transmission oil level is not cor-
Refer to TRANSMISSION Power step. rect. Check for leaks. Fill the trans-
Shuttle - General specification mission oil to the proper level. Re-
(C.20.C). Refer to Transmission fer to Transmission Fluid Level in the
Fluid Level in the Operator’s Man- Operator’s Manual.
ual.
Check for broken universal joint or The drive shaft and universal joint The drive shaft and universal joint
drive shaft. are free from damage. Go to next are damaged. Repair as required.
step.
Raise the rear wheels off the ground. The drive shaft turns when the trans- The drive shaft does not turn. Check
Check mission directional control lever the electrical connections to the
Verify that the drive shaft turns when (FNR) is moved into Forward or Re- transmission. Verify that there is
the transmission directional control verse. Go to next step. power to the clutch solenoids. Check
lever (FNR) is moved into Forward or fuse F-024.
Reverse.
Check transmission pressure and The transmission pressures and
pump flow. Refer to TRANSMIS- pump flow are within specifications. The transmission pressures
SION Power Shuttle - Pressure and pump flow are not within
test – 2 Wheel Drive, Test One — specifications. Possible causes
Engine at Idle 900 to 1100 rpm include:
(C.20.C). • Cold oil by-pass valve
may be stuck or dam-
aged.
• Faulty pressure regulator.
• Faulty transmission oil
pump. Refer to TRANS-
MISSION Power Shut-
tle - Check Checking
Supply Pump Pressure
(4WD Only) (C.20.C) or
TRANSMISSION Power
Shuttle - Test Check-
ing Supply Pump Flow
and Relief Pressure
(C.20.C).
Check the converter IN pressure. The converter IN pressure is within The converter IN pressure is not
Refer to TRANSMISSION Power specifications. Go to next step. within specifications. Check the
Shuttle - Test — Checking Con- transmission control valve. Repair
verter In Pressure (C.20.C) or replace as required. Refer to
Control valve - Inspect - Trans-
mission control valve (C.20.C)
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Check the Forward and Reverse The regulated clutch pressures are The regulated clutch pressures are
solenoid valve. Refer to TRANS- within the specified range. Go to not within the specified range. Re-
MISSION Power Shuttle - Test — next step. fer to Forward and Reverse solenoid
Checking Regulated Clutch Pres- troubleshooting in the Service Man-
sure (C.20.C). ual. .
Check regulated clutch pressure The regulated clutch pressure is
at test port 3. Refer to TRANS- within specifications. Refer to The regulated clutch pressure is
MISSION Power Shuttle - Test — TRANSMISSION Power Shuttle not within specifications. Possible
Checking Regulated Clutch Pres- - Pressure test – 2 Wheel Drive, causes include:
sure (C.20.C) Test One — Engine at Idle 900 to • Pressure remains zero in
1100 rpm (C.20.C) and TRANSMIS- Forward, Neutral and Re-
SION Power Shuttle - Pressure verse. Check the control
test — 2 Wheel Drive, Test Two — valve. Refer to Control
Engine at 2200 rpm (C.20.C) OR valve - Inspect - Trans-
TRANSMISSION Power Shuttle mission control valve
- Pressure test – 4 Wheel Drive, (C.20.C).
Test One — Engine at Idle 900 to
1100 rpm (C.20.C) and TRANSMIS- • Pressure is low, check the
SION Power Shuttle - Pressure control valve. Refer to
test — 4 Wheel Drive, Test Two — Control valve - Inspect
Engine at 2200 rpm (C.20.C). - Transmission control
valve (C.20.C).
• Pressure in Forward and
Reverse are the same.
Check the control valve.
Refer to Control valve -
Inspect - Transmission
control valve (C.20.C).
• Forward and Reverse
pressures are different.
Inspect the individual
clutch circuits. Refer to
Control valve - Inspect
- Transmission control
valve (C.20.C).
TRANSMISSION Power Shuttle - Testing - Will Not Go Into 4WD

Check for broken universal joint or The universal joint and front drive The universal joint or front drive shaft
front drive shaft. shaft are functioning properly. Go to are in need of repair. Repair or re-
next step. place as required.
Raise the machine off of the ground. The front drive shaft turns freely The front drive shaft does not turn
All four wheels should be able to ro- when the transmission control is in when the transmission control is in
tate freely. gear but the axle does not. There is gear. Go to next step.
Check a problem in the front axle. Repair
Verify that the front and rear drive as required.
shafts turn when the transmission
directional control lever (FNR) is
moved into Forward or Reverse.
84516378 05/07/2011
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Check the electrical connections to The solenoid is not receiving the cor-
The solenoid is receiving the cor-
the 4WD solenoid on the transmis- rect voltage Check the 4WD rocker
rect voltage and is operating prop-
sion. erly. Go to next step. switch connections. Verify the volt-
age to the switch. Check the fuse
F-017. Refer to Wiring harness
- Electrical schematic frame 05
Powershift Transmission Inputs
(A.30.A).
Check the 4WD solenoid. When The solenoid is performing correctly. The solenoid is not performing cor-
power is removed from the solenoid, Inspect the front drive shaft and rectly. Repair or replace as required.
4WD is engaged. clutch engagement teeth for dam-
age. Repair or replace as required.
TRANSMISSION Power Shuttle - Testing - Machine Hesitates When

Shifting Between Forward and Reverse
ual.
Check the pump supply pressure The pressure are all within specifica- The pressures are not within specifi-
at test port 10 for 4WD machines. tions. Go to next step. cations. Inspect the pressure regu-
Refer to TRANSMISSION Power lator. Repair or replace as required.
Shuttle - Check Checking Sup-
ply Pump Pressure (4WD Only)
(C.20.C). 2WD machines, test the
pressure on port 1 and port 2. Refer
to TRANSMISSION Power Shut-
tle - Test Checking Supply Pump
Flow and Relief Pressure (C.20.C)
Check the regulated clutch pressure The pressures are within specifica- The pressures were not within spec-
at test port 3. Refer to TRANS- tions. ifications. Inspect the modulation
MISSION Power Shuttle - Test — spool and piston for sticking or dam-
Checking Regulated Clutch Pres- age. Inspect the input shaft sealing
sure (C.20.C) rings and forward and reverse clutch
piston seals. Repair or replace as re-
quired.
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C.20.C / 211
TRANSMISSION Power Shuttle - Testing - Loss of Power

ual.
Verify that there is not a buildup of The wheel wells and drive train are There is mud and debris in the wheel
mud or foreign material on the inside free of mud and debris. Go to next well or along the drive train. Remove
of the wheel wells or along the drive step. all mud and debris. If the problem
train. still exists, go to nest step.
Perform a stall test according to The engine performed to specifica- The engine did not perform to speci-
the instructions in TRANSMISSION tions during the stall test. Go to next fications during the stall test. Repair
Power Shuttle - Test — Check- step. the engine as required.
ing Regulated Clutch Pressure
(C.20.C).
Check the regulated clutch pressure. The pressures are within specifi- The pressure is out of range. In-
Refer to TRANSMISSION Power cations. Go to TRANSMISSION spect the input shaft sealing rings
Shuttle - Test — Checking Regu- Power Shuttle - Testing — Ma- and clutch piston seals. Inspect the
lated Clutch Pressure (C.20.C) chine Will Not Move (C.20.C) forward and reverse clutch friction
discs. Repair or replace as required.
TRANSMISSION Power Shuttle - Testing - Transmission Oil is Too

Hot
ual.
The transmission oil cooler is clean. The transmission oil cooler is dirty
Check the transmission oil cooler for
Go to next step.
air flow restrictions. Clean the exte- and there are air flow restrictions.
rior of the transmission oil cooler as Clean the exterior of the transmis-
required. sion oil cooler as required. Go to the
next step if the problem still exists.
Check the converter IN pressure. The converter IN pressure is within The converter pressure is not within
Refer to TRANSMISSION Power specifications. Go to next step. specifications. Refer to TRANSMIS-
Shuttle - Test — Checking Con- SION Power Shuttle - Testing —
verter In Pressure (C.20.C) Machine Will Not Move (C.20.C)
84516378 05/07/2011
C.20.C / 212

Check the converter OUT pressure. The converter OUT pressure is The converter OUT pressure is
Refer to TRANSMISSION Power within specifications. Go to next not within specifications. Refer to
Shuttle - Test — Checking Con- step. TRANSMISSION Power Shuttle -
verter Out Pressure (C.20.C). Testing — Machine Will Not Move
(C.20.C)
Check the lube pressure. Refer to The lube pressure is within specifica-
TRANSMISSION Power Shuttle - tions. STOP. The pressure is not within
Test Checking Lubrication Pres- specifications. If the torque
sure (C.20.C). converter pressure is high and
the lube pressure is low, possible
causes include:
• Restriction in the oil
cooler. Replace the oil
cooler. The transmis-
sion oil cooler cannot be
flushed or cleaned out.
The complete oil cooler
must be replaced is a re-
striction is found.
• The oil cooler circuit is
restricted. Inspect the oil
cooler circuit and repair
as required.
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TRANSMISSION Power Shuttle - Testing Problem in the Parking

Brake System
Does the parking brake release? The parking brake will release. Re-
fer to Brake - Inspect (D.32.B) and Check the electrical and hydraulic
Brake - Test (D.32.B). If the parking circuits.
brake will not hold the machine, re- • Check the differential
pair or replace the disc brakes. lock pressure, refer to
TRANSMISSION Power
Shuttle - Test — Check-
ing Differential Lock
Valve (C.20.C). The dif-
ferential lock and the
parking brake are on the
same pressure circuit. If
the differential lock pres-
sure is within specifica-
tions, refer to TRANS-
MISSION Power Shut-
tle - Pressure test – 2
Wheel Drive, Test One
— Engine at Idle 900
to 1100 rpm (C.20.C)
and TRANSMISSION
Power Shuttle - Pres-
sure test — 2 Wheel
Drive, Test Two —
Engine at 2200 rpm
(C.20.C) OR TRANS-
MISSION Power Shut-
tle - Pressure test – 4
Wheel Drive, Test One
— Engine at Idle 900 to
1100 rpm (C.20.C) and
TRANSMISSION Power
Shuttle - Pressure test
— 4 Wheel Drive, Test
Two — Engine at 2200
rpm (C.20.C).
• Check fuses, replace
fuses as required.
• Check switch operation,
repair or replace as re-
quired.
• Measure the solenoid re-
sistance. The resistance
should be approximately
9.8 Ω at 20 °C (68 °F). Re-
place the solenoid as re-
quired.
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Index

Control valve - Assemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Control valve - Assemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Control valve - Disassemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control valve - Disassemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Control valve - Exploded view - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control valve - Exploded view - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control valve - Inspect - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Housing - Assemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Housing - Assemble - Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Housing - Disassemble - Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Housing - Disassemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Shaft - Adjust - Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Shaft - Assemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Shaft - Assemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Shaft - Assemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Shaft - Assemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Shaft - Assemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Shaft - Disassemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Shaft - Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Shaft - Disassemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Shaft - Disassemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Shaft - Disassemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Shaft - Disassemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Shaft - Exploded view - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Shaft - Exploded view - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Shaft - Exploded view - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shaft - Exploded view - Shift rod and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Shaft - Inspect - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Shaft - Inspect - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Shaft - Inspect - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Shaft - Inspect - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Shaft - Inspect - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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C.20.C / 215
Shaft - Inspect - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
TRANSMISSION Power Shuttle - Check Checking Supply Pump Pressure (4WD Only) . . . . . . . . . . . . . . . . . . . . 47
TRANSMISSION Power Shuttle - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSMISSION Power Shuttle - Exploded view - Four wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRANSMISSION Power Shuttle - Exploded view - Two wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TRANSMISSION Power Shuttle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION Power Shuttle - Hydraulic schema - Four Wheel Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . 18
TRANSMISSION Power Shuttle - Hydraulic schema - Two Wheel Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . 16
TRANSMISSION Power Shuttle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TRANSMISSION Power Shuttle - Pressure test - 4 Wheel Drive, Test Two - Engine at 2200 rpm . . . . . . . . . . . . . 61
TRANSMISSION Power Shuttle - Pressure test – 2 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm . . 54
TRANSMISSION Power Shuttle - Pressure test – 4 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm . . 60
TRANSMISSION Power Shuttle - Pressure test - 2 Wheel Drive, Test Two - Engine at 2200 rpm . . . . . . . . . . . . . 55
TRANSMISSION Power Shuttle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TRANSMISSION Power Shuttle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSMISSION Power Shuttle - Test - Checking Converter In Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
TRANSMISSION Power Shuttle - Test - Checking Converter Out Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TRANSMISSION Power Shuttle - Test - Checking Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
TRANSMISSION Power Shuttle - Test - Checking Regulated Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TRANSMISSION Power Shuttle - Test Checking Lubrication Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
TRANSMISSION Power Shuttle - Test Checking Supply Pump Flow and Relief Pressure . . . . . . . . . . . . . . . . . . . 50
TRANSMISSION Power Shuttle - Testing - Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
TRANSMISSION Power Shuttle - Testing - Machine Hesitates When Shifting Between Forward and Reverse 211
TRANSMISSION Power Shuttle - Testing - Machine Will Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
TRANSMISSION Power Shuttle - Testing - Transmission Oil is Too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
TRANSMISSION Power Shuttle - Testing - Will Not Go Into 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
TRANSMISSION Power Shuttle - Testing Problem in the Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . 214
TRANSMISSION Power Shuttle - Tool connection - Pressure Test Ports, Two Wheel Drive . . . . . . . . . . . . . . . . . . 57
TRANSMISSION Power Shuttle - Tool connection Pressure Test Ports 4 Wheel Drive . . . . . . . . . . . . . . . . . . . . . . 58
TRANSMISSION Power Shuttle - Tool connection Four Wheel Drive Port Identification . . . . . . . . . . . . . . . . . . . . . 59
TRANSMISSION Power Shuttle - Tool connection Two Wheel Drive Port Identification . . . . . . . . . . . . . . . . . . . . . 56
TRANSMISSION Power Shuttle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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TRANSMISSION Powershift - 20.E
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
TRANSMISSION Powershift
General specification - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General specification - S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Torque - S-type (SPS Power Synchro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General specification - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Special tools - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Torque - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General specification Trax Controller Pin Out Guide, S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . 17
FUNCTIONAL DATA
Exploded view - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exploded view - H-type - 1st, 3rd, 4th gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Exploded view - H-type - transmission assembly - 4 wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Exploded view - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exploded view - S-type (SPS Power Synchro) - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exploded view - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Exploded view - S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Exploded view - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Exploded view - S-Type (SPS Power Synchro) - Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Exploded view - S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Exploded view - S-type (SPS power synchro) - Shaft A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Exploded view - S-Type (SPS Power Synchro) - Shafts B - C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exploded view -S-type (SPS power synchro) - transmission assembly - 4 wheel drive shaft . . . . . . . . . 44
Exploded view - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Overview S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Hydraulic schema H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic schema S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Command
Overview S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Control valve
Drawing H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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Drawing S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Shaft
Exploded view - H-Type - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Clutch and gear
Exploded view - H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Electronic control
Detailed view Transmission Control Connectors, H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SERVICE
Disassemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Assemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Disassemble - S-type (SPS power synchro)- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Assemble - S-type (SPS power synchro) Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Remove - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Install - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Disassemble - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Cleaning - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Inspect - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Assemble - H-type - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
View Troubleshooting and Monitoring EST Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Tool connection Test Port and Component Locations, H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Tool connection Test Port and Component Locations, S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Warm up Heating the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Command
Service instruction Shift Rail Position Testing - S-type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Service instruction Shift Rail Position Physical Measurement - S-Type Transmission . . . . . . . . . . . . . . 195
Service instruction Hydraulic Pressure Testing Shift Rails - S-Type Transmission . . . . . . . . . . . . . . . . . 197
Control valve
Disassemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Assemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Shaft
Disassemble - S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Assemble -S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Disassemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Assemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Disassemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Assemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Disassemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Assemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Disassemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Assemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Disassemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Assemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
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Clutch and gear
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Back side measurement 285
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Front side measurement 290
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Dimension "D" measurement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Neutral position measure-
ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Check - S-Type (SPS Power Syncro) - Speed gears switches - Checking procedure . . . . . . . . . . . . . . 299
Housing
Disassemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Assemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Electronic control
Disassemble S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Assemble - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
DIAGNOSTIC
Testing Machine Will Not Move, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Testing Loss of Power, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Testing Wheels Rotate When Vehicle is Raised, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Testing Transmission Oil is Too Hot, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Testing Noisy Transmission, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Testing Irregular Clutch Activation, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Testing Gear Remains Engaged, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Testing Will Not Go Into 4WD, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Testing Problem in the Parking Brake System, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
TRANSMISSION Powershift - General specification - H-type

Type Carraro TLB1 2WD & 4WD SPS - SAHR Parking Brake
Lubricant - Carraro TLB1 2WD& 4WD SPS - SAHR Parking Brake

Total system capacity 19.5 l (20.6 US qt)
Refill capacity with or without filter change 16 l (16.9 US qt)
Type of fluid Case AKCELA Hy-Tran™ Ultra (CASE MS1209) (CNH
MAT 3505)
Specifications
NOTE: All pressures and flows must be measured with an oil temperature of 80 °C (176 °F).
Parameter Operating Pressure / Temperature

Forward and reverse clutch pressures at 2200 RPM 13.5 - 16.5 bar (196 - 239 psi), clutch activated
0 - 0.3 bar (0 - 4.4 psi), clutch released
Filter bypass valve 8 - 11 bar (116 - 160 psi)
Lube pressure 1 - 5 bar (15 - 73 psi)
Torque converter inlet pressure 3 - 9 bar (43.5 - 130.5 psi)
Differential lock 14 - 17 bar (203 - 246.5 psi)
Brake booster port 14 - 17 bar (203 - 246.5 psi)
Park brake pressure switch 9 - 11 bar (130.5 - 159.5 psi)
Park brake check port 13.5 - 15.5 bar (195.8 - 224.8 psi)
Vehicle may move during the park brake pressure check,
monitor park brake pressure from inside of cab by
removing the floor plate.
Pump flow at 900 RPM bench test before filter 19 l/min (5 US gpm)
1st gear at 900 RPM 11.5 - 14.5 bar (166.8 - 210.3 psi)
1st gear at 2200 RPM 13 - 15.5 bar (188.5 - 224.8 psi)
2nd gear at 900 RPM 14 - 16.5 bar (203.0 - 239.3 psi)
2nd gear at 2200 RPM 15.5 - 18 bar (224.8 - 261.0 psi)
3rd gear at 900 RPM 14 - 16.5 bar (203.0 - 239.3 psi)
3rd gear at 2200 RPM 15.5 - 18 bar (224.8 - 261.0 psi)
4th gear at 900 RPM 14 - 16.5 bar (203.0 - 239.3 psi)
4th gear at 2200 RPM 15.5 - 18 bar (224.8 - 261.0 psi)
4WD check port at 900 RPM 13.5 - 15 bar (195.8 - 217.5 psi)
4WD check port at 2200 RPM 14.5 - 16.5 bar (210.3 - 239.3 psi)
Forward/ Reverse clutch solenoids 7.15 Ω at 20 °C (68 °F)
4WD solenoid 7.15 Ω at 20 °C (68 °F)
Park brake solenoid 9.8 Ω at 20 °C (68 °F)
S 1/3 solenoid 7.15 Ω at 20 °C (68 °F)
S 2/4 solenoid 7.15 Ω at 20 °C (68 °F)
PWM 1/3 solenoid 7.25 Ω at 20 °C (68 °F)
PWM 2/4 solenoid 7.25 Ω at 20 °C (68 °F)
TRANSMISSION Powershift - General specification - S-Type

NOTE: All transmission pressures are to measured with an oil temperature of 80 °C (176 °F)
Item Pressure Minimum/Maximum

Control valve supply pressure 13 bar (189 psi) @ 900 RPM
17 bar (247 psi) @ 2400 RPM
Forward or reverse clutch pressure 12 bar (174 psi) @ 900 RPM
16 bar (232 psi) @ 2400 RPM
1N2, 3N4, 1st, 2nd, 3rd, 4th, HDL, 4WD 13 bar (189 psi) @ 900 RPM
17 bar (247 psi) @ 2400 RPM
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Item Pressure Minimum/Maximum

Torque converter inlet 1.5 bar (22 psi) @ 900 RPM
10 bar (145 psi) @ 900 RPM
Brake booster port 13 bar (189 psi) @ 900 RPM
17 bar (247 psi) @ 2400 RPM
TRANSMISSION Powershift - Special tools

RCPH11TLB020BAL 1
RCPH11TLB022BAL 2
CAS-10280 Flowmeter
RCPH11TLB024BAL 3
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TRANSMISSION Powershift - Torque - S-type (SPS Power Synchro)

(1) 28 N·m (20.7 lb ft)
(2) 23 N·m (17.0 lb ft)
(3) 40 N·m (29.5 lb ft)
(4) 50 N·m (36.9 lb ft)
(5) 139 N·m (102.5 lb ft)
(6) 50 N·m (36.9 lb ft)
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RCPH10TLB145GAL 1
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TRANSMISSION Powershift - General specification - H-type - 4WD

only
Type Carraro TLB2 PB CD 4WD 2WS
Lubricant
Total system capacity 17.9 l (18.9 US qt)
Refill capacity with or without filter change 11.3 l (11.9 US qt)
Type of fluid Case AKCELA Hy-Tran™ Ultra
TRANSMISSION Powershift - Special tools - H-type - 4WD only

380040161 - Teflon seal installation kit
RCPH10TLB828AAL 1
380002211 - Handle
RCPH10TLB059AAL 2
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380040161 - Teflon seal ring protector and shims - 1st,

3rd, 4th, and 4WD shafts
RCPH10TLB080AAL 3
380100081 - Teflon seal ring protector and shims - 2nd

gear
RCPH10TLB073AAL 4
380100082 - Teflon seal ring sizer - 2nd gear
RCPH10TLB074AAL 5
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380100083 - Teflon seal ring protector - 1st gea r
RCPH10TLB072AAL 6
380100084 - Teflon seal ring sizer - 1st gear
RCPH10TLB078AAL 7
380100085 - Teflon seal ring protector and shim - 1st gear

bushing
RCPH10TLB079AAL 8
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380100086 - Teflon seal ring sizer - 1st gear bushing
RCPH10TLB075AAL 9
380100087 - Holder bushing - 4WD shaft
RCPH10TLB076AAL 10
380100088 - Shaft puller/installer
RCPH10TLB077AAL 11
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CAS2379 - Holder and spring compressor
RCPH10TLB043ABL 12
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TRANSMISSION Powershift - Torque - H-type - 4WD only
RCPH10TLB14GAL 1
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RCPH10TLB15GAL 2
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TRANSMISSION Powershift - General specification Trax Controller

Pin Out Guide, S-Type Transmission
RCPH11TLB014FAL 1
Connector view from end of connector.
Pin Wire # Function Check Notes

1 2P01 Red TRAX B+ 12 volts at all times From fuse F-024
2 5207 Yellow In Gear input 12 volts in FWD or REV From forward and
reverse diodes
3 3053 White FWD Coil positive 12V PWM forward
4 3063 White REV Coil positive 12V PWM reverse
5 19ED Orange TRAX Key ON 12V when key is on From fuse F-009
6 3043 White S2 Solenoid pos 12V for 2nd gear
7 3593 White S3 Solenoid pos 12V for 3rd gear
8 19EC Orange TRAX Key ON 12V when key is on From fuse F-009
9 3013 White S1 Solenoid pos 12V for 1st gear
10 N/C
11 3573 White HDL Coil pos 12V when HDL is on
12 3073 Gray FWD Coil neg 12V PWM forward
13 N/C
14 N/C
15 3151 Pink 5V sensor + 5V to resistor network
16 21C7 Yellow Neutral Input 12V when in neutral From FNR Lever
17 0401 Blue Sensor ground Ground at all times For sensor and resistor
network
18 25A5 Light Forward input 12V when in forward From FNR lever
Blue
19 1902 Yellow Gear Command 1 12V in 1st and 4th From FNR lever
20 N/C
21 4062 Yellow Declutch input 12V when declutch From declutch switch
or SAHR relay
22 25C2 Yellow 4WD input 12V when 4WD From 4WD switch
23 N/C
24 N/C
25 3301 Blue Speed sensor Frequency 0–15 kHz Check using EST
26 N/C
27 E356 Yellow CAN High >2.5 VDC Connects to CAN bus
backbone
28 N/C
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Pin Wire # Function Check Notes

29 G101 Black TRAX Ground Ground at all times Chassis ground at
loader handle stud
30 N/C
31 N/C
32 N/C
33 N/C
34 19EB Orange TRAX key on 12V when key is on From fuse F-009
35 N/C
36 N/C
37 N/C
38 3023 White S4 Solenoid pos 12V for 4th gear
39 25X3 White 4WD coil pos 12V in 2nd Solenoid energized in
2WD
40 3083 Gray Rev coil neg 12V PWM reverse
41 N/C
42 N/C
43 3431 Yellow Temp sensor 10k ohms @ 25 °C (77 °F) Check using EST
44 3441 Yellow Pressure sensor Ground > 9.5 bar (138 psi) Check using EST
45 3451 Yellow 3rd/4th analog V 1, 2, 3 or 4 volts Depending on gear
position switches
46 25B6 Light Reverse Input 12V in reverse Fron FNR lever
Blue
47 3223 Yellow Gear command 2 12V in 3rd and 4th From FNR lever
48 N/C
49 3214 Yellow Kickdown input 12V to kickdown to 1st Active only when in
2nd gear
50 N/C
51 25S1 Yellow HDL input 12V when diff lock From HDL button on
loader handle
52 N/C
53 31S2 Yellow Tach Frequency from alternator Back up RPM signal
54 3541 Yellow 1st/2nd Analog V 1, 2, 3 or 4 volts Depending on gear
position switches
55 E346 Green CAN Low < 12VDC Connects to CAN bus
backbone
56 N/C
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TRANSMISSION Powershift - Exploded view - Powershift H-type

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)
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RCPH10TLB6GAL 1
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TRANSMISSION Powershift - Exploded view - H-type - 1st, 3rd, 4th

gear shaft
1st, 3rd, 4th gear shaft
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 bearing
13. Clutch piston 27. Lock ring 41. Clutch piston 55. Bearing
14. Teflon seal ring 28. Thrust washer 42. Teflon seal ring
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RCPH10TLB17GAL 1
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TRANSMISSION Powershift - Exploded view - H-type - transmission

assembly - 4 wheel drive shaft
Transmission Assembly
1. Bearing 13. Plug
2. Ring 14. Counter disk
3. Shim 15. Clutch pack
4. Washer 16. Thrust plate
5. Bellville washers 17. Lock ring
6. Bushing 18. Gear
7. O-ring 19. Needle bearing
8. Clutch piston 20. Spacer
9. O-ring 21. Bearing
10. Pin 22. Seal ring
11. O-ring 23. Seal ring
12. Clutch housing
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RCPH10TLB16GAL 1
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TRANSMISSION Powershift - Exploded view - S-Type (SPS Power

Synchro) - Filters
Filters
1. Drain plug 6. Spin-on filter
2. Cap screws 7. Connector
3. Cover 8. Cap screws
4. O-ring 9. Support
5. Oil filter 10. O-ring
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RCPH10TLB152GAL 1
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TRANSMISSION Powershift - Exploded view - S-type (SPS Power

Synchro) - Oil pump
Oil pump
1. Seal ring 3. Oil pump
2. Screws 4. O-ring
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RCPH10TLB153GAL 1
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Synchro) - Switches and sensors
Switches and sensors
1. Screws 9. Washer seal
2. Gaskets 10. Speed sensor
3. Pipe 11. Screw
4. Temperature sensor and thermostat 12. Bracket
5. Wiring harness 13. Switch gear
6. Regulating pressure valve 14. O-ring
7. Washer 15. Spring
8. Pressure switch 16. Switch detents
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RCPH10TLB154GAL 1
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Synchro) - Hydraulic control valve
Hydraulic control valve
1.Screw 7. Valve
2. Gasket 8. Valve
3 Control valve 9. Valve
4. Screws 10,11,12. O-ring
5. Screws 13. Screws
6. Valve
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RCPH10TLB155GAL 1
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Synchro) - Front housing
Front housing
1. O-ring 12. Gears
2. Retaining screw 13. Gears
3. Washer 14. Nut
4. O-ring 15. Oil pump
5. Flange 16. Screws
6. Cap screws 17. Housing
7. Cover 18. Primary shaft
8. O-ring 19. Secondary shaft
9. Seal 20. Front housing
10. Bearing 21. Drain plug
11. O-rings 22. Four-wheel drive clutch tube
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RCPH10TLB156GAL 1
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Synchro) - Rear cover
Rear cover
1. O-ring 11. Shims
2. Screws 12. Bearing snap ring
3. Flange 13. Screws
4. Rear cover 14. Drain plug
5. Teflon seal ring 15. Pin
6. PTO shaft 16.Rear front housing
7. Bearing 17. Housing
8. Snap ring 18. Screws
9. Screws 19. Parking brake
10. Screws 20. O-ring
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RCPH10TLB157GAL 1
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Synchro) - Gear pistons
Gear pistons
1. Screws 13. Screws
2. Plate 14. O-ring
3. Plugs 15. Drain plug
4. O-ring 16. Neutral piston
5. Plugs 17. O-ring
6. O-ring 18. 3rd gear piston
7. Shims 19. Seal ring
8. Screws 20. 1st gear piston
9. Neutral piston 21. O-ring
10. O-ring 22. 2nd gear piston
11. Screw 23. 4th gear piston
12. Oil circuit plate
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RCPH10TLB158GAL 1
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TRANSMISSION Powershift - Exploded view - S-type (SPS power

synchro) - Shaft A - D
Shafts A - D
1. Seal ring 11. Clutch plate lock ring 21. Teflon seal ring 31. Split pin
2. Snap ring 12. Needle cage 22. Teflon seal ring 32. Spring cover
3. Bearing 13. Spring cover 23. Snap ring 33. Snap ring
4. Spacer 14. Snap ring 24. Bearing 34. Spring
5. Sleeve 15. Spring 25. Thrust washer 35. Clutch drive plate
6. Gear 16. Shaft bearing 26. Gear 36. Clutch plate
7. Needle cage 17. Clutch drive plate 27. Sleeve 37. Shaft bearing
8. Thrust washer 18. Clutch plate 28. Thrust washer 38. Clutch piston
9. Split pin 19. Clutch piston 29. Lock ring 39. Teflon seal ring
10. Lock ring 20. Teflon seal ring 30. Teflon seal ring 40. Snap ring
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RCPH10TLB002GAN 1
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Synchro) - Shafts B - C
Shafts B - C
1. Bearing 12. Fourth speed gear 23. First/second speed 34. Springs
synchronizer assembly
2. Thrust washer 13. Snap ring 24. Steel ring 35. Hub
3. Third speed gear 14.4WD gear 25. Tapered friction ring 36.
4. Speed synchronizer 15. Outer race bearing 26. Sintered ring 37. First speed gear
assembly
5. Clutch ring 16. Snap ring 27. Synchronizer ring 38. Snap ring
6. Tapered friction ring 17. Thrust washer 28. Tapered friction ring 39. Inner race bearing
7. Sleeve 18. Second speed gear 29. Steel ring 40. Bearing
8. Plates 19. Split pin 30. Sintered ring 41. Shaft
9. Balls 20. Shims 31. Sleeve
10. Hub springs 21. Shaft 32. Balls
11. Synchronizer hub 22. Synchronizer ring 33. Plates
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RCPH10TLB160GAL 1
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TRANSMISSION Powershift - Exploded view -S-type (SPS power

synchro) - transmission assembly - 4 wheel drive shaft
Shaft E - 4WD
1. Snap ring 7. Four wheel drive clutch tube
2. Washer 8. Teflon sealing rings
3. Spacer 9. O-ring
4. Springs 10. Four wheel drive clutch gear
5. Sleeve 11. Bearing
6. O-ring
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RCPH10TLB161GAL 1
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Synchro) - Shift rails - forks
Shift rails - forks
1. Shift forks - 1st and 2nd gear 3. Shift rail
2. Shift forks - 3rd and 4th gear 4. Spring pins
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RCPH10TLB162GAL 1
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TRANSMISSION Powershift - Overview S-Type Transmission

The Powershift S-type transmission is an optional transmission introduced for the Case N series loader backhoes.
It is offered in 2WD and 4WD configurations, and incorporates a spring applied hydraulic release (SAHR) parking
brake at the rear transmission output shaft. Torque from the engine is transferred into the gearbox by a conventional
hydraulic torque converter. Gear reduction is achieved by constant-mesh spur gear type of gear train. Mechanically,
the Powershift S-type transmission is very similar to the Power shuttle transmission which has been used in the Case
loader backhoes for many years. This transmission offers 4 forward and 3 reverse speeds, and all speed range
gears are shifted by dog type synchronizers with blocking rings. The synchronizers are shifted by two shift forks, one
for the 1st and 2nd gears, and the other for the 3rd and 4th gears. The forks are mounted to shift rails which are
positioned by hydraulic pressure. Forward and Reverse are hydraulically engaged by multi-plate clutch packs. The
transmission oil to engage the clutches, shift, lubricate bearings, provide fluid for the torque converter, and cool the
transmission is supplied by a charge pump driven by tangs on the torque converter. The fluid to move the shift rails
and clutches is controlled by electric solenoids at a control valve manifold mounted to the top of the transmission. The
electric solenoids are actuated by an electronic transmission controller (TRAX). There is no automatic shifting mode
with this transmission, and the transmission will shift gears only as requested by input from the operator. A hydraulic
pump drive shaft engages splines in the front of the torque converter housing and carries torque through the center
of the hollow input shaft, engaging the machine hydraulic pump at a mounting flange at the rear. The Powershift
S-type transmission uses the same Case Hytran Ultra fluid as used in the hydraulic system, as well as the other two
transmission options for the N series loader backhoes.
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TRANSMISSION Powershift - Hydraulic schema H-Type
RCPH11TLB003HAL 1
(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
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(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
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TRANSMISSION Powershift - Hydraulic schema S-Type
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RCPH11TLB018GAL 1
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(1) SAHR parking brake (17) Forward

(2) SAHR park brake valve (18) S4
(3) TC relief (19) S2
(4) Breather (20) S3
(5) Cold oil by-pass (21) S1
(6) Oil filter and by-pass (22) Pressure sensor
(7) Screen (23) 1N2
(8) Pump (24) 3N4
(9) Pressure regulator (25) Forward clutch
(10) TC (26) Reverse clutch
(11) Oil cooler (27) SAHR 4WD
(12) Temperature sensor (28) 2nd gear
(13) Transmission control valve unit (29) 1st gear
(14) HDL (30) 4th gear
(15) 4WD (31) 3rd gear
(16) Reverse (32) Bearing
(33) Hose
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Command - Overview S-Type Transmission

Shift Rail Position Analog Voltages and Logical States
There is one gear position switch for each gear to monitor the position of the shift rails. The switch is open only when
the shift rail moves to that gear.
• A 5 V sensor supply voltage, ground, and the gear switches are connected to a “resistor network” that converts
the four switch states into two voltage signals.
• The 2 voltage signals should only be at distinct levels: 1V, 2V, 3V, or 4V.
• If the voltage signal is in between levels, like 3.55V for example, then look for water/contamination in the harness
especially in the 4 connectors for the gear position switches.
Gear 1 & 2 Analog Voltage Interpretation

1 Volt 1st gear switch is open, shift rail is in 1st gear position.
2 Volt Both 1st and 2nd gear switches are open, rail is between gears.
3 Volt Both 1st and 2nd gear switches are closed, rail is in neutral.
4 Volt 2nd gear switch is open, shift rail is in 2nd gear position.
Gear 3 & 4 Analog Voltage Interpretation

1 Volt 3rd gear switch is open, shift rail is in 3rd gear position.
2 Volt Both 3rd and 4th gear switches are open, rail is between gears.
3 Volt Both 3rd and 4th gear switches are closed, rail is in neutral.
4 Volt 4th gear switch is open, shift rail is in 4th gear position.
The TRAX controller interprets these analog voltages and creates a logical status for each of the 4 gear position
switches. The gear which is engaged is shown as “OFF”. The TRAX controller always makes sure the transmission
is shifted into neutral upon startup. After this initial check for neutral, the transmission will shift into which ever gear
is requested by the FNR lever position. The following table shows the gear switch logical status for each gear:
Gear Gear switch 1 logic Gear switch 2 logic Gear switch 3 logic Gear switch 4 logic
Neutral ON ON ON ON
1st OFF ON ON ON
2nd ON OFF ON ON
3rd ON ON OFF ON
4th ON ON ON OFF
Gear command 1 and 2 truth table

The selection of 1st through 4th gears with the FNR lever is commanded by 2 on/off inputs into the TRAX controller.
Note that Gear Command 2 is also controlled by the Comfort Steer Cutout Relay and fuse (See machine electrical
schematic). The TRAX controller interprets these two signals as follows:
Gear Command 1 (Trax pin 9) Command 2 (Trax pin 47)

1st 12 Volts 0 Volts
2nd 0 Volts 0 Volts
3rd 0 Volts 12 Volts
4th 12 Volts 12 Volts
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Control valve - Drawing H-Type
RCPH11TLB012FAL 1
Control Valve
(1) Pulse Width Modulation 2/4 solenoid, port (5) 4WD solenoid, port E
A
(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 (8) 1st/3rd solenoid, port H
D
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Control valve - Drawing S-Type

The transmission control valve, mounted on top of the transmission, contains the 8 actuating solenoids which control
the routing of the oil to shift the transmission.
RCPH11TLB016GAL 1
Solenoid Operation when energized

(1) HDL Engage the differential lock in the rear axle.
(2) 4WD Release the SAHR 4WD clutch for 2WD operation.
(3) REV PWM solenoid to ramp up pressure and engage the reverse clutch.
(4) FWD PWM solenoid to ramp up pressure and engage the forward clutch.
(5) S2 Engages 2nd gear by dumping pressure to the 1N2 piston.
(6) S4 Engages 4th gear by dumping pressure to the 3N4 piston.
(7) S3 Engages 3rd gear by sending pressure to the 3rd piston and dumping the 4th piston.
(8) S1 Engages 1st gear by sending pressure to the 1st piston and dumping the 2nd piston.
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Shaft - Exploded view - H-Type - Reverse shaft

Reverse shaft
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
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RCPH10TLB019GAL 1
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Clutch and gear - Exploded view - H-Type

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
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RCPH10TLB018GAL 1
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Electronic control - Detailed view Transmission Control Connectors,

H-Type
RCPH11TLB013FAL 1
Transmission control connector locations
(1) J1 Connector (2) J2 Connector
NOTE: Remove the floor plate to gain access to the transmission control connectors, J1 and J2.
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Transmission control J1 connector

1 S1/3 and S24 solenoid common
2 S1/3 solenoid
3 S2/4 solenoid
4 4WD and HDL solenoid common
5 4WD solenoid
6 Differential lock solenoid
7 Speed sensor
8 Speed sensor
9 Temperature sensor
10 Temperature sensor
11 Pressure sensor
12 Speed, Temperature and Pressure sensor
common
RCPH11TLB027BAL 2
Transmission control J2 connector

1 Forward solenoid
2 Forward solenoid
3 Reverse solenoid
4 Reverse solenoid
5 PWM 1/3 solenoid
6 PWM 1/3 solenoid
7 PWM 2/4 solenoid
8 PWM 2/4 solenoid
RCPH11TLB028BAL 3
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TRANSMISSION Powershift - Disassemble - S-Type (SPS Power

Synchro) - Filters
transmission
RCPH10TLB081AAL 1
2. Remove the two cap screws (1)which fasten the

cover for the oil screen. Remove the cover (2).
RCPH10TLB082AAL 2
3. Remove the oil filter (1)and the O-ring (2). Handle

and washer the filter according to authorized proce-
dures. In case of replacement, use only authorized
disposal procedures.
RCPH10TLB083AAL 3
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4. Remove the filter
RCPH10TLB249AAL 4
5. If necessary remove the connector for the filter.
RCPH10TLB092AAL 5
Next operation:
TRANSMISSION Powershift - Assemble (C.20.E)
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TRANSMISSION Powershift - Assemble - S-Type (SPS Power

Synchro) - Filters
Prior operation:
TRANSMISSION Powershift - Disassemble (C.20.E)
1. Assemble the O-Ring (1). Assemble the support

(2). Assemble the two screws (3)which fasten the
support of the spin-on filter. Torque to TRANSMIS-
SION Powershift - Torque (C.20.E) TRANSMIS-
SION Powershift - Torque (C.20.E)
RCPH10TLB035ACL 1
2. Assemble the connector (1)of the spin-on filter

(2). Torque wrench TRANSMISSION Powershift -
Torque (C.20.E).
RCPH10TLB034ACL 2
NOTE: Put a thin coat of oil transmission on the filter gasket, turn clockwise until the gasket makes contact with the
base, continue to turn the filter 2/3 turn.
3. Assemble filter and O-ring after having washed or
replaced it.
RCPH10TLB250AAL 3
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4. Assemble cover and screws Tightening torque 50

N·m (36.9 lb ft).
RCPH10TLB082AAL 4
5. Assemble plug (1). Tightening torque 139 N·m

(102.5 lb ft).
RCPH10TLB081AAL 5
Next operation:
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TRANSMISSION Powershift - Disassemble - S-type (SPS power

synchro)- Oil pump
1. Remove the screws.
RCPH10TLB094AAL 1
2. Remove the pump using the two levers.
RCPH10TLB251AAL 2
3. Remove the oil pump.
RCPH10TLB252AAL 3
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4. If replacement is necessary, remove the O-ring.
RCPH10TLB095AAL 4
5. Remove the seal ring, if replacement is necessary.
RCPH10TLB096AAL 5
Next operation:
TRANSMISSION Powershift - Assemble (C.20.E)
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TRANSMISSION Powershift - Assemble - S-type (SPS power

synchro) Oil pump
Prior operation:
1. Use a soft faced hammer and a suitable tool to as-

semble new seal ring (1) on oil pump (2).
RCPH10TLB014ACL 1
2. Install O-ring.
RCPH10TLB095AAL 2
3. Prior to oil pump assembly, ensure marks line up

between oil pump and half-case.
RCPH10TLB098AAL 3
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4. Grease the ring to keep it centered to the shaft slot

center line to help fit the pump.
RCPH10TLB099AAL 4
5. Apply a thin film of transmission oil on the coupling

seat with the front half-case. Assemble the oil pump.
RCPH10TLB099AAL 5
6. Install screws (1) and torque to TRANSMISSION

Powershift - Torque (C.20.E)
NOTE: Ensure the marks on the oil pump and bellhouse line up.
Next operation:
Electronic control - Disassemble (C.20.E)
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TRANSMISSION Powershift - Remove - Powershift H-type

hoe in the transport position with the stabilizers
down. Also put the loader bucket on the floor.
2. Raise the wheels off the floor high enough to re-
move 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.
3. 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.
RCPH10TLB060AAL 1
4. Loosen and remove the bolts, washers, and nuts (2)

that fasten the left rear mounting bracket to the front
drive shaft guard. Remove the left rear mounting
bracket.
RCPH10TLB062AAL 2
5. Put a floor jack under the drive shaft guard that will
hold the guard in place when the cap screws are
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.
RCPH10TLB061AAL 3
NOTE: Powershift transmission have spacers and O-rings on the bolts, they are required for assembly.
6. Remove the retainer and bolts that fasten the front
drive shaft to the transmission output shaft yoke. Re-
move 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).
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7. Remove the retainer and bolts that fasten the rear

drive shaft to the transmission output shaft yoke. Re-
move the rear drive shaft from the splined pinion
shaft on the rear axle.
RCPH10TLB069AAL 4
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).
8. Put a container under the drain plug that will hold
approximately 22 liters (6 U.S. gallons). Remove the
fill plug and the drain plug.
RCPH10TLB070AAL 5
9. Remove hydraulic pump from the transmission.

10. 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.
11. Disconnect the electrical connector for the transmis-
sion control valve harness, remove the mounting bolt
for the connector mounting bracket.
RCPH10TLB067AAL 6
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12. Disconnect the supply line (1) from the transmission,

disconnect the return line (2) from the transmission.
RCPH10TLB167ABL 7
13. Disconnect the electrical connector for the SAHR

parking brake.
14. Disconnect the hose for the differential lock.
15. Remove the starter from the engine. Remove the
access cover from the bell housing.
RCPH10TLB026AAL 8
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16. Install the engine turning tool, 380000988, to turn the

flywheel for access to the cap screws.
RCPH10TLB005BAL 9
17. Loosen and remove the four cap screws that fasten
the flywheel to the flex plate.
RCPH10TLB027AAL 10
NOTE: During installation make sure that the converter is in the correct position on the transmission shaft. Align the
hole sin the flex plate with the holes in the flywheel. 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).
18. Use acceptable stands or blocks to secure the en-
gine in place.
19. Install a transmission jack under the transmission
and apply light pressure.
20. Loosen and remove the 12 cap screws and flat wash-
ers that fasten the transmission to the engine.
21. Remove both the left and right transmission mount-
ing cap screw.
NOTE: During installation tighten the transmission mounting cap screws to a torque of 90 to 100 Nm (67 to 73 pound-
feet), install two nuts on the left mount.
22. Carefully slide the transmission away from the en-
gine. Lower to the ground and remove from under
the machine.
Next operation:
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TRANSMISSION Powershift - Install (C.20.E)
84516378 05/07/2011
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TRANSMISSION Powershift - Install - Powershift H-type

NOTE: Install the transmission in reverse of removal.
1. Mount the transmission to the engine, torque the
mounting bolts to 52 to 57 Nm (38 to 42 pound-feet).
NOTE: Rotate the torque converter through the bottom hole of the bell housing and slide it against the adapter plate.
Align the bolt hole with the bosses on the torque converter.
2. Install and hand tighten all four cap screws that fas-
ten the flywheel to the torque converter.
3. Final torque the cap screws to 52 to 57 NM (38 to 42
pound-feet).
4. Remove the engine turning tool.
5. Install the access cover on the bell housing. Install
the starter on the engine.
RCPH10TLB026AAL 1
NOTICE: Before starting the engine, do the following.

6. Make sure the transmission drain plug has been in-
stalled and tightened.
7. Fill the transmission.
NOTE: If removed, install the rear wheels.

8. Remove the stands from under the machine and
lower the machine to the ground.
9. 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.
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TRANSMISSION Powershift - Disassemble - H-type

1. Clean exterior of the transmission and place on a
suitable stand.
transmission.
RCPH10TLB081AAL 1
3. Remove the two cap screws which fasten the cover

for the oil suction filter.
RCPH10TLB082AAL 2
4. Remove the cover, filter, and O-ring.
RCPH10TLB083AAL 3
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5. Remove the filter.
RCPH10TLB249AAL 4
6. If necessary remove the connector for the filter.
RCPH10TLB092AAL 5
7. Loosen the oil filter bypass valve.
RCPH10TLB084AAL 6
8. Remove the filter bypass valve.
RCPH10TLB085AAL 7
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9. Remove the breather from the transmission only if

the breather is damaged or leaking.
RCPH10TLB086AAL 8
10. Remove forward clutch test port plug if O-ring is leak-

ing, replace O-ring and torque to 30 Nm (22 pound
feet).
RCPH10TLB087AAL 9
11. Remove reverse clutch test port plug if O-ring is leak-

ing, replace O-ring and torque to 30 Nm (22 pound
feet).
RCPH10TLB088AAL 10
12. Remove lubrication pressure test port plug if O-ring

is leaking, replace O-ring and torque to 30 Nm (22
pound feet).
RCPH10TLB089AAL 11
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13. Remove the speed sensor.
RCPH10TLB090AAL 12
14. Remove the thermostat.
RCPH10TLB091AAL 13
15. Remove the torque converter from the transmission.
RCPH10TLB093AAL 14
16. Remove the cap screws securing the pump in the

transmission.
RCPH10TLB094AAL 15
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17. Loosen the pump from the transmission with two pry
bars.
RCPH10TLB251AAL 16
18. Remove the pump from the transmission.
RCPH10TLB252AAL 17
19. Remove the O-ring from the pump.
RCPH10TLB095AAL 18
20. Remove the seal from the pump.
RCPH10TLB096AAL 19
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21. Tag and remove the lubrication tube.
RCPH10TLB100AAL 20
22. Tag and remove the 4th gear tube (1), 2nd gear tube
(2), 3rd gear tube (3), and the 1st gear tube (4.)
RCPH10TLB101AAL 21
23. Tag and remove the lubrication tube.
RCPH10TLB254AAL 22
24. Loosen the front flange cap screw.
RCPH10TLB596AAL 23
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25. Remove the cap screw and the front flange.
RCPH10TLB102AAL 24
26. Remove the seal from the housing.
RCPH10TLB103AAL 25
Parking Brake
27. Loosen the flange bolt.
RCPH10TLB596AAL 26
28. Remove the flange bolt and washer.
RCPH10TLB868AAL 27
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29. Remove the O-ring and flange.
RCPH10TLB869AAL 28
NOTE: The transmission was removed from the machine for clarity only, it is not necessary to remove the transmis-
sion.
30. Loosen brake housing bolts.
RCPH10TLB871AAL 29
31. Remove bolts (A), and alternately loosen bolts (B) to

release the load of bellville washers.
RCPH10TLB594AAL 30
NOTICE: The housing is under spring pressure, failure to follow these instructions could damage the transmission.
84516378 05/07/2011
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32. Remove the brake cover from the transmission.
RCPH10TLB872AAL 31
33. Remove and discard the O-ring.
RCPH10TLB873AAL 32
34. Remove back plate.
RCPH10TLB874AAL 33
35. Remove the springs and remove the friction disc.
RCPH10TLB875AAL 34
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36. Remove the reaction plates.
RCPH10TLB876AAL 35
37. Remove the hub.
RCPH10TLB877AAL 36
38. Remove the retaining plate.
RCPH10TLB599AAL 37
39. Remove and discard the O-rings and backup ring

from the retaining plate.
RCPH10TLB600AAL 38
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40. Use CAS2379 to compress the bellville washers, re-

move the retaining ring.
RCPH10TLB601AAL 39
41. Remove the piston from the brake housing.
RCPH10TLB602AAL 40
42. Remove and discard the O-rings and backup rings

from the piston.
RCPH10TLB603AAL 41
43. Remove the bellville washers from the brake hous-

ing.
RCPH10TLB604AAL 42
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44. Remove the seal from the brake housing.
RCPH10TLB605AAL 43
45. Remove and discard the O-ring from the brake hous-
ing.
RCPH10TLB606AAL 44
PTO Shaft
46. Remove the mounting screws for the pump flange.
RCPH10TLB255AAL 45
47. Remove the flange from the transmission.
RCPH10TLB104AAL 46
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48. Remove the PTO shaft from the transmission.
RCPH10TLB256AAL 47
49. Remove the teflon seal ring from the PTO shaft.
RCPH10TLB105AAL 48
50. Remove the snap ring from the PTO shaft.
RCPH10TLB257AAL 49

the PTO shaft.
RCPH10TLB106AAL 50
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Housing separation
52. Remove the cap screws that fasten the front and rear
housings together.
RCPH10TLB258AAL 51
53. Use pry bars in the slots to loosen the front housing
from the rear housing.
RCPH10TLB259AAL 52
54. Attach suitable lifting equipment to the front housing

and remove it from the transmission.
RCPH10TLB260AAL 53
55. Remove and discard the O-rings from the rear hous-
ing.
RCPH10TLB107AAL 54
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56. Pull the input shaft and reverse shaft together.
RCPH10TLB109AAL 55
57. Remove the cap screws and the shield from the 4
wheel drive clutch pack.
RCPH10TLB144AAL 56
58. Attach lifting bracket 380100088 to the shafts, re-

move them from the transmission.
RCPH10TLB145AAL 57
Input shaft
59. Remove the teflon seal ring.
RCPH10TLB110AAL 58
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RCPH10TLB111AAL 59
61. Install a bearing puller under the gear as shown, do

not install the bearing puller between the gear and
the bearing. Insert a shaft protector between the
puller and the end of the input shaft.
RCPH10TLB112AAL 60
RCPH10TLB113AAL 61
RCPH10TLB114AAL 62
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RCPH10TLB115AAL 63
RCPH10TLB116AAL 64
RCPH10TLB262AAL 65
RCPH10TLB262AAL 66
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68. Remove the lock ring.
RCPH10TLB117AAL 67
69. Use pry bars to lift and remove the thrust plate.
RCPH10TLB118AAL 68
70. Remove the clutch plates and the clutch discs.
RCPH10TLB119AAL 69
71. Place a mark below a groove on the clutch housing.
RCPH10TLB120AAL 70
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72. Place a mark on each thrust plate and the lock ring.
RCPH10TLB263AAL 71
73. Install the top piece of the CAS2379 special tool (not
shown). Use the three threaded rods and nuts to
fasten the two pieces together.
RCPH10TLB121AAL 72
RCPH10TLB264AAL 73
CAS2379 special tool (not shown).
RCPH10TLB121AAL 74
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RCPH10TLB122AAL 75
RCPH10TLB265AAL 76
78. Use compressed air in the piston pressure port to

remove the piston.
RCPH10TLB123AAL 77
protection.
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79. Remove the piston seal rings and backup rings.
RCPH10TLB266AAL 78
80. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 79
RCPH10TLB267AAL 80
82. Insert a shaft protector between the puller and the

end of the input shaft. Remove the bearing.
RCPH10TLB125AAL 81
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83. Remove the bearing and thrust washer.
RCPH10TLB126AAL 82
RCPH10TLB303AAL 83
RCPH10TLB127AAL 84
86. Repeat steps 68 to 78 and disassemble the clutch.
84516378 05/07/2011
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Reverse shaft
end of the reverse shaft. Remove the bearing.
RCPH10TLB128AAL 85
88. Turn the shaft over and insert a shaft protector be-
tween the puller and the end of the reverse shaft.
Remove the bearing.
RCPH10TLB268AAL 86
Primary shaft
89. Remove the teflon seal ring from the primary shaft.
RCPH10TLB272AAL 87
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90. Install a puller on the gear as shown.
RCPH10TLB273AAL 88
91. Remove the bearing and gear.
RCPH10TLB146AAL 89
RCPH10TLB274AAL 90
RCPH10TLB147AAL 91
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RCPH10TLB275AAL 92
RCPH10TLB148AAL 93
96. Remove the needle bearings and thrust washer.
RCPH10TLB149AAL 94
97. Remove the roll pin and spacer.
RCPH10TLB150AAL 95
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98. Drive the thrust plate down away from the lock ring.
RCPH10TLB276AAL 96
RCPH10TLB277AAL 97
100. Remove the thrust plate from the clutch pack.
RCPH10TLB151AAL 98
101. Remove discs and plates from the clutch pack.
RCPH10TLB278AAL 99
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RCPH10TLB152AAL 100
RCPH10TLB279AAL 101
RCPH10TLB152AAL 102
105. Remove the retaining ring and spring.
RCPH10TLB153AAL 103
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RCPH10TLB154AAL 104
107. Use compressed air and remove the piston from the
clutch pack.
RCPH10TLB155AAL 105
RCPH10TLB266AAL 106
RCPH10TLB156AAL 107
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110. Use a puller and remove the bearing from the shaft.
RCPH10TLB157AAL 108
1st, 3rd, and 4th gear shaft

111. Use a puller and remove the bearing.
RCPH10TLB172AAL 109
112. Remove the bushing.
RCPH10TLB173AAL 110
113. Remove the gear and clutch from the shaft.
RCPH10TLB174AAL 111
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114. Push down on the thrust plate.
RCPH10TLB284AAL 112
RCPH10TLB285AAL 113
RCPH10TLB175AAL 114
RCPH10TLB176AAL 115
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fasten the two pieces together, remove the snap ring.
RCPH10TLB286AAL 116
RCPH10TLB177AAL 117
120. Remove the snap ring, retaining ring, and spring.
RCPH10TLB287AAL 118
121. Use compressed air and remove the piston from the
clutch pack.
RCPH10TLB304AAL 119
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122. Remove the teflon ring and O-ring from the piston.
RCPH10TLB178AAL 120
123. Remove the teflon seal ring and O-ring from the
clutch housing.
RCPH10TLB179AAL 121
124. Use a puller and remove the gear.
RCPH10TLB180AAL 122
125. Remove the needle bearings and spacer.
RCPH10TLB181AAL 123
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126. Remove the O-rings from inside the spacer.
RCPH10TLB182AAL 124
127. Remove the teflon rings from the outside of the

spacer.
RCPH10TLB183AAL 125
RCPH10TLB288AAL 126
RCPH10TLB184AAL 127
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RCPH10TLB071AAL 128
RCPH10TLB310AAL 129
RCPH10TLB185AAL 130
RCPH10TLB289AAL 131
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RCPH10TLB186AAL 132
RCPH10TLB187AAL 133
RCPH10TLB121AAL 134
RCPH10TLB264AAL 135
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RCPH10TLB121AAL 136
RCPH10TLB188AAL 137
140. Used compressed air to remove the piston.
RCPH10TLB305AAL 138
141. Remove the piston and sleeve from the clutch hous-
ing.
RCPH10TLB189AAL 139
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RCPH10TLB266AAL 140
143. Turn the shaft over and remove the teflon seal rings.
RCPH10TLB190AAL 141
RCPH10TLB191AAL 142
RCPH10TLB192AAL 143
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RCPH10TLB193AAL 144
147. Remove the needle bearing and thrust washer.
RCPH10TLB194AAL 145
RCPH10TLB290AAL 146
RCPH10TLB310AAL 147
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RCPH10TLB185AAL 148
RCPH10TLB289AAL 149
RCPH10TLB186AAL 150
RCPH10TLB187AAL 151
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RCPH10TLB121AAL 152
RCPH10TLB264AAL 153
RCPH10TLB121AAL 154
RCPH10TLB188AAL 155
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158. Used compressed air to remove the piston.
RCPH10TLB305AAL 156
159. Remove the piston and sleeve from the clutch hous-
ing.
RCPH10TLB189AAL 157
RCPH10TLB195AAL 158
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4 wheel drive shaft

161. Remove the teflon seals.
RCPH10TLB221AAL 159
162. Use a puller and remove the bearing, remove the

spacer.
RCPH10TLB297AAL 160
RCPH10TLB222AAL 161
RCPH10TLB298AAL 162
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165. Locally fabricate a pipe with notch to access the snap

ring as shown. Remove the snap ring.
RCPH10TLB223AAL 163
166. Remove shims and thrust washer.
RCPH10TLB299AAL 164
167. Remove the bellville washers and spacer.
RCPH10TLB224AAL 165
168. Push down on the thrust plate and remove the lock
ring.
RCPH10TLB225AAL 166
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169. Remove thrust plate, discs, and plates from the

clutch pack.
RCPH10TLB226AAL 167
RCPH10TLB227AAL 168
171. Use a punch and remove the pistons.
RCPH10TLB228AAL 169
172. Remove the O-rings from the piston.
RCPH10TLB603AAL 170
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173. Remove the O-rings from the pistons.
RCPH10TLB229AAL 171
Next operation:
TRANSMISSION Powershift - Cleaning (C.20.E)
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TRANSMISSION Powershift - Cleaning - H-type - 4WD only

Cleaning
1. Clean all parts thoroughly using solvent type clean-
ing fluid. It is recommended that parts be immersed
in cleaning fluid and moved up and down slowly until
all old lubricant and foreign material is dissolved and
parts are thoroughly cleaned .
Bearings
2. Remove bearings from cleaning fluid and strike flat
against a block of wood to dislodge solidified par-
ticles of lubricant. Immerse again in cleaning fluid
to flush out particles. Repeat above operation until
bearings are thoroughly clean. Dry bearings using
moisture-free compressed air. Be careful to direct
air stream across bearing to avoid spinning. Do not
spin bearings when drying. Bearings may be rotated
slowly by hand to facilitate drying process.
Housings
3. Clean interior and exterior of housings, bearing caps,
etc., thoroughly. Cast parts may be cleaned in hot so-
lution tanks with mild alkali solutions providing these
parts do not have ground or polished surfaces. Parts
should remain in solution long enough to be thor-
oughly cleaned and heated. This will aid the evapo-
ration of the cleaning solution and rinse water. Parts
cleaned in solution tanks must be thoroughly rinsed
with clean water to remove all traces of alkali. Cast
parts may also be cleaned with steam cleaner. All
parts cleaned must be thoroughly dried immediately
by using moisture-free compressed air or soft, lint
free absorbent wiping rags free of abrasive materials
such as metal fillings, contaminated oil, or lapping
compound.
Next operation:
TRANSMISSION Powershift - Inspect (C.20.E)
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TRANSMISSION Powershift - Inspect - H-type - 4WD only

Inspection
1. The importance of careful and thorough inspection
of all parts cannot be overstressed. Replacement
of all parts showing indication of wear or stress will
eliminate costly and avoidable failures at a later date.
Bearings
2. 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.
Oil Seals, Gaskets, etc.

3. Replacement of spring load oil seals, O-rings, metal
sealing rings, gaskets, and snap rings is more eco-
nomical when uni t is disassembled than premature
overhaul to replace these parts at a future time. Fur-
ther loss of lubricant through a worn seal may result
in failure of other more expensive parts of the assem-
bly. Sealing members should be handled carefully,
particularly when being installed. Cutting, scratch-
ing, or curling under of lip of seal seriously impairs its
efficiency. When assembling new metal type sealing
rings, same should be lubricated with coat of chassis
grease to stabilize rings in their grooves for ease of
assembly of mating members. Lubricate all O-rings
and seals with recommended type transmission fluid
before assembly.
Gears and Shafts

4. Examine teeth on all gears carefully for wear, pit-
ting, chipping, nicks, cracks, or scores. If gear teeth
show spots where case hardening is worn through
or cracked, replace with new gear. Small nicks may
be removed with suitable hone. Inspect shafts and
quills to make certain they are not sprung, bent, or
splines twisted, and that shafts are true.
Housing, Covers, etc.

5. Inspect housings, covers and bearing caps to be cer-
tain they are thoroughly clean and that mating sur-
faces, bearing bores, etc., are free from nicks or
burrs. Check all parts carefully for evidence of cracks
or condition which would cause subsequent oil leaks
or failures.
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Clutches
6. Verify the total thickness of the clutch kit is within the
wear limits, if not, replace the clutch kit. Verify that
all the clutch plates do not appear burned or that the
friction material is not damaged and the splines are
intact. If using new clutch kit, soak the clutch plates
in clean transmission fluid for at least one hour before
assembly.
Forward and Reverse Clutch Kits

Number of clutch plates 6
Number of steel plates 6
Nominal clutch plate thickness 2.40 ± 0.05 MM (0.095 ± 0.002 INCHES)
Maximum clutch plate wear 0.25 MM (0.010 INCHES)
Nominal clutch kit thickness *29.00 - 29.20 MM (1.14 to 1.14 INCHES)
Maximum clutch kit wear 3.0 MM (0.12 INCHES)
*Measured under a load of 163 KG (360 Pound force)
1st Gear Clutch Kit

Maximum clutch kit wear 1.8MM (0.07 INCHES)
2nd Gear Clutch Kit

3rd Gear Clutch Kit

4th Gear Clutch Kit

84516378 05/07/2011
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4WD Gear Clutch Kit

Maximum clutch kit wear 2.7 MM (0.11 INCHES)
84516378 05/07/2011
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TRANSMISSION Powershift - Assemble - H-type -

1. Install new seal rings on clutch piston.
RCPH10TLB603AAL 1
2. Install new O-rings on the pins.
RCPH10TLB229AAL 2
3. Install the pins on the clutch piston.
RCPH10TLB300AAL 3
4. Lubricate the piston and pin O- rings with transmis-

sion fluid.
RCPH10TLB301AAL 4
84516378 05/07/2011
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5. Use a soft faced hammer and drive the clutch piston

into the clutch housing.
RCPH10TLB230AAL 5
6. Turn the clutch housing over, install the counter disk

in the clutch housing with the tapered edge facing
down.
RCPH10TLB231AAL 6
7. Install the clutch kit starting with a drive plate followed

by a clutch disc, continue to install until all clutch
plates and discs are installed.
RCPH10TLB232AAL 7
8. Install the thrust plate.
RCPH10TLB233AAL 8
84516378 05/07/2011
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9. Install the retaining ring.
RCPH10TLB234AAL 9
10. Align the clutch discs using a screwdriver then install

the gear.
RCPH10TLB235AAL 10
11. Install the needle bearing and the spacer.
RCPH10TLB236AAL 11
12. Use a suitable driver and install the bearing.
RCPH10TLB237AAL 12
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13. Turn the clutch pack over. Make sure that the disk/
counter disk pack and the piston are seated.
RCPH10TLB238AAL 13
14. Install the spacer and washer.
RCPH10TLB239AAL 14
15. Using a thickness gauge measure the gap between

the washer and lock ring (X).
RCPH10TLB240AAL 15
16. Subtract from X a known value of S1 (S1=1.80MM),

the result is S for the shim thickness required.
(X-1.80)=Shims required.
RCPH10TLB241AAL 16
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17. Select the shim thickness value among the range of

available shims.
RCPH10TLB242AAL 17
NOTE: Make sure there will be a stroke of 1.70 to 1.90 MM after shims are installed.
18. Remove the lock ring and washer from the shaft.
RCPH10TLB243AAL 18
19. Install the bellville washers, the washer must be in-

stalled with the outer rings touching and the inner
rings have a gap.
RCPH10TLB302AAL 19
20. Install the washer and the shim(s) that was deter-
mined in step 16.
RCPH10TLB244AAL 20
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21. Locally fabricate a pipe with notch to access the snap

ring as shown. Compress the bellville washers and
install the lock ring.
RCPH10TLB245AAL 21
RCPH10TLB246AAL 22
23. Use pusher 380001928 to install the teflon seal rings.

Using spacer and protector for the inner ring and
spacer for the outer ring from kit 380040161. Size
the seal rings using sizer 380001427.
RCPH10TLB247AAL 23
24. Mount a dial indicator as shown. Apply 10 Bar (145

psi) to the piston port, the stroke should be between
2.3 to 2.4 MM (0.090 to 0.095 inches).
RCPH10TLB248AAL 24
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1st Gear Clutch Pack

25. On the 1st gear clutch, install a new teflon seal ring
using protector 380100083 and pusher 380001928.
Install a new O-ring.
RCPH10TLB196AAL 25
26. Size the teflon seal ring using sizer 380100084.
RCPH10TLB197AAL 26
27. Install a new teflon seal ring and O-ring on the clutch
piston.
RCPH10TLB198AAL 27
28. Apply clean transmission fluid to the seal rings, install

the piston.
RCPH10TLB291AAL 28
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29. Insert the spring, thrust washer, and snap ring.
RCPH10TLB199AAL 29
30. Place the clutch in CAS2379 special tool (not

shown), and compress the spring.
RCPH10TLB177AAL 30
31. Install the snap ring, make sure the snap ring is prop-
erly seated.
RCPH10TLB286AAL 31
32. Remove the top plate of the spring compressor

CAS2379.
RCPH10TLB200AAL 32
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33. Starting with a reaction plate, install 6 reaction plates

and 6 friction discs. Then install the thrust plate into
the clutch housing.
RCPH10TLB201AAL 33
34. Install the retaining ring, make sure the retaining ring
is properly seated.
RCPH10TLB285AAL 34
35. Apply air pressure to the clutch pack to seat the thrust
plate against the retaining ring and release the air
pressure. Use a feeler gauge and measure the dis-
tance 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.
RCPH10TLB202AAL 35
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4th Gear Clutch Pack

36. Install new O-rings and backup rings on the 4th gear
piston.
RCPH10TLB266AAL 36
37. Apply a thin film of grease on the piston rings.
RCPH10TLB160AAL 37
38. Use 380001926 clutch pack piston installer to protect

the inner seal and install the clutch piston.
RCPH10TLB280AAL 38
39. Install the spring sleeve.
RCPH10TLB161AAL 39
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40. Install the spring and thrust washer.
RCPH10TLB203AAL 40

RCPH10TLB162AAL 41
erly seated.
RCPH10TLB163AAL 42

CAS2379.
RCPH10TLB162AAL 43
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44. Install a new roll pin in the shaft.
RCPH10TLB204AAL 44
45. Apply a thin coat of grease to the bottom of the thrust

washer to keep the washer in place while turning the
shaft.
RCPH10TLB292AAL 45
46. Align the slot in the thrust washer with the roll pin.
RCPH10TLB293AAL 46

and 9 friction discs.
RCPH10TLB205AAL 47
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48. Install the needle bearing and the thrust plate.
RCPH10TLB206AAL 48
is properly seated.
RCPH10TLB207AAL 49
pressure. Align the clutch disc splines.
RCPH10TLB208AAL 50
51. Use a feeler gauge and measure the distance be-

tween the thrust plat and the first clutch disc, a mea-
surement of 1.50 to 1.95 mm (0.060 to 0.075 inches)
should be obtained. If the distance is not within spec-
ification, check the clutch assembly.
RCPH10TLB209AAL 51
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52. Install the clutch hub into the clutch pack, make sure
the clutch hub seats completely.
RCPH10TLB210AAL 52
Assembling 1st Gear Onto The Shaft

53. Put 1st gear clutch hub onto the shaft.
RCPH10TLB294AAL 53
54. Put 1st gear clutch pack onto 1st gear clutch hub,
make sure the clutch hub seats completely.
RCPH10TLB174AAL 54
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55. Use a suitable driver and install the bushing onto the
shaft, install the needle bearing.
RCPH10TLB211AAL 55
56. Remove the old teflon seal rings from the bushing.
RCPH10TLB212AAL 56
57. Install new teflon seal rings on the bushing with

protector and shim set 380100085, use pusher
380001928.
RCPH10TLB307AAL 57
58. Size the teflon seal rings using 380100086 sizer.
RCPH10TLB308AAL 58
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59. With the reference marks up, install the bushing into
the clutch pack.
RCPH10TLB213AAL 59
60. Use a suitable driver and install the bushing onto the
shaft, install the needle bearing.
RCPH10TLB214AAL 60
RCPH10TLB215AAL 61
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3rd Gear Clutch Pack

62. Install new O-rings and backup rings on the piston.
RCPH10TLB266AAL 62
RCPH10TLB160AAL 63

RCPH10TLB280AAL 64
RCPH10TLB216AAL 65
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RCPH10TLB295AAL 66

RCPH10TLB162AAL 67
erly seated.
RCPH10TLB163AAL 68

CAS2379.
RCPH10TLB162AAL 69
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70. Install a new roll pin.
RCPH10TLB296AAL 70

RCPH10TLB205AAL 71
72. Install the thrust plate.
RCPH10TLB206AAL 72
is properly seated.
RCPH10TLB207AAL 73
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RCPH10TLB281AAL 74

RCPH10TLB209AAL 75
76. Install the thrust washer and roller bearing.
RCPH10TLB217AAL 76
77. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB218AAL 77
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RCPH10TLB219AAL 78
RCPH10TLB220AAL 79
80. Install the teflon seal rings starting with the inner most
ring first. Use protector and shims as required from
380040161 and pusher 380001928. Size the seal
rings using sizer 380001427.
RCPH10TLB140AAL 80
2nd Gear Clutch Pack

RCPH10TLB158AAL 81
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82. Install the teflon seal ring. Use protector and shims
as required from 380040161 and pusher 380001928.
Size the seal rings using sizer 380001427.
RCPH10TLB159AAL 82
RCPH10TLB266AAL 83
RCPH10TLB160AAL 84

RCPH10TLB280AAL 85
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RCPH10TLB216AAL 86
RCPH10TLB295AAL 87

RCPH10TLB162AAL 88
erly seated.
RCPH10TLB163AAL 89
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CAS2379.
RCPH10TLB162AAL 90

RCPH10TLB164AAL 91
92. Install the spacer and the roll pin.
RCPH10TLB165AAL 92
93. Align the slot on the thrust washer with the roll pin,
install the thrust washer and the needle bearing.
RCPH10TLB166AAL 93
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94. Install the thrust plate and drive it down evenly to the
clutch disc.
RCPH10TLB167AAL 94
is properly seated.
RCPH10TLB168AAL 95
RCPH10TLB281AAL 96
97. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB169AAL 97
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98. Install the roll pin.
RCPH10TLB170AAL 98
install the thrust washer and the snap ring.
RCPH10TLB282AAL 99

RCPH10TLB209AAL 100
101. Install the gear with the large hub down, use a suit-
able driver and install the bearing.
RCPH10TLB283AAL 101
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102. Install the teflon seal rings starting with the inner most
ring first. Use protector and shims as required from
380040161 and pusher 380001928. Size the seal
rings using sizer 380001427.
RCPH10TLB171AAL 102
Reverse Shaft
103. Use a suitable driver and install a bearing on one end
of the shaft.
RCPH10TLB141AAL 103
104. Turn the shaft over and install a bearing on the other
end of the shaft.
RCPH10TLB142AAL 104
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Forward and Reverse Clutch Packs

RCPH10TLB266AAL 105
RCPH10TLB160AAL 106

RCPH10TLB280AAL 107
RCPH10TLB216AAL 108
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RCPH10TLB295AAL 109

RCPH10TLB162AAL 110
erly seated.
RCPH10TLB163AAL 111

CAS2379.
RCPH10TLB162AAL 112
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113. Install the roll pin.
RCPH10TLB129AAL 113
install the thrust washer.
RCPH10TLB130AAL 114
115. Install the needle bearing.
RCPH10TLB131AAL 115
116. Place the clutch hub on a bench, install the thrust

plate on the hub.
RCPH10TLB132AAL 116
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117. Starting with a friction disc, install 6 friction discs and

6 reaction plates.
RCPH10TLB133AAL 117
118. Install the clutch pack in the clutch housing.
RCPH10TLB134AAL 118
is properly seated.
RCPH10TLB269AAL 119
RCPH10TLB114AAL 120
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121. Heat the bearing to 80° to 100° C (176° to 212° F),

use a suitable driver and install the bearing.
RCPH10TLB135AAL 121
RCPH10TLB136AAL 122

pander/protector.
RCPH10TLB826AAL 123
124. Slide the expander/protector and spacer onto the in-

put shaft. Heat the Teflon sealing ring to 80° to 100°
C (176° to 212° F). Install the Teflon sealing ring onto
the 380001428 expander/protector.
RCPH10TLB829AAL 124
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RCPH10TLB830AAL 125

RCPH10TLB840AAL 126
from the shaft.
RCPH10TLB827AAL 127

RCPH10TLB137AAL 128
129. Turn the shaft over and repeat steps 104to 118and
assemble the other clutch pack.
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130. Install the roll pin, align the slot on the thrust washer
with the roll pin, install the thrust washer.
RCPH10TLB270AAL 129
RCPH10TLB138AAL 130
RCPH10TLB139AAL 131

pander/protector.
RCPH10TLB821AAL 132
84516378 05/07/2011
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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.
RCPH10TLB831AAL 133

groove in the shaft. Remove the pusher, protector,
RCPH10TLB838AAL 134

RCPH10TLB839AAL 135
from the shaft.
RCPH10TLB840AAL 136
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pander/protector.
RCPH10TLB822AAL 137

RCPH10TLB832AAL 138

RCPH10TLB837AAL 139

RCPH10TLB839AAL 140
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from the shaft.
RCPH10TLB840AAL 141

pander/protector.
RCPH10TLB823AAL 142

RCPH10TLB833AAL 143

RCPH10TLB836AAL 144
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RCPH10TLB839AAL 145
from the shaft.
RCPH10TLB840AAL 146

pander/protector.
RCPH10TLB824AAL 147

RCPH10TLB834AAL 148
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RCPH10TLB835AAL 149

RCPH10TLB839AAL 150
from the shaft.
RCPH10TLB840AAL 151
Transmission Housings
153. Lubricate the bores of the transmission housing that
house teflon sealing rings.
RCPH10TLB143AAL 152
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154. Attach lifting bracket 380100088 to the three shafts

as shown, install the shafts into the housing.
RCPH10TLB145AAL 153
155. Install the 4WD clutch cover as shown, apply Loctite

542 to the threads and torque cap screws to 50 Nm
(37 pound feet).
RCPH10TLB144AAL 154
156. Install the forward and reverse clutch pack and the
reverse shaft into the housing as an assembly.
RCPH10TLB109AAL 155
157. Start the bearing of the reverse shaft into its bore in
the housing and mesh the gears at the same time.
RCPH10TLB271AAL 156
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158. Apply a thin coat of Loctite 510 to the mating surface

of the transmission housing.
RCPH10TLB261AAL 157
159. Install new O-rings in the housing.
RCPH10TLB107AAL 158
160. Lubricate the bores of the front transmission housing

that house teflon sealing rings.
161. Attach lifting equipment to the front housing, lower
the front housing onto the rear housing.
RCPH10TLB260AAL 159
NOTE: Do not bind the shafts to prevent damaging the teflon seal rings.
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162. Install and hand tighten all of the transmission hous-

ing cap screws.
RCPH10TLB108AAL 160
163. Torque the housing cap screws to 50 Nm (37 pound

feet).
RCPH10TLB258AAL 161
PTO Shaft
164. Slide the expander/protector onto the pump drive
shaft.
RCPH10TLB842AAL 162

380001428 expander/protector.
RCPH10TLB843AAL 163
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RCPH10TLB844AAL 164

RCPH10TLB845AAL 165
from the shaft.
RCPH10TLB846AAL 166
169. Install the bearing and snap ring on the PTO shaft.
170. Put the PTO shaft into the transmission.
RCPH10TLB256AAL 167
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of the pump mount and rear cover. Prepare the seal-
ing surface by rubbing with a 3M Scotch-Brite fiber
pad or equivalent. DO NOT use steel wool or any-
thing 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.
172. Clean the housing, use Loctite 518 sealer on the mat-
ing surfaces.
RCPH10TLB104AAL 168
173. Install the pump mount on the rear housing, torque

bolts to 50 Nm (37 pound-feet).
RCPH10TLB255AAL 169
Parking Brake
174. Install a new O-ring on the brake housing.
RCPH10TLB607AAL 170
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175. Install the bellville washers as shown.
RCPH10TLB595AAL 171
176. Install the backup ring, install the seal ring.
RCPH10TLB608AAL 172
NOTE: Make sure that the seal ring does not twist during installation.
177. Lubricate the piston seals with transmission fluid, in-
stall the piston into the brake housing.
RCPH10TLB602AAL 173
178. Use CAS2379 and compress the bellville washers,

install the retaining ring.
RCPH10TLB601AAL 174
NOTICE: Make sure the retainer is properly seated before removing spring compressor.
84516378 05/07/2011
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179. Install new O-rings and backup ring in the retaining

plate.
RCPH10TLB600AAL 175
180. Lubricate the O-rings on the retaining plate, install

the plate into the brake housing.
RCPH10TLB599AAL 176
RCPH10TLB877AAL 177
RCPH10TLB876AAL 178
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RCPH10TLB875AAL 179
RCPH10TLB874AAL 180
RCPH10TLB873AAL 181
RCPH10TLB872AAL 182
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sion. Torque the bolts to 50 Nm (37 pound feet).
RCPH10TLB871AAL 183
RCPH10TLB869AAL 184
RCPH10TLB868AAL 185
190. Torque bolt to 139 Nm (103 pound feet).
RCPH10TLB870AAL 186
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Lubrication and Clutch Tubes

191. Install tubes and torque to 30 Nm (22 pound-feet).
RCPH10TLB254AAL 187
Pump
RCPH10TLB095AAL 188
193. Install the seal.
RCPH10TLB097AAL 189
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194. When installing the pump align the pump holes.
RCPH10TLB098AAL 190
195. Lubricate the teflon seal ring with clean transmission

fluid.
RCPH10TLB253AAL 191
196. Lubricate the O-ring with clean transmission fluid.
RCPH10TLB099AAL 192
197. Push the pump into position.
RCPH10TLB252AAL 193
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198. Install and torque bolts to 23 Nm (17 pound-feet).
RCPH10TLB094AAL 194
199. Install the torque converter.
RCPH10TLB093AAL 195
200. Install a new suction filter.
RCPH10TLB250AAL 196
201. Install the cover and torque the bolts to 23 Nm (17

pound-feet).
RCPH10TLB082AAL 197
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202. Install and torque drain plugs to 80 Nm (59 pound-

feet).
RCPH10TLB081AAL 198
203. Install and torque the filter bypass to 23 Nm (17

pound-feet).
RCPH10TLB085AAL 199
204. Install and torque the speed sensor to 50 Nm (37

pound-feet).
RCPH10TLB090AAL 200
205. Install and torque the thermostat to 30 Nm (22 pound-

feet).
RCPH10TLB091AAL 201
206. Install a new oil filter.
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207. Fill transmission with approved fluid, see specifica-

tions.
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TRANSMISSION Powershift - View Troubleshooting and Monitoring

EST Parameters
When troubleshooting Powershift S-type transmission
shifting problems or fault codes, the EST should be the first
tool used to diagnose problems. By monitoring parameters
with the EST combined with other external tests, it can
quickly be determined whether the problem is electrical,
hydraulic, or mechanical in nature.
Connect the EST and monitor the following functions:
• Selected Gear: This is the gear which the
TRAX controllers interprets that has been
specified by the operator through the FNR
switch gear command 01 & 02.
• Current Gear: This is the gear that the
TRAX controller sees the transmission is
in.
• S-type – Gear 1 & 2 Analog voltage: input
from the resistor network
• S-type – Gear 3 & 4 Analog voltage: input
from the resistor network
• S-type – Gear Command 01 Status: input
from FNR switch
• S-type – Gear Command 02 Status: input
from FNR switch / Comfort Steer Cutout
relay
• S-type – Gear SW1 logical status: TRAX
interpretation of gear switch position
based on analog voltages from resistor
network
network
network
network
• S-type – Solenoid valve 1 Status: TRAX
controller is sending current to this sole-
noid.
noid.
noid.
noid.
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RCPH11TLB007FAL 1
EST screen shot showing parameters being monitored.
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TRANSMISSION Powershift - Tool connection Test Port and

Component Locations, H-Type
RCPH11TLB006GAL 1
Left Side View
(1) Valve body (5) 1st check port

(2) Oil filter bypass valve (6) 2nd check port
(3) Speed sensor (7) Lubrication check port
(4) 4th check port (8) Torque converter inlet pressure test port
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RCPH11TLB007GAL 2
Front View
(9) Spin on Filter (11) Dip stick port

(10) Oil pump (3) Speed sensor
84516378 05/07/2011
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RCPH11TLB008GAL 3
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
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RCPH11TLB009GAL 4
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
(3) Speed sensor
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RCPH11TLB010GAL 5
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
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TRANSMISSION Powershift - Tool connection Test Port and

Component Locations, S-Type
RCPH11TLB014GAL 1
Top Right View
(1) Cooler OUT (7) Charge pressure test port

(2) Cooler IN (8) Cooler IN test port
(3) Breather (9) Oil return port
(4) Forward test port (10) Oil pressure ports
(5) Reverse test port (11) Threaded holes, M12–1.75
(6) HDL out
84516378 05/07/2011
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RCPH11TLB015GAL 2
Left Side View
(12) TC IN test port (15) SAHR brake pressure switch

(13) Temperature sensor (16) SAHR brake pressure test port
(14) Speed sensor (17) SAHR brake control valve
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RCPH11TLB012GAL 3
Right Side View
(18) 1st gear switch (24) 2nd test port

(19) 3rd gear switch (25) Return oil from service brake
(20) 2nd gear switch (26) 3N4 test port
(21) 4th gear switch (27) 3rd test port
(22) SAHR 4WD test port (28) 1N2 test port
(23) 4th test port (29) 1st test port
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RCPH11TLB013GAL 4
Top Left View
(30) Charge pressure sensor (32) Transmission harness connector

(31) Pressure regulator valve
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TRANSMISSION Powershift - Warm up Heating the Oil

1. Check the oil level and type before proceeding.
2. Activate the parking brake.
4. Place the gear selector into 4th gear.
5. Put the FNR selector in forward.
6. Run the engine up to 1600 RPM ± 100 RPM for a
period of 30 seconds.
NOTE: Do not exceed 30 seconds.
7. Reduce the engine speed to low idle and place the
FNR lever in neutral for 15 seconds.
8. Repeat steps 6 and 7 until the oil temperature is be-
tween 78 °C (172 °F) and 82 °C (180 °F).
9. Perform an engine stall test before proceeding. Re-
fer to ENGINE - Speeds stall test normal (all mod-
els) (B.10.A).
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Command - Service instruction Shift Rail Position Testing - S-type

Transmission
To test the resistor network and the gear position switches
follow the procedure below. The tests can be done with the
engine off and the key on.
1. Remove all four 2-pin connectors that go to the gear
position switches.
2. Carefully Insert a jumper (piece of wire) into each
connector, shorting the pins together to simulate the
gear switches being closed.
3. With the EST monitor the fields in the slide above.
4. Remove one jumper at a time. If the 1stgear position
switch jumper is removed then the “gear 1 and 2 ana-
log voltage” and “gear switch 1 logical status” should
match the expected values below, 1V and OFF.
5. The actual gear position switches can also be
checked. If the unit is off, the shift rails should be in
neutral and all the switches will be closed. If one of
the switches is measured as open, either the switch
is faulty or the shift rail is not in neutral.
6. The individual switches can be removed and manu-
ally cycled by pressing the plunger while monitoring
with the EST. Depressing the switch plunger should
cause the switch to go open, with an ‘OFF’ indication
on the EST.
Following is a diagram of the switch locations as facing the
right side of the transmission:
RCPH11TLB081AAL 1
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Command - Service instruction Shift Rail Position Physical

Measurement - S-Type Transmission
If the previous electrical tests show that the problem is not
electrical, then the shift rails can be physically checked for
proper position. Remove the two plugs from the rear trans-
mission housing adjacent to the shift rails.
RCPH11TLB001GAL 1
(1) 3rd and 4th shift rail plug

. (2) 1st and 2nd shift rail plug
Measure the depth of the end of the rail in relation to the
edge of the transmission housing at the plug which was
removed.
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RCPH11TLB011FAL 2
(1) Measure the rail depth here
Measurement Interpretation
18 mm (0.71 in) Rail is in 1st gear or 3rd gear
29 mm (1.14 in) Neutral rail position
40 mm (1.57 in) Rail is in 2nd gear or 4th gear position
If the rail is out of position, then transmission hydraulic

pressure tests should be performed to determine whether
the correct hydraulic pressures are being sent to the shift
rail positioning pistons to center the shift rails into neu-
tral. The pressures to be checked should be determined
by which shift rail is out of position.
If the pressure tests show correct, then the shift rail is phys-
ically jammed in position.
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Command - Service instruction Hydraulic Pressure Testing Shift

Rails - S-Type Transmission
A pressure gauge can be installed at the check ports to
monitor pressure applied to the shifting pistons. All port
locations are 9/16-18 UNF ORB.
RCPH11TLB012GAL 1
Right Side View
(18) 1st gear switch (24) 2nd test port

(19) 3rd gear switch (25) Return oil from service brake
(20) 2nd gear switch (26) 3N4 test port
(21) 4th gear switch (27) 3rd test port
(22) SAHR 4WD test port (28) 1N2 test port
(23) 4th test port (29) 1st test port
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Gear 1N2 1st 2nd 3N4 3rd 4th

Neutral 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi) psi)
1st 13 - 17 bar 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi) psi)
2nd 0 bar (0.0 psi) 0 bar (0.0 psi) 13 - 17 bar 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi)
3rd 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar 13 - 17 bar 13 - 17 bar 0 bar (0.0 psi)
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi) psi)
4th 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar 0 bar (0.0 psi) 0 bar (0.0 psi) 13 - 17 bar
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi)
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Control valve - Disassemble S-Type (SPS Power Synchro) -

Hydraulic control valve
1. Disconnect all electrical wires and drain the transmis-
sion.
2. Remove the screws (1) and remove the control valve
(2).
RCPH10TLB152ACL 1
3. Remove the gasket (1).
RCPH10TLB153ACL 2
4. Remove the screws (1) and the HDL and 4WD valves
(2).
RCPH10TLB154ACL 3
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HDL and FWD valves positions:
RCPH10TLB155ACL 4
HDL and FWD valves dimensions:
RCPH10TLB040ACL 5
5. Remove the O-rings as needed.
RCPH10TLB158ACL 6
6. Remove the screws and the REV and FWD valves.
RCPH10TLB154ACL 7
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REV and FWD valves positions:
RCPH10TLB156ACL 8
REV and FWD valves dimensions:
RCPH10TLB041ACL 9
7. Remove the O-rings (1) as needed.
RCPH10TLB159ACL 10
8. Remove the S2 and S4 solenoid valves.

S2 and S4 solenoid valves positions:
RCPH10TLB160ACL 11
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S2 and S4 solenoid valves dimensions:
RCPH10TLB042ACL 12
9. Unscrew the nut.
RCPH10TLB192ACL 13
10. Remove the nut.
RCPH10TLB191ACL 14
11. Remove the solenoid.
RCPH10TLB190ACL 15
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RCPH10TLB190ACL 16
RCPH10TLB189ACL 17
14. Unscrew the solenoid tube.
RCPH10TLB188ACL 18
15. Remove the solenoid tube. Remove the O-rings as

needed.
RCPH10TLB187ACL 19
16. Remove the S1 (1st and 2nd gear) and S3 (3rd and
4th gear) solenoid valves.
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S1 and S3 solenoid valves positions:
RCPH10TLB252ACL 20
S1 and S3 solenoid valves dimensions:
RCPH10TLB043ACL 21
17. Unscrew the nut.
RCPH10TLB186ACL 22
18. Remove the nut.
RCPH10TLB185ACL 23
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RCPH10TLB184ACL 24
20. Unscrew the solenoid tube.
RCPH10TLB183ACL 25
21. Remove the solenoid tube. Remove the O-rings as

needed.
RCPH10TLB182ACL 26
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22. Remove the screws, circuit plate, and O-Rings. (1).
RCPH10TLB080ACL 27
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Control valve - Assemble S-Type (SPS Power Synchro) - Hydraulic

control valve
NOTE: Some of the following images may not represent your transmission, the procedures are the same.
1. Lubricate and install the O-rings, oil circuit plate, and
screws. .
RCPH10TLB080ACL 1
2. Lubricate and install the O-rings on the solenoid tube

for the S1 and S3 solenoid valves.
3. Install the solenoid tube.
RCPH10TLB182ACL 2
4. Tighten the solenoid tube to specifications.
RCPH10TLB183ACL 3
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RCPH10TLB184ACL 4
6. Install the nut.
RCPH10TLB185ACL 5
7. Tighten the nut to specifications. TRANSMISSION

Powershift - Torque (C.20.E)
RCPH10TLB180ACL 6
8. Lubricate and install the O-rings for the S2 and S4

solenoid valves.
9. Install the solenoid tube.
RCPH10TLB187ACL 7
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10. Tighten the solenoid tube to specifications.
RCPH10TLB181ACL 8
RCPH10TLB189ACL 9
RCPH10TLB189ACL 10
RCPH10TLB190ACL 11
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14. Install the nut.
RCPH10TLB191ACL 12
15. Tighten the nut to specifications TRANSMISSION

Powershift - Torque (C.20.E).
RCPH10TLB179ACL 13
16. Lubricate and install the O-rings for the REV and
FWD valves.
17. Install the valves.
RCPH10TLB159ACL 14
18. Lubricate and install the O-rings for the HDL and
4WD valves.
19. Install the valves.
RCPH10TLB158ACL 15
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20. Install the screws for the HDL, 4WD, REV and FWD
valves. Tighten the screws to specifications.
RCPH10TLB253ACL 16
21. Lubricate and install the gasket (1).
RCPH10TLB153ACL 17
22. Install the control valve (1) and the screws (2).
Tighten the screws to specifications. TRANSMIS-
SION Powershift - Torque (C.20.E)
RCPH10TLB152ACL 18
23. Disconnect all electrical wires and drain the transmis-

sion.
Next operation:
Housing - Disassemble (C.20.E)
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Shaft - Disassemble - S-Type (SPS Power Synchro) - Rear cover -

shafts
NOTE: To remove shaft B and C, remove the front half-housing, the parking brake, the rear cover, the bearing snap
ring of the secondary shaft and the switches group
NOTE: Steps 3 through 5 are for machines with a parking brake.
1. Remove the input shaft (1). Remove the idler shaft
(2).
RCPH10TLB109AAL 1
2. Remove the parking brake group.
RCPH10TLB045ACL 2
3. Remove O-Ring (1)Remove the 7 screws (2). Re-

move the flange (3). Remove the assembled PTO
shaft (4)
RCPH10TLB050ACL 3
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4. Remove the 4 screws (1)and the 3 screws (2). Re-

move the rear cover (3).
RCPH10TLB049ACL 4
NOTE: Steps 6 through 8 are for machines without a parking brake.

5. Remove the 5 screws (1), the 3 screws (2)and the 2
screws (3).
RCPH10TLB255ACL 5
6. Remove the rear cover (1)and the PTO shaft (2).
RCPH10TLB256ACL 6
7. Remove PTO shaft.
RCPH10TLB193ACL 7
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8. If necessary, remove teflon seal ring. It may be nec-

essary to cut the ring.
RCPH10TLB105AAL 8
9. Remove snap ring.
RCPH10TLB257AAL 9

the PTO shaft.
RCPH10TLB106AAL 10
11. Remove shims (1). Remove bearing snap ring (2).
RCPH10TLB194ACL 11
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12. Attach lifting bracket 380100088 to the shafts, re-

move them from the transmission.
RCPH10TLB145AAL 12
Next operation:
Shaft - Assemble (C.20.E)
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Shaft - Assemble -S-Type (SPS Power Synchro) - Rear cover - shafts

1. Assemble the 4WD shaft. Remove the secondary
shaft and the primary shaft.
RCPH10TLB719AAL 1
2. Assemble the input shaft. Assemble the idler shaft.

Install the front half housing on the rear half housing.
Tighten the screws. Assemble the switches group.
RCPH10TLB720AAL 2
3. 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. Assemble the
bearing snap ring on the secondary shaft Assemble
the shims on the secondary shaft.
RCPH10TLB732AAL 3
4. If you change bearing of the secondary shaft or rear

front-housing calculate the amount of shims to be
inserted between rear cover and rear half-housing.
RCPH10TLB732AAL 4
5. Rear cover. Determine the dimension Y.

6. Rear front-housing.. Determine the dimension Z.
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7. Prescribed end float (between rear cover and rear

half-housing) --> 0 ÷ 0,1 mm. Select an amount of
shims S , among the range of available shims see ta-
ble in next step), to make sure there is the prescribed
end float. S= Y-Z mm
RCPH10TLB257ACL 5
8. Select the shim of thickness value (S) among the

range of available shims. Note: choose the shim
(S) so that is guaranteed an end float of 0 ÷ 0.1 mm
between rear cover and rear half-housing
RCPH10TLB078ACL 6
9. Assemble the shims.
RCPH10TLB257ACL 7
10. Heat the bearing to 60 - 80 °C (140.0 - 176.0 °F)for

5 minutes. Assemble bearing on the shaft PTO.
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11. Assemble snap ring..
RCPH10TLB257AAL 8
12. For the assembly of teflon seal ring follow operations

from step 19 to step 23 using the following tools.
CA716225 (without shim) CA715497 CA715356.
RCPH10TLB087ACL 9
NOTE: Steps 13 through 15 are for machines without the parking brake.
13. Assemble PTO shaft (1)into the rear cover (2).
RCPH10TLB193ACL 10
14. Apply a thin film of sealant on the edge of the rear

cover. Assemble the rear cover group. Make sure
that the pin is correctly installed both in the rear hous-
ing and through the hole in the rear cover.
RCPH10TLB256ACL 11
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15. Tighten the 5 screws (1)the 3 screws (2)and the 2

screws (3)to fasten the rear cover to the rear half
housing. If necessary, tap the rear cover with a soft
faced hammer to close the gap between the rear
half housing and the rear cover before tightening the
screws. Tightening torque TRANSMISSION Power-
shift - Torque (C.20.E). Assemble the O-Ring (4).
RCPH10TLB255ACL 12
NOTE: Steps 16 through 22 are for machines with the parking brake.
16. Clean the cover (1). Apply a thin film of sealant on
the edge of the rear cover.
RCPH10TLB168ACL 13
17. Clean the rear half-housing. Assemble the O-Ring

(1)on the rear half-housing.
RCPH10TLB057ACL 14
18. Make sure that the pin (1)is correctly installed both
in the rear housing and through the hole in the rear
cover. Tighten the 4 screws (2)and the 3 screws (3)to
fasten the rear cover to the rear half housing. Tight-
ening torque TRANSMISSION Powershift - Torque
(C.20.E).
RCPH10TLB049ACL 15
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19. Clean the flange.
RCPH10TLB166ACL 16
20. Apply a thin film of sealant on the edge of the flange.
RCPH10TLB167ACL 17
21. Assemble the assembled PTO shaft (1)into the

transmission. Assemble the flange (2). Tighten the
7 screws (3)to fasten the flange to the cover. Tighten
torque TRANSMISSION Powershift - Torque
(C.20.E). Assemble the O-Ring (4).
RCPH10TLB002AAN 18
22. Assemble the parking brake group.
RCPH10TLB001AAN 19
Next operation:
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Shaft - Disassemble (C.20.E)
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Shaft - Disassemble -S-Type (SPS Power Synchro) - Gear pistons

NOTE: To remove gear and neutral piston, remove the parking brake group and rear cover and secondary shaft
lubrication pipe.
1. Remove the O-Rings.
RCPH10TLB062ACL 1
NOTE: O-rings cannot be re-used. Replace O-rings during assembly.

2. Remove 2nd (1)and 4th (2) gear pistons.
RCPH10TLB063ACL 2
NOTE: Use a M4 screw to remove the pistons. If replacement of pistons is needed see following step.
3. If dimension difference between the new piston and
the replaced one is more than 0.07 mm, shift rails
and switches adjustment is required.
RCPH10TLB217ACL 3
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4. 4th gear pistons - ø36 mm. If the replacement is

needed cut the seal ring and remove it. Remove the
O-Ring
RCPH10TLB251ACL 4
5. 2nd gear pistons- ø42 mm. If the replacement is

needed cut the seal ring and remove it. Remove the
O-Ring
RCPH10TLB251ACL 5
6. If one of the following parts is replaced : synchro-

nizer, shift rails, forks, secondary shaft, secondary
shaft gears or half-housings, the shims adjusting
must be revised. Remove the screw (1). Remove
the bushing (2). Collect the shims (3).
RCPH10TLB064ACL 6
7. Remove the screws (1). Remove the locking plugs.

(2).
RCPH10TLB065ACL 7
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8. Remove the plugs (1). See next step.
RCPH10TLB058ACL 8
9. Remove the screws (1). Remove the oil circuit plate

(2). Remove the O-Rings (3). Remove plugs by
blowing in air (just enough to pull out the plugs)
through the hole as shown in figure (see arrows).
RCPH10TLB081ACL 9
NOTE: Possible oil leakage. Carefully follow all the safety procedures indicated in this manual and in the vehicle
manual.
10. Plug (3). ø52 mm. Remove the O-Ring.
RCPH10TLB172ACL 10
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11. Plug (5). ø47 mm. Remove the O-Ring.
RCPH10TLB172ACL 11
12. Remove the NEUTRAL pistons.
RCPH10TLB059ACL 12
NOTE: Use a M4 screw to remove the pistons. If the replacement is needed remove the seal and O-Ring. See step
4 to disassemble the seals. If replacement of pistons is needed see step 15.
13. Remove 1st (1)and 3rd (2)gear pistons. If replace-
ment of pistons is needed see following step.
RCPH10TLB060ACL 13
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14. If dimension difference between the new piston and

the replaced one is more than 0.07 mm, shift rails
and switches adjustment is required.
RCPH10TLB217ACL 14

(1)must be revised. If necessary remove the screw
(2)and collect the shims (1). If the replacement is
needed remove the seal and O-Ring (3). See step 4
and 5 to disassemble the seals.
RCPH10TLB066ACL 15

(1)must be revised. Remove the screw (2). Remove
the bushing (3). Collect the shims (1).
RCPH10TLB061ACL 16
Next operation:
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Shaft - Assemble -S-Type (SPS Power Synchro) - Gear pistons

1. 4th gear pistons - ø36 mm. Assemble the O-Ring
into the piston.
RCPH10TLB233ACL 1
2. Assembly seal ring (1)into the piston (2).
RCPH10TLB048ACL 2
3. Slide the expander/protector tool onto the piston (1).

The expander/protector will stop in the correct posi-
tion to install the seal ring in the groove.
RCPH10TLB234ACL 3
4. Heat the Teflon seal ring (1)to 60 - 80 °C (140.0 -

176.0 °F)for 5 minutes. Install the teflon seal ring
onto the expander/protector.
RCPH10TLB196ACL 4
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5. Install the pusher tool over the expander/protector

and slide the seal ring until it reaches the groove in
the shaft. Remove the pusher, expander/protector,
RCPH10TLB197ACL 5
6. Install the end of the seal compressor with the deep

chamfer onto the piston and over the sealing ring.
Use a back and forth twisting motion to allow the seal
compressor to slip over the top of the sealing ring and
seat the sealing ring into the groove. Be careful not to
damage the seal ring. After the sealing ring is seated
in the groove, leave the seal compressor in place for
seal ring has cooled, remove the seal compressor
from the piston.
RCPH10TLB140ACL 6
7. 2nd gear pistons - ø42 mm. Assemble the O-Ring

into the piston.
RCPH10TLB233ACL 7
8. Assembly seal ring (1)into the piston (2).
RCPH10TLB048ACL 8
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9. For the installation of the seal ring (1), repeat the

operations from sequence 3 to sequence 6, using
the following tools: expander/protector, pusher, and
gauger service tool.
RCPH10TLB234ACL 9

must be revised.
RCPH10TLB046ACL 10
11. Assemble the special tool on the shaft rail. Assemble

the shims.
RCPH10TLB266ACL 11
12. Assemble the bushing (1). Assemble the bushing as

shown in figure.
RCPH10TLB267ACL 12
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13. Bushing figure.
RCPH10TLB067ACL 13
14. Remove the special tool.
RCPH10TLB269ACL 14
15. Check the switches have been proper assembled

and adjust the control gear shaft and than assem-
ble the screw (1)with sealant. Tighten the screws
(1)Tightening torque TRANSMISSION Powershift -
Torque (C.20.E).
RCPH10TLB270ACL 15
16. Engage the 3rd speed gear and check that the bush-
ing top is in range.
84516378 05/07/2011
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must be revised.
RCPH10TLB047ACL 16
18. Assemble the special tool on the shift rail. Assemble

the shims (1). Assemble the bushing (2). Assemble
the bushing as shown in figure.
RCPH10TLB146ACL 17
19. Assemble as shown.
RCPH10TLB068ACL 18
20. Check the switches have been properly assembled

adjust control gear shaft and then assemble the
screw (1)with sealant. Tighten the screws (1)Tight-
ening torque TRANSMISSION Powershift - Torque
(C.20.E).
RCPH10TLB147ACL 19
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21. Engage the 4th speed gear and check that bushing
top is in the range as shown in next figure.
RCPH10TLB148ACL 20

must be revised. Assemble the shims onto the
screw . Assemble the screw with sealant.
RCPH10TLB066ACL 21
23. Tighten the screws into the piston. Tightening torque

TRANSMISSION Powershift - Torque (C.20.E).
RCPH10TLB219ACL 22
24. Use a special tool to insert 3rd gear pistons (1). Use
a special tool to insert 1st gear pistons (2).
RCPH10TLB235ACL 23
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RCPH10TLB069ACL 24
26. Assemble 3rd and 1st gear pistons.
RCPH10TLB236ACL 25
27. Push the piston into the seat using a soft tool mate-
rial. Remove the special tools.
RCPH10TLB237ACL 26
28. Assemble as shown. Seal ring into the NEUTRAL

piston (16).
RCPH10TLB048ACL 27
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29. Assemble the O-Ring (1)into the NEUTRAL piston

. For the introduction of the seal ring , repeat the
operations from sequence 3 to sequence 6, using
the following tools: expander/protector, pusher and
gauger service tool.
RCPH10TLB196ACL 28
30. Seal ring into the NEUTRAL piston.
RCPH10TLB048ACL 29
31. Assemble the O-Ring into the NEUTRAL piston . For

the introduction of the seal ring , repeat the opera-
tions from sequence 3 to sequence 6, using the fol-
lowing tools: expander/protector, pusher and gauger
RCPH10TLB196ACL 30
32. 3N4 piston . Use special tool to insert the NEUTRAL

pistons . 1N2 piston . Use a special tool to insert the
NEUTRAL pistons.
RCPH10TLB170ACL 31
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33. Push the piston in your seat using a soft tool material.
Remove the special tool.
RCPH10TLB171ACL 32
RCPH10TLB070ACL 33
35. Plug (3). ø52 mm. Assemble the O-Ring.
RCPH10TLB172ACL 34
36. Plug (5). ø47 mm. Assemble the O-Ring.
RCPH10TLB172ACL 35
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37. Assemble the plug.
RCPH10TLB173ACL 36
38. Assemble the locking plugs (2). Tighten the screws

(1)Tightening torque TRANSMISSION Powershift -
Torque (C.20.E).
RCPH10TLB065ACL 37
39. Assemble group (B).
RCPH10TLB174ACL 38
40. Rear cover side: Use dealer supplied special tools

to insert 2nd and 4th gear pistons . Put the piston
into the tool and push out about 3 mm to allow the
centering on half housing.
RCPH10TLB144ACL 39
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41. Place the tool with piston on the half-housing. Push

the piston in its seat using a soft tool material. Re-
move the special tools.
RCPH10TLB145ACL 40
42. Assemble the O-Rings.
RCPH10TLB062ACL 41
43. Assemble the rear cover.
RCPH10TLB049ACL 42
Next operation:
Clutch and gear - Measure (C.20.E)
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Shaft - Disassemble - S-Type (SPS Power Synchro) - Shafts A - D

(2).
RCPH10TLB109AAL 1
RCPH10TLB110AAL 2
RCPH10TLB111AAL 3
4. Install a bearing separator under the gear as shown

(do not install the bearing separator between the
gear and the bearing). Use a puller on the bearing
separator and insert a shaft protector between the
puller and the end of the input shaft.
RCPH10TLB112AAL 4
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RCPH10TLB113AAL 5
RCPH10TLB117AAL 6
7. Remove the gear.
RCPH10TLB115AAL 7
RCPH10TLB116AAL 8
84516378 05/07/2011
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RCPH10TLB262AAL 9
RCPH10TLB262AAL 10
11. Remove lock ring.
RCPH10TLB117AAL 11
12. Use pry bars to lift and to remove the thrust plate.
RCPH10TLB118AAL 12
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13. Remove the clutch plates and the clutch discs.
RCPH10TLB119AAL 13
14. Place a mark below the groove on the clutch housing.
RCPH10TLB120AAL 14
15. Place a mark on each thrust plate and the lock ring.
RCPH10TLB263AAL 15
RCPH10TLB121AAL 16
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RCPH10TLB264AAL 17
RCPH10TLB121AAL 18
RCPH10TLB122AAL 19
RCPH10TLB265AAL 20
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21. Use compressed air in the piston pressure port to

remove the piston.
RCPH10TLB123AAL 21
RCPH10TLB266AAL 22
23. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 23
RCPH10TLB267AAL 24
84516378 05/07/2011
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end of the input shaft. Remove the bearing.
RCPH10TLB125AAL 25
26. Remove the bearing and thrust washer.
RCPH10TLB126AAL 26
27. Remove gear.
RCPH10TLB303AAL 27
RCPH10TLB127AAL 28
29. Repeat steps 9 to 22 to disassemble the clutch.
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30. Check the sealing ring grooves (large and small) for
wear and damage if necessary. Use new parts as
required.
31. Check on the output shaft for wear and damage.
Check oil passages in the output shaft to be sure that
the passages are open and free of foreign material.
32. Check the ball bearings and the needle bearings for
flat areas, pitting, and other damage. Use new parts
as required.
33. If the clutch discs are to be used again, keep the
clutch packs in the same previous assembly order
separate and record which clutch pack goes with
each clutch. Use new parts as required.
RCPH10TLB804AAL 29
34. Use a straight edge to check each clutch drive plate

and each clutch plate to be sure each part is flat. If
they are not flat a new part must be installed dur-
ing assembly. If the clutch plates are smooth or al-
most smooth, use new parts during assembly. If the
friction material is damaged or appears burned, use
new parts during assembly. Also, check the splines
for wear. Inspect the clutch drive plate for pitting,
scoring, or other damage. If there is any damage,
use new parts during assembly. If you will be us-
ing new clutch plates, soak the clutch plates in clean
transmission oil for at least an hour before assem-
bly. If you are using the old clutch plates, make sure
that the contact surfaces are coated with transmis- RCPH10TLB943AAL 30
sion oil before assembly, check the wear conditions

(see chart below). If it is 50% compared to the nom-
inal value it is suggested its replacement.
35. Inspect the bore and the shaft in the input shaft hous-
ing 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 tangs
on the clutch drive plates. Use new parts as required
during assembly.
FWD-RVS Gear Clutch *Under load of 163 kg (359.4 lb)

Clutch pack CA149306
Number of clutch steel plates 6
Nominal clutch plate thickness 2.4 ±0.05 mm
Nominal clutch kit thickness *29.00 - 29.20 mm
Maximum clutch plate wear (each side) 0.35 mm
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end of the reverse shaft. Remove the bearing.
RCPH10TLB128AAL 31
37. Turn the shaft over and insert a shaft protector be-
tween the puller and the end of the reverse shaft.
Remove the bearing.
RCPH10TLB268AAL 32
Next operation:
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Shaft - Assemble - S-Type (SPS Power Synchro) - Shafts A - D

1. Assemble new teflon ring and relevant inner O-rings,
respectively into the piston outer and inner seats.
RCPH10TLB266AAL 1
2. Apply a thin film of transmission oil on the sealing

rings just inserted.
RCPH10TLB198AAL 2
3. Insert clutch piston with 380001926 clutch pack pis-

ton installer.
RCPH10TLB931AAL 3
4. Assemble sleeve.
RCPH10TLB116AAL 4
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5. Assemble spring and lock spring cover.
RCPH10TLB122AAL 5
6. Lower the lock spring cover. Insert lock ring Use tool
380100109 or CAS2379.
RCPH10TLB121AAL 6
7. Insert pin.
RCPH10TLB129AAL 7
8. Insert thrust washer.
RCPH10TLB130AAL 8
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9. Insert needle cage.
RCPH10TLB131AAL 9
10. To assemble the clutch pack start with the gear on

the bench. Install the clutch plate lock ring so that
the reference mark on top of the plate made during
disassembly is facing towards the gear.
RCPH10TLB132AAL 10
11. Assemble clutch plates and clutch drive plates on the

gear . The assembled clutch pack must contain six
clutch drive plates and six clutch plates.
RCPH10TLB133AAL 11
12. Locate the pack assembly by means of two screw-

drivers.
RCPH10TLB134AAL 12
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13. Assemble lock ring and washer.
RCPH10TLB135AAL 13
14. Heat the bearing to ] 80 - 100 °C (176.0 - 212.0 °F)

Assemble bearing.
RCPH10TLB135AAL 14
RCPH10TLB136AAL 15
gear, spacer, bearing, and snap ring installed on the input shaft.
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16. Install the spacer and protector from kit 380040161

onto the input shaft with the chamfered end facing in.
RCPH10TLB140AAL 16
17. Slide the 380001428 expander/protector onto the in-

put shaft and over the spacer. The expander/protec-
tor will stop in the correct position to install the seal
ring in the groove.
RCPH10TLB826AAL 17
18. Heat the Teflon seal ring to 60 - 80 °C (140.0 - 176.0

°F) for 5 minutes. Install the teflon seal ring onto the
expander/protector.
RCPH10TLB826AAL 18

tector and slide the seal ring until it reaches the
groove in the shaft. Remove the pusher, ex-
pander/protector, and spacer from the shaft.
RCPH10TLB830AAL 19
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seal ring. Use a back and forth twisting motion to
RCPH10TLB831AAL 20
seal ring. Leave the seal compressor in place for
from the shaft.
RCPH10TLB841AAL 21
NOTE: Repeat steps 1 through 13 for the other shaft

side with the oil grooves is down.
RCPH10TLB170AAL 22
23. Heat the bearing to 80 - 100 °C (176.0 - 212.0 °F)Use

a suitable driver to drive the bearing onto the input
shaft until the bearing makes contact with the thrust
washer.
RCPH10TLB211AAL 23
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24. Assemble snap ring. Using two pry bars lift the bear-
ings toward the snap ring to have clearance between
gear and bearing.
RCPH10TLB169AAL 24
25. Assemble the teflon seal rings as follows: place

the 380001929 spacer into the 380001933 ex-
pander/protector.
RCPH10TLB897AAL 25

spacer onto the shaft. The expander/protector will
stop in the correct position to install the seal ring in
the groove.
RCPH10TLB899AAL 26
27. Heat the Teflon seal ring to 60 - 80 °C (140.0 - 176.0

°F) for 5 minutes. Install the teflon seal ring onto the
expander/protector.
tector and slide the seal ring until it reaches the
groove in the shaft. Remove the pusher, ex-
pander/protector, and spacer from the shaft.
RCPH10TLB902AAL 27
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Be careful not to damage the seal ring. After the
RCPH10TLB904AAL 28
seal ring. Leave the seal compressor in place for
from the shaft.
RCPH10TLB904AAL 29
NOTE: For the introduction of the other three teflon rings, repeat the operations from sequence 27 to sequence 31,
using the following spacer rings: 380001931 for the 2nd teflon ring, 380001930 for the 3rd teflon ring, 380001929 for
the 4th teflon ring.
31. See the illustration. Apply compressed air of approx-
imately 6 bar 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 for-
ward gear must not turn on the input shaft. Try to
move the reverse gear. The reverse gear must turn
freely on the input shaft. If the clutches do not work
correctly, disassemble the clutches to find the prob-
lem. RCPH10TLB054GAL 30
32. Apply compressed air of approximately 6 bar 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, disassemble the
clutches to find the problem.
RCPH10TLB054GAL 31
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33. Carry out the end float-check procedure of the clutch

pack on the both sides of the FWD-RVS GEAR
CLUTCH. In order to eliminate the end float position
the shaft on a suitable support(s) and apply a load
on the clutch counterdisk surface with a suitable
driver, as indicated in figure.
RCPH10TLB149ACL 32
34. In order to verify the end float feed the piston cham-
ber with compressed air at 6 bar (87.0 psi) and check
with a dial gauge located as shown in the photo the
real stroke “X”. Measure the end float X (see next
figure and figure 33 )
RCPH10TLB150ACL 33
35. Check the stroke of the piston. The end float value
must be: X= 1.60÷2.45 mm If the distance is not
within the range specified the clutch could be assem-
bled wrongly. Turn the clutch and repeat the same
operation for the other clutch pack (steps 33, 34 and
35).
RCPH10TLB004BAN 34
36. Assemble D shaft bearing using a suitable driver.
RCPH10TLB125ACL 35
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37. Assemble the input shaft (1). Assemble the idler

shaft (2).
RCPH10TLB177ACL 36
38. The operation is correct only if the two shafts are

fitted at the same time.
RCPH10TLB136ACL 37
Next operation:
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Shaft - Disassemble - S-Type (SPS Power Synchro) - Shafts B- C

1. Use approved lifting equipment to begin lifting the
secondary shaft while you use your hands to lift the
primary shaft. At the same time, move the primary
shaft back and forth to keep the primary shaft moving
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.
RCPH10TLB913AAL 1
2. Remove the shift rod and fork assembly.
RCPH10TLB915AAL 2
3. Remove bearing by means of an extractor.
RCPH10TLB113AAL 3
4. Remove thrust washer and third speed gear.
RCPH10TLB779AAL 4
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RCPH10TLB172AAL 5
RCPH10TLB173AAL 6
NOTE: Take care during removal of sleeve, this will free the spring plates, hub pins and hub springs.
7. Remove the gear and clutch from the shaft.
RCPH10TLB174AAL 7
RCPH10TLB284AAL 8
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9. This figure shows the relationship between the plates

(1), the balls (2), the hub springs (3), and the syn-
chronizer hub (4). The synchronizer hub contains 3
plates,3 pins, and 3 springs.
RCPH10TLB076ACL 9
10. Remove fourth speed gear.
RCPH10TLB288AAL 10
RCPH10TLB184AAL 11
12. Remove the inner race bearing with a suitable ex-

tractor.
RCPH10TLB098ACL 12
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RCPH10TLB785AAL 13
14. Remove the shims (1)and the thrust washer (2).
RCPH10TLB137ACL 14
RCPH10TLB187AAL 15
16. Remove second speed gear.
RCPH10TLB193AAL 16
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17. Remove the first/second speed synchronizer assem-

bly.
RCPH10TLB101ACL 17
18. Remove synchronizer ring.
RCPH10TLB051ACL 18
19. Remove the steel ring (1)and the ring (2)together.
RCPH10TLB052ACL 19
20. Remove the tapered friction ring (1).
RCPH10TLB053ACL 20
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21. Turn the synchronizer assembly over and remove the

synchronizer ring (1)from the other side.
RCPH10TLB054ACL 21
22. Remove the steel ring (1)and the sintered ring (2).
RCPH10TLB055ACL 22
23. Remove the tapered friction ring (1).
RCPH10TLB056ACL 23
24. Support the sleeve on blocks. Push down on the hub

while you use a punch to push the detent assemblies
out of the sleeve and hub. Remove the sleeve from
the hub.
RCPH10TLB079ACL-2 24
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25. This photo shows the relationship between the balls,

the plate, the spring, and the hub.
26. Remove first speed gear.
RCPH10TLB102ACL 26
RCPH10TLB103ACL 27
28. Remove the 4WD gear.
RCPH10TLB104ACL 28
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RCPH10TLB105ACL 29
30. Remove the inner race bearing (1)with an extractor.
31. Turn the shaft. Remove bearing.
Next operation:
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Shaft - Assemble - S-Type (SPS Power Synchro) - Shafts B- C

1. 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 snap ring as shown.
RCPH10TLB105ACL 1
2. Assemble 4WD gear.
RCPH10TLB104ACL 2
3. Assemble the snap ring.
RCPH10TLB103ACL 3
4. Assemble the first speed gear.
RCPH10TLB102ACL 4
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5. Assemble the first/second speed synchronizer. This

photo shows the correct positions of the hub, the
sleeve, the springs, the plates, and the balls prior to
final assembly. The springs are installed in the hub,
and the plates are on the springs. The plates 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 plates.
RCPH10TLB951AAL 5
6. Use a punch or screwdriver to push the balls into the

plates and to push the plates down so that the balls
are on the flat faces of the teeth, but not into the
detent grooves. When all the balls are in position,
push the hub and the plates down until the balls move
into the detent groove.
RCPH10TLB952AAL 6
7. Install the tapered friction ring on the synchronizer

assembly.
RCPH10TLB056ACL 7
8. Use clean transmission oil to lubricate the sintered

ring and the steel ring. Install the sintered ring and
the steel ring as shown in figure.
RCPH10TLB946AAL 8
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9. Install the synchronizer ring as shown in figure. The

flat sides of the teeth must be up.
RCPH10TLB945AAL 9
10. Turn the synchronizer assembly over and install the

tapered friction ring on the other side.
RCPH10TLB947AAL 10
11. Use clean transmission oil to lubricate the sintered

ring and the steel ring. Install the sintered ring and
the steel ring as shown. 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 syn-
chronizer 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 synchronizer assem-
bly over, and repeat the procedure with the bottom RCPH10TLB946AAL 11
synchronizer ring. If the sleeve does not engage

the teeth smoothly or does not stay in position when
moved to any of the three positions, the synchronizer
assembly has damaged parts or was not assembled
correctly. Disassemble the synchronizer assembly to
find the problem.
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12. Install the top synchronizing ring (1)so that the flat
sides of the teeth are up. Install the first/second
speed synchronizer assembly (2).
RCPH10TLB101ACL 12
13. Assemble the second speed gear.
RCPH10TLB100ACL 13
14. Assemble roll pin.
RCPH10TLB099ACL 14
15. Assemble thrust washer (1)and shims (2).
RCPH10TLB107ACL 15
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16. Assemble snap ring. Measure the backlash X be-

tween gear and thrust washer: the value must be
between 0.2 -0.42 mm.
17. Use a thickness gauge.
RCPH10TLB108ACL 17
18. If backlash X is more than the value prescribed re-

move the snap ring and the washer from their seat
and, using the shims shown in the chart reach the
prescribed value. Assemble shims between thrust
washer and snap ring.
RCPH10TLB137ACL 18
19. Heat the inner race of the bearing (1)to 80 - 100 °C

(176.0 - 212.0 °F). Assemble the inner race of the
bearing (1).Use a suitable driver.
RCPH10TLB082ACL 19
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20. Assemble the outer race bearing.
RCPH10TLB097ACL 20
21. Turn the shaft. Assemble the fourth speed gear.
RCPH10TLB135ACL 21
22. Assemble the third/fourth speed synchronizer This

figure shows the correct positions of the hub (1), the
sleeve (2), the springs (3), the plates (4), and the
balls (5)prior to final assembly. The springs are in-
stalled in the hub, and the plates are on the springs.
The plates are not yet pushed down into the sleeve
and are holding the hub up out of the sleeve. The
pins are loose in the recesses of the plates.
RCPH10TLB077ACL 22
23. Install the 3 sets of hub springs, hub pins and spring
plates into the synchronizer hub. Use a punch or
screwdriver to push the spring plates as the synchro-
nizer hub is installed into the sleeve. Be sure that
the spring plates are aligned with the grooves in the
sleeve.
RCPH10TLB952AAL 23
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24. Install the tapered friction ring on each side the syn-
chronizer assembly.
RCPH10TLB083ACL 24
25. Use clean transmission oil to lubricate and install the

clutch ring on each side of the synchronizer assem-
bly. Install the top synchronizer ring on the synchro-
nizer 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 over-
come the strength of the detent springs and balls.
When the synchronizer ring and the sleeve are com-
pletely engaged, the detent must hold the sleeve in
this position. Push the sleeve back down to the neu-
tral position, turn the synchronizer assembly over,
and repeat the procedure with the bottom synchro- RCPH10TLB134ACL 25
nizer ring. If the sleeve does not engage the teeth

smoothly or does not stay in position when moved to
any of the three positions, the synchronizer assembly
has damaged parts or was not assembled correctly.
Disassemble the synchronizer assembly to find the
problem.
26. Install the third/fourth speed synchronizer assembly
onto the shaft.
RCPH10TLB106ACL 26
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washer. Assemble third speed gear and the thrust
washer onto the shaft.
RCPH10TLB084ACL 27
28. Heat the bearing (1)to 80 - 100 °C (176.0 - 212.0 °F).

Assemble bearing (1). Use a suitable driver.
RCPH10TLB085ACL 28
29. Heat the inner race of the bearing (1)to 80 - 100 °C

(176.0 - 212.0 °F). Assemble the inner race of the
bearing. Use a suitable driver.
RCPH10TLB086ACL 29
30. Turn the shaft. Heat the bearing to 80 - 100 °C (176.0

- 212.0 °F). Assemble bearing. Use a suitable driver.
RCPH10TLB088ACL 30
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31. Fit the pre assembled forks 3rd and 4th speed and
1st and 2nd as shown in the photo.
RCPH10TLB163ACL 31
32. Assemble the 4WD shaft Remove the secondary

shaft and the primary shaft. Use suitable lifting
apparatus.
RCPH10TLB178ACL 32
33. Position the group with care paying attention to the

location of fork pins in their seats.
RCPH10TLB164ACL 33
Next operation:
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Shaft - Disassemble - S-Type (SPS Power Synchro) - Shaft E (4WD)

1. Remove shaft E.
RCPH10TLB719AAL 1
2. Remove the four-wheel drive clutch gear.
RCPH10TLB733AAL 2
NOTE: Make a mark on the top end of the reverse shaft so that you can install the reverse shaft with the same end
up during Assembly.
3. Remove bearing.
RCPH10TLB917AAL 3
RCPH10TLB188AAL 4
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5. Remove sleeve.
RCPH10TLB889AAL 5
6. Remove the two O-rings and sealing rings from the

shaft.
RCPH10TLB890AAL 6
7. Remove the four-wheel drive clutch tube (7) from the

front housing only if the front housing must be re-
placed or if the tube is leaking or damaged.
RCPH10TLB027ABL 7
Next operation:
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Shaft - Assemble - S-Type (SPS Power Synchro) - Shaft E (4WD)

1. Assemble the O-Rings on the shaft. Lubricate with
oil transmission.
RCPH10TLB090ACL 1
2. Assemble sleeve.
RCPH10TLB129ACL 2
3. Assemble springs.
RCPH10TLB128ACL 3
4. Install spacer.
RCPH10TLB127ACL 4
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5. Position washer (1)and snap ring (2).
RCPH10TLB092ACL 5
6. Use a suitable tool to press the springs retainer down

until you have access to the snap ring. Install the
snap ring in the groove. Release the tension and
remove the tool. Make sure that the snap ring is
seated in the recess in the spring retainer.
RCPH10TLB091ACL 6
7. Place the protector 380001430 onto the shaft. The

expander/protector will stop in the correct position to
install the teflon sealing ring in the groove. Heat the
teflon sealing ring to 60 - 80 °C (140.0 - 176.0 °F)
Install it onto the expander/protector.
RCPH10TLB093ACL 7

RCPH10TLB094ACL 8
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RCPH10TLB095ACL 9
from the shaft.
RCPH10TLB095ACL 10
11. Assemble protector 380001933. Repeat the opera-

tions from sequence 7 to sequence 10 for the intro-
duction of the second teflon ring. Lubricate the seals
with oil transmission.
RCPH10TLB096ACL 11
12. Apply air compressed at about 6 bar (87.0 psi)to

4WD clutch oil passage (see arrow) by plugging the
opposite hole with a finger. The sleeve should be
moving when compressing the springs . The 4WD
gear should move freely on 4WD shaft. If the opera-
tion is incorrect, dismantle to find the problem.
RCPH10TLB164GAL 12
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13. Install bearing.
RCPH10TLB124ACL 13
14. Install gear.
RCPH10TLB123ACL 14
15. Assemble shafts B and C. Assemble shaft E.
RCPH10TLB122ACL 15
16. If the four-wheel drive clutch tube (1)was removed

from the front housing, install the four-wheel drive
clutch tube. Torque wrench setting TRANSMISSION
Powershift - Torque (C.20.E). Assemble the front
half housing on the rear half housing
RCPH10TLB130ACL 16
Next operation:
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Shaft - Disassemble - S-Type (SPS Power Synchro) - Shift rails

- forks
1. Remove the secondary shaft and the primary shaft .
Use suitable lifting device.
RCPH10TLB178ACL 1
2. Remove shift forks 1st and 2nd gear (1)and shift rail
(2).
RCPH10TLB143ACL 2
3. Remove shift forks 3rd and 4th gear (1)and shift rail
(2).
RCPH10TLB142ACL 3
4. If disassembly is required, remove the spring pins

(1)and separate the shift forks from the shift rails.
Make sure that you remember how the parts are as-
sembled and which parts go together. Inspect all
parts for burrs and excessive wear.
RCPH10TLB198ACL 4
Next operation:
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Shaft - Assemble - S-Type (SPS Power Synchro) - Shift rails - forks

1. Pay attention to the proper forks assembly on the
shift rails holes. The shift rails are equal
RCPH10TLB141ACL 1
2. Assemble shift forks 1st and 2nd gear (1)onto the

shift rail (2). Dimension A: about 46 mm
RCPH10TLB073ACL 2
3. Assemble shift forks 3rd and 4th gear (1)onto the shift
rail (2). Dimension B: about 62 mm
RCPH10TLB074ACL 3
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4. Pay attention to the proper assembly
RCPH10TLB075ACL 4
5. Position the roll pin.
RCPH10TLB198ACL 5
6. 1st and 2nd gear shift fork. Assemble the spring pin
to lock the fork to the shift rail.
RCPH10TLB071ACL 6
7. 3rd and 4th gear shift fork. Assemble the spring pin
to lock the fork to the shift rail.
RCPH10TLB072ACL 7
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8. Assemble shift forks 3rd and 4th gear and shift rail
on the synchronizer.
RCPH10TLB142ACL 8
9. Assemble shift forks 1st and 2nd gear and shift rail
on the synchronizer.
RCPH10TLB143ACL 9
10. Assemble the 4WD shaft on the rear half-housing.

Assemble the secondary shaft and the primary shaft.
Use suitable lifting equipment.
RCPH10TLB178ACL 10
11. Position the group with care paying attention to the

location of fork pins in their seats.
RCPH10TLB164ACL 11
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Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed

gears shift rails adjustment - Back side measurement
1. Operate on the front side. Remove the screw and
the front engagement bushing with shims.
RCPH10TLB213ACL 1
2. Assemble the dealer made tool for the load applica-

tion.
RCPH10TLB242ACL 2
3. Pull the dealer made tool in order to apply a 2 kg (4.5

lb) load.
RCPH10TLB241ACL 3
4. Control and note the calibrated length A of the dealer

made tool (calibrated length A= 115 mm (4.5 in)).
RCPH10TLB263ACL 4
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5. Operate on the rear side. Assemble the tool and use

it as a guide for the special tool.
RCPH10TLB258ACL 5
6. Assemble the tool.
RCPH10TLB259ACL 6
7. Assemble the tool.
RCPH10TLB260ACL 7
8. Assemble the tool for the splined shaft blocking.
RCPH10TLB261ACL 8
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9. Measure the distance from the tool shoulder to the

upper shaft end by using a depth gauge. Note the
measured value M(R)
RCPH10TLB262ACL 9
10. Calculate the dimension C value: C= M(R)- A [ m m ]
RCPH10TLB026ACL 10
11. Measure the rear engagement bushing outer length

and note the measured value LE(R).
RCPH10TLB264ACL 11
12. Measure the rear engagement bushing depth and

note the measured value LI(R).
RCPH10TLB265ACL 12
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13. Calculate total shim SR value for the rear engage-

ment bushing: S(R)= C - (LE(R)- LI(R)) [ m m ]
RCPH10TLB016ACL 13
14. Operate on the rear side. Remove the tool and as-
semble the tool to the upper shaft. Assemble the
shims by using the tool as a guide.
RCPH10TLB266ACL 14
15. Assemble the rear engagement bushing by using the

special tool as a guide, in order to assemble the
shims too.
RCPH10TLB268ACL 15
NOTE: The bushing external slots must be positioned as shown in figure.

16. Shaft-bushing coupling: the bushing rotation stop
tooth must be coupled with the slot on the upper
shaft.
RCPH10TLB025ACL 16
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17. Operate on the front side. Remove the tool for the
load application. Operate on the rear side. Assemble
the tool to the upper shaft.
RCPH10TLB243ACL 17
Next operation:
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gears shift rails adjustment - Front side measurement
1. Operate on the front side. Assemble the special tool
and use it as a guide for the special tool . Assemble
the special tool . Assemble the special tool.
RCPH10TLB210ACL 1
2. Operate on the rear side. Pull the special tool in order

to apply a 2 kg load to the upper shaft.
RCPH10TLB243ACL 2
3. Operate on the front side. Measure the distance from

the special tool shoulder to the upper shaft end by
using a depth gauge. Note the measured value M(F).
RCPH10TLB210ACL 3
4. Calculate the dimension B value: B= M(F)- A [ m m

] Where A is the calibrated length on the special tool
(calibrated length A= 115 mm)
RCPH10TLB027ACL 4
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5. Measure the front engagement bushing outer length

and note the measured value LE(F).
RCPH10TLB264ACL 5
6. Measure the front engagement bushing depth and

note the measured value LI(F).
RCPH10TLB265ACL 6
7. Calculate total shim SF value for the rear engage-

ment bushing: SF= C - ( LE(F)- LI(F)) [mm]
RCPH10TLB016ACL 7
8. Operate on the front side. Remove the special tool

and assemble the special tool to the upper shaft.
Assemble the shims by using the special tool as a
guide.
RCPH10TLB211ACL 8
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9. Assemble the front engagement bushing by using

the special tool as a guide, in order to assemble the
shims too.
RCPH10TLB212ACL 9
NOTE: The bushing external slots must be positioned as shown

10. Remove the special tool . Assemble the bushing
fastening screw.
RCPH10TLB213ACL 10
11. Tighten the bushing fastening screw to the requested

torque TRANSMISSION Powershift - Torque
(C.20.E).
RCPH10TLB214ACL 11
Next operation:
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gears shift rails adjustment - Dimension "D" measurement
1. Operate on the rear side. Push the special tool (t1)
in order to apply a 2 kg load as shown in figure.
RCPH10TLB244ACL 1
2. Operate on the front side. Measure the distance D(1)

from the ledge to the upper shaft end by using a
depth gauge. Note the measured value D(1).
RCPH10TLB215ACL 2
3. Measure the depth D(2) from the ledge to the pistons

seat end by using a depth gauge. Note the measured
value D(2).
RCPH10TLB028ACL 3
4. D(2) measurement.
RCPH10TLB216ACL 4
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5. Calculate and note the dimension D value: D = D(2)-

D(1) [ m m ]
RCPH10TLB029ACL 5
Next operation:
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gears shift rails adjustment - Neutral position measurement
1. Remove the bolt from the front piston.
RCPH10TLB219ACL 1
2. Control and note the front piston length P (P= 19 mm)
RCPH10TLB247ACL 2
3. Measure and note the screw head height T.
RCPH10TLB247ACL 3
4. Operate on the front side. Measure and note the

depth D(1) from the ledge to the first shoulder into
the upper shaft pistons seat.
RCPH10TLB218ACL 4
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5. Measure and note the depth D(3). Calculate the

depth D(4): D(4)= D(2)- D(3) [ mm]
RCPH10TLB030ACL 5
6. - D4 is the dimension calculated in the previous step;

- D is the dimension calculated in the previous para-
graph.
RCPH10TLB031ACL 6
7. Calculate the value of the total shim S(V) that have to

be positioned under the screw (8) head: S(V)= D(4)-
(D/2) - P -T [ mm ]
RCPH10TLB032ACL 7
8. Assemble the screw and the shims to the front piston.
RCPH10TLB245ACL 8
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9. Stop the piston with a suitable open-end wrench then

tighten the screw to the requested torque.
RCPH10TLB219ACL 9
10. Verify the indicated distance: P+S(V)+ T [ mm ]
RCPH10TLB248ACL 10
11. Operate on the rear side. Engage the “neutral” posi-

tion by using the special tool.
RCPH10TLB243ACL 11
12. Remove the special tool. Assemble the bushing fas-

tening screw to the shift rail.
RCPH10TLB208ACL 12
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13. Tighten the rear bushing fastening screw to the re-

quested torque.
RCPH10TLB209ACL 13
14. Assemble the pistons.
RCPH10TLB015ACL 14
15. Proceed with the speed gear switches check proce-

dure.
RCPH10TLB033ACL 15
Next operation:
Clutch and gear - Check (C.20.E)
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Clutch and gear - Check - S-Type (SPS Power Syncro) - Speed gears
switches - Checking procedure
1. Fabricate a tool, composed of threaded tie-rod, nut,
the spacer tee-handle.
RCPH10TLB109ACL 1
2. On the backside of the transmission, Install the

dealer made tools as shown in figure 2.
RCPH10TLB220ACL 2
3. If not assembled, insert the switch detents and the

relative springs into the gear switches holes.
RCPH10TLB221ACL 3
4. If not assembled, assemble the gear switches.
RCPH10TLB222ACL 4
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5. Assemble the upper gear switches. (3rd) 3rd gear

switch; (4th) 4th gear switch; and the lower: (1st) 1st
gear switch; (2nd) 2nd gear switch.
RCPH10TLB151ACL 5
6. Tighten the switches to the specified torque TRANS-

MISSION Powershift - Torque (C.20.E).
RCPH10TLB223ACL 6
7. To tighten the 2nd and 4th gear switch, use a wrench.
RCPH10TLB224ACL 7
8. Prepare the data control electronic box for the

switches regulation: the electronic box must be sim-
ilar to the one schematic shown in figure 8. The box
must have four pilot light, each one corresponding
to a different engagement switch, that light when the
gear is engaged (in figure the pilot lights are marked
with “SW” followed by the gear number). The simul-
taneous lighting of two pilot lights corresponding to
switches installed on the same shaft, correspond to
the neutral gear engagement (in figure the neutral
position is marked with “N”).
RCPH10TLB018ACL 8
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9. Connect the switches cables to data control the elec-

tronic box.
RCPH10TLB225ACL 9
10. Connect the switches cables as shown in figure: A

- 3rd gear switch; B - 4th gear switch; C - 1st gear
switch; D - 2nd gear switch.
RCPH10TLB024ACL 10
11. Operate on the front side. Remove the screw from

bushing.
RCPH10TLB213ACL 11
NOTE: The gear switches check procedure starts with the switches assembled on the upper shaft (3rd and 4th gear
switches).
12. Assemble the dealer made tool to the upper shaft, by
screwing it to the shaft.
RCPH10TLB232ACL 12
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13. Push the dealer made tool until the end of stroke,
in order to engage the third gear. Fix the spacer on
the special tool to the transmission by using two M8
screws.
RCPH10TLB226ACL 13
14. Operate on the back side. Assemble a comparator

for linear measurement and position the comparator
stylus tip on contact with the upper shaft end.
RCPH10TLB227ACL 14
15. Positioning of the stylus tip on contact with the upper

shaft.
RCPH10TLB227ACL 15
16. It is possible to make the measurements with a depth

gauge instead of the comparator.
RCPH10TLB231ACL 16
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17. In the actual assembly position, on the electronic

box, must be lighted the pilot light corresponding to
the third gear engagement.
RCPH10TLB229ACL 17
NOTE: Set the comparator to zero.

18. Operate on the front side. Proceed to the switches
check for the FORWARD STROKE as indicated on
the following steps, by regulating the upper shaft po-
sition with the regulation nut installed on the dealer
made tool. Turn the nut in order to move the upper
shaft toward the fourth gear engagement (front side).
RCPH10TLB230ACL 18
19. During the checking procedure compile the check ta-

ble and compare the measured values with the refer-
ence ones. Insert the measured values on the “MEA-
SURED VALUE” column.
RCPH10TLB019ACL 19
20. The actual position (third gear engaged at end of the

stroke and SW3 light switched to ON) corresponds
to the “zero” position and is indicated in table with “0”
(THIRD GEAR ENGAGED).
RCPH10TLB020ACL 20
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NOTE: Reminder: The procedure starts with the upper shaft switch check (third and fourth gear), so the involved pilot
lights are the ones relative to SW3 and SW4 switches.
21. Operate slowly on the regulation nut as shown in step
[19], until the SW3 pilot light turns to OFF. Note on the
table the value measured by the comparator (THIRD
GEAR - MEASURE 1)
RCPH10TLB230ACL 21
22. Electronic box status in the current position.
RCPH10TLB018ACL 22
23. Operate slowly on the regulation nut, until the SW4

pilot light turns to ON. Note on the table the value
measured by the comparator (NEUTRAL POSITION
- MEASURE 2).
RCPH10TLB230ACL 23
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RCPH10TLB022ACL 24

- MEASURE 3).
RCPH10TLB230ACL 25
26. Electronic box status in the current position (neutral

position).
RCPH10TLB021ACL 26
27. Operate slowly on the regulation nut until the SW4

pilot light turns to OFF. Note on the table the value
- MEASURE 4).
RCPH10TLB230ACL 27
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RCPH10TLB020ACL 28
29. Operate slowly on the regulation nut until the SW3

pilot light turns to OFF. Note on the table the value
- MEASURE 5).
RCPH10TLB230ACL 29
RCPH10TLB018ACL 30

measured by the comparator (FOURTH GEAR -
MEASURE 6).
RCPH10TLB230ACL 31
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RCPH10TLB022ACL 32
33. Operate slowly on the regulation nut, until the end of

the stroke and note on the table the value measured
by the comparator (FOURTH GEAR - MEASURE 7)
RCPH10TLB230ACL 33
RCPH10TLB022ACL 34
35. Operate on the front side. Proceed to the switches

check for the BACKWARD STROKE by carrying out
backwards the steps from [21] to [34] and note the
measured values on the check table. Turn the nut in
order to move the upper shaft toward the third gear
engagement (back side).
RCPH10TLB230ACL 35
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36. Proceed with the lower shaft switches check (first

and second gear). Repeat the operations from step
[12] to step [34], where it must be used SW1 instead
of SW3 and SW2 instead of SW4. Carry out the
same measure by using the linear comparator and
note the values in the relative column on the checking
table.
RCPH10TLB230ACL 36
37. Compare the measured values obtained from the

procedure with the reference values.
RCPH10TLB023ACL 37
38. If the check results are not positive, adjust the shims
to obtain the prescribed tolerance range. Carry out
the switches check procedure again.
RCPH10TLB017ACL 38
Third and fourth gear check list

Stroke Gear Measure SW3 SW4 Measured Reference Result
Value (mm) Value (mm)
- ON OFF 0 Engaged
3rd
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
7.6/8.8
3 OFF ON OFF ON
Forward Neutral
4 OFF ON OFF ON
11.4/12.6
5 OFF OFF
6 OFF ON 18.7/19.6
4th
7 OFF ON End of stroke
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Third and fourth gear check list

- OFF ON Engaged
4th
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
7.6/8.8
3 OFF ON OFF ON
Backward Neutral
4 OFF ON OFF ON
11.4/12.6
5 OFF OFF
3rd 6 ON OFF 18.7/19.6
7 ON OFF End of stroke
First and second gear check list

Stroke Gear Measure SW1 SW2 Measured Reference Result
Value (mm) Value (mm)
- ON OFF 0 Engaged
1st
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
8.1/9.3
3 OFF ON OFF ON
Forward Neutral
4 OFF ON OFF ON
11.8/13.0
5 OFF OFF
6 OFF ON 19.6/20.5
2nd
7 OFF ON End of stroke
- OFF ON Engaged
2nd
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
8.1/9.3
3 OFF ON OFF ON
Backward Neutral
4 OFF ON OFF ON
11.8/13.0
5 OFF OFF
1st 6 ON OFF 19.6/20.5
7 ON OFF End of stroke
Next operation:
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Housing - Disassemble - S-Type (SPS Power Synchro) - Front

housing
1. Remove the cap screws that fasten the front and rear
housings together.
RCPH10TLB258AAL 1
2. Remove bearing snap ring
RCPH10TLB176ACL 2
3. Untighten and remove flange retaining screw. Use a

screwdriver and two screws to avoid flange rotation.
RCPH10TLB110ACL 3
4. Remove washer.
RCPH10TLB111ACL 4
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5. Remove flange (1)and O-ring (2).
RCPH10TLB112ACL 5
6. Remove the three cap screws.
RCPH10TLB113ACL 6
RCPH10TLB114ACL 7
RCPH10TLB115ACL 8
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9. Remove the seal from the cover.
RCPH10TLB116ACL 9
10. Remove screws.
RCPH10TLB132ACL 10
11. Remove screws.
RCPH10TLB117ACL 11
12. Use lever to remove the front half housing. Lift the
front half housing by means of two hooks.
RCPH10TLB133ACL 12
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13. Use a plastic mallet to detach the half housing if nec-

essary.
RCPH10TLB200ACL 13
NOTE: Do not lift the shafts of the transmission; remove the shaft from relative seats could produce seal rings damage.
14. The outer rings of the bearings for the primary shaft
(1)and for the secondary shaft (2)can stay with ei-
ther the shafts or the front housing. Remove the two
bearings.
RCPH10TLB119ACL 14
15. Remove the bearings of the primary shaft (1), and

secondary shaft (2) from the front half housing and
assemble all the bearings on the relative shaft.
RCPH10TLB250ACL 15
NOTE: Do not overturn the bearings; the bearings must be assembled in the same position.
16. Remove the 4WD shaft (1) with a plastic mallet.
RCPH10TLB206ACL 16
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17. Remove bearing.
RCPH10TLB118ACL 17
(2).
RCPH10TLB177ACL 18
19. Remove the four-wheel drive clutch tube (1)from the

front housing only if the front housing must be re-
placed or if the tube is leaking or damaged.
RCPH10TLB044ACL 19
20. Replace O-rings (N° 6), if necessary.

21. Close all oil pipe holes with rubber plugs.
RCPH10TLB249ACL 20
Next operation:
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Housing - Assemble (C.20.E)
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Housing - Assemble - S-Type (SPS Power Synchro) - Front housing

NOTE: Thoroughly inspect the transmission prior to assembly.
1. Remove the oil from the rear housing edge. Examine
with care the housing and the inner parts to check
the presence of any impurity (dirty, file dust or chips).
Clean with care to remove all the impurities.
RCPH10TLB161ACL 1
2. Remove all the old sealant from the rear housing cou-
pling surface with a suitable tool.
RCPH10TLB202ACL 2
3. Use a sealant solvent.
RCPH10TLB201ACL 3
4. Clean the O-Rings seats. Degrease and dry the cou-

pling surface of the rear housing.
RCPH10TLB203ACL 4
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5. Apply the prescribed sealant on the coupling surface

of the rear housing .
RCPH10TLB204ACL 5
6. Spread the sealant in a film of uniform thickness.
RCPH10TLB162ACL 6
NOTE: Do not put the sealant in the O-Ring seats.

7. Clean the O-Ring seats.
RCPH10TLB205ACL 7
8. Assemble the 6 O-rings.
RCPH10TLB254ACL 8
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9. Push the 6 O-Rings into their seats.
RCPH10TLB254ACL 9
10. Clean and assemble the 4WD shaft.
RCPH10TLB719AAL 10
11. Use clean transmission oil to lubricate the bearing

for the primary shaft (1)and the bearing for the sec-
ondary shaft (2). Install the bearings.
RCPH10TLB250ACL 11
12. If the four-wheel drive clutch tube (1)was removed

from the front housing, install the four-wheel drive
clutch tube. Torque to TRANSMISSION Powershift
- Torque (C.20.E).
RCPH10TLB044ACL 12
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13. Install the front half housing on the rear half housing.
Make sure that the bearings on the shafts go straight
into the bores in the front half housing. Push the
front half housing all the way down on the rear half
housing.
RCPH10TLB169ACL 13
14. Assemble screws (16). Torque to 100 N·m (73.8 lb

ft).
RCPH10TLB259AAL 14
15. Assemble screws (16). Tightening torque 50 N·m

(36.9 lb ft).
RCPH10TLB258AAL 15
16. Use clean transmission oil to lubricate the bearing

for the 4WD shaft. Install the bearing (1) on the 4WD
shaft. Use suitable driver.
RCPH10TLB089ACL 16
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17. The seal ring must be installed to the end of its seat
into the cover, if necessary push the seal ring to the
end of its seat with a suitable tool and a hammer.
RCPH10TLB115ACL 17
18. Use a suitable tool and a hammer to install a new

seal (1) in the cover (2).
RCPH10TLB120ACL 18
19. Use a suitable tool to push the seal just to the end.
After the assembly, lubricate the seal ring lip with
grease
RCPH10TLB013ACL 19
20. Assemble the O-Ring.
RCPH10TLB115ACL 20
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21. Install the cover in the front housing.
RCPH10TLB114ACL 21
22. Install the three cap screws which fasten the cover
to the front housing. Tightening torque TRANSMIS-
SION Powershift - Torque (C.20.E).
RCPH10TLB113ACL 22
23. Install a new O-ring in the four-wheel drive flange.
RCPH10TLB112ACL 23
24. Install the four-wheel drive flange on the four-wheel

drive shaft.
RCPH10TLB121ACL 24
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RCPH10TLB111ACL 25
26. Assemble screw. Use screwdriver to avoid flange ro-

tation. Tightening torque TRANSMISSION Power-
shift - Torque (C.20.E).
RCPH10TLB110ACL 26
27. Assemble the bearing snap ring. Assemble the oil

pump TRANSMISSION Powershift - Assemble
(C.20.E).
RCPH10TLB176ACL 27
28. Assemble the groups.
RCPH10TLB175ACL 28
Next operation:
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Electronic control - Disassemble S-Type (SPS Power Synchro)

- Switches and sensors
1. Drain the oil from the transmission hydraulic circuit.
Remove screws, (1)Remove pipe (3) Remove gas-
kets (2)
RCPH10TLB131ACL 1
2. Remove the wiring harness (1)Remove the temper-

ature sensor and thermostat (2)
RCPH10TLB036ACL 2
3. Remove the male pressure switch (2)and washer

(1)Remove the regulating pressure valve (3)Remove
the speed sensor (4)and washer seal (5)
RCPH10TLB037ACL 3
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4. Remove the screw (1)and bracket (2). Remove the

switch gear (3)and O-rings (4).
RCPH10TLB038ACL 4
5. If necessary, remove the O-rings and the back-up

rings from the valve.
RCPH10TLB242ACL 5
NOTE: Seal rings must not be re-used

6. Remove springs (1)and pins (2)
RCPH10TLB241ACL 6
Next operation:
Electronic control - Assemble (C.20.E)
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Electronic control - Assemble - S-Type (SPS Power Synchro) -

Switches and sensors
Prior operation:
Electronic control - Disassemble (C.20.E)
1. Assemble the switch detents (1) and springs (2). Use

a magnet, if necessary.
RCPH10TLB003BAN 1
2. Remove the screw (1) and bracket (2). Remove the

switch gears (3) and O-rings (4). Torque to TRANS-
MISSION Powershift - Torque (C.20.E)
RCPH10TLB038ACL 2
3. Assemble the switch gears as shown.
RCPH10TLB151ACL 3
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4. Use slotted sensor socket to assemble the 2nd and

4th gear switches.
RCPH10TLB157ACL 4
5. Assemble new O-rings and back-up rings on the

valve.
RCPH10TLB242ACL 5
6. Assemble the male pressure switch (1) with washer

(2). Assemble the regulating pressure valve (3).
Remove the speed sensor (4) with washer seal (5).
Torque to TRANSMISSION Powershift - Torque
(C.20.E)
RCPH10TLB037ACL 6
7. Assemble the temperature sensor and thermo-

stat (1). Torque to TRANSMISSION Powershift -
Torque (C.20.E). Assemble the wiring harness (2).
RCPH10TLB036ACL 7
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8. Assemble pipe (3)and screws (1)Replace gaskets

(2)and torque to TRANSMISSION Powershift -
Torque (C.20.E)
RCPH10TLB131ACL 8
Next operation:
Control valve - Disassemble (C.20.E)
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TRANSMISSION Powershift - Testing Machine Will Not Move,

H-Type and S-Type
Verify the transmission oil level. Re- The oil level is correct. Go to next The transmission oil level is not cor-
fer to TRANSMISSION Powershift step. rect. Check for leaks. Fill the trans-
- General specification (C.20.E). mission oil to the proper level. Re-
Refer to Transmission Fluid Level in fer to Transmission Fluid Level in the
the Operator’s Manual. Operator’s Manual.
Does the SAHR parking brake re- Yes, the SAHR parking brake does No, the SAHR parking brake does
lease? release. Go to next step. not release. Check transmission oil
pressure and electrical supply to the
solenoid. Repair as required.
Check for broken universal joint or The drive shaft and universal joint The drive shaft or universal joint is
drive shaft. are free from damage. Go to next damaged. Repair as required.
step.
Raise the rear wheels off the ground. The drive shaft turns when the trans- The drive shaft does not turn. Check
Check mission directional control lever the electrical connections to the
Verify that the drive shaft turns when (FNR) is moved into Forward or Re- transmission. Verify that there is
the transmission directional control verse. Go to next step. power to the clutch solenoids. Check
lever (FNR) is moved into Forward or fuse F-024.
Reverse.
Check transmission pressure and The transmission pressures and
pump flow. pump flow are within specifications. The transmission pressures
and pump flow are not within
specifications. Possible causes
include:
• Cold oil by-pass valve
may be stuck or dam-
aged.
• Faulty pressure regulator.
• Faulty transmission oil
pump. Repair or replace
as required.
Check the converter IN pressure. The converter IN pressure is within The converter IN pressure is not
specifications. Go to next step. within specifications. Check the
transmission control valve. Repair
or replace as required.
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Check the Forward and Reverse so- The regulated clutch pressures are The regulated clutch pressures are
lenoid valve. within the specified range. Go to not within the specified range. Re-
next step. fer to Forward and Reverse solenoid
troubleshooting in the Service Man-
ual.
Check regulated clutch pressure. The regulated clutch pressure is
within specifications. The regulated clutch pressure is
not within specifications. Possible
causes include:
• Pressure remains zero in
Forward, Neutral and Re-
verse. Check the control
valve.
• Pressure is low, check the
control valve.
• Pressure is Forward and
Reverse are the same.
Check the control valve.
• Forward and Reverse
pressures are different.
Inspect the individual
clutch circuits.
TRANSMISSION Powershift - Testing Loss of Power, H-Type and

S-Type
Verify that there is not a buildup of The wheel wells and drive train are There is mud and debris in the wheel
mud or foreign material on the inside free of mud and debris. Go to next well or along the drive train. Remove
of the wheel wells or along the drive step. all mud and debris. If the problem
train. still exists, go to next step.
Perform a stall test according to The engine performed to specifica- The engine did not perform to speci-
the instructions in TRANSMISSION tions during the stall test. Go to next fications during the stall test. Repair
Power Shuttle - Test — Check- step. the engine as required.
ing Regulated Clutch Pressure
(C.20.C).
Check the regulated clutch pressure. The pressures are within specifi- The pressure is out of range. In-
Refer to TRANSMISSION Power cations. Go to TRANSMISSION spect the input shaft sealing rings
Shuttle - Test — Checking Regu- Power Shuttle - Testing — Ma- and clutch piston seals. Inspect the
lated Clutch Pressure (C.20.C) chine Will Not Move (C.20.C) forward and reverse clutch friction
discs. Repair or replace as required.
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TRANSMISSION Powershift - Testing Wheels Rotate When Vehicle

is Raised, H-Type and S-Type
Verify the proper transmission oil The oil type is correct. Go to next The transmission oil type is not cor-
type. Refer to TRANSMISSION step. rect. Drain and fill the transmission
Powershift - General specifica- with the proper oil type. Refer to
tion (C.20.E). Refer to Transmission Transmission Fluid Level in the Op-
Fluid Level in the Operator’s Man- erator’s Manual.
ual.
Is the oil temperature low (high oil The oil is at the proper operating The oil temperature is low. Refer
viscosity) temperature, between 78 °C (172.4 to the warm-up procedure, TRANS-
°F) and 82 °C (179.6 °F). Go to next MISSION Powershift - Warm up
step. Heating the Oil (C.20.E).
Verify that the control valve is allow- The control valve is not allowing The control valve is allowing pres-
ing pressure to the clutches while in pressure to the clutches while in sure to the clutches while in neutral.
the neutral position. neutral. Stop. Replace or repair as required.
TRANSMISSION Powershift - Testing Transmission Oil is Too Hot,

H-Type and S-Type
The oil level is correct. Go to next The transmission oil level is not cor-
Verify the transmission oil level. Re-
The transmission oil cooler is clean. The transmission oil cooler is dirty
Check the transmission oil cooler for
Go to next step.
air flow restrictions. Clean the exte- and there are air flow restrictions.
rior of the transmission oil cooler as Clean the exterior of the transmis-
required. sion oil cooler as required. Go to the
next step if the problem still exists.
Check the converter IN pressure. The converter IN pressure is within The converter pressure is not within
Refer to TRANSMISSION Power specifications. Go to next step. specifications. Refer to TRANSMIS-
Shuttle - Test — Checking Con- SION Power Shuttle - Testing —
verter In Pressure (C.20.C) Machine Will Not Move (C.20.C)
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Check the converter OUT pressure. The converter OUT pressure is The converter OUT pressure is
Refer to TRANSMISSION Power within specifications. Go to next not within specifications. Refer
Shuttle - Test — Checking Con- step. to TRANSMISSION Powershift -
verter Out Pressure (C.20.C). Testing Machine Will Not Move,
H-Type and S-Type (C.20.E)
Check the lube pressure. Refer to The lube pressure is within specifica-
TRANSMISSION Powershift - Tool tions. STOP. The pressure is not within
connection Test Port and Compo- specifications. If the torque
nent Locations, H-Type (C.20.E). converter pressure is high and
the lube pressure is low, possible
causes include:
• Restriction in the oil
cooler. Replace the oil
cooler. The transmis-
sion oil cooler cannot be
flushed or cleaned out.
The complete oil cooler
must be replaced is a re-
striction is found.
• The oil cooler circuit is
restricted. Inspect the oil
cooler circuit and repair
as required.
TRANSMISSION Powershift - Testing Noisy Transmission, H-Type

and S-Type
Verify that the torque converter is not The torque converter is not dam- The torque converter is damaged.
damaged. aged. Go to next step. Repair or replace as required.
Verify that the oil pump is not dam- The oil pump is not damaged. Go to The oil pump is damaged. Repair or
aged. next step. replace as required.
Check for seized or broken gears, The gears, shafts, bearings, etc. are A gear, shaft, bearing, etc. is seized
shafts, bearings, etc. not seized or broken. or broken. Repair or replace as re-
quired.
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TRANSMISSION Powershift - Testing Irregular Clutch Activation,

H-Type and S-Type
The clutch pressure is in the speci- The clutch pressure is not in the
Check clutch pressure. Is the pres-
fied range. Go to next step.
sure in the specified range? Refer to specified range. Inspect the modu-
TRANSMISSION Powershift - Gen- lation spool and piston for sticking
eral specification - H-type (C.20.E) and damage. Repair or replace as
required.
Check for fault codes on the Trax There are no fault codes associated The Trax Controller does have active
Controller. with the Trax Controller. Check the fault codes. Troubleshoot and repair
electrical connections to the clutch as required.
solenoids.
TRANSMISSION Powershift - Testing Gear Remains Engaged,

H-Type and S-Type
The clutch pressure is in the speci- The clutch pressure is not in the
Check clutch pressure. Is the pres-
fied range. Go to next step.
sure in the specified range? Refer to specified range. Inspect the modu-
TRANSMISSION Powershift - Gen- lation spool and piston for sticking
eral specification - H-type (C.20.E) and damage. Repair or replace as
required.
solenoids.
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TRANSMISSION Powershift - Testing Will Not Go Into 4WD, H-Type

and S-Type
Check for broken universal joint or The universal joint and front drive The universal joint or front drive shaft
front drive shaft. shaft are functioning properly. Go to is in need of repair. Repair or replace
next step. as required.
Raise the machine off of the ground. The front drive shaft turns freely The front drive shaft does not turn
All four wheels should be able to ro- when the transmission control is in when the transmission control is in
tate freely. gear but the axle does not. There is gear. Go to next step.
Check a problem in the front axle. Repair
Verify that the front and rear drive as required.
shafts turn when the transmission
directional control lever (FNR) is
moved into Forward or Reverse.
solenoids.
TRANSMISSION Powershift - Testing Problem in the Parking Brake

System, H-Type and S-Type
Does the parking brake release? The parking brake will release. Re-
fer to Brake - Inspect (D.32.B) and Check the electrical and hydraulic
Brake - Test (D.32.B). If the parking circuits.
brake will not hold the machine, re- • Check the differential lock
pair or replace the disc brakes. pressure. The differen-
tial lock and the parking
brake are on the same
pressure circuit. If the dif-
ferential lock pressure is
within specifications, refer
to TRANSMISSION Pow-
ershift - General specifi-
cation - H-type (C.20.E).
• Check fuses, replace
fuses as required.
• Check switch operation,
repair or replace as re-
quired.
• Measure the solenoid re-
sistance. The resistance
should be approximately
9.8 Ω at 20 °C (68 °F). Re-
place the solenoid as re-
quired.
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Index

Clutch and gear - Check - S-Type (SPS Power Syncro) - Speed gears switches - Checking procedure . . . . . . 299
Clutch and gear - Exploded view - H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Back side mea-
surement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Dimension "D"
measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Front side mea-
surement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Clutch and gear - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Neutral position
measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Command - Overview S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Command - Service instruction Hydraulic Pressure Testing Shift Rails - S-Type Transmission . . . . . . . . . . . . . . 197
Command - Service instruction Shift Rail Position Physical Measurement - S-Type Transmission . . . . . . . . . . . 195
Command - Service instruction Shift Rail Position Testing - S-type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Control valve - Assemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . 207
Control valve - Disassemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . 199
Control valve - Drawing S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Control valve - Drawing H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Electronic control - Assemble - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . 325
Electronic control - Detailed view Transmission Control Connectors, H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Electronic control - Disassemble S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . 323
Housing - Assemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Housing - Disassemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Shaft - Assemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Shaft - Assemble -S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Shaft - Assemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Shaft - Assemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Shaft - Assemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Shaft - Assemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Shaft - Disassemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Shaft - Disassemble - S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Shaft - Disassemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Shaft - Disassemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Shaft - Disassemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Shaft - Disassemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Shaft - Exploded view - H-Type - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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TRANSMISSION Powershift - Assemble - H-type - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
TRANSMISSION Powershift - Assemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 68
TRANSMISSION Powershift - Assemble - S-type (SPS power synchro) Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . 72
TRANSMISSION Powershift - Cleaning - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
TRANSMISSION Powershift - Disassemble - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
TRANSMISSION Powershift - Disassemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . 66
TRANSMISSION Powershift - Disassemble - S-type (SPS power synchro)- Oil pump . . . . . . . . . . . . . . . . . . . . . . 70
TRANSMISSION Powershift - Exploded view - H-type - 1st, 3rd, 4th gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TRANSMISSION Powershift - Exploded view - H-type - transmission assembly - 4 wheel drive shaft . . . . . . . . . 24
TRANSMISSION Powershift - Exploded view - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . 26
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . 34
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . 38
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . 32
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Rear cover . . . . . . . . . . . . . . . . . 36
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Shafts B - C . . . . . . . . . . . . . . . . 42
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . 46
TRANSMISSION Powershift - Exploded view - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . 30
TRANSMISSION Powershift - Exploded view - S-type (SPS Power Synchro) - Oil pump . . . . . . . . . . . . . . . . . . . . 28
TRANSMISSION Powershift - Exploded view - S-type (SPS power synchro) - Shaft A - D . . . . . . . . . . . . . . . . . . . 40
TRANSMISSION Powershift - Exploded view -S-type (SPS power synchro) - transmission assembly - 4 wheel drive
shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TRANSMISSION Powershift - General specification - S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION Powershift - General specification Trax Controller Pin Out Guide, S-Type Transmission . . . . . 17
TRANSMISSION Powershift - General specification - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRANSMISSION Powershift - General specification - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSMISSION Powershift - Hydraulic schema H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TRANSMISSION Powershift - Hydraulic schema S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
TRANSMISSION Powershift - Inspect - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
TRANSMISSION Powershift - Install - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
TRANSMISSION Powershift - Overview S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
TRANSMISSION Powershift - Remove - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
TRANSMISSION Powershift - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSMISSION Powershift - Special tools - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSMISSION Powershift - Testing Gear Remains Engaged, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . 332
TRANSMISSION Powershift - Testing Irregular Clutch Activation, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . 332
TRANSMISSION Powershift - Testing Loss of Power, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
TRANSMISSION Powershift - Testing Machine Will Not Move, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . 328
TRANSMISSION Powershift - Testing Noisy Transmission, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . 331
TRANSMISSION Powershift - Testing Transmission Oil is Too Hot, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . 330
TRANSMISSION Powershift - Testing Wheels Rotate When Vehicle is Raised, H-Type and S-Type . . . . . . . . . 330
TRANSMISSION Powershift - Testing Will Not Go Into 4WD, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . 333
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TRANSMISSION Powershift - Testing Problem in the Parking Brake System, H-Type and S-Type . . . . . . . . . . . 333
TRANSMISSION Powershift - Tool connection Test Port and Component Locations, H-Type . . . . . . . . . . . . . . . 184
TRANSMISSION Powershift - Tool connection Test Port and Component Locations, S-Type . . . . . . . . . . . . . . . 189
TRANSMISSION Powershift - Torque - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
TRANSMISSION Powershift - Torque - S-type (SPS Power Synchro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TRANSMISSION Powershift - View Troubleshooting and Monitoring EST Parameters . . . . . . . . . . . . . . . . . . . . . 182
TRANSMISSION Powershift - Warm up Heating the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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PRINTED IN U.S.A.
84516378 05/07/2011
EN
SERVICE MANUAL
AXLES, BRAKES AND STEERING
580N
580SN WT
580SN
590SN
84516378 05/07/2011
D
Contents
AXLES, BRAKES AND STEERING - D
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.10.A

580N , 580SN WT , 580SN , 590SN
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.12.A

580N , 580SN WT , 580SN , 590SN
STEERING Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.20.C

580N , 580SN WT , 580SN , 590SN
SERVICE BRAKE Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.30.C

580N , 580SN WT , 580SN , 590SN
PARKING BRAKE Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.B

580N , 580SN WT , 580SN , 590SN
WHEELS AND TRACKS Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.50.C

580N , 580SN WT , 580SN , 590SN
84516378 05/07/2011
D
FRONT AXLE - 10.A
580N
580SN WT
580SN
590SN
84516378 05/07/2011
D.10.A / 1
Contents
FRONT AXLE - 10.A
TECHNICAL DATA
FRONT AXLE
General specification - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General specification - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools - CNH Front axle Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General specification - CNH Front Axle Four Wheel Drive - 580N and 580SN . . . . . . . . . . . . . . . . . . . . . . 7
General specification - CNH Front Axle Four Wheel Drive - 580SN-WT and 590SN . . . . . . . . . . . . . . . . . 7
Special tools - CNH Front Axle Four Wheel Drive - 580N, 580SN, 580SN-WT, 590SN . . . . . . . . . . . . . . . 8
General specification - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . 14
Special tools - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . 15
General specification - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . 17
Special tools - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . 18
FUNCTIONAL DATA
Axle
Exploded view - CNH Four wheel drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Drawing - Front axle-four wheel drive- measuring toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Differential
Exploded view - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . 24
Exploded view - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . 26
Exploded view - Carraro Front axle-four wheel drive limited slip differential- 580SN-WT and 590SN only
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exploded view - CNH- Front Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Housing
Exploded view - Carraro Front axle- swivel housing- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Exploded view - CNH Front axle - swivel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Planetary and hub
Exploded view - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . 36
Exploded view - Carraro Front axle-four wheel drive - 580SN-WT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Exploded view - Carraro Front axle-four wheel drive - 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Exploded view - CNH Front Axle - Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SERVICE
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FRONT AXLE
Remove - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Install - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Remove - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Install - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassemble - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Inspect - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Assemble - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Disassemble - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspect - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Assemble - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Differential
Remove - CNH Front Axle -Four Wheel Drive - Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Disassemble - CNH Front Axle -Four Wheel Drive- Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Disassemble - CNH Front Axle -Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Inspect - CNH Front Axle - Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Assemble - CNH Front Axle - Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Assemble - CNH Front Axle - Four Wheel Drive - Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Remove - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . . . . . . . 95
Disassemble - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . . . 98
Disassemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . 103
Inspect - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Assemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . 107
Assemble - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . . . . . 111
Remove - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . . . . . . 123
Disassemble - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . . 126
Disassemble - Carraro Front axle-four wheel drive - differential - 580SN-WT and 590SN only . . . . . . 131
Inspect - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . 134
Assemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . 135
Assemble - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . . . . . 140
Housing
Disassemble - CNH Front Axle -Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Assemble - CNH Front Axle- Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Disassemble - Carraro Front axle-four wheel drive swivel housing and universal joint- 580N and 580SN
only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Assemble - Carraro Front axle-four wheel drive swivel housing and universal joint- 580N and 580SN only
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Disassemble - Carraro Front axle-four wheel drive swivel housing- 580SN-WT and 590SN only . . . . 177
Assemble - Carraro Front axle-four wheel drive swivel housing- 580SN-WT and 590SN only . . . . . . . 187
Planetary and hub
Disassemble - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Inspect - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Assemble - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Disassemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . 207
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Inspect - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Assemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . 214
Disassemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . 220
Inspect - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . 228
Assemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . 229
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AXLES, BRAKES AND STEERING - FRONT AXLE
FRONT AXLE - General specification - Carraro Front axle two wheel

drive
Bolts for steering cylinder 335 N·m (247.1 lb ft)
Tie rod ball joint to steering cylinder 300 N·m (221.3 lb ft)
Tie rod to steering knuckle 165 N·m (121.7 lb ft)
Jam nut for tie rod 120 N·m (88.5 lb ft)
Bolts for king pin 120 N·m (88.5 lb ft)
Bolts for bearing caps 120 N·m (88.5 lb ft)
Bearing cap plug 15 N·m (11.1 lb ft)
FRONT AXLE - Special tools - Carraro Front axle two wheel drive
CAS-1842 Wheel stud removal and installation
RCPH10TLB466ABL 1
CAS-2159 Wrench to loosen and tighten tie rods for steer-

ing cylinder
RCPH10TLB235ABL 2
FRONT AXLE - General specification - CNH Front Axle - Two Wheel

Drive
Specifications
Tie rod length securing nut 213 - 263 N·m (157.1 - 194.0 lb ft)
Tie rod ball joint nut 162 - 200 N·m (119.5 - 147.5 lb ft)
Tie rod ball joint 255 - 315 N·m (188.1 - 232.3 lb ft)
Breather 11 - 14 N·m (8.1 - 10.3 lb ft)
Plug, oil drain 54 - 66 N·m (39.8 - 48.7 lb ft)
Lube fitting, king pin 20 - 30 N·m (14.8 - 22.1 lb ft)
Planet carrier retention screw 21 - 26 N·m (15.5 - 19.2 lb ft)
King pin bolt 154 - 188 N·m (113.6 - 138.7 lb ft)
Differential cover bolt 96 - 118 N·m (70.8 - 87.0 lb ft)
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Specifications
Steering cylinder bolt 358 - 442 N·m (264.0 - 326.0 lb ft)
Steering stop nut 200 - 244 N·m (147.5 - 180.0 lb ft)
Sun shaft retention nut 358 - 442 N·m (264.0 - 326.0 lb ft)
Ring gear support bolt 96 - 118 N·m (70.8 - 87.0 lb ft)
Planet pin screw 95 - 105 N·m (70.1 - 77.4 lb ft)
Drain plug 72 - 88 N·m (53.1 - 64.9 lb ft)
Bearing cap bolt 96 - 118 N·m (70.8 - 87.0 lb ft)
Ring nut retainer bolt 21 - 26 N·m (15.5 - 19.2 lb ft)
Bevel crown bolt 96 - 118 N·m (70.8 - 87.0 lb ft)
Pinion shaft 1.7 - 2.2 N·m (1.3 - 1.6 lb ft)
Differential 1.5 - 2.5 N·m (1.1 - 1.8 lb ft)
Wheel bearing with seal 12 - 25 N·m (8.9 - 18.4 lb ft)
Open differential 0 - 1 N·m (0.0 - 0.7 lb ft)
Limited slip differential 1 - 5 N·m (0.7 - 3.7 lb ft)
Capacities
Axle
Differential 8.6 l (9.1 US qt) or bottom of fill hole.
Planetary 1.0 l (1.1 US qt) or fill to line.
Type of Fluid Wet Brake/Transmission Lubricant - SAE 80W140
(MAT3510)
Lubricant Kluberplus 84279121
NOTE: All hardware is self-locking and uses pre-applied loctite. It is recommended replacing all hardware.
FRONT AXLE - Special tools - CNH Front axle Two Wheel Drive
CAS-1842 Wheel stud removal and installation
RCPH10TLB466ABL 1
CAS-2159 Wrench to loosen and tighten tie rods for steer-

ing cylinder
RCPH10TLB235ABL 2
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FRONT AXLE - General specification - CNH Front Axle Four Wheel

Drive - 580N and 580SN
Specifications
Breather 11 - 14 N·m (8.1 - 10.3 lb ft)
Beam drain plug/fill 54 - 66 N·m (39.8 - 48.7 lb ft)
Planetary drain plug 72 - 88 N·m (53.1 - 64.9 lb ft)
Pinion shaft bearing rolling torque 1.7 - 2.2 N·m (1.3 - 1.6 lb ft)
Differential bearing rolling torque 1.5 - 2.5 N·m (1.1 - 1.8 lb ft)
Wheel bearing with seal rolling torque 8 - 30 N·m (5.9 - 22.1 lb ft)
Open differential rolling torque (Internal diff gears) 0 - 1 N·m (0.0 - 0.7 lb ft)
Limited slip differential rolling torque (Internal diff gears) 1 - 5 N·m (0.7 - 3.7 lb ft)
Capacities
(MAT3510)
NOTE: All new or used hardware should have Loctite 242 applied prior to installation. The manufacturer recommends
replacement of all hardware to include O-rings.
FRONT AXLE - General specification - CNH Front Axle Four Wheel

Drive - 580SN-WT and 590SN
Specifications
Breather 11 - 14 N·m (8.1 - 10.3 lb ft)
Beam drain plug/fill 54 - 66 N·m (39.8 - 48.7 lb ft)
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Specifications
Planetary drain plug 72 - 88 N·m (53.1 - 64.9 lb ft)
Pinion shaft bearing rolling torque 1.7 - 2.2 N·m (1.3 - 1.6 lb ft)
Differential bearing rolling torque 1.5 - 2.5 N·m (1.1 - 1.8 lb ft)
Wheel bearing with seal rolling torque 12 - 25 N·m (8.9 - 18.4 lb ft)
Open differential rolling torque (Internal diff gears) 0 - 1 N·m (0.0 - 0.7 lb ft)
Limited slip differential rolling torque (Internal diff gears) 1 - 5 N·m (0.7 - 3.7 lb ft)
Capacities
Axle
(MAT3510)
NOTE: All new or used hardware should have Loctite 242 applied prior to installation. The manufacturer recommends
replacement of all hardware to include O-rings.
FRONT AXLE - Special tools - CNH Front Axle Four Wheel Drive -
580N, 580SN, 580SN-WT, 590SN
CAS1840C or DMT100002 Spanner Wrench
RCPH10TLB633ABL 1
Yoke to hold shaft
RCPH10TLB638ABL 2
CAS-1980 V-Block. Used to support coupling when replacing a universal joint.
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RCPH10TLB684ABL 3
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380100092 Wrench to loosen and tighten tie rods for steering cylinder.
RCPH10TLB235ABL 4
CAS2369 or 380100103- Seal protector
RCPH10TLB635ABL 5
DMT100001- Pinion Seal Installation Tool
RCPH10TLB025FAL 6
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DMT100002- Thrust Bearing Installation/Removal Tool
RCPH10TLB026FAL 7
DMT100003- Sun Shaft Seal Installation Tool
RCPH10TLB027FAL 8
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DMT100004- Hub Seal Installation Tool
RCPH10TLB033FAL 9
DMT100005- Axle Housing Shaft Bushing Installation Tool
RCPH10TLB029FAL 10
DMT100006- Axle Housing Shaft Seal Installation Tool
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RCPH10TLB030FAL 11
3800000468- Pinion Nut Wrench
RCPH10TLB261ACL 12
380100102- Pinion Shaft Wrench
RCPH10TLB260ACL 13
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FRONT AXLE - General specification - Carraro Front axle-four

wheel drive - 580N and 580SN only
General specifications
Backlash for ring gear 0.20 - 0.25 mm (0.008 - 0.010 in)
Rotating torque for pinion shaft without seal 1.1 - 2.3 N·m (9.74 - 20.36 lb in)
Lubricant 580N and 580SN

Capacity - center bowl 5.5 l (5.8 US qt)
Capacity - each wheel end 0.71 l (0.75 US qt)
Type of fluid Wet brake/Transmission lubricant - SAE 80W140
MAT3510
Special torques
Studs for wheels 70 N·m (51.6 lb ft)
Allen head bolts for carrier 25 N·m (18.4 lb ft)
Self locking nut for tie rod ball joint 165 N·m (121.7 lb ft)
Jam nut for tie rod 120 N·m (88.5 lb ft)
Nut for ball joint for steering cylinder 300 N·m (221.3 lb ft)
Jam nuts for steering stops 150 N·m (110.6 lb ft)
Bolts for king pin 120 N·m (88.5 lb ft)
Bolts for adjusting ring lock 13 N·m (115.1 lb in)
Bolts for hub for planetary ring gear 95 N·m (70.1 lb ft)
Bolts for differential carrier 169 N·m (124.6 lb ft)
Oil drain plugs in axle housing 60 N·m (44.3 lb ft)
Oil drain plugs in planetary ends 80 N·m (59.0 lb ft)
Breather 10 N·m (88.5 lb in)
Grease zerks 8 N·m (70.8 lb in)
Wheel nuts 350 N·m (258.1 lb ft)
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FRONT AXLE - Special tools - Carraro Front axle-four wheel drive -

580N and 580SN only
CAS 1839 Pinion setting kit
1. CAS1839-1 Gauge tube
RCPH10TLB461ABL 1
2. CAS1839-2 Gauge block

3. CAS1668 Metric feeler gauge
4. CAS2401 Pilot
5. CAS1596A-4 Handle
6. CAS1596A Stud
CAS1840C Spanner wrench
RCPH10TLB468ABL 2
CAS2151A Wrench for pinion nut
RCPH10TLB465ABL 3
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Yoke to hold shaft
RCPH10TLB467ABL 4
CAS1842 Wheel stud removal and installation
RCPH10TLB466ABL 5
CAS1980 V-Block used to support coupling when replac-

ing a universal joint
RCPH10TLB469ABL 6
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380100091 for all two wheel drive and the 580N, 580SN
four wheel drive front axle
RCPH10TLB235ABL 7
38010092 for the 580SN - WT and 590SN four wheel drive

front axle
CAS2369 - Seal protector
CAS2375 - Shaft adapter
CAS10468 - Puller
FRONT AXLE - General specification - Carraro Front axle-four

wheel drive - 580SN-WT and 590SN only
Rotating torque for pinion shaft without seal 1.1 - 2.3 N·m (9.7 - 20.4 lb in)
Lubricant - 580SN
Type of fluid Wet brake/transmission lubricant - SAE 80W140
MAT3510
Lubricant - 590SN
Type of fluid Wet brake/transmission lubricant - SAE 80W140 MAT
3510
Special torques
Stud for wheels 70 N·m (51.6 lb ft)
Allen head bolts for carrier 25 N·m (18.4 lb ft)
Nut for ball joint for steering cylinder 300 N·m (221.3 lb ft)
Jam nuts for steering stops 150 N·m (110.6 lb ft)
Bolts for king pins 190 N·m (140.1 lb ft)
Bolts for adjusting ring lock 13 N·m (115.1 lb in)
Bolts for differential case 169 N·m (124.6 lb ft)
Bolts for differential carrier 169 N·m (124.6 lb ft)
Oil drain plugs in axle housing 60 N·m (44.3 lb ft)
Oil drain plugs in planetary ends 80 N·m (59.0 lb ft)
Breather 10 N·m (88.5 lb in)
Grease zerks 8 N·m (70.8 lb in)
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Self locking nut for tie rod ball joint

580SN-WT 165 N·m (121.7 lb ft)
590SN 220 N·m (162.3 lb ft)
Jam nut for tie rod

580SN-WT 120 N·m (88.5 lb ft)
590SN 250 N·m (184.4 lb ft)
Bolts for hub for planetary ring gear

580SN-WT 95 N·m (70.1 lb ft)
590SN 120 N·m (88.5 lb ft)
FRONT AXLE - Special tools - Carraro Front axle-four wheel drive -

580SN-WT and 590SN only
CAS 1839 Pinion setting kit
1. CAS1839-1 Gauge tube
RCPH10TLB461ABL 1
2. CAS1839-2 Gauge block

3. CAS1668 Metric feeler gauge
4. CAS2401 Pilot
5. CAS1596A-4 Handle
6. CAS1596A Stud
CAS1840C Spanner wrench
RCPH10TLB633ABL 2
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CAS2151A Wrench for pinion nut
RCPH10TLB637ABL 3
Yoke to hold shaft
RCPH10TLB638ABL 4
CAS1842 Wheel stud removal and installation
RCPH10TLB683ABL 5
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CAS1980 V-Block used to support coupling when replac-

ing a universal joint
RCPH10TLB684ABL 6
38010092 Wrench to loosen and tighten tie rods for steer-

ing cylinder
RCPH10TLB235ABL 7
Seal driver 380002431
RCPH10TLB636ABL 8
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Seal protector CAS2369
RCPH10TLB635ABL 9
RCPH10TLB634ABL 10
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Axle - Exploded view - CNH Four wheel drive axle
RCPH10TLB388ACL 1
(1) Axle (7) Retainer

(2) Bolt (8) Bolt
(3) Snap ring (9) Bolt
(4) Spacer (10) Washer
(5) Pivot pin (11) Drive shaft guard
(6) Drive shaft
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Axle - Drawing - Front axle-four wheel drive- measuring toe-in

1. Mark around center of tire
2. Steering cylinder
3. Loosen the jam nut and turn the piston rod as required
4. Top axle measurement must be equal to or up to 5 mm (0.2 in) less than bottom axle measurement.
RCPH10TLB001FAL 1
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Differential - Exploded view - Carraro Front axle-four wheel drive -

580N and 580SN only
1. Cover 12. O-ring
2. Seal 13. Lock
3. Pinion nut 14. Shim
4. Washer 15. Pinion gear
5. Bearing 16. Ring gear
6. Flat washer 17. Case half
7. Spacer 18. Thrust washer
8. Bearing cup 19. Side gear
9. Differential carrier 20. Pinion gear
10. Adjusting ring 21. Pinion shaft
11. Bearing cap 22. Dowel pin
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RCPB10TLB002HAL 1
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Differential - Exploded view - Carraro Front axle-four wheel drive -

1. Cover 12. O-ring
2. Seal 13. Lock
3. Pinion nut 14. Shim
4. Washer 15. Pinion gear
5. Bearing 16. Ring gear
6. Flat washer 17. Case half
7. Spacer 18. Thrust washer
8. Bearing cup 19. Side gear
9. Differential carrier 20. Pinion gear
10. Bearing cap 21. Pinion shaft
11. Bearing cap 22. Dowel pin
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RCPB10TLB002HAL 1
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Differential - Exploded view - Carraro Front axle-four wheel drive

limited slip differential- 580SN-WT and 590SN only
1. Locking plate and bolt 7. Friction plate special (2)
2. Ring nut 8. Thrust washer
3. Bearing 9. Side and pinion gears
4. Differential housing 10. Pin
5. Reaction plate (10) 11. Shaft
6. Friction plate (8) 12. Bolt (12)
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RCPH10TLB004GAL 1
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Differential - Exploded view - CNH- Front Axle - Differential

Differential
1. Differential Carrier 7. Crush sleeve 13. Side gear 19. Bolt 25. Bolts
2. Cover 8. Bearing 14. Thrust Washer 20. Bearing caps 26. Locking finger
bolts
3. O-ring 9. Spacer 15. Differential 21. Side gear 27. Locking pin for
housing diff. cross shaft
4. Seal 10. Pinion shaft 16. Bearing 22. Crown gear 28. Differential cross
shaft
5. Outboard bearing 11. Thrust Washer 17. Spanner nut 23. Bearing
6. Washer 12. Spider gear 18. Locking finger 24. Spanner nut
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RCPH10TLB171GAL 1
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Housing - Exploded view - Carraro Front axle- swivel housing-

1. Bolt 4. Bushing 7. Swivel housing
2. Top king pin 5. Seal 8. Grease zerk
3. Belleville washer 6. Bushing 9. Bottom king pin
RCPH10TLB001GAL 1
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Housing - Exploded view - CNH Front axle - swivel housing

Swivel Housing
1. Bolt
2. Bottom king pin
3. Grease zirk
4. Bushing
5. Bellville washer
6. Swivel housing
7. Top king pin
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RCPH10TLB182GAL 1
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Planetary and hub - Exploded view - Carraro Front axle-four wheel

drive - 580N and 580SN only
1. Seal 11. Thrust washer
2. Wheel bearing 12. Snap ring
3. Bearing cup 13. Retainer
4. Planetary housing 14. Pinion gear
5. Stud 15. Pin
6. Retaining ring 16. O-ring
7. Hub 17. Carrier
8. Bolt 18. Allen head bolt
9. Ring gear 19. Pinion shaft
10. Thrust plate 20. Bushing
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RCPH10TLB001HAL 1
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drive - 580SN-WT
1. Axle shaft 16. Snap ring
2. Seal 17. Retainer
3. Bearing assembly 18. Pinion gear
4. Planetary housing 19. Needles
5. Stud 20. O-ring
6. Bearing assembly 21. Allen head bolt
7. Retaining ring 22. Carrier
8. Hub 23. Pinion shaft
9. Ring gear 24. Plug
10. Bolt 25. O-ring
11. Bushing 26. Nut
12. Snap ring 27. Washer
13. Thrust plate 28. Pin
14. Thrust plate 29. Thrust washer
15. Thrust washer
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RCPH10TLB002GAL 1
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drive - 590SN
1. Seal 11. Bushing
2. Bearing assembly 12. Needles
3. Planetary housing 13. Plug
4. Stud 14. Allen head bolt
5. O-ring 15. Carrier
6. Bearing assembly 16. Thrust button
7. Retaining ring 17. Pinion shaft
8. Hub 18. Pinion gear
9. Ring gear 19. Retainer
10. Bolt 20. Snap ring
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RCPH10TLB003GAL 1
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Planetary and hub - Exploded view - CNH Front Axle - Planetary

Planetary
1. Drain Plug 6. Planet pinion gear 11. Ring gear 16. Stud
w/needles
2. Drain Plug O-ring 7. Retainers 12. Hub 17. Seal
3. Allen head bolts 8. Bolts 13. Retaining ring
4. Planetary Carrier 9. T-dowels 14. Wheel Bearing
5. O-ring 10. Pinion nut 15. Wheel hub
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RCPH10TLB180GAL 1
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FRONT AXLE - Remove - Two wheel drive machines

Prior operation:
Prior operation:
Front wheel - Remove (D.50.C)
Prior operation:
TRANSMISSION Power Shuttle - Remove (C.20.C) Steps 2, 3, 4 and 5.
1. Raise and support the machine.

2. Install blocks.
RCPH11TLB136AAM 1
3. Identify, tag and disconnect steering hoses. Cap all

open ports.
RCPH11TLB146AAM 2
4. Remove pivot pin lube line.
RCPH11TLB139AAM 3
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5. Support the front axle.
RCPH11TLB140AAM 4
6. Remove rear pivot pin snap ring.
RCPH11TLB141AAM 5
7. Remove bolt and install slide hammer.
RCPH11TLB142AAM 6
8. Remove pivot pin.
RCPH11TLB143AAM 7
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9. Record and remove shims at the front and rear of the

axle pin tube.
RCPH11TLB144AAM 8
10. Carefully lower and remove the front axle.
RCPH11TLB145AAM 9
Next operation:
FRONT AXLE - Install (D.10.A)
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FRONT AXLE - Install - Two wheel drive machines

Prior operation:
FRONT AXLE - Remove (D.10.A)
1. Raise the axle into alignment with the machine.
RCPH11TLB140AAM 1
2. Install a spacer (5) between the front of the axle and

the frame.
RCPH11TLB144AAM 2
3. Start the pivot pin (4) into the frame, spacer(s) (5)
and axle.
4. Drive the pivot pin (4) into the rear pivot of the axle
but not through the rear pivot.
5. Install the washer (2) between the rear of the axle
and the frame.
NOTE: Remove or install washer(s) (2) as required be-
tween the axle and the frame to remove any and play.
6. Drive the pivot pin (4) through the rear pivot and the
frame.
7. Install the bolt and snap rings.
RCPH11TLB142AAM 3
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8. Connect the lubrication hose (1) to the fitting.
RCPH11TLB139AAM 4
9. Loosen and remove the plugs from the hoses and the
caps from the fittings for the steering cylinder.
10. Connect the hoses to the steering cylinder.
RCPH11TLB146AAM 5
11. Install the wheels and wheel bolts. do not use an

impact wrench to tighten the wheel bolts. Refer to
Front wheel - Install (D.50.C)
12. Remove the stands and lower the wheels to the floor.
13. Lubricate the pivot pin (4) for the axle.
14. Check and adjust the toe-in according to Axle -
Drawing (D.10.A) .
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RCPH10TLB129GAL 6
(1) Remote grease hose (4) Pivot pin

(2) Washer thrust (5) Spacer
(3) Snap ring
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FRONT AXLE - Remove - Four wheel drive machines

Prior operation:
Prior operation:
Front wheel - Remove (D.50.C)
RCPH10TLB388ACL 1
1. Put a floor jack under the drive shaft guard (11) to

hold the drive shaft guard in position.
2. Loosen and remove the bolts (9) and flat washers
(10) that fasten the drive shaft guard (11) to the
frame.
3. Lower the drive shaft guard (11) and remove it from
under the machine.
4. Loosen and remove the bolts (8) and retainers (7)
that fasten the drive shaft (6) to the flange on the
transmission. Remove the drive shaft (6).
5. Install blocks between the axle (1) stops and the
frame to prevent the axle from tilting.
RCPH11TLB136AAM 2
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6. Identify, tag and disconnect the steering hoses. Cap

all open ports.
RCPH11TLB146AAM 3
7. Disconnect the lubrication hose from the axle (1).
RCPH11TLB139AAM 4
8. Put a floor jack under the axle (1) to hold the axle in
position.
RCPH11TLB140AAM 5
9. Remove the snap ring (3) from the rear of the pivot
pin (5).
RCPH11TLB141AAM 6
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10. Remove bolt (2) and install a slide hammer into the
pivot pin (5), pull the pivot pin (5) out of the frame.
RCPH11TLB143AAM 7
11. Washers are used at the front and rear of the axle
(1), between the axle and the frame. Lower the axle
(1) and remove the washers (4).
RCPH11TLB144AAM 8
12. Remove the axle (1) from under the machine.
RCPH11TLB145AAM 9
Next operation:
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FRONT AXLE - Install - Four wheel drive machines

Prior operation:
1. Raise the axle (1) into alignment with the frame.
RCPH11TLB140AAM 1
2. Install the pivot pin (5) with the bolt hole end of the
pivot pin toward the front of the machine.
RCPH11TLB147AAM 2
3. Install a washer (4) between the front of the axle (1)

and the frame. Use washer(s) as required for mini-
mum end play between the frame and the axle (1).
4. Start the pivot pin (5) into the frame, washer (4), and
axle (1).
5. Drive the pivot pin (5) into the rear pivot of the axle
(1) but not through the rear pivot.
6. Install a washer (4) between the rear of the axle (1)
and the frame.
7. Drive the pivot pin (5) through the rear pivot and the
frame.
8. Install the snap ring (3) on the pivot pin (5).
9. Drive the pivot pin (5) toward the front of the machine
as far as possible.
10. Check the end play between the frame and the snap
ring (3) on the pivot pin (5) at the front of the machine.
Use washers (4) as required to remove any end play.
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11. Connect the lubrication hose to the axle (1).
RCPH11TLB139AAM 3
12. Loosen and remove the plugs from the hoses and the
caps from the fittings for the steering cylinder.
RCPH11TLB146AAM 4

14. Install the wheels, hardened washers , and nuts.
15. Tighten the wheel nuts to 122 N·m (90 lb ft)+ 3 - 10
N·m (2 - 7 lb ft). Then turn nut an additional 90 ° ±
5 °.
16. Remove the blocks from between the axle (1) stops
and the frame.
17. Remove the stands and lower the wheels to the floor.
18. Lubricate the pivot pin (5) for the axle (1).
19. Install the drive shaft (6). Install the bolts (8) and re-
tainers (7) that fasten the drive shaft (6) to the flange
on the transmission.
20. Tighten the bolts to 33 - 39 N·m (24 - 29 lb ft).
21. Raise the drive shaft guard (11) in position.
NOTE: If your machine is equipped with a powershift trans-
mission, install O-ring and spacer on the bolts, use the
O-ring to hold the hardware in place.
22. Install the bolts (9) and flat washers (10) that fasten
the drive shaft guard (11) to the frame.
23. Torque the bolts (9) to 50 - 90 N·m (36.9 - 66.4 lb ft).
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FRONT AXLE - Disassemble - Carraro Front axle two wheel drive

1. Loosen and remove the tie rod ends from the swivel
housings.
RCPH10TLB603ABL 1
2. Remove the steering cylinder, ball joints, and tie rod

ends from the axle.
RCPH10TLB716ABL 2
3. Attach suitable lifting equipment to the wheel hub.

Remove the wheel hub cover, bearing retainer plate
bolts, and bearing retainer plate.
RCPH10TLB604ABL 3
4. Remove the wheel hub from the axle.
RCPH10TLB605ABL 4
NOTE: Repeat steps 3 and 4 for the other wheel hub.
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5. Remove the bearing cups from the wheel hubs.
RCPH10TLB606ABL 5
6. Remove the bearing cone from the swivel housing.
RCPH10TLB607ABL 6
7. Attach suitable lifting equipment to the swivel hous-

ing. Remove the upper and lower king pins.
RCPH10TLB608ABL 7
8. Remove the swivel housing from the axle beam.
RCPH10TLB609ABL 8
NOTE: Repeat steps 7 and 8 for the other swivel housing.
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9. Remove the bevelled washers from the axle beam.
RCPH10TLB610ABL 9
10. If required, remove the upper bushing and lower

bearing cup for the king pins.
RCPH10TLB611ABL 10
11. If required, remove the front and rear pivot seals and
bushings.
RCPH10TLB612ABL 11
Next operation:
FRONT AXLE - Inspect (D.10.A)
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FRONT AXLE - Inspect - Carraro Front axle two wheel drive

Prior operation:
FRONT AXLE - Disassemble (D.10.A)
1. Clean all parts in cleaning solvent.

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 ar-
eas, pitting, scoring, and other damage. Replace as
needed.
4. Inspect axle pivot bushings and pivot pin for flat ar-
needed.
5. Remove and discard all seals and O-rings.
Next operation:
FRONT AXLE - Assemble (D.10.A)
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FRONT AXLE - Assemble - Carraro Front axle two wheel drive

Prior operation:
1. Install bushings and seals in the pivot on the axle

beam.
RCPH10TLB612ABL 1
NOTE: To ease installation, cool bushings to -100 °C (-148.0 °F).

2. Install the upper bushing and lower bearing cup using
suitable bearing drivers.
RCPH10TLB611ABL 2

3. Apply grease to the bevelled washers to assist hold-
ing them in place during assembly.
RCPH10TLB610ABL 3
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4. Use suitable lifting equipment and install the swivel

housing on the axle.
RCPH10TLB609ABL 4
5. Make sure the bevelled washers are in place, install

the upper and lower king pins. Torque the bolts to
120 N·m (88.5 lb ft)
RCPH10TLB608ABL 5
6. Grease the bearing cone and install it onto the swivel

housing.
RCPH10TLB607ABL 6
7. Use suitable drivers and install new bearing cups and

seal into wheel hub.
RCPH10TLB613ABL 7
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8. Use suitable lifting equipment and install wheel hub

onto the swivel housing.
RCPH10TLB614ABL 8
9. Grease and install the outer bearing on the swivel

housing. Use LOCTITE® 270 on the bolts, position
the thrust washer, install and torque the bolts to 120
N·m (88.5 lb ft).
RCPH10TLB615ABL 9
10. Install a new O-ring on the wheel hub cover, lubricate

the O-ring with grease. Use a suitable driver and
install the wheel hub cover into the wheel hub.
RCPH10TLB616ABL 10
11. Use LOCTITE® 270 on the bolts, mount the steering

cylinder and torque the bolts to 335 N·m (247.1 lb ft).
RCPH10TLB717ABL 11
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12. Install the ball joints to the steering cylinder, torque

the ball joints to 300 N·m (221.3 lb ft).
RCPH10TLB717ABL 12
13. Loosen the locking nut for the tie rod end, place the
swivel housing parallel with the axle. Adjust the tie
rod end so that it can be slipped into the swivel hous-
ing.
RCPH10TLB617ABL 13
14. Tighten the tie rod end to a torque of 165 N·m (121.7
lb ft).
RCPH10TLB603ABL 14
Toe-in Adjustment
15. Place two 1 m (39.37 in) bars on the wheel hubs with
500 mm (19.69 in) on each side of the center line of
the axle.
RCPH10TLB618ABL 15
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16. Use lug nuts to hold the bars into place on the wheel
hub.
RCPH10TLB619ABL 16
17. Measure the distance between the bars, adjust the

toe-in so that (A) is -12 - -24 mm (-0.47 - -0.94 in).
RCPH10TLB718ABL 17
18. Snug the jam nuts for the tie rods and recheck toe-in.
RCPH10TLB620ABL 18
19. Torque the jam nut to 120 N·m (88.5 lb ft).
RCPH10TLB621ABL 19
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FRONT AXLE - Disassemble - CNH Front Axle - Two Wheel Drive

1. Raise the wheel(s) off the floor and use acceptable
supports to hold the machine in position.
2. Remove the nuts and hardened washers and remove
the wheel(s). FRONT AXLE - Remove (D.10.A)
Drain the oil from the carrier.
RCPH10TLB303ACL 1
3. Loosen and remove the tie rod ends from the swivel
housings.
RCPH10TLB951ABL 2
4. Remove the steering cylinder, ball joints, and tie rod

ends from the axle.
RCPH10TLB240ACL 3
5. Attach suitable lifting equipment to the wheel hub.

Remove the wheel hub cover, bearing retainer plate
bolts, and bearing retainer plate.
RCPH10TLB311ACL 4
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6. Remove the wheel hub from the axle.
RCPH10TLB605ABL 5
NOTE: Repeat steps 3 through 6 for the other wheel hub.

7. Remove the bearing cups from the wheel hubs.
RCPH10TLB606ABL 6
8. Remove the bearing cone from the swivel housing.
RCPH10TLB607ABL 7
9. Attach suitable lifting equipment to the swivel hous-

ing. Remove the upper and lower king pins.
RCPH10TLB954ABL 8
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10. Remove the swivel housing from the axle beam.
RCPH10TLB956ABL 9
NOTE: Repeat steps 9 and 10 for the other swivel housing.

11. Remove the bevelled washers from the axle beam.
RCPH10TLB699ABL 10
12. If required, remove the upper bushing and lower

bearing cup for the king pins.
RCPH10TLB926ABL 11
13. If required, remove the front and rear pivot seals and
bushings.
RCPH10TLB612ABL 12
Next operation:
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FRONT AXLE - Inspect - CNH Front Axle - Two Wheel Drive

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 ar-
needed.
4. Inspect axle pivot bushings and pivot pin for flat ar-
needed.
5. Remove and discard all seals and O-rings.
Next operation:
FRONT AXLE - Assemble (D.10.A)
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FRONT AXLE - Assemble - CNH Front Axle - Two Wheel Drive

1. Install bushings and seals in the pivot on the axle
beam.
RCPH10TLB612ABL 1

2. Install the upper bushing and lower bearing cup using
suitable bearing drivers.
RCPH10TLB926ABL 2

3. Apply grease to the bevelled washers to assist hold-
ing them in place during assembly.
RCPH10TLB699ABL 3
4. Use suitable lifting equipment and install the swivel

housing on the axle.
RCPH10TLB269ACL 4
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5. Make sure the bevelled washers are in place, install

the upper and lower king pins. Torque the bolts to
120 N·m (88.5 lb ft)
RCPH10TLB002ACL 5
6. Grease the bearing cone and install it onto the swivel

housing.
RCPH10TLB607ABL 6
7. Use suitable drivers and install new bearing cups and

seal into wheel hub.
RCPH10TLB613ABL 7
8. Use suitable lifting equipment and install wheel hub

onto the swivel housing.
RCPH10TLB614ABL 8
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9. Grease and install the outer bearing on the swivel

housing. Use LOCTITE® 270 on the bolts, position
the thrust washer, install and torque the bolts to 120
N·m (88.5 lb ft).
RCPH10TLB311ACL 9
10. Install a new O-ring on the wheel hub cover, lubricate

the O-ring with grease. Use a suitable driver and
install the wheel hub cover into the wheel hub.
RCPH10TLB616ABL 10
11. Use LOCTITE® 270 on the bolts, mount the steering

cylinder and torque the bolts to 335 N·m (247.1 lb ft).
RCPH10TLB240ACL 11
12. Install the ball joints to the steering cylinder, torque

the ball joints to 300 N·m (221.3 lb ft).
RCPH10TLB239ACL 12
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13. Tighten the tie rod end to a torque of 165 N·m (121.7
lb ft).
RCPH10TLB006ACL 13
Toe-in Adjustment
14. Place two 1 m (39.37 in) bars on the wheel hubs with
500 mm (19.69 in) on each side of the center line of
the axle.
RCPH10TLB618ABL 14
15. Use lug nuts to hold the bars into place on the wheel
hub.
RCPH10TLB619ABL 15
16. Measure the distance between the bars, adjust the

toe-in so that (A) is -12 - -24 mm (-0.47 - -0.94 in).
RCPH10TLB718ABL 16
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17. Snug the jam nuts for the tie rods and recheck toe-in.
RCPH10TLB620ABL 17
18. Torque the jam nut to 120 N·m (88.5 lb ft).
RCPH10TLB621ABL 18
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Differential - Remove - CNH Front Axle -Four Wheel Drive -

Differential Carrier
Prior operation:
Planetary and hub - Disassemble (D.10.A)
1. Drain oil.
RCPH10TLB276ACL 1
2. Remove knuckle assembly.

3. Loosen and remove the steering cylinder bolts and
washers.
RCPH10TLB957ABL 2
4. Remove the differential carrier bolts (12).
RCPH10TLB958ABL 3
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5. Use suitable lifting equipment and remove the differ-

ential carrier.
RCPH10TLB255ACL 4
Next operation:
Differential - Disassemble (D.10.A)
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Differential - Disassemble - CNH Front Axle -Four Wheel Drive-

1. See differential and differential carrier and exploded
view Differential - Exploded view (D.10.A)
2. Place the differential on an approved working area
so the differential gear is free to rotate.
RCPH10TLB962ABL 1
3. Prevent the pinion shaft from turning. Measure the

backlash of the ring gear. Record the reading.
RCPH10TLB963ABL 2
4. Make an identification mark on the bearing cap and

leg on one side of the differential carrier.
RCPH10TLB964ABL 3
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5. Loosen the bolt.
RCPH10TLB964ABL 4
6. Loosen both adjusting rings. Use DMT100002 tool or

suitable alternative, such as CAS1840C, if available.
RCPH10TLB964ABL 5
NOTE: Record the number of turns while removing the nuts.

7. Remove the bolts. Loosen the 2 bearing caps.
RCPH10TLB966ABL 6
8. Remove the adjusting rings, bearing cups and differ-

ential.
RCPH10TLB989ABL 7
9. If the bearing cups are to be used again, fasten an

identification tag to one bearing cup for the current
installation.
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10. Remove the seal and cover.
RCPH10TLB972ABL 8
11. Use a very narrow chisel/round end punch to unstake

the nut.
RCPH10TLB512ABL 9
12. Use special tool 380000468 and 380100102 or yolk

to remove the pinion nut.
RCPH10TLB263ACL 10
13. Remove the tab washer.
RCPH10TLB976ABL 11
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14. Use a press and drive the pinion shaft out of the outer
bearing.
RCPH10TLB977ABL 12
NOTE: Take care to avoid pinion shaft falling on the ground.

15. Remove the flat washers and crush sleeve. Discard
the crush sleeve. The crush sleeve MUST NOT be
used again.
RCPH10TLB978ABL 13
16. Press the pinion shaft out of the inner bearing.
RCPH10TLB979ABL 14
RCPH10TLB535ABL 15
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18. Use a soft punch to remove the bearing cups only if

inspection indicates the need for new parts.
RCPH10TLB531ABL 16
19. Use an acceptable puller to remove the seal from the

cover, if needed. Discard the seal.
RCPH10TLB713ABL 17
20. Remove and discard the O-ring from the cover.
RCPH10TLB974ABL 18
Next operation:
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Differential - Disassemble - CNH Front Axle -Four Wheel Drive

1. Remove the bolts (12).
RCPH10TLB967ABL 1
2. Use a soft faced hammer to remove the ring gear and

bushings.
RCPH10TLB968ABL 2
3. Remove the outer side gear, as required.
RCPH10TLB970ABL 3
4. Use a suitable punch to remove retaining pin.
RCPH10TLB928ABL 4
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5. Remove cross pin.
RCPH10TLB930ABL 5
6. Remove the thrust washer, spider gears and remain-

ing side gear, as required.
RCPH10TLB931ABL 6
Next operation:
Differential - Inspect (D.10.A)
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Differential - Inspect - CNH Front Axle - Four Wheel Drive

2. Inspect all bearing assemblies for flat areas, pitting,
scoring, and other damage. Also check the races for
damage. If any of these defects are found, a new
wheel 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 cross pin, and the teeth of
the spider gears for pitting, scoring, and other dam-
age. Also inspect the thrust surfaces and the bore of
each spider gear. Check the splines (limited slip op-
tion only) in the side gears for wear. Use new parts
as required. Differential gears must be replaced as
a set.
5. Inspect the thrust washers for pitting, scoring, and
other damage. Use new parts as required.
6. Inspect the spider shaft for wear. If wear can be felt
with a finger nail, then replace.
Next operation:
Differential - Assemble (D.10.A)
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Differential - Assemble - CNH Front Axle - Four Wheel Drive

NOTE: For limited slip differentials install 5 reaction and 4 friction plates starting with a reaction plate. Make sure the
one sided friction plate with friction material on one side is placed against the side gear with the friction material facing
away from the gear.
1. Install the thrust gear and washer, as required.
RCPH10TLB931ABL 1
2. Install the cross pin and spider gears.
RCPH10TLB930ABL 2
NOTE: For limited slip option: Install one spider and washer with differential shaft, then insert second spider and
washer rolling next to first one. Hold up the side gear and roll spider and washer into place. Then push the shaft
through the second spider. Finish inserting plates.
3. Use a suitable punch to install the retaining pin.
RCPH10TLB928ABL 3
NOTE: Grease all gear and plate contact surfaces before assembly with specified oil.
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4. Install the outer side gear.
RCPH10TLB970ABL 4
5. Make sure that the mounting surfaces for the ring

gear are clean and install the ring gear.
RCPH10TLB987ABL 5
6. Use the vise to prevent the differential from turning

and install and tighten the (12) bolts to 96 - 118 N·m
(70.8 - 87.0 lb ft). Tighten in a star pattern and use
medium thread Loctite 242.
RCPH10TLB988ABL 6
Next operation:
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Differential - Assemble - CNH Front Axle - Four Wheel Drive -

1. Use a suitable driver and drive the bearing cup(s) into
the differential carrier. Use a feeler gauge to ensure
cups are fully seated to 0.008 mm (0.003 in).
RCPH10TLB532ABL 1
2. Install the spacer. The chamfer on the ID of the

spacer must be towards the pinion gear.
RCPH10TLB535ABL 2
3. Use a suitable tool and press the inner bearing

against the spacer. Use a feeler gauge to ensure
bearing is fully seated.
RCPH10TLB981ABL 3
NOTE: Bearing heating is permitted as long as checked with feeler gauge when bearing is cooled.
4. Lubricate the bearings with gear lubricant.
RCPH10TLB542ABL 4
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5. Install a new crush sleeve and two flat washers. The

old crush sleeve MUST NOT be used again. One flat
washer goes on each side of the crush sleeve.
RCPH10TLB533ABL 5
6. Install the pinion shaft and the outer bearing.
RCPH10TLB982ABL 6
7. Install the tab washer, round edges down.
RCPH10TLB983ABL 7
8. Install a new pinion nut.
RCPH10TLB984ABL 8
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9. Use the yoke and 380000468 wrench for the follow-

ing procedure.
RCPH10TLB263ACL 9
10. The pinion shaft and bearings will still be loose.

Tighten the pinion nut in SMALL amounts until the
bearings becomes seated.
NOTICE: If the pinion nut is tightened too much (rotating torque more than specified), the pinion will have to be re-
moved and a new crush sleeve installed on the pinion shaft.
11. Use 380100102 and a pound-inch torque wrench to
check the rotating torque of the pinion shaft. The
shaft must be rotated during tightening of the nut.
Final reading to be verified after 3 complete revolu-
tions of the shaft. The rotating torque must be 1.7 -
2.2 N·m (15.0 - 19.5 lb in). If the rotating torque is
less than specified, tighten the pinion nut a SMALL
amount and check the rotating torque again. Record
actual rolling torque for later use.
RCPH10TLB546ABL 10
12. When the rotating torque is as specified, use a ham-

mer and punch and drive part of the pinion nut into
the slot in the pinion shaft.
RCPH10TLB985ABL 11
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13. Install the differential carrier and lubricate the bear-

ings with gear lubricant.
RCPH10TLB989ABL 12
14. Install bearing cups and bearing caps with the align-
ment marks.
RCPH10TLB990ABL 13
15. Tighten the bolts to pull the bearing caps against the
differential carrier. Do not overtighten the bolts. The
bearings must be able to rotate. Tighten to 20 N·m
(14.8 lb ft)
RCPH10TLB990ABL 14
USED BEVEL SET

NOTE: All bearings in axle should get a few drops of oil before setup. Never rotate the axle dry.
16. Use the CAS1840C or DMT100002 and tighten both
adjusting rings while making sure that there is clear-
ance (backlash) between the ring gear and pinion
gear. Bring adjusting rings into position using the
counted turns from Step 5 of the disassembly sec-
tion Differential - Disassemble (D.10.A). Small fi-
nal alignment may be needed to align marks. Verify
locking finger is aligned.
RCPH10TLB715ABL 15
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17. Tighten the adjusting nut on gear teeth side, to get

rolling torque measured on pinion shaft. See chart
below:
Diff Preload (Nm)

Measured at Pinion
Pinion, Z Crown Z Bevel Ratio FD Ratio Total Ratio Min Max
16 32 2.0 6.0 12.0 0.75 1.25
14 32 2.3 6.0 13.7 0.66 1.09
15 32 2.1 6.0 12.8 0.70 1.17
14 32 2.3 6.0 13.7 0.66 1.09
13 31 2.4 6.0 14.3 0.63 1.05
14 31 2.2 6.0 13.3 0.68 1.13
13 35 2.7 6.0 16.2 0.56 0.93
18. In chart above using Total Ratio field (12.0) as a ref-

erence. Use value from step 20 to determine differ-
ential preload. So: a value of 2.0 Nm would result in
a minimum value of 2.75 Nm and a maximum value
of 3.25 Nm.
19. Rotate bevel set approximately 3 or 4 turns, ensure
proper seating. Use a dial indicator to check for back-
lash. Check in 3 places, approximately 120 degrees
apart. Current value should be (0.008 - 0.013 in). . If
values vary more than (0.005 in), then replace bevel
set. .
RCPH10TLB991ABL 16
20. If backlash value is to large, loosen the adjusting nut

1 slot on gear side and tighten the adjusting nut 1
slot on the back face of the bevel gear. Recheck
backlash. Each slot ~ .004 in.
21. If the backlash value is to small, do the opposite of
step 20.
22. Confirm backlash with dial indicator. Value should be
(0.008 in - 0.013 in).
RCPH10TLB992ABL 17
23. Make final adjustment of nuts to align locking fingers

and confirm rolling torque. See chart, step 17.
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24. Apply bevel set pattern yellow compound in 3 places

120 degrees apart, on 3 teeth each. Rotate bevel set
enough to see pattern in yellow compound. Pattern
should be per chart below. Normal wear will flatten
(elongate) the contact pattern.
NOTE: This is a nonadjustable bevel set. If pattern is significantly different than spec, then replace bevel set.
25. If the original ring gear and pinion gear are being
used, the backlash should be close to the measure-
ment made during disassembly.
RCPH10TLB352ACL 18
26. When the backlash is correct, tighten the bolts to 96

- 118 N·m (70.8 - 87.0 lb ft).
RCPH10TLB990ABL 19
27. Install the lock bolt and lock washer that hold each
adjusting ring. Tighten to 21 - 26 N·m (15.5 - 19.2 lb
ft)
28. Apply form-in-place gasket material, Loctite 515.
RCPH10TLB995ABL 20
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NEW BEVEL SET

29. Install the adjusting rings. Turn nuts into position.
Leave enough clearance on gear teeth side nut to
prevent any bearing preload while tightening the ad-
justing nut on back face of bevel gear. Tighten to
zero backlash.
RCPH10TLB715ABL 21
NOTE: All bearings in axle should get a few drops of oil before setup. Never rotate the axle dry.
30. Tighten the adjusting nut on gear teeth side, to get
rolling torque measured on pinion shaft. See chart
below: In chart above using Total Ratio field (12.0)
as a reference. Use value from step 20 to determine
differential preload. So: a value of 2.0 Nm would re-
sult in a minimum value of 2.75 Nm and a maximum
value of 3.25 Nm.
Diff Preload (Nm)

Measured at Pinion
Pinion, Z Crown Z Bevel Ratio FD Ratio Total Ratio Min Max
16 32 2.0 6.0 12.0 0.75 1.25
14 32 2.3 6.0 13.7 0.66 1.09
15 32 2.1 6.0 12.8 0.70 1.17
14 32 2.3 6.0 13.7 0.66 1.09
13 31 2.4 6.0 14.3 0.63 1.05
14 31 2.2 6.0 13.3 0.68 1.13
13 35 2.7 6.0 16.2 0.56 0.93
31. Rotate bevel set approximately 3 or 4 turns, ensure

proper seating of bearings. Use a dial indicator to
check for backlash. Check in 3 places, approxi-
mately 120 degrees apart. Current value should be
0. If values vary more than 0.005 inch, then replace
bevel set. If not, repeat steps 32 and 33 to get zero
backlash.
RCPH10TLB991ABL 22
32. Loosen the adjusting nut 2 teeth/slots on back face

of bevel gear. Tighten the adjusting nut on gear teeth
side the same amount. Maintain input rolling torque
throughout the process. Each slot ~ 0.00045 N·m
(0.004 lb in). Hold adjusting nut locking finger in
place and move adjusting nut to closest slot that al-
lows finger in slot.
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33. Check backlash with dial indicator. Value should be

(0.010 in). Try for lowest value.
RCPH10TLB992ABL 23
34. Make final adjustments to adjusting nuts to bring

backlash in line with step 33.
35. Confirm rolling torque per step 33:
36. If backlash value is to large, loosen the adjusting nut
1 slot on gear side and tighten the adjusting nut 1
slot on the back face of the bevel gear. Recheck
backlash. Each slot ~ (0.004) in.
37. If the backlash value is to small, do the opposite of
step 36.
38. Confirm backlash with dial indicator. Value should be
(0.010) in.
RCPH10TLB992ABL 24
39. Apply bevel set pattern yellow compound in 3 places

120 degrees apart, on 3 teeth each. Rotate bevel set
enough to see pattern in yellow compound. Pattern
should be per chart.
RCPH10TLB352ACL 25
NOTE: This is a non-adjustable bevel set. If pattern is significantly does not match, then replace bevel set.
NOTE: Each tooth is ~ 0.004 inches.
84516378 05/07/2011
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- 118 N·m (70.8 - 87.0 lb ft).
RCPH10TLB990ABL 26
41. Install the locking finger bolts and lock washer that
hold each adjusting ring. Tighten to 21 - 26 N·m (15.5
- 19.2 lb ft)
42. Install a new O-ring on the cover.
RCPH10TLB973ABL 27
43. Use DMT100001 and drive a new seal into the cover.
The OD of the seal should be lightly coated with Klu-
berplus. The seal will be approximately 1/16 from the
inner face of the cover. Pack seal lips with approved
grease.
RCPH10TLB714ABL 28
44. Lubricate the O-ring with clean oil FRONT AXLE -

General specification (D.10.A). Install the cover
RCPH10TLB264ACL 29
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45. Apply form-in-place gasket material, Loctite 515.
RCPH10TLB995ABL 30
46. Install the differential carrier.
RCPH10TLB996ABL 31
47. Install and tighten the bolts to 96 - 118 N·m (70.8 -

87.0 lb ft).
RCPH10TLB997ABL 32
48. Proceed with knuckle installation procedure Hous-

ing - Assemble (D.10.A)
49. See specifications for the correct lubricant for the
axle housing.
50. Lubricate the removed king pins with molydisulfide
grease.
51. Measuring to in, if required Axle - Drawing (D.10.A)
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Differential - Remove - Carraro Front axle-four wheel drive

differential carrier- 580N and 580SN only
1. Drain the lubricant from the center bowl.
2. Loosen the nut.
RCPH10TLB693ABL 1
3. Use the CAS10468 puller to loosen the ball joint.
RCPH10TLB692ABL 2
4. Remove the nut and ball joint.
RCPH10TLB484ABL 3
5. Loosen and remove the bolts that hold the top king
pin.
RCPH10TLB695ABL 4
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6. Fasten suitable lifting equipment as shown and re-

move the top king pin.
RCPH10TLB697ABL 5
7. Remove the planetary and axle assembly.
RCPH10TLB698ABL 6

axle.
9. Use tool 380100091 and loosen and remove the right
steering cylinder.
RCPH10TLB502ABL 7
10. Remove the fitting from the closed end of the steering
cylinder.
11. Remove the bolts.
RCPH10TLB639ABL 8
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12. Remove the plug from the cylinder.
RCPH10TLB287ABL 9
13. Remove the steering cylinder.
RCPH10TLB288ABL 10
RCPH10TLB508ABL 11

ential carrier.
RCPH10TLB509ABL 12
Next operation:
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Differential - Disassemble - Carraro Front axle-four wheel drive

1. Fasten the differential carrier in a repair stand.
RCPH10TLB462ABL 1

RCPH10TLB701ABL 2

leg on one side of the differential carrier.
RCPH10TLB702ABL 3
4. Remove the bolt and lock that hold each adjusting

ring.
RCPH10TLB703ABL 4
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5. Loosen the bolts.
RCPH10TLB704ABL 5
6. Loosen both adjusting rings.
RCPH10TLB715ABL 6
7. Remove the 4 bolts. Use a hammer to loosen the 2

bearing caps.
RCPH10TLB706ABL 7
8. Remove the adjusting rings, bearing cups and differ-

ential.
RCPH10TLB707ABL 8

installation.
84516378 05/07/2011
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RCPH10TLB511ABL 9
11. Use a narrow chisel to push the nut out of the pinion
shaft.
RCPH10TLB512ABL 10
12. Use the yoke and CAS2151 tool to remove the pinion
nut.
RCPH10TLB471ABL 11
RCPH10TLB529ABL 12
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14. Use a soft hammer and drive the pinion shaft out of
the outer bearing.
RCPH10TLB530ABL 13
15. Remove the flat washers and spacer. Discard the

spacer. The spacer MUST NOT be used again.
RCPH10TLB533ABL 14
RCPH10TLB534ABL 15
17. Remove the shim.
RCPH10TLB535ABL 16
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18. Remove the bearing cups only if inspection indicates

the need for new parts.
RCPH10TLB531ABL 17
19. Use an acceptable puller and remove the seal form

the cover.
RCPH10TLB713ABL 18
RCPH10TLB691ABL 19
Next operation:
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Differential - Disassemble - Carraro Front axle-four wheel drive -

580N and 580SN only
RCPH10TLB513ABL 1
2. Remove the ring gear.
RCPH10TLB514ABL 2
3. Separate the case halves.
RCPH10TLB515ABL 3
4. Remove the thrust washer and side gear.
RCPH10TLB516ABL 4
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5. Remove the pinion shaft assembly and pin.
RCPH10TLB518ABL 5
6. Remove the side gear.
RCPH10TLB520ABL 6
RCPH10TLB521ABL 7
8. Remove and install new bushings in the case halves

as required.
RCPH10TLB522ABL 8
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9. Remove the bearing from either case half as shown.
RCPH10TLB464ABL 9
Next operation:
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Differential - Inspect - Carraro Front axle-four wheel drive - 580N

and 580SN only
2. Inspect the bearing cup and the rollers in the bear-
ings for flat areas, pitting, scoring, and other dam-
age. Also check the inner race for damage. If any of
these defects are found, a new bearing and bearing
cup must be installed.
4. Inspect the side gears, the pinion shaft, and the teeth
of the pinion gears for pitting, scoring, and other dam-
each pinion gear. Check the splines in the side gears
for wear. Use new parts as required.
Next operation:
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Differential - Assemble - Carraro Front axle-four wheel drive - 580N

and 580SN only
1. Use the CAS 2395 and press a new bearing onto
each case half.
RCPH10TLB463ABL 1
2. Find the case half that has the threaded holes. Make
sure that the threads are free of lubricant.
RCPH10TLB523ABL 2
3. Lubricate the thrust washers, pinion gears and pinion

shaft with gear lubricant.
RCPH10TLB524ABL 3
4. Install a thrust washer in the case half that has

threaded holes.
RCPH10TLB521ABL 4
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5. Install a side gear.
RCPH10TLB520ABL 5
6. Install the thrust washers and pinion gears on the

pinion shaft.
RCPH10TLB525ABL 6
7. Install the pin.
RCPH10TLB519ABL 7
8. Install the pinion shaft assembly.
RCPH10TLB518ABL 8
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9. Apply 270 Loctite to the threads in the case half.
RCPH10TLB526ABL 9
10. Install the other side gear.
RCPH10TLB517ABL 10
11. Install the other thrust washer in the other case half.
RCPH10TLB527ABL 11
NOTE: For limited slip differentials install 5 reaction and 4 friction plates starting with a reaction plate. Make sure the
special friction plate is against the side gear.
12. Using the two reference notches on the case halves,
assemble the two case halves.
RCPH10TLB515ABL 12
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13. Make sure the mounting surfaces for the ring gear
are clean and install the ring gear.
RCPH10TLB514ABL 13
14. Use the press to prevent the differential from turning

and install and tighten the bolts to 95 Nm (70 pound-
ft).
RCPH10TLB528ABL 14
Next operation:
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Differential - Assemble - Carraro Front axle-four wheel drive

1. Use a suitable driver and drive the bearing cup(s) into
the differential carrier.
RCPH10TLB532ABL 1
2. Assemble the gauge block, pilot and stud from the

CAS1839 pinion setting kit.
3. Install the gauge block, pilot, bearings and handle.
See special tools. Tighten the handle until the bear-
ings become difficult to turn.
RCPH10TLB537ABL 2
4. Install the gauge tube and bearing caps with marks

aligned.
RCPH10TLB538ABL 3
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5. Tighten the bolts to 156Nm (115 pound-feet).
RCPH10TLB539ABL 4
6. 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 8.
RCPH10TLB540ABL 5
7. Write the number on the end of the pinion shaft on

line "d" in step 8.
RCPH10TLB458ABL 6
8. The number on line "a" does not change. Add line "a"
and line "b" and write the answer on link "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: Use 2.75 MM. thick shim
A. 109.75 MM A. 109.75 MM
B.+ MM B. +0.45 MM
C. MM C. 110.20MM
D. - MM D. -107.45MM
E. MM E. 2.75 MM
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9. Remove the bolts, bearing caps, gauge tube, handle,

gauge block assembly and the bearings.
RCPH10TLB541ABL 7
10. Install the shim with the thickness specified in step 8.

The chamfer on the ID of the shim must be towards
the pinion gear.
RCPH10TLB535ABL 8
11. Use the CAS2370 inner/outer pinion bearing cone in-

staller and press the inner bearing against the shim.
RCPH10TLB536ABL 9
RCPH10TLB542ABL 10
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13. Install a new spacer and flat washers. The old spacer
MUST NOT be used again.
RCPH10TLB533ABL 11
RCPH10TLB543ABL 12
RCPH10TLB544ABL 13
RCPH10TLB545ABL 14
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17. Use the yolk and the CAS2151 wrench and tighten
the pinion nut to 68Nm (50 pound-feet).
RCPH10TLB470ABL 15

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.
19. The art shows a socket being used, use the
CAS2375 and a pound-inch torque wrench to check
the rotating torque of the pinion shaft. The ro-
tating 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.
RCPH10TLB546ABL 16
20. When the rotating torque is as specified, use a ham-

mer and punch and drive part of the pinion nut into
the slot in the pinion shaft.
RCPH10TLB547ABL 17
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RCPH10TLB691ABL 18
22. Use a suitable driver and drive a new seal into the
cover.
RCPH10TLB714ABL 19
23. Put the CAS2369 seal protector on the pinion shaft.
RCPH10TLB709ABL 20
24. Lubricate the O-ring and the seal with clean oil. In-
stall the cove.
RCPH10TLB710ABL 21
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RCPH10TLB707ABL 22
26. Install the bearing cups and bearing caps with the
alignment marks.
RCPH10TLB700ABL 23
27. Tighten the bolts to pull the bearing caps against the
bearings must be able to rotate.
RCPH10TLB704ABL 24
28. Install the adjusting rings.
RCPH10TLB715ABL 25
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29. Use the CAS1840C and tighten both adjusting rings

while making sure that there is clearance (backlash)
between the ring gear and pinion gear.
RCPH10TLB715ABL 26
30. Use a dial indicator to check for end play.
RCPH10TLB555ABL 27
31. If there is end play, tighten the adjusting ring on the

tooth side of the ring gear until there is no end play.
32. 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 gear
and tighten the opposite adjusting ring until there is
no end play.
33. When there is no end play, tighten each adjusting
ring one notch.
34. Use the dial indicator and check the backlash for the
ring gear at 90 degree intervals. If the reading are not
equal, adjust the backlash at the position that had the
smallest reading.
RCPH10TLB701ABL 28
used, the backlash must be equal to the measure-
36. If a new ring and pinion gear ar being used, the back-
lash must be 0.002 to 0.0025 MM )0.008 to 0.010
inch)
84516378 05/07/2011
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37. If there is not enough backlash, use the CAS1840C

and loosen the adjusting ring on the back face side
of the ring gear one notch and tighten the opposite
adjusting ring one notch. Check the backlash again.
Continue with this step until the backlash is correct.
RCPH10TLB715ABL 29
38. If there is too much backlash, use the CAS1840C

and loosen the adjusting ring on the tooth side of the
ring gear one notch and tighten the opposite adjust-
ing ring one notch. Check the backlash again. Con-
tinue with this step until the backlash is correct.
RCPH10TLB557ABL 30

Nm (197 pound-feet).
RCPH10TLB705ABL 31
40. Install the lock, bolt and lock washer that hold each
adjusting ring. Tighten the bolts to 13 Nm (120
pound-inches).
RCPH10TLB708ABL 32
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41. Apply form-in-place gasket material.
RCPH10TLB559ABL 33
RCPH10TLB560ABL 34
43. Install and tighten the bolts to 169 Nm (125 pound-

feet).
RCPH10TLB508ABL 35
44. Install the steering cylinder.

feet).
RCPH10TLB504ABL 36
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46. Install and tighten the tie rod using the 380100091
for the 580N and 580SN and torque to 300 Nm (222
pound-feet)
RCPH10TLB503ABL 37
47. Install and tighten the fitting at the closed end of the
steering cylinder.
48. Install the planetary and axle assembly. It may be
necessary to have another person turn the pinion
shaft.
RCPH10TLB698ABL 38
49. Install the top kin pin, spacer, and bolts. Tighten the
bolts to a torque of 120 Nm (89 pound-feet).
RCPH10TLB696ABL 39
50. Install the bottom kin pin, belleville washer and bolts.
Tighten the bolts to a torque of 120 Nm (89 pound-
feet).
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51. Install the ball join and nut.
RCPH10TLB498ABL 40
52. Tighten the nuts to 165 Nm (122 pound-feet).
RCPH10TLB694ABL 41
53. Repeat steps 47 through 51 for the opposite end of

the axle.
54. See specifications for the correct lubricant for the
center bowl.
55. Lubricate the king pins with molydisulfide grease.
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Differential - Remove - Carraro Front axle-four wheel drive

differential carrier- 580SN-WT and 590SN only
1. Drain the lubricant from the center bowl.
2. Loosen but do not remove the nut.
RCPH10TLB482ABL 1
3. Use an acceptable puller to loosen the ball joint.
RCPH10TLB483ABL 2
RCPH10TLB484ABL 3
5. Fasten suitable lifting equipment as shown and re-

move the bolts from the top king pin. Use acceptable
tools and remove the top king pin.
RCPH10TLB711ABL 4
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6. Remove the bolts and use acceptable tools to re-

move the bottom king pin.
RCPH10TLB500ABL 5
7. Remove the planetary and axle assembly.
RCPH10TLB712ABL 6

axle.
9. Use tool 38010092 and remove the right tie rod.
RCPH10TLB502ABL 7
10. Remove the fitting from the closed end of the steering
cylinder.
RCPH10TLB505ABL 8
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12. Use a soft-faced hammer to remove the steering

cylinder.
RCPH10TLB506ABL 9
RCPH10TLB508ABL 10

ential carrier.
RCPH10TLB509ABL 11
Next operation:
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Differential - Disassemble - Carraro Front axle-four wheel drive

1. Fasten the differential carrier in a repair stand.
RCPH10TLB462ABL 1

RCPH10TLB701ABL 2

leg on the ring gear side of the differential carrier.
RCPH10TLB702ABL 3
4. Remove the bolt and lock that hold each adjusting

ring.
RCPH10TLB703ABL 4
84516378 05/07/2011
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RCPH10TLB704ABL 5
6. Loosen both adjusting rings.
RCPH10TLB715ABL 6
7. Remove the 4 bolts. Use a soft-faced hammer to

loosen the 2 bearing caps.
RCPH10TLB706ABL 7
8. Remove the adjusting rings, bearing cups, and dif-

ferential.
RCPH10TLB707ABL 8

installation.
84516378 05/07/2011
D.10.A / 127
RCPH10TLB511ABL 9
11. Use a narrow chisel to push the nut out of the pinion
shaft.
RCPH10TLB512ABL 10
12. Use the yoke and CAS-2151 tool to remove the pin-
ion nut.
RCPH10TLB471ABL 11
RCPH10TLB529ABL 12
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14. Use a soft hammer and drive the pinion shaft out of
the outer bearing.
RCPH10TLB530ABL 13
15. Remove the flat washers and spacer. Discard the

spacer. The spacer MUST NOT be used again.
RCPH10TLB533ABL 14
RCPH10TLB534ABL 15
17. Remove the shim.
RCPH10TLB535ABL 16
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18. Remove the bearing cups only if inspection indicates

the need for new parts.
RCPH10TLB531ABL 17
19. Use an acceptable puller and remove the seal form

the cover.
RCPH10TLB713ABL 18
RCPH10TLB691ABL 19
Next operation:
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Differential - Disassemble - Carraro Front axle-four wheel drive -

differential - 580SN-WT and 590SN only
RCPH10TLB513ABL 1
RCPH10TLB514ABL 2
3. Separate the case halves.
RCPH10TLB515ABL 3
4. Remove the thrust washer and side gear.
RCPH10TLB516ABL 4
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RCPH10TLB518ABL 5
RCPH10TLB520ABL 6
RCPH10TLB521ABL 7
NOTE: Steps 8 through 10 are for limited slip differentials.

RCPH10TLB632ABL 8
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RCPH10TLB631ABL 9
10. Remove the reaction and friction plates.
RCPH10TLB630ABL 10
NOTE: The plate at the side gear must be kept in that position.
11. Remove and install new bushings in the case halves
as required.
RCPH10TLB522ABL 11
12. Remove the bearing from either case half as shown.
RCPH10TLB463ABL 12
Next operation:
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Differential - Inspect - Carraro Front axle-four wheel drive -

2. Inspect the bearing cup and the rollers in the bear-
ings for flat areas, pitting, scoring, and other dam-
age. Also check the inner race for damage. If any of
these defects are found, a new bearing and bearing
cup must be installed.
4. Inspect the side gears, the pinion shaft and the teeth
of the pinion gears for pitting, scoring, and other dam-
each pinion gear. Check the splines in the side gears
for wear. Use new parts as required.
6. Limited slip differentials, check reaction and friction
plates for discoloration, scarring and chipping. Mea-
sure thickness of friction and separator plates, use
new parts as required.
NOTICE: 1. Separator plate new 1.5 +- 0.03MM. (0.059+- 0.001 IN) minimum thickness 1.4 MM (0.055 IN). 2. Friction
plate new 1.6 +- 0.03 MM. (0.063 +- 0.001 IN) minimum thickness 1.45MM. (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).
Next operation:
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Differential - Assemble - Carraro Front axle-four wheel drive -

1. Use the CAS-2395 and press a new bearing onto
each case half.
RCPH10TLB463ABL 1
2. Find the case half that has the threaded holes. Make
sure that the threads are free of lubricant.
RCPH10TLB523ABL 2
3. Lubricate the thrust washers, pinion gears and pinion

shaft with gear lubricant.
RCPH10TLB524ABL 3
NOTE: Step 4 through 7 pertain to the limited slip differential.

4. Lubricate and place a reaction plate in the case half.
RCPH10TLB629ABL 4
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5. 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.
RCPH10TLB628ABL 5
6. Lubricate and place the side gear friction plate on the

side gear.
RCPH10TLB627ABL 6
7. Work the side gear in a rotating motion until the gear

has engaged all of the friction plates.
RCPH10TLB632ABL 7
NOTE: Repeat steps 4 through 7 for the other case half.

8. Install a thrust washer in the case half that has
threaded holes.
RCPH10TLB521ABL 8
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9. Install a side gear.
RCPH10TLB520ABL 9
10. Install the thrust washers and pinion gears on the

pinion shaft.
RCPH10TLB525ABL 10
RCPH10TLB519ABL 11
12. Install the pinion shaft assembly.
RCPH10TLB518ABL 12
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13. Apply Loctite to the threads in the case half.
RCPH10TLB526ABL 13
14. Install the other side gear.
RCPH10TLB517ABL 14
15. Install the other thrust washer in the other case half.
RCPH10TLB527ABL 15
16. Using the two reference marks on the case halves,

assemble the two case halves.
RCPH10TLB515ABL 16
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17. Make sure that the mounting surfaces for the ring
gear are clean and install the ring gear.
RCPH10TLB514ABL 17
18. Use the press to prevent the differential from turning

and install and tighten the bolts to: 580SN - WT -
95 Nm (70 pound-feet), 590SN - 120 Nm (88 pound-
feet).
RCPH10TLB528ABL 18
Next operation:
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Differential - Assemble - Carraro Front axle-four wheel drive

1. Use a soft-faced hammer and a suitable driver and
drive the bearing cup(s) into the differential carrier.
RCPH10TLB532ABL 1
2. Assemble the gauge block, pilot and stud from the

CAS-1839 pinion setting kit.
3. Install the gauge block, pilot, bearings and handle.
See special tools. Tighten the handle until the bear-
ings become difficult to turn.
RCPH10TLB537ABL 2
4. Install the gauge tube and bearing caps with marks

aligned.
RCPH10TLB538ABL 3
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5. Tighten the bolts to 156 Nm (115 pound-feet).
RCPH10TLB539ABL 4

between the gauge black and the gauge tube. Write
the measurement on line "b" in step 8.
RCPH10TLB540ABL 5
NOTE: The pinion gear shown is for a Powershift transmission. The helix spiral is opposite of the Carraro pinion gear.
The procedure is the same.
7. Write the number on the end of the pinion shaft on
line "d" in step 8.
RCPH10TLB458ABL 6
8. 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. Use 2.75 MM thick
shim.
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
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9. Remove the bolts, bearing caps, gauge tube, handle,

gauge block assembly and the bearings.
RCPH10TLB541ABL 7
10. Install the shim with the thickness specified in step 8.

The chamfer on the ID of the shim must be towards
the pinion gear.
RCPH10TLB535ABL 8
11. Use the CAS-2370 inner/outer pinion bearing cone

installer and press the inner bearing against the
shim.
RCPH10TLB536ABL 9
RCPH10TLB542ABL 10
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13. Install a new spacer and flat washers. The old spacer
MUST NOT be used again.
RCPH10TLB533ABL 11
RCPH10TLB543ABL 12
RCPH10TLB544ABL 13
RCPH10TLB545ABL 14
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17. Use the yoke and the CAS-2151A wrench and

tighten the pinion nut to 68 Nm (50 pound-feet).
RCPH10TLB470ABL 15

bearings become seated.
NOTE: If the pinion nut is tightened too much (rotating
torque more than specified), the pinion will have to be re-
moved and a new spacer installed on the pinion shaft.
19. The art shows a socket being used. Use the
CAS-2375 and a pound-inch torque wrench to
check the rotating torque of the pinion shaft. The
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.
RCPH10TLB546ABL 16
20. 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.
RCPH10TLB547ABL 17
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RCPH10TLB691ABL 18
22. Use a soft-faced hammer and a suitable driver and

drive a new seal into the cover.
RCPH10TLB714ABL 19
23. Put the CAS-2369 seal protector on the pinion shaft.
RCPH10TLB709ABL 20
stall the cover.
RCPH10TLB710ABL 21
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RCPH10TLB548ABL 22
26. Install the bearing cups.
RCPH10TLB549ABL 23
27. Install the bearing caps.
RCPH10TLB550ABL 24
NOTE: Align marks made during disassembly.

28. Tighten the bolts to pull the bearing caps against then
bearings must be able to rotate.
RCPH10TLB551ABL 25
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29. Install the adjusting rings.
RCPH10TLB552ABL 26
30. Use the CAS-1840C and tighten both adjusting rings

while making sure that there is clearance (backlash)
between the ring gear and pinion gear.
RCPH10TLB553ABL 27
31. Use a dial indicator and check for end play.
RCPH10TLB555ABL 28
32. If there is end play, tighten the adjusting ring on the

tooth side of the ring gear until there is no end play.
33. 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 gear
and tighten the opposite adjusting ring until there is
no end play.
34. When there is no end play, tighten each adjusting
ring one notch.
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35. Use the dial indicator and check the backlash for the
ring gear at 90 degree intervals. If the readings are
not equal, adjust the backlash at the position that had
the smallest reading.
RCPH10TLB510ABL 29
used, the backlash must be equal to the measure-
37. 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).
38. If there is not enough backlash, use the CAS-1840C
and loosen the adjusting ring on the backface side
of the ring gear one notch and tighten the opposite
adjusting ring one notch. Check the backlash again.
Continue with this step until the backlash is correct.
RCPH10TLB556ABL 30
39. If there is too much backlash, use the CAS-1840C

and loosen the adjusting ring on the tooth side of the
ring gear one notch and tighten the opposite adjust-
ing ring one notch. Check the backlash again. Con-
tinue with this step until the backlash is correct.
RCPH10TLB557ABL 31
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RCPH10TLB554ABL 32
41. Install the lock, bolt and lock washer that hold each
adjusting ring. Tighten the bolts to 13 Nm (120
pound-inches).
RCPH10TLB558ABL 33
42. Apply Loctite 510
RCPH10TLB559ABL 34
RCPH10TLB560ABL 35
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feet).
RCPH10TLB508ABL 36
45. Install the steering cylinder.
RCPH10TLB507ABL 37
46. Install and tighten the bolts to 120 Nm (88.5 pound -

feet).
RCPH10TLB504ABL 38
47. Install and tighten the tie rod using the 38010092 to
a torque of 300 Nm (222 pound-feet).
RCPH10TLB503ABL 39
48. Install and tighten the fitting at the closed end of the
steering cylinder.
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49. Install the planetary and axle assembly. It may be

necessary to have another person turn the pinion
shaft.
RCPH10TLB712ABL 40
50. Install the top king pin, belville washer, spacer, blots
and lock washers. Tighten the bolts to a torque of
190 Nm (140 pound-feet).
RCPH10TLB501ABL 41
51. Install the bottom king pin, belville washer, bolts and
lock washers. Tighten the bolts to a torque of 190
52. Install the ball joint and nut. Tighten the nut to
a torque of 165 Nm (122 pound-feet) for the 580
SN-WT and 220 Nm (162 pound-feet) for the 590
SN.
53. Repeat steps 47 through 51 for the opposite end of
the axle.
54. Fill the center bowl. Refer to the specifications.
55. Lubricate the king pins with molydisulfide grease.
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Housing - Disassemble - CNH Front Axle -Four Wheel Drive

1. See housing exploded view: Housing - Exploded
view (D.10.A)
NOTE: Steering stop screws are set per tires/loader combinations.

2. Do the necessary steps under disassembly of Plane-
tary Planetary and hub - Disassemble (D.10.A) for
access to the swivel housing.
3. Loosen the tie rod nut.
RCPH10TLB951ABL 1
4. Use a two jaw puller to loosen the ball joint. Remove

the tie rod nut and remove the ball joint from the
swivel housing. Remove the tie rod.
RCPH10TLB952ABL 2
NOTE: Remove and discard nut. DO NOT reuse.

RCPH10TLB484ABL 3
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6. Fasten acceptable lifting equipment as shown.
RCPH10TLB390ACL 4
7. Remove the bolts (3)and use acceptable tools to re-

move the top king pin.
RCPH10TLB391ACL 5
8. Remove top king pin.
RCPH10TLB405ACL 6
9. Repeat steps 7 through 9 for the bottom king pin.

10. Remove the swivel housing.
RCPH10TLB956ABL 7
NOTE: Take care when removing shaft. Do not cut the seal and bushing the splines on the axle shaft.
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11. Repeat steps1 through 11 for the other swivel hous-

ing.
12. Remove the belleville washer from the top and bot-
tom of the axle housing.
RCPH10TLB699ABL 8
NOTE: Mark washers for reassembly.

13. Remove the top cylindrical bushing and bottom
spherical bushing. using an acceptable puller.
RCPH10TLB926ABL 9
14. Use an acceptable puller and remove the axle shaft

seal.
RCPH10TLB959ABL 10
15. Use an acceptable puller and remove the axle shaft

bushing.
RCPH10TLB492ABL 11
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16. Use a hammer and a chisel that has a long taper to

remove the bearing cone from the bottom king pin.
RCPH10TLB459ABL 12
Replacing a Universal Joint

17. Remove the four snap rings.
RCPH10TLB472ABL 13
18. Use the CAS1980 V-block to support the coupling.

Adjust the Allen bolts in the V-block to hold the cou-
pling level and use additional support as required.
Use an acceptable driver and press the bottom bear-
ing cap against the V-block.
RCPH10TLB599ABL 14
19. Fasten the bearing cap in a vise and drive the cou-
pling off the bearing cap.
RCPH10TLB473ABL 15
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20. Use the V-block to support the coupling and press

the other bearing cap against the V-block.
RCPH10TLB593ABL 16
21. Remove the long axle shaft (or short axle shaft) from
the coupling.
RCPH10TLB594ABL 17
22. Remove the coupling from the bearing cap.
RCPH10TLB596ABL 18
23. Use an acceptable support and driver to press the

bottom bearing cap out of the yoke as far as possible.
RCPH10TLB474ABL 19
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24. Remove the yoke from the bearing cap. DO NOT hit
the axle shaft in the seal area.
RCPH10TLB475ABL 20
25. Press the other bearing cap out of the yoke as far as
possible.
RCPH10TLB476ABL 21
26. Remove the cross.
RCPH10TLB477ABL 22
27. Use an acceptable driver and press the bearing cap

out of the yoke.
RCPH10TLB478ABL 23
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28. Press a bearing cap into the yoke until the top of the
bearing cap is 6 mm (0.24 in) above the top of the
yoke.
RCPH10TLB585ABL 24
29. Carefully install the cross in the bearing cap.
RCPH10TLB586ABL 25
30. Press the other bearing cap into the yoke until the
top of the bearing cap is 9 mm (0.35 in) above the
top of the yoke.
RCPH10TLB587ABL 26
31. Carefully raise the cross into the bearing cap so that
the cross is in both bearing caps.
RCPH10TLB588ABL 27
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32. Hold the cross and press the bearing caps into the
yoke.
RCPH10TLB589ABL 28
33. Use an acceptable driver and press a bearing cap

into the yoke so that a snap ring can be installed.
RCPH10TLB590ABL 29
34. Install a snap ring.
RCPH10TLB591ABL 30
35. Repeat steps 30 and 31 for the other bearing cap.

36. Use the V-block to support the coupling and press a
bearing cap into the coupling even with the OD of the
coupling.
RCPH10TLB592ABL 31
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RCPH10TLB595ABL 32
38. Use an acceptable driver and press the other bearing

cap into the coupling until the top of the bearing cap
is 6 mm (0.24 in) above the top of the coupling.
RCPH10TLB597ABL 33
39. Carefully raise the cross into the top bearing cap so
that the cross is in both bearing caps.
RCPH10TLB598ABL 34
40. Hold the cross and press the bearing cap into the
coupling so that a snap ring can be installed.
RCPH10TLB600ABL 35
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RCPH10TLB601ABL 36
Next operation:
Housing - Assemble (D.10.A)
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Housing - Assemble - CNH Front Axle- Four Wheel Drive

1. Drive the bushing into the bore until the bushing is
3.175 mm (0.125 in) beyond the end of the bore.
Then install the seal. Use DMT100005 for the bush-
ing and DMT100006 for the seal.
RCPH10TLB994ABL 1
2. Install the cylindrical bushing for the top king pin on a

driver that has a pilot. Drive the bushing all the way
into the bore until fully seated.
RCPH10TLB490ABL 2
NOTE: Freezing of part to enable assembly is acceptable.

3. Repeat step 2 for the bottom bushing.
4. Insert shaft without cutting seal. Maneuver shaft to
align splines with the differential.
RCPH10TLB956ABL 3
NOTE: Take care not to cut seal during installation. It is necessary to rotate the input shaft to align splines.
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5. Install the belleville washer on the top of the axle

housing. Then install the belleville washer on the
bottom of the axle housing. Make final adjustments
of the swivel housing to align king pins..
RCPH10TLB002ACL 4
6. Install the top king pin, and bolts. Tighten the bolts
(3) to a torque of 154 - 188 N·m (113.6 - 138.7 lb ft).
RCPH10TLB004ACL 5
7. Install the bottom king pin and bolts. Tighten the bolts
(3) to 154 - 188 N·m (113.6 - 138.7 lb ft). If bearing
cone is removed in the previous step replace with
new cone at this time.
RCPH10TLB497ABL 6
8. Install the ball joint and new nut.
RCPH10TLB005ACL 7
NOTE: Nut must be replaced with new nut each time it is removed.
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9. Tighten the nut for models 580N & 580SN to: 129 -
160 N·m (95.1 - 118.0 lb ft) Tighten the nut for mod-
els 580SN-WT & 590SN to: 162 - 200 N·m (119.5 -
147.5 lb ft).
RCPH10TLB006ACL 8

axle.
11. Lubricate the king pins.
12. Assemble the planetary according to instructions
Planetary and hub - Assemble (D.10.A).
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Housing - Disassemble - Carraro Front axle-four wheel drive swivel

housing and universal joint- 580N and 580SN only
1. Do the necessary steps under Disassembly of plan-
etary for access to the swivel housing.
2. Loosen the nut.
RCPH10TLB693ABL 1
3. Use the CAS10468 puller to loosen the ball joint.

Remove the nut and remove the ball joint from the
swivel housing.
RCPH10TLB692ABL 2
4. Loosen the bolts that hold the top king pin.
RCPH10TLB695ABL 3
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5. Fasten acceptable lifting equipment as shown. Re-

move the bolts and use acceptable tools to remove
the top king pin.
RCPH10TLB697ABL 4
6. Repeat steps 4 and 5 for the bottom kin pin.

RCPH10TLB698ABL 5
8. Remove the belleville washer from the bottom of the

axle housing.
RCPH10TLB699ABL 6
9. Remove the belleville washer from the top of the axle

housing.
RCPH10TLB640ABL 7
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10. Use an acceptable puller and remove the top and

bottom bushings.
RCPH10TLB489ABL 8
11. Use an acceptable puller and remove the seal.
RCPH10TLB491ABL 9
12. Use an acceptable puller and remove the bushing.
RCPH10TLB492ABL 10
13. Use an acceptable puller and remove the seal from

the swivel housing.
RCPH10TLB456ABL 11
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14. Support the swivel housing on a sleeve and press the

bushing out of the swivel housing.
RCPH10TLB457ABL 12
15. Use a hammer and a chisel that has a long taper to

start the bushing off the bottom of the kin pin.
RCPH10TLB459ABL 13
16. Press the bottom kin pin out of the bushing.
RCPH10TLB460ABL 14
Replacing a universal joint

RCPH10TLB472ABL 15
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18. Use the CAS1980 V-block to support the coupling.

Adjust the allen bolts in the V-block to hold the cou-
RCPH10TLB599ABL 16
19. Fasten the bearing cap in a vise and drive the cou-
pling off the bearing cap.
RCPH10TLB473ABL 17

RCPH10TLB593ABL 18
the coupling.
RCPH10TLB594ABL 19
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22. Remove the coupling from the bearing cap.
RCPH10TLB596ABL 20

RCPH10TLB474ABL 21
24. Remove the yoke from the bearing cap. DO NOT hit
the axle shaft in the seal area.
RCPH10TLB475ABL 22
possible.
RCPH10TLB476ABL 23
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RCPH10TLB477ABL 24

out of the yoke.
RCPH10TLB478ABL 25
28. Press a bearing cap into the yoke until the top of the
bearing cap is 6 MM. (1/4 inch) above the top of the
yoke.
RCPH10TLB585ABL 26
RCPH10TLB586ABL 27
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30. 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.
RCPH10TLB587ABL 28
31. Carefully raise the cross into the bearing cap so that.
RCPH10TLB588ABL 29
yoke.
RCPH10TLB589ABL 30

RCPH10TLB590ABL 31
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RCPH10TLB591ABL 32
35. Repeat steps 31and 32for the remaining bearing

cap.
coupling.
RCPH10TLB592ABL 33
RCPH10TLB595ABL 34

cap into the coupling until the top of the bearing cap
is 6 MM. (1/4 inch) above the top of the coupling.
RCPH10TLB597ABL 35
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RCPH10TLB598ABL 36
RCPH10TLB600ABL 37
RCPH10TLB601ABL 38
Next operation:
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Housing - Assemble - Carraro Front axle-four wheel drive swivel

housing and universal joint- 580N and 580SN only
1. Drive the bushing into the bore until the bushing is 8
MM. (5/16 inch) beyond the end of the bore. Then
install the seal.
RCPH10TLB493ABL 1
2. 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.
RCPH10TLB490ABL 2
3. Repeat step 2for the bottom bushing.

4. Install the belleville washer on the top of axle frame.
Then install the belleville washer on the bottom of the
axle frame. Install the swivel housing.
RCPH10TLB698ABL 3
5. Install the top king pin, belleville washer, spacer, and

bolts. Tighten the bolts to a torque of 120 Nm (88.5
pound-feet).
RCPH10TLB696ABL 4
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6. Install the bottom king pin, belleville washer and self-

locking bolts. Tighten the bolts to 120 Nm (88.5
pound-feet).
RCPH10TLB497ABL 5
7. Install the ball joint and nut.
RCPH10TLB498ABL 6
8. Tighten the nut to 165 Nm (122 pound-feet).
RCPH10TLB693ABL 7

axle.
11. Assemble the planetary according to instructions.
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Housing - Disassemble - Carraro Front axle-four wheel drive swivel

housing- 580SN-WT and 590SN only
1. Loosen but do not remove the tie rod nut.
RCPH10TLB482ABL 1
2. Use the CAS-10468 puller to loosen the ball joint.
RCPH10TLB483ABL 2
3. Remove the nut and remove the ball joint from the
swivel housing.
RCPH10TLB484ABL 3
4. Loosen and remove the self-locking bolts that hold

the top king pin.
RCPH10TLB486ABL 4
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5. Remove the top king pin.
RCPH10TLB487ABL 5
6. Repeat steps 4 and 5 for the bottom king pin.

RCPH10TLB488ABL 6
8. Remove the bellville washer and spacer for the top.

Remove the bellville washer from the bottom.
RCPH10TLB640ABL 7
9. Remove the axle shaft.
RCPH10TLB488ABL 8
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10. Use an acceptable puller and remove the top and

bottom bushings.
RCPH10TLB489ABL 9
11. Use an acceptable puller and remove the seal.
RCPH10TLB491ABL 10
12. Use an acceptable puller and remove the bushing.
RCPH10TLB492ABL 11
13. Use an acceptable puller and remove the seal from

the swivel housing.
RCPH10TLB456ABL 12
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14. Support the swivel housing on a sleeve and press the

bushing out of the swivel housing.
RCPH10TLB457ABL 13
15. Use a soft-faced hammer and a chisel that has a long

taper to start the bushing off the bottom king pin.
RCPH10TLB459ABL 14
16. Press the bottom king pin out of the bushing.
RCPH10TLB460ABL 15
Replacing a universal joint

RCPH10TLB472ABL 16
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18. Use the CAS-1980 V-block to support the coupling.

Adjust the Allen bolts in the V-block to hold the cou-
RCPH10TLB599ABL 17
19. Fasten the bearing cap in a vise and use a soft-faced

hammer to drive the coupling off the bearing cap.
RCPH10TLB473ABL 18

RCPH10TLB593ABL 19
the coupling.
RCPH10TLB594ABL 20
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22. Use a soft-faced hammer to remove the coupling

from the bearing cap.
RCPH10TLB596ABL 21

RCPH10TLB474ABL 22
24. Use a soft-faced hammer to remove the yoke from

the bearing cap. DO NOT hit the axle shaft in the
seal area.
RCPH10TLB475ABL 23
possible.
RCPH10TLB476ABL 24
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RCPH10TLB477ABL 25

out of the yoke.
RCPH10TLB478ABL 26
28. Press a bearing cap into the yoke 6mm (1/4 inch)
from the top of the yoke.
RCPH10TLB585ABL 27
29. Carefully install the cross into the bearing cap.
RCPH10TLB586ABL 28
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30. Press the other bearing cap into the yoke 9mm (3/8
inch) from the tops of the yoke.
RCPH10TLB587ABL 29
31. Carefully raise the cross into the bearing cap so that
RCPH10TLB588ABL 30
yoke.
RCPH10TLB589ABL 31

RCPH10TLB590ABL 32
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RCPH10TLB591ABL 33

coupling.
RCPH10TLB592ABL 34
RCPH10TLB595ABL 35

cap into the coupling 6mm (1/4 inch) from the top of
the coupling.
RCPH10TLB597ABL 36
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RCPH10TLB598ABL 37
RCPH10TLB600ABL 38
RCPH10TLB601ABL 39
Next operation:
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Housing - Assemble - Carraro Front axle-four wheel drive swivel

housing- 580SN-WT and 590SN only
1. Use a soft-faced hammer to drive the bushing into the
bore until the bushing is 8 mm (5/16 inch) beyond the
end of the bore. The install the seat.
RCPH10TLB493ABL 1
2. 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.
RCPH10TLB490ABL 2
3. Repeat step 2 for the bottom bushing.

4. Use a soft-faced hammer to install the axle shaft.
RCPH10TLB494ABL 3
5. Install the swivel housing.
RCPH10TLB488ABL 4
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6. Install the top king pin, beveled washer, spacer, and

self-locking bolts.
RCPH10TLB495ABL 5
7. Tighten the self-locking bolts to 190 Nm (141 pound-

feet).
RCPH10TLB485ABL 6
8. Install the bottom king pin, beveled washer, and self-

locking bolts.
RCPH10TLB496ABL 7
9. Tighten the self-locking cap screws to 190 Nm (141

pound-feet).
RCPH10TLB497ABL 8
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10. Install the ball joint and nut.
RCPH10TLB498ABL 9
11. Tighten the nut to: 580SN - WT 165Nm (122 pound

feet) and 590SN - 220 Nm (162 pound-feet).
RCPH10TLB499ABL 10

axle.
14. Assemble the planetary according to instructions in
this section.
Next operation:
Differential - Remove (D.10.A)
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Planetary and hub - Disassemble - CNH Front Axle Four Wheel Drive
Prior operation:
1. See planetary exploded view: Planetary and hub -

Exploded view (D.10.A)
NOTE: The following procedures show the axle already removed from the machine for ease of explanation.
the wheel(s). FRONT AXLE - Remove (D.10.A)
4. Drain the oil.
RCPH10TLB276ACL 1
5. Remove the two Allen head bolts 6mm that hold the
carrier.
RCPH10TLB946ABL 2
6. Separate the carrier from the planetary housing us-

ing the 2 prybar slots.
RCPH10TLB277ACL 3
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Planetary Carrier
7. Remove the carrier from the planetary housing.
RCPH10TLB947ABL 4
NOTE: Take care when removing the cover. Pull the cover evenly on both sides to prevent gear damage. Capture
and discard residual oil from the cover.
8. Discard the O-ring.
RCPH10TLB275ACL 5
NOTE: Hub seal should be replaced.

9. Loosen 3 retaining screws 8 mm.
RCPH10TLB292ACL 6
NOTE: Use a hand wrench, not impact gun to avoid gear damage. Use care to avoid stripping socket in bolt head.
Replace bolt if needed. Easy out size 11/32" is effective for stripped bolt head hex sockets.
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10. Mark retainers, gears and pins.
RCPH10TLB360ACL 7
11. Remove retainers.
RCPH10TLB361ACL 8
12. Inspect retainers for dents or damage in roller contact

area.
RCPH10TLB362ACL 9
NOTE: Visually inspect. Also, inspect by running finger around the outer edge of the lower surface. Any detected
dents or damage will require rework to polish off rough edges.
13. During inspection, the use of a magnifying glass is
recommended.
RCPH10TLB363ACL 10
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14. Any dent or rough edge that can be felt or seen must
be reworked.
RCPH10TLB364ACL 11
15. Example of an unacceptable dent in the bearing con-

tact area.
RCPH10TLB365ACL 12
16. For slight damage rework retainer using 400 grit

sandpaper, as shown or replace, as required.
RCPH10TLB366ACL 13
17. Example of reworked retainer with the bearing con-

tact area removed.
RCPH10TLB367ACL 14
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18. Remove gear, as necessary. and place rollers into

individual containers for possible reuse.
RCPH10TLB360ACL 15
NOTE: . The drain plug has a powerful magnet. The technician may choose to cover the magnet with a rag, tape or
cardboard to allow rollers to be more easily removed from the carrier.
19. Ensure all rollers have been removed and wipe off
any contamination on the drain plug.
RCPH10TLB369ACL 16
NOTE: Thoroughly inspect entire carrier for rollers, including inside the threaded holes in the gear pins.
Hub
20. Use acceptable tools to loosen the crimping on the
nut.
RCPH10TLB279ACL 17
NOTE: Use a very narrow chisel/round end punch to unstake the nut. to avoid gear damage.
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21. Loosen nut. Use a 55mm socket or special tool

380000468.
RCPH10TLB961ABL 18
22. Remove the nut.
RCPH10TLB281ACL 19
23. Remove the bolts for the hub The axle will have either
10 bolts (M10) or 8 bolts (M12).
RCPH10TLB282ACL 20
24. Install two bolts in the two threaded holes in the hub.
Tighten the two bolts evenly until the ring gear is free
of the swivel housing. Use 2 bolts removed from step
22.
RCPH10TLB284ACL 21
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25. Remove the ring gear assembly. See section Hous-

ing - Disassemble (D.10.A) for knuckle removal.
RCPH10TLB285ACL 22
NOTE: Ensure you slide the axle shaft from the swivel housing assembly.
26. If necessary, remove the retaining ring which fastens
the hub in the ring gear.
RCPH10TLB289ACL 23
27. Separate the hub and ring gear.
RCPH10TLB290ACL 24
28. Press the T-dowels from the hub and discard.
RCPH10TLB625ABL 25
NOTE: Manufacturer recommends replacement of T-dowels if they are pressed out of the hub.
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29. Use an acceptable puller to remove the wheel hub

assembly from the swivel housing.
RCPH10TLB299ACL 26
30. Remove the outer wheel bearing.
RCPH10TLB300ACL 27
31. Remove the wheel hub assembly.
RCPH10TLB301ACL 28
32. Remove the cassette seal and bearing cups, as nec-

essary.
RCPH10TLB302ACL 29
NOTE: Cassette seal must be replaced. Replace bearing cups as necessary.
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33. Remove the wheel bearing from the swivel housing,

if necessary.
RCPH10TLB400ACL 30
34. Remove the axle shaft seal.
RCPH10TLB401ACL 31
36. Remove axle shaft ball bearing.
Next operation:
Planetary and hub - Inspect (D.10.A)
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Planetary and hub - Inspect - CNH Front Axle Four Wheel Drive
2. Inspect all bearing assemblies for flat areas, pitting,
scoring, and other damage. Also check the races for
damage. If any of these defects are found, a new
wheel bearing and bearing cup must be installed.
3. Inspect the planetary shafts for wear and damage.
4. Inspect the teeth of the planet gears, sun gear and
ring gear for wear, pitting, scoring, and other dam-
age. Use new parts as required.
Next operation:
Planetary and hub - Assemble (D.10.A)
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Planetary and hub - Assemble - CNH Front Axle Four Wheel Drive
Planetary Carrier
1. Install planetary gear over installation tool
DMT100002
RCPH10TLB370ACL 1
2. Insert rollers between installation assembly tool and

gear as shown. Apply petroleum jelly to help retain
rollers.
RCPH10TLB371ACL 2
3. Ensure all rollers are installed.
RCPH10TLB372ACL 3
4. Install gears on the same pin they were removed

from using marks as a guide.
RCPH10TLB374ACL 4
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5. Push roller installation tool (DMT100002) off of gear

as gear & rollers engage pin.
RCPH10TLB375ACL 5
6. Confirm all lower rollers are properly installed. After

all 3 gears are installed, confirm all lower rollers are
properly installed. After all 3 gears are installed, re-
orient planetary carrier horizontally.
RCPH10TLB376ACL 6
7. Install upper rollers into gears, as shown. Ensure all

rollers are installed.
RCPH10TLB402ACL 7
8. Where possible align retainers with the original pin

using the marks applied previously. Align dowel with
offset hole on retainer.
RCPH10TLB378ACL 8
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9. Use an 8mm allen wrench and tighten. Use torque

wrench Do not use an impact gun.
RCPH10TLB380ACL 9
NOTE: Apply 3 drops of Loctite 242.

10. Tighten to 95 - 105 N·m (70.1 - 77.4 lb ft)
NOTE: Apply approximately 5 drops of MS1317 oil at top of all rollers. Ensure gear has free end play by moving it up
and down. Should be approximately 1 mm play. Spin each gear to make sure they are free to rotate.
11. If bearing cups were removed, use an acceptable
driver to press new bearing cups into the planetary
housing. Special Tool DMT100004
RCPH10TLB578ABL 10
12. The words "OUTSIDE" on the seal must be facing

up. Use hub seal installation tool (DMT100004) to
drive the new seal into the wheel hub. . Use the
flat side of the hub seal installer. Do not damage
the seal. Lightly coat outside diameter of seal with
Kluberplus.. Depth: 580N & 580SN 1.5 mm (0.059
in), 580SN-WT & 590SN 6.5 mm (0.256 in)
RCPH10TLB622ABL 11
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13. Install two new T-dowels 180 degrees apart such that
they protrude 4 mm (0.157 in).
RCPH10TLB626ABL 12
14. Install the hub to the ring gear.
RCPH10TLB624ABL 13
15. Install the retaining ring. Ensure it is fully seated into

the groove.
RCPH10TLB998ABL 14
16. Install inner wheel bearing.
RCPH10TLB400ACL 15
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17. Install the hub. Use a press to pshl hub on evenly

and square to ensure proper seal seating. Seal ID
must have light coat of Kluberplus.
RCPH10TLB387ACL 16
18. Install a wheel bearing on the swivel housing. In-

stallation will be easier if you heat the wheel bearing
slightly. Do not heat the wheel bearing higher than
149 °C (300.2 °F). Use clean gear lubricant to lubri-
cate the wheel bearing.
RCPH10TLB388ACL 17
19. Install the axle shaft bearing. Install snap ring. Install
axle shaft seal to a depth of 6.1 mm (0.240 in).
NOTE: Ensure proper seating of snap ring into groove.

20. Align the two bushings with two of the holes on the
swivel housing, then simultaneously press the heads
of the bushings to install the ring gear assembly.
RCPH10TLB285ACL 19
21. Press remaining T- dowels into place 2 at a time 180

degrees apart.
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22. Apply Loctite to bolts . Instal bolts l and tighten evenly

to pull the ring gear assembly against the swivel
housing. Tighten the bolts in a star pattern to a final
torque of: 580N & 580SN 55 - 68 N·m (40.6 - 50.2
lb ft) and 580SN-WT & 590SN 96 - 118 N·m (70.8 -
87.0 lb ft).
RCPH10TLB282ACL 20
NOTE: Tighten bolts in a star pattern. Rotate hub while tightening bolts to avoid damage to wheel bearings.
23. Install the nut. Use 3 to 4 drops of Loctite 242.
Tighten to 358 - 442 N·m (264.0 - 326.0 lb ft). Use
special tool 380000468 to tighten. Stake the nut in 2
places approximately 180 degrees apart.
RCPH10TLB961ABL 21
NOTE: Nut staking material should be crimped and not cracked or torn. Ensure opposite side of shaft is secure while
tightening nut.
24. Install a new O-ring on the planetary carrier.
RCPH10TLB275ACL 22
NOTE: Lubricate O-ring with oil prior to installation

25. Install the planetary carrier. Hold planetary carrier in
a level position. Do not force, it may be necessary to
turn input pinion.
RCPH10TLB947ABL 23
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26. Install and tighten the two Allen head bolts to a torque
of 21 - 26 N·m (15.5 - 19.2 lb ft)
RCPH10TLB945ABL 24
27. Lubricate the planetary FRONT AXLE - General

specification (D.10.A)
28. Install the wheel(s), hardened washers, and nuts.
FRONT AXLE - Install (D.10.A) Tighten the nuts.
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Planetary and hub - Disassemble - Carraro Front axle-four wheel

drive - 580N and 580SN only
the wheel(s). Drain the oil from the carrier.
3. Remove the two Allen head bolts that hold the carrier.
RCPH10TLB561ABL 1
4. Separate the carrier from the planetary housing.
RCPH10TLB562ABL 2
5. Remove the carrier.
RCPH10TLB563ABL 3
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RCPH10TLB564ABL 4
7. Remove the thrust washer with the internal tabs.
RCPH10TLB565ABL 5
8. Remove the thrust plate with the external tabs.
RCPH10TLB566ABL 6
9. Remove the bolts for the hub.
RCPH10TLB567ABL 7
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10. Install two 10mm. bolts in the two threaded holes in

the hub. Tighten the two bolts evenly until the ring
gear is free of the swivel housing.
RCPH10TLB568ABL 8
RCPH10TLB569ABL 9
12. Use an acceptable puller to remove the outer wheel

bearing from the swivel housing.
RCPH10TLB570ABL 10
13. Remove the planetary housing and the wheel bear-

ing.
RCPH10TLB571ABL 11
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14. Use prybars to remove the inner wheel bearing from

the swivel housing. Be careful so that you do not
damage the inner wheel bearing.
RCPH10TLB572ABL 12
15. Remove the retaining ring which fastens the hub in

the ring gear.
RCPH10TLB660ABL 13
16. Remove the hub.
RCPH10TLB624ABL 14
17. Press the bushings from the hub only if new bush-
ing(s) are needed or a new hub is installed.
RCPH10TLB625ABL 15
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18. Remove the snap rings.
RCPH10TLB573ABL 16
19. Remove the retainer.
RCPH10TLB574ABL 17
20. Remove the pinion gears and thrust washers. Be

careful so that you do not lose the needles.
RCPH10TLB575ABL 18
21. Press the pinion shafts out of the carrier.
RCPH10TLB576ABL 19
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22. Remove the bearing cups and the seal as necessary.
RCPH10TLB577ABL 20
Next operation:
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Planetary and hub - Inspect - Carraro Front axle-four wheel drive -

580N and 580SN only
Refer to Planetary and hub - Exploded view (D.10.A) for
more details
1. Clean all parts with cleaning solvent.
2. Inspect the bearing cup and the rollers in the wheel
damage. Also check the inner face 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 shafts,
and the ring gear for wear, pitting, scoring, and other
damage. Use new parts as required.
5. Inspect the needles for the pinion gears for flat areas,
pitting, scoring, and other damage. If any of these
defects are found, also inspect the bore of the pinion
gears and use new parts as required.
6. Inspect the thrust washer for the axle shaft in the bore
in the carrier. Do not remove the thrust washer un-
less there is wear or damage. The thrust washer is
held in position with adhesive. If replacement is nec-
essary, use B500621 kit (324 Loctite and 707 Activa-
tor) to install the new thrust washer. Use the instruc-
tions on the container. Curing time is approximately
five minutes.
Next operation:
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Planetary and hub - Assemble - Carraro Front axle-four wheel drive

- 580N and 580SN only
1. If bearing cups were removed, use an acceptable
driver to press new bearing cups into the planetary
housing.
RCPH10TLB578ABL 1
2. 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.
RCPH10TLB622ABL 2
3. 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 car-
rier.
4. Apply petroleum jelly to one side and the bore of the
pinion gears.
RCPH10TLB479ABL 3
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5. Install a thrust washer.
RCPH10TLB480ABL 4
6. Install 30 needles in each pinion gear using petro-

leum jelly to hold the needles in place.
RCPH10TLB481ABL 5
7. Install the pinion gears so that each thrust washer is

toward the carrier.
RCPH10TLB575ABL 6
8. Install the retainer.
RCPH10TLB574ABL 7
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9. Install the snap rings.
RCPH10TLB573ABL 8
10. Press bushings into the hub as required.
RCPH10TLB626ABL 9
11. Install the hub.
RCPH10TLB624ABL 10
RCPH10TLB623ABL 11
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13. Install a wheel bearing on the swivel housing. In-

stallation will be easier if you heat the wheel bearing
slightly. Do not heat the wheel bearing higher than
149° C (300° F). Use clean gear lubricant to lubri-
cate the wheel bearing.
RCPH10TLB579ABL 12
14. Install the planetary housing.
RCPH10TLB580ABL 13
15. 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).
RCPH10TLB581ABL 14
16. Align the holes in the hub with the holes in the swivel
housing and install the ring gear.
RCPH10TLB582ABL 15
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17. Put 270 Loctite in the female threads in the swivel

housing. Install and tighten the bolts evenly to pull
the hub against the swivel housing. Tighten the bolts
to a final torque of 95 Nm (70 pound-feet).
RCPH10TLB567ABL 16
18. Install the thrust plate with the external tabs.
RCPH10TLB566ABL 17
19. Install the thrust washer with the internal tabs.
RCPH10TLB565ABL 18
RCPH10TLB564ABL 19
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21. Install a new O-ring on the planetary housing.
RCPH10TLB583ABL 20
22. Install the carrier.
RCPH10TLB584ABL 21
23. Install and tighten the Allen head bolts to a torque of

25 Nm (19 pound-feet).
RCPH10TLB561ABL 22
24. See Specifications for the correct lubricant for the

planetary.
25. Install the wheel(s), hardened washers, and nuts.
Tighten the nuts to specifications.
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Planetary and hub - Disassemble - Carraro Front axle-four wheel

drive - 580SN-WT and 590SN only
support to hold the machine in position.
the wheel(s).
3. Remove the drain plug from the carrier.
RCPH10TLB642ABL 1
4. Drain the oil from the carrier.
RCPH10TLB641ABL 2
5. Remove the two allen head bolts that hold the carrier.
RCPH10TLB643ABL 3
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6. Use a soft-faced hammer to separate the carrier from

the planetary housing.
RCPH10TLB645ABL 4
7. Remove the carrier.
RCPH10TLB646ABL 5
8. Discard O-ring.
RCPH10TLB680ABL 6
RCPH10TLB647ABL 7
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10. Remove the thrust washer with the internal tabs.
RCPH10TLB648ABL 8
11. Remove the thrust washer with the external tabs.
RCPH10TLB649ABL 9
12. Remove the bolts from the hub.
RCPH10TLB650ABL 10
13. 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.
RCPH10TLB652ABL 11
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RCPH10TLB653ABL 12
15. Use an acceptable puller to remove the outer wheel

bearing from the wheel hub.
RCPH10TLB654ABL 13
16. Remove the wheel bearing.
RCPH10TLB655ABL 14
17. Remove the planetary housing from the wheel hub.
RCPH10TLB656ABL 15
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18. Use prybars to remove the inner wheel bearing form

the swivel housing. Be careful so that you do not
damage the inner wheel bearing.
RCPH10TLB657ABL 16
19. Remove the retaining ring.
RCPH10TLB660ABL 17
20. Remove the hub.
RCPH10TLB662ABL 18
21. Press the busings from the hub only if new bushing(s)
are needed or a new hub is installed.
RCPH10TLB670ABL 19
NOTE: Steps 22 through 24 is for the 580SN-WT
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22. Remove the snap rings securing the retaining plate.
RCPH10TLB688ABL 20
RCPH10TLB689ABL 21
24. Remove the pinion gears and thrust washers. Be

careful so that you do not lose the needles.
RCPH10TLB690ABL 22
NOTE: Steps 25 through 27 are for the 590 SN.

25. Remove the snap rings from the pinion gears.
RCPH10TLB665ABL 23
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26. Remove the retainer.
RCPH10TLB664ABL 24
27. Remove the pinion gears being careful not to lose

the needles.
RCPH10TLB669ABL 25
28. Press the pinion shafts out of the carrier if new ones
are to be installed.
RCPH10TLB672ABL 26
29. Remove the bearing cups and seal as required.
RCPH10TLB674ABL 27
Next operation:
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Planetary and hub - Inspect - Carraro Front axle-four wheel drive -

2. Inspect the bearing cup and the rollers in the wheel
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, and other
damage. Use new parts as required.
5. Inspect the needles for the pinion gears for flat areas,
pitting, scoring and other damage. If any of these
defects are found, also inspect the bore of the pinion
gears and use new parts as required.
6. Inspect the thrust washer for the axle shaft in the bore
in the carrier. Do not remove the thrust washer un-
less there is wear or damage. The thrust washer is
held in position with adhesive. If replacement is nec-
essary, use B500621 kit (324 Loctite and 707 Activa-
tor) to install the new thrust washer. Use the instruc-
tions on the container. Curing time is approximately
five minutes.
Next operation:
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Planetary and hub - Assemble - Carraro Front axle-four wheel drive

- 580SN-WT and 590SN only
1. If bearing cups were removed, use a suitable driver
to press new bearing cups into the wheel hub.
2. Clean hub prior to seal installation
RCPH10TLB682ABL 1
3. The lip on the seal must be facing in towards bearing.
RCPH10TLB675ABL 2
4. Use seal driver 380002431 to drive the new seal into

the wheel hub. Be careful not to damage the seal.
RCPH10TLB673ABL 3
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5. 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.
RCPH10TLB676ABL 4
NOTE: Steps 1 through 10 are for the 580SN-WT.

6. Apply petroleum jelly to one side of the bore of the
pinion gears.
RCPH10TLB685ABL 5
7. Install a thrust washer.
RCPH10TLB686ABL 6
8. Install 30 needles in each pinion gear using petro-

leum to hold the needles in place.
RCPH10TLB687ABL 7
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9. Install the pinion gears so that each thrust washer is

toward the carrier.
RCPH10TLB690ABL 8
RCPH10TLB689ABL 9
11. Install the snap rings.
RCPH10TLB688ABL 10
NOTE: Steps 12 through 17 are for the 590SN.

12. Apply petroleum jelly to the inside of the pinion gears.
RCPH10TLB666ABL 11
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13. Install needles in each pinion gear using petroleum

jelly to hold the needles in place.
RCPH10TLB667ABL 12
14. Install the pinion gears onto the pinion shafts.
RCPH10TLB668ABL 13
15. Install needles into the top of the pinion gears.
RCPH10TLB679ABL 14
RCPH10TLB664ABL 15
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RCPH10TLB665ABL 16
18. Press bushings into the hub as required.
RCPH10TLB671ABL 17
19. Install the hub.
RCPH10TLB663ABL 18
20. Install the retaining rings.
RCPH10TLB661ABL 19
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21. Install inner bearing on the swivel housing.
RCPH10TLB658ABL 20
RCPH10TLB659ABL 21
23. Clean seal surface prior to wheel hub installation.
RCPH10TLB678ABL 22
24. Ensure the surface of the seal is clean and dry prior
to installing the wheel hub.
RCPH10TLB681ABL 23
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25. Install the wheel hub onto the swivel housing.
RCPH10TLB656ABL 24
26. Install outer bearing.
RCPH10TLB655ABL 25
27. Align the holes in the hub with the holes in the swivel
housing and install the ring gear.
RCPH10TLB677ABL 26
28. Put Loctite 270 in the female threads in the wheel

hub. Install and tighten the bolts evenly to pull the
hub against the wheel hub. Tighten the bolts to a
final torque of 95 Nm (70 pound-feet).
RCPH10TLB651ABL 27
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29. Ensure shaft is all the way out prior to installing thrust
washers and snap ring.
RCPH10TLB649ABL 28
30. Install the thrust washer with the external tabs.
RCPH10TLB649ABL 29
31. Install the thrust washer with the internal tabs.
RCPH10TLB648ABL 30
RCPH10TLB647ABL 31
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33. Install new O-ring on the carrier.
RCPH10TLB680ABL 32
34. Install the carrier.
RCPH10TLB646ABL 33
35. Install and tighten the Allen head bolts to 80 Nm (59

pound-feet).
RCPH10TLB644ABL 34
36. Fill the 580 SN-WT planetary(ies) with 80W/40 0.59

liters (0.63 U.S. quarts). Fill the 590 SN plane-
tary(ies) with 80W/40 0.65 liters (0.69 U.S. quarts).
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37. Install the plug and torque to 80Nm (59 pound-feet).
RCPH10TLB642ABL 35
Next operation:
Housing - Disassemble (D.10.A)
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Index
FRONT AXLE - 10.A

Axle - Drawing - Front axle-four wheel drive- measuring toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Axle - Exploded view - CNH Four wheel drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Differential - Assemble - CNH Front Axle - Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Differential - Assemble - CNH Front Axle - Four Wheel Drive - Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Differential - Assemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . 107
Differential - Assemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . 135
Differential - Assemble - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . 111
Differential - Assemble - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . 140
Differential - Disassemble - CNH Front Axle -Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Differential - Disassemble - CNH Front Axle -Four Wheel Drive- Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . 75
Differential - Disassemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . 103
Differential - Disassemble - Carraro Front axle-four wheel drive - differential - 580SN-WT and 590SN only . . . 131
Differential - Disassemble - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . 98
Differential - Disassemble - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only 126
Differential - Exploded view - CNH- Front Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Differential - Exploded view - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . 24
Differential - Exploded view - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . 26
Differential - Exploded view - Carraro Front axle-four wheel drive limited slip differential- 580SN-WT and 590SN
only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Differential - Inspect - CNH Front Axle - Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Differential - Inspect - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . 106
Differential - Inspect - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . 134
Differential - Remove - CNH Front Axle -Four Wheel Drive - Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Differential - Remove - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . . . . 95
Differential - Remove - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . . . 123
FRONT AXLE - Assemble - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
FRONT AXLE - Assemble - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
FRONT AXLE - Disassemble - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FRONT AXLE - Disassemble - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
FRONT AXLE - General specification - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT AXLE - General specification - CNH Front Axle Four Wheel Drive - 580N and 580SN . . . . . . . . . . . . . . . . 7
FRONT AXLE - General specification - CNH Front Axle Four Wheel Drive - 580SN-WT and 590SN . . . . . . . . . . . 7
FRONT AXLE - General specification - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT AXLE - General specification - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . 14
FRONT AXLE - General specification - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . 17
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FRONT AXLE - Inspect - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
FRONT AXLE - Inspect - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FRONT AXLE - Install - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FRONT AXLE - Install - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
FRONT AXLE - Remove - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
FRONT AXLE - Remove - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
FRONT AXLE - Special tools - CNH Front Axle Four Wheel Drive - 580N, 580SN, 580SN-WT, 590SN . . . . . . . . . 8
FRONT AXLE - Special tools - CNH Front axle Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FRONT AXLE - Special tools - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT AXLE - Special tools - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . 15
FRONT AXLE - Special tools - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . 18
Housing - Assemble - CNH Front Axle- Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Housing - Assemble - Carraro Front axle-four wheel drive swivel housing and universal joint- 580N and 580SN only
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Housing - Assemble - Carraro Front axle-four wheel drive swivel housing- 580SN-WT and 590SN only . . . . . . 187
Housing - Disassemble - CNH Front Axle -Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Housing - Disassemble - Carraro Front axle-four wheel drive swivel housing and universal joint- 580N and 580SN
only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Housing - Disassemble - Carraro Front axle-four wheel drive swivel housing- 580SN-WT and 590SN only . . . 177
Housing - Exploded view - CNH Front axle - swivel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Housing - Exploded view - Carraro Front axle- swivel housing- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Planetary and hub - Assemble - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Planetary and hub - Assemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . 214
Planetary and hub - Assemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . 229
Planetary and hub - Disassemble - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Planetary and hub - Disassemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . 207
Planetary and hub - Disassemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . 220
Planetary and hub - Exploded view - CNH Front Axle - Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Planetary and hub - Exploded view - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . 36
Planetary and hub - Exploded view - Carraro Front axle-four wheel drive - 580SN-WT . . . . . . . . . . . . . . . . . . . . . . 38
Planetary and hub - Exploded view - Carraro Front axle-four wheel drive - 590SN . . . . . . . . . . . . . . . . . . . . . . . . . 40
Planetary and hub - Inspect - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Planetary and hub - Inspect - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . 213
Planetary and hub - Inspect - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . 228
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REAR AXLE - 12.A
580N
580SN WT
580SN
590SN
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Contents
REAR AXLE - 12.A
TECHNICAL DATA
REAR AXLE
General specification - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General specification - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Special tools - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUNCTIONAL DATA
Differential
Exploded view - Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exploded view - Differential - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exploded view - Ring and pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exploded view - Differential - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Housing
Drawing - Axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hub
Exploded view - Wheel hub and final reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE
REAR AXLE
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Differential
Remove - Carrier removal 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassemble - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Remove - Differential lock fork removal - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Install - Differential lock housing and piston - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Install - Differential lock fork installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assemble - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Adjust - Pinion gear backlash adjustment - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Adjust - Differential bearing preload adjustment - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Install - Pinion shaft seal installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Install - Carrier installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Check - Checking the differential lock - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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Remove - Carrier removal - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Disassemble - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Remove - Differential lock for removal - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Install - Differential lock for installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Assemble - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Adjust - Pinion gear backlash adjustment - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . 101
Adjust - Differential bearing preload adjustment - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . 102
Install - Pinion shaft seal installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Install - Carrier Installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Check - Checking the differential lock - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Hub
Disassemble - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Inspect - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Assemble - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Disassemble - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Inspect - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Assemble - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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AXLES, BRAKES AND STEERING - REAR AXLE
REAR AXLE - General specification - 580N and 580SN only

Gear lubricant Wet brake/Transmission lubricant - SAE 80W140 MAT
3510
Capacity 13.6 l (14.4 US qt)
Special torques
Allen head bolts for hub housing 226 N·m (166.7 lb ft)
Bolts for ring gear 155 N·m (114.3 lb ft)
Bolts for differential support long bolts 80 N·m (59.0 lb ft)
Bolts for differential support short bolts 169 N·m (124.6 lb ft)
Drain hole plugs at wheel hub 60 N·m (44.3 lb ft)
Fill and drain hole plugs at differential 80 N·m (59.0 lb ft)
Ring nut for wheel hub 1000 N·m (737.6 lb ft)
Differential adjusting ring lock screws 10 N·m (88.5 lb in)
Brake self adjuster shouldered bolt 16 N·m (141.6 lb in)
Brake bleeder 8 - 12 N·m (70.8 - 106.2 lb in)
Differential pin plug 25 N·m (18.4 lb ft)
Differential lock plug 180 N·m (132.8 lb ft)
Wheel studs 70 N·m (51.6 lb ft)
Pinion rotating torque (without seal) 2 - 2.4 N·m (17.7 - 21.2 lb in)
Differential bearing preload rotating torque (with seal) 2.6 - 3.3 N·m (23.0 - 29.2 lb in)
REAR AXLE - Special tools - 580N and 580SN only

Differential ring nut wrench 380002433
RCPH10TLB379AAL 1
Pinion depth gauge

1. CAS1596A-4
2. CAS1596A-7
3. CAS1596A-6
4. 380002436
RCPH10TLB380AAL 2
CAS2151A offset spanner wrench used to remove and

install the pinion nut
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OEM4185 universal bearing cup installer - used to install

the hub bearing cups
RCPH10TLB484AAL 3
CAS1716-3 handle (part of CAS1716 Ag tool kit) - Used

with CAS2374 hub seal installer
RCPH07SPT024AAA 4
Yoke to hold shaft. Order p/n 144279A1

Self adjusting brake tools 380002435
RCPH10TLB378AAL 5
Socket for ring nut on wheel flange 380002434
RCPH10TLB377AAL 6
84516378 05/07/2011
D.12.A / 5
Seal protector CAS2369

Pinion depth gauge bar 380000407
RCPH10TLB381AAL 7
Wheel hub seal driver 380002431

Spanner wrench CAS1840C
CAS1968 Stud remover/installer - used to remove shoul-
der studs from wheel hubs
RCPH10TLB590AAL 8
Fabricate from locking differential cylinder, used to com-

press differential lock spring to remove "C" clip
RCPH10TLB584AAL 9
REAR AXLE - General specification - 580SN-WT and 590SN only

Gear lubricant Wet brake/transmission lubricant - SAE 80W140 MAT
3510
Special torques
Bolts for ring gear 155 N·m (114.3 lb ft)
84516378 05/07/2011
D.12.A / 6
Special torques
Bolts for differential support long bolts 80 N·m (59.0 lb ft)
Bolts for differential support short bolts 169 N·m (124.6 lb ft)
Ring nut for wheel hub 1000 N·m (737.6 lb ft)
Differential adjusting ring lock screws 10 N·m (88.5 lb in)
Differential pin plug 25 N·m (18.4 lb ft)
Differential lock plug 180 N·m (132.8 lb ft)
Pinion rotating torque (without seal) 2 - 2.4 N·m (17.7 - 21.2 lb in)
Differential bearing preload rotating torque (without seal) 2.6 - 3.3 N·m (23.0 - 29.2 lb in)
REAR AXLE - Special tools - 580SN-WT and 590SN only

Differential ring nut wrench - 380002433
RCPH10TLB379AAL 1
False pinion - 380100090
RCPH10TLB380AAL 2
84516378 05/07/2011
D.12.A / 7
Offset spanner wrench - used to remove and install the

pinion nut - 380100093
RCPH10TLB637ABL 3
Universal bearing cup installer - used to install the hub

bearing cups - OEM4185
RCPH10TLB484AAL 4
Handle (part of CAS1716 Ag tool kit) - Used with CAS2374

hub seal installer - CAS1716-3
RCPH10TLB485AAL 5
84516378 05/07/2011
D.12.A / 8
Yoke to hold shaft - 144279A1
RCPH10TLB638ABL 6
Self adjusting brake tools - 380002435
RCPH10TLB378AAL 7
Socket for ring nut on wheel flange - 380002434
RCPH10TLB377AAL 8
84516378 05/07/2011
D.12.A / 9
Seal protector - CAS2369
RCPH10TLB635ABL 9
Pinion depth gauge bar - 380000407
RCPH10TLB381AAL 10
Wheel hub seal driver - 380002431
RCPH10TLB636ABL 11
84516378 05/07/2011
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Seal driver - 380002432
RCPH10TLB634ABL 12
Spanner wrench - CAS1840C
RCPH10TLB633ABL 13
84516378 05/07/2011
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Differential - Exploded view - Differential lock

Differential lock
1. Cylinder 6. Bushing
2. Cylinder O-ring 7. Spring
3. Piston 8. Shaft
4. Piston O-rings 9. Fork
5. Locking ring
84516378 05/07/2011
D.12.A / 12
RCPH10TLB9GAL 1
84516378 05/07/2011
D.12.A / 13
Differential - Exploded view - Differential - 580N and 580SN only

Differential
1. Ring nut 11. Spider gear
2. Bearing 12. Differential pin
3. Sleeve 13. Pin
4. Cap screw M12 x 25 14. Spacer
5. Pin 15. Housing cover
6. O-ring 16. Locking ring
7. Housing 17. Locking side spider gear
8. Thrust washer 18. Differential pin
9. Plug 19. Side spider gear
10. Thrust washer 20. Pin
84516378 05/07/2011
D.12.A / 14
RCPH10TLB10GAL 1
84516378 05/07/2011
D.12.A / 15
Differential - Exploded view - Ring and pinion

Ring and pinion
1. Ring gear 7. Outer bearing
2. Pinion gear 8. Lock washer
3. Shim 9. Ring nut
4. Inner bearing 10. Seal
5. Washer 11. O-ring
6. Crush sleeve 12. Cap
84516378 05/07/2011
D.12.A / 16
RCPH10TLB11GAL 1
84516378 05/07/2011
D.12.A / 17
Differential - Exploded view - Differential - 580SN-WT and 590SN

only
(1) Ring nut
(2) Bearing
(3) Sleeve
(4) Cap screw M12 x 25
(5) Pin
(6) O-ring
(7) Housing
(8) Thrust washer
(9) Plug
(10) Thrust washer
(11) Spider gear
(12) Differential pin
(13) Pin
(14) Spacer
(15) Housing cover
(16) Locking ring
(17) Locking side spider gear
(18) Differential pin
(19) Side spider gear
(20) Pin
(21) Thrust washer
(22) Plug
84516378 05/07/2011
D.12.A / 18
RCPH10TLB13GAL 1
84516378 05/07/2011
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Housing - Drawing - Axle housing

Axle housing
(1) Vent
(2) Axle housing
(3) Plugs
(4) Pin D15x35
(5) Bolt M6x25
(6) Differential support
(7) Bolt M12x100
(8) Bolt M12x1.75
84516378 05/07/2011
D.12.A / 20
RCPH10TLB7GAL 1
84516378 05/07/2011
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Hub - Exploded view - Wheel hub and final reduction unit

Wheel hub and final reduction unit
(1) Ring nut

(2) Inner bearing
(3) O-ring
(4) Ring gear (not serviced)
(5) Bleeder valve
(6) Shipping plug
(7) Hub
(8) Spacer
(9) Outer bearing
(10) Cassette seal
(11) Pad
(12) Wheel flange
(13) Snap ring
(14) Gear
(15) Snap ring
(16) Bearing
(17) Planetary carrier
(18) Bolt
(19) Stud
84516378 05/07/2011
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RCPH10TLB12GAL 1
84516378 05/07/2011
D.12.A / 23
REAR AXLE - Remove

1. Raise and support the machine.
2. Drain oil from the differential. Use a container capa-

ble of holding 20 l (22 US qt).
RCPH11TLB122AAM 3
3. Drain oil from brake hubs.
RCPH11TLB123AAM 4
84516378 05/07/2011
D.12.A / 24
4. Reinstall drain plugs.
RCPH11TLB124AAM 5
RCPH11TLB123AAM 6
5. Remove rear shaft drive hardware.
RCPH11TLB125AAM 7
6. Remove the shaft from the yoke.
RCPH11TLB076AAL 8
84516378 05/07/2011
D.12.A / 25
7. Remove rear drive shaft.
RCPH11TLB125AAM 9
8. Disconnect differential lock hose. Cap all open ports.
RCPH11TLB124AAM 10
9. Remove left hand and right hand brake hose guard

hardware.
RCPH11TLB126AAM 11
10. Disconnect brake hoses and cap all open ports.

11. Remove guards.
RCPH11TLB127AAM 12
84516378 05/07/2011
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12. Position jack underneath axle.
RCPH11TLB128AAM 13
13. Remove hardware securing the axle to the frame.
RCPH11TLB129AAM 14
14. Carefully lower and remove axle.
RCPH11TLB130AAM 15
Next operation:
REAR AXLE - Install (D.12.A)
84516378 05/07/2011
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REAR AXLE - Install

1. Position the rear axle under the machine, slowly raise
the axle and align with the mounting holes in the
chassis wheel wells.
RCPH11TLB130AAM 1
2. Install the bolts. Tighten the bolts evenly to pull the

axle against the frame, torque bolts to 610 - 680 N·m
(450 - 500 lb ft) .
RCPH11TLB129AAM 2
3. Remove the jack from underneath axle.
RCPH11TLB128AAM 3
4. Slide the guards over the brake hoses. Remove the

caps from the hoses and connectors. Reconnect the
brake hoses.
RCPH11TLB127AAM 4
84516378 05/07/2011
D.12.A / 28
5. Install the left hand and right hand brake hose guard
hardware.
RCPH11TLB126AAM 5
6. Reconnect the differential lock hose.
RCPH11TLB124AAM 6
7. Install the rear drive shaft.

8. Install the shaft into the yoke.
9. Install the rear shaft drive hardware.
RCPH11TLB125AAM 7
10. Refill the brake hubs with oil.

11. Refill the differential with oil.
RCPH11TLB123AAM 8
84516378 05/07/2011
D.12.A / 29
12. Reinstall the rear wheels. Raise the machine and

remove the supports.
RCPH11TLB120AAM 9
RCPH11TLB121AAM 10
84516378 05/07/2011
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Differential - Remove - Carrier removal 580N and 580SN only

1. Remove the wheel hubs and brakes, see Wheel
Hubs And Brakes Disassembly in this section.
2. Remove the differential mounting bolts.
RCPH10TLB373AAL 1
3. Use pry bars in slots.
RCPH10TLB374AAL 2
4. Have an assistant hold the differential housing up

away from the axle housing, attach a lifting eye to
the bottom of the differential housing.
RCPH10TLB370AAL 3
84516378 05/07/2011
D.12.A / 31

away from the axle housing, attach a lifting eye to
the top of the differential housing.
RCPH10TLB371AAL 4
6. Attach lifting equipment to lifting eyes.
RCPH10TLB369AAL 5
7. Remove the differential and place on a work bench.
Next operation:
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Differential - Disassemble - 580N and 580SN only

1. Remove the bolts securing the ring nut.
RCPH10TLB364AAL 1
2. Remove the ring nuts.
RCPH10TLB362AAL 2
3. Remove the differential from the carrier.

4. The bearing cups can be removed with a roll head
pry bar if replacement is needed.
RCPH10TLB432AAL 3
84516378 05/07/2011
D.12.A / 33
5. Remove the locking ring.
RCPH10TLB433AAL 4
6. Remove the differential housing cover, remove the

anti rotation pin.
RCPH10TLB434AAL 5
7. The thrust washer may stay on the cover, remove the

thrust washer.
RCPH10TLB435AAL 6
8. Remove the gear from the housing.
RCPH10TLB436AAL 7
84516378 05/07/2011
D.12.A / 34
9. Remove three plugs from the differential.
RCPH10TLB437AAL 8
10. Remove the three pins securing the spider pins in the
differential.
RCPH10TLB438AAL 9
11. Remove the ring gear cap screws, remove the ring
gear.
RCPH10TLB440AAL 10
NOTE: Large amounts of Loctite was used during assembly, remove cap screws slowly. If screw binds, turn back in
and then back out.
84516378 05/07/2011
D.12.A / 35
12. Note the flat surface on pin (1) and spacer (2).
RCPH10TLB441AAL 11
13. Push the pin towards the flat surface side noted in
the previous step.
RCPH10TLB442AAL 12
NOTE: DO NOT force the pin, it will not come out of the housing at this time.
14. Remove the spider gear and thrust washer.
RCPH10TLB443AAL 13
15. Push the pin out of the housing.
RCPH10TLB444AAL 14
84516378 05/07/2011
D.12.A / 36
RCPH10TLB445AAL 15
17. Push one of the short spider pins out of the spacer
by pushing it through the hole in the spacer.
RCPH10TLB446AAL 16
NOTE: Do not remove the pin at this time, leave the pin in far enough to support the spider gear and thrust washer.
18. Push the other short spider pin out of the spacer by
pushing it through the hole in the spacer.
RCPH10TLB447AAL 17
84516378 05/07/2011
D.12.A / 37
19. Remove the spacer from the housing.
RCPH10TLB448AAL 18
20. Remove the spider pin, gear and thrust washer from
the housing.
RCPH10TLB449AAL 19
21. Remove the other pin, gear and thrust washer from
the housing.
RCPH10TLB450AAL 20
22. Remove the gear and thrust washer from the hous-
ing.
RCPH10TLB452AAL 21
84516378 05/07/2011
D.12.A / 38
23. Remove the differential locking pins from the hous-

ing.
RCPH10TLB359AAL 22
24. Remove the cover and seal from the carrier.
RCPH10TLB340AAL 23
25. The pinion gear nut is staked into place on the pinion
shaft.
RCPH10TLB341AAL 24
26. Use a chisel punch to remove the stake from the

pinion shaft NUT.
RCPH10TLB342AAL 25
84516378 05/07/2011
D.12.A / 39
27. Use the offset spanner, CAS2151A, and yoke P/N

144279A1 to remove the pinion gear ring nut.
RCPH10TLB343AAL 26
28. Use a soft faced hammer and drive the pinion out of
the carrier housing.
29. Remove the crush sleeve and shims from the pinion
shaft.
RCPH10TLB344AAL 27
30. Press the bearing from the pinion shaft.
RCPH10TLB345AAL 28
84516378 05/07/2011
D.12.A / 40
31. Remove the shim from the pinion.
RCPH10TLB346AAL 29
32. Remove the outer bearing cup from the carrier.
RCPH10TLB347AAL 30
33. Remove the inner bearing cup from the carrier.
RCPH10TLB348AAL 31
Next operation:
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D.12.A / 41
Differential - Remove - Differential lock fork removal - 580N and

580SN only
NOTE: The differential lock fork may look different for machines equipped with a Power Shift transmission. The
procedure is the same.
1. Loosen the differential lock cylinder from the carrier.
RCPH10TLB349AAL 1
2. Hold the differential lock fork down to catch a block

inside of the housing, remove the cylinder.
RCPH10TLB350AAL 2
NOTE: Use caution removing the cylinder, it is under spring pressure.

3. Place a flat washer over the shaft.
RCPH10TLB351AAL 3
84516378 05/07/2011
D.12.A / 42
4. Start the modified cylinder into the differential hous-

ing.
RCPH10TLB352AAL 4
5. Block the fork from moving.
RCPH10TLB353AAL 5
6. Tighten the modified cylinder and press down on the

bushing, remove the snap ring.
RCPH10TLB354AAL 6
RCPH10TLB355AAL 7
84516378 05/07/2011
D.12.A / 43
RCPH10TLB356AAL 8
9. Remove the shaft.
RCPH10TLB357AAL 9
10. Remove the fork, spring and bushing from the shaft.
RCPH10TLB460AAL 10
Next operation:
Differential - Install (D.12.A)
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D.12.A / 44
Differential - Install - Differential lock housing and piston - 580N

and 580SN only
1. 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.
RCPH10TLB459AAL 1
2. Lubricate the bore in the cover for the piston with

clean hydraulic oil. Install the piston in the cover for
the differential lock.
Next operation:
84516378 05/07/2011
D.12.A / 45
Differential - Install - Differential lock fork installation - 580N and

580SN only
NOTE: The differential lock fork will look different for machines equipped with a Power Shift transmission. The pro-
cedure is the same.
1. When installing the bushings on the shaft make sure
the chamfer is over the snap ring.
RCPH10TLB461AAL 1
2. 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.
RCPH10TLB460AAL 2
3. Install the shaft into the carrier.
RCPH10TLB357AAL 3
84516378 05/07/2011
D.12.A / 46
RCPH10TLB356AAL 4
5. Place the bushing on the shaft, make sure the cham-

fer in the bushing is facing out.
RCPH10TLB355AAL 5
6. Place a flat washer over the shaft.
RCPH10TLB351AAL 6
7. Start the modified cylinder into the differential hous-

ing.
RCPH10TLB352AAL 7
84516378 05/07/2011
D.12.A / 47
8. Block the fork from moving.
RCPH10TLB353AAL 8
9. Compress the spring by tightening the modified cylin-

der and install the snap ring.
RCPH10TLB354AAL 9
10. Remove the block, push the fork into the carrier and
lock it behind the block inside of the carrier. Hand
start the locking cylinder.
RCPH10TLB350AAL 10
11. Torque the locking cylinder to 180 Nm (133 pound-

feet).
RCPH10TLB360AAL 11
Next operation:
84516378 05/07/2011
D.12.A / 48
84516378 05/07/2011
D.12.A / 49
Differential - Assemble - 580N and 580SN only

1. Install new O-rings on the pins. Lubricate the O-rings
with clean hydraulic oil.
RCPH10TLB481AAL 1
2. Install the pins in the differential housing.
RCPH10TLB358AAL 2
3. Lubricate the gear and thrust washer with clean hy-

draulic oil. Install the gear and thrust washer.
RCPH10TLB452AAL 3
4. When installing the pins and thrust washers, align the

flats on the pins with the flats in the thrust washer.
RCPH10TLB451AAL 4
84516378 05/07/2011
D.12.A / 50
5. Install the pin, thrust washer and spider gear.
RCPH10TLB450AAL 5
NOTE: Push the pin in just far enough to hold the thrust washer and spider.
6. Install the pin, thrust washer, and spider gear.
RCPH10TLB449AAL 6
7. Install the spacer as shown, push the pins into the
spacer.
RCPH10TLB448AAL 7
84516378 05/07/2011
D.12.A / 51
8. Make sure to install the pin so that the dowel pin hole
aligns with the dowel pin hole in the housing.
RCPH10TLB445AAL 8
9. Place the spider gear and thrust washer into the

housing. Align the bushing with the pin and push the
pin in as far as possible.
RCPH10TLB444AAL 9
10. Install the spider gear and thrust washer, push the
pin into the gear and washer.
RCPH10TLB443AAL 10
11. Install the retaining pins for the spider gear pins into
the housing.
84516378 05/07/2011
D.12.A / 52
12. The pinion gear and ring gear are a matched set.
Make sure the numbers on the pinion gear and ring
gear are the same.
RCPH10TLB589AAL 11
13. Use LOCTITE 270 on cap screws, install and torque

ring gear cap screws to 155 Nm (114 pound-feet).
RCPH10TLB439AAL 12
NOTE: Torque cap screws in a staggered pattern in order to draw the ring gear up flush.
14. Install plugs and torque to 25 Nm (18.5 pound-feet).
RCPH10TLB437AAL 13
15. Use an acceptable driver and install a bearing cup

into the housing.
RCPH10TLB457AAL 14
84516378 05/07/2011
D.12.A / 53
NOTE: The bearing cup will stay raised above the housing even when properly seated.
16. Place the gear into the housing while aligning the
teeth.
RCPH10TLB436AAL 15
17. Apply a light coat of grease to the thrust washer to

hold it in place on the differential housing cover. The
ears of the thrust washer must align with the slots in
the cover.
RCPH10TLB435AAL 16
18. 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.
RCPH10TLB453AAL 17
19. Install the cover into the housing, install the locking
ring.
RCPH10TLB434AAL 18
84516378 05/07/2011
D.12.A / 54
20. Use an acceptable driver and install the bearing cup.
RCPH10TLB491AAL 19
21. 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.
RCPH10TLB458AAL 20
22. Use an acceptable driver and install the inner bearing

cup.
RCPH10TLB454AAL 21
23. Use an acceptable driver and install the outer bearing

cup.
RCPH10TLB455AAL 22
84516378 05/07/2011
D.12.A / 55
24. Install the inner bearing.
RCPH10TLB390AAL 23
25. Install depth gauge 380002436, adapter

CAS1596A-6, and bolt CAS1596A-7 into the
bearing.
RCPH10TLB389AAL 24
26. CAS1596A-4 must be facing up as shown.
RCPH10TLB391AAL 25
27. Place the outer bearing on CAS1596-A as shown.
RCPH10TLB392AAL 26
84516378 05/07/2011
D.12.A / 56
28. Tighten CAS1596A-4 and 380002436 until the bear-

ings are tight.
RCPH10TLB388AAL 27
29. Place CAS1716-3 handle in bearing cradles of the

carrier housing.
RCPH10TLB387AAL 28
NOTE: Make sure the carrier housing is level.

between the gauge block and the gauge tube. Write
the measurement on line “b” in step 32.
RCPH10TLB386AAL 29
84516378 05/07/2011
D.12.A / 57
31. Find the number on the end of the pinion shaft. Write
this number on line “d” of the worksheet.
RCPH10TLB480AAL 30
32. 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
d. - 68 mm d. Reading on pinion
e. 6.803 mm e. Required shim thickness
Worksheet
a. 74.6 mm a. Tool constant
b. + mm b. Gap measurement
c. mm c. Total distance
d. - mm d. Reading on pinion
e. mm e. Required shim thickness
33. Remove the special tools from the center section.

34. Install the shim with the thickness specified in step
32. The chamfer on the ID of the shim must be to-
ward the pinion gear.
RCPH10TLB482AAL 31
84516378 05/07/2011
D.12.A / 58
35. Put the inner bearing in position on the shaft.
RCPH10TLB483AAL 32
36. Use a suitable driver and press the inner bearing

against the shim.
RCPH10TLB483AAL 33
37. Lubricate the bearing with hydraulic oil. Install the

washers and a new collapsible spacer on the pinion
gear. The old collapsible spacer MUST NOT be used
again.
RCPH10TLB462AAL 34
38. Lubricate the outer bearing with hydraulic oil. Install

the outer bearing.
RCPH10TLB463AAL 35
84516378 05/07/2011
D.12.A / 59
39. Install the special washer, make sure to align the

washer with the slot in the pinion shaft.
RCPH10TLB464AAL 36
40. Lubricate the face of the nut, special washer and

threads with hydraulic oil. Install the pinion nut.
RCPH10TLB465AAL 37
41. Use the P/N 144279A1 Yoke and the CAS2151A to

start the pinion nut onto the pinion gear.
RCPH10TLB466AAL 38
42. Install the CAS2375 on the pinion shaft.
NOTICE: 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.
84516378 05/07/2011
D.12.A / 60
43. 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).
RCPH10TLB467AAL 39
44. Remove the torque wrench and the CAS2375 from

the pinion shaft.
45. Use the yoke and the CAS2151A to tighten the pinion
nut in SMALL amounts as required. Repeat steps 40
through 44 until the rotating torque is as specified in
step 43.
RCPH10TLB466AAL 40
46. Stake the lip on the pinion nut into the slot in the
pinion shaft.
RCPH10TLB468AAL 41
84516378 05/07/2011
D.12.A / 61
47. Use an acceptable driver and install the bearings

onto the ring nuts.
RCPH10TLB456AAL 42
48. Install the differential housing into the carrier. Tighten

the ring nuts evenly and center the differential hous-
ing in the carrier.
RCPH10TLB362AAL 43
Next operation:
Differential - Adjust (D.12.A)
84516378 05/07/2011
D.12.A / 62
Differential - Adjust - Pinion gear backlash adjustment - 580N and

580SN only
1. Mount a dial indicator onto the carrier, set the shaft
of the dial indicator onto the center of a tooth of the
ring gear.
RCPH10TLB361AAL 1
2. 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.
3. 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.
4. If there is not enough backlash, loosen (turn counter-
clockwise) the adjusting ring on the other side of the
center section one notch. tighten (turn clockwise) the
adjusting ring one notch on the side shown. Continue
with this step until the backlash is 0.20 to 0.29 mm
(0.008 to 0.011 inch). If there is too much backlash,
loosen (turn counterclockwise) the adjusting ring on
the side shown one notch. tighten (turn clockwise)
the adjusting ring one notch on the side opposite of
that shown. Continue with this step until the back-
lash is 0.20 to 0.29 mm (0.008 to 0.011 inch).
RCPH10TLB362AAL 2
Next operation:
84516378 05/07/2011
D.12.A / 63
Differential - Adjust - Differential bearing preload adjustment - 580N

and 580SN only
1. Install the CAS2375 on the pinion shaft. Check
the rotating torque of the pinion shaft. The ro-
tating torque must be 2.6 to 3.3 Nm (23 to 29
pound-inches).
RCPH10TLB469AAL 1
2. If the rotating torque is not correct do the following

procedure.
3. If the rotating torque is too high, loosen (turn counter-
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). If the rotating
torque is too low, tighten (turn clockwise) the adjust-
ing 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).
RCPH10TLB362AAL 2
4. Secure the adjusting rings with the Allen screws,

torque the Allen screws to 10 Nm (88.5 pound
inches).
RCPH10TLB363AAL 3
Next operation:
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Differential - Install - Pinion shaft seal installation - 580N and 580SN

only
1. Use seal driver, 380002432, and drive the seal into
the cover. The lips on the seal must be toward the
inside of the cover.
RCPH10TLB366AAL 1
RCPH10TLB365AAL 2
3. Put the CAS2369 Pinion Spline Seal Protector on the

pinion gear shaft.
RCPH10TLB367AAL 3
84516378 05/07/2011
D.12.A / 65
stall the cover on the center section.
RCPH10TLB368AAL 4
5. Remove the CAS2369 from the pinion gear shaft.
Next operation:
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Differential - Install - Carrier installation - 580N and 580SN only

1. Apply a coat of Loctite 510 to the mating surface for
the carrier.
RCPH10TLB470AAL 1
2. Attach lifting equipment to the carrier and place onto

the axle housing.
RCPH10TLB369AAL 2
3. Remove the lifting equipment from the carrier, use a

rubber mallet and tap the carrier until the dowel pins
are fully seated.
4. 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).
RCPH10TLB372AAL 3
NOTE: DO NOT use any thread locking compound on these bolts.
Next operation:
Differential - Check (D.12.A)
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Differential - Check - Checking the differential lock - 580N and

580SN only
1. 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.
84516378 05/07/2011
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Differential - Remove - Carrier removal - 580SN-WT and 590SN only

1. Remove the wheel hubs and brakes, see Wheel
Hubs And Brakes Disassembly in this section.
2. Remove the differential mounting bolts.
RCPH10TLB532AAL 1
3. Use pry bars in slots to loosen the carrier from the

axle housing.
RCPH10TLB531AAL 2

away from the axle housing, attach suitable lifting
equipment to the differential housing.
RCPH10TLB530AAL 3
Next operation:
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Differential - Disassemble - 580SN-WT and 590SN only

2. Remove the bolts securing the ring nut.
RCPH10TLB535AAL 1
3. Remove the ring nuts.
RCPH10TLB362AAL 2
4. Remove the differential from the carrier.

5. Remove the differential lock sleeve.
RCPH10TLB552AAL 3
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6. Remove the locking ring.
RCPH10TLB545AAL 4
7. Use a plate just large enough to cover the side gear

and will not interfere with the removal of the differen-
tial housing cover.
RCPH10TLB544AAL 5
8. Use an acceptable puller to remove the differential

housing cover.
RCPH10TLB546AAL 6
RCPH10TLB547AAL 7
84516378 05/07/2011
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10. Remove the bearing cup.
RCPH10TLB550AAL 8
RCPH10TLB548AAL 9
12. Remove the anti-rotation pin.
RCPH10TLB549AAL 10
13. Remove three plugs from the differential.
RCPH10TLB551AAL 11
84516378 05/07/2011
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14. Remove the three pins securing the spider pins in the
differential.
RCPH10TLB553AAL 12
15. Note the flat surface on pin.
RCPH10TLB554AAL 13
16. Push the pin towards the flat surface side noted in
the previous step.
RCPH10TLB512AAL 14
NOTE: DO NOT force the pin, it will not come out of the housing at this time.
RCPH10TLB511AAL 15
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18. Push the pin out of the housing.
RCPH10TLB516AAL 16
RCPH10TLB511AAL 17
20. Push one of the short spider pins out of the spacer
by pushing it through the hole in the spacer.
RCPH10TLB585AAL 18
21. Push the other short spider pin out of the spacer by
pushing it through the hole in the spacer.
RCPH10TLB586AAL 19
84516378 05/07/2011
D.12.A / 74
22. Remove the spacer from the housing.
RCPH10TLB555AAL 20
23. Remove the spider pin, gear and thrust washer from
the housing.
RCPH10TLB556AAL 21
24. Remove the other pin, gear and thrust washer from
the housing.
RCPH10TLB556AAL 22
25. Remove the gear from the housing.
RCPH10TLB504AAL 23
84516378 05/07/2011
D.12.A / 75
26. Remove the thrust washer from the housing.
RCPH10TLB502AAL 24
27. Remove the ring gear cap screws, remove the ring.
RCPH10TLB492AAL 25
NOTE: Large amounts of Loctite was used during assembly, remove cap screws slowly. If screws bind, turn back in
and then back out.
28. Remove the differential locking pins from the hous-
ing.
RCPH10TLB495AAL 26
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D.12.A / 76
29. Remove the cover and seal from the carrier.
RCPH10TLB538AAL 27
30. The pinion gear nut is staked into place on the pinion
shaft.
RCPH10TLB539AAL 28
31. Use a chisel punch to remove the stake from the

pinion shaft nut.
RCPH10TLB540AAL 29
32. Use the offset spanner, 380100093, and yoke P/N

144279A1 to remove the pinion gear ring nut.
RCPH10TLB541AAL 30
84516378 05/07/2011
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33. Use a soft faced hammer and drive the pinion out of
the carrier housing.
RCPH10TLB559AAL 31
34. Remove the crush sleeve and shims from the pinion
shaft.
RCPH10TLB561AAL 32
35. Press the bearing from the pinion shaft.
RCPH10TLB575AAL 33
36. Remove the shim from the pinion.
RCPH10TLB576AAL 34
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37. Remove the outer bearing cup from the carrier.
RCPH10TLB580AAL 35
38. Remove the inner bearing cup from the carrier.
RCPH10TLB579AAL 36
Next operation:
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Differential - Remove - Differential lock for removal - 580SN-WT

and 590SN only
1. Remove elbow from the differential lock cylinder.
RCPH10TLB562AAL 1
2. Loosen the differential lock cylinder from the carrier.
RCPH10TLB563AAL 2
NOTE: Use caution removing the cylinder, it is under spring pressure.

3. Loosen the differential cylinder plug.
RCPH10TLB564AAL 3
84516378 05/07/2011
D.12.A / 80
4. Remove the differential cylinder plug from the carrier.
RCPH10TLB566AAL 4
5. Remove the differential lock fork.
RCPH10TLB567AAL 5
6. Place differential lock fork in a soft-jawed vise.

Tighten vise enough to gain access to the snap ring.
Remove the snap ring.
RCPH10TLB570AAL 6
7. Remove the fork.
RCPH10TLB572AAL 7
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RCPH10TLB573AAL 8
RCPH10TLB574AAL 9
Next operation:
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Differential - Install - Differential lock for installation - 580SN-WT

and 590SN only
NOTE: When installing the bushings on the shaft, make sure the chamfer is over the snap ring.
1. When installing the bushings on the shaft make sure
the chamfer is over the snap ring.
RCPH10TLB574AAL 1
2. Install the spring onto the shaft.
RCPH10TLB573AAL 2
3. Install the fork onto the shaft with collar of fork to-
wards the retaining ring.
RCPH10TLB572AAL 3
NOTE: Position fork as shown.
84516378 05/07/2011
D.12.A / 83
4. Place differential lock fork in a soft-jawed vise.

Tighten vise enough to gain access to the snap ring.
Install the snap ring.
RCPH10TLB571AAL 4
5. Install shaft into the carrier.
RCPH10TLB569AAL 5
6. Install the bushing and spring.
RCPH10TLB568AAL 6
7. Position bushing in the opening in the carrier.
RCPH10TLB567AAL 7
84516378 05/07/2011
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8. Install a new O-ring on the plug for the differential

lock.
RCPH10TLB566AAL 8
9. Tighten the differential lock plug to a torque of Nm

180 (133 Pound-feet).
RCPH10TLB565AAL 9
10. Install and tighten the differential lock cylinder to a

torque of 180 Nm (133 Pound-feet).
RCPH10TLB563AAL 10
11. Install new O-ring on elbow. Install elbow to the

proper position and tighten jam nut to a torque of 30
Nm (262 Pound-inches).
RCPH10TLB562AAL 11
Next operation:
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Differential - Assemble - 580SN-WT and 590SN only

1. Install ring gear.
RCPH10TLB494AAL 1
2. Use two Allen head screws to hold the ring gear in

place.
RCPH10TLB496AAL 2
3. Tighten the screws evenly to pull the ring gear par-

tially into position.
RCPH10TLB497AAL 3
4. Install two ring gear screws in the ring gear.
RCPH10TLB498AAL 4
84516378 05/07/2011
D.12.A / 87
5. Tighten the screws evenly to draw up the ring gear.
RCPH10TLB499AAL 5
6. Remove the two long Allen head screws.
RCPH10TLB500AAL 6
7. Apply Loctite 270 on the screws. Install ring gear cap

screws.
RCPH10TLB501AAL 7
8. Tighten cap screws to a torque of 155 Nm (114

Pound-feet).
RCPH10TLB493AAL 8
84516378 05/07/2011
D.12.A / 88
RCPH10TLB503AAL 9
10. Install the side gear with differential lock slots.
RCPH10TLB504AAL 10
11. When installing the pins and thrust washers, align the
flats on the pins with the flats in the thrust washer.
RCPH10TLB506AAL 11
12. Lubricate thrust washer and spider gear. Install the

spider gear.
RCPH10TLB505AAL 12
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D.12.A / 89
13. Make sure to install the pin so that the pin hole aligns
with the pin hole in the housing.
RCPH10TLB507AAL 13
14. Push the pin in just far enough to hold the thrust
washer and spider.
RCPH10TLB508AAL 14
15. Install the pin, thrust washer and spider gear on the
opposite side.
RCPH10TLB509AAL 15
16. Place the spacer between the spider gears as
shown.
RCPH10TLB510AAL 16
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D.12.A / 90
17. Make sure to install the pin so that the pin hole (1),
aligns with the pin hole in the housing.
RCPH10TLB513AAL 17
NOTE: Notice the position of the shoulder (2), on the pin.

18. Install the spider gear and thrust washer.
RCPH10TLB511AAL 18
19. Align the bushing with the pin and push the pin into
the bushing.
RCPH10TLB514AAL 19
20. Install the spider gear and thrust washer into the
housing.
RCPH10TLB515AAL 20
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21. Push the pin into the gear and washer.
RCPH10TLB516AAL 21
22. Install the pins for the spider gear shaft.
RCPH10TLB517AAL 22
23. Install plugs and tighten to a toque of 25 Nm (221

Pound-inches).
RCPH10TLB518AAL 23
24. Install side gear.
RCPH10TLB519AAL 24
84516378 05/07/2011
D.12.A / 92
25. Install thrust washer.
RCPH10TLB588AAL 25
26. Install bearing cup if removed.
RCPH10TLB550AAL 26
27. Install anti-rotation pin.
RCPH10TLB549AAL 27
28. Align the notch in the bearing housing with the anti-
rotation pin. Install the bearing housing.
RCPH10TLB520AAL 28
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D.12.A / 93
RCPH10TLB521AAL 29
30. Install new O-rings on the differential lock pins. Lu-

bricate the O-rings with clean oil. Install pins.
RCPH10TLB522AAL 30
NOTE: Position differential lock sleeve with chaffered side down.

31. Install the lock ring.
RCPH10TLB524AAL 31
32. Install outer bearing cup into the carrier.
RCPH10TLB581AAL 32
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D.12.A / 94
33. Install inner bearing cup into the carrier.
RCPH10TLB582AAL 33
34. The pinion gear and ring gear are a matched set.
Make sure the numbers on the pinion gear and ring
gear are the same.
RCPH10TLB480AAL 34
35. Insert bearing (7) and (8) in the housing. Assemble

the false pinion 380100090 (1a) , spacer (2) , and
ring nut (1) , on the differential carrier (9). Tighten
with the ring nut until the bearings are tight.
RCPH10TLB487AAL 35
36. Place special tool 380000407 (2a) in the differential

group supports (3).
RCPH10TLB583AAL 36
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D.12.A / 95
37. Use a depth gauge to measure distance “X” (distance

between the axis of the differential bearings and the
point at which the pinion head is supported, or the
base of the bearing).
RCPH10TLB488AAL 37
38. To adjust bevel gear/pinion, measure the distance

“A” with a depth gauge. Calculate the value “X” as fol-
lows: X=(A+C)-B mm Where “B” and “C” are known.
RCPH10TLB489AAL 38
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).
39. S=(X-V) mm In order to determine the necessary
thickness value (S) between the pinion and the bear-
ing, subtract the value (V), stamped on the pinion
head (V = requested distance), from the measured
value (X).
RCPH10TLB480AAL 39
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40. Select the shim with the thickness value (S) among
the range of available shims. Shim thickness-mm
RCPH10TLB576AAL 40
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
NOTE: The chamfer of the shim goes toward the gear.

41. 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).
RCPH10TLB487AAL 41
42. Install the bearing on the shaft.
RCPH10TLB577AAL 42
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D.12.A / 97
43. Use a suitable driver and press the bearing onto the
shaft.
RCPH10TLB578AAL 43
44. Lubricate the bearing with hydraulic oil. Install the

washers and a NEW crush sleeve on the shaft. The
old collapsible spacer MUST NOT be used again.
RCPH10TLB561AAL 44
45. Install shaft into the carrier.

46. Heat the outer bearing and install on the shaft.
RCPH10TLB560AAL 45
47. Install the special washer, make sure to align the

washer with the slot in the pinion shaft.
RCPH10TLB558AAL 46
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48. Lubricate the face of the nut, special washer and

threads with hydraulic oil. Install the pinion nut.
RCPH10TLB557AAL 47
49. Use the P/N 144279A1 Yoke and the 380100093 to

start the pinion nut onto the pinion gear.
RCPH10TLB541AAL 48
RCPH10TLB528AAL 49
NOTICE: 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.
51. 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).
RCPH10TLB587AAL 50
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D.12.A / 99
52. Remove the torque wrench and the CAS2375 from

the pinion shaft.
53. Use the yoke and the 380100093 to tighten the pinion
nut in SMALL amounts as required. Repeat steps
49through 53 until the rotating torque is as specified
in step 51.
RCPH10TLB542AAL 51
54. Stake the lip on the pinion nut into the slot in the
pinion shaft.
RCPH10TLB539AAL 52
55. Use an acceptable driver and install the bearings

onto the ring nuts.
56. Install the differential housing into the carrier. Tighten
the ring nuts evenly and center the differential hous-
ing in the carrier.
RCPH10TLB362AAL 53
Next operation:
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Differential - Adjust - Pinion gear backlash adjustment - 580SN-WT

and 590SN only
1. Mount a dial indicator onto the carrier, set the shaft
of the dial indicator onto the center of a tooth of the
ring gear.
RCPH10TLB525AAL 1
2. 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.
RCPH10TLB526AAL 2
3. 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.
4. If there is too much backlash, loosen (turn counter-
clockwise) the adjusting ring on the other side of the
center section one notch. tighten (turn clockwise) the
adjusting ring one notch on the side shown. Continue
with this step until the backlash is 0.20 to 0.29 mm
(0.008 to 0.011 inch). If there is not enough backlash,
loosen (turn counterclockwise) the adjusting ring on
the side shown one notch. tighten (turn clockwise)
the adjusting ring one notch on the side opposite of
that shown. Continue with this step until the back-
lash is 0.20 to 0.29 mm (0.008 to 0.011 inch).
RCPH10TLB362AAL 3
Next operation:
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Differential - Adjust - Differential bearing preload adjustment -

RCPH10TLB528AAL 1
2. Check the rotating torque of the pinion shaft. The

rotating torque must be 2.6 to 3.3 Nm (23 to 29
pound-inches).
RCPH10TLB587AAL 2
3. If the rotating torque is not correct do the following

procedure.
4. If the rotating torque is too high, loosen (turn counter-
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). If the rotating
torque is too low, tighten (turn clockwise) the adjust-
ing 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).
RCPH10TLB362AAL 3
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5. Secure the adjusting rings with the Allen screws,

torque the Allen screws to 10 Nm (88.5 pound
inches).
RCPH10TLB527AAL 4
Next operation:
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Differential - Install - Pinion shaft seal installation - 580SN-WT and

590SN only
1. Use seal driver, 380002432, and drive the seal into
the cover. The lips on the seal must be toward the
inside of the cover.
RCPH10TLB366AAL 1
RCPH10TLB365AAL 2
3. Put the CAS2369 Pinion Spline Seal Protector on the

pinion gear shaft.
RCPH10TLB536AAL 3
84516378 05/07/2011
D.12.A / 104
stall the cover on the center section.
RCPH10TLB543AAL 4
5. Use a soft-face hammer to seat the seal.
RCPH10TLB537AAL 5
6. Remove the CAS2369 from the pinion gear shaft.
Next operation:
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Differential - Install - Carrier Installation - 580SN-WT and 590SN only

1. Apply a coat of Loctite 510 to the mating surface for
the carrier.
RCPH10TLB534AAL 1
2. Attach lifting equipment to the carrier and place onto

the axle housing.
RCPH10TLB529AAL 2

away from the axle housing, remove the lifting at-
tached equipment from the differential housing. Use
a soft-face hammer and tap the carrier until the dowel
pins are fully seated.
RCPH10TLB530AAL 3
4. 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).
RCPH10TLB533AAL 4
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D.12.A / 106
NOTE: DO NOT use any thread locking compound on these bolts.
Next operation:
Differential - Check (D.12.A)
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Differential - Check - Checking the differential lock - 580SN-WT

and 590SN only
1. 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.
84516378 05/07/2011
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Hub - Disassemble - Wheel hub and brakes - 580N and 580SN only
1. Remove the axle vent to relieve any pressure inside
of the axle.
RCPH10TLB384AAL 1
2. Place an oil receptacle under the outer housings of

the axle and drain the oil.
RCPH10TLB385AAL 2
3. Place an oil receptacle under the differential carrier

and drain the oil.
RCPH10TLB376AAL 3
4. Remove all but two of the cap screws.

NOTICE: Large amounts of Loctite were used during as-
sembly, remove cap screws slowly. If screw binds, turn
back in and then back out.
RCPH10TLB382AAL 4
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D.12.A / 109
5. Insert three long dowel rods for in vehicle service or

two short dowel rods for bench service.
RCPH10TLB393AAL 5
6. Remove the remaining cap screws.
RCPH10TLB394AAL 6
7. Pry the hub from the axle using slots.
RCPH10TLB395AAL 7
8. Slowly pull hub away from axle, make sure that the
brake disks and plates stay with the hub.
RCPH10TLB396AAL 8
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9. Pull the half shaft out with the hub and brakes.
RCPH10TLB397AAL 9
10. Place the hub, brakes and half shaft on a suitable

work bench.
RCPH10TLB398AAL 10
11. Stand the hub up, mark the reaction plat that was
against the axle housing. Remove the reaction and
brake disks.
NOTE: Keep brake surfaces in same relationship to each
other if being reused.
RCPH10TLB399AAL 11
12. Remove the half shaft from the planetary gears.
RCPH10TLB311AAL 12
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D.12.A / 111
13. Left hand shaft is 807 mm (31.8 in) long and the right
hand shaft is 701 mm (27.6 in) long.
RCPH10TLB375AAL 13
14. Loosen and remove the shouldered bolts, and spring

washers from the brake self adjusters.
RCPH10TLB312AAL 14
15. Check springs and shouldered bolt for damage. If

brakes are being replaced, replace springs and bolts
with kit.
RCPH10TLB401AAL 15
RCPH10TLB314AAL 16
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17. Remove the self adjuster. If brakes are being re-

placed replace adjusters.
NOTE: Once removed the self adjusters spring clips must
be replace with genuine parts, DO NOT use after market
parts.
RCPH10TLB315AAL 17
18. Place the tapered end of the self adjuster (1) on tool
380002435.
RCPH10TLB404AAL 18
19. Place the 380002435 driver tool (1) onto the self ad-
juster (2) and drive the spring clips (3) off of the ad-
juster.
RCPH10TLB405AAL 19
20. Inspect adjuster bushing for wear.
RCPH10TLB406AAL 20
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21. Use two acceptable flat bars and evenly pry the brake
piston up from the hub.
RCPH10TLB316AAL 21
22. Remove the piston from the hub.
RCPH10TLB317AAL 22
23. Remove the inner cylinder.
RCPH10TLB421AAL 23
24. If the cylinder remained in the housing, use a suitable

pry bar to remove the cylinder.
RCPH10TLB318AAL 24
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25. If the machine has high work hours, remove and dis-
card the outer brake piston O-ring.
RCPH10TLB415AAL 25
card the inner brake piston O-ring.
RCPH10TLB416AAL 26
card the brake cylinder O-ring.
RCPH10TLB418AAL 27
28. Remove and discard the hub O-ring.
RCPH10TLB319AAL 28
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29. Attach suitable lifting equipment to the planetary

gears.
RCPH10TLB320AAL 29
30. Locate the snap ring slot and place snap ring pliers
in slot.
RCPH10TLB334AAL 30
31. Hold the snap ring open. Carefully raise and remove
the planetary set from the hub. Release the snap ring
after the end of the wheel flange shaft is cleared.
RCPH10TLB321AAL 31
32. Remove planetary gear retainer snap rings.
RCPH10TLB322AAL 32
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33. Remove planetary gear and bearings.
RCPH10TLB323AAL 33
34. Place the wheel end in a suitable press and lock the
wheel hub so it can will not turn.
NOTICE: Do not use excessive force, otherwise damage
to the hub will occur.
RCPH10TLB326AAL 34
35. Loosen the wheel flange nut using a ring nut socket
tool 380002434 and a torque multiplier.
RCPH10TLB320AAL 35
36. Remove ring nut from wheel hub.
RCPH10TLB423AAL 36
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37. Do not press directly against the sun gear pad.
RCPH10TLB329AAL 37
38. Place the wheel hub in a press.
RCPH10TLB330AAL 38
39. Press the wheel flange from the wheel hub.
RCPH10TLB331AAL 39
40. Attach lifting equipment to hub housing and remove

from the wheel flange.
RCPH10TLB332AAL 40
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D.12.A / 118
41. Remove the inner bearing race.
RCPH10TLB425AAL 41
42. Remove the cassette seal.
RCPH10TLB426AAL 42
43. Remove the outer race.
RCPH10TLB429AAL 43
44. Remove spacer from wheel flange.
RCPH10TLB431AAL 44
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45. To remove the inner bearing, use a die grinder to cut

the roller retainer and race. Use a chisel in the slot
cut in the race to crack the race, remove the race.
RCPH10TLB430AAL 45
Next operation:
Hub - Inspect (D.12.A)
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Hub - Inspect - Wheel hub and brakes - 580N and 580SN only
2. Discard all seals and O-rings.
you find any of these defects, you must install new
wheel bearings and bearing cups.
The planetary shaft bushings are not sold separately.
If a shaft bushing is damaged, you must use a new
carrier.
5. Inspect the teeth on the planetary gears, the half
shaft, and the ring gear for wear, pitting, scoring, and
6. 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 re-
quired.
7. Inspect the brake disks and reaction plates for pitting,
scoring, excessive surface wear, and other damage.
8. Inspect brake pistons and cylinders for scaring on
sliding surfaces, brake pistons for pitting, scoring,
and excessive surface wear at brake contact point.
Use new pars as required.
9. Replace O-rings on brake cylinders and pistons.
NOTICE: Use only genuine parts. DO NOT use after market O-rings, they will fail.
Next operation:
Hub - Assemble (D.12.A).
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Hub - Assemble - Wheel hub and brakes - 580N and 580SN only
When installing new brake discs, soak the new brake discs in oil for 24 hours prior to installation.
1. If the outer bearing cups were removed, use an Uni-

versal Bearing Cup Installer or a suitable tool to in-
stall the bearing cups.
NOTE: The illustration shows the cassette seal installed,
the cassette seal will be installed during a later step.
RCPH10TLB427AAL 1
2. If the inner bearing cups were removed, use an Uni-

versal Bearing Cup Installer or other acceptable tool
to install the bearing cups.
RCPH10TLB428AAL 2
NOTICE: Caution possible component damage. The word

"OUTSIDE" on the hub seal must face outward. Do not
push the hub seal further than required during the instal-
lation. Failure to comply may result in damage to the hub
seal.
3. Attach the 380002431 hub seal installer with handle
to install the hub seal. Push only until the hub seal
makes contact with the shoulder inside the hub.
RCPH10TLB333AAL 3
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4. Install the outer wheel flange bearing with a suitable

driver.
RCPH10TLB430AAL 4
5. Install spacer on wheel flange.
RCPH10TLB431AAL 5
6. Clean all sealing surfaces with an alcohol based

cleaner, if any oil residue is on sealing surfaces the
seal will leak.
NOTICE: Caution possible component damage. 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. Failure to comply may damage the wheel
flange of hub seal.
7. Attach lifting equipment to hub and carefully install
onto wheel flange.
RCPH10TLB332AAL 6
84516378 05/07/2011
D.12.A / 123
8. Install inner bearing with a suitable driver and the ring

nut.
RCPH10TLB423AAL 7
9. Attach the ring nut socket, 380002434, and torque to

1000 N·m (738 lb ft).
NOTE: The use of a torque multiplier as shown is accept-
able.
RCPH10TLB328AAL 8
10. With a suitable driver, press the planetary gears onto

the planet carrier.
RCPH10TLB324AAL 9
11. Install the retaining snap rings on the carrier.
RCPH10TLB325AAL 10
84516378 05/07/2011
D.12.A / 124
12. Attach lifting equipment to the planetary set and

lower into the hub.
13. Engage the locking ears on the planetary carrier to
secure the ring nut.
RCPH10TLB424AAL 11
14. Hold the snap ring open and lower the planetary as-
sembly into position.
RCPH10TLB334AAL 12
15. Make sure that the snap ring is fully closed, the two
tips touch before removing the lifting equipment.
RCPH10TLB335AAL 13
84516378 05/07/2011
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16. Install a new O-ring on the hub.
RCPH10TLB336AAL 14
17. Apply hydraulic oil to the brake cylinder O-ring.
RCPH10TLB419AAL 15
18. Apply hydraulic oil to the inner O-ring of the brake

piston. Press the brake cylinder into the brake piston.
RCPH10TLB420AAL 16
19. Apply hydraulic oil to the outer O-ring of the brake

piston.
RCPH10TLB422AAL 17
84516378 05/07/2011
D.12.A / 126
20. Apply hydraulic oil to the brake cavity of the hub

housing.
RCPH10TLB337AAL 18
NOTE: Use brake pins as guides.

21. Place the brake piston and cylinder onto the hub.
RCPH10TLB417AAL 19
22. Tighten the three shoulder bolts to pull the brake pis-
ton and cylinder into the hub.
RCPH10TLB339AAL 20
23. Place the tapered edge of the brake adjuster into the
depth setting tool, part of tool kit 380002435.
RCPH10TLB407AAL 21
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D.12.A / 127
24. Place aligning tool into brake adjuster tool, part of

tool kit 380002435.
RCPH10TLB408AAL 22
NOTE: For ease of installation, look at the inside of the

adjuster ring, place tapered end down.
25. Place the first adjuster ring onto aligning tool.
RCPH10TLB409AAL 23
26. Place the second adjuster ring onto aligning tool with
the slot at 90° from the slot of the first ring.
RCPH10TLB410AAL 24
84516378 05/07/2011
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27. Place the third adjuster ring onto aligning tool with
RCPH10TLB411AAL 25
28. Place the fourth adjuster ring onto aligning tool with
RCPH10TLB412AAL 26
29. Place driver tool onto aligning tool, driver part of tool
kit 380002435.
RCPH10TLB413AAL 27
30. Drive the rings onto the adjuster until they are seated
against the depth setting tool.
RCPH10TLB414AAL 28
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D.12.A / 129
31. Insert the adjuster into the brake piston, make sure
that the chaffered side is up.
RCPH10TLB403AAL 29
32. Make sure the tabs of the snap ring face the adjuster
during installation.
RCPH10TLB490AAL 30
33. Install the snap ring into the self adjuster bore.
RCPH10TLB314AAL 31
34. Make sure the snap ring fully engages the groove in
the brake piston.
RCPH10TLB338AAL 32
84516378 05/07/2011
D.12.A / 130
35. Place spring washers onto the shoulder bolt facing

as shown.
RCPH10TLB400AAL 33
36. Hand tighten the shouldered bolt until seated into

adjuster, spring washers can become bound on the
shoulder of the bolt and be damaged.
RCPH10TLB402AAL 34
37. Torque shoulder bolts to 16 N·m (142 lb in).
RCPH10TLB313AAL 35
38. Put the half shaft (1) and brake separator plate pins
(2) into the axle housing.
RCPH10TLB473AAL 36
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D.12.A / 131
39. Using the reference mark made during disassembly,

place the thinner of the two inner brake separator
plate into the axle housing.
RCPH10TLB474AAL 37
40. Place the inner brake disc onto the half shaft, do not
damage any of the splines or teeth.
RCPH10TLB475AAL 38
NOTE: For the 580N there is only one brake disc, for all Super N models there are two brake discs.
41. Install the second brake separator, SN models only.
RCPH10TLB476AAL 39
NOTE: The thicker of the two separator plates is used here.
84516378 05/07/2011
D.12.A / 132
42. Place the outer brake disc onto the half shaft, do not
RCPH10TLB477AAL 40
43. Make sure the slots of the inner and outer brake discs
are aligned with each other.
RCPH10TLB471AAL 41
44. Install dowel rods into axle housing, two short rods
for bench repair, three long for in vehicle repair.
RCPH10TLB472AAL 42
NOTE: Care needs to be taken that the self adjusters are

not damaged by falling plates or by hitting them on the
housing when bringing hub into position.
84516378 05/07/2011
D.12.A / 133
45. Attach lifting equipment to hub assembly and guide

onto dowel rods.
RCPH10TLB478AAL 43
NOTE: The input shaft for the differential may need to be

turned in order to align the splines on the half shaft sun
gear and the planetary gears.
46. Wrap a piece of rope around the axle shaft and lift
the shaft into the planetary gears while pushing the
hub onto the axle. Remove the rope once the axle is
in the planetary gears.
RCPH10TLB479AAL 44
47. Apply LOCTITE® 270 to the threads of the bolts and

systematically tighten the bolts to a torque to 226
N·m (167 lb ft).
RCPH10TLB383AAL 45
48. Install and tighten drain plugs.

49. Fill the axle with oil.
Next operation:
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Hub - Disassemble - Wheel hub and brakes - 580SN-WT and 590SN

only
of the axle.
RCPH10TLB384AAL 1

RCPH10TLB385AAL 2

and drain the oil.
RCPH10TLB376AAL 3
84516378 05/07/2011
D.12.A / 135
RCPH10TLB382AAL 4
NOTE: Large amounts of Loctite was used during assembly, remove cap screws slowly. If screw binds, turn back in
and then back out.
5. Insert dowel rods to guide the wheel hubs off.
RCPH10TLB393AAL 5
RCPH10TLB394AAL 6
84516378 05/07/2011
D.12.A / 136
RCPH10TLB395AAL 7
RCPH10TLB396AAL 8
RCPH10TLB397AAL 9

work bench.
RCPH10TLB398AAL 10
84516378 05/07/2011
D.12.A / 137
brake disks.
RCPH10TLB399AAL 11
NOTE: Keep brake surfaces in same relationship to each other if being reused.
RCPH10TLB311AAL 12
RCPH10TLB375AAL 13

RCPH10TLB312AAL 14
84516378 05/07/2011
D.12.A / 138

with kit.
RCPH10TLB401AAL 15
RCPH10TLB314AAL 16

RCPH10TLB315AAL 17
NOTE: Once removed the self adjusters spring clips must be replace with genuine parts, DO NOT use after market
parts.
84516378 05/07/2011
D.12.A / 139
18. Place the self adjuster on 3800002435.
RCPH10TLB404AAL 18
19. Place the driver 3800002435 onto self adjuster and

drive the spring clips from the adjuster.
RCPH10TLB405AAL 19
RCPH10TLB406AAL 20
21. Use an acceptable flat bars and pry the brake piston
up from the hub.
RCPH10TLB316AAL 21
84516378 05/07/2011
D.12.A / 140
RCPH10TLB317AAL 22
RCPH10TLB421AAL 23
24. The cylinder may remain in the housing, use pry bar
and remove the cylinder.
RCPH10TLB318AAL 24
25. Remove and discard outer brake piston O-ring only

if machine has high hours.
RCPH10TLB415AAL 25
84516378 05/07/2011
D.12.A / 141
26. Remove and discard inner brake piston O-ring only

RCPH10TLB416AAL 26
27. Remove and discard brake cylinder O-ring only if ma-

chine has high hours.
RCPH10TLB418AAL 27
28. Remove and discard the hub O-ring.
RCPH10TLB319AAL 28
29. Attach lifting equipment to the planetary gears.
RCPH10TLB320AAL 29
84516378 05/07/2011
D.12.A / 142
30. Locate the snap ring slot and place snap ring pliers
in slot.
RCPH10TLB334AAL 30
31. Carefully raise the planetary set, hold the snap ring
open until it has cleared the end of the wheel flange
shaft.
RCPH10TLB321AAL 31
32. Remove planetary set from the hub.

33. Remove planetary gear retainer snap rings.
RCPH10TLB322AAL 32
34. Remove planetary gear and bearings.
RCPH10TLB323AAL 33
84516378 05/07/2011
D.12.A / 143
35. Place the wheel end in a press and lock the wheel
hub so it can not turn.
RCPH10TLB326AAL 34
NOTE: Do not use excessive force.

36. Use ring nut socket, 380002434, a torque multiplier,
and loosen wheel flange ring nut.
RCPH10TLB327AAL 35
37. Remove ring nut from wheel hub.
RCPH10TLB423AAL 36
38. Do not press directly against the sun gear pad.
RCPH10TLB329AAL 37
84516378 05/07/2011
D.12.A / 144
39. Place the wheel hub in a press.
RCPH10TLB330AAL 38
40. Press the wheel flange from the wheel hub.
RCPH10TLB331AAL 39
41. Attach lifting equipment to hub housing and remove

from the wheel flange.
RCPH10TLB332AAL 40
42. Remove the inner bearing race.
RCPH10TLB425AAL 41
84516378 05/07/2011
D.12.A / 145
43. Remove the cassette seal.
RCPH10TLB426AAL 42
44. Remove the outer race.
RCPH10TLB429AAL 43
45. Remove spacer from wheel flange.
RCPH10TLB431AAL 44
46. To remove the inner bearing, use a die grinder to cut

the roller retainer and race. Use a chisel in the slot
cut in the race to crack the race, remove the race.
RCPH10TLB430AAL 45
Next operation:
84516378 05/07/2011
D.12.A / 146
Hub - Inspect (D.12.A)
84516378 05/07/2011
D.12.A / 147
Hub - Inspect - Wheel hub and brakes - 580SN-WT and 590SN only
2. Discard all seals and O-rings.
you find any of these defects, you must install new
wheel bearings and bearing cups.
The planetary shaft bushings are not sold separately.
If a shaft bushing is damaged, you must use a new
carrier.
5. Inspect the teeth on the planetary gears, the half
shaft, and the ring gear for wear, pitting, scoring, and
6. 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 re-
quired.
Use new pars as required.
NOTICE: Use only genuine parts. DO NOT use after market O-rings, they will fail.
Next operation:
Hub - Assemble (D.12.A)
84516378 05/07/2011
D.12.A / 148
Hub - Assemble - Wheel hub and brakes - 580SN-WT and 590SN

only
1. If the outer bearing cups were removed, use an
OEM-4185 Universal Bearing Cup Installer or other
acceptable tool to install the bearing cups.
RCPH10TLB427AAL 1
NOTE: The above photo shows the cassette seal installed, the cassette seal will be installed during a later step.
2. If the inner bearing cups were removed, use an
OEM-4185 Universal Bearing Cup Installer or other
acceptable tool to install the bearing cups.
RCPH10TLB428AAL 2
NOTICE: The words “OUTSIDE” on the hub seal must be facing out.
3. Use the 380002431 hub seal installer with handle
to install the hub seal. Push only until the hub seal
makes contact with the shoulder inside the hub. Con-
tinued pushing can damage the hub seal.
RCPH10TLB333AAL 3
84516378 05/07/2011
D.12.A / 149
4. Install the outer wheel flange bearing with a suitable

driver.
RCPH10TLB430AAL 4
5. Install spacer on wheel flange.
RCPH10TLB431AAL 5
6. Clean all sealing surfaces with an alcohol based

cleaner, if any oil residue is on sealing surfaces the
seal will leak.
7. Attach lifting equipment to hub and carefully install
onto wheel flange.
RCPH10TLB332AAL 6
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.
84516378 05/07/2011
D.12.A / 150
8. Install inner bearing with a suitable driver, install ring

nut.
RCPH10TLB423AAL 7
NOTE: The ring nut can be installed with either side up or down.
9. Use ring nut socket, 380002434, torque ring nut to
1000 Nm (737.5 pound-feet).
RCPH10TLB328AAL 8
NOTE: The use of a torque multiplier as shown is acceptable.

10. Use a suitable driver and press the planetary gears
onto the planet carrier.
RCPH10TLB324AAL 9
84516378 05/07/2011
D.12.A / 151
11. Install the retaining snap rings on the carrier.
RCPH10TLB325AAL 10
12. Attach lifting equipment to planetary set and lower

into hub.
13. During installation the locking ears on the planetary
carrier must engage the ring nut as shown.
RCPH10TLB424AAL 11
14. Hold the snap ring open and lower the planetary as-
sembly into position.
RCPH10TLB334AAL 12
84516378 05/07/2011
D.12.A / 152
15. Make sure that the snap ring is fully closed, two tips
touch, remove lifting equipment.
RCPH10TLB335AAL 13
16. Install a new O-ring onto the hub.
RCPH10TLB336AAL 14
17. Use hydraulic oil to lubricate the brake cylinder

O-ring.
RCPH10TLB419AAL 15
18. Use hydraulic oil to lubricate the inner O-ring of the

brake piston, press the brake cylinder into the brake
piston.
RCPH10TLB420AAL 16
84516378 05/07/2011
D.12.A / 153
19. Use hydraulic oil to lubricate the outer O-ring of the

brake piston.
RCPH10TLB422AAL 17
20. Use hydraulic oil to lubricate the brake cavity of the

hub housing.
RCPH10TLB337AAL 18
RCPH10TLB417AAL 19
NOTE: Use brake pins for guides.

22. Use the three shouldered bolts and washers to pull
the brake piston and cylinder into the hub.
RCPH10TLB339AAL 20
84516378 05/07/2011
D.12.A / 154
23. Place the brake adjuster with tapered edge facing up

into depth setting tool, part of tool kit 380002435.
RCPH10TLB407AAL 21

tool kit 380002435.
RCPH10TLB408AAL 22
RCPH10TLB409AAL 23
NOTE: For ease of installation, look at the inside of the adjuster ring, place tapered end down.
RCPH10TLB410AAL 24
84516378 05/07/2011
D.12.A / 155
RCPH10TLB411AAL 25
RCPH10TLB412AAL 26
kit 380002435.
RCPH10TLB413AAL 27
RCPH10TLB414AAL 28
84516378 05/07/2011
D.12.A / 156
RCPH10TLB403AAL 29
32. Make sure the tips of the snap ring face the adjuster
RCPH10TLB490AAL 30
RCPH10TLB314AAL 31
34. Make sure the snap ring fully engages the grove in
the brake piston.
RCPH10TLB338AAL 32
84516378 05/07/2011
D.12.A / 157
35. Place spring washers onto shouldered bolt facing as

shown.
RCPH10TLB400AAL 33

RCPH10TLB402AAL 34
37. Torque shouldered bolts to 16 Nm (141.4 pound-

inches).
RCPH10TLB313AAL 35
38. Put the half shaft and brake separator plate pins into
the axle housing.
RCPH10TLB473AAL 36
84516378 05/07/2011
D.12.A / 158

place the inner brake separator plate into the axle
housing.
RCPH10TLB474AAL 37
NOTE: The thinner of the two separator plates is used here.

NOTICE: If using new brake disks they must be soaked in oil for 24 hours prior to installation.
40. Place the inner brake disk onto the half shaft, do not
RCPH10TLB475AAL 38
NOTE: For the 580N there is only one brake disk, for all Super N models there are two brake disks.
RCPH10TLB476AAL 39
84516378 05/07/2011
D.12.A / 159
42. Place the outer brake disk onto the half shaft, do not
RCPH10TLB477AAL 40
43. Make sure the slots of the inner and outer brake disks
RCPH10TLB471AAL 41
RCPH10TLB472AAL 42

onto dowel rods.
RCPH10TLB478AAL 43
84516378 05/07/2011
D.12.A / 160
NOTE: Care must be taken so the self adjusters are not damaged by falling plates or by hitting them on the housing
when bringing the hub into position.
46. Use a piece of rope and lift the axle shaft into the
planetary gears while pushing the hub onto the axle.
RCPH10TLB479AAL 44
NOTE: The input shaft for the differential may need to be turned in order to align the splines on the half shaft sun gear
and the planetary gears.
47. Use Loctite 270 on thread of the bolts and torque to
226 Nm (166.5 pound-feet).
RCPH10TLB383AAL 45
48. Install and tighten drain plugs.

49. Fill the axle with oil, see specification for quantity and
type.
Next operation:
84516378 05/07/2011
D.12.A / 161
Index
REAR AXLE - 12.A

Differential - Adjust - Differential bearing preload adjustment - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . 64
Differential - Adjust - Differential bearing preload adjustment - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . 102
Differential - Adjust - Pinion gear backlash adjustment - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Differential - Adjust - Pinion gear backlash adjustment - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . 101
Differential - Assemble - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Differential - Assemble - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Differential - Check - Checking the differential lock - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Differential - Check - Checking the differential lock - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . 108
Differential - Disassemble - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Differential - Disassemble - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Differential - Exploded view - Differential - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Differential - Exploded view - Differential - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Differential - Exploded view - Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Differential - Exploded view - Ring and pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Differential - Install - Carrier Installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Differential - Install - Carrier installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Differential - Install - Differential lock for installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Differential - Install - Differential lock fork installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Differential - Install - Differential lock housing and piston - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Differential - Install - Pinion shaft seal installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Differential - Install - Pinion shaft seal installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Differential - Remove - Carrier removal - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Differential - Remove - Carrier removal 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Differential - Remove - Differential lock for removal - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Differential - Remove - Differential lock fork removal - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Housing - Drawing - Axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hub - Assemble - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Hub - Assemble - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Hub - Disassemble - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Hub - Disassemble - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Hub - Exploded view - Wheel hub and final reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hub - Inspect - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Hub - Inspect - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
REAR AXLE - General specification - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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REAR AXLE - General specification - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR AXLE - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REAR AXLE - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REAR AXLE - Special tools - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR AXLE - Special tools - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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STEERING Hydraulic - 20.C
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
STEERING Hydraulic
General specification - Steering relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General specification - Rotor and stator clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools - Pressure fitting kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Special tools - Rotor and stator clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Steering cylinder
FUNCTIONAL DATA
STEERING Hydraulic
Drawing - Steering control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drawing - Optional comfort steering control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Control valve
Exploded view - 580N, 580SN, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exploded view - Comfort steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exploded view - Steering control valve - Standard Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sectional view Standard Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sectional view Optional Comfort Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering cylinder
Exploded view - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Steering column
Exploded view - Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Exploded view - Cab models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Exploded view - Canopy models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE
Control valve
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Relief valve
Pressure test - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pressure test - 580SN, 580SN WT and 590SN machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Steering cylinder
Remove - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Install - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Remove - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Install - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Check - Piston packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassemble - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Inspect - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assemble - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Disassemble - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Inspect - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assemble - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Steering column
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
STEERING Hydraulic - General specification

Special torques
Nut for the steering wheel 41 - 54 N·m (30.2 - 39.8 lb ft)
Steering cylinder two wheel drive axle 335 N·m (247.1 lb ft)
Steering cylinder four wheel drive axle 120 N·m (88.5 lb ft)
Front drive shaft 33 - 39 N·m (24.3 - 28.8 lb ft)
Front drive shaft guard 50 - 90 N·m (36.9 - 66.4 lb ft)
Nut that fastens the tie rod end to the pivot arm
Four wheel drive axle (580N, 580SN, 165 N·m (121.7 lb ft)
580SN-WT)
Four wheel drive axle (590SN) 220 N·m (162.3 lb ft)
Two wheel drive axle all models 165 N·m (121.7 lb ft)
Wheel nuts 4 WD axles 122 N·m (90.0 lb ft)+ 3 - 10 N·m (2.2 - 7.4 lb ft) Then turn nut
an additional 90 ° +/- 5 °
Wheel bolts 2 WD axles 251 N·m (185.1 lb ft)
STEERING Hydraulic - General specification - Steering relief valve

SPECIFICATIONS
Location of steering relief valve In steering control valve
Pressure setting 172 +0/-10 bar (2500 +0/-150 psi)
STEERING Hydraulic - General specification - Rotor and stator

clearance
Rotor and stator clearance 0.13 mm (0.005 in)
Special torques
Allen Head Plug 11 N·m (97.4 lb in)
Ferry Head Screws 25 - 31 N·m (221.3 - 274.4 lb in)
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STEERING Hydraulic - Special tools

The tool shown is needed to remove the steering wheel.
Make the tool in your shop.
Make from 6 mm (0.24 in) Cold Rolled Steel
RCPH10TLB077GAL 1
1. 50.4 mm (2 in) 5. 19 mm (0.750 in)

2. 25.4 mm (1 in) 6. Two holes 5.5 mm
(0.217 in)
3. 15.9 mm (0.625 in) 7. Use No.4 drill for 1/4-24
4. 9.5 mm (0.375 in) 8. Threads metric thread
optional two 10-32 x 1 inch
screws required
CAS10486 Puller This tool is used to remove the ball joint
for the steering cylinder from the axle.
RCPH10TLB300ABL 2
380100091 for all two wheel drive and the 580N, 580SN
four wheel drive front axle. 38010092 for the 580SN+ and
590SN and 590SN+ four wheel drive front axle. This tool
is used to remove and install the tie rod.
RCPH10TLB235ABL 3
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STEERING Hydraulic - Special tools - Pressure fitting kit

Special Tool
RCPH10TLB234ABL 1
STEERING Hydraulic - Special tools - Rotor and stator clearance

CAS-1239 Centering spring tool
RCPH10TLB233ABL 1
380002000 and 380002001
RCPH10TLB284ABL 2
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Steering cylinder - General specification

Four wheel drive steering cylinder mounting screws 120 N·m (89 lb ft)
Two wheel drive steering cylinder mounting screws 335 N·m (247 lb ft)
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STEERING Hydraulic - Drawing - Steering control valve

Illustrations
RCPH10TLB001HAM 1
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
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STEERING Hydraulic - Drawing - Optional comfort steering control

valve
RCPH10TLB070GAL 1
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
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Control valve - Exploded view - 580N, 580SN, 590SN only

Steering control valve hydraulic installation 580N, 580SN AND 590SN
RCPH10TLB071GAL 1
Steering Control Valve Hydraulic Installation 580N, 580SN and 590SN
1. Hydraulic filter 4. Return hose 7. Left hose for steering cylinder

2. Hydraulic pump 5. Pressure hose 8. Load sense hose
3. Steering pump 6. Right hose for steering cylinder
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Control valve - Exploded view - 580SN-WT only

Steering control valve hydraulic installation 580 SN-WT only
RCPH10TLB072GAL 1
1. Hydraulic filter 4. Return hose 7. Left hose for steering cylinder

2. Loader valve 5. Pressure hose 8. Load sense hose
3. Steering pump 6. Right hose for steering cylinder
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Control valve - Exploded view - Comfort steering valve
RCPH10TLB073GAL 1
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
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Control valve - Exploded view - Steering control valve - Standard

Steering
RCPH10TLB076GAL 1
1. Cap Screws 7. O-ring 13. Sleeve 19. Needle thrust bearing

2. End plate 8. Gerotor 14. Pin 20. Bearing race
3. Spring 9. O-ring 15. Spring 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. Bearing race 24. Dust seal
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Control valve - Sectional view Standard Steering Control Valve
RCPH10TLB001HAM 1
1. Inlet 4. Check Valve 7. Gerotor

2. Outlet 5. Spool and Sleeve Assembly 8. Steering Relief Valve
3. Load Sense 6. Drive Link 9. Anti-cavitation check valve
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Control valve - Sectional view Optional Comfort Steering Control

Valve
RCPH10TLB070GAL 1
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
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Steering cylinder - Exploded view - Two wheel drive steering

cylinder
1. Left end cap
2. Seals
3. Piston shaft
4. O-rings
5. Tube
6. O-rings
7. Right end cap
8. Piston
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RCPH10TLB068GAL 1
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Steering column - Exploded view - Front console

1. Cover
2. O-Ring
3. Nut
4. Steering wheel
5. Bolt
6. Upper steering column cover
7. Turn signal indicator connector
8. Lower steering wheel column cover
9. Turn signal/driving light switch
10. Transmission shift lever connector
11. Power shift controller wire harness
12. Screw
13. Transmission shift lever
14. Rocker switches
15. Front console cover
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RCPH10TLB128GAL 1
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Steering column - Exploded view - Cab models
RCPH10TLB075GAL 1
Cab Models
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
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Steering column - Exploded view - Canopy models
RCPH10TLB074GAL 1
Canopy Models
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
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Control valve - Remove
NOTE: Put identification tags on all disconnected hoses.

Close disconnected hoses and fittings with caps and plugs.
parking brake.
2. Raise the loader and lock the support strut to hold
the loader.
3. Open the hood.
4. Tag and disconnect the wires for the air restriction
switch. Cut the tie strap from the wires.
RCPH10TLB025AAL 1
5. Loosen the clamp on the air cleaner hose. Discon-

nect the air cleaner hose from the turbo. Put a shop
cloth in the turbo opening or the intake opening.
RCPH10TLB024AAL 2
6. Remove the bolts and flat washers that fasten the

fixed hood to the uprights. Use acceptable lifting
equipment and remove the fixed hood and air cleaner
as an assembly.
RCPH10TLB023AAL 3
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7. Push the wires for the air restriction switch through

the hole in the curtain. Remove the bolts and the
engine curtain from the engine compartment.
RCPH10TLB240ABL 4
8. Tag and disconnect the hoses from the fittings in the

steering control valve.
NOTE: Refer to illustration this page for the following steps.
RCPH10TLB289ABL 5
9. If your machine has a cab go to step 12. If the ma-

chine has a canopy go to step 10.
10. Have another person hold the steering control valve
in position. Remove the bolts (1) and washers (2)
that fasten the steering control valve (3) to the steer-
ing column.
11. Remove the steering control valve from the canopy.
12. Remove the bolts (4), washers (5), and mount (6)
that fasten the steering control valve (7) to the cab.
13. Remove the steering control valve (7), mount (8),
and spacer (9) from the cab.
RCPH10TLB066GAL 6
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1. Bolt 6. Mount
2. Washer 7. Control Valve
3. Control valve 8. Mount
4. Bolt 9. Spacer
5. Washer
Next operation:
Control valve - Install (D.20.C)
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Control valve - Install

Prior operation:
Control valve - Remove (D.20.C)

in position.
2. If your machine is equipped with a cab go to step 3.
If it is equipped with a canopy go to step 5.
NOTE: Refer to illustration.
3. Put the spacer (9), mount (8), and steering control
valve (7) into position.
4. Install the mounts (6), washers (5), and bolts (4). Go
to step 7.
5. Put the steering control valve (3) into position.
6. Install the washers (2) and bolts (1) that fasten the
steering control valve (3) to the steering column.
7. Connect hoses to the fittings on the steering control
valve, remove the tags.
RCPH10TLB289ABL 1
8. Remove the shop cloth from the turbo opening, start

and run the engine at low idle.
9. Turn the steering wheel all the way to the right and
left several times to remove any air from the steering
system.
10. Stop the engine and check for oil leaks, put a shop
cloth in the turbo opening.
as required.
the hole in the engine curtain. Put the engine curtain
in position on the mounting bracket and install the
bolts that fasten the engine curtain to the mounting
bracket.
RCPH10TLB240ABL 2
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13. Put the fixed hood and air cleaner assembly in posi-
tion on the uprights. Install the bolts and flat washers
that fasten the fixed hood to the uprights.
RCPH10TLB023AAL 3
14. Remove the shop cloth from the turbo opening. Con-
nect the air cleaner hose to the turbo. Tighten the
clamp on the air cleaner hose.
RCPH10TLB024AAL 4
15. Connect the electrical connector for the air restriction

switch. Install a new tie strap.
RCPH10TLB025AAL 5
16. Close the hood.
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Control valve - Disassemble

1. Mark the pump for proper alignment during assem-
bly.
RCPH10TLB241ABL 1
2. Put the steering control valve in the vise so that the

end plate is up.
RCPH10TLB242ABL 2
3. Remove the cap screws and end cap.
RCPH10TLB243ABL 3
4. Remove the O-ring from the stator of the metering

gear set.
RCPH10TLB244ABL 4
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5. Lift the spacer plate from the body.
RCPH10TLB245ABL 5
6. Remove the metering gear from the pump.
RCPH10TLB246ABL 6
7. Remove the O-ring from the spacer plate, remove the

spacer plate. Remove and discard the O-ring from
the body.
RCPH10TLB247ABL 7
8. Find the anti-cavitation valves (1) in the body. Put

identification marks on the body for use during as-
sembly.
RCPH10TLB248ABL 8
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9. Remove the 4 springs, the pins, and the balls from

the ports in the body.
RCPH10TLB249ABL 9
10. Find the manual steering check valve. Remove the

manual steering check valve ball and roll pin.
NOTE: The manual steering check valve is located in the
bolt hole with the thread insert.
RCPH10TLB250ABL 10
11. Pull the sleeve and spool out of the body.

NOTE: The diagram shows the steering control in a hori-
zontal position, disassemble steering control unit in a verti-
cal position, the pin that links the sleeve, spool, and driver
could possibly slip and lock the parts in the housing.
RCPH10TLB251ABL 11
12. Use a punch to push the pin out of the sleeve and
spool.
RCPH10TLB252ABL 12
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13. Remove the drive shaft from the sleeve and spool.
RCPH10TLB253ABL 13
14. Remove the thrust washer, the thrust bearing, and

lower thrust washer.
RCPH10TLB254ABL 14
15. Remove the spring retainer.

NOTE: Hold the spring into the sleeve and spool while re-
moving the ring, they can come out unexpectedly.
RCPH10TLB255ABL 15
16. Remove the springs and centering spacers from the

sleeve and spool.
RCPH10TLB256ABL 16
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17. Pull the spool straight out of the sleeve.
RCPH10TLB257ABL 17
18. There are four centering springs and three spacers.
RCPH10TLB258ABL 18
19. Remove the seal from the gland.
RCPH10TLB259ABL 19
20. Remove the spool seal.
RCPH10TLB260ABL 20
Next operation:
Control valve - Inspect (D.20.C)
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Control valve - Inspect

Prior operation:
Control valve - Disassemble (D.20.C)
Use cleaning solvent to clean all parts. Put the parts on

paper towels until the parts are dry. Do not use cloths to
wipe the parts dry.
Check all machined surfaces for wear or damage. If 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. Then check to see if the rough places have
been removed. Use this method until all rough places are
gone. Make sure that you keep the part flat on the emery
cloth as you move the part across the emery cloth. Use
cleaning solvent to remove any grit from the parts.
RCPH10TLB064GAL 1
1. If the spool (1), sleeve (2), or bore in the body (3)is

damaged or worn, replace the steering control valve.
The spool (1), sleeve (2), and body (3) are not avail-
able separately.
2. Inspect the thrust washers (1) and the thrust bearing
(2) for damage or wear. Replace as required.
RCPH10TLB065GAL 2
3. Inspect the springs, the pins, and the balls of the

anticavitation valve for damage or wear. Use new
parts as required.
4. Inspect the roll pin and ball of the manual steering
valve for damage or wear. Use new parts as re-
quired.
84516378 05/07/2011
D.20.C / 32

tween the rotor and the stator. If the clearance is
more than 0.13 mm (0.005 in), a new metering gear
set must be used.
RCPH10TLB283ABL 3
Next operation:
Control valve - Assemble (D.20.C)
84516378 05/07/2011
D.20.C / 33
Control valve - Assemble

Prior operation:
Control valve - Inspect (D.20.C)
1. Install the sleeve into the body.
RCPH10TLB261ABL 1
2. Put the “O” ring of the two piece seal on the recessed
tip of the plunger.
RCPH10TLB262ABL 2
3. Place the seal cup onto the recessed tip of the

plunger.
RCPH10TLB263ABL 3
4. Press the seal cup into the “O” ring.
RCPH10TLB264ABL 4
84516378 05/07/2011
D.20.C / 34
5. Lubricate the seal with hydraulic oil.
RCPH10TLB265ABL 5
6. Install the plunger into the bore of the sleeve.
RCPH10TLB266ABL 6
7. Push the plunger into the sleeve until it bottoms out,

remove the special tools.
RCPH10TLB267ABL 7
8. Inspect the seal to make sure that it is seated prop-

erly in the body.
RCPH10TLB268ABL 8
NOTE: Seal and “O” ring must both be within shaft seal counterbore of the housing.
84516378 05/07/2011
D.20.C / 35
9. 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.
RCPH10TLB269ABL 9
10. Use clean hydraulic oil to lubricate the inside of the

sleeve.
11. Use clean hydraulic oil to lubricate the outside of the
spool.
12. 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.
RCPH10TLB071ABL 10
13. There are four centering springs and three spacers.
RCPH10TLB258ABL 11
14. Insert the spring spacers and springs one at a time

into the spool and sleeve.
RCPH10TLB270ABL 12
84516378 05/07/2011
D.20.C / 36
15. Place the spring retainer onto the sleeve.
RCPH10TLB271ABL 13
16. Work the retaining ring into place over the springs.
RCPH10TLB272ABL 14
17. Install the inner thrust washer, the thrust bearing, and
the outer thrust washer on the spool.
RCPH10TLB273ABL 15
18. Put the drive shaft into the spool.
RCPH10TLB274ABL 16
84516378 05/07/2011
D.20.C / 37
19. Align the holes for the sleeve, spool, and drive shaft.
Press the pin into the sleeve until it is flush with the
sleeve.
RCPH10TLB275ABL 17
20. Find the port with the screw insert, install the ball and
roll pin for the manual steering check valve.
RCPH10TLB276ABL 18
21. Install the anti cavitation balls, pins, and springs into
the holes that were marked during disassembly.
RCPH10TLB277ABL 19
22. Assembly the steering control unit in a vertical po-

sition. The pin can move out of the sleeve and the
spool. If the pin moves out of the sleeve and the
spool, the pin can keep the sleeve and the spool from
being pushed into the body.
RCPH10TLB278ABL 20
NOTE: The diagram shows 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.
84516378 05/07/2011
D.20.C / 38
23. 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.
RCPH10TLB279ABL 21
24. Align the timing mark on the drive shaft with a valley
of the gerotor.
RCPH10TLB280ABL 22
25. Align the marks made during disassembly, install the

gerotor spacer.
RCPH10TLB281ABL 23
26. 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.
RCPH10TLB282ABL 24
27. Torque the cap screws to a torque of 11 - 17 N·m

(100 - 150 lb in) in the sequence shown. Then final
torque the cap screws to a final torque of 25 - 31 N·m
(225 - 275 lb in) in the sequence shown.
84516378 05/07/2011
D.20.C / 39
RCPH10TLB003BAM 25
28. Assembled unit should rotate smoothly.
84516378 05/07/2011
D.20.C / 40
Relief valve - Pressure test - 580N only

Checking the pressure setting of the relief valve 580N
hoe in the transport position and lower the loader
the oil, do the following steps:
A. With the engine running at full throttle,
hold the loader control lever in the rollback
position for 15 s.
B. Put the loader control lever in the neutral
position for 15 s.
3. See the illustration below. Use a pressure gauge with
a capacity of at least 276 bar (4000.0 psi). Connect
the pressure gauge to the quick is connect fitting at
the test port. The quick disconnect fitting is located
on the pump at the rear of the transmission.
4. With the engine running at full throttle, turn and hold
the steering wheel all the way to the right or to the left
and read the gauge. Make a record of the reading.
5. Decrease the engine speed to low idle for two min-
utes and stop the engine.
6. Compare the reading with the specification STEER-
ING Hydraulic - General specification (D.20.C) If
the reading is not correct, repair or replace the steer-
ing control valve.
84516378 05/07/2011
D.20.C / 41
RCPH10TLB014FAM 1
(1) To inlet of loader control valve (3) Hydraulic pump 580N

(2) Test port 1
84516378 05/07/2011
D.20.C / 42
Relief valve - Pressure test - 580SN, 580SN WT and 590SN machines

only
Checking the pressure setting of the relief valve 580SN, 580SN WT and 590SN machines
hoe in the transport position and lower the loader
the oil, do the following steps:
A. With the engine running at full throttle,
hold the loader control lever in the rollback
position for 15 s.
B. Put the loader control lever in the neutral
position for 15 s.
3. See illustration. Use a pressure gauge with a ca-
pacity of at least 276 bar (4000.0 psi). Connect the
pressure gauge to the quick disconnect fitting that
was installed at “D” port.
4. With the engine running at full throttle, turn and hold
the steering wheel all the way to the right or to the left
and read the gauge. Make a record of the reading.
5. Decrease the engine speed to low idle for two min-
utes and stop the engine.
6. Compare the reading with the specification STEER-
ING Hydraulic - General specification (D.20.C). If
the reading is not correct, repair or replace the steer-
ing control valve.
NOTE: A Tee connection will have to be installed at the “D” port on the loader valve for steering pressure tests.
RCPH10TLB285ABL 1
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Steering cylinder - Remove - Two wheel drive machines

1. Clean the hose connection at the steering cylinder.
2. Put and identification tag on one of the hoses.
3. Disconnect the hoses from the steering cylinder and
cap the fittings and plug the hoses.
4. Loosen and remove the tie rod end.
RCPH10TLB238ABL 1
5. Remove the mounting bolts for the cylinder, remove

the steering cylinder from the axle.
RCPH10TLB237ABL 2
Next operation:
Steering cylinder - Install (D.20.C)
84516378 05/07/2011
D.20.C / 44
Steering cylinder - Install - Two wheel drive machines

Prior operation:
Steering cylinder - Remove (D.20.C)
1. Install the steering cylinder on the axle and install the

bolts.
2. Torque the bolts to 335 N·m (247 lb ft).
3. Install the tie rod ends and torque to 165 N·m (122
lb ft).
system.
7. Stop the engine and check for oil leaks.
8. Check the level of the oil in the reservoir and add oil
as required.
9. Grease the pins for the steering links.
10. Check and adjust the toe-in according to the instruc-
tions in FRONT AXLE - Assemble (D.10.A).
84516378 05/07/2011
D.20.C / 45
Steering cylinder - Remove - Four wheel drive machines
NOTE: The following photographs show the steering cylin-

der 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.
1. Clean the hose connections and the steering cylin-
der.
2. Fasten an identification tag to one of the hoses to the
steering cylinder.
3. Disconnect the hoses from the steering cylinder. In-
stall a plug is each hose and a cap on each fitting.
NOTE: Some of the photo may look different than your
machine. The procedure is the same.
4. Loosen the nut several turns. Do not remove the nut
at this time.
RCPH10TLB301ABL 1
5. Install the CAS10486 puller and tighten the screw to

loosen the ball joint.
6. Remove the nut and remove the ball joint from the
arm.
RCPH10TLB302ABL 2
7. Repeat steps 4, 5 and 6 for the other end of the axle.
84516378 05/07/2011
D.20.C / 46
8. 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 and loosen the
tie rod.
RCPH10TLB303ABL 3
9. Remove the tie rod and ball joint assembly from the
piston rod.
10. Loosen and remove the bolts that fasten the steering
cylinder to the axle.
RCPH10TLB286ABL 4
11. A hose fitting will be installed in your steering cylin-

der. Remove the hose fitting.
RCPH10TLB287ABL 5
12. Hit the steering cylinder with a soft hammer to drive

the steering cylinder out of the axle.
RCPH10TLB288ABL 6
13. Remove the steering cylinder from the axle.
84516378 05/07/2011
D.20.C / 47
Next operation:
Steering cylinder - Install (D.20.C)
84516378 05/07/2011
D.20.C / 48
Steering cylinder - Install - Four wheel drive machines

Prior operation:
Steering cylinder - Remove (D.20.C)
1. Install the steering cylinder in the axle.

2. Install the bolts that fasten the steering cylinder to the
axle. Tighten the bolts to 120 N·m (89 lb ft).
RCPH10TLB286ABL 1
3. Start the ball joint assembly and tie rod onto the pis-
ton rod.
4. 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 N·m (221 lb ft).
RCPH10TLB304ABL 2
5. Install the ball joint in the arm.
RCPH10TLB302ABL 3
84516378 05/07/2011
D.20.C / 49
6. Install the nut on the ball joint and tighten the nut to
165 N·m (122 lb ft) for the 580N, 580SN and 580SN
+. Tighten to 220 N·m (162 lb ft) for the 590SN.
RCPH10TLB305ABL 4
7. Repeat steps 5, 6, and 7 for the other end of the axle.

8. Connect the hoses to the fittings in the steering cylin-
der.
system.
11. Stop the engine and check for oil leaks.
12. Check the level of the oil in the reservoir and add oil
as required.
84516378 05/07/2011
D.20.C / 50
Steering cylinder - Check - Piston packing

Checking piston packing for the steering cylinder
1. Apply the parking brake and lower the loader bucket
to the floor.
stop the engine.
3. Disconnect the hose at the left side of the steering
cylinder.
4. Install a plug in the hose.
5. Start the engine and run the engine at full throttle.
continue to turn the steering wheel to the right while
another person checks for leakage at the open fitting.
7. If there is constant leakage, the piston packing is
damaged and must be repaired.
84516378 05/07/2011
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Steering cylinder - Disassemble - Two wheel drive steering cylinder

1. Clean the outside of the steering cylinder.
2. Fasten the steering cylinder in a vise or other hold-
ing equipment. Be careful to prevent damage to the
tube. (5)
3. Remove the right (7) and left (1) end caps.
4. Pull the piston rod (3) out of the tube (5).
5. Remove and discard all O-rings and seals.
RCPH10TLB068GAL 1
Next operation:
Steering cylinder - Inspect (D.20.C)
84516378 05/07/2011
D.20.C / 52
Steering cylinder - Inspect - Two wheel drive steering cylinder

Prior operation:
Steering cylinder - Disassemble (D.20.C)

age. If there is damage to the tube (5), a new steering
cylinder must be used.
3. Verify that the piston rod (3) is straight. If the piston
rod (3) is not straight, a new steering cylinder must
be used.
4. Inspect the piston (8) for damage and wear. If the
piston (8) is damaged, or worn, a new steering cylin-
der must be used.
5. 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 rotary motion.
6. 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.
7. Inspect all components for rust. Clean and remove
rust as necessary.
RCPH10TLB068GAL 1
Next operation:
Steering cylinder - Assemble (D.20.C)
84516378 05/07/2011
D.20.C / 53
Steering cylinder - Assemble - Two wheel drive steering cylinder

Prior operation:
1. Install a new seals and O-rings.

2. Fasten the tube (5) in the vise or other holding equip-
ment. Be careful to prevent damage to the tube (5).
3. Lubricated the bore of the tube (5) with clean oil.
4. Lubricate the O-rings (6) on both end caps (1) and
(7) and the bore of both end caps (1) and (7) with
clean oil.
5. Lubricate the piston (3) with clean oil.
6. Push the piston rod assembly (3) straight into the
tube (5).
7. Carefully start the end caps (1) and (7) onto the pis-
ton (3).
8. Verify the ports in both glands (8) are installed cor-
rectly and drive the end caps (1) and (7) into the tube
(5).
RCPH10TLB068GAL 1
84516378 05/07/2011
D.20.C / 54
Steering cylinder - Disassemble - Four wheel drive steering cylinder

1. Remove the tie rod ball joint assembly.
2. Fasten the tube in a vise or other holding equipment.
Do not damage the tube.
RCPH10TLB290ABL 1
3. Use a soft faced hammer and separate the gland

from the tube.
RCPH10TLB291ABL 2
4. Remove the gland from the piston rod assembly.
RCPH10TLB292ABL 3
5. Use a soft faced hammer and drive the piston against

the gland, remove the gland from the tube.
RCPH10TLB293ABL 4
84516378 05/07/2011
D.20.C / 55
6. Pull the piston rod assembly straight out of the tube

to prevent damage to the tube.
RCPH10TLB294ABL 5
7. Remove the gland from the piston rod.
RCPH10TLB295ABL 6
8. Remove the wiper and the seal from the gland. Re-
move the seal ring from the gland. Repeat the pro-
cedure for the other gland.
RCPH10TLB296ABL 7
9. Remove the seals from the piston rod assembly.
RCPH10TLB297ABL 8
Next operation:
84516378 05/07/2011
D.20.C / 56
Steering cylinder - Inspect - Four wheel drive steering cylinder

Prior operation:
Steering cylinder - Disassemble (D.20.C)
1. Discard the parts that were removed from the glands

and piston rod assembly.
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.
Next operation:
Steering cylinder - Assemble (D.20.C)
84516378 05/07/2011
D.20.C / 57
Steering cylinder - Assemble - Four wheel drive steering cylinder

1. Install a new seal in the grooves of the piston rod
assembly.
RCPH10TLB299ABL 1
2. Install a new seal in the gland. The lip of the seal

must be toward the inside of the gland.
RCPH10TLB297ABL 2
3. Install a new wiper in the gland. The lip of the wiper

must be toward the outside of the gland.
RCPH10TLB298ABL 3
4. Install a new seal ring in the groove on the gland.

5. Lubricate the piston seals with clean oil.
6. Fasten the tube in a vise with soft jaws. Start the
piston rod assembly into the tube, be careful not to
damage the seals.
RCPH10TLB294ABL 4
84516378 05/07/2011
D.20.C / 58
7. Push the piston rod assembly all the way into the
tube, use a soft faced hammer and drive the gland
into the tube.
8. Lubricate the wiper, seal, and seal ring on the gland
with clean oil.
9. 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.
RCPH10TLB292ABL 5
84516378 05/07/2011
D.20.C / 59
Steering column - Remove

parking brake.
2. Lower the bucket to the floor.
NOTE: Refer to Steering column - Exploded view
(D.20.C) for the following steps.
3. Remove the cover (1) from the steering wheel (4).
The cover is held by the fit of an O-ring (2).
4. Loosen and remove the nut (3) that holds the steering
wheel (4) in place. Remove the steering wheel (4).
5. Remove the screws (5) that fasten the upper and
lower steering column cover (6) and (8) in place.
6. Remove the upper steering column cover (6). Dis-
connect the wiring connector from the turn signal in-
dicator (7).
7. Remove the lower steering column cover (8). Dis-
connect the wiring connector from the turn signal/
driving light switch (9).
8. Disconnect the connector (10) from the transmission
shift lever (13).
9. Loosen and remove the screws (12) that fasten the
transmission shift lever (13) to the steering column.
Remove the transmission shift lever (13).
10. Disconnect the connectors from the rocker switches
(14) in the front console (15).
11. Remove the bolts that fasten the instrument console
cover (15) to the cab.
12. If equipped, remove the filler cap from the windshield
washer reservoir. Remove the front console (15).
If it is equipped with a canopy go to step 16
(D.20.C) and Steering column - Exploded view (D.20.C)
for steps 14 and 15.
14. Remove the nuts (1) from the steering column (5).
15. Remove the nuts (2), washers (3), and U-bolt (4)
from the steering column (5). Go to step 18.
(D.20.C) for steps 16
(3) in place and remove the bolts (1) and washers (2)
that fasten the steering column (8) to the canopy and
the steering control valve (3).
17. Remove the nuts (4), washers (5), U-bolt (6), and
spacer (7) from the steering column (8).
18. Remove the steering column from the machine.
Next operation:
Steering column - Install (D.20.C)
84516378 05/07/2011
D.20.C / 60
Steering column - Install

Prior operation:
Steering column - Remove (D.20.C)

If it is equipped with a canopy go to step 4.
(D.20.C) for steps 2 and 3.
2. Grease the splines of the steering column and control
valve with high temperature grease. Put the steering
column (5) in place and install the nuts (1). Tighten
the nuts (1) to a torque of 46 - 50 N·m (34 - 37 lb ft).
3. Install the U-bolt (4), washers (3), and nuts (2). Go
to step 7.
(D.20.C) for steps 4 through 6.
4. Grease the splines of the steering column and control
valve with high temperature grease. Put the steering
column in place on the machine.
(3) in place. Install the washers (2) and bolts (1) that
fasten the steering column (8) to the canopy and the
steering control valve (3). Tighten the bolts (1) to a
torque of 46 - 50 N·m (34 - 37 lb ft).
6. Install the spacer (7), U-bolt (6), washers (5), and
nuts (4).
(D.20.C) for the following steps.
7. Put the front console cover (15) in position. If
equipped, install the cap on the windshield washer
reservoir.
8. Install the bolts that fasten the front console cover
(15) to the cab.
9. Connect the connectors to the rocker switches (14)
in the front console (15).
10. Put the transmission shift lever (13) in place. In-
stall the screws (12) that fasten the transmission shift
lever (13) to the steering column.
11. Connect the connector (10) to the transmission shift
lever.
12. Connect the wiring connector (9) to the turn signal/
driving light switch. Put the lower steering column
cover (8) in place.
13. Connect the wiring connector to the turn signal indi-
cator (7). Install the upper steering column cover (6).
14. Install the screws (5) that fasten the upper and lower
steering column cover (6) and (8) in place.
15. Put the steering wheel (4) in place. Install the nut (3)
that holds the steering wheel in place. Tighten the
nut to a torque of 41 - 54 N·m (30 - 40 lb ft)
84516378 05/07/2011
D.20.C / 61
16. Install the cover (1) on the steering wheel (4). The
cover is held by the fit of an O-ring (2).
17. With the engine off, turn the steering wheel about 5
° in either direction. Effort will be light when work-
ing against the springs, but stiff when 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.
84516378 05/07/2011
D.20.C / 62
Index

Control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control valve - Exploded view - 580N, 580SN, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control valve - Exploded view - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control valve - Exploded view - Comfort steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control valve - Exploded view - Steering control valve - Standard Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Control valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control valve - Sectional view Optional Comfort Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control valve - Sectional view Standard Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Relief valve - Pressure test - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Relief valve - Pressure test - 580SN, 580SN WT and 590SN machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
STEERING Hydraulic - Drawing - Optional comfort steering control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING Hydraulic - Drawing - Steering control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STEERING Hydraulic - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING Hydraulic - General specification - Rotor and stator clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING Hydraulic - General specification - Steering relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING Hydraulic - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING Hydraulic - Special tools - Pressure fitting kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING Hydraulic - Special tools - Rotor and stator clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Steering column - Exploded view - Cab models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Steering column - Exploded view - Canopy models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Steering column - Exploded view - Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Steering column - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Steering cylinder - Assemble - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Steering cylinder - Assemble - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Steering cylinder - Check - Piston packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Steering cylinder - Disassemble - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Steering cylinder - Disassemble - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Steering cylinder - Exploded view - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Steering cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering cylinder - Inspect - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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Steering cylinder - Inspect - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Steering cylinder - Install - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Steering cylinder - Install - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Steering cylinder - Remove - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Steering cylinder - Remove - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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SERVICE BRAKE Hydraulic - 30.C
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
SERVICE BRAKE Hydraulic

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Master cylinder
Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brake
Exploded view - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE

Adjust - Brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Master cylinder
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjust - Brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Brake
Remove - Removing air from the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
84516378 05/07/2011
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
SERVICE BRAKE Hydraulic - General specification

Rear Axle
580N, 580SN
MAT3510
580SN-WT, 590SN
Type of Fluid. Wet Brake/Transmission Lubricant - SAE 80W140
MAT3510
Axle Special Torques

Wheel Nuts Special Torques

Initial torque 136 N·m (100.3 lb ft)
2nd torque 271 N·m (199.9 lb ft)
NOTE: Turn nuts an additional 30 ° after second torque.
Transmission Special Torques

Park brake housing 50 N·m (36.9 lb ft)
Output flange bolt 139 N·m (102.5 lb ft)
Park brake solenoid 20 N·m (14.8 lb ft)
SERVICE BRAKE Hydraulic - Special tools
RCPH10TLB378AAL 1
Self adjusting brake tools 380002435
NOTE: Part of rear axle service tools.
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RCPH10TLB043ABL 2
CAS-2379 input shaft holder and spring compressor
NOTE: Part of transmission service tools.
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SERVICE BRAKE Hydraulic - Exploded view - Brake pedal
RCPH10TLB033GAL 1
1. Bolt 7. Bolt 13. Height adjusting bolt

2. Pivot pin 8. 60 mm (2.36 in) 14. Spring
3. Spacer 9. 27 mm (1.06 in) 15. Brake 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
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Master cylinder - Exploded view - Brake pedal
RCPH10TLB033GAL 1
1. Bolt 7. Bolt 13. Height adjusting nut

2. Pivot pin 8. 60 mm (2.36 in) 14. Spring
3. Spacer 9. 27 mm (1.06 in) 15. Brake 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
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Brake - Exploded view - Brakes

Rear brakes
1. Lock ring
2. Self adjusting kit
3. Brake piston
4. O-ring
5. O-ring
6. Brake cylinder
7. O-ring
8. Pin
9. Hub
10. Axle housing
11. Pin
12. Half shaft
13. Brake plate
14. Brake disk
15. Brake plate
16. Brake disk
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RCPH10TLB8GAL 1
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SERVICE BRAKE Hydraulic - Adjust - Brake pedal height adjustment

1. Using the adjustment bolts, adjust the LH and RH
pedals to 90 - 92 mm (3.54 - 3.62 in).
2. Adjust the master cylinder push rods in order to
achieve 1 - 3 mm (0.039 - 0.118 in) of free play
measured at the pedal pad.
RCPH10TLB591AAL 1
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Master cylinder - Remove

2. Open the hood.
striction switch.
nect the hose from the turbo. Put a shop cloth in the
turbo opening.
RCPH10TLB024AAL 1
5. Remove the bolts and flat washers that fasten the

fixed hood to the uprights. Remove the fixed hood
and air cleaner as an assembly.
RCPH10TLB023AAL 2

the hole in the curtain. Remove the bolts, flat wash-
ers, and insulator curtain that covers the master
cylinders.
RCPH10TLB240ABL 3
7. Remove any dirt from the master cylinder and the

area around the master cylinder.
84516378 05/07/2011
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8. Disconnect the supply and return hoses from the

master cylinder. Put caps on the fittings and plugs
in the hoses.
RCPH10TLB593AAL-2 4
NOTE: Supply hose and fitting are located behind the return elbow.
9. Disconnect the tubes from the master cylinder. Put
caps on the fittings and plugs in the tubes.
RCPH10TLB593AAL 5
10. Remove the cotter pins and clevis pins. Loosen and
remove the nuts that fasten the master cylinder to the
frame.
RCPH10TLB592AAL 6
11. Remove the master cylinder from the frame.
Next operation:
Master cylinder - Install (D.30.C)
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D.30.C / 12
Master cylinder - Install

Prior operation:
Master cylinder - Remove (D.30.C)
1. Hold the master cylinder in alignment with the holes

in the frame and install the nuts that fasten the master
cylinder to the frame.
2. Connect the tubes to the master cylinder.
RCPH10TLB593AAL 1
3. 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).
RCPH10TLB167ABL 2
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4. Put the clevis on the master cylinder in position on

the brake pedal. Install the clevis pin that fastens the
clevis to the brake pedal. Install the cotter pin in the
clevis pin.
RCPH10TLB592AAL 3
5. Adjust the push rods in order to achieve 1 - 3 mm

(0.039 - 0.118 in)1 to 3 MM (0.039 to 0.118 inches)
of free play measured at the pedal pad.
6. See Brake - Remove (D.30.C) and remove the air
from the brake system.
7. Check for leakage at the master cylinder.
the hole in the curtain. Put the insulator curtain into
position and install the washers and bolts.
RCPH10TLB240ABL 4
9. Put the fixed hood and air cleaner assembly in posi-

tion on the uprights. Install the bolts and flat washers
that fasten the fixed hood to the uprights.
RCPH10TLB023AAL 5
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D.30.C / 14
10. Remove the shop cloth from the turbo. Connect the
air cleaner hose to the turbo. Tighten the clamp on
the air cleaner hose.
RCPH10TLB024AAL 6
11. Connect the electrical connector for the air restriction

switch.
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Master cylinder - Adjust - Brake pedal height adjustment

1. Using the adjustment bolts, adjust the LH and RH
pedals to 90 - 92 mm (3.54 - 3.62 in).
2. Adjust the master cylinder push rods in order to
achieve 1 - 3 mm (0.039 - 0.118 in) of free play
measured at the pedal pad.
RCPH10TLB591AAL 1
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Brake - Remove - Removing air from the brake system

NOTE: Two people are required to perform this procedure, one to actuate the master cylinder and the other to open
and close the brake bleeder valve on the rear axle.
1. Raise the machine up with the stabilizers at full
height. Support back end of machine with appropri-
ate stands.
2. Remove rear wheels.
3. Attach clear brake bleeding hoses to the LH and RH
bleeding ports.
4. Loosen LH and RH brake bleeders.
5. Start engine and leave at low idle. Ensure that the
transmission oil level is correct.
6. Fully stroke both pedals together 15 times.
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.
8. Repeat for LH side.
9. Verify that the park brake is not engaged. Ensure
that the service brakes will stop both rear wheels with
the tractor in 2nd gear at 1500 RPM with the brake
pedal pads 30 mm (1.181 in) above the top of the
floor plate 37 mm (1.457 in) above the top of the floor
plate for units that will be equipped with a floormat).
If the service brakes do not stop the wheels as noted
above, open each bleeder and repeat steps 7 and 8
until columns of oil without air bubbles are observed
in the LH and RH bleeder hoses. Verify that the ser-
vice brakes hold the tractor in 2nd gear at 1500 RPM
as noted above.
10. Shut engine off.
11. Remove brake bleeding hoses.
12. Replace covers on LH and RH brake bleeders.
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Brake - Disassemble
1. Park the machine on a level surface, apply the park-
ing brake.
2. Raise the rear tires off of the ground, support the
machine with suitable stands.
3. Remove the tires from the machine.
4. Remove the mounting bolts for the brake hose guard,
disconnect the brake hose. Plug the hose and cap
the fitting.
RCPH10TLB066AAL 1

of the axle.
RCPH10TLB384AAL 2

RCPH10TLB385AAL 3
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D.30.C / 18

and drain the oil.
RCPH10TLB376AAL 4

NOTE: Large amounts of LOCTITE® was used during as-
sembly, remove cap screws slowly. If screw binds, turn
back in and then back out.
RCPH10TLB382AAL 5
9. Insert 3 long dowel rods, (tool number), for in vehicle

service or two short dowel rods, (tool number), for
bench service.
RCPH10TLB393AAL 6
RCPH10TLB394AAL 7
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RCPH10TLB395AAL 8
RCPH10TLB396AAL 9
RCPH10TLB397AAL 10

work bench.
RCPH10TLB398AAL 11
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D.30.C / 20
brake disks.
NOTE: Keep brake surfaces in same relationship to each
other if being reused.
RCPH10TLB399AAL 12
RCPH10TLB311AAL 13
RCPH10TLB375AAL 14

RCPH10TLB312AAL 15
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D.30.C / 21

with kit.
RCPH10TLB401AAL 16
RCPH10TLB314AAL 17

NOTE: Once removed the self adjusters spring clips must
be replace with genuine parts, DO NOT use after market
parts.
RCPH10TLB315AAL 18
22. Place the self adjuster on (tool number).

NOTE: Place the tapered end of the self adjuster into (tool
number).
RCPH10TLB404AAL 19
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23. Place the driver (tool number) onto self adjuster and
drive the spring clips from the adjuster.
RCPH10TLB405AAL 20
RCPH10TLB406AAL 21
25. Use an acceptable flat bars and pry the brake piston
up from the hub.
RCPH10TLB316AAL 22
RCPH10TLB317AAL 23
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RCPH10TLB421AAL 24
28. The cylinder may remain in the housing, use pry bar
and remove the cylinder.
RCPH10TLB318AAL 25
29. Remove and discard outer brake piston O-ring only

RCPH10TLB415AAL 26
30. Remove and discard inner brake piston O-ring only

RCPH10TLB416AAL 27
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D.30.C / 24
31. Remove and discard brake cylinder O-ring only if ma-

chine has high hours.
RCPH10TLB418AAL 28
32. Remove and discard the hub o-ring.
RCPH10TLB319AAL 29
Next operation:
Brake - Inspect (D.30.C)
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D.30.C / 25
Brake - Inspect
Prior operation:
Brake - Disassemble (D.30.C)

NOTE: Use only genuine parts. DO NOT use after market
O-rings, they will fail.
Next operation:
Brake - Assemble (D.30.C)
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D.30.C / 26
Brake - Assemble
Prior operation:
Brake - Inspect (D.30.C).
1. Install a new O-ring onto the hub.
RCPH10TLB336AAL 1
2. Use hydraulic oil to lubricate the brake cylinder

O-ring.
RCPH10TLB419AAL 2
3. Use hydraulic oil to lubricate the inner O-ring of the

brake piston, press the brake cylinder into the brake
piston.
RCPH10TLB420AAL 3
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D.30.C / 27
4. Use hydraulic oil to lubricate the outer O-ring of the

brake piston.
RCPH10TLB422AAL 4
5. Use hydraulic oil to lubricate the brake cavity of the

hub housing.
RCPH10TLB337AAL 5

NOTE: Use brake pins for guides.
RCPH10TLB417AAL 6
7. Use the three shouldered bolts and washers to pull

the brake piston and cylinder into the hub.
RCPH10TLB339AAL 7
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8. Place the brake adjuster with tapered edge facing up

into depth setting tool, part of tool kit 380002435.
RCPH10TLB407AAL 8

tool kit 380002435.
RCPH10TLB408AAL 9

NOTE: For ease of installation, look at the inside of the
adjuster ring, place tapered end down.
RCPH10TLB409AAL 10
RCPH10TLB410AAL 11
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D.30.C / 29
RCPH10TLB411AAL 12
RCPH10TLB412AAL 13
kit 380002435.
RCPH10TLB413AAL 14
RCPH10TLB414AAL 15
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D.30.C / 30
RCPH10TLB403AAL 16
17. Make sure the tips of the snap ring face the adjuster
RCPH10TLB490AAL 17
RCPH10TLB314AAL 18
19. Make sure the snap ring fully engages the grove in
the brake piston.
RCPH10TLB338AAL 19
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D.30.C / 31
20. Place spring washers onto shouldered bolt facing as

shown.
RCPH10TLB400AAL 20

RCPH10TLB402AAL 21
22. Torque shouldered bolts to 16 N·m (141.6 lb in).
RCPH10TLB313AAL 22
23. Put the half shaft and brake separator plate pins into
the axle housing.
RCPH10TLB473AAL 23
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D.30.C / 32

place the inner brake separator plate into the axle
housing.
NOTE: The thinner of the two separator plates is used here.
NOTICE: If using new brake disks they must be soaked in
oil for 24 hours prior to installation.
RCPH10TLB474AAL 24
25. Place the inner brake disk onto the half shaft, do not
NOTE: For the 580N there is only one brake disk, for all
SN models there are two brake disks.
RCPH10TLB475AAL 25

RCPH10TLB476AAL 26
27. Place the outer brake disk onto the half shaft, do not
RCPH10TLB477AAL 27
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28. Make sure the slots of the inner and outer brake disks
RCPH10TLB471AAL 28
RCPH10TLB472AAL 29

onto dowel rods.
NOTE: Care needs to be taken that the self adjusters are
not damaged by falling plates or by hitting them on the
housing when bringing hub into position.
RCPH10TLB478AAL 30
31. Use a piece of rope and lift the axle shaft into the
planetary gears while pushing the hub onto the axle.
NOTE: The input shaft for the differential may need to be
turned in order to align the splines on the half shaft sun
gear and the planetary gears.
RCPH10TLB479AAL 31
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D.30.C / 34
32. Use LOCTITE® 270 on thread of the bolts and torque

to 226 N·m (166.7 lb ft).
RCPH10TLB383AAL 32
33. Install and tighten drain plugs and torque to 60 N·m

(44.3 lb ft).
34. Fill the axle with oil, see section 1002 for quantity and
type.
35. Connect the brake hose to the wheel cylinder, install
and tighten the hose guard mounting bolts.
RCPH10TLB066AAL 33
36. Bleed the brake according to instructions in this sec-

tion.
37. Install the wheel, do an initial torque of 136 N·m
(100.3 lb ft) in sequence shown, do a second torque
of 271 N·m (199.9 lb ft) in sequence shown, turn the
lug nuts an additional 30°.
RCPH10TLB306AAL 34
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Brake - Test
Vehicle Brakes
NOTE: Check brake pedal free travel before proceeding.

See Master cylinder - Adjust - Brake pedal height ad-
justment (D.30.C) section. Check the brake system for
leaks or damaged lines. Repair or replace as necessary.
1. Place the backhoe in the travel lock position, use the
stabilizers and raise the rear wheels off of the floor.
2. Lock the brake pedals with the brake pedal locking
pin.
3. Place the range selector in 2nd gear, release the
parking brake and place the FNR selector in F or R
position.
NOTE: Make sure the differential lock is not engaged.
4. Slowly apply the brakes, both tires should stop rotat-
ing at the same time.
5. Move the machine to a clear level area with sufficient
space to accelerate the machine to 5 km/h (3 mph).
6. Once the machine has reached 5 km/h (3 mph),
quickly apply the brakes, both tires should lock and
slide.
7. Accelerate the machine to 5 km/h (3 mph).
8. Slowly apply the brakes, there should be no chat-
tering, growling, or squealing sound from the brake
system.
9. Unlock the brake pedal locking pin.
10. Accelerate the machine to 1 km/h (0.6 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.
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Brake - Check
NOTE: Check brake pedal free travel before proceeding.
1. Place the backhoe n the travel lock position, use the
stabilizers and raise the rear wheels off the floor.
2. Place stands under the machine, lower the machine
onto the stands making sure the wheels remain off
of the floor.
3. Attach a hose to the right bleeder valve, place the
other end in a clear container.
4. Have an assistant press the left brake pedal. Open
the bleeder valve for one minute and take measure-
ment of hydraulic fluid from the system.
5. Attach a hose to the left bleeder valve, place the
other end in a clear container.
6. Have an assistant press the right brake pedal. Open
the bleeder valve for one minute and take a measure-
ment of hydraulic fluid from the system.
NOTE: If measurements are not equal there is a restriction on the side with the lesser amount of fluid. Check lines
from axle to master cylinder and from brake reservoir to master cylinder. If no oil was present, check the feed line to
the reservoir from the oil filter.
7. Stop the engine.
8. Disconnect the brake lines from the axle, cap the
fittings on the axle, attach pressure gauges capable
of reading pressure of 3500 kPa (500 psi) to both
hoses.
pin.
10. Have another person apply the brakes and observe
the pressure readings, the pressure readings should
be the same on both gauges.
NOTE: If pressure readings are not equal, replace the mas-
ter cylinder with the lower reading,.
11. Hold the pedals in place for one minute, the pressure
should stay the same on both gauges.
NOTE: If one of the pressure readings begins to drop replace that master cylinder,.
12. Remove the gauges from the hoses, plug the hoses.
13. Remove one of the caps from the axle and con-
nect a hand pump and gauge to the brake section.
Loosen the air bleeder screw and pump the hand
pump until oil with no air flows from the air bleeder
screw. Tighten the air bleeder screw to 12 Nm (108
pound-inches). Apply 10 342 kPa (1500 psi) pres-
sure to the brake and turn off the valve on the hand
pump.
14. Observe the pressure reading for one minute, the
pressure should not drop.
NOTE: If pressure drops the brake piston seal is leaking and needs to be replaced.
NOTE: Repeat the procedure for the other side of the axle.
15. Connect the hoses to the axle and bleed the brakes.
16. Adjust the parking brake.
84516378 05/07/2011
D.30.C / 37
Index

Brake - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Brake - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Brake - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Brake - Exploded view - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Brake - Remove - Removing air from the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Master cylinder - Adjust - Brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Master cylinder - Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Master cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Master cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE BRAKE Hydraulic - Adjust - Brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE BRAKE Hydraulic - Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE BRAKE Hydraulic - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE BRAKE Hydraulic - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84516378 05/07/2011
D.30.C / 38
PARKING BRAKE Mechanical - 32.B
580N
580SN WT
580SN
590SN
84516378 05/07/2011
D.32.B / 1
Contents
SERVICE
Brake
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
84516378 05/07/2011
D.32.B / 2
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
Brake - Disassemble
NOTE: Some of the following images may not represent

your transmission, the procedures are the same.
1. Park the machine on a level surface, apply the park-
ing brake.
2. Block the wheels to keep the machine from moving.
3. Drain the transmission.
4. Remove the rear drive shaft.
5. Loosen the flange bolt.
RCPH10TLB596AAL 1
6. Remove the flange bolt and washer.
RCPH10TLB868AAL 2
7. Remove the O-ring and flange.

NOTE: The transmission was removed from the machine
for clarity only, it is not necessary to remove the transmis-
sion.
RCPH10TLB869AAL 3
84516378 05/07/2011
D.32.B / 3
8. Loosen brake housing bolts.
RCPH10TLB871AAL 4
9. Remove bolts (A), and alternately loosen bolts (B) to

release the load of bellville washer.
NOTE: Housing is under spring pressure, failure to fol-
low instructions will result in serious injury and damage to
equipment.
RCPH10TLB594AAL 5
10. Remove the brake cover from the transmission.
RCPH10TLB872AAL 6
11. Remove and discard the O-ring.
RCPH10TLB873AAL 7
84516378 05/07/2011
D.32.B / 4
12. Remove back plate.
RCPH10TLB874AAL 8
13. Remove the springs and remove the friction disc.
RCPH10TLB875AAL 9
14. Remove the reaction plates.
RCPH10TLB876AAL 10
15. Remove the hub.
RCPH10TLB877AAL 11
84516378 05/07/2011
D.32.B / 5
RCPH10TLB599AAL 12
17. Remove and discard the O-rings and backup ring

from the retaining plate.
RCPH10TLB600AAL 13
18. Use CAS2379 to compress the bellville washers, re-

move the retaining ring.
RCPH10TLB601AAL 14
19. Remove the piston from the brake housing.
RCPH10TLB602AAL 15
84516378 05/07/2011
D.32.B / 6
20. Remove and discard the O-rings and backup rings

from the piston.
RCPH10TLB603AAL 16
21. Remove the bellville washers from the brake hous-

ing.
RCPH10TLB604AAL 17
22. Remove the seal from the brake housing.
RCPH10TLB605AAL 18
23. Remove and discard the O-ring from the brake hous-
ing.
RCPH10TLB606AAL 19
Next operation:
Brake - Inspect (D.32.B)
84516378 05/07/2011
D.32.B / 7
Brake - Inspect
Prior operation:
Brake - Disassemble (D.32.B)

3. Inspect the bellville washer for cracking and exces-
sive surface wear at contact points. Use new parts
as required.
4. Inspect brake pistons and housing for scaring on slid-
ing surfaces, brake pistons for pitting, scoring, and
excessive surface wear at brake contact point. Use
NOTE: Use only genuine parts. DO NOT use after market
O-rings, they will fail.
Next operation:
Brake - Assemble (D.32.B)
84516378 05/07/2011
D.32.B / 8
Brake - Assemble
Prior operation:
Brake - Inspect (D.32.B)
1. Install a new O-ring on the brake housing.
RCPH10TLB607AAL 1
2. Install the bellville washers as shown.
RCPH10TLB595AAL 2
3. Install the backup ring, install the seal ring.
RCPH10TLB608AAL 3
NOTE: Make sure that the seal ring does not twist during installation.
84516378 05/07/2011
D.32.B / 9
4. Lubricate the piston seals with transmission fluid, in-

stall the piston into the brake housing.
RCPH10TLB602AAL 4
5. Use CAS2379 and compress the bellville washers,

install the retaining ring.
NOTICE: Make sure the retainer is properly seated before
removing spring compressor.
RCPH10TLB601AAL 5
6. Install new O-rings and backup ring in the retaining

plate.
RCPH10TLB600AAL 6
7. Lubricate the O-rings on the retaining plate, install

the plate into the brake housing.
RCPH10TLB599AAL 7
84516378 05/07/2011
D.32.B / 10
RCPH10TLB877AAL 8
RCPH10TLB876AAL 9

RCPH10TLB875AAL 10
RCPH10TLB874AAL 11
84516378 05/07/2011
D.32.B / 11
RCPH10TLB873AAL 12
RCPH10TLB872AAL 13

sion. Torque the bolts to 50 N·m (37 lb ft).
RCPH10TLB871AAL 14
RCPH10TLB869AAL 15
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D.32.B / 12
RCPH10TLB868AAL 16
17. Torque bolt to 139 N·m (103 lb ft).
RCPH10TLB870AAL 17
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D.32.B / 13
Brake - Check
1. Block the wheels of the vehicle to prevent any move-
ment.
2. Remove the floor plates in the cab to gain access to
the brake solenoid.
RCPH10TLB597AAL 1
3. Remove the solenoid mounting bolts, remove the so-

lenoid from the transmission.
RCPH10TLB598AAL 2
4. Turn the solenoid 90° and torque the solenoid to 20

N·m (14.8 lb ft). Pump grease into the grease fitting
until the brake releases.
NOTE: Do not use excess pressure or damage can be done to internal components.
Activate
5. Slowly remove the bolts from the brake solenoid to
release the pressure.
NOTE: Do not unscrew the grease fitting to release the
pressure.
6. Clean excess grease from the solenoid and trans-
mission housing.
7. Install new O-rings on the transmission.
8. Install the solenoid on the transmission, torque the
solenoid to 20 N·m (14.8 lb ft).
9. Activate and release the brake several times to re-
move excess grease from the system.
10. Change the transmission filter, check the oil level in
the transmission, add oil as required.
11. Replace the floor plates in the cab.
84516378 05/07/2011
D.32.B / 14
Brake - Test
Parking brake
pin.
NOTICE: Be prepared to stop the machine in case of sud-
den movement.
3. Place the gear selector in 3rd gear on manual trans-
mission machines. For power shift transmission,
place the auto/manual switch to manual, select 3rd
gear on the FNR lever.
4. With engine running at low idle place the selector
lever in F position.
5. Raise engine RPM to 1500 RPM, the machine should
not move.
6. Repeat the procedure with the selector in the R po-
sition.
NOTE: If the machine moves the parking brake will have
to be repaired, see Brake - Disassemble (D.30.C).
84516378 05/07/2011
D.32.B / 15
Index

Brake - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
84516378 05/07/2011
D.32.B / 16
WHEELS AND TRACKS Wheels - 50.C
580N
580SN WT
580SN
590SN
84516378 05/07/2011
D.50.C / 1
Contents
TECHNICAL DATA
WHEELS AND TRACKS Wheels

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front wheel
Torque - Front wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tire pressure - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tire pressure - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tire pressure - 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear wheel
Torque - Rear wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tire pressure - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tire pressure - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tire pressure - 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Front wheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear wheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
84516378 05/07/2011
D.50.C / 2
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels
WHEELS AND TRACKS Wheels - General specification

NOTE: 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.
NOTE: The rear wheel mounting nuts on this machine are metric. Use only the mounting nuts shown in the parts
catalog for this machine.
NOTE: Check the torque with a dial or click wrench. If the
nut does not move on the following torques, it is tight and
does not need re-torqued:
Front wheel, two wheel 156 N·m (115.1 lb ft)

drive
Front wheel, four wheel 251 N·m (185.1 lb ft)
drive
Rear wheel, mounting nuts 305 N·m (225.0 lb ft)
WHEELS AND TRACKS Wheels - Torque

Front wheel, two wheel drive 156 - 203 N·m (115.1 - 149.7 lb ft)
Front wheel, four wheel drive 251 N·m (185.1 lb ft)
Rear wheel, mounting nuts 305 N·m (225.0 lb ft)
84516378 05/07/2011
D.50.C / 3
Front wheel - Torque - Front wheel mounting nut torque procedure

1. Install all eight (8) mounting nuts. Tighten all mount-
ing 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 re-
quired pre-load on the front wheel mounting nuts.
RCPH10TLB610AAL 1
Front wheel - Tire pressure - 580N and 580SN only

11L x 16 (2wd), 10 PR, F3 52 psi (358 kPa, 3.6 bar)
4WD - 12 x 16.5 (4wd), 8 PR, Lug 50 psi (345 kPa, 3.4 bar)
Front wheel - Tire pressure - 580SN-WT only

12.5/80x18 42wd), 10 PR 4.1 bar (59.5 psi)
Front wheel - Tire pressure - 590SN only

14.5 x 17.5 (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)
84516378 05/07/2011
D.50.C / 4
Rear wheel - Torque - 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.
RCPH10TLB611AAL 1
Rear wheel - Tire pressure - 580N and 580SN only

16.9 x 28, 10 PR, R4 32 psi (220 kPa, 2.2 bar)
17.5Lx24, 10 PR, R4 32 psi (220 kPa, 2.2 bar)
19.51L x 24, 10 PR, R4 28 psi (193 kPa, 2.3 bar)
Rear wheel - Tire pressure - 580SN-WT only

21L x 24, 10 PR 26 psi (179 kPa, 1.8 bar)
Rear wheel - Tire pressure - 590SN only

21 L x 24, 10 PR, R4 26 psi (179 kPa, 1.8 bar)
84516378 05/07/2011
D.50.C / 5
Front wheel - Remove

1. Raise and support the backhoe.
RCPH11TLB119AAM 1
2. Remove hardware.
RCPH11TLB135AAM 2
3. Remove the wheel.
RCPH11TLB136AAM 3
84516378 05/07/2011
D.50.C / 6
Front wheel - Install

1. Carefully position the wheel onto the hub.
RCPH11TLB135AAM 1
2. Tighten the eight mounting nuts in sequence until the

wheel is snug against the axle hub.
3. Tighten the nuts in sequence to a torque of 122 N·m
(90 lb ft)
4. Turn the nuts in sequence an additional 90 ° to set
the preload.
5. Tighten the nuts in sequence to a torque of
Two Wheel Drive Machines — 156 - 203 N·m (115 - 150 lb
ft).
Four Wheel Drive Machines — 251 N·m (185 lb ft).
RCPH10TLB074AAF 2
84516378 05/07/2011
D.50.C / 7
Rear wheel - Remove

1. Raise and support the backhoe.
RCPH11TLB138AAM 1
2. Remove hardware.
RCPH11TLB138AAM 2
3. Remove the wheel.
RCPH11TLB120AAM 3
84516378 05/07/2011
D.50.C / 8
Rear wheel - Install

1. Carefully position the wheel onto the hub.
RCPH11TLB138AAM 1
2. Tighten the ten mounting nuts in sequence until the

wheel is snug against the axle hub.
(100 lb ft).
4. Tighten the nuts a second time, in sequence to a
torque of 271 N·m (200 lb ft).
5. Turn the nuts in sequence an additional 30 ° to set
the preload.
(225 lb ft).
RCPH10TLB075AAF 2
84516378 05/07/2011
D.50.C / 9
Index

Front wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front wheel - Tire pressure - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheel - Tire pressure - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheel - Tire pressure - 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheel - Torque - Front wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear wheel - Tire pressure - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear wheel - Tire pressure - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear wheel - Tire pressure - 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear wheel - Torque - Rear wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WHEELS AND TRACKS Wheels - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WHEELS AND TRACKS Wheels - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
84516378 05/07/2011
EN
SERVICE MANUAL
FRAME AND CAB
580N
580SN WT
580SN
590SN
84516378 05/07/2011
E
Contents
FRAME AND CAB - E
FRAME Primary frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.10.B

580N , 580SN WT , 580SN , 590SN
SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.20.A
580N , 580SN WT , 580SN , 590SN
USER CONTROLS AND SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.A

580N , 580SN WT , 580SN , 590SN
USER CONTROLS AND SEAT Operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.C

580N , 580SN WT , 580SN , 590SN
USER PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.34.A

580N , 580SN WT , 580SN , 590SN
ENVIRONMENT CONTROL Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.40.C

580N , 580SN WT , 580SN , 590SN
84516378 05/07/2011
E
FRAME AND CAB - E
FRAME Primary frame - 10.B
580N
580SN WT
580SN
590SN
84516378 05/07/2011
E.10.B / 1
Contents
FRAME AND CAB - E
SERVICE
Front
Remove - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
84516378 05/07/2011
E.10.B / 2
FRAME AND CAB - FRAME Primary frame
Front - Remove - Loader Frame

1. Position loader above hood to access cylinder pins.
RCPH11TLB098AAM 1
2. Install lifting device.
RCPH11TLB099AAM 2
3. Remove the left-hand and right-hand rod end snap

rings.
RCPH11TLB100AAM 3
4. Remove the left-hand and right-hand rod end pins.

Leave tool in place to hold cylinder.
RCPH11TLB101AAM 4
84516378 05/07/2011
E.10.B / 3
5. Remove lifting device.
RCPH11TLB102AAM 5
6. Lower loader frame to the floor.
RCPH11TLB103AAM 6
7. Support the left-hand cylinder. Remove the tool and

safety lock.
RCPH11TLB104AAM 7
8. Lower the left-hand and right-hand cylinders onto the

front axle.
RCPH11TLB105AAM 8
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E.10.B / 4
9. Turn the ignition to the ON position. Relieve pressure

from the hydraulic lines by moving the control stick in
all positions.
RCPH11TLB106AAM 9
10. Identify, tag and disconnect bucket hoses from the

right-hand side.
RCPH11TLB107AAM 10
11. Identify, tag and disconnect bucket hoses from the

left-hand side.
RCPH11TLB108AAM 11
12. Cap open hydraulic lines.
RCPH11TLB109AAM 12
84516378 05/07/2011
E.10.B / 5
13. Remove the Return To Dig switch.
RCPH11TLB110AAM 13
14. Disconnect anti-rollback rod from the bucket link.
RCPH11TLB111AAM 14
15. Disconnect the anti-rollback rod self leveling cam.
RCPH11TLB112AAM 15
16. Remove the right-hand side snap ring (1).

17. Remove the right-hand side washers. (2)
RCPH11TLB113AAM 16
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E.10.B / 6
18. Support loader with lifting device.
RCPH11TLB114AAM 17
19. Drive the pivot pin from the right-hand side.
RCPH11TLB115AAM 18
20. Remove the pivot pin.
RCPH11TLB116AAM 19
21. Remove the loader arm.
RCPH11TLB117AAM 20
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E.10.B / 7
22. Remove the self-leveling cam and washer.
RCPH11TLB118AAM 21
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E.10.B / 8
Front - Install - Loader Frame

1. Install the self-leveling cam and washer.
RCPH11TLB118AAM 1
2. Carefully move the loader arm into position.
RCPH11TLB117AAM 2
3. Drive the pivot pin into place.
RCPH11TLB116AAM 3
4. Remove the loader lifting device.
RCPH11TLB114AAM 4
84516378 05/07/2011
E.10.B / 9
5. Install the right-hand washer (2). Install the right-

hand side snap ring (1).
RCPH11TLB113AAM 5
6. Connect the anti-rollback rod self leveling cam.
RCPH11TLB112AAM 6
7. Connect anti-rollback rod from the bucket link.
RCPH11TLB111AAM 7
8. Install the Return To Dig switch.
RCPH11TLB110AAM 8
84516378 05/07/2011
E.10.B / 10
9. Reconnect bucket hoses on the left-hand side.
RCPH11TLB108AAM 9
10. Reconnect bucket hoses on the right-hand side.
RCPH11TLB107AAM 10
11. Raise the left-hand and right-hand cylinders into po-

sition.
RCPH11TLB105AAM 11
12. Support the left-hand cylinder. Install safety lock.
RCPH11TLB104AAM 12
84516378 05/07/2011
E.10.B / 11
13. Lower loader frame to the floor.
RCPH11TLB103AAM 13
14. Install a suitable lifting device.
RCPH11TLB102AAM 14
15. Install the left-hand and right-hand rod end pins. Re-
move the tool that is holding the cylinders in place.
RCPH11TLB101AAM 15
16. Install the left-hand and right-hand rod end snap

rings.
RCPH11TLB100AAM 16
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E.10.B / 12
RCPH11TLB099AAM 17
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E.10.B / 13
Index
FRAME AND CAB - E

Front - Install - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front - Remove - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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E.10.B / 14
FRAME AND CAB - E
SHIELD - 20.A
580N
580SN WT
580SN
590SN
84516378 05/07/2011
E.20.A / 1
Contents
FRAME AND CAB - E
SHIELD - 20.A
SERVICE
Engine hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84516378 05/07/2011
E.20.A / 2
FRAME AND CAB - SHIELD
Engine hood - Remove

Prior operation:
1. Raise the loader in the full upright position. Lock the

support strut to hold the loader in the upright position.
RCPH11TLB001AAM 1
2. Open hood and remove hood struts.
RCPH11TLB002AAM 2
3. Remove hood straps.
RCPH11TLB002AAM 3
4. Lower hood and attach lifting device.
RCPH11TLB004AAM 4
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E.20.A / 3
5. Remove hood pivot point hardware.
RCPH11TLB005AAM 5
6. Remove pivot point tubes.
RCPH11TLB006AAM 6
7. Remove hood.
RCPH11TLB008AAM 7
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E.20.A / 4
Engine hood - Install

1. Lower the hood into place.
RCPH11TLB008AAM 1
2. Install pivot point tubes.
RCPH11TLB006AAM 2
3. Install the hood pivot point hardware.
RCPH11TLB005AAM 3
4. Remove the lifting straps.
RCPH11TLB004AAM 4
84516378 05/07/2011
E.20.A / 5
5. Install the hood straps.
RCPH11TLB002AAM 5
6. Open hood and install the hood struts.
RCPH11TLB002AAM 6
7. Remove the support strut that are holding the loader

in the upright position.
RCPH11TLB001AAM 7
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E.20.A / 6
Index
FRAME AND CAB - E
SHIELD - 20.A
Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FRAME AND CAB - E
USER CONTROLS AND SEAT - 32.A
580N
580SN WT
580SN
590SN
84516378 05/07/2011
E.32.A / 1
Contents
FRAME AND CAB - E
FUNCTIONAL DATA
USER CONTROLS AND SEAT

Exploded view - Backhoe controls with foot swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view - Backhoe controls with hand swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
USER CONTROLS AND SEAT

Adjust - Adjustment of the backhoe control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspect - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Instrument panel
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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FRAME AND CAB - USER CONTROLS AND SEAT
USER CONTROLS AND SEAT - Exploded view - Backhoe controls

with foot swing
RCPH10TLB095GAL 1
1. Extendahoe (if used) 7. RH stabilizer

2. Spacer (used without 8. LH swing pedal
extendahoe)
3. Boom 9. Swing control shaft
4. Dipper 10. RH swing pedal
5. Bucket 11. Shim washers. Use as necessary between the control levers to remove end play. Use
at least one shim washer (11) between each two control levers.
6. LH stabilizer 12. Clevis. Adjust so that the swing pedals (8) and (10) are at an angle of 19 - 20 ° from
the floor when the “J” lug on the swing bellcrank (9) is parallel to the floor.
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USER CONTROLS AND SEAT - Exploded view - Backhoe controls

with hand swing
RCPH10TLB096GAL 1
1. Bucket and dipper 7. RH stabilizer

2. Bucket 8. LH stabilizer
3. Dipper 9. Control lever mounting bracket
4. Boom and swing 10. Extendahoe control pedal (if equipped)
5. Boom 11. Extendahoe control pivot (mounted on RH side of backhoe
control tower)
6. Swing
84516378 05/07/2011
E.32.A / 4
USER CONTROLS AND SEAT - Adjust - Adjustment of the backhoe

control levers
1. All control levers (1) must be in alignment and cen-
tered in the slots in the control tower (2). See the
illustration below.
2. All control levers (1) must be within 71 - 73 ° from the
floor plate as seen from the right side of the backhoe.
RCPH10TLB094GAL 1
(Right Side Shown)
1. Control levers 3. Floor plate

2. Control tower 4. 71 - 73 °
84516378 05/07/2011
E.32.A / 5
USER CONTROLS AND SEAT - Disassemble - Air suspension seat

1. Loosen and remove the 4 bolts from the seat assem-
bly. Remove the seat assembly from the base.
RCPH10TLB858ABL 1
2. Place the seat assembly on the workbench. Cut and

remove the plastic clips from the backrest cover. Re-
move the backrest cover.
RCPH10TLB922ABL 2
3. Push in on the plastic retainer (1) and remove the

lumbar support adjustment knob.
RCPH10TLB924ABL 3
4. Remove the mounting screw (1) from the housing.
RCPH10TLB923ABL 4
84516378 05/07/2011
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5. Disconnect the cable from the lumbar support. Re-

move the cable and housing assembly.
RCPH10TLB923ABL 5
6. Tilt the right arm rest up until it is against the upper

stop. Push in on the arm rest as shown in the above
photo. Rotate the arm rest counter-clockwise past
the upper stop.
RCPH10TLB857ABL 6
7. Remove the arm rest as shown in the above photo.

Repeat the above procedure for the left arm rest.
RCPH10TLB856ABL 7
8. Loosen and remove the 2 Allen head bolts from the

slide travel limiter. Remove the slide travel limiter
from the upper slide plate.
RCPH10TLB859ABL 8
84516378 05/07/2011
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9. Loosen the 2 Allen head set bolts in the 2 slide pucks

on the right side of the upper slide plate.
NOTE: Access for the set screws is through the 2 holes in
the side rail of the upper slide plate. Slide the plate fore or
aft until the set screws are visible.
RCPH10TLB861ABL 9
10. Lift the handle to release the lock on the upper slide
plate.
RCPH10TLB863ABL 10
11. Move the upper slide plate forward and remove from
the slide swivel assembly.
RCPH10TLB864ABL 11
12. Use acceptable tools and remove the roll pin and re-
taining ring from the slide control lever (1). Remove
the return spring and the slide control lever from the
upper slide plate assembly. Repeat this procedure
and remove the swivel control lever (2) from the up-
per slide plate assembly.
RCPH10TLB916ABL 12
84516378 05/07/2011
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13. 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.
RCPH10TLB917ABL 13
14. Use a soft hammer and remove the slide pucks from
the slide swivel assembly.
RCPH10TLB865ABL 14
15. Loosen and remove the 2 - 5/16 inch bolts from the
front side of the slide swivel assembly.
RCPH10TLB867ABL 15
16. Loosen and remove the 2 - 3/8 inch bolts and 2 tether
straps from the rear of the slide swivel assembly.
RCPH10TLB868ABL 16
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17. Remove the slide swivel assembly from the lateral

isolator plate.
RCPH10TLB869ABL 17
18. Loosen and remove the 2 bolts from the swivel con-
tact switch assembly. Remove the switch from the
lateral isolator plate.
RCPH10TLB870ABL 18
19. Remove the 2 screws from the swivel contact switch

and remove the wiring harness from the switch.
RCPH10TLB872ABL 19
20. Disconnect the wiring harness from the height adjust-

ment switch.
RCPH10TLB871ABL 20
84516378 05/07/2011
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21. Remove the 2 bolts from the switch bracket. Remove

the switch and bracket.
RCPH10TLB873ABL 21
22. Press in on the top and bottom tabs on the rear of

the switch and push the switch forward until the tabs
are free from the bracket. Remove the switch from
the bracket.
RCPH10TLB874ABL 22
23. Loosen and remove the 4 bolts from the lateral iso-
lator plate.
RCPH10TLB875ABL 23
24. Remove the isolator plate from the upper housing.
RCPH10TLB876ABL 24
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25. Turn the isolator plate over and place on the work-
bench. Use acceptable tools and remove the 2 iso-
lator springs from the isolator plate.
RCPH10TLB909ABL 25
26. Use acceptable tools and remove the nut from the
isolator shock.
RCPH10TLB910ABL 26
27. Remove the top washer and rubber insulator from the
shock.
RCPH10TLB911ABL 27
28. Use acceptable tools and remove the retaining ring

from the lateral isolator shock.
RCPH10TLB912ABL 28
84516378 05/07/2011
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29. Remove the pin from the isolator shock.
RCPH10TLB913ABL 29
30. Remove the shock from the isolator plate.
RCPH10TLB914ABL 30
31. Inspect the parts of the isolator shock for wear and
damage.
RCPH10TLB915ABL 31
32. Use acceptable tools and remove the 2 roll pins (1)
from the lateral isolator control.
RCPH10TLB909ABL 32
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33. Use acceptable tools and remove the bolts (1) from
the isolator control mounting bracket. Remove the
lateral isolator control (2) from the isolator plate.
RCPH10TLB909ABL 33
34. Slide bottom of the isolator plate to the left until the
isolator roller bearings are exposed and remove the
rollers bearings from the shaft. Slide the bottom of
the isolator plate to the right until the isolator roller
bearings (1) are exposed and remove the roller bear-
ings from the shaft.
NOTE: The above photo is for reference only.
RCPH10TLB909ABL 34
35. Remove the plastic pins from the boot assembly and
fold the boot down to the base plate. Note the loca-
tion of the tether straps behind the boot.
RCPH10TLB877ABL 35
36. Loosen and remove the 2 bolts from the fore/aft iso-
lator shock mounting bracket. Remove the bracket
from the upper housing plate. Allow the other end of
the isolator shock to hang from the suspension arm.
RCPH10TLB878ABL 36
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37. Loosen and remove the 2 bolts from the fore and aft
isolator control.
NOTE: Be sure to use the same screws during the assem-
bly procedure of the isolator control.
RCPH10TLB879ABL 37
38. Slide the upper housing to the rear and lift the hous-
ing free of the roller bearings on the rear suspension
arms.
RCPH10TLB880ABL 38
39. Slide the upper housing forward and lift the housing
free of the roller bearings on the front suspension
arms. Note the location of the rubber bumpers on
the upper housing.
RCPH10TLB881ABL 39
40. Remove the 2 wide roller bearings from the front sus-
pension arms.
RCPH10TLB882ABL 40
84516378 05/07/2011
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41. Remove the 2 narrow roller bearings from the rear

suspension arms.
RCPH10TLB883ABL 41
42. Remove the bushing and the isolator control from the
suspension arm.
RCPH10TLB884ABL 42
43. Use acceptable tools and remove the roll pins (1)
from each end of the isolator control. Remove the
2 plastic bushings and 2 springs and latch assembly
from the control.
RCPH10TLB907ABL 43
44. Use acceptable tools and remove the roll pin from the
control housing. Remove the isolator control knob
from the housing.
RCPH10TLB907ABL 44
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45. Remove the 2 bushings and the isolator shock from

the suspension arm.
RCPH10TLB885ABL 45
46. Inspect the parts of the isolator shock assembly for

wear and damage.
RCPH10TLB908ABL 46
47. Place an acceptable block between the suspension

assembly and the front of the lower housing assem-
bly.
RCPH10TLB886ABL 47
48. Note the location of the wire 3 wire ties on the lower
housing assembly.
RCPH10TLB918ABL 48
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49. Cut and remove the 3 wire ties from the wiring har-
ness.
RCPH10TLB892ABL 49
50. Note the location of the 2 wire ties on the suspension

assembly. Cut and remove the wire ties.
RCPH10TLB887ABL 50
51. Disconnect the wiring harness from the air compres-

sor assembly.
RCPH10TLB888ABL 51
52. Loosen the air line fitting and allow the air to escape
from the air spring assembly. Remove the air line
from the air spring.
RCPH10TLB889ABL 52
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53. Loosen and remove the 2 bolts from the air compres-
sor mounting bracket.
RCPH10TLB890ABL 53
54. Remove the air compressor assembly.
RCPH10TLB891ABL 54
55. Loosen and remove the 4 bolts from the pedestal

mounting plate. Remove the pedestal from the lower
housing assembly.
RCPH10TLB894ABL 55
56. Loosen and remove the lower screw from the air
spring.
RCPH10TLB895ABL 56
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57. Loosen and remove the bolt from the top of the air
spring.
RCPH10TLB893ABL 57
58. Remove the air spring assembly.
RCPH10TLB896ABL 58
59. Cut and remove the plastic pins from the rubber boot.
RCPH10TLB897ABL 59
60. Remove the rubber boot from the lower housing as-
sembly.
RCPH10TLB898ABL 60
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61. Loosen and remove the nut from the shaft.
RCPH10TLB906ABL 61
62. Use acceptable tools and remove the shaft from the
lower housing assembly.
RCPH10TLB905ABL 62
63. Tilt the suspension assembly forward. Turn the sus-

pension assembly counter clockwise and remove
from the lower housing.
RCPH10TLB903ABL 63
64. Remove the 2 roller bearings from the shaft. Use

acceptable tools and remove the 2 plastic bushings
from the tube.
RCPH10TLB899ABL 64
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65. Remove the retaining clip from the isolator shock.

Remove the isolator shock and 2 plastic bushings
from the suspension assembly.
RCPH10TLB900ABL 65
66. Inspect the parts of the isolator shock and the sus-
pension assembly for wear and damage.
RCPH10TLB901ABL 66
Next operation:
USER CONTROLS AND SEAT - Inspect (E.32.A)
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USER CONTROLS AND SEAT - Inspect - Air suspension seat

Prior operation:
USER CONTROLS AND SEAT - Disassemble (E.32.A)
1. Inspect the seat cushion, backrest cushion, arm rests

and lumbar support control for wear and damage.
2. Inspect the upper slide plate assembly, swivel con-
trol, slide control, and slide latch for wear and dam-
age. Use new parts as required.
3. Inspect the slide/swivel assembly and slide pucks for
wear and damage. Lubricate slide pucks with moly-
disulfide grease. Use new parts as required.
4. Inspect the swivel switch, height adjustment switch,
and wire harness for damage. Use new parts as
required.
5. Inspect the lateral isolator plate, isolator shock, bush-
ings, springs, roller bearings, and control for wear
and damage. Lubricate the roller bearings and con-
tact points with molydisulfide grease. Use new parts
as required.
6. Inspect the boot assembly for damage. Use new
parts as required.
7. Inspect the upper housing and rubber bumpers for
8. Inspect the suspension assembly and roller bearings
for wear and damage. Lubricate the roller bearings
and contact points with molydisulfide grease. Use
9. Inspect the fore/aft isolator shock and bushings for
10. Inspect the fore/aft isolator control and bushing for
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 har-
ness for wear and damage. Use new parts as re-
quired.
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.
Next operation:
USER CONTROLS AND SEAT - Assemble (E.32.A)
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USER CONTROLS AND SEAT - Assemble - Air suspension seat

Prior operation:
USER CONTROLS AND SEAT - Inspect (E.32.A)
1. Install the isolator shock and 2 plastic bushings onto

the suspension assembly.
RCPH10TLB901ABL 1
2. Use acceptable tools and install the retaining clip

onto the shaft.
RCPH10TLB902ABL 2
3. Lubricate the 2 roller bearings (1) with molydisulfide

grease and install onto the shaft. Install the 2 plastic
bushings (2) into the tube.
RCPH10TLB899ABL 3
4. Install the suspension assembly roller bearings into

the lower housing at a slight angle indicated in the
photo above. Turn the suspension assembly clock-
wise and align the rear tube into the lower housing.
RCPH10TLB903ABL 4
84516378 05/07/2011
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5. Install the shaft into the lower housing.
RCPH10TLB904ABL 5
6. Install and tighten the nut on the shaft.
RCPH10TLB906ABL 6
7. Install the rubber boot over the suspension assembly

and onto the lower housing assembly.
RCPH10TLB898ABL 7
8. Install the air spring into the suspension assembly.
RCPH10TLB896ABL 8
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9. Install and tighten the screw into the bottom of the air
spring.
RCPH10TLB895ABL 9
10. Install and tighten the bolt into the top of the air
spring.
RCPH10TLB893ABL 10
11. Install the pedestal onto the lower housing. Install

the tether straps between the rubber boot and lower
housing. Install and tighten the 4 bolts.
RCPH10TLB894ABL 11
12. Install the plastic pins into the lower mounting holes
of the rubber boot. Drive the pins into the mounting
holes in the lower housing assembly.
RCPH10TLB919ABL 12
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13. Install the air compressor into the suspension as-

sembly.
RCPH10TLB891ABL 13
14. Install and tighten the 2 air compressor mounting

screws.
RCPH10TLB890ABL 14
15. Install the air line into the fitting on the air spring.
Tighten the fitting nut.
RCPH10TLB889ABL 15
16. Connect the air compressor wiring harness.
RCPH10TLB888ABL 16
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17. Install the 5 wire ties for the wiring harness in the
proper locations as indicated in the photo above.
RCPH10TLB918ABL 17
18. Install the 2 plastic bushings and the isolator shock

onto the suspension assembly. Make sure that the
white plastic bushing is on the outside.
RCPH10TLB885ABL 18
19. Assemble the parts of the isolator control.
RCPH10TLB907ABL 19
20. Install the isolator control and plastic bushing onto

RCPH10TLB884ABL 20
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21. Lubricate the 2 narrow roller bearings with molydisul-

fide grease and install on the rear shafts of the sus-
pension assembly.
RCPH10TLB883ABL 21
22. Lubricate the 2 wide roller bearings with molydisul-

fide grease and install on the front shafts of the sus-
pension assembly.
RCPH10TLB882ABL 22
23. Install the upper housing slide rail onto the wide roller
bearings on the suspension assembly. Make sure
the rubber bumpers are facing to the rear of the sus-
pension assembly.
RCPH10TLB881ABL 23
24. Slide the upper housing to the rear until the narrow
roller bearings will engage the slide rails of the upper
housing.
RCPH10TLB880ABL 24
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25. Install and tighten the 2 bolts in the isolator control.

NOTE: Be sure to use the same bolts that were removed
during the disassembly procedure.
RCPH10TLB879ABL 25
26. Install and tighten the 2 bolts in the fore/aft isolator

shock bracket.
RCPH10TLB878ABL 26
27. Slide the rubber boot into position on the upper hous-
ing. Install the plastic pins into the mounting holes
in the rubber boot. Drive the pins into the mounting
holes in the upper housing.
RCPH10TLB920ABL 27
28. Slide the bottom of the isolator plate to the left. Lu-
bricate the 2 roller bearings (1) with molydisulfide
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.
RCPH10TLB909ABL 28
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29. Install the isolator control (2) onto the isolator plate.
Install and tighten the bolts (1) in the mounting
bracket. Use acceptable tools and install the 2 roll
pins in the isolator control.
RCPH10TLB909ABL 29
30. Install the isolator shock and 2 plastic bushings into

the mounting brackets on the isolator plate.
RCPH10TLB914ABL 30
31. Install the pin into the isolator shock.
RCPH10TLB913ABL 31
32. Install the retaining clip onto the pin.
RCPH10TLB912ABL 32
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33. Install the rubber insulator and washer onto the

shock.
RCPH10TLB911ABL 33
34. Install and tighten the lock nut on the shock.
RCPH10TLB910ABL 34
35. Turn the isolator plate over and install onto the upper
housing.
RCPH10TLB876ABL 35
36. Install and tighten the 4 bolts which mount the isolator
plate to the upper housing.
RCPH10TLB875ABL 36
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37. Install the height adjustment switch into the mounting

bracket.
RCPH10TLB874ABL 37
38. Install and tighten the bolts in the switch bracket.
RCPH10TLB873ABL 38
39. Connect the wiring harness.
RCPH10TLB871ABL 39
40. Connect the wiring harness to the swivel switch.

Tighten the screws.
RCPH10TLB872ABL 40
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41. Install the 2 bolts in the swivel switch. Tighten the

screws.
RCPH10TLB870ABL 41
42. Install the swivel assembly on the lateral isolator

plate.
RCPH10TLB869ABL 42
43. Install the 2 - 3/8 inch bolts through the tether strap
mounting holes. Install the bolts into the swivel plate
mounting holes. Install the bolts into the swivel plate
mounting holes. Tighten the bolts.
RCPH10TLB868ABL 43
44. Install the 2 - 5/16 inch bolts into the swivel plate
mounting holes. Tighten the bolts.
RCPH10TLB867ABL 44
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45. Use a soft hammer and install the slide pucks (1) on
the slide/swivel assembly. Make sure the adjustable
slide pucks are installed in the proper location as in-
dicated in the photo above.
RCPH10TLB866ABL 45
46. Use acceptable tools and install the slide latch,

spring, roll pin, and retaining clip on the upper slide
plate.
RCPH10TLB917ABL 46
47. Use acceptable tools and install the spring, roll pin,
slide control lever (1), and retaining ring on the upper
slide plate. Repeat this procedure to install the swivel
control lever (2) on the upper slide plate.
RCPH10TLB916ABL 47
48. Lubricate the slide pucks and slide track on the upper
slide plate with molydisulfide grease. Install the up-
per slide plate over the front slide pucks on the swivel
assembly.
RCPH10TLB864ABL 48
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49. Lift the slide control and slide the upper slide plate
into position on the swivel assembly.
RCPH10TLB863ABL 49
50. Install the slide travel limiter on the upper slide plate.
RCPH10TLB860ABL 50
51. Install the 2 Allen head bolts in the slide travel limiter.
Tighten the bolts.
RCPH10TLB859ABL 51
52. Install the right side arm rest as indicated in the photo
above.
RCPH10TLB856ABL 52
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53. Rotate the arm rest clockwise past the upper stop.
Repeat the procedure for the left side arm rest.
RCPH10TLB857ABL 53
54. Connect the cable assembly to the lumbar support

assembly.
RCPH10TLB923ABL 54
55. Install and tighten the mounting screw (1) in the lum-
bar support housing. Install the lumbar support ad-
justment knob (2) on the housing. Push the knob
onto the housing until the plastic retainer is locked in
position.
RCPH10TLB924ABL 55
56. Place the backrest cover in position on the seat top.

Install the plastic clips in the mounting holes of the
backrest cover. Drive the plastic clips into the mount-
ing holes of the seat top with a soft hammer.
RCPH10TLB921ABL 56
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57. Place the seat assembly into position on the seat

base. Install and tighten the 4 bolts.
RCPH10TLB858ABL 57
58. After the seat has been assembled, adjust the slide
pucks to the desired lateral movement of the seat.
NOTE: After installing the seat into the machine, check the
seat for proper operation.
RCPH10TLB862ABL 58
59. Mount seat belts at an angle of 45 ° +/- 5°.
RCPH10TLB753ABL 59
60. Torque bolts in accordance with general bolt torque

specifications.
RCPH10TLB754ABL 60
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Instrument panel - Visual inspection

The backlighting for the instrument cluster is illuminated only when the driving lamp switch is in the ON position.
When the ignition (key) switch is in the ON position and the engine is not running the Air Filter Restriction, Hydraulic
Oil Filter Restriction, Alternator, and Low Engine Oil Pressure Warning Lamps are illuminated.
When the ignition (key) switch is first turned to the ON position the Air Filter Restriction Warning Lamp, Hydraulic Oil
Filter Restriction Warning Lamp, Parking Brake Indicator Lamp and the Air Conditioning System Pressure Indicator
Lamp (if equipped), will illuminate for 3 seconds for a bulb self test.
Warning and indicator lamp status at power on

1. Turn the ignition (key) switch to the ON position.
2. All LED’s (Light Emitting Diodes) will illuminate for 2
- 3 seconds.
3. The warning alarm will sound for 1 second.
4. If an active fault is found, the associated visualization
will occur with the display, LEDs, and alarm. Refer
to Instrument panel Digital instrument cluster -
Special instruction (E.32.A) for more details.
5. If no active fault is found, the display will be green in
color showing the current machine hour meter value.
Self test procedure

1. Simultaneously turn the ignition (key) switch ON and
press any display function switch (up arrow, down
arrow, enter, or escape). However, simultaneously
pressing the down arrow and escape switches will
initiate the system configuration mode.
2. The following occurs during the self test. Watch
for burnt out lamps and incorrect movement of the
gauges:
A. Lamps turn on at full intensity.
B. Lamps turn off after 2 seconds.
C. Wait 2 seconds.
D. Instrument backlighting turns on at full in-
tensity.
E. Instrument backlighting turns off after 2
seconds.
F. Wait 2 seconds.
G. All gauges sweep to the maximum angle.
H. Wait 2 seconds, applicable gauges sweep
to the maximum red/green border.
I. Wait 2 seconds, applicable gauges sweep
to the red/green border.
J. Wait 2 seconds, gauges release to their
resting position and the display test
(checkered screen) is initiated.
K. After completion of the display test, an au-
dible alarm occurs for 2 seconds.
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3. The self test is now complete and the display will

default into configuration mode. Proceed to step of
the Configuration mode procedure or turn the ignition
(key) switch to the OFF position.
NOTE: When defective gauges are found refer to Instru-
ment panel - Check (E.32.A) for more details.
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Instrument panel - Check - Instrument cluster

The backlighting for the instrument cluster is illuminated only when the driving lamp switch is in the ON position.
When the ignition (key) switch is in the ON position and the engine is not running the Air Filter Restriction, Hydraulic
Oil Filter Restriction, Alternator, and Low Engine Oil Pressure Warning Lamps are illuminated.
When the ignition (key) switch is first turned to the ON position the Air Filter Restriction Warning Lamp, Hydraulic Oil
Filter Restriction Warning Lamp, Parking Brake Indicator Lamp and the Air Conditioning System Pressure Indicator
Lamp (if equipped), will illuminate for 3 seconds for a bulb self test.
Low engine oil pressure warning lamp

The warning lamp for low engine oil pressure will il-
luminate with the key switch in the ON position and
the engine NOT running. If the warning lamp does
not illuminate:
1. Check for a defective lamp.
2. Check for corrosion or bad connections at
the socket in the instrument cluster and at
the switch for engine oil pressure.
3. Check the wire between the oil pressure
switch and the instrument cluster.
4. See Instrument panel - Check (E.32.A)
in this Manual for complete troubleshoot-
ing procedure for the instrument cluster.
Alternator warning lamp

The warning lamp for the alternator will illuminate
with the key switch in the ON position and the en-
gine NOT running. If the warning lamp does not illu-
minate:
1. Check for a defective lamp.
2. Check for corrosion or bad connections at
the alternator.
3. Check the wire between the alternator and
the instrument cluster.
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Hydraulic oil filter restriction

1. The Hydraulic oil filter restriction warning lamp will
illuminate with the key switch in the ON position and
the engine NOT running. If the warning lamp does
not illuminate:
A. Check for a defective lamp.
B. Check for corrosion or bad connections at
the Hydraulic oil filter restriction switch.
C. Check the wire between the Hydraulic oil
filter restriction switch and the instrument
cluster.
D. Check for a damaged wire between the
instrument cluster and the IGN terminal of
the key switch.
E. Defective switch.
2. When the warning lamp for the Hydraulic oil filter re-
striction is illuminated while the engine is running, the
cause can be:
1. Dirty filter.
2. Defective switch for the warning lamp.
3. Short circuit in the wire between the switch
and the warning lamp.
4. Cold hydraulic oil will also cause the
switch to activate.
Air filter restriction

1. The Air filter restriction warning lamp will illuminate
with the key switch in the ON position and the en-
gine NOT running. If the warning lamp does not illu-
minate:
A. Check for a defective lamp.
B. Check for corrosion or bad connections at
the Hydraulic Oil Filter Restriction switch.
C. Check the wire between the Air filter re-
striction switch and the instrument cluster.
D. Check for a damaged wire between the
instrument cluster and the IGN terminal of
the key switch.
E. Defective switch.
84516378 05/07/2011
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2. When the warning lamp for the Hydraulic oil filter re-
striction is illuminated while the engine is running, the
cause can be:
A. Dirty filter.
B. Defective switch for the warning lamp.
C. Short circuit in the wire between the switch
and the warning lamp.
D. See Instrument panel - Check (E.32.A)
Parking brake indicator

1. The parking brake indicator will illuminate when the
parking brake is applied.
2. See Instrument panel - Check (E.32.A) in this Man-
ual for the procedure to check the Parking brake in-
dicator lamp.
Driving lamps indicator

1. The Driving lamps indicator will illuminate when the
driving lamp switch is in the ON position.
ual for the procedure to check the Driving lamps in-
dicator.
Low fuel level indicator

1. The Low fuel level indicator illuminates when the ma-
chine's fuel level is low.
ual for the procedure to check the Fuel Level Sender.
Air conditioning system pressure indicator (if equipped)

1. The Air conditioning system pressure indicator illu-
minates when the air conditioner has stopped due to
refrigerant pressures that are too high.
ual for the procedure to check the Air conditioning
system high and or low pressure switch.
Grid heater indicator (if equipped)

1. The Grid heater indicator illuminates when the en-
gine temperature is below 0 °C (32 °F) and the grid
heater is functioning.
ual for the procedure to check the Grid Heater and
the Grid Heater Indicator Lamp.
Configuration mode
NOTE: This procedure can also be used for diagnostic pur-
poses.
84516378 05/07/2011
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1. Simultaneously press and hold the down arrow and

the escape buttons. Turn the ignition (key) switch to
the ON position.
2. The display will show the configuration mode.
3. To reset the instrument cluster, turn the ignition (key)
switch to the Off position.
4. A total of nine settings may be changed. Press the up
or down arrow to scroll through the settings. Press
the enter key to select the desired setting.
• Transmission oil temperature and
Vehicle Voltage
• Fuel level % and Fuel Tank #
• Requested RPM
• Foot Throttle % and Hand Throttle %
• Hand Throttle Voltage Output and
Hand Throttle Signal Voltage Out
• Foot Throttle Voltage Output and
Foot Throttle Signal Voltage Out
• Oil Temperature and Fuel Temperature
• Coolant Temperature and Air Temperature
• Brake Enable ON/OFF and RPM (580N
only)
5. Press the up or down arrows to change the current
setting.
6. Press the enter key to save any changes.
7. Press the escape key repeatedly until the main
screen (hourmeter) is displayed.
Software version retrieval

1. Turn the ignition (key) switch to the ON position.
2. Press the enter key.
3. Press the up arrow 3 times.
4. The software version will be displayed.
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Instrument panel - Check

The Engine coolant temperature, Oil temperature, Voltmeter, Fuel level gauges, and the Tachometer are all serviced
as one unit. If one gauge or the tachometer is defective, they must all be replaced as one unit in the instrument panel
cluster.
Prior operation:
Instrument panel - Visual inspection (E.32.A)
Engine coolant, Oil temperature or Fuel level gauges

1. If the gauge does not work correctly:
A. Disconnect the wire from the sender.
B. Turn the ignition (key) switch to the ON
position.
C. Hold the wire against the frame or the en-
gine until you have a good ground connec-
tion.
D. Have another person look at the gauge. If
you 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 checking the fuel level gauge,
the needle must move all the way to the
left (empty position).
E. If the needle moved, the sender is bad and
must be replaced. If the needle did not
move, the gauge is bad or there is an open
circuit in the wires between the sender and
the gauge.
F. Install the wire on the sender.
G. Refer to Instrument panel - Remove
(E.32.A) for removal procedure.
H. Refer to Wiring harness - Electrical
schematic frame 11 (A.30.A) for the
location of the terminal in the connector
on the wiring harness. Connect one lead
of an ohmmeter to the terminal in the
connector. Connect the other lead of the
ohmmeter to a 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 indi-
cated continuity, the wires are good and
the gauge assembly must be replaced.
84516378 05/07/2011
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2. If the gauge only works part of the time, the cause

could be one of the following:
A. A bad connection at the sender.
B. A bad connection at the instrument panel.
C. A bad connection in the connectors in the
wiring harness.
D. A short circuit or an open circuit in the
wires between the instrument panel and
the sender.
E. Defective sender.
F. Defective gauge.
See Instrument panel - Check (E.32.A) for complete trou-
bleshooting procedure for the instrument cluster.
Voltage gauge
1. Connect the positive lead of a test voltmeter to the
positive post of the batteries. Connect the negative
lead of the test voltmeter to the negative post of the
batteries. If the machine has two batteries, make
sure the leads are connected to the same battery.
2. Start and run the engine at 1500 RPM.
3. Read the test voltmeter, the reading should be
greater than 12 V.
4. Check the voltage gauge on the machine:
• If the needle on the gauge is within the
green field it is working properly.
• If the needle on the gauge is not in the red
field replace the gauge assembly.
5. See Instrument panel - Check (E.32.A)for complete
troubleshooting procedure for the instrument cluster.
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Tachometer gauge
1. The tachometer shows the engine speed in revolu-
tions per minute (rpm). The engine rpm signal comes
from the alternator “W” terminal. If the tachometer is
not working the cause could be the operation of the
alternator.
Check the operation of the alternator. Refer to In-
strument panel - Check (E.32.A)
• If the alternator is not working correctly
repair or replace the alternator. Refer to
NEED IU REFERENCE for servicing the
alternator.
• If the alternator is working correctly,
A. Remove the instrument clus-
ter from the console and dis-
connect the electrical connec-
tor from the console.
B. Connect one lead of an ohm-
meter to terminal T19 in the
connector and connect the
other lead of the ohmmeter to
a good ground.
C. The ohmmeter should indicate
continuity, however if the ohm-
meter does not indicate conti-
nuity, check the wire between
the connector and the alterna-
tor. If necessary repair or re-
place the wire.
2. If the tachometer still does not operate, check the in-
strument cluster. Refer to Instrument panel - Visual
inspection (E.32.A) for the procedure to check the
instrument cluster. Replace the gauge and tachome-
ter assembly as required refer to Instrument panel
- Disassemble (E.32.A) for details.
84516378 05/07/2011
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Instrument panel - Remove

1. Remove the two screws from the front of the instru-
ment cluster panel. Lift the panel off the side console.
RCPH10TLB339AAF 1
2. On a clean nonabrasive surface, place the instru-

ment panel face down.
Next operation:
Instrument panel - Disassemble (E.32.A)
84516378 05/07/2011
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Instrument panel - Disassemble

NOTICE: Adhere to the Electromagnetic Compatibility (EMC) standards when working with electronic components.
At the very minimum be sure you are properly grounded, the proper tools are used and electrical circuit boards are
held by the edges.
Prior operation:
Instrument panel - Remove (E.32.A)
1. Remove the two screws that secure the rear cover to

the frame.
2. Remove the rear cover (1) from the frame (2).
3. When replacing a defective bulb, turn the bulb/socket
assembly counter-clockwise and remove. Replace
assembly as required.
NOTE: The bulb and socket assembly are serviced as one
unit. Do not replace individual components.
4. From the back of the circuit board, remove the 15
nuts and washers that secure the four gauges and
tachometer to the circuit board.
5. From the outside edges of the circuit board, remove
the 12 screws that fasten the circuit board to the
frame.
6. Remove the circuit board with dot matrix display from
the frame.
NOTE: The circuit board with dot matrix display are ser-
viced as one unit. Do not replace individual components.
The circuit board typically does not cause problems but you
may test the continuity of the unit for faults. With an Ohm
meter, test each strip on the circuit board for continuity. Re-
place the circuit board if continuity is not achieved on any
of the circuit board strips.
7. Remove the two screws that secure the front trim to
the frame. Remove the trim.
8. Remove the eight screws that fasten the lens to the
frame. Remove the lens.
9. Remove the five screws that fasten the overlay,
gauges, tachometer, and light pipe to the frame as
one unit. Remove the assembly and replace as
required.
NOTE: The gauges, tachometer, overlay, and light pipe are
serviced as one unit. Do not replace as individual compo-
nents.
10. Inspect the O-ring on the rear cover. Replace as
required.
Next operation:
Instrument panel - Assemble (E.32.A)
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Instrument panel - Assemble

Prior operation:
Instrument panel - Disassemble (E.32.A)
1. When required, insert new bulb/socket assemblies

into the circuit board and turn clockwise to secure in
place.
2. Position the overlay, gauges, tachometer, and light
pipe as one unit into the frame. Secure the assembly
in place with five screws.
3. Secure the lens to the frame with 8 screws. Tighten
to a torque of 1.1 N·m (10 lb in).
4. Position the front trim over the lens and secure it in
place with two screws.
5. Align the circuit board with dot matrix display into
the frame. Ensure the screw posts from the gauges
and tachometer are exposed on the back side of the
circuit board.
6. Secure the outside edges of the circuit board to the
frame with 12 screws.
7. Secure the gauges and tachometer to the circuit
board with nuts and washers.
8. Place the O-ring over the rear cover.
9. Place the rear cover over the back of the frame and
secure it in place with two screws.
Next operation:
Instrument panel - Install (E.32.A)
84516378 05/07/2011
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Instrument panel - Install

Prior operation:
Instrument panel - Remove (E.32.A)
1. Align the back pins on the instrument cluster panel

with the connector in the opening on the right-hand
side console. Gently and evenly push the assembly
into the opening.
2. Secure the assembly in place with two screws.
RCPH10TLB339AAF 1
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Index
FRAME AND CAB - E

Instrument panel - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Instrument panel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Instrument panel - Check - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Instrument panel - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Instrument panel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Instrument panel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Instrument panel - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
USER CONTROLS AND SEAT - Adjust - Adjustment of the backhoe control levers . . . . . . . . . . . . . . . . . . . . . . . . . 5
USER CONTROLS AND SEAT - Assemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
USER CONTROLS AND SEAT - Disassemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
USER CONTROLS AND SEAT - Exploded view - Backhoe controls with foot swing . . . . . . . . . . . . . . . . . . . . . . . . . 3
USER CONTROLS AND SEAT - Exploded view - Backhoe controls with hand swing . . . . . . . . . . . . . . . . . . . . . . . . 4
USER CONTROLS AND SEAT - Inspect - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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FRAME AND CAB - E
USER CONTROLS AND SEAT Operator seat - 32.C
580N
580SN WT
580SN
590SN
84516378 05/07/2011
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Contents
FRAME AND CAB - E
FUNCTIONAL DATA
USER CONTROLS AND SEAT Operator seat

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Seat suspension system
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
USER CONTROLS AND SEAT Operator seat

Replace - Pivot safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassemble - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspect - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assemble - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Disassemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspect - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Assemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Seat belt
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
USER CONTROLS AND SEAT Operator seat - Exploded view
RCIL10TLB002GAF 1
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
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Seat suspension system - Exploded view
RCPH10TLB009HAL 1
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
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USER CONTROLS AND SEAT Operator seat - Replace - Pivot safety

switch
1. Remove the guard that protects the switch.
2. Remove the nuts from the seat screws.
3. Remove the switch.
RCPH10TLB776ABL 1
4. Remove the screws and the seat harness wires from

the switch.
RCPH10TLB777ABL 2
5. Discard the switch.

6. Place the seat harness wires onto the new switch.
7. Install and tighten the wire screws.
RCPH10TLB777ABL 3
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8. Mount the switch onto the seat screws so that the

arm of the switch is to the rear of the seat.
9. Install and tighten the nuts.
RCPH10TLB776ABL 4
10. Reinstall the switch guard.
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USER CONTROLS AND SEAT Operator seat - Disassemble -

Pedestal seat
1. Remove the seat stop.
RCPH10TLB832ABL 1
2. Remove the seat from the slide.
RCPH10TLB833ABL 2
Slide
1. Remove the slide bushings from the left side of the
slide assembly.
RCPH10TLB836ABL 3
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2. Remove the adjustable bushings from the right side

of the slide assembly.
RCPH10TLB837ABL 4
Swivel
1. Remove the cotter pin from the swivel bolt.
RCPH10TLB838ABL 5
2. Remove the nut from the swivel bolt.
RCPH10TLB839ABL 6

4. Remove the top half of the swivel assembly.
RCPH10TLB841ABL 7
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5. Remove the bearing separator from the lower half of

the swivel assembly.
6. Remove the bearings.
RCPH10TLB843ABL 8
Pedestal
1. Place the pedestal in a press. Press down on the
pedestal assembly while holding out on the height
adjustment handle.
RCPH10TLB845ABL 9
2. Loosen and remove the stop bolt.
RCPH10TLB846ABL 10
3. Release the pressure on the press while holding out

on the height adjusting handle.
RCPH10TLB848ABL 11
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4. Make sure you see all three of the height adjustment

holes, if not the pedestal is still under spring pres-
sure.
RCPH10TLB849ABL 12
RCPH10TLB850ABL 13
6. Remove the upper bushing by spreading it at the slot.
RCPH10TLB851ABL 14
7. Remove the lower bushing by spreading it at the slot.
RCPH10TLB852ABL 15
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8. Remove the self-locking nut from the height adjust-

ment handle.
RCPH10TLB855ABL 16
9. Hold onto the height adjustment plunger and remove

the handle bolt.
RCPH10TLB853ABL 17
10. Remove the height adjustment plunger and the

spring.
RCPH10TLB854ABL 18
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USER CONTROLS AND SEAT Operator seat - Inspect - Pedestal seat

Prior operation:
USER CONTROLS AND SEAT Operator seat - Disassemble - Pedestal seat (E.32.C)
Slide
1. Check the position locking teeth for damage.
RCPH10TLB835ABL 1
2. Check the slide locking plate, springs, pivots, and

rails for damage.
RCPH10TLB834ABL 2
3. If damage if found, replace the slide and the swivel

as an assembly.
Swivel
1. Inspect the bearing tracks, the bearings, and the
bearing separator plate for wear or damage.
2. Repair or replace as needed.
RCPH10TLB844ABL 3
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Pedestal
1. Inspect the height spring for cracks or damaged coils.
2. Inspect the plunger and plunger spring for wear or
damage.
3. Inspect the bushings for wear or damage.
4. Inspect the height adjustment holes for elongation.
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USER CONTROLS AND SEAT Operator seat - Assemble - Pedestal

seat
Prior operation:
USER CONTROLS AND SEAT Operator seat - Inspect - Pedestal seat (E.32.C)
Pedestal
1. Place the height adjustment plunger and the spring
into the pedestal shaft.
RCPH10TLB854ABL 1
2. Hold onto the height adjustment plunger and install

the handle bolt.
RCPH10TLB853ABL 2
3. Install the self-locking nut and tighten.

NOTICE: Overtightening the nut can cause binding of the
height adjustment handle.
RCPH10TLB855ABL 3
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4. Install the lower bushing by spreading it at the slot

and sliding it onto the pedestal shaft.
RCPH10TLB852ABL 4
5. Install the upper bushing by spreading it at the slot

and sliding it onto the pedestal shaft.
RCPH10TLB851ABL 5
RCPH10TLB850ABL 6
7. Press the pedestal together while holding out on the

height adjustment handle.
NOTE: Press down until the slot for the stop bolt is visible
through an adjustment hole.
RCPH10TLB848ABL 7
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8. Apply thread locking compound onto the stop bolt.

9. Install and tighten the stop bolt.
10. Remove the seat from the press.
RCPH10TLB847ABL 8
Swivel
1. Place the bearing separator plate onto the lower por-
tion of the swivel.
2. Place the bearings into the separator plate.
RCPH10TLB842ABL 9
3. Install the top half of the swivel assembly over the

separate plate.
4. Place the nut onto the swivel bolt.
5. Hand tighten the swivel nut until there is no play in
the bearing.
6. Tighten the nut two more flats and align it with the
cotter pin hole.
RCPH10TLB841ABL 10
7. Install the cotter pin. Make sure the cotter pin is bent
over enough so it will not interfere with sliding oper-
ations.
RCPH10TLB766ABL 11
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Slide
1. Install the adjustable slide bushings on the right side
of the slide frame.
2. Lubricate the nonadjustable slide bushings with
molydisulfide grease.
3. Install the nonadjustable slide bushings on the left
side of the slide frame.
RCPH10TLB837ABL 12
4. Align the adjuster holes with the adjustable bushings.
RCPH10TLB775ABL 13
5. Adjust the bushings for the side to side motion of the

seat.
NOTE: Slides adjusted too tightly can cause difficulty ad-
justing the seat fore and aft.
RCPH10TLB829ABL 14
Seat
1. Install the seat.
2. Install and tighten the seat stop.
RCPH10TLB832ABL 15
Next operation:
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Seat belt - Install (E.32.C)
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USER CONTROLS AND SEAT Operator seat - Disassemble -

Mechanical suspension seat
Cushions
1. Push up on the bottom seat cushion and remove.
RCPH10TLB755ABL 1
2. Remove the retaining screws for the back cushion.
RCPH10TLB756ABL 2
3. Pull forward and lift the back cushion off of the mount-
ing tabs to remove.
RCPH10TLB757ABL 3
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Lumber adjustment
1. Drive the roll pin out of the lumbar adjustment knob.
RCPH10TLB759ABL 4
2. Remove the mounting screws and the lumber adjust-

ment knob.
RCPH10TLB758ABL 5
3. Drill out the rivets and remove the lumbar assembly.
RCPH10TLB761ABL 6
Recliner
1. Remove the mounting screws and the stop plate from
the rear of the seat bottom.
RCPH10TLB762ABL 7
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2. Remove the four nuts and the four washers from the
seat bottom.
3. Remove the seat bottom and the seat back from the
slide/swivel assembly.
RCPH10TLB778ABL 8
4. Pivot the back rest forward and remove the four nuts
and the two bolts that mount the seat bottom to the
seat back.
RCPH10TLB817ABL 9
5. Remove the seat bottom.

6. Remove the spring retaining nut.
RCPH10TLB816ABL 10
RCPH10TLB815ABL 11
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8. Remove the spring from the pivot pin.
RCPH10TLB814ABL 12
9. Remove the arm rest from the seat back.
RCPH10TLB813ABL 13
10. Remove the spring for the recliner handle from the
arm rest bracket.
RCPH10TLB801ABL 14
11. Remove the handle return spring from the recliner.
RCPH10TLB810ABL 15
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12. Remove the nut from the recliner.
RCPH10TLB809ABL 16
13. Remove the washer from the recliner.
RCPH10TLB808ABL 17
14. Remove the bushing from the recliner, remove the

arm rest from the seat back.
RCPH10TLB807ABL 18
15. Remove the handle from the seat back.
RCPH10TLB802ABL 19
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16. Remove the two bolts from the recliner bracket, re-
move the bracket.
RCPH10TLB803ABL 20
17. Remove the retainer and recliner gear.
RCPH10TLB804ABL 21
Slide
1. Remove the slide bushings from the left side of the
slide assembly.
RCPH10TLB763ABL 22
2. Remove the adjustable slide bushings from the right

side of the slide assembly.
RCPH10TLB764ABL 23
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Swivel
1. Remove the cotter pin from the swivel bolt.
RCPH10TLB766ABL 24
2. Place a suitable wedge under the bottom of the

swivel bolt to hold it into the swivel assembly.
RCPH10TLB767ABL 25
RCPH10TLB768ABL 26
4. Remove the bushing from the swivel bolt.

5. Remove the top half of the swivel assembly.
RCPH10TLB769ABL 27
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6. Remove the bearing separator from the lower half of

the swivel assembly.
RCPH10TLB770ABL 28
7. Remove the bearings.
RCPH10TLB771ABL 29
Suspension
1. If you have not already done so, obtain access to the
suspension system.
A. Remove the upper tether mounting bolts
and nuts.
RCPH10TLB782ABL 30
B. Remove the front slide/swivel mounting

bolts.
RCPH10TLB783ABL 31
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C. Remove the slide/swivel assembly.

NOTE: The slide/swivel assembly does not have to be dis-
assembled.
RCPH10TLB784ABL 32
2. Remove the lower mounting bolts and the tether

straps, keep all of the components together for the
tether straps.
RCPH10TLB787ABL 33
3. Remove the front mounting nuts and washers.

4. Remove the suspension assembly from the seat
mount.
RCPH10TLB785ABL 34
5. Remove the roll pin from the height/weight adjuster

knob and remove the knob.
NOTE: Remove the knob to prevent damage while remov-
ing the boot for the suspension assembly.
RCPH10TLB781ABL 35
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6. Remove the boot from the suspension assembly.
RCPH10TLB786ABL 36
7. • If reusing the boot, pry out the retaining

pins. Place the cutting edge of the side
cutters close to the pressed in button
shaft.
• If replacing the boot, cut the retaining pins
with the side cutter and remove the pins.
RCPH10TLB828ABL 37
8. Place the suspension assembly in a press.

9. Push down on the suspension.
RCPH10TLB788ABL 38
10. Remove the nut on the shock.

11. Remove the bolt from the shock.
RCPH10TLB789ABL 39
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12. Slowly release the pressure on the suspension as-

sembly.
RCPH10TLB790ABL 40
13. Remove the nut from the upper and lower pivots.
RCPH10TLB791ABL 41
14. Pull the pivot bolt back just far enough to remove the
shock from the suspension assembly.
RCPH10TLB793ABL 42
15. Remove the upper pivot bolt.

16. Remove the upper plate from the suspension assem-
bly.
RCPH10TLB792ABL 43
17. Disassemble the height/weight adjustment assembly

as needed.
1. Remove the top half of the upper plate.
84516378 05/07/2011
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B. Remove the gear for the height/weight

knob.
NOTE: You do not have remove the knob from the gear.
RCPH10TLB797ABL 44
C. Remove the adjustment gear.
RCPH10TLB797ABL 45
D. Remove the bushing for the adjustment

gear.
RCPH10TLB798ABL 46
18. Remove the lower pivot bolt for the lower plate of the
suspension assembly.
RCPH10TLB794ABL 47
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19. Remove the scissor assembly.
RCPH10TLB795ABL 48
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USER CONTROLS AND SEAT Operator seat - Inspect - Mechanical

suspension seat
Prior operation:
USER CONTROLS AND SEAT Operator seat - Disassemble - Mechanical suspension seat (E.32.C)
Slide
1. Check the position locking teeth for damage.
RCPH10TLB765ABL 1
2. Check the slide locking plate, springs, pivots, and

rails for damage.
RCPH10TLB831ABL 2
3. If damage if found, replace the slide and the swivel

as an assembly.
Swivel
1. Inspect the bearing tracks, the bearings, and the
bearing separator plate for wear or damage.
RCPH10TLB772ABL 3
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Suspension
1. Inspect the slider blocks and the bushings for wear
and damage.
RCPH10TLB796ABL 4
2. Inspect the threads and the teeth of the height/weight

adjustment gear and the knob gear.
RCPH10TLB797ABL 5
3. Inspect the bushing on the bottom of the gear.
RCPH10TLB798ABL 6
4. Inspect the rubber stops.
RCPH10TLB799ABL 7
84516378 05/07/2011
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5. Inspect the shock for leaks.

6. Inspect the bushings for wear.
RCPH10TLB007ACL 8
7. Inspect the spring for damage.

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USER CONTROLS AND SEAT Operator seat - Assemble -

Mechanical suspension seat
Prior operation:
USER CONTROLS AND SEAT Operator seat - Inspect - Mechanical suspension seat (E.32.C)
Suspension
1. Install the slider blocks on the lower plate as shown.
NOTE: Do not lubricate the slider blocks.
RCPH10TLB818ABL 1
2. Install the scissor assembly.
RCPH10TLB795ABL 2
3. Lubricate the pivot bushing with molydisulfide

grease.
4. Install the pivot bolt and the nut in the slotted hole on
the lower plate of the suspension assembly.
NOTE: The 'L' portion of the pivot bolt goes to the inside of
5. Tighten the nut.
RCPH10TLB819ABL 3
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6. Install the height/weight adjustment assembly as

needed.
A. Lubricate the bushing for the bottom of the
gear with molydisulfide grease.
B. Place the bushing on the lower half of the
upper plate for the suspension system.
RCPH10TLB821ABL 4
C. Lubricate the gear threads with molydisul-

fide grease.
D. Install the gear so it aligns with the bush-
ing.
RCPH10TLB822ABL 5
E. Install the gear for the height/weight ad-

justment knob.
RCPH10TLB797ABL 6
F. Install the top half of the upper plate.

7. Install the upper plate assembly.
8. Install the upper pivot bolt in the slotted hole.
RCPH10TLB792ABL 7
84516378 05/07/2011
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9. Start the pivot bolt into the scissor assembly.

NOTE: The “L” portion of the pivot bolt goes to the inside
of the suspension assembly.
RCPH10TLB824ABL 8
10. Install the shock.
RCPH10TLB825ABL 9
11. Insert the pivot bolt completely and install and tighten
the nut.
12. Place the suspension assembly into a press.
13. Compress the spring to mount the shock.
14. Install the bolt and nut for the shock.
RCPH10TLB788ABL 10
15. Slowly release the pressure on the suspension as-

sembly.
16. Check for proper operation of the weight/height ad-
justment.
NOTE: Turn the handle to the '+' to raise the plate and apply
more pressure the spring, turn the handle to the '-' will to
lower the plate and decrease the pressure on the spring.
RCPH10TLB826ABL 11
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17. Install the boot. Use a non-marring hammer to tap in

the retaining pins.
RCPH10TLB827ABL 12
18. Place the suspension assembly onto the stand,

19. Install and tighten the front mounting nuts and wash-
ers.
RCPH10TLB785ABL 13
20. Install the tether straps on the rear of the stand.
RCPH10TLB787ABL 14
Swivel
1. Place the bearing separator plate onto the lower por-
tion of the swivel.
RCPH10TLB773ABL 15
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2. Place the bearings into the separator plate.
RCPH10TLB774ABL 16
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3. Install the top half of the swivel assembly over the

separate plate.
4. Place the nut onto the swivel bolt.
5. Hand tighten the swivel nut until there is no play in
the bearing.
6. Tighten the nut two more flats and align it with the
cotter pin hole.
RCPH10TLB769ABL 17
7. Install the cotter pin. Make sure the cotter pin is bent
over enough so it will not interfere with sliding oper-
ations.
RCPH10TLB766ABL 18
Slide
1. Install the adjustable slide bushings on the right side
of the slide frame.
RCPH10TLB764ABL 19
2. Lubricate the bushings with molydisulfide grease.

3. Install the nonadjustable slide bushings on the left
side of the slide frame.
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4. Align the adjuster holes with the adjustable bushings.
RCPH10TLB775ABL 20
5. Adjust the bushings for the side to side motion of the

seat.
NOTE: Slides adjusted too tightly can cause difficulty ad-
justing the seat fore and aft.
RCPH10TLB829ABL 21
6. Install the slide/swivel assembly onto the suspen-

sion.
RCPH10TLB784ABL 22
A. Install and tighten the upper tether mount-

ing bolts and nuts.
RCPH10TLB782ABL 23
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B. Install and tighten the front slide/swivel

mounting bolts.
RCPH10TLB783ABL 24
Seat
1. Install the seat.
2. Install the seat stop.
RCPH10TLB762ABL 25
3. If removed, place the height/weight adjuster knob

onto the shaft and install a new roll pin.
RCPH10TLB780ABL 26
Recliner
1. Place the gear onto the pivot.
2. Drive a new retainer onto the pivot.
NOTE: The gear must pivot freely.
RCPH10TLB805ABL 27
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3. Install the brackets,

4. Install and tighten the two bolts.
RCPH10TLB803ABL 28
5. Place the handle into the seat back.
RCPH10TLB802ABL 29
6. Place the seat back onto the arm rest pivot.

NOTE: Align the handle pin into the recliner gear.
RCPH10TLB806ABL 30
7. Install the bushing onto the recliner.
RCPH10TLB807ABL 31
84516378 05/07/2011
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8. Install the washer onto the recliner.
RCPH10TLB808ABL 32
9. Install and tighten the nut onto the recliner.
RCPH10TLB809ABL 33
10. Place the handle return spring into the recliner.
RCPH10TLB810ABL 34
11. Install the handle return spring into the mounting hole
in the arm rest.
RCPH10TLB811ABL 35
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12. Make sure the handle return spring is completely

seated into the mounting hole.
RCPH10TLB812ABL 36
13. Install the arm rest into the seat back.
RCPH10TLB813ABL 37
14. Place the spring onto the pivot pin and hook the
spring onto the seat back.
RCPH10TLB814ABL 38
RCPH10TLB815ABL 39
84516378 05/07/2011
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16. Install and tighten the self-locking nut.
RCPH10TLB816ABL 40
17. Attach the seat bottom to the seat back.

A. Place the seat bottom into the arm rests.
B. Install and tighten the bolts and nuts.
RCPH10TLB817ABL 41
18. Place the spacers onto the slide/swivel assembly.
RCPH10TLB779ABL 42
19. Place the seat frame onto the slide/swivel assembly.

20. Tighten the four mounting bolts.
RCPH10TLB778ABL 43
21. Check the recliner for proper operation.
84516378 05/07/2011
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Lumbar
1. Place the lumbar assembly into position on the seat
back and install new rivets.
RCPH10TLB761ABL 44
2. Put the knob and shaft bushing onto the shaft.

3. Mount the bushing to the seat back.
RCPH10TLB758ABL 45
4. Install a new roll pin into the knob.
RCPH10TLB760ABL 46
Cushion
1. Install the back seat cushion by aligning the retaining
tabs with the slots.
RCPH10TLB830ABL 47
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2. Install and tighten the seat back retaining screws.
RCPH10TLB756ABL 48
3. Align the retaining tabs with the slots and push the
seat bottom into position.
RCPH10TLB755ABL 49
Next operation:
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USER CONTROLS AND SEAT Operator seat - Disassemble - Air

suspension seat
1. Loosen and remove the four bolts from the seat as-
sembly.
2. Remove the seat assembly from the base.
RCPH10TLB858ABL 1
3. Place the seat assembly on the workbench.

4. Cut and remove the plastic clips from the backrest
cover.
5. Remove the backrest cover.
RCPH10TLB922ABL 2
6. Push in on the plastic retainer and remove the lumbar

support adjustment knob.
RCPH10TLB924ABL 3
7. Remove the mounting screw from the housing for the

lumber support adjustment knob.
RCPH10TLB923ABL 4
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8. Disconnect the cable from the lumbar support.

9. Remove the cable and housing assembly.
RCPH10TLB923ABL 5
10. Remove the armrests.

A. Tilt the armrest up until it is against the
upper stop.
B. Push in on the armrest as shown.
C. Rotate the armrest counter-clockwise past
the upper stop.
RCPH10TLB857ABL 6
D. Remove the armrest from the seat.
RCPH10TLB856ABL 7
11. Loosen and remove the two Allen head bolts from
the seat stop.
12. Remove the seat stop from the upper slide plate.
RCPH10TLB859ABL 8
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13. Loosen the two Allen head bolts in the two slide
pucks on the right side of the upper slide plate.
NOTE: Slide the upper plate fore or aft until the set screws
are visible through the holes in the side rail.
RCPH10TLB861ABL 9
14. Lift the handle to release the lock on the upper slide
plate.
RCPH10TLB863ABL 10
15. Move the upper slide plate forward and remove from
the slide/swivel assembly.
RCPH10TLB864ABL 11
retaining ring from the slide control lever (1).
17. Remove the return spring and the slide control lever
from the upper slide plate assembly.
18. Repeat this procedure and remove the swivel control
lever (2) from the upper slide plate assembly.
RCPH10TLB916ABL 12
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retaining ring from the slide latch.
20. Remove the return spring and the slide latch from the
upper slide plate assembly.
RCPH10TLB917ABL 13
21. Use a soft hammer and remove the slide pucks from
the slide/swivel assembly.
RCPH10TLB865ABL 14
22. Loosen and remove the two 5/16 inch bolts from the
front side of the slide/swivel assembly.
RCPH10TLB867ABL 15
23. Loosen and remove the two 3/8 inch bolts and the
two tether straps from the rear of the slide/swivel as-
sembly.
RCPH10TLB868ABL 16
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24. Remove the slide/swivel assembly from the lateral

isolator plate.
RCPH10TLB869ABL 17
25. Loosen and remove the two bolts from the swivel
contact switch assembly.
26. Remove the switch from the lateral isolator plate.
RCPH10TLB870ABL 18
27. Remove the two screws from the swivel contact

switch.
28. Disconnect the wiring harness from the swivel con-
tact switch.
RCPH10TLB872ABL 19
29. Disconnect the wiring harness from the height adjust-

ment switch.
RCPH10TLB871ABL 20
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30. Remove the two bolts from the mounting bracket for
the height adjustment switch.
31. Remove the height adjustment switch assembly.
RCPH10TLB873ABL 21
32. From the rear of the height adjustment switch, press

in on the top and bottom tabs and push the switch for-
ward until the tabs are free of the mounting bracket.
33. Remove the height adjustment switch from the
mounting bracket.
RCPH10TLB874ABL 22
34. Loosen and remove the four bolts from the lateral
isolator plate.
RCPH10TLB875ABL 23
35. Remove the isolator plate from the upper housing.
RCPH10TLB876ABL 24
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36. Turn the isolator plate over and place on the work-
bench.
37. Use acceptable tools and remove the two isolator
springs from the isolator plate.
RCPH10TLB909ABL 25
38. Use acceptable tools and remove the nut from the
isolator shock.
RCPH10TLB910ABL 26
39. Remove the top washer and rubber insulator from the
shock.
RCPH10TLB911ABL 27
40. Use acceptable tools and remove the retaining ring

from the lateral isolator shock.
RCPH10TLB912ABL 28
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41. Remove the pin from the isolator shock.
RCPH10TLB913ABL 29
42. Remove the shock from the isolator plate.
RCPH10TLB914ABL 30
43. Use acceptable tools and remove the two roll pins
from the lateral isolator control.
RCPH10TLB909ABL 31
44. Use acceptable tools and remove the bolts (1) from
the isolator control mounting bracket.
45. Remove the lateral isolator control (2) from the iso-
lator plate.
RCPH10TLB909ABL 32
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46. Slide bottom of the isolator plate to the left until the
isolator roller bearings are exposed.
47. Remove the rollers bearings from the shaft.
48. Slide the bottom of the isolator plate to the right until
the isolator roller bearings are exposed
49. Remove the roller bearings from the shaft.
NOTE: Illustration is for reference only.
RCPH10TLB909ABL 33
50. Remove the plastic pins from the boot assembly and
fold the boot down to the base plate. Note the loca-
tion of the tether straps behind the boot.
RCPH10TLB877ABL 34
51. Loosen and remove the two bolts from the fore/aft
isolator shock mounting bracket.
52. Remove the bracket from the upper housing plate.
53. Allow the other end of the isolator shock to hang from
the suspension arm.
RCPH10TLB878ABL 35
54. Loosen and remove the two bolts from the fore/aft
isolator control. Retain the bolts for reassembly.
RCPH10TLB879ABL 36
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55. Slide the upper housing to the rear and lift the hous-
ing free of the roller bearings on the rear suspension
arms.
RCPH10TLB880ABL 37
56. Slide the upper housing forward and lift the housing
free of the roller bearings on the front suspension
arms. Note the location of the rubber bumpers on
the upper housing for reassembly.
RCPH10TLB881ABL 38
57. Remove the two wide roller bearings from the front
suspension arms.
RCPH10TLB882ABL 39
58. Remove the two narrow roller bearings from the rear
suspension arms.
RCPH10TLB883ABL 40
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59. Remove the bushing and the isolator control from the
suspension arm.
RCPH10TLB884ABL 41
60. Use acceptable tools and remove the roll pins from
each end of the isolator control.
61. Remove the two plastic bushings, the two springs,
and the latch assembly from the isolator control.
RCPH10TLB907ABL 42
62. Use acceptable tools and remove the roll pin from
the control housing.
63. Remove the isolator control knob from the housing.
RCPH10TLB907ABL 43
64. Remove the two bushings and the isolator shock

from the suspension arm.
RCPH10TLB885ABL 44
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65. Place an acceptable block between the suspension

assembly and the front of the lower housing assem-
bly.
RCPH10TLB886ABL 45
66. Note the location of the three wire ties on the lower
housing assembly.
RCPH10TLB918ABL 46
67. Cut and remove the three wire ties from the wiring
harness.
RCPH10TLB892ABL 47
68. Note the location of the two wire ties on the suspen-
sion assembly.
RCPH10TLB918ABL 48
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69. Cut and remove the wire ties.
RCPH10TLB887ABL 49
70. Disconnect the wiring harness from the air compres-

sor assembly.
RCPH10TLB888ABL 50
71. Loosen the air line fitting and allow the air to escape
from the air spring assembly.
72. Remove the air line from the air spring.
RCPH10TLB889ABL 51
73. Loosen and remove the two bolts from the air com-
pressor mounting bracket.
RCPH10TLB890ABL 52
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74. Remove the air compressor assembly.
RCPH10TLB891ABL 53
75. Loosen and remove the four bolts from the pedestal
mounting plate.
76. Remove the pedestal from the lower housing assem-
bly.
RCPH10TLB894ABL 54
77. Loosen and remove the lower screw from the air
spring.
RCPH10TLB895ABL 55
78. Loosen and remove the bolt from the top of the air
spring.
RCPH10TLB893ABL 56
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79. Remove the air spring assembly.
RCPH10TLB896ABL 57
80. Cut and remove the plastic pins from the rubber boot.
RCPH10TLB897ABL 58
81. Remove the rubber boot from the lower housing as-
sembly.
RCPH10TLB898ABL 59
82. Loosen and remove the nut from the shaft.
RCPH10TLB906ABL 60
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83. Use acceptable tools and remove the shaft from the
RCPH10TLB905ABL 61
84. Tilt the suspension assembly forward.

85. Turn the suspension assembly counter-clockwise
and remove from the lower housing.
RCPH10TLB903ABL 62
86. Remove the two roller bearings (1) from the shaft.
87. Use acceptable tools and remove the two plastic
bushings (2) from the tube.
RCPH10TLB899ABL 63
88. Remove the retaining clip from the isolator shock.
RCPH10TLB900ABL 64
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89. Remove the isolator shock and two plastic bushings

from the suspension assembly.
RCPH10TLB901ABL 65
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USER CONTROLS AND SEAT Operator seat - Inspect - Air

suspension seat
Prior operation:
USER CONTROLS AND SEAT Operator seat - Disassemble - Air suspension seat (E.32.C)
1. Inspect the seat cushion, backrest cushion, arm rests

and lumbar support control for wear and damage.
2. Inspect the upper slide plate assembly, swivel con-
trol, slide control, and slide latch for wear and dam-
age.
3. Inspect the slide/swivel assembly and slide pucks for
wear and damage.
4. Inspect the swivel switch, height adjustment switch,
and wire harness for damage.
5. Inspect the lateral isolator plate, isolator shock, bush-
ings, springs, roller bearings, and control for wear
and damage.
6. Inspect the boot assembly for damage.
7. Inspect the upper housing and rubber bumpers for
8. Inspect the suspension assembly and roller bearings
9. Inspect the fore/aft isolator shock and bushings for
wear and damage.
10. Inspect the fore/aft isolator control and bushing for
wear and damage.
11. Inspect the suspension isolator shock and bushings
12. Inspect the air compressor, air line, and wiring har-
ness for wear and damage.
13. Inspect the air spring for wear and damage.
14. Insect the lower housing, bearing shaft, and rubber
bumper for wear and damage.
15. Inspect the pedestal for damage.
16. Repair or replace worn or damaged parts as needed.
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USER CONTROLS AND SEAT Operator seat - Assemble - Air

suspension seat
Prior operation:
USER CONTROLS AND SEAT Operator seat - Inspect - Air suspension seat (E.32.C)
1. Install the isolator shock and the two plastic bushings

onto the suspension assembly.
RCPH10TLB901ABL 1
2. Use acceptable tools and install the retaining clip

onto isolator shock.
RCPH10TLB902ABL 2
3. Lubricate the two roller bearings (1) with molydisul-

fide grease and install onto the shaft.
RCPH10TLB899ABL 3
4. Install the two plastic bushings (2) into the tube.
84516378 05/07/2011
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5. Install the suspension assembly roller bearings into

the lower housing at a slight angle, as shown.
RCPH10TLB903ABL 4
6. Turn the suspension assembly clockwise and align

the rear tube into the lower housing assembly.
7. Install the shaft into the lower housing assembly.
RCPH10TLB904ABL 5
8. Install and tighten the nut on the shaft.
RCPH10TLB906ABL 6
9. Install the rubber boot over the suspension assembly

and onto the lower housing assembly.
RCPH10TLB898ABL 7
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10. Install the plastic pins into the lower mounting holes
of the rubber boot.
RCPH10TLB919ABL 8
11. Install the air spring assembly into the suspension

assembly.
RCPH10TLB896ABL 9
12. Install and tighten the bolt into the top of the air
spring.
RCPH10TLB893ABL 10
13. Install and tighten the screw into the bottom of the air
spring.
RCPH10TLB895ABL 11
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14. Install the pedestal onto the lower housing.

15. Install the tether straps between the rubber boot and
lower housing.
16. Install and tighten the four bolts for the pedestal
mounting plate.
17. Drive the pins into the mounting holes in the lower
housing assembly.
RCPH10TLB894ABL 12
18. Install the air compressor into the suspension as-

sembly.
RCPH10TLB891ABL 13
19. Install and tighten the two air compressor mounting

bolts.
RCPH10TLB890ABL 14
20. Install the air line into the fitting on the air spring.
21. Tighten the fitting nut.
RCPH10TLB889ABL 15
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22. Connect the air compressor wiring harness.
RCPH10TLB888ABL 16
23. Install three wire ties for the wiring harness on the
RCPH10TLB918ABL 17
24. Install two wire ties on the suspension assembly.
RCPH10TLB918ABL 18
25. Install the two plastic bushings and the isolator shock
onto the suspension assembly. Make sure that the
white plastic bushing is on the outside.
RCPH10TLB885ABL 19
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26. Assemble the parts of the isolator control.
RCPH10TLB907ABL 20
27. Install the isolator control and plastic bushing onto

RCPH10TLB884ABL 21
28. Lubricate the two narrow roller bearings with moly-

disulfide grease.
29. Install the narrow roller bearings onto the rear shafts
RCPH10TLB883ABL 22
30. Lubricate the two wide roller bearings with molydisul-

fide grease.
31. Install the wide roller bearings onto the front shafts
RCPH10TLB882ABL 23
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32. Install the upper housing slide rail onto the wide roller
bearings on the suspension assembly. Make sure
the rubber bumpers are facing to the rear of the sus-
pension assembly.
RCPH10TLB881ABL 24
33. Slide the upper housing to the rear until the narrow
roller bearings engage the slide rails of the upper
housing.
RCPH10TLB880ABL 25
34. Install and tighten the two bolts in the fore/aft isolator
control.
NOTE: Ensue you use the same bolts that you removed
during disassembly.
RCPH10TLB879ABL 26
35. Install the bracket on the upper housing plate.

36. Position the isolator shock in the upper housing plate.
37. Install and tighten the two bolts in the fore/aft isolator
mounting bracket.
RCPH10TLB878ABL 27
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38. Slide the rubber boot into position on the upper hous-
ing.
39. Install the plastic pins into the mounting holes in the
rubber boot.
40. Drive the pins into the mounting holes in the upper
housing.
RCPH10TLB920ABL 28
41. Slide the bottom of the isolator plate to the left until
the holes for the roller bearings are visible.
42. Lubricate the two roller bearings with molydisulfide
grease.
43. Install the roller bearings onto the shafts of the isola-
tor plate.
44. Slide the bottom of the isolator plate to the right until
the holes for the roller bearings are visible.
45. Lubricate the two roller bearings with molydisulfide
grease.
46. Install the roller bearings onto the shafts of the isola- RCPH10TLB909ABL 29
tor plate.
NOTE: Illustration is for reference only.
47. Install the lateral isolator control (2) onto the isolator
plate.
48. Install and tighten the bolts (1) in the mounting
bracket.
RCPH10TLB909ABL 30
49. Use acceptable tools and install the two roll pins in
the isolator control.
RCPH10TLB909ABL 31
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50. Install the isolator shock and two plastic bushings

into the mounting brackets on the isolator plate.
RCPH10TLB914ABL 32
51. Install the pin into the isolator shock.
RCPH10TLB913ABL 33
52. Install the retaining clip onto the pin.
RCPH10TLB912ABL 34
53. Install the rubber insulator and top washer onto the
shock.
RCPH10TLB911ABL 35
84516378 05/07/2011
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54. Install and tighten the lock nut on the shock.
RCPH10TLB910ABL 36
55. Install the two isolator springs on the isolator plate.
RCPH10TLB909ABL 37
56. Turn the isolator plate over and install onto the upper
housing.
RCPH10TLB876ABL 38
57. Install and tighten the four bolts that mount the lateral
isolator plate to the upper housing.
RCPH10TLB875ABL 39
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58. Install the height adjustment switch into the mounting

bracket.
RCPH10TLB874ABL 40
59. Install the height adjustment switch assembly.

60. Install and tighten the bolts in the mounting bracket
for the height adjustment switch.
RCPH10TLB873ABL 41
61. Connect the wiring harness to the height adjustment

switch.
RCPH10TLB871ABL 42
62. Connect the wiring harness to the swivel switch.

63. Tighten the screws to secure the harness on the
swivel switch.
RCPH10TLB872ABL 43
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64. Install the swivel contact switch assembly on the lat-

eral isolator plate.
65. Install and tighten the two bolts.
RCPH10TLB870ABL 44
66. Install the slide/swivel assembly on the lateral isola-

tor plate.
RCPH10TLB869ABL 45
67. Install the two 3/8 inch bolts through the tether strap
mounting holes.
68. Install and tighten the bolts into the swivel plate
mounting holes.
69. Install and tighten the bolts into the swivel plate
mounting holes.
RCPH10TLB868ABL 46
70. Install and tighten the two 5/16 inch bolts into the
swivel plate mounting holes.
RCPH10TLB867ABL 47
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71. Place the adjustable slide pucks on the slide/swivel

assembly, as shown.
72. Use a soft hammer to install the side pucks.
RCPH10TLB866ABL 48
73. Use acceptable tools and install the return spring and
slide latch on the upper plate assembly.
74. Use acceptable tools and install the roll pin and the
retaining clip on the slide latch.
RCPH10TLB917ABL 49
75. Place the slide control lever (1) and the swivel lever
(2) on the upper slide plate assembly.
76. Use acceptable tools and install the spring, roll pin
and the retaining ring to secure the levers on the
upper slide plate.
RCPH10TLB916ABL 50
77. Lubricate the non-adjusting slide pucks and slide

track on the upper slide plate with molydisulfide
grease.
78. Install the upper slide plate over the front slide pucks
on the swivel assembly.
RCPH10TLB864ABL 51
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79. Lift the slide control and slide the upper slide plate
into position on the swivel assembly.
RCPH10TLB863ABL 52
80. Install and tighten the two Allen head bolts in the two
slide pucks on the right side of the upper slide plate.
NOTE: Slide the upper plate fore or aft until the bolt holes
in the side rail are visible.
RCPH10TLB861ABL 53
81. Install the seat stop on the upper slide plate.
RCPH10TLB860ABL 54
82. Install and tighten the two Allen head bolts in the seat
stop.
RCPH10TLB859ABL 55
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83. Install the armrests.

A. Place the armrest in the hole on the seat.
RCPH10TLB856ABL 56
84. Instal the armrests.

B. Push in on the armrest as shown.
C. Rotate the armrest clockwise past the up-
per stop.
RCPH10TLB857ABL 57
85. Connect the cable assembly to the lumbar support

assembly.
RCPH10TLB923ABL 58
86. Install and tighten the mounting screw (1) in the hous-
ing for the lumbar support adjustment knob.
87. Install the lumbar support adjustment knob (2) on the
housing.
88. Push the knob onto the housing until the plastic re-
tainer is locked in position.
RCPH10TLB924ABL 59
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89. Place the backrest cover in position on the seat top.

90. Install the plastic clips in the mounting holes of the
backrest cover.
91. Use a soft hammer to drive the plastic clips into the
mounting holes of the seat top.
RCPH10TLB921ABL 60
92. Place the seat assembly into position on the seat

base.
93. Install and tighten the four bolts.
RCPH10TLB858ABL 61
94. After the seat has been assembled, adjust the slide
pucks to the desired lateral movement of the seat.
RCPH10TLB862ABL 62
95. Check the seat for proper operation.
Next operation:
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Seat belt - Install

1. Install the retractable belt strap on the right-hand side
of the seat.
A. Place at 45 ° +/- 5 ° angle.
RCPH10TLB753ABL 1
B. Secure using the spacer (1) and the bolt

(2).
C. Torque the bolt to 94 - 106 N·m (69 - 78 lb
ft).
RCPH10TLB439AAF 2
2. Install the buckle/latch mechanism on the left-side of

the seat.
A. Use the spacer (1), washers (2), bracket
(3), and bolt (4).
B. Torque the bolt to 94 - 106 N·m (69 - 78 lb
ft).
RCPH10TLB440AAF 3
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Index
FRAME AND CAB - E

Seat belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Seat suspension system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
USER CONTROLS AND SEAT Operator seat - Assemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
USER CONTROLS AND SEAT Operator seat - Assemble - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . 35
USER CONTROLS AND SEAT Operator seat - Assemble - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
USER CONTROLS AND SEAT Operator seat - Disassemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . 49
USER CONTROLS AND SEAT Operator seat - Disassemble - Mechanical suspension seat . . . . . . . . . . . . . . . . 19
USER CONTROLS AND SEAT Operator seat - Disassemble - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
USER CONTROLS AND SEAT Operator seat - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
USER CONTROLS AND SEAT Operator seat - Inspect - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
USER CONTROLS AND SEAT Operator seat - Inspect - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . 32
USER CONTROLS AND SEAT Operator seat - Inspect - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
USER CONTROLS AND SEAT Operator seat - Replace - Pivot safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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FRAME AND CAB - E
USER PLATFORM - 34.A
580N
580SN WT
580SN
590SN
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Contents
FRAME AND CAB - E
TECHNICAL DATA
USER PLATFORM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
ROPS
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Door, window and windscreen
Exploded view Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view - Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
USER PLATFORM
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ROPS
Remove Rops cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Door, window and windscreen
Remove - Rear window - top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Install - Rear window - top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Remove - Rear window - middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Install - Rear window - middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Remove - Rear window - bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Install - Rear window - bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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FRAME AND CAB - USER PLATFORM
USER PLATFORM - Torque

Cab and ROPS canopy
Mounting bolts: 298 - 358 N·m (220 - 264 lb ft)
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ROPS - Exploded view
RCPH10TLB020FAL 1
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
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Door, window and windscreen - Exploded view Rear window
RCPH10TLB001GAD 1
(A) Top latch assembly (right-hand and left-hand sides)

(B) Middle latch assembly (right-hand and left-hand sides)
(1) Rear window frame
(2) Flocked channel seal (right-hand and left hand side)
(3) Rubber block window stop
(4) Top window
(5) Middle window
(6) Bottom window
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Door, window and windscreen - Exploded view - Door

Machines equipped with two doors have similar components however most of the components will not be
interchangeable because of the curvature of the cab design. The exploded view shown is for the standard
left-hand side door.
(1) Door gasket
(2) Window latch bracket
(3) Door frame
(4) Hinge pin and circlip
(5) Window latch
(6) Window hinge hardware with rubber washer
(7) Window gasket
(8) Window
(9) Window hinge
(10) Window hinge mounting plate
(11) Button latch
(12) Door handle with gasket
(13) Door latch cover
(14) Gas spring stud
(15) Door latch assembly
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RCPH10TLB001HAD 1
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Door, window and windscreen - Exploded view - Side window

Rear side window components (both sides)
The curvature of the rear side window creates a distinct difference between the left and right-hand side windows
which is not interchangeable. However, the component layout is the same for both sides.
(1) Latch bracket
(2) Latch locking mechanism
(3) Hinge hardware
(4) Gasket
(5) Window glass
(6) Rubber door stop
(7) Hinge with rubber gasket
(8) Hinge hardware
(9) Button latch
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RCPH10TLB003GAD 1
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Front side window components (no door)

Machines equipped with only one door will have a similar front side windows with the exception of a few
components only applicable to the door version.
(1) Hinge pin with circlip
(2) Hinge hardware with rubber washers
(3) Hinge bracket
(4) Hinge bracket hardware
(5) Latch bracket
(6) Latch locking mechanism
(7) Gasket
(8) Window glass
(9) Button latch
(10) Hinge with rubber gasket
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RCPH10TLB004GAD 2
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USER PLATFORM - Inspect

DANGER
Crushing hazard!
Do not change the Roll Over Protective Structure (ROPS) in any way. Unauthorized changes such as
welding, drilling, or cutting will weaken the ROPS and decrease your protection. Have an authorized
dealer replace the ROPS if damage of any kind occurs. DO NOT TRY TO REPAIR THE ROPS.
Failure to comply will result in death or serious injury.
D0037A
After an accident, fire, tip over, or roll over, have a qualified

technician inspect and replace cab or ROPS canopy and
other protective structure components (such as the seat
belt), before returning the machine to operation.
1. Replace the cab or ROPS canopy.
2. Inspect the mounting and suspension for the cab
or ROPS canopy, the operator's seat and suspen-
sion, the seat belt and mounting components, and
the wiring for damage. Replace damaged parts.
3. Tighten all bolts and mounted equipment to specifi-
cations.
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USER PLATFORM - Remove Cab

Prior operation:
Prior operation:
Radiator - Remove - 580SN, 580SN-WT, 590SN only (B.50.A) Steps 1 through 4 and step 10.
Refer to illustration ROPS - Exploded view (E.34.A).

1. Lower backhoe and stabilizers to the ground.
RCPH11TLB063AAM 1
2. Raise the loader in the full upright position and en-

gage the lockout.
RCPH11TLB001AAM 2
RCPH11TLB064AAM 3
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4. Remove four screws from the right hand and left

hand side of the front floor mat.
RCPH11TLB065AAM 4
5. Remove front floor mat.
RCPH11TLB066AAM 5
6. Remove vent louver.
RCPH11TLB067AAM 6
7. Remove louver mounting plate.
RCPH11TLB068AAM 7
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8. Remove the screw from the loader control boot.
RCPH11TLB069AAM 8
9. Pull the loader boot up over the control stick.
RCPH11TLB070AAM 9
10. Remove the snap ring and remove the boot.
RCPH11TLB075AAL 10
11. Remove the loader control console cover.
RCPH11TLB071AAM 11
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12. Remove floor plate hardware.
RCPH11TLB072AAM 12
13. Remove both floor plates.
RCPH11TLB073AAM 13
14. Disconnect electrical connection 1.
RCPH11TLB074AAM 14
15. Disconnect electrical connection 2.
RCPH11TLB074AAM 15
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16. Disconnect the main harness connector.
RCPH11TLB075AAM 16
17. Identify, tag and remove the bolts securing the loader
control rods.
RCPH11TLB076AAM 17
18. Remove the screws from the backhoe control boot

and raise the boot.
RCPH11TLB077AAM 18
19. Remove the screws from the backhoe control tower

cover.
RCPH11TLB078AAM 19
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20. If equipped, remove the auxiliary control stick cover.
RCPH11TLB079AAM 20
21. Remove the backhoe control tower covers.
RCPH11TLB080AAM 21
22. If equipped, remove the rear floor mat.
RCPH11TLB081AAM 22
23. Remove the bolts on the rear floor plate. Remove

the floor plate.
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24. Remove the bolts on the front floor plate. Remove

the floor plate.
RCPH11TLB084AAM 25
25. Disconnect the power shift electrical connector.
RCPH11TLB009AAL 26
26. Disconnect brake tubes. Cap all open lines.
RCPH11TLB085AAM 27
27. Label and disconnect heater hoses.
RCPH11TLB085AAM 28
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28. Disconnect the A/C lines. Cap all open lines.
RCPH11TLB086AAM 29
29. Remove the cotter pin and clevis pin from the boom
lock lever.
RCPH11TLB087AAM 30
30. Remove the bolt securing the boom lock cable to the
latch.
RCPH11TLB088AAM 31
31. Disconnect the air restriction indicator.
RCPH11TLB089AAM 32
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32. Remove air cleaner to turbo tube. Cap all open ports.
RCPH11TLB036AAM 33
33. Remove aspirator tube.
RCPH11TLB037AAM 34
34. Remove crank case vent.
RCPH11TLB038AAM 35
35. Remove fixed hood hardware.
RCPH11TLB039AAM 36
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36. Lift fixed hood and remove washer hose.
RCPH11TLB040AAM 37
37. Remove fixed hood with air cleaner together. A lifting

device may be needed to remove hood.
RCPH10TLB031AAL 38
38. Remove the bolts securing the rubber insulator to the

firewall. Remove the rubber.
RCPH11TLB090AAM 39
39. Disconnect the brake tubes from the master cylinder.

Cap all open lines.
RCPH11TLB091AAM 40
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40. Remove steering valve mount hardware and steering

valve.
RCPH11TLB092AAM 41
41. Remove rear cab mount hardware.
RCPH11TLB093AAM 42
42. Remove front cab mount hardware.
RCPH11TLB094AAM 43
43. Remove the right hand rear wheel well inner mud
flap.
RCPH11TLB095AAM 44
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RCPH11TLB096AAM 45
45. Slowly raise and remove the cab. When lifting the
cab, make sure all cables or hoses still connected to
the cab are free from the machine.
RCPH11TLB097AAM 46
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USER PLATFORM - Install Cab

Refer to illustration ROPS - Exploded view (E.34.A).
1. Slowly lower the cab onto the machine. When lower-
ing the cab, make sure all cables or hoses connected
to the cab will not be crushed as the cab is lowered
onto the chassis.
RCPH10TLB624AAL 1
RCPH11TLB096AAM 2
3. Install the right hand rear wheel well inner mud flap.
RCPH11TLB095AAM 3
4. Install front cab mount hardware.
RCPH11TLB094AAM 4
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5. Install rear cab mount hardware.
RCPH11TLB093AAM 5
6. Install steering valve mount hardware and steering

valve.
RCPH11TLB092AAM 6
7. Remove caps. Connect the brake tubes to the mas-

ter cylinder.
RCPH11TLB091AAM 7
8. Place the rubber on the firewall. Secure rubber to

firewall using the existing bolts.
RCPH11TLB090AAM 8
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9. Slowly lower the fixed hood with air cleaner together

into place.
RCPH10TLB031AAL 9
10. Install fixed hood hardware.
RCPH11TLB039AAM 10
11. Reconnect the washer hose.
RCPH11TLB040AAM 11
12. Connect crank case vent.
RCPH11TLB038AAM 12
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13. Connect aspirator tube.
RCPH11TLB037AAM 13
14. Install the air cleaner to turbo tube.
RCPH11TLB036AAM 14
15. Connect the air restriction indicator.
RCPH11TLB089AAM 15
16. Install the bolt securing the boom lock cable to the
latch.
RCPH11TLB088AAM 16
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17. Install the cotter pin and clevis pin into the boom lock
lever.
RCPH11TLB087AAM 17
18. Reconnect the A/C lines.
RCPH11TLB086AAM 18
19. Connect heater hoses.
RCPH11TLB085AAM 19
20. Connect brake tubes.
RCPH11TLB085AAM 20
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21. Connect the power shift electrical connector.
RCPH11TLB009AAL 21
22. Lower the front floor plate into place. Install the bolts.
RCPH11TLB084AAM 22
23. Lower the rear floor plate into place. Install the bolts
into the rear floor plate.
24. If equipped, install the rear floor mat.
RCPH11TLB081AAM 25
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25. Install the backhoe control tower covers.
RCPH11TLB080AAM 26
26. If equipped, install the auxiliary control stick cover.
RCPH11TLB079AAM 27
27. Install the screws into the backhoe control tower

cover.
RCPH11TLB078AAM 28
28. Slide the backhoe control boot into place. Fasten the
boot to the console with the existing screws.
RCPH11TLB077AAM 29
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29. Reconnect the loader control rods.
RCPH11TLB076AAM 30
30. Connect the main harness connector.
RCPH11TLB075AAM 31
31. Connect electrical connection 2.
RCPH11TLB074AAM 32
32. Connect electrical connection 1.
RCPH11TLB074AAM 33
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33. Lower the floor plates into place.
RCPH11TLB073AAM 34
34. Secure the floor plate to the floor with the existing
hardware.
RCPH11TLB072AAM 35
35. Install the loader control console cover.
RCPH11TLB071AAM 36
36. Slide the boot over the control stick. Install the snap
ring.
RCPH11TLB075AAL 37
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37. Pull the loader boot down over the control stick.
RCPH11TLB070AAM 38
38. Attach the boot to the console using the existing

hardware.
RCPH11TLB069AAM 39
39. Install the louver mounting plate.
RCPH11TLB068AAM 40
40. Install the vent louver.
RCPH11TLB067AAM 41
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41. Install the front floor mat.
RCPH11TLB066AAM 42
42. Secure the front floor mat to the floor using the four
screws.
RCPH11TLB065AAM 43
Next operation:
Radiator - Install - 580SN, 580SN-WT, 590SN only (B.50.A)
Next operation:
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ROPS - Remove Rops cab

1. Park the machine on a level surface.
2. Raise the loader and lock the support strut to hold
the loader.
3. Lower the backhoe and stabilizers to the ground.
7. Disconnect the negative ground cable from the bat-
tery, be sure to move the ground cable away from the
battery.
RCPH10TLB030AAL 1
8. Remove the screws from the right hand side and the
left hand side of the front floor mat.
RCPH10TLB318ABL 2
9. Remove the front floor mat from the machine.

10. Pull the cover off of the louver assembly.
RCPH10TLB314ABL 3
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11. Push the four tabs inward while pulling louver assem-
bly out.
RCPH10TLB312ABL 4
12. Pull the louver assembly off of the hose. Push the
hose into the cover.
RCPH10TLB313ABL 5
13. Remove the screw from the loader control boot.
RCPH10TLB012ACL 6
14. Remove the boot from the loader control cover. Pull
the boot up turning it inside out. This will allow the
boot to slide through the opening when the cover is
removed.
RCPH10TLB311ABL 7
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15. Remove the three screws from the loader control

cover and remove the cover.
16. Remove the four bolts (1) from the loader control
lever plates. Remove the front plate (2) first then the
back plate (3).
NOTE: Back plate is sealed with silicone sealant.
RCPH10TLB309ABL 8
17. Loosen the screw (1) on the main harness (2) to side
console harness connector and disconnect the con-
nector. Disconnect the main harness to side option
harness connector (3).
RCPH10TLB619AAL 9
18. 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.
RCPH10TLB615AAL 10
19. Remove the four screws securing the rubber boot to

the backhoe control tower.
RCPH10TLB316ABL 11
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20. Remove the bolt from the front cover (1) and four
bolts from the rear cover (2) on the backhoe tower.
RCPH10TLB317ABL 12
21. Pull the rubber boot up. This will allow clearance
when removing the covers. Remove the front cover
(1) and the rear cover (2).
RCPH10TLB315ABL 13
22. If equipped remove the rear floor mat. Remove the

bolts on the rear floor plate and remove the plate.
RCPH10TLB621AAL 14
23. Remove the front floor plate.
RCPH10TLB620AAL 15
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24. Remove the bolt (1) from the gear shift lever (2) and
remove the gear shift lever from the transmission
lever (3).
RCPH10TLB617AAL 16
25. Disconnect powershift electrical connectors and

mounting brackets from cab.
NOTE: For powershift machines only.
RCPH10TLB067AAL 17
26. Remove the grill from the machine. Slowly remove

the radiator cap. Install a hose on the drain valve and
drain the radiator into a clean container that holds
approximately 19 l (5 US gal).
RCPH10TLB050AAL 18
27. If equipped with air conditioning see ENVIRON-

Charging (E.40.C) for discharging the system.
28. Slowly loosen and disconnect the two brake tubes.
Cap the fittings and plug the brake tube ends.
RCPH10TLB626AAL 19
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29. Put a container under the heater hoses (1) to catch

any remaining coolant when disconnected. Discon-
nect the heater and air conditioning hoses (2). Cap
the fittings and plug the hoses.
RCPH10TLB618AAL 20
30. Remove the cotter pin and clevis pin from the boom
lock lever.
RCPH10TLB045GAL 21
31. Remove the bolt securing the boom lock cable to the
latch.
RCPH10TLB616AAL 22
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32. Disconnect the throttle cable from the fuel injection

pump.
NOTE: 580N only.
RCPH10TLB035AAL 23
33. Remove the throttle cable from the bracket.

NOTE: 580N only.
RCPH10TLB034AAL 24
34. Tag and disconnect the wires for the air filter restric-
tion switch.
RCPH10TLB025AAL 25

nect the air cleaner hose from the turbo. Put a shop
cloth in the turbo opening or the intake opening.
RCPH10TLB024AAL 26
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36. Remove the bolts that fasten the cover to the up-
rights. Use acceptable lifting equipment and remove
the cover and air cleaner as an assembly.
RCPH10TLB023AAL 27
the hole in the curtain. Remove the bolts from the
rubber curtain on the firewall and remove the curtain.
RCPH10TLB240ABL 28
38. Loosen the screw (1) on the main harness to firewall

connector (2). Connector is located on the firewall
under the front console cover.
RCPH10TLB622AAL 29
39. Disconnect the positive (1) and negative (4) wire on

the firewall. Disconnect the main harness to firewall
connector (2). Disconnect the front console options
harness connector (3).
RCPH10TLB625AAL 30
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40. Disconnect the brake tubes from the brake master

cylinder. Cap fittings and plug the brake tube ends.
41. If your machine has a canopy go to Step 42. If the
machine has a cab go to step 44.
NOTE: See illustration in Step 46.
in position. Remove the bolts (1) and washers (2)
that fasten the steering control valve (3) to the steer-
ing column.
43. Go to Step 47.
44. Remove the bolts (4), washers (5), and mounts (6)
that fasten the steering control valve (7) to the cab.
45. Remove the steering control valve (7), mount (8),
and spacer (9) from the cab.
RCPH10TLB167ABL 31
46. Set the control valve out of the way.
RCPH10TLB066GAL 32
1. Bolt 6. Mount
2. Washer 7. Control Valve
3. Control valve 8. Mount
4. Bolt 9. Spacer
5. Washer
47. Remove the nuts (1) and washers (2) from the rear
corners of the cab (10).
NOTE: See illustration ROPS - Exploded view (E.34.A)
for steps 47 to 50.
84516378 05/07/2011
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48. Remove the bolts (3) and washers (4).

49. Remove the nuts (5) and mounts (6) from the front
corners of the cab (10).
50. Remove the bolts (7) and washers (8) and (9).
51. 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.
RCPH10TLB623AAL 33
1. Lifting points
RCPH10TLB624AAL 34
NOTE: See illustration ROPS - Exploded view (E.34.A) for the following step.
52. Remove mounts (11) and (12) and washers (13) from
the frame (14).
Next operation:
ROPS - Install (E.34.A)
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E.34.A / 45
ROPS - Install
Prior operation:
ROPS - Remove (E.34.A).
NOTE: See illustration ROPS - Exploded view (E.34.A) for the following steps.
1. Install washers (13) and mounts (12) and (11) on the
frame (14).
2. Use acceptable lifting equipment and place cab on
the machine. Lower cab slowly and make sure all
wires and hoses are in there proper location.
NOTE: See illustration ROPS - Exploded view (E.34.A)
for steps 3 to 7.
RCPH10TLB624AAL 1
3. Install the washers (8) and (9) and bolts (7).

4. Install mounts (6) and nuts (5) on the front corners of
the cab (10).
5. Install the washers (4) and bolts (3).
6. Install the washers (2) and nuts (1) on the rear cor-
ners of the cab (10).
7. Tighten the four bolts which secure the cab to the
frame. 298 - 358 N·m (220 - 264 lb ft).
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 ROPS - Exploded view
(E.34.A) in installation Step 12.
9. Grease the splines on the steering column and con-
trol valve. Put the spacer (1) and mounts (2) in place.
Have another person hold the steering control valve
(3) in position.
10. Install the mounts (4), washers (5), and bolts (6) that
fasten the steering control valve (3) to the cab.
11. Go to Step 13.
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12. Grease the splines on the steering column and con-

trol valve. Have another person hold the steering
control valve (7) in position. Install the washers (8)
and bolts (9) that fasten the steering control valve (7)
to the steering column.
RCPH10TLB066GAL 2
1. Spacer 6. Bolt
2. Mount 7. Control valve
3. Control valve 8. Washer
4. Mount 9. Bolt
5. Washer
13. Remove caps from fittings and plugs from brake

tubes. Connect the brake tubes to the brake master
cylinder.
RCPH10TLB167ABL 3
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14. Connect the positive (1) and negative wire (4) on the
firewall. Connect the main harness to firewall con-
nector (2). Connect the front console options har-
ness connector (3).
RCPH10TLB625AAL 4
15. Tighten the screw (1) on the main harness to firewall

connector (2).
RCPH10TLB622AAL 5
the hole the curtain. Install the curtain and bolts on
the fire wall.
RCPH10TLB240ABL 6
17. Put the cover and air cleaner assembly in position on

the uprights. Install the bolts and flat washers that
fasten the cover to uprights.
RCPH10TLB023AAL 7
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18. Remove the shop cloth from the turbo opening or the
intake opening. Connect the air cleaner hose to the
turbo. Tighten the clamp on the air cleaner hose.
RCPH10TLB024AAL 8
19. Connect the wires to the air restriction switch and

install a new tie strap.
RCPH10TLB025AAL 9
20. Connect the throttle cable to the bracket.

NOTE: 580N only.
RCPH10TLB034AAL 10
21. Connect the throttle cable to the fuel injection pump.

NOTE: 580N only.
RCPH10TLB035AAL 11
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22. Install the bolt securing the boom lock cable to the
latch.
RCPH10TLB616AAL 12
23. Connect the cable to the boom lock lever. Install the
clevis pin and cotter pin.
RCPH10TLB045GAL 13
24. Remove the caps and plugs from the hoses and fit-
tings. Connect the heater (1) and air conditioning (2)
hoses.
RCPH10TLB618AAL 14
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25. Remove the caps and plugs from the fittings and
brake tubes. Connect the two brake line tubes.
RCPH10TLB626AAL 15
26. Connect powershift electrical connectors and mount-

ing brackets to cab.
NOTE: For powershift machines only.
RCPH10TLB067AAL 16
27. Install the gear shift lever (2) on the transmission

lever (3) and tighten the bolt (1).
RCPH10TLB617AAL 17
28. Install the rear floor plate. If equipped install the rear
floor mat.
RCPH10TLB614AAL 18
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1. Rear floor plate mechanical linkage machine

2. Rear floor mat mechanical linkage machine
3. Rear floor plate pilot controlled machine
29. Install the front floor plate.
RCPH10TLB079GAL 19
1. Front floor plate

2. Front floor mat
30. Put the covers (1) (2) on the backhoe control tower
and install the bolts.
RCPH10TLB317ABL 20
31. Install the four screws securing the rubber boot to the
backhoe control tower.
RCPH10TLB316ABL 21
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32. 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.
RCPH10TLB615AAL 22
33. Connect the main harness to side console harness

connector (2) and tighten the screw (1). Connect the
main harness to side option harness connector (3).
RCPH10TLB619AAL 23
34. Put a bead of RTV silicone sealant on the mating

surface of the back plate (3) and install the plate.
Install the front plate (2) and tighten the bolts (1).
RCPH10TLB309ABL 24
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.
36. Put the loader control boot in place and install the
screw.
RCPH10TLB447ABL 25
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37. Push the louver assembly on the hose and push the
assembly onto the cover.
RCPH10TLB313ABL 26
38. Push the cover onto the louver assembly.
RCPH10TLB314ABL 27
39. Put the front floor mat in place. Install the screws on
the right hand side and the left hand side of the front
floor mat.
RCPH10TLB318ABL 28
40. Connect the negative ground cable to the battery.

43. Fill the radiator with the proper amount of coolant.
44. See Brake - Remove (D.30.C) for bleeding the brake
system.
45. If equipped with air conditioning see ENVIRON-
Charging (E.40.C) for charging the system.
RCPH10TLB030AAL 29
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Door, window and windscreen - Remove - Rear window - top

All instructions are written viewing the machine from the rear.
It is recommended that two people work on the following procedure.
1. Park the machine on a level surface. Lower all at-

tachments to the ground. Apply the parking brake.
2. Raise the top window to the closed position.
3. Remove the lower flocked channel seal (1) from the
left-hand side of the frame.
RCPH10TLB001CAD 1
4. From inside the cab, have a helper lower the middle

window into the lowest position and the top window
one setting above the middle window.
5. Have the helper hold the top window in place.
6. Remove the left-hand side latch assembly (1) from
the window.
RCPH10TLB126AAF 2
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7. Guide the top window horizontally into the left chan-

nel until the right-hand side of the top window (1) is
exposed.
RCPH10TLB001AAD 3
NOTICE: Forcing the window to bend during removal may cause damage to the window.
8. Remove the top window from the frame.
9. If the top window is not being replaced, install the
previously removed flocked channel seal into the left
channel.
Next operation:
Door, window and windscreen - Remove - Rear window - middle (E.34.A)
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Door, window and windscreen - Install - Rear window - top

All instructions are written viewing the machine's rear window from the rear.
Prior operation:
Door, window and windscreen - Remove - Rear window - top (E.34.A)
NOTE: Replace worn or damaged seals, gaskets and latch components.

1. Install the seal trim (1) across the bottom of the top
window.
RCPH10TLB004AAD 1
2. Secure the top right-hand latch assembly to the right

side of the top window.
RCPH10TLB006AAD 2
NOTE: The right-hand latch rubber bumper (1) must be above the middle window.
NOTICE: Forcing the window to bend during installation may cause damage to the window.
3. Guide the top window horizontally into the left chan-
nel where the flocked channel seal was previously
removed from.
RCPH10TLB001AAD 3
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4. Slide the top window into the right-hand side channel.

Have a helper hold the top window in place while the
latch assembly is installed.
5. Secure the top left-hand latch assembly (1) to the top
window.
RCPH10TLB126AAF 4
6. Slide the top window up until it locks into the closed

position.
7. Install the flocked channel seal (1) into the frame.
RCPH10TLB001CAD 5
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Door, window and windscreen - Remove - Rear window - middle


2. Place the top window (1) and the middle window (2)
in the highest position.
3. Remove the lower flocked channel seal (3) from the
left-hand side of the frame rail the middle window is
in.
RCPH10TLB001CAD 1
4. Have a helper lower the middle window until the left-

hand latch assembly (1) is accessible from the out-
side.
CAUTION
Burn hazard!
Always wear heat-resistant protective gloves
when handling heated parts.
Failure to comply could result in minor or mod-
erate injury.
C0047A
NOTE: If there is difficulty removing the latch assembly

Permabond F246 was used during the installation, you will
need to apply heat to the adhesive to remove the latch.
Use a heat gun that does not exceed 538 °C (1000 °F) at
the tip. Apply heat to the outside latch mounting plate, take
care not to damage the cab.
5. Have the helper support the window. Remove the
left-hand latch assembly from the middle window.
RCPH10TLB002CAD 2
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6. Lower the window until even with the open channel

area. Guide the middle window horizontally into the
left channel until the right-hand side of the window
(1) is exposed.
RCPH10TLB003CAD 3
7. Remove the middle window from the frame.
Next operation:
Door, window and windscreen - Install (E.34.A)
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Door, window and windscreen - Install - Rear window - middle

Prior operation:
Door, window and windscreen - Remove (E.34.A)
NOTE: Replace worn or damaged seals, gaskets and latch components.

1. Install a seal across the bottom of the middle window.
RCPH10TLB009AAD 1
NOTE: Do not get Permabond F246 adhesive into the slot on the latch mounting surface.
NOTICE: The latch parts must be completely assembled within 3 min of applying the Permabond F246 adhesive.
NOTICE: Do not overtighten Allen head screws otherwise damage to the glass may occur.
2. Secure the right-hand latch assembly to the middle
window. Use the following procedure to secure the
latch:
A. Clean the mounting surface on the middle
window with a commercial glass cleaner.
B. Clean the mounting surface on the latch
assembly with alcohol.
C. Apply a thin film of the initiator to the
mounting surface on the middle window.
D. Apply a bead of Permabond F246 adhe-
sive to the latch mounting surface.
E. Align the gasket and plate on the outside
of the window. The protrusions on the
gasket fit into the holes on the window.
F. Assemble the latch on the inside of the
window. RCPH10TLB010AAD 2
G. Apply LOCTITE® 243 to the threads on the
Allen head screws.
Install and tighten the Allen head screws
to a torque of 0.56 - 1.13 N·m (5 - 10 lb
in).
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3. Slide the middle window horizontally into the left

channel where the flocked channel seal was previ-
ously removed from the frame until the right side of
the window (1) can be moved into the channel on
the right side of the frame.
RCPH10TLB003CAD 3
4. Slide the middle window to the right and up until the

middle window is out of the way. Have a person on
the inside of the machine hold the middle window in
position.
RCPH10TLB003CAD 4
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5. Install the left-hand side middle latch assembly (1)

and raise the window to it's highest position. Follow
the previous procedure (Step 2) for latch assembly.
6. Install the previously removed flocking channel seal
(2) into the frame.
RCPH10TLB002CAD 5
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Door, window and windscreen - Remove - Rear window - bottom

The following procedure is performed from inside the cab.

2. Remove the upper flocked channel seal from the left
side of the frame rail that the bottom window is in.
RCPH10TLB349AAF 1
3. Remove the rubber blocks located on both sides of

the frame directly above the bottom window.
RCPH10TLB342AAF 2
4. Move the top and middle window into the highest

positions.
5. Raise the bottom window until the window is in the
area the flocked channel seal was removed from.
6. Guide the bottom window into the left channel until
the right side of the window is exposed.
7. Move the right side of the bottom window away from
the frame until the window can be removed from the
frame.
8. Remove the bottom window.
9. If the bottom window is not being replaced. Make
sure the flocked channel seal is installed in the left
channel.
Next operation:
Door, window and windscreen - Install (E.34.A)
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Door, window and windscreen - Install - Rear window - bottom

Prior operation:
Door, window and windscreen - Remove (E.34.A)
1. Install a new seal on the bottom of the bottom window

as required.
RCPH10TLB012AAD 1
2. Place the top and middle windows in their highest

position.
3. Slide the bottom window into the left channel where
the flocked channel seal was removed from the
frame. When the right side of the bottom window
clears the inside of the frame guide the window into
the right side channel of the frame.
4. Slide the bottom window to the right and down until
the bottom window is in position.
5. Install the flocked channel seal in the frame.
6. Install the rubber blocks on both sides above the bot-
tom window.
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Index
FRAME AND CAB - E

Door, window and windscreen - Exploded view - Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Door, window and windscreen - Exploded view - Side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Door, window and windscreen - Exploded view Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Door, window and windscreen - Install - Rear window - bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Door, window and windscreen - Install - Rear window - middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Door, window and windscreen - Install - Rear window - top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Door, window and windscreen - Remove - Rear window - bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Door, window and windscreen - Remove - Rear window - middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Door, window and windscreen - Remove - Rear window - top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
ROPS - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ROPS - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ROPS - Remove Rops cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
USER PLATFORM - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
USER PLATFORM - Install Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
USER PLATFORM - Remove Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
USER PLATFORM - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FRAME AND CAB - E
ENVIRONMENT CONTROL Air-conditioning system - 40.C
580N
580SN WT
580SN
590SN
84516378 05/07/2011
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Contents
FRAME AND CAB - E
TECHNICAL DATA
ENVIRONMENT CONTROL Air-conditioning system

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Overview - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Compressor
Exploded view - Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Expansion valve
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE

Charging - Air conditioner system evacuation and recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure test and temperature testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Compressor
Adjust - Belt check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Check - Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassemble - Clutch disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assemble - Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Condenser
Check - Condenser, receiver-drier, and tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Evaporator
Remove Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Expansion valve
Test Expansion valve testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
84516378 05/07/2011
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
ENVIRONMENT CONTROL Air-conditioning system - General

specification
Air conditioning system refrigerant capacity 1.48 kg (3.26 lb)
ENVIRONMENT CONTROL Air-conditioning system - Special tools

OEM 1415 Belt Tension Tool
299L7C 1
OEM 1415 Refrigerant Recovery, Recycling and Charging

Station
In the USA and Canada order Service Tool from:
OTC Division/ SPX Corporation
655 Eisenhower Drive
Owatonna, MN. 55060
Phone: 1-800-533-0492
RCPH07SPT081AAA 2
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OEM-1437 Electronic Leak Detector
RCPH07SPT096AAA 3
Safety Goggles - Obtain locally
RCPH10TLB677AAL 4
84516378 05/07/2011
E.40.C / 4
ENVIRONMENT CONTROL Air-conditioning system - Overview -

Safety procedures
ATTENTION: Only authorized technicians certified by an
approved training and certification organization may ser-
vice or repair motor vehicle or mobile air conditioning sys-
tems. It is mandatory that all refrigerant be recovered and
recycled when removed from a system during servicing.
Refrigerant HFC134a is the most stable, and easiest to

work with of the refrigerants now used in air conditioner
systems. Refrigerant HFC134a does not contain any
chlorofluorocarbons (CFC’s) which are harmful to the
earth’s ozone layer.
Safety procedures must be followed when working with

Refrigerant HFC134a to prevent possible personal injury.
1. Always wear safety goggles when doing any service
work near an air conditioner system. Liquid refrig-
erant getting into the eyes can cause serious injury.
Do the following if you get refrigerant near or in your
eyes:
A. Flush your eyes with water for 15 min minutes.
B. See a physician immediately.
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 conditioner system.
Your skin must be treated for frostbite or a physician
must be seen if you get refrigerant on your skin.
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 condi-
tioner 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 mixtures of
HFC134a and air can form a combustible gas.
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Operation
The refrigerant circuit of the air conditioning system contains five major components: compressor, condenser, re-
ceiver-drier, expansion valve and evaporator. These components are connected by tubes and hoses and operate as
a closed system. The air conditioner system is charged with HFC134a refrigerant.
The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant
and sends it in the form of a high pressure gas to the condenser. The air flow through the condenser then removes
the heat from the refrigerant. As the heat is removed the refrigerant changes to a high pressure liquid.
The high pressure refrigerant liquid then flows from the condenser to the receiver drier. The receiver-drier is a con-
tainer filled with moisture removing material, which removes any moisture that may have entered the air conditioner
system in order to prevent corrosion of the internal components of the air conditioner system.
The refrigerant still in a high pressure liquid form, then flows from the receiver-drier to the expansion valve. The
expansion valve then causes a restriction in flow of refrigerant to the evaporator core.
As the refrigerant flows through the evaporator core the refrigerant is heated by the air around and flowing through
the evaporator fins. The combination of increased heat and decreased pressure causes the air flow through the
evaporator fins to become very cool and the liquid refrigerant to become a low pressure gas. The cooled air then
passes from the evaporator to the cab for the operator’s comfort.
The electrical circuit of the Air Conditioning System consists of a fan speed control, temperature control, three (3) mini
relays, two (2) 10 amp circuit breakers, two (2) fan motors, a blower motor, blower resistor, compressor clutch, low
pressure switch, high pressure switch, and warning light.
RCPH10TLB137GAL 1
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1. Expansion valve 4. Condenser

2. Evaporator 5. Receiver-drier
3. Compressor
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Safety procedures
ATTENTION: Only authorized technicians certified by an approved training and certification organization may service
or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be recovered and
recycled when removed from a system during servicing.
Refrigerant HFC-134a is the most stable and easiest to
work with of the refrigerants now used in air conditioning
systems. Refrigerant HFC-134a does not contain chlo-
rofluorocarbons (CFC’s) which are harmful to the Earth’s
ozone layer.
Safety procedures must be followed when working with
refrigerant HFC-134a to prevent possible personal injury.
1. Always wear safety goggles when doing any service
work near an air conditioner system. Liquid refrig-
erant getting into the eyes can cause serious injury.
Do the following if you get refrigerant near or in your
eyes:
A. Flush your eyes with water for 15 min.
B. See a physician immediately.
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 conditioner system.
Your skin must be treated for frostbite or a physician
must be seen if you get refrigerant on your skin.
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 condi-
tioner 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 mixtures of
HFC-134a and air can form a combustible gas.
8. Always reclaim refrigerant from the system before
removing any air conditioning component.
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Compressor - Exploded view - Clutch assembly
RCPH10TLB001EAL 1
1. Compressor 5. Bearing dust cover

2. Coil assembly 6. Front plate
3. Pulley 7. Shim(s)
4. Bearing 8. Dust cover
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Expansion valve - Exploded view
RCPH10TLB036GAL 1
1. Evaporation core 4. O-rings 7. Pressure switch

2. Expansion valve 5. Suction tube 8. Control switch
3. O-rings 6. Pressure tube
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ENVIRONMENT CONTROL Air-conditioning system - Charging - Air

conditioner system evacuation and recharging
NOTICE: Replace the receiver-drier if one or 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).
E. Too much air or moisture in system.
F. Removal of compressor caused the sys-
tem to be open (uncapped) longer than 5
min.
1. With the charging station manifold gauge valves in
the closed position, connect the hoses from the test
gauges to the service ports as follows:
A. Connect the hose from the low pressure

gauge to the port on the suction hose.
B. Connect the hose from the high pressure
gauge to the port on the discharge hose.
C. 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 damage to the system components.
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 vacuum
pump. A vacuum pump is the only 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.
2. Connect the main power plug to a 115 V AC outlet.
Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 min and press the Enter key. The display will
flash once indicating the programmed data has been
accepted
RCPH10TLB660AAL 1
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3. Press the Charge key. “Program” and “Charge” will

appear on the display.
RCPH10TLB663AAL 2
4. Program 3.75 lb and press the enter key. The display

will flash once indicating the programmed data has
been accepted.
RCPH10TLB661AAL 3
5. Fully open the low and high pressure valves.
RCPH10TLB662AAL 4
6. Open the red (vapor) and blue (liquid) valves on the

tank.
RCPH10TLB656AAL 5
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7. Press the Vacuum key. “Automatic” will appear on

the display. Vacuum will appear on the display and
after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
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 - 29-1/2 in Hg of mercury
(Hg). The low pressure gauge must not increase faster
than 1 in of mercury (Hg) in 10 min . A previously charged,
leak-free system will leach refrigerant from 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. RCPH10TLB665AAL 6
8. Press the charge key to begin refrigerant charging.

“Automatic” and “Charge” will appear on the display.
The display shows the programmed amount and
counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.
RCPH10TLB661AAL 7
9. Completely close the high and low pressure manifold

valves.
RCPH10TLB662AAL 8
ATTENTION: Check the OEM equipment manual before performing Step 10 to avoid damaging the recovery unit.
The pressure reading should be obtainable with valves closed. Damage may occur if the machine is started with the
valves accidently open or if either or both valves are opened while the A/C system is operating.
10. 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 pres-
sure is too low or too high. The pressure indicator lamp will
illuminate when the relay is actuated by a low or high pres-
sure 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 po-
sition.
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11. Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered
the system. See Temperature Pressure Chart for
temperature and pressure variations.
RCPH10TLB664AAL 9
12. Stop the engine, close any open valves and carefully
remove the manifold gauge hoses.
13. Install the caps on the service ports on the suction
and discharge hoses.
RCPH10TLB042AAL 10
Pressure temperature chart

Ambient Normal low pressure Normal high pressure Air louver (behind seat)
temperature indication indication maximum temperature
27 °C (81 °F) 0.62 - 0.83 bar (9 - 12 psi) 10 - 11.5 bar (145 - 167 psi) 14 °C (57 °F)
32 °C (90 °F) 0.76 - 1.04 bar (11 - 15 psi) 13.1 - 14.5 bar (190 - 210 psi) 18 °C (64 °F)
43 °C (109 °F) 1.93 - 2.14 bar (22 - 24 psi) 20 - 21.4 bar (290 - 310 psi) 25 °C (77 °F)
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The pressure-temperature chart is based on the fol-

lowing conditions:
1. Engine operating at 1500 RPM.
2. No engine load.
3. Fan speed control in maximum position
(full clockwise) and all louvers open.
4. Cab temperature control set to maximum
cooling (full counterclockwise).
5. Both cab doors open.
6. All panels and access doors installed and
closed.
7. Cab filters clean and installed.
8. Heater valve at engine closed.
9. Measurements taken 15 min after start-
up.
Air conditioner system refrigerant recovery

Recovered refrigerant passes through an oil separator and
a filter-drier before entering the refrigerant tank. The mois-
ture 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.
1. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on
the suction and pressure hoses.
2. With the charging station manifold gauge valves in
the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor
Connect the hose from the high pressure gauge to
the port on the discharge hose. Turn in valve de-
pressor.
RCPH10TLB042AAL 11
3. Open the high and low valves.
RCPH10TLB662AAL 12
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4. Make certain the refrigerant tank gas and liquid

valves are open.
RCPH10TLB656AAL 13
5. Connect the main power plug to a 115 V AC outlet.

Move the main power switch to the ON position and
depress the recovery start switch.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 min and observe
the manifold pressure gauges for a pressure rise.
If pressure rises above 0 bar (0 psi), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
RCPH10TLB660AAL 14
6. 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 sepa-
rator.
RCPH10TLB657AAL 15
7. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.
RCPH10TLB658AAL 16
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8. Fill the A/C compressor with fresh SP-15 PAG oil

equal to the amount in the reservoir.
RCPH10TLB659AAL 17
9. Remove the hoses from the service ports and install

the caps.
RCPH10TLB042AAL 18
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ENVIRONMENT CONTROL Air-conditioning system - Pressure test

and temperature testing
Use either a Manifold gauge set tool 380000239 or an appropriate refrigerant recovery, recycling and charging station
capable of taking high and low pressure/vacuum tests simultaneously.
Refer to the testing tool operator's manual for testing procedures before servicing the air conditioning system.
Prepare the machine for service: Park the machine and place the transmission gears in a neutral position, secure the
loader bucket in a fully raised position, turn the engine off, chock the wheels, and raise the engine hood.
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 reads both the high (dis-
charge) and low (suction) sides at the same time,
since pressure must be compared in order to make
a diagnosis of the system's 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 neces- RCPH10TLB001BAD 1
sary to use a compound gauge that will in-
dicate both pressure and vacuum.
• High pressure gauge – The high pressure
gauge is used to indicate pressures in the
high side of the system.
Refrigerant recovery, recycling and charging station

A refrigerant recover, recycling and charging station
shown is a full service air conditioning system ma-
chine. It can perform multiple procedures such as:
• Recover and recycle refrigerant.
• Charge the air conditioning system.
• High and low pressure tests.
• Remove air and condensation from the
system.
RCPH10TLB655AAL 2
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Pressure and temperature test

1. Clean the external surfaces of the compressor and
tubes. Remove the caps from the service ports on
the suction (1) and pressure (2) tubes.
2. Connect an appropriate pressure testing gauge
hoses to the air conditioning system's service ports.
• Close the gauge valves and attach the low
pressure gauge hose to the suction ser-
vice port (1).
• Close the gauge valves and attach the
high pressure gauge hose to the pressure
service port (2).
RCPH10TLB042AAL 3
3. The following conditions are required for an accurate

pressure/temperature test.
• Measurements taken 15 minutes after en-
gine start up.
• Engine operating at 1800 RPM with no en-
gine load present.
• Air conditioning system charged at 1.48
kg (3.26 lb) of CNH REFRIGERANT HFC-
134A.
• A/C switch on.
• Fan speed control in maximum position
and all louvers open.
• Cab temperature control set to maximum
cooling (full counterclockwise position).
• All panels and component access doors
installed and closed.
• Cab filters clean and installed.
• Cab doors open and back windows down.
• Heater valve closed at engine.
4. Record the following temperature and pressure read-
ings:
• Ambient temperature inside the cab and
directly in front of the air louver behind the
seat.
• Low and high pressure gauge readings.
5. Turn the engine off.
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39 ° Steel fan – 580N and 580SN

Ambient Normal low Normal high Air louver (behind seat)
temperature pressure indication pressure indication maximum temperature
27 °C (80.6 °F) 1.10 - 1.24 bar (16 - 18 psi) 13.1 - 14.4 bar (190 - 209 psi) 12 °C (53.6 °F)
Viscous fan – 580SN WT, 590SN and 580SN with cab convenience package
Ambient Normal low Normal high Air louver (behind seat)
temperature pressure indication pressure indication maximum temperature
6. Compare the recorded test results with the appropri-

ate chart and continue with one of the following:
• Results are not within the acceptable
range – Refer to the appropriate trouble
shooting guide based on the recorded
results.
• Results are within the acceptable range –
Disconnect the test equipment hoses and
secure the service port caps. The pres-
sure test is complete.
Next operation:
ENVIRONMENT CONTROL Air-conditioning system - Check (E.40.C)
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ENVIRONMENT CONTROL Air-conditioning system - Check

NOTE: The low pressure switch is located in the roof of the cab in the low pressure tube to the evaporator.The high
pressure switch is located at the front of the tractor and behind the grill.
1. Engine OFF, key switch ON, blower switch ON, and
temperature control switch turned fully clockwise.
Both pressure switches should remain in the open
position.
NOTE: With the engine OFF, system pressure will equalize on both sides of system to approximately 75 PSI (520
kPa) at room temperature.
2. Low pressure switch located in cab roof. Check for
12 VDC at low pressure switch with a test lamp. If
no voltage, check temperature control switch. The
low pressure switch is open whenever the pressure is
above 2 to 6 PSI (14 to 41 kPa). Below this the switch
closes and sends a signal to the relay to disengage
the compressor clutch. Check both terminals of the
low pressure switch with a test lamp. If voltage is
available at both terminals and pressure is not below
2 PSI (14 kPa), replace the switch.
RCPH10TLB667AAL 1
3. High pressure switch located at the condenser.

Check for 12 VDC at high pressure switch. If no
voltage, check temperature control switch. Check
both terminals of high pressure switch with a test
lamp. If voltage is present at both terminals and
pressure is not above 385 PSI (2 654 kPa), replace
the switch.
RCPH10TLB669AAL 2
Next operation:
ENVIRONMENT CONTROL Air-conditioning system - Check (E.40.C)
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ENVIRONMENT CONTROL Air-conditioning system - Check

Current Check
1. The temperature control switch is located in the in-
strument panel.
2. The temperature control switch senses evaporator
temperature and controls current flow for compressor
clutch operation.
3. 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.
4. If the temperature control switch malfunctions, re-
place it.
5. Remove instrument cluster to gain access to the tem-
perature control switch.
RCPH10TLB668AAL 1
6. Engine OFF, key switch ON, and blower switch ON.

7. Turn temperature control switch fully clockwise. Re-
move sensing tube from evaporator.
8. Place end of sensing tube (1) in a container (2) with
ice and water mixture.
RCPH10TLB680AAL 2
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9. When the sensing tube has cooled to the tempera-

ture of the ice and water mixture, the temperature
control switch (1)should interrupt the current flow to
the compressor.
RCPH10TLB668AAL 3
10. Check for current at temperature control switch ter-

minal with the No. 60 and No. 85 wires. Use a test
lamp connected to a good ground.
11. If current is not interrupted, replace the temperature
control switch.
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Compressor - Adjust - Belt check and adjustment

WARNING
Rotating parts!
The engine is running. Keep clear of rotating fans and belts.
W0275A
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.
Measure the compressor belt for correct tension using a
belt tension gage. Check the belt to the following specifi-
cations.
RCPH10TLB672AAL 1
Belt tension 200 - 245 N (45 - 55 lb)
To adjust the belt tension, loosen the compressor adjust-

ing 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.
Measure the compressor belt for correct tension using a
belt tension gage. Check the belt to the following specifi-
cations.
Belt tension 400 - 490 N (90 - 110 lb)
To adjust the belt tension, loosen the pivot bolt, loosen the
slot bolt, loosen the jam nut on the adjusting bolt. Turn
the adjusting bolt in until the proper tension for the belt is
reached. Tighten the jam nut, tighten the slot bolt, tighten
the pivot bolt.
RCPH10TLB670AAL 2
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Compressor - Check - Oil level check

Check the oil level in the compressor when any of the fol-
lowing 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.
1. Start the engine and run at 1500 RPM maximum.
Operate the air conditioner for 10 - 15 min at maxi-
mum cooling and high blower speed.
2. Stop the engine. Connect the compressor to the air
conditioner charging, recovery, and recycling station.
Discharge the system.
NOTE: Wear safety goggles when working with refrigerant.
3. 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 de-
gree mark. Make a note of the degree reading for
reference later.
RCPH10TLB630AAL 1
4. Remove the oil filler plug.
RCPH10TLB675AAL 2
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5. 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.
RCPH10TLB011ACL 3
6. Put the dipstick in the oil filler hole to the stop posi-
tion. Make sure the dipstick is inserted all the way to
the stop.
NOTE: The illustration shows the front view of the com-
pressor with the dust cover removed.
RCPH10TLB015BAL 4
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 (degrees) Dipstick 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
8. If the oil level is not correct, add or subtract oil to the

correct level as shown in the above chart.
NOTICE: Use only CNH PAG OIL.
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9. Install a new O-ring on the oil filler plug. Install the

plug and tighten to a torque of 15 - 24 N·m (11 - 18
lb ft).
RCPH10TLB676AAL 5
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Compressor - Disassemble - Clutch disassembly

1. See Compressor - Disassemble (E.40.C) in this
service manual for compressor removal. Clean the
external surfaces of the compressor before doing
any work on the compressor.
RCPH10TLB631AAL 1
2. Remove the mounting bolts for the clutch dust cover.
RCPH10TLB632AAL 2
3. Remove the clutch dust cover.
RCPH10TLB633AAL 3
4. Remove the retaining nut for the front plate. Use the
special spanner wrench from the service tool set to
keep the plate and shaft from turning.
RCPH10TLB634AAL 4
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5. Install the special puller from the service tool set on

the clutch front plate.
RCPH10TLB635AAL 5
6. Turn the center screw to pull the clutch front plate.
RCPH10TLB636AAL 6
7. Remove the shim(s) from the shaft.
RCPH10TLB637AAL 7
8. Remove the bearing dust cover. Be careful not to

bend the dust cover.
RCPH10TLB638AAL 8
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9. Remove the key from the rotor shaft.
RCPH10TLB639AAL 9
10. Remove the external snap ring for the bearing and
pulley assembly.
RCPH10TLB641AAL 10
11. Install the special puller internal collars into the

groove in the pulley. Install the special tool onto the
shaft. Tighten the mounting screws finger tight.
RCPH10TLB642AAL 11
12. Turn the center screw on the puller.
RCPH10TLB643AAL 12
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13. Remove the pulley and bearing assembly.
RCPH10TLB644AAL 13
14. Remove the snap ring for the clutch coil assembly.
RCPH10TLB646AAL 14
15. Disconnect the clip for the lead wire.
RCPH10TLB645AAL 15
16. Remove the clutch coil assembly.
RCPH10TLB647AAL 16
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17. Remove the internal snap ring and remove the bear-
ing from the pulley.
RCPH10TLB648AAL 17
Next operation:
Compressor - Assemble (E.40.C)
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Compressor - Assemble - Clutch assembly

Prior operation:
Compressor - Disassemble (E.40.C)
1. Use a ammeter (1), voltmeter and a 12 V battery (2)

to check the amperage of the clutch coil. The current
draw must be 3.6 - 4.2 A at 12 V.
A reading of more than 4.2 A 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 cor-
rect.
RCPH10TLB933ABL 1
2. Install the clutch coil assembly. Align the detent ball

and socket on the coil and housing.
RCPH10TLB647AAL 2
3. Install the clip for the coil lead wire.
RCPH10TLB645AAL 3
4. Install the snap ring for the clutch coil assembly.
RCPH10TLB646AAL 4
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5. Install the bearing in the pulley and install the internal

snap ring.
RCPH10TLB648AAL 5
6. Put the pulley and bearing assembly on the front

housing hub. Install a driver on the pulley assem-
bly. Make sure that the tool is on the inner race of
the bearing.
RCPH10TLB649AAL 6
7. Support the compressor on the four mounting ears at

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.
RCPH10TLB649AAL 7
8. Install the external snap ring on the front housing

hub.
RCPH10TLB641AAL 8
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9. Install the key in the rotor shaft.
RCPH10TLB640AAL 9
10. Place the bearing dust cover in the bore. Place driver
from special tool kit over the dust cover.
RCPH10TLB650AAL 10
11. Gently tap the dust cover until it is seated.
RCPH10TLB651AAL 11
12. Install the shim(s) on the rotor shaft.
RCPH10TLB637AAL 12
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13. 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.
RCPH10TLB652AAL 13
14. Use a hammer to tap the plate onto the shaft. Make
sure the plate is against the clutch shims. As the
plate is tapped onto the shaft you can hear the differ-
ence in sound when the plate is fully installed.
RCPH10TLB653AAL 14
15. Install the nut on the rotor shaft. Use the spanner
wrench and a torque wrench to tighten the nut to a
torque of 15 - 20 N·m (11 - 15 lb ft).
RCPH10TLB634AAL 15
16. Use a feeler gauge to measure the gap between the

front plate and pulley assembly. The gap must be
0.41 - 0.79 mm (0.016 - 0.031 in). 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.
RCPH10TLB679AAL 16
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17. Install the dust cover.
RCPH10TLB633AAL 17
18. Install and tighten the six bolts that hold the dust
cover to the compressor to 7 - 11 N·m (5 - 8 lb ft).
RCPH10TLB632AAL 18
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Condenser - Check - Condenser, receiver-drier, and tubes

WARNING
Explosion hazard!
Air-conditioning refrigerant boils at -12 °C (10 °F)!
-NEVER expose any part of the air-conditioning system to a direct flame or excessive heat.
-NEVER disconnect or disassemble any part of the air-conditioning system.
Discharging refrigerant gas into the atmosphere is illegal in many countries.
W0340A
Keep the condenser fins clean and straight to make sure

there is maximum flow through the condenser and radiator
at all times. Use compressed air or a rigid brush to clean
the condenser. Also check and clean the grille screen and
radiator. Maximum air flow will prevent the engine from
getting too hot and will give the most efficient operation of
the air conditioner system.
NOTICE: Because the condenser fins bend easily, be care-
ful 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 condi-
tions:
A. In an area where there is high moisture
content in the air.
B. If the system has been open for a long
period of time because of a leak (broken
hoses, loose connections) that has per-
mitted air and moisture to enter the sys-
tem.
C. When the expansion valve is replaced
(because of corrosion caused by moisture
in the system).
D. When the receiver-drier or inlet and out-
let lines feel cool to your hand when the
system is operating. This condition is an
indication of too much moisture in the sys-
tem.
The receiver-drier must be installed with the inlet con-
nected to the hose from the condenser and the outlet
connected to the tube going to the evaporator. Always
install new O-rings when you connect the receiver-drier to
the system.
Use the two hand, two wrench method to prevent damage
to the tubes and fittings when you loosen or tighten the tube
connections.
Always replace the O-rings when you separate connec-
tions to make sure you get a good tight seal when you make
the connections again. Apply clean refrigerant oil onto the
O-rings.
84516378 05/07/2011
E.40.C / 38
RCPH10TLB669AAL 1
1. Condenser 4. Receiver-drier
2. High pressure switch 5. Hose - receiver-drier to cab
3. Hose - condenser to receiver-drier 6. Hose - compressor to condenser
84516378 05/07/2011
E.40.C / 39
Evaporator - Remove Evaporator Core

1. Remove the screws that hold the cover on the right-
hand center post. Then remove the cover.
2. Remove headliner.
RCPH10TLB674AAL 1
3. Remove the hose clamps (1) and disconnect the four

drain hoses (2) at the housing. Disconnect the low
pressure switch (3). Remove the bolts (4) retaining
the air ducts and remove the air ducts. Disconnect
the blower.
4. Carefully remove the four nuts that hold the housing
to the roof of the cab and lower the housing including
the blower, heater core, and air conditioner evapora-
tor 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.
RCPH10TLB671AAL 2
5. If the insulation (1) has not been removed, remove

it now from the expansion valve and the evaporator
lines.
To test the valve see Expansion valve - Test (E.40.C)
in this section. Discharge the A/C system to remove the
evaporator core. See Evaporator - Remove (E.40.C)l.
6. 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.
7. Remove the thermostat probe for the air conditioner
control that is in the evaporator core.
8. Remove the evaporator core from the housing and
put the evaporator on a clean bench. Remove the
expansion valve from the evaporator core. It can be
necessary to use a back-up wrench to prevent dam-
age to the tubes. Remove and discard the O-rings
from between the expansion valve and the evapora-
tor core lines.
RCPH10TLB666AAL 3
Next operation:
Evaporator - Install (E.40.C)
84516378 05/07/2011
E.40.C / 40
Evaporator - Install
Prior operation:
Evaporator - Remove (E.40.C)
1. Put new O-rings on the evaporator core lines. Lubri-

cate the O-rings with clean refrigerant oil.
2. Install the expansion valve. Tighten the fittings to a
torque of 25 - 34 N·m (18 - 25 lb ft). It may be nec-
essary to use a backup wrench to prevent damage
to the evaporator tubes.
3. Install the evaporator core in the housing.
4. Install the thermostat probe for the air conditioner.
NOTE: Position capillary tube so it does not interfere with
the air filter during installation and removal.
RCPH10TLB037GAL 1
1. 25 mm (1 in) 2. 150 mm (6 in) 3. 75 mm (3 in)
5. 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 25 - 34 N·m (18 - 25 lb ft). It may be necessary
to use a backup wrench to prevent damage to the
evaporator tubes.
6. Connect the air conditioner discharge and suction
lines to the expansion valve. Wrap the valve and the
lines with insulation.
7. 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.
RCPH10TLB666AAL 2
84516378 05/07/2011
E.40.C / 41
8. Raise the housing into place, including the blower,

heater core and air conditioner evaporator. Fasten
with four nuts to the roof. Be sure the top insulation
strip is in place.
9. Connect the blower. Install the hose clamps (1) and
the air ducts using bolts (4). Make sure the seals on
the air ducts are in place. Connect the low pressure
switch (3). Connect the four drain hoses (2) to the
housing and tape in place to the air ducts. Connect
the blower. Make sure the seals are in place when
installing air ducts.
RCPH10TLB671AAL 3
10. Install headliner.

11. Install the cover on the center post.
RCPH10TLB673AAL 4
84516378 05/07/2011
E.40.C / 42
Expansion valve - Test Expansion valve testing

The following test is to be made with the expansion valve
mounted in the system. No repair, cleaning or adjustment
is recommended for the valve.
1. Remove headliner.
RCPH10TLB674AAL 1
2. Install low pressure hose to the low pressure service

port. Close both manifold valves.
3. Make sure the flow of air continues through the evap-
orator core. Start the engine and run at 1500 RPM.
Turn the blower switch to the high position, and with
the temperature control valve turned fully clockwise,
check the low pressure gauge reading.
The low pressure reading will range from 180 - 355
kPa (26 - 51 psi) when the compressor is operating.
4. 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
reaches 28 kPa (4 psi), the low pressure indicator
will illuminate and the compressor will stop. The re-
lay must be reset after the compressor has stopped
before the system will operate again. To reset the re-
lay, turn the air conditioner to the OFF position and
then back to the desired temperature setting.
RCPH10TLB666AAL 2
5. Warm the expansion valve and watch the low pres-

sure gauge.
Within minutes, the expansion valve will open and
the pressure must rise at the low pressure gauge.
The pressure will rise to a range of 310 - 520 kPa
(45 - 75 psi).
6. If the pressure does not rise per step 5, the valve is
not operating. Replace the valve.
Evaporator and expansion valve

The refrigerant must be reclaimed from the system and all
the black insulation must be removed from the fittings and
expansion valve before the evaporator core or the expan-
sion valve are replaced.
84516378 05/07/2011
E.40.C / 43
The expansion valve must be installed with the sensor to-

ward the rear of the tractor. The port nearest to the IN
mark must point away from the evaporator core. Connect
the evaporator core fittings to the expansion valve. Install
O-rings between the evaporator core and the expansion
valve.
Connect the expansion valve to the evaporator inlet tube.
Install an O-ring between the expansion valve inlet and the
pressure hose from the receiver-drier.
Connect the suction hose to the evaporator outlet. Install
an O-ring between the fittings.
NOTE: Tighten all the connections. Use two wrenches to
prevent damage to the parts when tightening tubes and
hoses. Always replace O-rings and put clean refrigerant
oil on the O-rings.
NOTE: CNH PAG OIL must be added whenever a com-
ponent is replaced. Refer to the chart below for recom-
mended quantities.
Component Oil amount

Evaporator 44 - 50 ml (1.5 - 1.7 US fl oz)
Condenser 35 - 38 ml (1.2 - 1.3 US fl oz)
Receiver-drier 20 - 25 ml (0.7 - 0.8 US fl oz)
Hoses (normal length) 10 - 20 ml (0.3 - 0.7 US fl oz)
84516378 05/07/2011
E.40.C / 44
Index
FRAME AND CAB - E

Compressor - Adjust - Belt check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Compressor - Assemble - Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Compressor - Check - Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compressor - Disassemble - Clutch disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Compressor - Exploded view - Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Condenser - Check - Condenser, receiver-drier, and tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ENVIRONMENT CONTROL Air-conditioning system - Charging - Air conditioner system evacuation and recharging
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENVIRONMENT CONTROL Air-conditioning system - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ENVIRONMENT CONTROL Air-conditioning system - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ENVIRONMENT CONTROL Air-conditioning system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENVIRONMENT CONTROL Air-conditioning system - Overview - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENVIRONMENT CONTROL Air-conditioning system - Overview - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . 8
ENVIRONMENT CONTROL Air-conditioning system - Overview - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . 5
ENVIRONMENT CONTROL Air-conditioning system - Pressure test and temperature testing . . . . . . . . . . . . . . . 18
ENVIRONMENT CONTROL Air-conditioning system - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Evaporator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Evaporator - Remove Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Expansion valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Expansion valve - Test Expansion valve testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
84516378 05/07/2011
E.40.C / 45
PRINTED IN U.S.A.
84516378 05/07/2011
EN
SERVICE MANUAL
FRAME POSITIONING
580N
580SN WT
580SN
590SN
84516378 05/07/2011
F
Contents
FRAME POSITIONING - F
STABILISING Working stabilising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F.20.D

580N , 580SN WT , 580SN , 590SN
84516378 05/07/2011
F
STABILISING Working stabilising - 20.D
580N
580SN WT
580SN
590SN
84516378 05/07/2011
F.20.D / 1
Contents
TECHNICAL DATA
Cylinder
Torque - Stabilizer cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Cylinder
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84516378 05/07/2011
F.20.D / 2
FRAME POSITIONING - STABILISING Working stabilising
Cylinder - Torque - Stabilizer cylinder

Apply LOCTITE® 243 to the cylinder piston bolt.
580N and 580SN

Cylinder piston bolt 1600 - 1820 N·m (1180 - 1342 lb ft)
Cylinder gland 135 - 542 N·m (100 - 400 lb ft)
Cylinder lock screw 2.3 N·m (20 lb in)
580SN WT and 590SN

84516378 05/07/2011
F.20.D / 3
Cylinder - Exploded view

(A) Stabilizer cylinder assembly (9) Piston seal
(1) Cylinder tube (10) Backup ring
(2) Gland (11) Wear ring
(3) Wiper rod (12) Piston rod
(4) Rod and buffer seal (13) Bolt with hardened washer
(5) Rod bearing (14) Locking screw
(6) Static head seal (15) Lube fitting
(7) Piston (16) Plug
(8) Loader ring
84516378 05/07/2011
F.20.D / 4
RCPH11TLB021HAN 1
84516378 05/07/2011
F.20.D / 5
Index

Cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder - Torque - Stabilizer cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84516378 05/07/2011
F.20.D / 6
84516378 05/07/2011
F.20.D / 7
PRINTED IN U.S.A.
84516378 05/07/2011
EN
SERVICE MANUAL
TOOL POSITIONING
580N
580SN WT
580SN
590SN
84516378 05/07/2011
G
Contents
TOOL POSITIONING - G
LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.10.A
580N , 580SN WT , 580SN , 590SN
84516378 05/07/2011
G
LIFTING - 10.A
580N
580SN WT
580SN
590SN
84516378 05/07/2011
G.10.A / 1
Contents
LIFTING - 10.A
SERVICE
Cylinder
Remove Loader Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install Loader Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove Loader Cylinder and Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install - Loader Cylinder and Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84516378 05/07/2011
G.10.A / 2
TOOL POSITIONING - LIFTING
Cylinder - Remove Loader Lift Cylinder

WARNING
Escaping fluid!
doctor immediately.
W0178A
RCPH11TLB158AAM 1
2. Raise and support the loader arms.
RCPH11TLB159AAM 2
3. Remove the hydraulic tube clamp.
RCPH11TLB160AAM 3
84516378 05/07/2011
G.10.A / 3
4. Disconnect and cap the rod end hydraulic tube.
RCPH11TLB161AAM 4
5. Disconnect and cap the closed end hydraulic fittings.
RCPH11TLB162AAM 5
6. Remove the inner snap ring.
RCPH11TLB163AAM 6
7. Attach a suitable lifting device to the cylinder.
RCPH11TLB164AAM 7
84516378 05/07/2011
G.10.A / 4
8. Remove pin.
RCPH11TLB165AAM 8
9. Remove snap ring and washer.
RCPH11TLB166AAM 9
10. Carefully lift and remove the cylinder from the ma-
chine.
RCPH11TLB164AAM 10
NOTE: Repeat for the opposite cylinder if needed.
84516378 05/07/2011
G.10.A / 5
Cylinder - Install Loader Lift Cylinder

WARNING
Escaping fluid!
doctor immediately.
W0178A
1. Move the cylinder into place.
RCPH11TLB164AAM 1
2. Install the inner snap ring.
RCPH11TLB163AAM 2
3. Install the pin.

RCPH11TLB165AAM 3
84516378 05/07/2011
G.10.A / 6
5. Install the inner snap ring.
RCPH11TLB163AAM 4
6. Connect the closed end hydraulic fittings.
RCPH11TLB162AAM 5
7. Connect the rod end hydraulic tube.
RCPH11TLB161AAM 6
8. Reinstall the hydraulic tube clamp.
RCPH11TLB160AAM 7
84516378 05/07/2011
G.10.A / 7
9. Remove the supports from the loader arms.
RCPH11TLB159AAM 8
RCPH11TLB158AAM 9
NOTE: Repeat for the opposite cylinder if needed.
84516378 05/07/2011
G.10.A / 8
Cylinder - Remove Loader Cylinder and Link

WARNING
Escaping fluid!
doctor immediately.
W0178A
1. Attach a suitable lifting device and support the loader

arm.
RCPH11TLB167AAM 1
2. Remove the hardware securing the pin.
3. Remove pin.
RCPH11TLB170AAM 4
84516378 05/07/2011
G.10.A / 9
4. Remove link.
RCPH11TLB171AAM 5
5. Remove tube clamp.
RCPH11TLB172AAM 6
6. Remove hydraulic tubes. Caps all open ports.
RCPH11TLB173AAM 7
7. Support cylinder.
RCPH11TLB174AAM 8
84516378 05/07/2011
G.10.A / 10
8. Remove self leveling link.
RCPH11TLB175AAM 9
9. Remove pin securing hardware.
RCPH11TLB176AAM 10
10. Remove inner bell crank arm.
RCPH11TLB177AAM 11
11. Remove bucket cylinder rod end snap ring.
RCPH11TLB163AAM 12
84516378 05/07/2011
G.10.A / 11
12. Remove pin.
RCPH11TLB178AAM 13
13. Remove bucket cylinder.
RCPH11TLB179AAM 14
NOTE: If needed, repeat operation on other side.
84516378 05/07/2011
G.10.A / 12
Cylinder - Install - Loader Cylinder and Link

1. Move the bucket cylinder into place.
RCPH11TLB179AAM 1
2. Install the pin.
RCPH11TLB178AAM 2
3. Install the snap ring on the bucket cylinder rod end.
RCPH11TLB163AAM 3
4. Install the inner bell crank arm.
RCPH11TLB177AAM 4
84516378 05/07/2011
G.10.A / 13
5. Install the pin securing hardware.
RCPH11TLB176AAM 5
6. Reconnect the self leveling link.
RCPH11TLB175AAM 6
7. Remove supports and reconnect hydraulic tubes.
RCPH11TLB173AAM 7
8. Install the tube clamp.
RCPH11TLB172AAM 8
84516378 05/07/2011
G.10.A / 14
9. Reinstall the link.
RCPH11TLB171AAM 9
10. Install pin.
RCPH11TLB170AAM 10
11. Install the hardware securing the pin.
12. Remove lifting device and supports from the loader

arm.
RCPH11TLB167AAM 13
84516378 05/07/2011
G.10.A / 15
Index
LIFTING - 10.A
Cylinder - Install - Loader Cylinder and Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cylinder - Install Loader Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder - Remove Loader Cylinder and Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder - Remove Loader Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84516378 05/07/2011
G.10.A / 16
84516378 05/07/2011
G.10.A / 17
PRINTED IN U.S.A.
84516378 05/07/2011
EN
SERVICE MANUAL
HITCH AND WORKING TOOL
580N
580SN WT
580SN
590SN
84516378 05/07/2011
H
Contents
HITCH AND WORKING TOOL - H
BOOM Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.20.B

580N , 580SN WT , 580SN , 590SN
BOOM Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.20.D

580N , 580SN WT , 580SN , 590SN
DIPPER Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.25.B

580N , 580SN WT , 580SN , 590SN
DIPPER Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.25.F

580N , 580SN WT , 580SN , 590SN
ARM TOOL ATTACHMENT Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.30.C

580N , 580SN WT , 580SN , 590SN
84516378 05/07/2011
H
BOOM Lift - 20.B
580N
580SN WT
580SN
590SN
84516378 05/07/2011
H.20.B / 1
Contents
BOOM Lift - 20.B
TECHNICAL DATA
Cylinder
Torque - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Cylinder
Exploded view - Boom cylinder (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Arm
Exploded view - Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Relief valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder
Remove - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Overhaul - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assemble - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Arm
Remove - Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install - Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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H.20.B / 2
HITCH AND WORKING TOOL - BOOM Lift
Cylinder - Torque - Boom cylinder

580N, 580SN,and 580SN WT

590SN
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H.20.B / 3
Cylinder - Exploded view - Boom cylinder (all models)

Cylinder components are similar for all models, the difference being in the dimensions of the components.
(A) Boom cylinder assembly (9) Wear ring

(1) Cylinder tube (10) 4 piece piston seal assembly
(2) Gland (11) Piston rod
(3) Rod bearing (12) Internal bushing
(5) Static head seal (14) Locking screw
(6) Wiper rod (15) Lube fitting
(8) Cast iron ring
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RCPH11TLB019HAN 1
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Arm - Exploded view - Boom

Boom components are similar for all models, the difference being in the dimensions of the components.
(1) Pin – Boom arm to dipper arm

(2) Lubrication fitting
(3) Locking bolt
(4) Washer
(5) Spacer
(6) Pin – Cylinder
(7) Shims
(8) Snap ring
(9) Boom guard
(10) Boom bumper pad with hardware
(11) Locking bolt
(12) Pin retainer bracket
(13) Washer
(14) Pin – Boom arm to swing tower
(15) Shims
(16) Washer
(17) Swing tower assembly
(18) Boom lock
(19) Snap ring
(21) Shim
(23) Shim
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RCPH10TLB006HAD 1
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Relief valve - Pressure test
RCPH10TLB057GAL 1
1. Swing B 3. Dipper B 5. Swing A 7. Dipper A

2. Boom B 4. Bucket B 6. Boom A 8. Bucket A
1. Remove the suspect relief valve.

2. Connect the relief valve to the test block.
ducer to the test block. Set the transducer to 600
Bar.
34500 kPa (5000 psi) or greater.
4. Actuate the hand pump and record the highest pres-
sure reading. Check the pressure setting several
time to verify the reading.
5. Compare the reading with the Specifications. See
PRIMARY HYDRAULIC POWER SYSTEM - Gen-
eral specification (A.10.A).
6. If the pressure setting is not correct, replace the
circuit relief valve. See Relief valve - Replace
(H.20.B).
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H.20.B / 8
Relief valve - Replace

1. Remove the circuit relief valve from the test block.
2. Lubricate the O-ring with hydraulic oil.
3. Install the relief valve and torque to 65 N·m (48 lb ft)
± 6.8 N·m (5 lb ft).
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Cylinder - Remove - Boom cylinder

Hydraulic fluid will be released during this procedure be prepared to direct the fluid into a suitable container and
dispose of properly.
1. Provide adequate support to the boom arm.
RCPH10TLB779AAD 1
RCPH10TLB586AAD 2
3. Disconnect and cap hydraulic tubes or hoses.
RCPH10TLB585AAD 3
4. Remove the snap ring and washer from the swing

tower to boom cylinder pin.
RCPH10TLB588AAD 4
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H.20.B / 10
5. Remove the pin.
RCPH10TLB584AAD 5
6. Remove the snap ring and washer from the upper

boom cylinder pin.
RCPH10TLB589AAD 6
7. Remove the pin.

8. Remove the cylinder from the boom arm.
RCPH10TLB778AAD 7
Next operation:
Cylinder - Disassemble - Boom cylinder (H.20.B)
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Cylinder - Disassemble - Boom cylinder

Prior operation:
Cylinder - Remove - Boom cylinder (H.20.B)
NOTE: Refer to the Cylinder - Exploded view - Boom cylinder (all models) (H.20.B) illustration.
1. Clean the outside of cylinder using appropriate
cleaning solvent.
2. Secure tube (1) in a vise. Use care to prevent dam-
age to tube.
3. Loosen and remove lock screw (14) from gland (2)
and tube (1).
4. Use gland wrench to loosen and remove the gland
(2) from tube (1).
5. Remove piston rod (11) from tube (1). Ensure piston
rod is removed straightly to prevent damage to tube.
6. Secure piston rod (11) eye in vise. Place a support
below piston rod eye, near piston (7). To prevent
damage, place shop cloth between support and pis-
ton rod.
7. Remove bolt with hardened washer (13). Use torque
multiplier tool for bolts having high torque value.
8. Remove piston (7) from piston rod (11).
9. Remove gland (2) from piston rod (11).
10. Remove four piece piston seal assembly (10), wear
ring (9), and cast iron ring (8) from piston (7).
11. Remove static head seal (5), rod bearing (3), rod and
buffer seal (4), and wiper rod (6) from gland (2).
Next operation:
Cylinder - Overhaul - Boom cylinder (H.20.B)
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Cylinder - Overhaul - Boom cylinder

Prior operation:
Cylinder - Disassemble (H.20.B)
1. Clean piston (7), gland (2), piston rod (11), tube (1),
bolt with hardened washer (13). Use appropriate
cleaning solvent.
2. Discard removed parts from piston (7) and gland (2).
3. Inspect inside of tube (1) using a light source. Check
for deep grooves or scoring. If tube is damaged,
replace with new tube weldment.
4. Ensure piston rod (11) is straight. If not straight, re-
place with new piston rod.
5. Remove small scratches inside of tube (1) by using
a medium grit emery cloth. Ensure emery cloth is
applied using a circular motion.
6. Inspect bushings (12) in piston rod (11) eye and
closed end of tube (1) for damage. Replace as
required.
7. Inspect gland (2) for rust. Clean as required.
8. Inspect gland end of tube (1) for sharp edges, which
could damage gland O-ring. Remove as required.
9. Inspect piston (7) for damage or excessive wear. If
damaged or worn, replace with new piston.
10. Inspect all seals for damage or excessive wear. Re-
place as required.
Next operation:
Cylinder - Assemble - Boom cylinder (H.20.B)
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Cylinder - Assemble - Boom cylinder

Refer to illustration Cylinder - Exploded view (H.20.B).
Prior operation:
1. Install cast iron ring (8) in gland (2).

2. Install rod and buffer seal (6) in gland (2). Ensure lip
side of buffer seal faces small end of gland.
3. Install static head seal (5) in gland (2). Ensure lip of
seal faces small end of gland . Seal can be difficult
to install. Use the tool shown on CAS1660.
4. Install new wiper (4) in gland (2). Ensure lips of wiper
faces large end of gland .
7. Fasten piston rod (11) eye in vise.
8. Remove sharp edges or marks on chamfer at end of
piston rod (11).
9. Use clean oil to lubricate bore of gland (2) and piston
rod (11).
10. Slide gland (2) on piston rod (11). If required, use
soft hammer to drive gland onto piston rod.
11. Place a support below and near end of piston rod
(11). To prevent damage to piston (7), use a shop
cloth between support and piston rod.
12. Position piston (7) on end of piston rod (11).
13. Clean threads on piston rod and bolt using Loctite
cleaning solvent. Allow to dry.
14. Apply LOCTITE® 243 to piston rod threads approxi-
mately 6.35 mm (0.25 in) from open end of piston
rod. Ensure threads are minimally coated 12.7 mm
(0.50 in). Do not apply Loctite to the first 6.35 mm
(0.25 in) threads of piston rod.
15. Install and tighten bolt with hardened washer (13). A
torque multiplier can aid tightening bolt to the follow-
ing torque value:
• 580N, 580SN, and 580SN WT– 2160 -
2450 N·m (1593 - 1807 lb ft)
• 590SN – 2830 - 3210 N·m (2087 - 2368 lb
ft)
16. Install new wear ring (9) in groove located in center
of piston (7).
17. Install 4 piece piston seal assembly (10) in groove
located on outside end of piston (7). Seal must be in
groove at end of the piston with large bore.
18. Install cast iron ring (8) in remaining outside groove
piston (7).
19. Fasten tube (1) in vise. Use care to prevent damage
to tube.
20. Use clean oil to lubricate inside of tube (1) and piston
(7).
21. Push piston (7) straight into tube (1).
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H.20.B / 14
22. When the piston (7) is in smooth part of tube (1), slide
gland (2) into the tube (1).
23. Use clean oil to lubricate static head seal (5) located
on gland (2).
24. Tighten gland (2) to 135 - 542 N·m (100 - 400 lb ft).
25. Ensure tube (1) lock screw hole aligns with hole in
gland (2) after setting torque.
If holes align, do the following:
• Install and tighten lock screw (14) to
torque value of 2.3 N·m (20 lb in).
If holes do not align, do the following:
A. If required, tighten gland (2) so screw
hole on tube (1) does not align with gland
wrench holes located on face of gland.
B. Use a No. 26 drill bit to drill a hole 11 mm
(0.43 in) deep, as measured from outside
of tube (1).
C. Install and tighten lock screw (14) to
torque of 2.3 N·m (20 lb in).
26. If equipped, install new O-rings on hose fittings. Use
clean oil to lubricate the O-rings. Install the hoses.
Next operation:
Cylinder - Install - Boom cylinder (H.20.B)
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H.20.B / 15
Cylinder - Install - Boom cylinder

Prior operation:
1. Move the cylinder (1) into position in the boom arm

(2). Align the cylinder eyelet with the boom arm
opening.
RCPH10TLB778AAD 1
2. Insert the upper cylinder pin.
RCPH10TLB779AAD 2
3. Secure the pin in place with a retaining washer (1)

and a snap ring (2).
RCPH10TLB589AAD 3
4. Adjust the cylinder rod length until the cylinder rod

eyelet is aligned with the swing tower opening.
RCPH10TLB584AAD 4
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H.20.B / 16
5. Insert the pin.

6. Secure the pin in place with a retaining washer (1)
and a snap ring (2).
RCPH10TLB588AAD 5
7. Connect the previously disconnected hydraulic tubes

or hoses to the boom cylinder.
8. Remove the boom cylinder lifting device.
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H.20.B / 17
Arm - Remove - Boom

Prior operation:
Arm - Remove - Backhoe Boom (H.25.B) or DIPPER Extension - Remove Dipper Arm (H.25.F)
1. Support the boom arm.
RCPH10TLB777AAD 1
2. Identify, tag and disconnect all backhoe hydraulic

hoses.
3. Cap all open ports and hoses.
RCPH10TLB129AAD 2
4. Support the boom cylinder.
RCPH10TLB586AAD 3
5. Remove snap ring and shims from boom cylinder pin.
RCPH10TLB018AAD 4
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H.20.B / 18
6. Remove the boom cylinder pin.
RCPH10TLB584AAD 5
7. Support the boom cylinder on the boom arm.
RCPH10TLB101AAD 6
8. Attach a suitable lifting device to the boom arm as-

sembly.
RCPH10TLB777AAD 7
9. Remove the locking bolt (1) and retainer bracket (2).
RCPH10TLB100AAD 8
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H.20.B / 19
10. Remove the boom arm pin.
RCPH10TLB098AAD 9
11. Remove the boom arm from the machine.
Next operation:
Arm - Install - Boom (H.20.B)
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H.20.B / 20
Arm - Install - Boom

Prior operation:
Arm - Remove - Boom (H.20.B)

sembly.
2. Align the boom arm assembly with the swing tower.
RCPH10TLB777AAD 1
3. Install the boom arm pin.
RCPH10TLB098AAD 2
4. Secure the boom arm pin with the locking bolt and
retainer bracket. Tighten to a torque of 301 - 407
N·m (222 - 300 lb ft).
RCPH10TLB100AAD 3
5. Align the boom cylinder rod eye with the swing tower
pin opening.
6. Insert the cylinder rod pin.
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H.20.B / 21
7. Secure the pin in place with shims and snap rings.
RCPH10TLB018AAD 4
8. Remove caps and plugs from the hydraulic hoses

and ports.
9. Connect the hydraulic hoses.
RCPH10TLB129AAD 5
Next operation:
Arm - Install Backhoe Boom (H.25.B) or DIPPER Extension - Install (H.25.F)
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H.20.B / 22
Index
BOOM Lift - 20.B

Arm - Exploded view - Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Arm - Install - Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Arm - Remove - Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cylinder - Assemble - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cylinder - Disassemble - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder - Exploded view - Boom cylinder (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder - Install - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder - Overhaul - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cylinder - Remove - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder - Torque - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Relief valve - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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BOOM Swing - 20.D
580N
580SN WT
580SN
590SN
84516378 05/07/2011
H.20.D / 1
Contents
BOOM Swing - 20.D
TECHNICAL DATA
Cylinder
Torque - Swing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Cylinder
Exploded view - Swing tower cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional view - Swing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing tower
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview - 580N with mechanical linkage controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Overview - 580SN, 580SN WT, and 590SN with mechanical linkage controls . . . . . . . . . . . . . . . . . . . . . . 14
Overview - All models with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERVICE
Relief valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cylinder
Remove - Swing cylinder (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassemble - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overhaul - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble - Swing cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Swing tower
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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HITCH AND WORKING TOOL - BOOM Swing
Cylinder - Torque - Swing cylinder


84516378 05/07/2011
H.20.D / 3
Cylinder - Exploded view - Swing tower cylinder

(A) Swing tower cylinder (complete assembly)
(1) Gland
(2) Seal buffer
(3) Piston rod seal
(4) Seal protection
(5) Piston rod
(6) Snap ring
(7) Bushing
(9) Snap ring
(10) Bushing
(11) Backup ring
(12) O-ring
(13) Piston ring
(14) Gasket
(15) Oil seal
(16) Piston
(17) Cast iron oil seal
(18) Bolt with hardened washer
(19) Bushing
(20) Self tapping lock screw
(22) Bushing
(23) Cylinder tube
(25) O-ring
(26) Backup ring
(27) Cap
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RCPH10TLB003HAD 1
84516378 05/07/2011
H.20.D / 5
Cylinder - Sectional view - Swing cylinder

(1) Gland
(2) Seal buffer
(3) Piston rod seal
(4) Seal protection
(5) Piston rod
(6) Snap ring
(7) Bushing
(9) Snap ring
(10) Bushing
(11) Backup ring
(12) O-ring
(13) Piston ring
(14) Gasket
(15) Oil seal
(16) Piston
(17) Cast iron oil seal
(18) Bolt with hardened washer
(19) Bushing
(22) Bushing
(23) Cylinder tube
(25) O-ring
(26) Backup ring
(27) Cap
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H.20.D / 6
RCPH10TLB143GAL 1
84516378 05/07/2011
H.20.D / 7
Swing tower - Exploded view

The following component list is the same for all machine models with the exception of some of the hardware
dimensions.
(1) Swing tower body
(2) Swing tower lock pin
(3) Upper tower pin with lube fitting
(4) Shim
(5) Snap ring
(6) Boom bumper with hardware
(7) Boom cylinder pin
(8) Shim
(9) Snap ring
(10) Shim
(11) Pin retainer plate with hardware
(12) Boom to Tower Pin
(13) Snap ring
(14) Shim
(15) Swing cylinder pin
(16) Retainer bolt and washer
(17) Snap ring
(18) Shim
(19) Swing tower cylinder
(20) Spacer
(21) Bolt hardware
(22) Swing tower cylinder retaining bracket
(23) Snap ring
(24) Shim(s)
(25) Lower tower pin with lube fitting
(26) Swing tower washer
(27) Shim(s)
(28) Snap ring
(29) Shim(s)
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H.20.D / 8
RCPH10TLB002HAD 1
84516378 05/07/2011
H.20.D / 9
Swing tower - Sectional view

The following component list is the same for all machine models with the exception of some of the hardware
dimensions.
(1) Swing tower body
(2) Swing tower lock pin
(3) Upper tower pin with lube fitting
(4) Shim
(5) Snap ring
(6) Boom bumper with hardware
(7) Boom cylinder pin
(8) Shim
(9) Snap ring
(10) Shim
(11) Pin retainer plate with hardware
(12) Boom to Tower Pin
(13) Snap ring
(14) Shim
(15) Swing cylinder pin
(16) Retainer bolt and washer
(17) Snap ring
(18) Shim
(19) Swing tower cylinder (not shown)
(20) Spacer (not shown)
(21) Bolt hardware (not shown)
(22) Swing tower cylinder retaining bracket (not shown)
(23) Snap ring
(24) Shim(s)
(25) Lower tower pin with lube fitting
(26) Swing tower washer
(27) Shim(s)
(28) Snap ring
(29) Shim(s)
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H.20.D / 10
RCPH10TLB006HAD 1
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H.20.D / 11
Swing tower - Overview - 580N with mechanical linkage controls

(1) Backhoe mechanical control valve
(2) Swing cushion valve
(3) Left-hand side swing cylinder
(4) Right-hand side swing cylinder
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H.20.D / 12
RCPH10TLB097GAL 1
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H.20.D / 13
Swing tower - Overview - 580SN, 580SN WT, and 590SN with

mechanical linkage controls
(A) Left-hand side rear view of components
(B) Right-hand side rear view of components
(C) Left-hand side front view of components
(2) Left-hand swing cylinder
(3) Right-hand swing cylinder
(4) Backhoe mechanical control valve
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H.20.D / 14
RCPH10TLB103GAL 1
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H.20.D / 15
Swing tower - Overview - All models with pilot controls

(1) Backhoe pilot control valve
(4) Right-hand swing cylinder
(5) Left-hand swing cylinder
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H.20.D / 16
RCPH10TLB008GAD 1
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H.20.D / 17
RCPH10TLB057GAL 1


Bar.
(H.20.D).
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H.20.D / 18

± 6.8 N·m (5 lb ft).
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H.20.D / 19
Cylinder - Remove - Swing cylinder (all models)

WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the
engine off, turn the key on, and move the hydraulic control lever through all movements several times
to relieve residual pressure in the system.
W0161A
When disconnecting hydraulic components be prepared to cap and plug hoses and ports. Direct the flow of oil into a
suitable container.
1. Extend and support the backhoe boom. Turn the

engine off, remove the ignition key and release the
pressure in the hydraulic system.
2. Identify and tag the swing cylinder hoses.
RCPH10TLB061AAD 1
3. Remove the top support mount hardware.
RCPH10TLB069AAD 2
4. Remove the cylinder top mount support. Record the

location and number of shims.
RCPH10TLB055AAD 3
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H.20.D / 20
5. Remove the swing cylinder hose clamps.
RCPH10TLB059AAD 4
6. Remove the hydraulic hoses. Cap all open ports.
RCPH10TLB063AAD 5
7. Remove quick detach hose bracket.
RCPH10TLB057AAD 6
8. Remove the rod end snap ring and washer.

9. Remove pin.
RCPH10TLB094AAD 7
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H.20.D / 21
10. Compress piston rod into the cylinder.
RCPH10TLB054AAD 8
11. Carefully remove the cylinder.
RCPH10TLB051AAD 9
Next operation:
Cylinder - Disassemble - Swing cylinders (all models) (H.20.D)
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H.20.D / 22
Cylinder - Disassemble - Swing cylinders (all models)

Prior operation:
Cylinder - Remove - Swing cylinder (all models) (H.20.D)
NOTE: Refer to illustrations Cylinder - Exploded view - Swing tower cylinder (H.20.D) and Cylinder - Sectional
view - Swing cylinder (H.20.D).
1. Clean the outside of the cylinder.
2. Fasten the tube (23) in a vise or other holding equip-
3. Remove the lock screw (20) from the gland (1) and
tube (23).
4. Use the gland wrench CAS1456 to remove the gland
(1) from the tube (23).
5. Pull the piston rod (5) straight out of the tube (23) to
prevent damage to the tube (23).
6. Fasten the piston rod (5) eye in a vise and put a
support below the piston rod (5) near the piston (16).
Use a shop cloth between the support and the piston
rod (5) to prevent damage to the piston rod (5).
7. Remove the bolt with hardened washer (18). If nec-
essary use tool CAS1039.
8. Remove the piston (16) from the piston rod (5).
9. Remove the gland (1) from the piston rod (5).
10. Remove the wear ring (15), seal (17), backup ring
(14), and piston ring (13) from the piston (16).
11. Remove the O-ring (12), backup ring (11), wiper (3),
wide seal (4), buffer seal (2), and bushing (10) from
the gland (1).
12. Remove the end cap lock screw (24).
13. Remove the end cap (13) from the tube (23).
14. Remove the backup ring (26) and O-ring (25) from
the end cap (27).
Next operation:
Cylinder - Overhaul - Swing cylinders (all models) (H.20.D)
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H.20.D / 23
Cylinder - Overhaul - Swing cylinders (all models)

Prior operation:
Cylinder - Disassemble - Swing cylinders (all models) (H.20.D)
1. Clean the piston (16), gland (1), piston rod (5), tube
(23), bolt with hardened washer (18) in cleaning sol-
vent. Make sure the orifice in the piston (16) is open.
2. Discard the parts that were removed from the piston
(16), gland (1) and the end cap (27).
3. Illuminate the inside of the tube (23). Inspect the
inside of the tube (23) for deep grooves and other
damage. If there is damage to the tube (23), a new
tube (23) must be used.
4. Check to be sure that the piston rod (5) is straight. If
the piston rod (5) is not straight, install a new piston
rod (5).
5. Remove small scratches on the piston rod (5) or in-
side the tube (23) with emery cloth of medium grit.
Use the emery cloth with a rotary motion.
6. Inspect the bushing (7) and snap rings (6): (9) in the
piston rod (5) eye and bushings (19): (22) on the
trunnions on the tube (23), replace as required.
7. Inspect the gland (1). Clean and remove rust as re-
quired.
8. Inspect the gland end of the tube (23) for sharp edges
that will cut the gland O-ring (12), remove as re-
quired.
Next operation:
Cylinder - Assemble - Swing cylinders (H.20.D)
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H.20.D / 24
Cylinder - Assemble - Swing cylinders
Prior operation:
Cylinder - Overhaul - Swing cylinders (all models) (H.20.D)
NOTE: If a new gland (1) is being installed, put the part number of the cylinder on the new gland.
1. Install the bushing (10) in the gland (1).
2. Install the buffer seal (2) in the gland (1). The side
of the buffer seal (2) with the lip must be toward the
small end of the gland (1).
3. Install the wide seal (4) in the gland. The wide seal
(4) is to be installed so that the lips of the wide seal
(4) are toward the small end of the gland (1). The
wide seal (4) can be difficult to install. If necessary
use tool CAS1039.
4. Install a new wiper (3) in the gland (1). The lips of the
wiper (3) must be toward the large end of the gland
(1).
5. Install a new backup ring (11) in the groove on the
outside of the gland (1). If both sides of the backup
ring (11) are not flat, the side that is not flat must be
toward the small end of the gland (1).
6. Install the O-ring (12) next to the backup ring (11) in
the groove on the outside of the gland (1). The O-ring
(12) must be toward the small end of the gland (1).
7. Fasten the piston rod (5) eye in the vise.
8. Lubricate the bore of the gland (1) with clean oil.
9. Push the gland (1) onto the piston rod (5). If neces-
sary, use a soft hammer to drive the gland (1) onto
the piston rod (5).
10. Put a support below and near the end of the piston
rod (5). Use a shop cloth between the support and
the piston rod (5) to prevent damage to the piston
(16).
11. Put the piston (16) on the end of the piston rod (5).
12. Clean the threads on the end of the piston rod and
the threads of the bolt using Loctite cleaning sol-
vent. Allow to dry. Apply LOCTITE® 243 to the piston
rod threads 6.35 mm (0.25 in) from the open end of
the piston rod so that there is 3.7 mm (0.15 in) of
LOCTITE® 243 on the piston rod threads. Do not ap-
ply Loctite to the first 6.35 mm (0.25 in) of the piston
rod threads.
13. Install and tighten the bolt (18) to a torque value be-
tween 810 - 925 N·m (597 - 682 lb ft). A torque mul-
tiplier tool CAS1039 can be used to tighten the bolt
within the torque specifications.
14. Install a new piston ring (13) in the groove at the bolt
end of the piston (16).
15. Install a new wear ring (15) in the center grove on the
outside of the piston (16).
16. Install a new backup ring (14) in the groove on the
outside of the piston (16).
84516378 05/07/2011
H.20.D / 25
17. Install a new seal (17) on top of the backup ring (14)
on the outside of the piston (16).
18. Fasten the tube (23) in a vise or other holding equip-
19. Install a new backup ring (26) and O-ring (25) in the
groove on the outside of the end cap (23).
20. Lubricate the O-ring (25) on the end cap (27) with
clean oil.
21. Install the end cap (27) in the tube (23).
22. Install and tighten the lock screw (24) to a torque of
2.3 N·m (20 lb in).
23. Lubricate the inside of the tube (23) and the piston
(16) with clean oil.
24. Use a piston ring compression tool to hold the new
wear ring (15) in place.
25. Push the tube (23) straight onto the piston (16).
26. Start the tube (23) onto the piston rod assembly.
Push the tube onto the piston rod assembly until the
compression tool is pushed off the piston rod assem-
bly. Be careful not to damage the wear ring (15) and
seal (17).
27. Lubricate the O-ring (12) on the gland (1) with clean
oil.
28. Tighten the gland (1) to 135 - 542 N·m (100 - 400 lb
ft).
29. Confirm the tube (23) lock screw hole aligns with the
hole in the gland (1) after setting the torque.
Holes align:
• Install and tighten the lock screw (20) to a
Holes not aligned:
A. If necessary, tighten the gland (1) so the
screw hole on the tube (23) does not align
with the gland wrench holes on the face of
the gland.
B. Use a No. 26 drill bit and drill a hole 11 mm
(0.43 in) deep measured from the outside
of the tube (23).
C. Install and tighten the lock screw (20) to a
Next operation:
Cylinder - Install - Swing cylinders (all models) (H.20.D)
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H.20.D / 26
Cylinder - Install - Swing cylinders (all models)

Prior operation:
Cylinder - Assemble - Swing cylinders (H.20.D)
1. Position the swing cylinder on the machine.

NOTE: Replicate the original location and number of shims
on the cylinder.
RCPH10TLB051AAD 1
2. Extend and align the cylinder rod eyelet with the

swing tower opening.
RCPH10TLB054AAD 2
3. Install the swing cylinder pin. Secure the pin with a

snap ring (1) and washer (2).
RCPH10TLB090AAD 3
4. Secure the quick detach hose bracket.
RCPH10TLB057AAD 4
84516378 05/07/2011
H.20.D / 27
5. Attach cylinder hoses and remove the identification

tags.
RCPH10TLB063AAD 5
6. Secure the hoses to the cylinder with clamps.
RCPH10TLB059AAD 6
7. Position the cylinder top support retaining bracket (1)

over the swing cylinder (2).
RCPH10TLB055AAD 7
8. Tighten the bolt hardware to a torque of 410 - 455

N·m (302 - 336 lb ft).
RCPH10TLB069AAD 8
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H.20.D / 28
Swing tower - Remove

When removing the complete boom assembly as one unit (boom, dipper and tool attachment), use the prior operation
procedure listed with additional support provided to the dipper and tool attachment.
Prior operation:
Arm - Remove - Boom (H.20.B)
1. Remove the hose guard.
RCPH10TLB094AAD 1
2. Remove snap ring and washers from rod end pins.
RCPH11TLB036AAL 2
3. Use a suitable driver to remove both swing cylinder

pins.
RCPH10TLB088AAD 3
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H.20.D / 29
4. Remove the boom lock pin (3) snap ring (1) and
washer (2).
RCPH10TLB095AAD 4
5. Remove the boom lock pin (1) and latch arm (2).
RCPH10TLB093AAD 5
6. Attach a suitable lifting device to the swing tower.

NOTE: If required install the boom arm pins on the swing
tower for attachment points.
RCPH10TLB081AAD 6
NOTE: A combination of shims and washers are used to close the spacing between the swing tower and the machine.
The location, orientation and size of the shims and washers are critical to the smooth operation of the swing tower.
Record the location and orientation before removing from the assembly.
7. Remove the snap ring (1) and shims (2) from the
swing tower's lower pin.
RCPH10TLB017AAD 7
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H.20.D / 30
8. Use a suitable driver (1) to remove the lower pin (2).
RCPH10TLB783AAD 8
RCPH10TLB079AAD 9
9. Remove the lubrication fitting (1), snap ring (2) and

shim(s) (3) from the swing tower's upper pin.
RCPH10TLB086AAD 10
10. Drive the upper pin out of the assembly.
RCPH10TLB073AAD 11
Record the location and orientation before removing from the assembly.
84516378 05/07/2011
H.20.D / 31
11. Remove the shims and washers from the lower pin
locations on the swing tower.
RCPH10TLB072AAD 12
RCPH10TLB071AAD 13
12. Remove the swing tower from the frame.
RCPH10TLB070AAD 14
Next operation:
Swing tower - Install (H.20.D)
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H.20.D / 32
Swing tower - Install

Prior operation:
Swing tower - Remove (H.20.D)
1. On the lower and upper swing tower pins, install a

flat washer(s) and a snap ring to the end without the
lubrication fitting.
2. Move the swing tower into position on the machine.
RCPH10TLB081AAD 1
Place the washers and shims in their original position.
3. On the lower part of the swing tower frame make sure
that the washer with the tab is installed on underside
of the lower top frame plate. The tab must engage
the notch on the swing tower.
RCPH10TLB071AAD 2
4. Position the flat washers and shims in their original

position on the topside of the lower bottom frame
plate.
RCPH10TLB072AAD 3
NOTE: Install pins until the retaining washers rest on the swing tower frame.
5. Install the top swing tower pin with the lubrication
point facing downward.
84516378 05/07/2011
H.20.D / 33
6. Install the bottom swing tower pin with the lubrication

fitting upward.
RCPH10TLB017AAD 4
7. Install the remaining snap ring (2) and shim(s) (1) to

the swing tower's upper and lower pins.
RCPH10TLB086AAD 5
8. Install the boom lock pin (1) and boom latch arm (2).
RCPH10TLB093AAD 6
9. Install the snap ring (1) and washer (2) on the boom
lock pin (3).
RCPH10TLB095AAD 7
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H.20.D / 34
10. Move the swing cylinders as necessary to align the

rod eyes with the mounting holes in the swing tower.
11. Install the swing cylinder pins into the rod eyes of the
swing cylinders.
RCPH10TLB054AAD 8
12. From underneath the swing tower, install the washer

(2) and bolt (1).
RCPH10TLB776AAD 9
13. Secure the hose guard (1) in place on the swing

tower with bolts (2).
RCPH10TLB094AAD 10
Next operation:
Arm - Install - Boom (H.20.B)
The procedure will be the same even if the boom assembly was removed as one unit (boom, dipper and tool attach-
ment).
84516378 05/07/2011
H.20.D / 35
Index
BOOM Swing - 20.D

Cylinder - Assemble - Swing cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cylinder - Disassemble - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cylinder - Exploded view - Swing tower cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder - Install - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cylinder - Overhaul - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cylinder - Remove - Swing cylinder (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cylinder - Sectional view - Swing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder - Torque - Swing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Relief valve - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Swing tower - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Swing tower - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Swing tower - Overview - 580SN, 580SN WT, and 590SN with mechanical linkage controls . . . . . . . . . . . . . . . . . 14
Swing tower - Overview - All models with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Swing tower - Overview - 580N with mechanical linkage controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Swing tower - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Swing tower - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84516378 05/07/2011
H.20.D / 36
DIPPER Lift - 25.B
580N
580SN WT
580SN
590SN
84516378 05/07/2011
H.25.B / 1
Contents
DIPPER Lift - 25.B
TECHNICAL DATA
Cylinder
Torque - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Cylinder
Exploded view - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Relief valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder
Remove - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overhaul - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Arm
Remove - Backhoe Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install Backhoe Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
84516378 05/07/2011
H.25.B / 2
HITCH AND WORKING TOOL - DIPPER Lift
Cylinder - Torque - Dipper cylinder

580N, 580SN, and 580SN WT

590SN
84516378 05/07/2011
H.25.B / 3
Cylinder - Exploded view - Dipper cylinder

(A) Dipper cylinder assembly (9) Wear ring
(2) Gland (11) Internal bushing
(3) Wiper rod (12) Piston rod
(5) Bearing rod (14) Locking screw
(6) Static head seal (15) Lube fitting
(8) Cast iron ring
84516378 05/07/2011
H.25.B / 4
RCPH11TLB018HAN 1
84516378 05/07/2011
H.25.B / 5
RCPH10TLB057GAL 1


Bar.
(H.25.B).
84516378 05/07/2011
H.25.B / 6

± 6.8 N·m (5 lb ft).
84516378 05/07/2011
H.25.B / 7
Cylinder - Remove - Dipper cylinder

Be prepared to cap or plug hydraulic tubes, hoses, or ports.
The dipper removal procedure is the same for standard dipper and Extendahoe models.
Prior operation:
Cylinder - Remove - Boom cylinder (H.20.B)
1. Remove cylinder tube clamps.
RCPH10TLB576AAD 1
2. Remove the cylinder hydraulic tubes.
RCPH10TLB577AAD 2
RCPH10TLB579AAD 3
84516378 05/07/2011
H.25.B / 8
3. Cap or plug hydraulic tubes and hoses.
RCPH10TLB572AAD 4
RCPH10TLB571AAD 5
5. Remove snap ring and washer from the dipper cylin-

der and arm connection.
6. Remove the dipper cylinder pin.
RCPH10TLB581AAD 6
7. Remove the snap ring and washer from the dipper

cylinder boom arm connection.
8. Remove the dipper cylinder pin.
RCPH10TLB580AAD 7
84516378 05/07/2011
H.25.B / 9
9. Remove the cylinder from the boom arm.
RCPH10TLB569AAD 8
Next operation:
Cylinder - Disassemble - Dipper cylinder (H.25.B)
84516378 05/07/2011
H.25.B / 10
Cylinder - Disassemble - Dipper cylinder

Prior operation:
Cylinder - Remove - Dipper cylinder (H.25.B)
NOTE: Refer to illustration Cylinder - Exploded view - Dipper cylinder (H.25.B).

1. Clean the outside of cylinder.
2. Secure tube (1) in a vise. Use care to prevent dam-
age to tube.
3. Remove lock screw (14) from gland (2) and tube (1).
4. Use gland wrench to remove gland (2) from tube (1).
5. Pull piston rod (12) straight out of tube (1) to prevent
damage to tube.
6. Secure piston rod (12) eye in a vise. Place a support
below piston rod near the piston (7). Use a shop cloth
between the support and the piston rod to prevent
damage to the piston rod.
7. Remove bolt with hardened washer (13). If neces-
sary use a torque multiplier.
8. Remove piston (7) from the piston rod (12).
9. Remove gland (2) from piston rod (12).
10. Remove four piece piston seal assembly (10), wear
ring (9), and cast iron ring (8) from piston (7).
11. Remove static head seal (6), rod bearing (5), rod and
buffer seal (4), and wiper rod (3), from gland (2).
Next operation:
Cylinder - Overhaul - Dipper cylinder (H.25.B)
84516378 05/07/2011
H.25.B / 11
Cylinder - Overhaul - Dipper cylinder

Prior operation:
Cylinder - Disassemble - Dipper cylinder (H.25.B)
NOTE: Refer to illustration Cylinder - Exploded view (H.25.B).

1. Clean piston (7), gland (2), piston rod (12), tube (1),
and bolt with hardened washer (13). Use appropriate
cleaning solvent.
2. Discard removed parts from piston (7) and gland (2).
3. Inspect inside of tube (1) using a light source. Check
for deep grooves or scoring. If tube is damaged,
replace with new tube weldment.
4. Ensure piston rod (11) is straight. If not straight, re-
place with new piston rod.
5. Remove small scratches inside of tube (1) by using
a medium grit emery cloth. Ensure emery cloth is
applied using a circular motion.
6. Inspect bushings (12) in piston rod (11) eye and the
closed end of tube (1) for damage. Replace as re-
quired.
7. Inspect gland (2) for rust. Clean as required.
8. Inspect gland (2) end of tube (1) for sharp edges,
which could damage gland O-ring. Remove as re-
quired.
9. Inspect piston (7) for damage or wear. Replace as
required.
10. Inspect all seals for damage or excessive wear. Re-
place as required.
Next operation:
Cylinder - Assemble - Dipper cylinder (H.25.B)
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H.25.B / 12
Cylinder - Assemble - Dipper cylinder

Prior operation:
Cylinder - Overhaul - Dipper cylinder (H.25.B)
NOTE: Refer to illustration Cylinder - Exploded view - Dipper cylinder (H.25.B).

1. Install cast iron ring (8) in gland (2).
2. Install rod and buffer seal (4) in gland (2). Lip side of
rod and buffer seal must face small end of gland.
3. Install static head seal (6) in gland (2). Seal is in-
stalled so that lips of wide seal are facing small end
of the gland. Seal can be difficult to install. Use tool
CAS1660.
4. Install new wiper (3) in gland (2). Lips of wiper must
face large end of gland.
7. Secure piston rod (12) eye in a vise.
8. Lubricate bore of gland (2) and piston rod (12) with
clean oil.
9. Push gland (2) onto piston rod (12). If necessary, use
a soft hammer to drive gland onto piston rod.
10. Put a support below and near end of piston rod (12).
To prevent piston (7) damage, use a shop cloth be-
tween support and piston rod.
11. Position piston (7) on end of piston rod (12).
12. Clean threads on end of piston rod and bolt us-
ing Loctite cleaning solvent. Allow to dry. Apply
LOCTITE® 243 to piston rod threads 6.35 mm (0.25
in) from the open end of the piston rod so that there
is 12.7 mm (0.50 in) of LOCTITE® 243 on piston rod
threads. Do not apply Loctite to the first 6.35 mm
(0.25 in) of the piston rod threads.
13. Install and tighten bolt with hardened washer (13). A
torque multiplier can be used to help tighten bolt to a
torque value of:
• 580N, 580SN, and 580SN WT – 2160 -
2450 N·m (1593 - 1807 lb ft)
• 590SN – 2830 - 3210 N·m (2087 - 2368 lb
ft)
14. Install new wear ring (9) in groove in center of piston
(12).
15. Install 4 piece piston seal assembly (10) in groove
located on outside end of piston (4). Seal must be in
groove at end of piston with large bore.
16. Install cast iron ring (8) in remaining outside groove
of piston (7).
17. Fasten tube (15) in vise. Use care to prevent damage
to tube.
18. Use clean oil to lubricate inside of tube (1) and piston
(7).
19. Push piston (7) straight into tube (1).
20. When piston (7) is in smooth part of tube (1), slide
gland (2) into the tube.
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H.25.B / 13
21. Use clean oil to lubricate static head seal (6) located
on gland (2) .
22. Tighten gland (2) to 135 - 542 N·m (100 - 400 lb ft).
23. Ensure tube (1) lock screw hole aligns with the hole
in gland (2) after setting torque.
If holes align, do the following:
• Install and tighten lock screw (14) to a
If holes do not align, do the following:
A. If necessary, tighten gland (2) so screw
hole on tube (1) does not align with gland
wrench holes on face of gland.
B. Use a No. 26 drill bit to drill a hole 11 mm
(0.43 in) deep as measured from outside
of tube (23).
C. Install and tighten lock screw (14) to a
24. If equipped, install new O-rings on hose fittings. Use
clean oil to lubricate O-rings. Install the hoses.
Next operation:
Cylinder - Install - Dipper cylinder (H.25.B)
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H.25.B / 14
Cylinder - Install - Dipper cylinder

The dipper install procedure is the same for standard dipper and Extendahoe models.
Prior operation:
Cylinder - Assemble - Dipper cylinder (H.25.B)
1. Position the cylinder inside the boom arm.

2. Install the cylinder pin for the boom to dipper cylinder
connection.
RCPH10TLB569AAD 1
3. Secure the pin with a washer and snap ring.

4. Adjust the cylinder rod and install the cylinder pin for
the dipper arm to cylinder connection.
RCPH10TLB580AAD 2
5. Secure with a washer and snap ring.
RCPH10TLB581AAD 3
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H.25.B / 15
6. Connect the cylinder hydraulic tubes.
RCPH10TLB577AAD 4
RCPH10TLB579AAD 5
7. Secure the cylinder tubes with clamps.
RCPH10TLB576AAD 6
8. Connect hydraulic hoses.
RCPH10TLB572AAD 7
Next operation:
Cylinder - Install - Boom cylinder (H.20.B)
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H.25.B / 16
Arm - Remove - Backhoe Boom

WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the
engine off, turn the key on, and move the hydraulic control lever through all movements several times
to relieve residual pressure in the system.
W0161A
Be prepared to cap or plug hydraulic hoses and tubes.
Prior operation:
DIPPER Extension - Remove Dipper Arm (H.25.F)
1. Remove the tool attachment from the boom arm.

2. Provide adequate support to the boom arm.
RCPH11TLB050AAL 1
3. Support the boom cylinder.
RCPH11TLB051AAL 2
4. Remove snap ring and washers from rod end pin.
RCPH11TLB052AAL 3
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H.25.B / 17
5. Remove pin.
RCPH11TLB053AAL 4
6. Lower cylinder onto boom.
RCPH11TLB054AAL 5
7. Identify, tag and disconnect all backhoe hoses. Cap

all open hose connections.
RCPH11TLB056AAL 6
8. Attach lifting device to boom arm.
RCPH11TLB050AAL 7
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H.25.B / 18
9. Remove bolts securing the pivot pins.
RCPH11TLB055AAL 8
10. Remove boom pivot pins.
RCPH11TLB057AAL 9
11. Carefully remove backhoe boom.
RCPH11TLB058AAL 10
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H.25.B / 19
Arm - Install Backhoe Boom

sembly.
RCPH11TLB058AAL 1
2. Align the boom arm and boom arm pin openings.

Support the backhoe boom for installation.
NOTICE: Use caution not to damage hydraulic hoses,
tubes, or the dipper cylinder during the placement of the
dipper arm.
RCPH11TLB058AAL 2
3. Install the boom pivot pins.

NOTE: If applicable install any shims that were present
during the removal process.
RCPH11TLB057AAL 3
4. Secure the pin in place with the bolt. Tighten to a

torque between 425 - 575 N·m (313 - 424 lb ft).
RCPH11TLB055AAL 4
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H.25.B / 20
5. Secure boom. Remove the lifting device from the

boom.
RCPH11TLB050AAL 5
6. Reconnect all hydraulic hoses. Remove tags.
RCPH11TLB056AAL 6
7. Use a suitable tool to extend the boom rod to the

swing arm. Install pins.
RCPH11TLB053AAL 7
8. Install the snap ring and washers on the rod end.
RCPH11TLB052AAL 8
9. Identify and connect the hydraulic hoses.
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10. Secure the hydraulic hose with the clamp.
RCPH10TLB784AAD 9
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H.25.B / 22
Index
DIPPER Lift - 25.B

Arm - Install Backhoe Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Arm - Remove - Backhoe Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cylinder - Assemble - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cylinder - Disassemble - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder - Exploded view - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder - Install - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cylinder - Overhaul - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder - Remove - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder - Torque - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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DIPPER Extension - 25.F
580N
580SN WT
580SN
590SN
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H.25.F / 1
Contents
TECHNICAL DATA
Cylinder
Torque - Extendable dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
DIPPER Extension
Exploded view - Extendable dipper installation - 580N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Extendable dipper installation - 580SN, 580SN-WT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view - Extendable dipper installation - 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder
Exploded view - Extendable dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
DIPPER Extension
Remove Dipper Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replace - Wear plates - extendable dipper - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replace - Wear plates - extendable dipper - 580SN, 580SN-WT, 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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HITCH AND WORKING TOOL - DIPPER Extension
Cylinder - Torque - Extendable dipper cylinder


84516378 05/07/2011
H.25.F / 3
DIPPER Extension - Exploded view - Extendable dipper installation

- 580N
RCPH10TLB126GAL 1
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H.25.F / 4

- 580SN, 580SN-WT
RCPH10TLB127GAL 1
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H.25.F / 5

- 590SN
RCPH10TLB119GAL 1
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H.25.F / 6
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H.25.F / 7
Cylinder - Exploded view - Extendable dipper cylinder

(A) Extendable dipper cylinder assembly (8) Cylinder
(1) Cylinder tube (9) Loader
(2) Gland (10) Piston
(3) Backup ring (11) Wear ring
(4) Rod and buffer seal (12) Piston rod
(5) Wiper rod (13) Bolt with hardened washer
(6) Bearing rod (14) Locking screw
(7) O-ring (15) Plug with O-ring
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H.25.F / 8
RCPH11TLB020HAN 1
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H.25.F / 9
DIPPER Extension - Remove Dipper Arm

Prior operation:
Bucket - Remove Quick Attach Backhoe Bucket (J.20.B)
1. Support backhoe boom for dipper arm removal.
RCPH11TLB074AAL 1
2. Relieve hydraulic pressure by moving all backhoe

control sticks in all directions.
RCPH11TLB077AAL 2
3. Remove the tie securing the protective hose cover.

4. Remove hose clamp.
RCPH11TLB078AAL 3
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H.25.F / 10
5. Identify and disconnect hydraulic hoses.

6. Cap all open tube and hoses.
RCPH11TLB079AAL 4
7. Remove auxiliary hose mounting brackets.
RCPH11TLB059AAL 5
8. Attach a suitable lifting device to the dipper cylinder.
RCPH11TLB060AAL 6
9. Remove snap ring and washers from rod end pin.
RCPH11TLB061AAL 7
84516378 05/07/2011
H.25.F / 11
10. Remove cylinder rod end pin.
RCPH11TLB062AAL 8
11. Lower cylinder.
RCPH11TLB063AAL 9
12. Support dipper with appropriate lifting device.
RCPH11TLB064AAL 10
13. Remove bolt securing pin.
RCPH11TLB065AAL 11
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H.25.F / 12
14. Remove dipper pivot pin. Record shim placement, if

installed.
RCPH11TLB066AAL 12
15. Remove dipper arm.
RCPH11TLB067AAL 13
Next operation:
DIPPER Extension - Install (H.25.F)
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H.25.F / 13
DIPPER Extension - Install

Prior operation:
DIPPER Extension - Remove (H.25.F)
1. Carefully move dipper arm into place.

2. Install dipper pivot pin and shims.
RCPH11TLB066AAL 1
3. Install bolt to secure pin into frame.
RCPH11TLB065AAL 2
RCPH11TLB064AAL 3
84516378 05/07/2011
H.25.F / 14
5. Move cylinder into position.
RCPH11TLB063AAL 4
6. Install cylinder rod end pin.
RCPH11TLB062AAL 5
7. Install snap ring and washers on rod end pin.
RCPH11TLB061AAL 6
8. Remove cylinder lifting device.
RCPH11TLB060AAL 7
84516378 05/07/2011
H.25.F / 15
9. Install auxiliary hose mounting brackets.
RCPH11TLB059AAL 8
10. Install hose clamp. Install tie to secure protective

hose cover.
RCPH11TLB078AAL 9
11. Verify hydraulic oil level is correct. Fill as needed.

Refer to Capacities ()
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H.25.F / 16
DIPPER Extension - Replace - Wear plates - extendable dipper -

580N only
1. Remove the dipper extension according to the in-
structions in this section.
2. On 580N machines only, plastic pins are used to hold
the wear plates and the shims in position during as-
sembly. Usually, these pins wear away during op-
eration. Remove any remaining plastic pins. Then
remove the wear plates and the shims.
3. Remove the grease from the sides and the bottom
of the dipper and from the inside of the dipper exten-
sion.
4. Select shims for the side wear plates so that the total
distance from one wear surface to the other is 146 -
147 mm (5.75 - 5.79 in). The wear surface of each
side wear plate must be even with or up to 0.8 mm
(0.031 in) beyond the rails on the dipper.
5. Use new plastic pins to install the side wear plates
and shims.
6. Use new plastic pins to install the top and bottom
wear plates.
7. Apply molydisulfide grease to the rails on the dipper.
8. Install the dipper extension according to the instruc-
tions in this section.
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H.25.F / 17
DIPPER Extension - Replace - Wear plates - extendable dipper -

580SN, 580SN-WT, 590SN
1. Remove the dipper extension according to the in-
structions in this section.
2. Remove the bolts, the washers, the wear plates, and
the shims.
3. Remove the grease from the sides and the bottom
of the dipper and from the inside of the dipper exten-
sion.
4. Select shims for the side wear plates so that the to-
tal distance from one wear surface to the other is
146 - 147 mm (5.75 - 5.79 in). The wear surface
of each wear plate must be even with or up to 0.08
mm (0.003 in) beyond the rails on the dipper.
5. Install the shim(s), the side wear plates, the stepped
washers, and the bolts.
NOTE: On 590 Super N machines only, 9.5 mm (0.374 in)
flat washers are used in addition to the stepped washers.
Use a 9.5 mm (0.374 in) flat washer only when there is no
more than one shim installed under that side wear plate.
6. Tighten the bolts to a torque of 70.5 - 77.3 N·m (52 -
57 lb ft).
7. Select shims for the top and bottom wear plates so
that the total distance from one wear surface to the
other is 234 - 235 mm (9.21 - 9.25 in).The wear sur-
face of each wear plate must be even with or up to
0.8 mm (0.031 in) beyond the rails on the dipper.
8. Install the shim(s), the side wear plates, the stepped
washers, and the bolts.
NOTE: On 590 Super N machines only, 9.5 mm (0.374 in)
flat washers are used in addition to the stepped washers.
Use a 9.5 mm (0.374 in) flat washer only when there are
no more than three shims installed under that top or bottom
wear plate.
9. Tighten the cap screws to a torque of 70.5 - 77.3 N·m
(52 - 57 lb ft).
10. Apply molydisulfide grease to the rails on the dipper.
11. Install the dipper extension according to the instruc-
84516378 05/07/2011
H.25.F / 18
Index

Cylinder - Exploded view - Extendable dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder - Torque - Extendable dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIPPER Extension - Exploded view - Extendable dipper installation - 580N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIPPER Extension - Exploded view - Extendable dipper installation - 580SN, 580SN-WT . . . . . . . . . . . . . . . . . . . . 5
DIPPER Extension - Exploded view - Extendable dipper installation - 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIPPER Extension - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIPPER Extension - Remove Dipper Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIPPER Extension - Replace - Wear plates - extendable dipper - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIPPER Extension - Replace - Wear plates - extendable dipper - 580SN, 580SN-WT, 590SN . . . . . . . . . . . . . . . 18
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H.25.F / 19
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H.25.F / 20
ARM TOOL ATTACHMENT Tilt - 30.C
580N
580SN WT
580SN
590SN
84516378 05/07/2011
H.30.C / 1
Contents
TECHNICAL DATA
Cylinder
Torque - Arm tool attachment cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Cylinder
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Relief valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cylinder
Remove - Backhoe Dipper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install Backhoe Dipper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
84516378 05/07/2011
H.30.C / 2
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
Cylinder - Torque - Arm tool attachment cylinder


84516378 05/07/2011
H.30.C / 3
Cylinder - Exploded view

(A) Arm attachment cylinder assembly (9) Wear ring
(2) Gland (11) Rod eye
(3) Rod bearing (12) Internal bushing
(4) Rod and buffer seal (13) Piston rod
(5) Static head seal (14) Bolt with hardened washer
(6) Wiper rod (15) Locking screw
(7) Piston (16) Lube fitting
(8) Cast iron ring (17) Plug O-ring
84516378 05/07/2011
H.30.C / 4
RCPH11TLB017HAN 1
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H.30.C / 5
RCPH10TLB057GAL 1


Bar.
(H.30.C).
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H.30.C / 6

± 6.8 N·m (5 lb ft).
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H.30.C / 7
Cylinder - Remove - Backhoe Dipper Cylinder

1. Support boom and dipper arm so pins are accessible.
RCPH11TLB025AAL 1
2. Remove ram end tube clamps.
RCPH11TLB026AAL 2
3. Remove ram end hydraulic tube.
RCPH11TLB027AAL 3
4. Remove base end hydraulic tube.
RCPH11TLB028AAL 4
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H.30.C / 8
5. Cap all open tubes and hoses.
RCPH11TLB029AAL 5
6. Use a suitable lifting device to support the cylinder.
RCPH11TLB030AAL 6
7. Remove rod end snap ring.
RCPH11TLB031AAL 7
8. Remove rod end pin.
RCPH11TLB032AAL 8
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H.30.C / 9
9. Remove base end snap ring.
RCPH11TLB033AAL 9
10. Remove base end pin.
RCPH11TLB032AAL 10
11. Carefully remove the cylinder.
RCPH11TLB034AAL 11
Next operation:
Cylinder - Install Backhoe Dipper Cylinder (H.30.C)
84516378 05/07/2011
H.30.C / 10
Cylinder - Install Backhoe Dipper Cylinder

1. Position the cylinder inside the dipper arm.
RCPH10TLB608AAD 1
2. Install the base end pin.
RCPH10TLB610AAD 2
3. Install the base end snap ring.
RCPH11TLB033AAL 3
4. Install the rod end pin.
RCPH11TLB032AAL 4
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H.30.C / 11
5. Secure the pin with the snap ring and washer.
RCPH10TLB611AAD 5
6. Remove the supports from the cylinder.
RCPH11TLB030AAL 6
7. Connect the base end hydraulic tube.
RCPH11TLB028AAL 7
8. Install the ram end hydraulic tube.

9. Install the ram end tube clamps.
RCPH11TLB027AAL 8
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10. Remove the supports from the boom and dipper arm.
RCPH11TLB025AAL 9
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Index

Cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder - Install Backhoe Dipper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder - Remove - Backhoe Dipper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder - Torque - Arm tool attachment cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
84516378 05/07/2011
EN
SERVICE MANUAL
EXCAVATING AND LANDSCAPING
580N
580SN WT
580SN
590SN
84516378 05/07/2011
J
Contents
EXCAVATING AND LANDSCAPING - J
DIGGING Non-articulated digging tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.20.B

580N , 580SN WT , 580SN , 590SN
CARRYING Articulated tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.50.C

580N , 580SN WT , 580SN , 590SN
84516378 05/07/2011
J
DIGGING Non-articulated digging tools - 20.B
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Bucket
General specification - Weld specifications for standard bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
DIGGING Non-articulated digging tools

Exploded view - Adjustment for return to dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view - Antirollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Loader lift bucket control - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exploded view - Loader lift bucket control - N and SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view - Bucket frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view - Lift cylinder hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exploded view - Bucket cylinder hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exploded view - Clam cylinder circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exploded view - Clam cylinder hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exploded view - Antirollback linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Bucket
Drawing - Boom latch mechanical linkage machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drawing - Boom latch pilot controlled machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exploded view - Backhoe auxiliary control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drawing - Bucket teeth locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Sectional view Clam Control Valve - Clam Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE
DIGGING Non-articulated digging tools

Adjust - Adjustment for return to dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjust - Adjustment of antirollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Bucket
Replace - Replacement of weld on cutting edge for standard buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Replace - Replacement of bolt - on cutting edge for standard bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Replace - Replacement of bolt - on cutting edge for clam bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Replace - Replacement of tooth shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Replace - Replacement of tooth point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Remove - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Install - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Remove Loader Clam Shell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install Loader Clam Shell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Remove Quick Attach Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Install Quick Attach Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Replace - Universal and heavy duty buckets - replacing bottom cutting edge . . . . . . . . . . . . . . . . . . . . . . 40
Replace - Universal and heavy duty buckets - replacing side cutting edge . . . . . . . . . . . . . . . . . . . . . . . . 42
Replace - High capacity buckets - bottom cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Replace - High capacity buckets - side cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Replace - Tooth point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Replace - Tooth shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
Bucket - General specification - Weld specifications for standard

bucket
1. 6 mm (0.25 in) Fillet
2. Fill groove
3. Fill corner
RCPH10TLB681AAL 1
RCPH10TLB682AAL 2
RCPH10TLB683AAL 3
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DIGGING Non-articulated digging tools - Exploded view -

Adjustment for return to dig
RCPH10TLB038GAL 1
1. Cap screw 3. Switch 5. Wave washer

2. Switch bracket 4. Cam
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Antirollback
RCPH10TLB053GAL 1
1. Rollback cable 4. Cap screw 7. Snap ring

2. Nut 5. Washers 8. Rollback rod
3. Clevis 6. Bearing
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DIGGING Non-articulated digging tools - Exploded view - Loader lift

bucket control - 580SN-WT only
RCPH10TLB039GAL 1
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
NOTE: Adjust length and offset of bucket control rod (20) and lift control rod (30) using clevis (27).
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DIGGING Non-articulated digging tools - Exploded view - Loader lift

bucket control - N and SN machines
RCPH10TLB040GAL 1
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 16. Bearing 25. Bellows
trans)
8. Boot 17. Bearing 26. Plug
9. Screw 18. Shaft 27. Lift control rod
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DIGGING Non-articulated digging tools - Exploded view - Loader

frame
RCPH10TLB043GAL 1
Loader frame
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DIGGING Non-articulated digging tools - Exploded view - Bucket

frame
RCPH10TLB041GAL 1
Bucket frame
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DIGGING Non-articulated digging tools - Exploded view - Lift

cylinder hydraulic installation
RCPH10TLB004HAL 1
Lift cylinder hydraulic installation
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DIGGING Non-articulated digging tools - Exploded view - Bucket

RCPH10TLB003HAL 1
Bucket cylinder hydraulic installation
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DIGGING Non-articulated digging tools - Exploded view - Clam

cylinder circuit
RCPH10TLB042GAL 1
Clam cylinder circuit
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DIGGING Non-articulated digging tools - Exploded view - Clam

RCPH10TLB047GAL 1
Clam cylinder hydraulic installation
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Antirollback linkage
RCPH10TLB936ABL 1
Antirollback linkage
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Bucket - Drawing - Boom latch mechanical linkage machines
RCPH10TLB084GAL 1
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Bucket - Drawing - Boom latch pilot controlled machines
RCPH10TLB045GAL 1
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Bucket - Exploded view - Backhoe auxiliary control
RCPH10TLB046GAL 1
1. Control lever
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Bucket - Drawing - Bucket teeth locations

Tooth locations for universal and heavy duty buckets
RCPH10TLB144GAL 1
1. Center tooth 5. 304 mm (11.97 in) bucket - 131.1 mm (5.16 in)

2. 12 mm (0.47 in) 406 mm (15.98 in) bucket - 182.2 mm (7.17 in)
3. 457 mm (17.99 in) bucket - 141.18 mm (5.56 in) 457 mm (17.99 in) bucket - 271.36 mm (10.68 in)
610 mm (24.02 in) bucket - 139.5 mm (5.49 in) 610 mm (24.02 in) bucket - 282.5 mm (11.12 in)
762 mm (30 in) bucket - 141.2 mm (5.56 in) 762 mm (30 in) bucket - 286.1 mm (11.26 in)
914 mm (35.98 in) bucket - 156.6 mm (6.17 in) 914 mm (35.98 in) bucket - 434.9 mm (17.12 in)
4. 914 mm (35.98 in) bucket - 297.7 mm (11.72 in) 6. 914 mm (35.98 in) bucket - 573.7 mm (22.59 in)
7. 610 mm (24.02 in) bucket - 425.5 mm (16.75 in)
762 mm (30 in) bucket - 576 mm (22.68 in)
914 mm (35.98 in)bucket - 712.8 mm (28.06 in)
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Tooth locations for high capacity buckets
RCPH10TLB018FAL 2
1. Centerline
2. Center tooth
3. 610 mm (24.02 in) bucket - 98 mm (3.86 in)
762 mm (30 in) bucket - 130.6 mm (5.14 in)
4. Put tooth shank as near corner as possible and keep tooth point 15 mm (0.59 in) outside of cutting edge.
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Bucket - Sectional view Clam Control Valve - Clam Lock Valve
RCPH10TLB005CAM 1
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
NOTICE: The clam control valve can be under pressure. See the Service Manual for instructions on releasing pres-
sure in the clam hydraulic circuit before disconnecting any hoses from the clam control valve.
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DIGGING Non-articulated digging tools - Adjust - Adjustment for

return to dig
parking brake.
2. Lower the loader frame and put the bucket flat on the
floor or in the correct digging position.
3. Stop the engine.
4. Loosen the cap screws (1) and move the switch
bracket (2) and switch (3) until the roller on the switch
(3) touches the cam (4). Tighten the cap screws
(1). See the illustration DIGGING Non-articulated
digging tools - Exploded view (J.20.B)
NOTE: Make sure the switch bracket is moved toward the inside of the machine so that the roller on the switch is fully
in contact with the cam.
5. Start the engine. Raise the loader frame all the way
and dump the bucket completely.
6. Increase the engine speed to full throttle.
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.
8. Check the position of the bucket on the floor. When
the bucket reaches a level surface the lip should be
flat within 38 mm (1.5 in).
9. If the bucket is not in the correct position, do steps
11 through 14.
10. If the bucket is in the correct position, adjust the
pointer on the loader dump link to match the pointer
on the guide link.
11. Loosen the cap screws (1).
12. Move the switch bracket (2) and switch (1) forward if
the bucket did not roll back far enough.
13. Move the switch bracket (2) and switch (1) rearward
if the bucket rolled back too far.
14. Repeat steps 5 through 13 until the bucket returns to
the correct position.
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DIGGING Non-articulated digging tools - Adjust - Adjustment of

antirollback
1. Check to see that the cable assembly, which includes
the rollback cable (1), the nut (2), and the clevis (3), is
adjusted to a length of approximately 702 mm (27.64
in). See the illustration DIGGING Non-articulated
digging tools - Exploded view (J.20.B).
2. Roll the bucket all the way back.
3. Raise the loader frame all the way.
4. Look at the side cutting edge of the bucket.
5. The side cutting edge must be approximately level.
6. If the side cutting edge is not in the specified position,
adjust the nut (2) and the clevis (3) on the rollback
cable (1) to change the length of the cable assembly.
Lengthen the cable assembly to increase the amount
of rollback. Shorten the cable assembly to decrease
the amount of rollback.
7. Use washers (5) as required to remove any space
between the bearings (6) and the snap rings (7) at
both ends of the rollback rod (8). If the washers are
not required, leave on rollback rod (8) between the
snap rings (7).
8. Tighten the cap screw (4) to 27 N·m (20 lb ft).
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Bucket - Replace - 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 sup-
ports to hold the loader frame and bucket in place.
2. If the bucket is equipped with bucket teeth, use car-
bon 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 cutting
edge do not cut through the floor of the bucket.
1. Long lipped bucket weld
RCPH10TLB681AAL 1
5. Use a grinder to remove any welds or extra metal on

the bucket that will prevent the new cutting edge from
fitting correctly.
6. Put the cutting edge in place and use C-clamps to
hold the cutting edge in place. See the illustration for
the correct position of the cutting edge.
1. Long lip bucket 688 mm (27 in)
RCPH10TLB935ABL 2
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:
84516378 05/07/2011
J.20.B / 24
A. Start at one end of the bucket and weld

toward the center until one welding rod is
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 toward the center until one welding
rod is used.
D. Continue to weld the cutting edge to the
bucket using this method until welding is
complete.
9. If bucket teeth were removed from the old cutting
edge, install the bucket teeth according to instruc-
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Bucket - Replace - Replacement of bolt - on cutting edge for

standard bucket
2. Remove all bolt-on cutting edge retaining bolts.
NOTE: If the plow bolt threads or the nut is damaged, it
might be necessary to use an acetylene 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. Thoroughly clean the mounting surface on the bucket
lip with a wire brush to remove any dirt or debris.
4. Install the new cutting edge using new mounting
hardware.
5. Torque the cutting edge mounting bolt nuts to 461 -
569 N·m (340 - 420 lb ft).
RCPH10TLB003GAN 1
1. Cutting edge 2. Plow bolt 3. Nut
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Bucket - Replace - Replacement of bolt - on cutting edge for clam

bucket
2. Remove all cutting edge retaining bolts.
NOTE: If the plow bolt threads or the nut is damaged, it
night be necessary to use an acetylene 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. Thoroughly clean the mounting surface on the bucket
lip with a wire brush to remove any dirt or debris.
4. Install the new cutting edge using new mounting
hardware.
5. Torque the cutting edge mounting bolt nuts to 461 -
569 N·m (340 - 420 lb ft).
RCPH10TLB011BAL 1
1. Clam bucket assembly 3. Plow bolt

2. Cutting edge 4. Nut
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Bucket - Replace - Replacement of tooth shank

NOTE: Bucket teeth are only available on bucket with weld−on cutting edges.
remove the welds that hold the tooth shank in place.
2. Use a grinder to remove any welds or extra 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.
RCPH10TLB052GAL 1
1. 2362 mm (93 in) Short lip and clam bucket - 246 mm (9.685 in).
2. All buckets − 229 mm (9 in).
3. Put tooth shank as close to corner as possible and keep corner of the tooth point even with outer surface of
cutting edge.
4. See the following illustration for weld specifications
and instructions.
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J.20.B / 28
RCPH10TLB049GAL 2
Welding instructions
1. 10 mm (0.394 in) fillet. Weld around each corner 10 mm (0.394 in). Weld two times.
2. 63 mm (2.48 in).
3. 10 mm (0.394 in) fillet. Weld around each corner 10 mm (0.394 in) fillet. Weld both sides and rear of tooth
shank. Weld two times.
4. Long lip bucket 10 mm (0.394 in)Fillet. Weld around each corner 10 mm (0.394 in) fillet. Weld two times.
5. Bent areas of tooth point.
6. Do not weld over edge of blade.
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Bucket - Replace - Replacement of tooth point

1. Heat the part of the tooth point that has been pressed
into the dent on each side of the tooth shank.
2. Bend the tooth point out of the dent on each side of
the tooth shank.
3. Use a pair of pliers to remove the tooth point from the
tooth shank.
4. Install a new tooth point on the tooth shank.
5. Heat the part of the tooth point that will be pressed
into the dent on each side of the tooth shank.
6. Have another person hold the tooth point against the
tooth shank.
7. Use a suitable tool and drive the heated part of the
tooth point into the dent on each side of the tooth
shank.
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Bucket - Remove - Loader frame

1. Raise the loader frame until the pivot pins for the
piston rod eyes of the lift cylinders are above the
hood. Stop the engine.
2. Fasten suitable lifting equipment to the loader frame
to hold the loader frame in place.
3. Remove the outer snap ring that holds the pivot pins
for the piston rod eyes of the lift cylinders.
4. Use suitable drivers and drive the pivot pins out of
the loader frame. Do not remove the drivers at this
time.
5. Disconnect the lifting equipment and lower the
6. Hold the right lift cylinder and remove the driver.
Lower the lift cylinder onto the front axle.
7. Hold the left lift cylinder and remove the driver. Lower
the lift cylinder and strut onto the front axle.
8. Move the loader control lever to the right or left to
relieve any pressure in the bucket circuit.
9. Disconnect the bucket cylinder hoses from the tubes
on the right side of the machine chassis upright. Fas-
ten 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 up-
right. Fasten an identification tag on each tube.
12. Install a cap on each hose and a plug in each tube.
Thread size is 7/8-14.
13. Remove both retaining bolts for the return-to-dig
switch mounting bracket. It is not necessary to
disconnect the return-to-dig switch wiring.
14. Disconnect the antirollback rod from the right bucket
cylinder link.
15. Disconnect the antirollback rod from the self-leveling
cam. Put the antirollback rod out of the way.
16. Remove the snap ring and the two hardened flat
washers from the right end of the loader lift frame
pivot shaft.
17. Fasten suitable lifting equipment to the loader frame
to hold the loader frame in place.
18. Use a suitable driver and drive the pivot shaft out of
the loader frame.
19. A wave washer and the self-leveling cam are located
between the loader frame and the machine chassis
upright. Raise the loader frame and remove these
parts.
20. Carefully move the machine out of the loader frame.
Next operation:
Bucket - Install (J.20.B)
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Bucket - Install - Loader frame

Prior operation:
Bucket - Remove (J.20.B)
1. Carefully move the machine into the loader frame.

2. Lower the loader frame into alignment with the ma-
chine chassis upright.
NOTE: It may be necessary to spread the loader arms to
position them over the pivot tube in the chassis uprights.
Use caution. Do not over spread the loader frame arms.
3. Install the wave washer (2)and self-leveling cam (1)
between the machine chassis upright and the loader
frame as shown.
RCPH10TLB934ABL 1
4. Start the pivot shaft into the loader frame from the left
side of the machine chassis upright.
5. Drive the pivot all the way through into the right
loader frame.
6. Install the two flat hardened washers and the snap
ring.
7. Install the antirollback rod. Make the connection at
the right bucket cylinder link as well as at the self-
leveling cam.
8. Install the return-to-dig switch mounting bracket us-
ing the 10 x 15 mm hex flange bolts. Torque to 26 -
31 N·m (19 - 23 lb ft).
9. Replace any tie straps required to hold wiring har-
ness in place.
10. Connect the bucket cylinder hoses with the appro-
priate tubes on the right side of the machine chassis
upright.
11. If equipped, connect the clam cylinder hoses with
the appropriate tubes on the left side of the machine
chassis upright.
12. Move the loader control lever to the float position.
13. Raise the left loader lift cylinder and strut. Posi-
tion the pivot pin in the loader frame bore and drive
through the strut and cylinder piston rod eye.
15. Connect the right loader lift cylinder in the same man-
ner as the left lift cylinder. Install the snap ring.
84516378 05/07/2011
J.20.B / 32
16. Lubricate the pivot pins for the piston rod eyes of the
lift cylinders and the pivot shaft.
17. With the engine running at low idle, extend and re-
tract all loader cylinders three times to remove any
air from the circuits.
84516378 05/07/2011
J.20.B / 33
Bucket - Remove Loader Clam Shell Bucket

WARNING
Escaping fluid!
doctor immediately.
W0178A
1. Turn the power off. Activate the hydraulic controls to

relieve pressure in the system.
RCPH11TLB151AAM 1
2. Disconnect and cap hydraulic tubes.
RCPH11TLB152AAM 2
3. Remove pivot arm to bucket snap rings and pins.
4. Remove lift arm to bucket snap rings and pins.
84516378 05/07/2011
J.20.B / 34
5. Remove bucket.
RCPH11TLB157AAM 7
84516378 05/07/2011
J.20.B / 35
Bucket - Install Loader Clam Shell Bucket

WARNING
Escaping fluid!
doctor immediately.
W0178A
1. Move the bucket into place.
RCPH11TLB157AAM 1
2. Install the lift arm to bucket snap rings and pins.
3. Install the pivot arm to bucket snap rings and pins.
84516378 05/07/2011
J.20.B / 36
4. Remove the caps from the hydraulic lines. Recon-

nect the hydraulic lines.
RCPH11TLB151AAM 6
84516378 05/07/2011
J.20.B / 37
Bucket - Remove Quick Attach Backhoe Bucket

1. Position backhoe.
RCPH11TLB131AAM 1
2. Position the backhoe bucket.
RCPH11TLB132AAM 2
3. Press both release buttons up to retract pins.
RCPH11TLB133AAM 3
4. Remove backhoe bucket.
RCPH11TLB134AAM 4
84516378 05/07/2011
J.20.B / 38
Bucket - Install Quick Attach Backhoe Bucket

1. Move the backhoe into position over the bucket.
RCPH11TLB132AAM 1
2. Press both engage buttons up to pull the pins into

place.
RCPH11TLB133AAM 2
3. Lift the bucket.
RCPH11TLB132AAM 3
84516378 05/07/2011
J.20.B / 39
Bucket - Replace - Universal and heavy duty buckets - replacing

bottom cutting edge
1. Remove the bucket teeth. Use carbon arc rod or an
acetylene cutting torch to remove the welds.
NOTICE: When you remove the bottom weld at the rear of the bottom cutting edge, do not cut through the bottom of
the bucket.
remove the welds that hold the bottom cutting edge.
3. Use a grinder to remove any welds or extra metal still
on the bucket so that the new bottom cutting edge will
fit the bucket.
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. Use E7018 welding rod
to weld the bottom cutting edge in position.
RCPH10TLB937ABL 1
1.Universal bucket - 147 mm (5.79 in)
Heavy duty bucket - 151 mm (5.94 in)
2. Universal bucket - 44 mm (1.732 in)
Heavy duty bucket - 47 mm (1.850 in)
3. 10 mm (0.394 in) fillet top and bottom
4. Fill groove between wear plates and bottom cutting edge
5. 6 mm (0.236 in) fillet all around
6. Two pass 6 mm (0.236 in) weld to fill void
6. See the following illustration. Install the corner

bucket teeth and weld the bucket teeth in position.
Use E7018 welding rod.
84516378 05/07/2011
J.20.B / 40
RCPH10TLB051GAL 2
1. 14 mm (0.551 in)
2. 20 mm (0.787 in)
3. No weld, top only
4. First weld. 10 mm (0.394 in) flare bevel weld.
Second weld. 10 mm (0.394 in) fillet weld.
5. Bottom all around 8 mm (0.315 in) fillet. weld two times.
6. 8 mm (0.315 in) fillet. weld two times.
7. Weld the remaining bucket teeth to the bottom cutting

edge according to the instructions in this section.
84516378 05/07/2011
J.20.B / 41
Bucket - Replace - Universal and heavy duty buckets - replacing

side cutting edge
remove the welds that hold the side cutting edge.
on the bucket so that the new side cutting edge will
fit the bucket.
3. Use E7018 welding rod to weld the side cutting edge
to the bucket with a 6 mm (0.24 in) fillet all around
the side cutting edge.
84516378 05/07/2011
J.20.B / 42
Bucket - Replace - High capacity buckets - bottom cutting edge

1. Remove the bucket teeth. Use carbon arc rod or an
acetylene cutting torch to remove the welds.
2. Remove all welds that hold the bottom cutting edge in
position. Use carbon arc rod or an acetylene cutting
torch to remove the welds.
3. Remove the cutting edge from the bucket.
on the bucket so that the new cutting edge will fit the
bucket.
5. Put the new bottom cutting edge in position and 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.
RCPH10TLB007EAL 1
1. 48 mm (1.89 in)
2. 6 mm (0.24 in) fillet top and bottom
3. Fill groove between wear plates and bottom.
84516378 05/07/2011
J.20.B / 43
Bucket - Replace - High capacity buckets - side cutting edge

1. Remove all welds that hold the side cutting edge in
position. Use carbon arc rod or an acetylene cutting
torch to remove the welds.
2. Remove the side cutting edge from the bucket.
on the bucket so that the new side cutting edge will
fit the bucket.
4. Put the side cutting edge in position and use a
C-clamp to hold it.
5. Use E7018 welding rod to weld the side cutting edge
to the bucket. Use a 6 mm (0.24 in) fillet weld all
around the side cutting edge.
84516378 05/07/2011
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Bucket - Replace - Tooth point

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
into the tooth point. Install the flex pin so that the
shoulders are toward the cutting edge.
84516378 05/07/2011
J.20.B / 45
Bucket - Replace - Tooth shank

remove the welds that hold the tooth shank.
2. Use a grinder to remove any welds or extra metal that
will prevent the new tooth shank from fitting correctly.
3. If a new cutting edge has been installed, see the
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 posi-
tion.
RCPH10TLB006EAL 1
1. 20 mm (0.79 in) no weld
2. No weld
3. 8 mm (0.31 in) fillet both sides. Weld two times.
5. Universal and heavy duty buckets only. See the fol-

lowing illustration for the weld specifications for the
corner bucket teeth. Use E7018 welding rod to weld
the tooth shanks in position.
RCPH10TLB051GAL 2
1. 14 mm (0.55 in)
2. 20 mm (0.79 in)
3. No weld, top only
4. First weld. 10 mm (0.39 in) flare bevel weld.
Second weld. 10 mm (0.39 in) fillet weld.
5. Bottom all around 8 mm (0.31 in) fillet. Weld two times.
6. 8 mm (0.31 in) fillet. Weld two times.
84516378 05/07/2011
J.20.B / 46
Index

Bucket - Drawing - Boom latch mechanical linkage machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bucket - Drawing - Boom latch pilot controlled machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Bucket - Drawing - Bucket teeth locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bucket - Exploded view - Backhoe auxiliary control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bucket - General specification - Weld specifications for standard bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bucket - Install - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Bucket - Install Loader Clam Shell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Bucket - Install Quick Attach Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Bucket - Remove - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bucket - Remove Loader Clam Shell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Bucket - Remove Quick Attach Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bucket - Replace - High capacity buckets - bottom cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Bucket - Replace - High capacity buckets - side cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Bucket - Replace - Replacement of bolt - on cutting edge for clam bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bucket - Replace - Replacement of bolt - on cutting edge for standard bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Bucket - Replace - Replacement of tooth point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Bucket - Replace - Replacement of tooth shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bucket - Replace - Replacement of weld on cutting edge for standard buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Bucket - Replace - Tooth point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Bucket - Replace - Tooth shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Bucket - Replace - Universal and heavy duty buckets - replacing bottom cutting edge . . . . . . . . . . . . . . . . . . . . . . 40
Bucket - Replace - Universal and heavy duty buckets - replacing side cutting edge . . . . . . . . . . . . . . . . . . . . . . . . 42
Bucket - Sectional view Clam Control Valve - Clam Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIGGING Non-articulated digging tools - Adjust - Adjustment for return to dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIGGING Non-articulated digging tools - Adjust - Adjustment of antirollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DIGGING Non-articulated digging tools - Exploded view - Adjustment for return to dig . . . . . . . . . . . . . . . . . . . . . . . 5
DIGGING Non-articulated digging tools - Exploded view - Antirollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIGGING Non-articulated digging tools - Exploded view - Antirollback linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIGGING Non-articulated digging tools - Exploded view - Bucket cylinder hydraulic installation . . . . . . . . . . . . . . 12
DIGGING Non-articulated digging tools - Exploded view - Bucket frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIGGING Non-articulated digging tools - Exploded view - Clam cylinder circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIGGING Non-articulated digging tools - Exploded view - Clam cylinder hydraulic installation . . . . . . . . . . . . . . . 14
DIGGING Non-articulated digging tools - Exploded view - Lift cylinder hydraulic installation . . . . . . . . . . . . . . . . . 11
DIGGING Non-articulated digging tools - Exploded view - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
84516378 05/07/2011
J.20.B / 47
DIGGING Non-articulated digging tools - Exploded view - Loader lift bucket control - 580SN-WT only . . . . . . . . . 7
DIGGING Non-articulated digging tools - Exploded view - Loader lift bucket control - N and SN machines . . . . . . 8
84516378 05/07/2011
J.20.B / 48
CARRYING Articulated tools - 50.C
580N
580SN WT
580SN
590SN
84516378 05/07/2011
J.50.C / 1
Contents
TECHNICAL DATA
Control valve
Torque - Special torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Control valve
Exploded view - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder
Exploded view - Typical cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - Typical cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Control valve
Check - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cylinder
Disassemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inspect - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
84516378 05/07/2011
J.50.C / 2
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
Control valve - Torque - Special torques

Relief valves, item numbers (1), (2), (3), (4), and (14) 65 N·m +/- 6.7 (48 lb ft +/- 5)
Check valves, item number (7) 122 N·m +/- 12 (90 lb ft +/- 9)
Anti void assembly, item number (6) 65 N·m +/- 6.7 (48 lb ft +/- 5)
End cap inner mounting bolts, item number (36) 65 N·m +/- 6.7 (48 lb ft +/- 5)
End cap outer mounting bolt, item number (18) 100 N·m +/- 10.8 (74 lb ft +/- 8)
Check valve assembly, item number (40) 65 N·m +/- 6.7 (48 lb ft +/- 5)
Center spring and seal retainer plate mounting screws, item numbers (32) and 9.4 N·m +/- 1.3 (7 lb ft +/- 1)
(37)
Centering spring retaining bolt, item number (46) 9.4 N·m +/- 1.3 (7 lb ft +/- 1)
RCPH10TLB057GAL 1
1. Relief valve 206.8 bar (3000 psi) 11. Stabilizer spool 21. Dipper B port
2. Relief valve 331 bar (4800 psi) 12. Dipper spool 22. Bucket B port
3. Relief valve 237.8 bar (3450 psi) 13. Bucket spool 23. Extend-A-Hoe B port
4. Relief valve 221 bar (3205 psi) 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. Auxiliary 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 preset and have a tolerance of 2.4 bar +/- (35 psi +/- )
84516378 05/07/2011
J.50.C / 3
Control valve - Exploded view - Mechanical linkage backhoe

machines only
RCPH10TLB058GAL 1
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
84516378 05/07/2011
J.50.C / 4

machines only
RCPH10TLB008FAL 1
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.
84516378 05/07/2011
J.50.C / 5

machines only
RCPH10TLB059GAL 1
Valve cut away view
RCPH10TLB007FAL 2
Valve schematic
84516378 05/07/2011
J.50.C / 6

machines only
RCPH10TLB009FAL 1
Circuit relief valve
1. Poppet 6. Back-up ring 11. Back-up ring

2. Sleeve 7. O-ring 12. Shim 0.127 cm (0.050 in)
3. O-ring 8. Spring 13. Shim 0.0508 cm (0.020 in)
4. Spring 9. Retaining ring 14. Shim 0.0177 cm (0.007 in)
5. Screw 10. O-ring 15. Shim 0.0127 cm (0.0050 in)
84516378 05/07/2011
J.50.C / 7
Cylinder - Exploded view - Typical cylinder
RCPH10TLB060GAL 1
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
84516378 05/07/2011
J.50.C / 8
Cylinder - Exploded view - Typical cylinder
RCPH10TLB162ABL 1
RCPH10TLB161ABL 2
3. Gland 11. Wear ring 15. Rod seal

4. Piston 12. O-ring 16. Buffer seal
9. Seal 13. Backup ring 17. Bushing
10. Backup ring 14. Wiper
84516378 05/07/2011
J.50.C / 9
Cylinder - Exploded view - Quick coupler cylinder
RCPH10TLB010FAL 1
1. Tube 3. Spacer 5. Gland

2. Snap ring 4. Snap ring
Coupler cylinder piston
RCPH10TLB003FAL 2
6. Piston rod 9. Ring

7. Seal 10. O-ring
8. Ring
84516378 05/07/2011
J.50.C / 10
Coupler cylinder gland

11. Wiper seal 13. Seal 15. Backup ring
12. Bushing 14. O-ring
RCPH10TLB020AAL 3
84516378 05/07/2011
J.50.C / 11
Control valve - Check - Mechanical linkage backhoe machines only

Pressure relief valves
1. Remove valve from valve body.
2. Lubricate O-ring with hydraulic oil.
3. Install valve and torque to 65 N·m +/- 6.7 (48 lb ft +/-
5)
Spool valve seals

1. Disconnect the linkage from the spool to be removed.
2. Remove the spool end cap retainer screws (37),
spool end cap (47), and seal retaining plate (44).
3. Remove the spool from the valve body.
4. Remove the spool seal retainer plate mounting
screws (32), spool seal retainer plate (42), and spool
seal (41).
5. Remove the spool centering spring retaining bolt (46)
and centering spring with caps (45) from the spool.
6. Clean and inspect spool and spool bore for scoring
or scratches, repair or replace as necessary.
7. Lubricate the spool with clean hydraulic oil, install the
spool in the valve body.
8. Install the lower spool seal (43) and seal retainer
plate (44).
NOTICE: When replacing spool seals, place spool in section, insert seal into section. Do not place seal in first and
install spool, this will damage the seal.
9. Install the centering spring with caps (45), centering
spring retaining bolt and torque to 9.4 N·m +/- 1.3 (7
lb ft +/- 1)
10. Install the spool end cap (47), spool end cap retaining
screws (37) and torque to 9.4 N·m +/- 1.3 (7 lb ft +/-
1)
11. Install the upper seal (41), upper seal retaining plate
(42) and torque to 9.4 N·m +/- 1.3 (7 lb ft +/- 1)
12. Connect linkage to the spool.
Check valves
1. Remove the check valve (7).
NOTE: Make sure all components of check valve come
out of the valve body, see cutaway view. Control valve
- Exploded view (J.50.C)
2. Lubricate O-ring with hydraulic oil.
3. Install check valve (7) and torque to 122 N·m +/- 12
(90 lb ft +/- 9)
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J.50.C / 12
End cap and auxiliary hydraulics section

1. Remove end cap mounting bolts (18) and (36), re-
move end cap (17), and if equipped auxiliary hy-
draulic section (16).
2. Replace all O-rings.
3. Place bolts through end cap (17) and if equipped aux-
iliary hydraulic section (16).
4. Install bolts into main valve body and torque outer
bolts (18) to 100 N·m +/- 10.8 (74 lb ft +/- 8) and
inner bolts (36) to 65 N·m +/- 6.7 (48 lb ft +/- 5).
Low leak valve

1. Remove the low leak valve (40).
NOTE: Make sure all components of low leak valve come
out of the valve body, see cutaway view. Control valve -
Exploded view (J.50.C)
2. Lubricate O-rings with hydraulic oil.
3. Install low leak valve (40) and torque to 65 N·m +/-
6.7 (48 lb ft +/- 5).
84516378 05/07/2011
J.50.C / 13
Control valve - Remove - Mechanical linkage backhoe machines

only
NOTICE: Do not remove more than one spool at a time from the valve body.
1. Clean the valve body.
2. If equipped, remove the cap screws from the auxiliary
section centering spring cover.
RCPH10TLB102ABL 1
3. Remove the centering spring cover.
RCPH10TLB103ABL 2
4. Remove the spool from the section.
RCPH10TLB105ABL 3
84516378 05/07/2011
J.50.C / 14
5. Loosen the plug.
RCPH10TLB107ABL 4
6. Remove the plug from the valve section.
RCPH10TLB108ABL 5
7. Loosen the end cap bolts.
RCPH10TLB110ABL 6
8. Remove the end cap and if equipped, auxiliary sec-

tion.
RCPH10TLB111ABL 7
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J.50.C / 15
9. Lay the end cap and auxiliary section on to the

bench, remove the bolts.
NOTE: Make a note of the size and location of the bolts.
RCPH10TLB112ABL 8
10. Remove the end cover from the auxiliary section.
RCPH10TLB113ABL 9
RCPH10TLB114ABL 10
RCPH10TLB115ABL 11
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J.50.C / 16
13. Remove the seal retaining plate, remove and discard

seal and wiper.
RCPH10TLB117ABL 12
14. Number the valve body and the components.

NOTE: The relief valves are set at different pressures and
must be placed back in the same location from which they
were removed.
RCPH10TLB121ABL 13
15. Loosen the relief valve.
RCPH10TLB123ABL 14
16. Remove the relief valve from the valve body.
RCPH10TLB124ABL 15
17. Repeat steps 15 and 16 for the remaining relief

valves.
84516378 05/07/2011
J.50.C / 17
18. If equipped, loosen the plug from the extend-a-hoe

section.
RCPH10TLB126ABL 16
19. Remove the plug from the valve body.
RCPH10TLB127ABL 17
20. Repeat steps 15 though 19 for the other side of the

valve body.
21. Make sure to mark the centering spring covers with
identification numbers.
RCPH10TLB128ABL 18
22. Loosen the cap screws for the centering spring cover.
RCPH10TLB130ABL 19
84516378 05/07/2011
J.50.C / 18
23. Remove the centering spring cover.
RCPH10TLB131ABL 20
24. Repeat steps 22 and 23 for the remaining centering

spring covers.
25. Note any color coding on the centering springs.
RCPH10TLB132ABL 21
26. Make a note on the valve body of the color of the

spring.
RCPH10TLB133ABL 22
RCPH10TLB134ABL 23
84516378 05/07/2011
J.50.C / 19
28. Remove the seal from the spool.
RCPH10TLB138ABL 24
29. Remove the wipe seal from the spool.
RCPH10TLB137ABL 25
30. Remove the seal retaining plate.
RCPH10TLB136ABL 26
31. Remove the spool end.
RCPH10TLB141ABL 27
84516378 05/07/2011
J.50.C / 20
32. Reassemble the spool and insert back into the valve
body, make sure the wiper seal faces out towards the
retainer plate.
RCPH10TLB142ABL 28
RCPH10TLB135ABL 29
34. Remove the O-ring from the spacer.
RCPH10TLB140ABL 30
35. Remove the spacer from the spool.
RCPH10TLB139ABL 31
84516378 05/07/2011
J.50.C / 21
36. Remove the seal from the spool.
RCPH10TLB138ABL 32
37. Remove the wipe seal from the spool.
RCPH10TLB137ABL 33
RCPH10TLB136ABL 34
39. Reassemble the spool and insert back into the valve
body, make sure the wiper seal faces out towards the
retainer plate.
RCPH10TLB142ABL 35
40. Repeat steps 27 though 39 for the remaining spools.
84516378 05/07/2011
J.50.C / 22
41. Remove the cap screws for the seal retaining plate.
RCPH10TLB143ABL 36
RCPH10TLB144ABL 37
43. Remove the wiper seal.
RCPH10TLB145ABL 38
44. Remove the spool seal.
RCPH10TLB146ABL 39
84516378 05/07/2011
J.50.C / 23
Control valve - Install - Mechanical linkage backhoe machines only

Prior operation:
Control valve - Remove (J.50.C)
1. Install a new spool seal.
RCPH10TLB147ABL 1
2. Install a new wiper seal.
RCPH10TLB148ABL 2
NOTE: Make sure the lip of the wiper seal is facing out towards the seal retaining plate.
3. Install the seal retaining plate.
RCPH10TLB144ABL 3
84516378 05/07/2011
J.50.C / 24
4. Install seal retaining plate cap screws and torque to

9.4 N·m +/- 1.3 (7 lb ft +/- 1)
RCPH10TLB074ABL 4
5. Repeat steps 41 through 48 for the remaining spool

seals.Loosen and remove the check valve.
RCPH10TLB075ABL 5
6. Install the check valve and spring into the valve body,
replace the O-ring on the plug. Hand tighten the plug
into the valve body making sure not to bind the valve.
RCPH10TLB076ABL 6
7. Torque the check valve to 122 N·m +/- 12 (90 lb ft

+/- 9)
RCPH10TLB149ABL 7
8. Repeat steps 5 to 7 for the remaining check valves.
84516378 05/07/2011
J.50.C / 25
9. Loosen the anti void plug.
RCPH10TLB159ABL 8
10. Replace the O-rings and backup ring on the anti void
valve and plug.
RCPH10TLB157ABL 9
11. Install and hand tighten the plug into the valve body
making sure not to bind the valve.
RCPH10TLB160ABL 10
12. Torque the anti void to 65 N·m +/- 6.7 (48 lb ft +/- 5)
RCPH10TLB158ABL 11
84516378 05/07/2011
J.50.C / 26
13. Loosen the plug for the check valve.
RCPH10TLB150ABL 12
14. Remove the plug, spacer, spring, and valve from the
valve body.
RCPH10TLB152ABL 13
15. Install the valve.
RCPH10TLB153ABL 14
RCPH10TLB154ABL 15
84516378 05/07/2011
J.50.C / 27
RCPH10TLB155ABL 16
18. Make sure the washer is seated flat on the spring.
RCPH10TLB156ABL 17
19. Install a new O-ring on the plug, install the plug and
torque to 65 N·m +/- 6.7 (48 lb ft +/- 5)
RCPH10TLB151ABL 18
20. Install centering spring covers and torque to 9.4 N·m

+/- 1.3 (7 lb ft +/- 1)
RCPH10TLB130ABL 19
84516378 05/07/2011
J.50.C / 28
21. Install a new O-ring on the plug and torque to 65 N·m

+/- 6.7 (48 lb ft +/- 5)
RCPH10TLB126ABL 20
22. Install new O-rings on relief valves and torque to 65

N·m +/- 6.7 (48 lb ft +/- 5)
RCPH10TLB123ABL 21
RCPH10TLB120ABL 22
24. Install a new spool seal and wiper seal.
RCPH10TLB119ABL 23
84516378 05/07/2011
J.50.C / 29
25. Install the seal retaining plate and cap screws.

Torque cap screws to 9.4 N·m +/- 1.3 (7 lb ft +/- 1)
RCPH10TLB117ABL 24
26. Replace the O-ring.
RCPH10TLB116ABL 25
27. Install the valve.
RCPH10TLB115ABL 26
RCPH10TLB114ABL 27
84516378 05/07/2011
J.50.C / 30
29. Place the end cap on the auxiliary section.
RCPH10TLB113ABL 28
30. Set the bolts through the end cover into the auxiliary
section.
NOTE: The larger of the three bolts goes into the top hole.
RCPH10TLB112ABL 29
31. Pull the end cap and auxiliary section up evenly,

torque the end cover bolts to 100 N·m +/- 10.8 (74
lb ft +/- 8)
RCPH10TLB110ABL 30
32. Install a new O-ring on the plug.
RCPH10TLB108ABL 31
84516378 05/07/2011
J.50.C / 31
33. Install and torque the plug to 65 N·m +/- 6.7 (48 lb ft
+/- 5).
RCPH10TLB107ABL 32
34. Install the spool in the valve body.
RCPH10TLB105ABL 33
35. Install the centering spring cover.
RCPH10TLB103ABL 34
36. Install and torque the cap screws to 9.4 N·m +/- 1.3
(7 lb ft +/- 1)
RCPH10TLB102ABL 35
84516378 05/07/2011
J.50.C / 32
Cylinder - Disassemble - Quick coupler cylinder

NOTE: Refer to illustrations Cylinder - Disassemble (J.50.C).
1. Remove the snap ring (2) from the gland (5). Then
push the gland (5) slightly into the cylinder.
2. Remove the spacer (3).
3. Remove the snap ring (4) from the tube (1).
4. Install the plastic service ring into the snap ring
groove in the tube (1).
NOTICE: See illustration Cylinder - Assemble (J.50.C) for

orientation of the plastic service ring.
5. Pull the rod assembly (6) out of the tube (1).
6. Remove the plastic service ring from the tube (1).
7. Remove the gland (5) from the rod (6).
8. Fasten the rod (6) in a vise with soft jaws.
9. Remove the seal (7), ring (8), ring (9), and O-ring
10. Remove the wiper seal (11), bushing (12), seal (13),
O-ring (14), and backup ring (15) from the gland (5).
11. Do steps 1 through 10 for the other side.
Next operation:
Cylinder - Inspect (J.50.C)
84516378 05/07/2011
J.50.C / 33
Cylinder - Inspect - Quick coupler cylinder

Prior operation:
Cylinder - Disassemble - Quick coupler cylinder (J.50.C)
1. Clean the glands (5), piston rods (6) and tube (1) in
cleaning solvent.
2. Discard the parts that were removed from the pistons
and the glands (5).
age. If there is damage to the tube (1), a new tube
(1) must be used. See section 8001 for removal of
cylinder tube.
4. Remove small scratches on the inside of the tube (1)
with emery cloth of medium grit. Use the emery cloth
with a rotary motion.
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).
Next operation:
Cylinder - Assemble - Quick coupler cylinder (J.50.C)
84516378 05/07/2011
J.50.C / 34
Cylinder - Assemble - Quick coupler cylinder

Prior operation:
Cylinder - Inspect (J.50.C)
1. Install the wiper seal (11) in the gland (5). The lips
must be toward the small end of the gland (5).
2. Install the seal (13) and bushing (12) in the gland (5).
3. Install the backup ring (15) and O-ring (14) on the
outside of the gland (5).
4. Install a new O-ring (10), ring (9), ring (8), and seal
(7) on the piston.
5. Lubricate the bore of the gland (5) with clean oil and
push the gland assembly onto the piston rod (6). The
wide end of the gland (5) should contact the piston.
6. Do steps 1 through 5 for the other gland (5) and pis-
ton rod (6).
7. Lubricate the seals of the piston rod (6) and the gland
(5) with clean oil. Push the piston rod and gland
sub-assembly into the bore of the tube (1) far enough
to allow the installation of the snap ring (4). If nec-
essary, use a soft hammer to drive the piston rod (6)
and gland (5) into the tube (1).
8. Install the snap ring (4) in the tube (1).
9. Pull the rod (6) outwards until the gland (5) is seated
against the snap ring (4).
10. Install the spacer (3)on the gland (5).
11. Install the snap ring (2) on the gland (5).
12. Do steps 7 through 12 for the other side.
Plastic service ring orientation
RCPH10TLB019AAL 1
84516378 05/07/2011
J.50.C / 35
Index

Control valve - Check - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control valve - Exploded view - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Control valve - Install - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Control valve - Remove - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control valve - Torque - Special torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder - Assemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cylinder - Disassemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cylinder - Exploded view - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder - Exploded view - Typical cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder - Exploded view - Typical cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder - Inspect - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
84516378 05/07/2011
J.50.C / 36
84516378 05/07/2011
J.50.C / 37
PRINTED IN U.S.A.
84516378 05/07/2011
EN
SPECIAL TOOL INDEX
Genuine IU PAGE
CAS10147 [Battery Capacity Battery - Test A.30.A / 181
(Load) Tester]
CAS10147 [Battery Capacity Battery - Test A.30.A / 181
(Load) Tester]
380040185 [Harness 3006-Coolant Temperature Sensor - Signal Not Plausible A.50.A / 143
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3007-Coolant temperature signal - signal above range A.50.A / 145
380040185 [Harness 3008-Coolant Temperature Signal - Signal Below Range Minimum A.50.A / 147
380040185 [Harness 3010-Air intake temperature sensor signal above maximum range A.50.A / 149
380040185 [Harness 3011-Air intake temperature sensor signal below minimum range A.50.A / 152
380040185 [Harness 3016-Fuel Temperature Sensor - Signal Below Range Minimum A.50.A / 157
380040185 [Harness 3019-Boost Pressure Sensor - Signal Above Range Maximum A.50.A / 160
05/07/2011
39
Genuine IU PAGE
380040185 [Harness 3022-Boost Pressure Sensor - Signal Not Plausible A.50.A / 162
380040185 [Harness 3028-Oil pressure too low A.50.A / 167
380040185 [Harness 3029-Oil Pressure Sensor - Short Circuit To Battery A.50.A / 170
380040185 [Harness 3030-Oil Pressure Sensor - Short Circuit To Ground A.50.A / 172
380040185 [Harness 3031-Oil pressure sensor - hardware error A.50.A / 174
380040185 [Harness 3032-Oil Pressure Sensor - Value Too High A.50.A / 176
380040185 [Harness 3033-Oil Temperature Sensor - Signal Not Plausible A.50.A / 179
380040185 [Harness 3034-Oil Temperature Sensor - Signal Above Range Maximum A.50.A / 182
380040185 [Harness 3035-Oil Temperature Sensor - Signal Below Range Minimum A.50.A / 184
380040185 [Harness 3037-Boost Pressure Sensor - Signal Low A.50.A / 186
05/07/2011
40
Genuine IU PAGE
380040185 [Harness 3061-Cylinder 1 - Injector Cable Short Circuit A.50.A / 201
380040185 [Harness 3088-Crankshaft sensor lost synchronization A.50.A / 235
380040185 [Harness 3089-Crankshaft Sensor - Invalid Signal A.50.A / 238
380040185 [Harness 3089-Crankshaft Sensor - Invalid Signal A.50.A / 238
380040185 [Harness 3090-Phase defect of camshaft speed sensor signal detected A.50.A / 240
380040185 [Harness 3091-Camshaft sensor phase synchronization failure A.50.A / 243
380040185 [Harness 3093-Offset Between Camshaft And Crankshaft - Outside A.50.A / 246
Diagnostic /Repair Kit (NEF)] Boundaries
05/07/2011
41
Genuine IU PAGE
380040185 [Harness 3095-Operating With Camshaft Sensor Only - Backup Mode A.50.A / 251
380040185 [Harness 3147-Oil Temperature Too High A.50.A / 280
380000988 [Flywheel Rotation ENGINE - Remove - 580N only B.10.A / 15
Blocker]
380000988 [Flywheel Rotation ENGINE - Install - 580N only B.10.A / 18
Blocker]
CAS1716-3 [Driver Handle] REAR AXLE - Special tools - 580N and 580SN only D.12.A / 5
380000239 [Manifold Gauge ENVIRONMENT CONTROL Air-conditioning system - Pressure E.40.C / 18
Set (High And Low Pressure)] test and temperature testing
CAS1660 [Buffer Seal Installer Cylinder - Assemble - Boom cylinder H.20.B / 14
/ Remover]
CAS1456 [Gland Wrench] Cylinder - Disassemble - Swing cylinders H.20.D / 23
CAS1039 [Torque Multiplier] Cylinder - Disassemble - Swing cylinders H.20.D / 23
CAS1039 [Torque Multiplier] Cylinder - Assemble - Swing cylinders H.20.D / 25
CAS1039 [Torque Multiplier] Cylinder - Assemble - Swing cylinders H.20.D / 25
CAS1660 [Buffer Seal Installer Cylinder - Assemble - Dipper cylinder H.25.B / 13
/ Remover]
Kit IU PAGE
380001737 [Nitrogen Accumulator - Special tools - Ride control A.10.A / 10
Charging Kit]
380001737 [Nitrogen Accumulator - Check - Ride control A.10.A / 182
Charging Kit]
380001737 [Nitrogen Accumulator - Charging - Ride control A.10.A / 183
Charging Kit]
380001737 [Nitrogen Accumulator - Discharging - Ride control A.10.A / 184
Charging Kit]
05/07/2011
42
05/07/2011
43
PRINTED IN U.S.A.
84516378 05/07/2011
EN
CRANK SIGNAL
ALTERNATOR
TO CLUSTER
INSTRUMENT CLUSTER
STARTER
KEY ON
FRONT WIPER
FRT WRK LIGHT ALTERNATOR, WIF SENSOR

ECU KEY ON
FLASHER
HOUSINGS ACTUATORS
GROUND POWER RELAYS
COLOR ABBREVIATIONS SPL-XX

INDICATES CIRCUIT SPLICE ALTERNATOR
IGNITION SWITCH B+
ABBREVIATION-------COLOR ABBREVIATION------COLOR
V P T R----------------------------RED OR-------------- ----------ORANGE INDICATES CIRCUIT CONNECTION BRAKE LIGHTS
T----------------------------TAN K--------------------------PINK DRV LIGHTS

LEVER HAND FOOT TEMPERATURE
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LAMP W---------------------------WHITE P--------------------------VIOLET (PURPLE) INDICATES CIRCUIT CROSSING BEACON
Y----------------------------YELLOW DU------------------------DARK BLUE NOT CONNECTED

CONTACT CONFIGURATIONS BK -------------------------BLACK LU------------------------LIGHT BLUE
GROUND
HORN
S ---------------------------GRAY DG------------------------DARK GREEN
ECM DIAG PORT
BK/W----------------------BLACK/WHITE LG------------------------LIGHT GREEN INDICATES INTERNALLY STARTER SOLENOID B+
LIQUID LEVER FLOAT PRESSURE COIL DIODE GROUNDED UNITS IGN SW SUPPLY
NEUTRAL RELAY SIGNAL
INSTR CLUSTER FROM FNR SWITCH
CONTACTS CRANK REQUEST ECU
STARTER SOLENOID
MOMENTARY ECU WIF CRANK REQUEST ECU
SENSOR DOME LAMP
S.P.S.T. S.P.D.T. D.P.S.T. D.P.D.T.
MAINTAINED CRANK ENABLE ECU
AIR SEAT
MISCELLANEOUS SYMBOLS VARIABLE RESISTOR RESISTOR
CIRCUIT 1 CIRCUIT 1 CRANK ENABLE ECU
PWR POINTS
CIRCUIT 2 WIRE BUNDLE CIRCUIT 2
POSITIVE BATT
CIRCUIT 3 CIRCUIT 3 TRAX CABLE
CIRCUIT 4 CIRCUIT 4
CIRCUIT DIAGRAM LEGENDS
ALTERNATOR
RADIO
FUSE RELAY GROUND BATTERY CAB POWER
REAR LIGHTS CABLE
B+ FROM
STARTER
SIDE LIGHTS
INSTALLER TAP
WIRE BREAKOUT
ALT TACH
WB-255 SPL WB-254 GROUND

Sheet ? Y 0.8 255 Y 0.8 254 Sheet ?
HVAC BLOWER
COLOR
WIRE ID SPLICE RETURN TO DIG
CUSTOMER
TRANS SPEED SENSOR
WIRE SIZE IGNITION FROM QC,EH CLAM,
KEY ON
KEY SWITCH BOOM LOCK, RADIO TRAX
COMFORT STEER
TRAX
WB - WIRE BREAKOUT
PILOT CONTROL
FB - FUSE BREAKOUT TRAX
GB - GROUND BREAKOUT HEAVY LIFT
TRAX DC SUPPLY
4WD/ RC
DIFF LOCK, KD, DC, CO BUTTON
ACC FROM REAR WIPER
WASHER TRAX BRAKE PRESSURE SWITCH
KEY SWITCH
13 ACC TO GROUND
F&R
SAHR BRAKE
LEGEND POWER DISTRIBUTION/ CHARGING SYSTEM 1 STARTING SYSTEM 2

DIAG PORT QC LDR SOLENOID CLAMP RETURN TO DIG
KEY ON
POWER POINT 1 ECU GROUND
QC LS SOLENOID CLAMP
POWER POINT 2
QC BHOE COLENOID CLAMP
TRAX PWR GND, SEAT POS
RETURN TO DIG
SWITCH, AIR SEAT
GROUND
INSTRUMENT CLUSTER A/C RELAY COIL ECU B+
RADIO GROUND
REAR LIGHTS
SWITCH LAMP QC, EH CLAM, BOOM
LOCK RADIO
RC SW LAMP
PARK BRAKE SOLENOID
4WD SW LAMP
RADIO KEY ON
FUEL SENDER
AUDIBLE ALARM
ECU
GB-046
EH CLAM
BACK UP ALARM
POWER RELAY 2
COIL COMFORT STEER SOLENOID
POWER RELAY 1
COIL AIR FILTER RESTRICTION
NEUTRAL REALY
COIL EH CLAM GROUND
Q COUPLER
INTERLOCK LS SOLENOID CRANK
RELAY COIL Q COUPLER LDR ENABLE ECU
SAHR BRAKE TRANS SOLENOID
CRANK
CIRCUIT RELAY COIL Q COUPLER REQUEST ECU
REAR LIGHTS BHOE SOLENOID
CRANK
RELAY COIL TORQUE CONTROL REQUEST ECU
HEAVY LIFT SOLENOID
CRANK
RELAY COIL
ENABLE ECU
SAHR BRAKE
PILOT CONTROL
RELAY COIL
CS POWER
RELAY COIL
RTD SWITCH
POWER RELAY 3
COIL
HORN
CS CUTOUT
RELAY COIL ECU KEY ON POWER
RIDE CONTROL
FLASHER RELAY ACCUMULATOR SOLENOID GROUND
RIDE CONTROL
POWER RELAY 4 TANK SOLENOID
COIL
FRONT WORK LIGHT
SWITCH LAMP HEAVY LIFT SOLENOID
ROTATING BEACON
SWITCH LAMP GROUND
HAZARD SWITCH
LAMP
TURN INDC LAMPS AUTO/MAN SWITCH
LAMP
FRONT WASHER PUMP COMFORT STEER
SWITCH LAMP GROUND
REAR WASHER PUMP CAN TO TRAX
REAR LIGHTS CAB
FRONT LIGHTS CAB
CAN TO TRAX
REAR LIGHTS CANOPY
FRONT LIGHTS CANOPY
CAN TO INSTRUMENT CLUSTER
QC LS SOLENOID CLAMP GROUND

QC LDR SOLENOID CLAMP GROUND
DIAG PORT GROUND QC BHOE SOLENOID CLAMP GROUND
GROUNDING 3 ENGINE CONTROL 4 POWERSHIFT TRANSMISSION INPUTS 5 HYDRAULICS 6

FRONT WORK LIGHTS FRONT WASHERS AND WIPERS
KEY ON KEY ON
FRONT WASHER
PUMP GROUND
FRONT LIGHTS
SIGNAL LIGHTS CAB GROUND
KEY ON
DOME LIGHT B+
FRONT WIPER DOME LIGHT GROUND

MOTOR GROUND
FRONT WORKLIGHT SWITCH
LAMP GROUND REAR WASHERS AND WIPERS
RIGHT REAR TURN SIGNAL KEY ON
FRONT WIPER
FRONT WORK LIGHT MOTOR GROUND
BACKLIGHT
REAR TAIL LIGHTS
LEFT REAR TURN SIGNAL

REAR WASHER
FLASHER RELAY GROUND PUMP GROUND
TURN SIGNAL
INDICATOR GROUND
HAZARD LIGHTS
SWITCH GROUND
FRONT DRIVING LIGHTS

KEY ON
REAR WIPER
MOTOR GROUND
PILOT CONTROLS 7 FRONT EXTERIOR LIGHTS 8 INTERIOR LIGHTING 9 WINDSHIELD WIPERS 10
INSTRUMENT CLUSTER B+
GROUND SAHR BRAKE
580SN, 580SN-WT AND 590SN

SOLENOID
GROUND
ELECTRICAL SCHEMATIC
POWER POINT B+ HPCR ENGINE
SPS/PS TRANSMISSION
GROUND
SAHR PARK BRAKE

POWER POINT 1 GROUND SIGNAL TO CLUSTER
SAHR PARK BRAKE

KEY ON
RAC 84470420
DRIVING LIGHTS BACKLIGHT
FRONT WORK LIGHTS BACKLIGHT
REAR WORK LIGHTS BACKLIGHT

LEGEND
BRAKE LIGHTS TO CLUSTER GROUND
INSTRUMENT CLUSTER KEY ON
INDICATES CONSTANT POWER

POWER POINT 2 GROUND
HEAVY LIGHT OUTPUT
NEUTRAL SIGNAL TO CLUSTER

INDICATES POWER WHEN KEY
A/C FAULT SIGNAL
CRANK SIGNAL SAHR PARK BRAKE

SWITCH IS ON
DE-CLUTCH RELAY KEY ON
SAHR PARK BRAKE SIGNAL
CAN BUS LOW AUDIBLE ALARM
CAN BUS HIGH

GROUND
SWITCH IS IN START POSITION

HEAVY LIFT INPUT
INDICATES SWITCHED POWER

FROM CONTROL RELAYS
ALTERNATOR CHARGE SIGNAL FRONT DC BUTTON
SAHR BRAKE DECLUTCH

RELAY GROUND
DECLUTCH TO TRAX
ONE-TOUCH DECEL INSTRUMENT CLUSTER GROUND

SAHR BRAKE SOLENOID
GROUND
INSTRUMENT CLUSTER 11 POWER POINTS 12 SAHR PARK BRAKE 13

RAC84470420S1S1
RADIO B+
A/C RELAY COIL

HOUSINGS ACTUATORS GROUND
V P T
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LAMP
RADIO KEY ON
CONTACT CONFIGURATIONS
A/C FAULT SIGNAL
TO CLUSTER
RADIO GROUND
LIQUID LEVER FLOAT PRESSURE COIL DIODE
CONTACTS
MOMENTARY
MAINTAINED
FUSE RELAY GROUND BATTERY
HVAC BLOWER
KEY ON BLOWER MOTOR GROUND
FUSE LOCATIONS HVAC 14 RADIO 15

COMFORT STEER
REAR LIGHTS KEY ON SW LAMP GROUND
AIR SEAT MOTOR B+
REAR LIGHTS
RELAY GROUND
HORN B+
REAR LIGHTS SWITCH
LAMP GROUND
DRIVING LIGHTS
BACKLIGHT
REAR TAIL LIGHTS
CS CUTOUT RELAY
COIL GROUND
3/4 GEAR
COMMANG SIGNAL
RIGHT REAR TURN SIGNAL
SIDE LIGHTS
AIR SEAT MOTOR GROUND
KEY ON
3/4 GEAR COMMAND SIGNAL

REAR LIGHTS
CAB GROUND
COMFORT STEER KEY ON
LEFT REAR TURN SIGNAL DECLUTCH TO TRAX
REAR WIPER MOTOR KICK DOWN TO TRAX

GROUND
BLOWER MOTOR CS POWER RELAY
GROUND DIFF LOCK TO TRAX COIL GROUND
DOME LIGHT
GROUND
COMFORT STEER
KEY ON POWER SOLENOID
GROUND
ROTATING BEACON
KEY ON
RIDE CONTROL SWITCH COMFORT STEER

KEY ON SOLENOID GROUND
RIDE CONTROL ACCUMULATOR

HORN SOLENOID GROUND
BRAKE LIGHTS REAR WORK LIGHTS BACKLIGHT GROUND
KEY ON
BRAKE LIGHTS TO CLUSTER
ROTATING BEACON
SWITCH LAMP GROUND
RIDE CONTROL TANK
SOLENOID GROUND
REAR EXTERIOR LIGHTS 16 OPTIONS 17 HORN 18 COMFORT STEER/ RIDE CONTROL 19
POWER LIFT KEY ON
HYDRAULIC POWER
LIFT SWITCH
POWER LIFT REQUEST
TO CLUSTER
POWER LIFT ACTIVATED WHEN SWITCH IS CLOSED
POWER LIFT
RELAY
POWER LIFT ENABLE

FROM CLUSTER
POWER LIFT RELAY COIL
POWER LIFT
SOLENOID
POWER LIFT
SOLENOID GROUND
TORQUE CONTROL
SOLENOID GROUND
CANOPY EXTERIOR LIGHTS 20 POWERSHIFT TRANSMISSION JUMPER HARNESS 21 TRAX SPS/ PS CONTROLLER 22 HYDRAULIC POWER LIFT 23

HPCR ENGINE
SPS/PS TRANSMISSION
RAC 84470420
LEGEND

SWITCH IS ON
FROM CONTROL RELAYS
RAC84470420S1S2
COMBO HYDRAULICS 24 PILOT CONTROL INPUTS 25 DIA KITS 26
ALTERNATOR B+
CRANK SIGNAL TO CLUSTER
STARTER
INSTRUMENT CLUSTER KEY ON
FRONT WIPER
FRONT WORK
LIGHT ALTERNATOR, GRID HEATER
FLASHER FUEL SOLENOID
WB-009
21 GRID HEATER MODULE 1511 OG 20GA
HOUSINGS ACTUATORS GROUND KEY ON
POWER RELAYS
COLOR ABBREVIATIONS SPL-XX ALTERNATOR

INDICATES CIRCUIT SPLICE
IGNITION SWITCH B+
T
BRAKE LIGHT
V P R----------------------------RED OR-------------- ----------ORANGE INDICATES CIRCUIT CONNECTION

DRIVE LIGHTS
T----------------------------TAN K--------------------------PINK
LEVER HAND FOOT TEMPERATURE BEACON
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LAMP W---------------------------WHITE P--------------------------VIOLET (PURPLE) INDICATES CIRCUIT CROSSING
Y----------------------------YELLOW DU------------------------DARK BLUE NOT CONNECTED GROUND
CONTACT CONFIGURATIONS BK -------------------------BLACK LU------------------------LIGHT BLUE HORN
SP-103
S ---------------------------GRAY DG------------------------DARK GREEN ECM/DIAG PORT
BK/W----------------------BLACK/WHITE LG------------------------LIGHT GREEN INDICATES INTERNALLY
IGNITION SW STARTER SOLENOID B+
LIQUID LEVER FLOAT PRESSURE COIL DIODE GROUNDED UNITS SUPPLY
INSTRUMENT NEUTRAL RELAY SIGNAL P050 RD 2GA GRID HEATER
21
CLUSTER FROM FNR SWITCH POWER
CONTACTS GRID HEATER
STARTER 21BB WH 16GA CRANK CUTOUT
21
SOLENOID
MOMENTARY FUEL SHUTOFF SOLENOID
DOME LAMP
MAINTAINED AIR SEAT
ALTERNATOR CHARGING SIGNAL 3405 YE 20GA
CIRCUIT 1 CIRCUIT 1 POWER POINTS
TRAX
CIRCUIT 3 CIRCUIT 3
CIRCUIT 4 CIRCUIT 4

CIRCUIT DIAGRAM LEGENDS CAB B+ POWER
RADIO
REAR LIGHTS CAB POWER

CABLE
SIDE LIGHTS
INSTALLER TAP
WIRE BREAKOUT
ALT TACH TO TRAX
WB-255 SPL WB-254

GROUND
Sheet ? Y 0.8 255 Y 0.8 254 Sheet ?
HVAC BLOWER
COLOR RTD
WIRE ID SPLICE
CUSTOMER KEY ON TRANS SPEED SENSOR
WIRE SIZE IGNITION FROM KEY SWITCH QC, EH CLAM
BOOM LOCK RADIO TRAX KEY ON
COMFORT STEER
TRAX KEY ON
WB - WIRE BREAKOUT
PILOT CONTROL
FB - FUSE BREAKOUT TRAX KEY ON
GB - GROUND BREAKOUT
TRAX DC SUPPLY
4WD/RC
DIFF LOCK, KD, DC, CO BUTTONS
ACCESSORY FROM KEY SWITCH REAR WIPER

WASHER
ACCESSORY TO SAHR BRAKE GROUND F&R
LEGEND POWER DISTRIBUTION/ CHARGING SYSTEM 1 STARTING SYSTEM 2
FUEL SHUTOFF
SOLENOID Y-020
WB-011
Sheet 1 FUEL SHUTOFF SOLENOID
1504 OG 20GA
ENGINE TEMPERATURE
X-462 X-463
CORRECTION RESISTOR
WB-006 SP-240 1 1 1 1 84271440
Sheet 11 ENGINE TEMP SENDER
TO CLUSTER
31T1 BL 20GA 31T5 BL 20GA
2 2 2 2 430 Ohms
WB-112
Sheet 1 DIAGNOSTIC PORT B+
430 OHM RESISTOR GROUND
GB-157
G217 BK 20GA Sheet 3
P011 RD 20GA
X-001
X-051 ENGINE TEMPERATURE
R-004 RESISTOR
43 43
4 4 31T4 BL 20GA 31T2 BL 20GA
F-001 8 8
10A
1010 RD 16GA
X-013
DIAGNOSTIC PORT
X-009
B
B+
E
K LINE
C SP-220 WB-066
E353 YE 20GA CAN TO INSTRUMENT CLUSTER
CAN HIGH E354 YE 20GA Sheet 11
D
SP-221 CAN TO INSTRUMENT CLUSTER
WB-065
CAN LOW E343 YE 20GA E344 GN 20GA Sheet 11
A
DIAGNOSTIC PORT GROUND
GB-028
GROUND G076 BK 20GA Sheet 3
E341 GN 20GA
E351 YE 20GA
SP-223
SP-222
CAN TO TRAX
WB-051
E346 GN 20GA Sheet 22
CAN TO TRAX
WB-050
E356 YE 20GA Sheet 22
X-460 X-461
CAN BUS TERMINATING
1 1 1 1 RESISTOR
E357 YE 20GA
2 2 2 2 120 Ohms
E347 GN 20GA
GROUNDING 3 ENGINE CONTROL 4 SPS TRANSMISSION INPUTS 5 HYDRAULICS 6

FRONT WORK LIGHTS
FRONT WASHER AND WIPERS
KEY ON
KEY ON
FRONT WASHER PUMP

GROUND
FRONT LIGHTS
CAB GROUND
SIGNAL LIGHTS
KEY ON
DOME LIGHT B+
FRONT WIPER MOTOR GROUND
FRONT WORK LIGHT SWITCH

LAMP GROUND
RIGHT REAR TURN SIGNAL DOME LIGHT GROUND FRONT WIPER MOTOR
REAR WASHERS AND WIPERS GROUND
FRONT WORK LIGHTS BACKLIGHT KEY ON
TAIL LIGHTS

REAR WASHER PUMP
FLASHER RELAY GROUND GROUND
TURN SIGNAL INDICATOR GROUND
HAZARD LIGHT SWITCH GROUND

KEY ON
REAR WIPER MOTOR GROUND

CLUSTER B+
SAHR BRAKE
SOLENOID GROUND
580N ELECTRICAL SCHEMATIC

28-25
31P1 BL 20GA
39 39
31P2 BL 20GA
MECHANICAL ENGINE
SPS TRANSMISSION
RAC 84470422
SAHR PARK BRAKE
SIGNAL TO CLUSTER
POWER POINT B+
SAHR PARK BRAKE

DRIVING LIGHTS BACKLIGHT KEY ON
FRONT WORK LIGHT BACKLIGHT
ENGINE OIL PRESSURE
LEGEND

88-1 S-012
INSTRUMENT CLUSTER
KEY ON
SEAT POSITION
SWITCH GROUND
NEUTRAL SIGNAL TO CLUSTER INDICATES POWER WHEN KEY

SWITCH IS ON
A/C FAULT SIGNAL
CRANK SIGNAL SAHR PARK BRAKE DECLUTCH

RELAY KEY ON

CAN BUS LOW
CAN BUS HIGH
ENGINE TEMP SENDER

AUDIBLE ALARM GROUND
ALTERNATOR CHARGE SIGNAL
FROM CONTROL RELAYS
FRONT DC BUTTON
GRID HEATER ON SIGNAL

SAHR BRAKE DECLUTCH RELAY GROUND
DECLUTCH TO TRAX
INSTRUMENT CLUSTER GROUND
SAHR BRAKE RELAY GROUND
INSTRUMENT CLUSTER 11 POWER POINTS 12 SAHR PARK BRAKE 13 RAC84470422S1S1

RADIO B+
HOUSINGS ACTUATORS

V P T R----------------------------RED OR-------------- ----------ORANGE INDICATES CIRCUIT CONNECTION
A/C RELAY COIL GROUND
T----------------------------TAN K--------------------------PINK
LEVER HAND FOOT TEMPERATURE A/C FAULT SIGNAL
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LAMP W---------------------------WHITE P--------------------------VIOLET (PURPLE) INDICATES CIRCUIT CROSSING TO CLUSTER
Y----------------------------YELLOW DU------------------------DARK BLUE NOT CONNECTED

RADIO KEY ON

LIQUID LEVER FLOAT PRESSURE COIL DIODE GROUNDED UNITS RADIO GROUND
CONTACTS
MOMENTARY
MAINTAINED
CIRCUIT 1 CIRCUIT 1
CIRCUIT 3 CIRCUIT 3
CIRCUIT 4 CIRCUIT 4

WIRE BREAKOUT
WB-255 SPL WB-254

Sheet ? Y 0.8 255 Y 0.8 254 Sheet ?
COLOR
WIRE ID SPLICE
HVAC BLOWER
WIRE SIZE KEY ON
BLOWER MOTOR GROUND
WB - WIRE BREAKOUT
FB - FUSE BREAKOUT
HVAC 14 AUDIO 15
COMFORT STEER SWITCH
AIR SEAT MOTOR B+ LAMP GROUND
HORN B+
CS CUTOUT RELAY
COIL GROUND
3/4 GEAR COMMAND
AIR SEAT MOTOR GROUND SIGNAL
3/4 GEAR
COMMAND SIGNAL
DECLUTCH TO TRAX
KICK DOWN TO TRAX

COMFORT STEER
KEY ON
DIFF LOCK TO TRAX
CS POWER RELAY
KEY ON POWER COIL GROUND
CS SOLENOID
GROUND
RIDE CONTROL SWITCH RC SW LAMP GROUND

KEY ON
RIDE CONTROL
ACCUMULATOR
SOLENOID GROUND
HORN GROUND
RIDE CONTROL
TANK SOLENOID
GROUND
REAR EXTERIOR LIGHTS 16 OPTIONS 17 HORN 18 COMFORT STEER / RIDE CONTROL 19

GRID HEATER
R-013
X-249
GRID HEATER
RELAY K-010
87A
F-036 30
GRID HEATER POWER GRID
Sheet 2 P050 RD 2GA 87
HEATER BAR
GRID HEATER MODULE 300A
Sheet 2 KEY ON 1511 OG 20GA
X-012 85 86 X-248
X-001
X-051 GRID HEATER
MODULE
F-035
41 41 6 6 7
1512 OG 20GA 1514 OG 20GA CRANK CUTOUT
5A 1 1 1 RELAY K-016
31C3 YE 20GA
3 87A
3 5 6 30
X-001 21BB WH 16GA
X-051 87
2 2 4
3405 YE 20GA
GRID HEATER ON 5 5 1 2 10
Sheet 11 SIGNAL TO CLUSTER
31C1 YE 20GA 3500 YE 20GA 85 86
R-011
3 8
KKSB CUTOUT
4 4
ENGINE TEMP RELAY K-009
GRID HEATER CRANK CUTOUT
Sheet 2 SENDER 87A
30
ALTERNATOR CHARGING SIGNAL
Sheet 1 87
85 86
GRID HEATER ENGINE

TEMP. SENDER
R-012
C B
G270 BK 16GA GRID HEATER HARNESS GROUND

Sheet 3
GRID HEATER TEMP SENDER GROUND

G271 BK 20GA Sheet 3
CANOPY EXTERIOR LIGHTS 20 MECH. ENGINE GRID HEATER 21 TRAX SPS CONTROLLER 22 PILOT CONTROLS INPUT 23
580N ELECTRICAL SCHEMATIC

MECHANICAL ENGINE
SPS TRANSMISSION
RAC 84470422
LEGEND

SWITCH IS ON
FROM CONTROL RELAYS
RAC84470422S1S2
COMBO HYDRAULICS 24 FUSE DIAGRAMS
ST FROM IGNITION SWITCH
INSTRUMENT CLUSTER
FRONT WIPER
FRONT WORK
LIGHT ALT/ECU
FLASHER
HOUSINGS ACTUATORS GROUND

ACC FROM IGNITION SWITCH

ALTERNATOR
IGNITION SW B+
V P T R----------------------------RED OR-------------- ----------ORANGE INDICATES CIRCUIT CONNECTION
BRAKE LIGHTS
DRIVE LIGHTS
T----------------------------TAN K--------------------------PINK
BEACON
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LAMP W---------------------------WHITE P--------------------------VIOLET (PURPLE) INDICATES CIRCUIT CROSSING
Y----------------------------YELLOW DU------------------------DARK BLUE NOT CONNECTED GROUND
CONTACT CONFIGURATIONS BK -------------------------BLACK LU------------------------LIGHT BLUE HORN
SP-103
ECM/DIAGNOSTIC
BK/W----------------------BLACK/WHITE LG------------------------LIGHT GREEN INDICATES INTERNALLY PORT
STARTER SOLENOID B+
IGN SWITCH
LIQUID LEVER FLOAT PRESSURE COIL DIODE GROUNDED UNITS SUPPLY
NEUTRAL SIGNAL TO NEUTRAL RELAY
INSTRUMENT
CLUSTER
CONTACTS CRANK REQUEST/ ECU
STARTER SOLENOID
MOMENTARY ECU WIF SENSOR CRANK REQUEST/ ECU

DOME LIGHT
MAINTAINED AIR SEAT
CRANK REQUEST/ ECU

CIRCUIT 1 CIRCUIT 1 POWER POINTS
CRANK REQUEST/ ECU

CIRCUIT 3 CIRCUIT 3
CIRCUIT 4 CIRCUIT 4

CIRCUIT DIAGRAM LEGENDS RADIO
REAR LIGHTS
CAB B+ POWER
B+ FROM STARTER
SIDE LIGHTS
INSTALLER TAP
WIRE BREAKOUT 3 3
F-009 19E8 OG 20GA

7 7
WB-255 SPL WB-254 GROUND 19E6 OG 20GA NEUTRAL RELAY COIL
7.5A X-040
19E2 OG 20GA
Sheet ? Y 0.8 255 Y 0.8 254 Sheet ?
CLUTCH INTERLOCK RELAY COIL
HVAC BLOWER X-150
COLOR 21 21 16 16 RELAY K-009
WIRE ID SPLICE RETURN TO DIG
19E7 OG 20GA 19E3 OG 20GA 87A
30
WIRE SIZE 15 15 DE-CLUTCH BUTTON (SHIFT HANDLE)
87
IGNITION FROM KEY SWITCH QC,EH CLAM, S-041 B B WB-009
BOOM LOCK, RADIO 24 24 LOADER CONTROL HARNESS KEY ON
Sheet 17
COMFORT STEER 1 2
WB-077
WB - WIRE BREAKOUT FNR KEY ON FROM 19 19 85 86 A A
PILOT CONTROL Sheet 5
THE CLUTCH RELAY 2103 YE 20GA 2508 BL 20GA 2508 BL 20GA
FB - FUSE BREAKOUT WB-053 INSTALLER TAP
GB - GROUND BREAKOUT HEAVY LIFT KEY ON AP52 OG 12GA
CUSTOMER
Sheet 1
35 35 OPTION DECLUTCH TO
4WD/RIDE CONTROL TAP INTO 35 35 WB-035
CLUTCH RELAY
F-034 X-003 2501 BL 20GA 2506 BL 20GA 2503 BL 20GA Sheet 17
ACCESSORY FROM IGNITION SWITCH REAR WIPER, WASHER 39 39
AP53 OG 12GA CLUTCH
GB-032
WB-010
SAHR PARK BRAKE GROUND
30A G005 BK 20GA RELAY COIL Sheet 3
4041 OG 20GA X-013
POWER DISTRIBUTION/ CHARGING SYSTEM 1 STARTING SYSTEM 2
RETURN TO DIG
KEY ON
ECU GROUND
ECU B+
RETURN TO DIG GROUND
QC, EH CLAM, BOOM LOCK, RADIO
RADIO KEY ON
EH CLAM GROUND
CRANK ENABLE/ ECU
CRANK REQUEST/ ECU
CRANK REQUEST/ ECU
CRANK ENABLE/ ECU
ECU KEY ON POWER

G018 BK 20GA QC LS SOLENOID CLAMP GROUND
CAN TO INSTRUMENT CLUSTER QC LDR SOLENOID CLAMP GROUND

G017 BK 20GA
DIAGNOSTIC PORT GROUND G019 BK 20GA QC BHOE SOLENOID CLAMP GROUND
GROUNDING 3 ENGINE CONTROL 4 DRIVES 5 HYDRAULICS 6

FRONT WORK LIGHTS FRONT WASHERS AND WIPERS
HAL EFFECT SWITCH KEY ON KEY ON
+5V OUTPUT
LEFT HAND STABILIZER
RIGHT HAND STABILIZER
EHOE RETRACT
EHOE EXTEND FRONT WASHER

PUMP GROUND
LEFT HAND STABILIZER PRESSURE SWITCH
FRONT LIGHTS
RIGHT HAND STABILIZER PRESSURE SWITCH
CAB GROUND
SIGNAL LIGHTS
BI-DIR AUX FORWARD KEY ON
BI-DIR AUX REVERSE
DOME LIGHT B+
PILOT
CONTROLS
SOLENOID
GROUND
PILOT CONTROLS
ON OFF SW
MIDDLE POS
PILOT
CONTROLS FRONT WIPER
MODULE MOTOR GROUND
GROUND
FRONT WORK LIGHT SWITCH
LAMP GROUND DOME LIGHT GROUND
REAR WASHERS AND WIPERS
RIGHT REAR TURN SIGNAL KEY ON
TAIL LIGHTS
PILOT REAR WASHER PUMP GROUND

CONTROLS FLASHER RELAY GROUND
SOLENOID
GROUND
PILOT CONTROLS TURN SIGNAL INDICATOR

ON OFF SW GROUND
ALL ON POS
HAZARD LIGHT SWITCH

GROUND

KEY ON
PATTERN CHANGE SWITCH OUTPUT
HAMMER VALVE GROUND REAR WIPER MOTOR GROUND
CLUSTER B+

HPCR ENGINE
28-25 39 39
31P1 BL 20GA 31P2 BL 20GA
POWERSHUTTLE TRANSMISSION
POWER POINT B+
RAC 84470423
DRIVING LIGHTS BACKLIGHT

ENGINE OIL PRESSURE
88-1 S-012
LEGEND
INSTRUMENT CLUSTER
KEY ON
SEAT POSITION
SWITCH GROUND
NEUTRAL SIGNAL TO CLUSTER POWER POINT 2 GROUND

A/C FAULT SIGNAL
SWITCH IS ON
CRANK SIGNAL

CAN BUS LOW
CAN BUS HIGH AUDIBLE ALARM GROUND

62 28-9
20 POWER LIFT INPUT

ALTERNATOR CHARGE SIGNAL
FROM CONTROL RELAYS
X-054 X-001
28-21
E E 17 17
ONE TOUCH DECEL 1212 BL 20GA 1211 BL 20GA
PILOT CONTROL HARNESS X-051 INSTRUMENT CLUSTER GROUND
RAC84470423S1S1
RADIO B+
HOUSINGS ACTUATORS

V P T R----------------------------RED OR-------------- ----------ORANGE INDICATES CIRCUIT CONNECTION A/C RELAY COIL
GROUND
T----------------------------TAN K--------------------------PINK
A/C FAULT SIGNAL
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LAMP W---------------------------WHITE P--------------------------VIOLET (PURPLE) INDICATES CIRCUIT CROSSING TO CLUSTER
Y----------------------------YELLOW DU------------------------DARK BLUE NOT CONNECTED RADIO KEY ON
RADIO GROUND
LIQUID LEVER FLOAT PRESSURE COIL DIODE GROUNDED UNITS
CONTACTS
MOMENTARY
MAINTAINED
CIRCUIT 1 CIRCUIT 1
CIRCUIT 3 CIRCUIT 3
CIRCUIT 4 CIRCUIT 4

WIRE BREAKOUT
WB-255 SPL WB-254

Sheet ? Y 0.8 255 Y 0.8 254 Sheet ?
COLOR
WIRE ID SPLICE HVAC BLOWER
WIRE SIZE KEY ON
BLOWER MOTOR GROUND
WB - WIRE BREAKOUT
FB - FUSE BREAKOUT
HVAC 14 AUDIO 15
HORN B+
HORN GROUND
REAR EXTERIOR LIGHTS 16 OPTIONS 17 HORN 18 COMFORT STEER / RIDE CONTROL 19
HYDRAULIC POWER
LIFT SWITCH S-012
HYDRAULIC OPTIONS 20 PILOT CONTROL INPUTS 21 COMBO / AUX / UNI HYDRAULICS 22 CANOPY EXTERIOR LIGHTS 23

HPCR ENGINE
RAC 84470423
LEGEND

SWITCH IS ON
FROM CONTROL RELAYS
FUSE DIAGRAMS RAC84470423S1S2

ALTERNATOR
INSTRUMENT CLUSTER
STARTER
RESISTOR FRONT WIPER
PIN CONTACT ALT/ECU
RD - RED
FRONT WORK
LIGHTS
BATTERY SOCKET CONTACT
GRID HEATER
FLASHER
ACC. FROM IGNITION
BK - BLACK DIODE GROUND SWITCH
WIRE ID ALTERNATOR
FALUT SIGNAL
IGNITION SWITCH
B+
YE - YELLOW
BRAKE LIGHTS
WIRE COLOR CONNECTOR
WIRE BREAKOUT PIN NUMBER
DRIVE LIGHTS
WIRE SIZE
OG - ORANGE BEACON
1 2
GN - GREEN NORMALLY OPEN SWITCH GROUND
SPLICE SOLENOID HORN

CHASSIS STARTER
LB - LIGHT BLUE GROUND

IGNITION SW
SUPPLY
STARTER
SOLENOID B+
NEUTRAL SIGNAL
DIRECTION OF 1 2
SOLENOID
TO NEUTRAL RELAY
CONNECTION NORMALLY CLOSED SWITCH GRID HEATER B+ CABLE
GY - GRAY CURRENT FLOW

DOME
LAMP
FUEL SOLENOID
AIR SEAT
ALT. SIGNAL TO
PK - PINK GRID HEATER POWER

POINTS
WH - WHITE RADIO Sheet 1 B+ FROM

BATTERY
REAR Sheet 1 B+ FROM
LIGHTS ALTERNATOR
BL - BLUE LAMP SIDE

LIGHTS
Sheet 1 CAB B+
POWER
NORMALLY OPEN SWITCH

B+ FROM
STARTER
STARTER INSTALLER
TAP
VT - VILOT WITH LIGHT

ALT TACH
FUSE GROUND NEUTRAL RELAY COIL
TN - TAN HVAC
BLOWER
STARTER RELAY COIL
CONNECTOR RTD CRANK SIG TO GRID

HEATER MODULE
BN - BROWN NUMBER QC,EH CLAM BOOM

LOCK, RADIO
COMFORT
STEER
PILOT LOADER CONTROL HARNESS
CONTROL
MOTOR
KEY ON
FNR KEY ON FROM
SPEAKER
CLUTCH RELAY
INSTALLER TAP
KEY ON
RELAY ALARM IGNITION FROM KEY SWITCH 4WD/RC

DECLUTCH TO
ACC. FROM KEY SWITCH REAR WIPER CLUTCH RELAY
WASHER
ACC. TO SAHR BRAKE GROUND CLUTCH RELAY COIL
CIRCUIT LEGEND SCHEMATIC SYMBOLS POWER DISTRIBUTION/ CHARGING SYSTEM 1 STARTING SYSTEM 2
QC LDR SOLENOID RETURN TO DIG
CLAMP IN GEAR SIGNAL KEY ON
TO CLUSTER
POWER POINT 1
QC LS SOLENOID
CLAMP
POWER POINT 2
INSTR CLUSTER
RETURN TO DIG GROUND
RADIO GROUND A/C REALY COIL FUEL SENDER
KEY ON
REAR LIGHTS
SWITCH LAMP PARK BRAKE
RC SW LAMP SOLENOID
FUEL SENDER
4WD SW LAMP
BACK UP ALARM
GRID HEATER QC, EH CLAM, RADIO KEY ON

EH CLAM TEMP SENDER BOOM LOCK, RADIO
COMFORT STEER
POWER RELAY SOLENOID
2 COIL
TRANS RELAYS POWER
POWER RELAY
1 COIL Q COUPLER
NEUTRAL REALY COIL LS SOLENOID SAHR PARK BRAKE
Q COUPLER DECLUTCH RELAY KEY ON
INTERLOCK LDR SOLENOID
FORWARD RELAY
RELAY COIL GROUND
SAHR BRAKE TRANS EH CLAM GROUND
REVERSE RELAY
CUTOUT REALY COIL GRID HEATER GROUND
REAR LIGHTS
RELAY COIL
FNR KEY ON
FWD RELAY FROM THE NEUTRAL SIGNAL TO
PILOT CONTROL
CLUTCH RELAY NEUTRAL RELAY
REV RELAY SHUTTLE INTER
TIMING GROUND
RETURN TO DIG
CS CUTOUT SWITCH DIFF LOCK FROM
RELAY COIL
HORN LOADER CONTROL
SAHR BRAKE
RELAY COIL
RIDE CONTROL
POWER RELAY
ACCUM SOLENOID
3 COIL
RIDE CONTROL
FLASHER RELAY TANK SOLENOID
POWER RELAY AIR FILTER

4 COIL RESTRICTION
FRONT WRK
LIGHT SW LAMP LOAD SENSE GROUND
REVERSE SOLENOID
ROTATING BEACON
SW LAMP FORWARD SOLENOID
HAZARD
SW LAMP DIFF LOCK SOLENOID
BACKUP ALARM GROUND
TURN INDIC.
LAMPS 4WD SOLENOID LOADER QUICK COUPLER
SOLENOID GROUND
FRONT WASHER
PUMP SEAT SWITCH
REV SOLENOID GROUND
REAR WASHER
PUMP AIR SEAT MOTOR
4WD/ RIDE CONTROL
SHUTTLE INTERLOCK KEY ON
RELAY GROUND
FWD SOLENOID GROUND
CLUTCH REALY
COIL
AUTO/MAN DIFF LOCK SOLENOID GND
FRONT LIGHTS CAB SW LAMP
COMFORT STEER
FRONT LIGHT CANOPY SWITCH LAMP 4WD SW LAMP
GROUND QC LS SOLENOID CLAMP GROUND
REAR LIGHTS CAB
RIDE CONTROL KEY ON
REAR LIGHTS CANOPY QC LDR SOLENOID CLAMP GROUND
SHUTTLE INTERLOCK RELAY GROUND
GROUNDING 3 ENGINE CONTROL 4 DRIVES 5 HYDRAULICS 6

HAL EFFECT
SWITCH +5V FRONT WASHERS AND
FRONT WORK LIGHTS
OUTPUT WIPERS KEY ON
LEFT-HAND STABILIZER KEY ON
RIGHT-HAND STABILIZER
EHOE RETRACT
FROT WASHER
PUMP GROUND
EHOE EXTEND
LEFT-HAND STABILIZER PRESSURE SWITCH

FRONT
SIGNAL LIGHTS LIGHTS
RIGHT-HAND STABILIZER PRESSURE SWITCH
KEY ON GROUND
BI-DIR AUX FORWARD
BI-DIR AUX REVERSE

DOME LIGHT B+
PILOT
CONTROLS
SOLENOID
GROUND
PILOT CONTROLS
ON/OFF SWITCH
PILOT CONTROLS FRONT WIPER MOTOR GROUND DOME LIGHT GROUND
MIDDLE POSITION
MODULE GROUND
G062 BK 20GA
FRONT WORK LIGHT SWITCH LAMP GROUND
RIGHT REAR TURN SIGNAL

REAR WASHERS AND
FRONT WORK LIGHT BACKLIGHT WIPERS KEY ON
TAIL LIGHTS

REAR WASHER
PILOT PUMP GROUND
FLASHER RELAY GROUND
CONTROLS
SOLENOID
GROUND
PILOT CONTROLS
ON/OFF SWITCH TURN SIGNAL INDICATOR GROUND
ALL ON POSITION
HAZAD LIGHT SWITCH GROUND
FRONT DRIVING
LIGHTS KEY ON
PATTERN CHANGE SWITCH OUTPUT
HAMMER VALVE GROUND

REAR WIPER MOTOR GROUND
PILOT CONTROLS 7 FRONT EXTERIOR LIGHTS 8 INTERIOR LIGHTING 9 WIPERS AND WASHERS 10
AIR FILTER

DRIVING LIGHTS BACKLIGHT RESTRICTION
GROUND
SAHR BRAKE
SOLENOID
GROUND
ALT TACH
POWER POINT B+
POWER POINT 1 GROUND MECHANICAL ENGINE

FUEL SENDER
GROUND
RAC84470424
SAHR PARK BRAKE
SIGNAL TO CLUSTER
SAHR PARK BRAKE

KEY ON
INSTRUMENT CLUSTER
KEY ON
POWER POINT 2 GROUND LEGEND
IN-GEAR SIGNAL TO CLUSTER

SEAT SWITCH
GROUND
A/C FAULT SIGNAL TO CLUSTER
TRANS RELAYS POWER
SWITCH IS ON
SAHR PARK BRAKE DECLUTCH

REALY KEY ON
SAHR PARK BRAKE SIGNAL TO CLUSTER
GRID HEATER ON INDICATOR

FROM CONTROL RELAYS
ALTERNATOR NOT CHARGING FAULT SIGNAL
SAHR BRAKE DECLUTCH
RELAY GROUND
SAHR BRAKE
RELAY GROUND
INSTRUMENT CLUSTER GROUND
RAC84470424S1S1
RADIO B+
RESISTOR
PIN CONTACT
RD - RED BATTERY SOCKET CONTACT
BK - BLACK DIODE
WIRE ID
YE - YELLOW WIRE COLOR CONNECTOR
RADIO KEY ON
WIRE BREAKOUT PIN NUMBER

WIRE SIZE
OG - ORANGE RADIO GROUND
1 2
GN - GREEN NORMALLY OPEN SWITCH

SPLICE SOLENOID
CHASSIS
LB - LIGHT BLUE GROUND
DIRECTION OF 1 2
CONNECTION NORMALLY CLOSED SWITCH

GY - GRAY CURRENT FLOW
PK - PINK
WH - WHITE
BL - BLUE LAMP
STARTER NORMALLY OPEN SWITCH
VT - VILOT FUSE WITH LIGHT
TN - TAN
CONNECTOR
BN - BROWN NUMBER HVAC BLOWER
KEY ON
MOTOR
SPEAKER
RELAY ALARM
CIRCUIT LEGEND SCHEMATIC SYMBOLS HVAC 14 AUDIO 15

COMFORT STEER SWITCH
AIR SEAT B+ LAMP GROUND
REAR LIGHTS
KEY ON
REAR LIGHTS
RELAY GROUND
REAR LIGHTS
SWITCH LAMP GROUND HORN B+ 36-2 36-3
DRIVING LIGHTS
BACKLIGHT
REAR TAIL LIGHTS
AIR SEAT MOTOR GROUND
DECLUTCH TO CLUTCH RELAY
DIFF LOCK FROM LOADER CONTROL
LOADER CONTROL HARNESS KEY ON COMFORT STEER RELAY

RIGHT REAR COIL GROUND
TURN SIGNAL
SIDE LIGHTS
KEY ON COMFORT STEER
SOLENOID GROUND
COMFORT STEER
REAR LIGHTS
CAB GROUND
REAR WIPER
MOTOR GROUND
BLOWER MOTOR GRID HEATER B+ CABLE
GROUND
DOME LIGHT
GROUND
GRID HEATER KEY ON
ROTATING BEACON
KEY ON
HORN GROUND RIDE CONTROL SWITCH RIDE CONTROL SWITCH

KEY ON LAMP GROUND
GRID HEATER
ON INDICATOR
TO CLUSTER
RIDE CONTROL ACCUMULATOR

CRANK SIGNAL TO SOLENOID GROUND
REAR WORK LIGHTS GRID HEATER MODULE
BRAKE LIGHTS BACKLIGHT
ALT. SIGNAL TO GRID HEATER
KEY ON
GRID HEATER ENGINE

TEMP SENDER
ROTATING BEACON
SWITCH LAMP GROUND RIDE CONTROL
TANK SOLENOID GROUND
GRID HEATER TEMP SENDER
GRID HEATER COMMON GROUND
REAR LIGHTS EXTERIOR 16 OPTIONS 17 HORN 18 COMFORT STEER/ RIDE CONTROL 19

PILOT CONTROLS
KEY ON
PILOT CONTROLS ON/OFF SWITCH

MIDDLE POSITIONS
PILOT CONTROLS ON/OFF SWITCH
ALL ON POSITIONS
PATTERN CHANGE SWITCH

PILOT CONTROLS SOLENOID GROUND OUTPUT
PILOT CONTROLS SOLENOID GROUND
HAL EFFECT SWITCH +5V OUTPUT
EHOE EXTEND
EHOE RETRACT
BI-DIR AUX FORWARD
BI-DIR AUX REVERSE
RH STABILIZER
PILOT CONTROLS
MODULE GROUND
HORN B+
LH STABILIZER
PILOT CONTROLS GROUND

ONE-TOUCH DECEL
COMBO AUX SWITCH GND
LH STAB PRESSURE SW
HAMMER VALVE
GROUND RH STAB PRESSURE SW
HORN OUTPUT
PILOT CONTROL INPUTS 20 COMBO/ AUX/ UNI HYDRAULICS 21 CANOPY EXTERIOR LIGHTS 22 FUSE DIAGRAM 23

MECHANICAL ENGINE
RAC 84470424
LEGEND

SWITCH IS ON
FROM CONTROL RELAYS
RAC
RAC
580N MECHANICAL
RAC 84390774
LEGEND
VARIABLE PISTON PUMP SUPPLY STEERING PRIORITY

VARIABLE PISTON PUMP SUPPLY LOADER VALVE SUPPLY
VARIABLE PISTON SUPPLY BACKHOE VALVE SUPPLY
RETURN TO TANK/SUMP
RAC 84390774S1
580SN, 580SN-WT AND 590SN RAC 84390776
HYRDAULIC VVOC WITHOUT BOOST (HEAVYLIFT)
RETURN TO TANK/SUMP
HPCO PUMP CONTROL TO BE SET

AT 238 BAR (3450 psi)
RAC 84390776S1S1
CONNECTIONS BETWEEN THE JOYSTICKS, BACKHOE VALVE AND MULTI-FUNCTION
PRERSSURE REDUCING VALVE ARE SHOWN ON SHEET 2.
580N
PILOT HYDRAULICS
RAC 84390777
GEAR PUMP SUPPLY STEERING UNIT

GEAR PUMP SUPPLY TO CONTROLS
RETURN TO TANK/SUMP
RAC 84390777S1S1
580N
PILOT HYDRAULICS
RAC 84390777

RETURN TO TANK/SUMP
RAC 84390777S1S2
580SN, 580SN-WT AND 590SN RAC 84390776
HYRDAULIC VVOC WITH BOOST (HEAVYLIFT)
RETURN TO TANK/SUMP
HEAVY LIFT RELIEF SET AT

250 BAR FOR 580SN & 590SN UNITS.
580SN-WT UNITS WILL HAVE RELIEF SET AT 261 BAR.
NORMAL MODE RELIEF TO BE SET AT 238 BAR.
DIPPER CYLINDER SHOWN WITH

DUAL ORIFICE CUSHION FOR 590SN UNITS.
580SN & 580SN-WT UNITS HAVE A SINGLE ORIFICE CUSHION.
RAC 84390776S1S2
NOTES ON PAGE 2.
HYDRAULIC VVCC RAC 84390778
RETURN TO TANK/SUMP
RAC 84390778S1S1
HYDRAULIC VVCC RAC 84390778
RETURN TO TANK/SUMP
HEAVY RELIEF VALVE SET AT 250 BAR FOR 580SN & 590SN. DIPPER CYLINDER SHOWN WITH DUAL ORIFICE CUSHION FOR 590SN UNITS.
580SN-WT UNITS HAVE RELIEF SET AT 261 BAR. 580SN & 580SN-WT UNITS HAVE A SINGLE ORIFICE CUSHION.
NORMAL MODE RELIEF TO BE SET AT 238 BAR. COMMECTIONS BETWEEN THE JOYSTICK, BACKHOE VALVE AND MULTI-FUNCTION
PRESSURE REDUCING VALVE ARE SHOWN ON THIS PAGE.
RAC 84390778S1S1

580N Manual de Servicio Retroexcavadora

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580N Manual de Servicio Retroexcavadora

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580N

Printed in U.S.A. Part number 84516378

ENGINE AND PTO IN ................................................................... B

TRANSMISSION, DRIVE AND PTO OUT ........................................ C

AXLES, BRAKES AND STEERING................................................. D

SERVICE BRAKE Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.30.C

PARKING BRAKE Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.32.B

FRAME AND CAB ........................................................................ E

USER PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.34.A

FRAME POSITIONING ................................................................. F

TOOL POSITIONING .................................................................... G

HITCH AND WORKING TOOL ....................................................... H

DIPPER Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.25.B

EXCAVATING AND LANDSCAPING ............................................... J

CARRYING Articulated tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J.50.C

Plastic and resin parts

• Disconnect the batteries.

• Disconnect the controller for backhoe pilot controls,

Battery - Basic instructions

• Do not run the engine with the alternator wires disconnected.

2. Remove the battery cover hardware.

3. Remove the battery cover.

4. Disconnect the negative battery cable from the neg-

ELECTRONIC SYSTEM - Basic instructions

2. Unscrew the cap for the diagnostic/service tool port.

Heater - Basic instructions

• In warm ambient temperatures, turn the shutoff

Raise and support loader lift arms:

4. Remove the retaining pin.

7. Start the engine.

Lower supported loader lift arms:

3. Remove the retaining pin from the support strut.

5. Start the engine.

3. Lift the hood and rotate forward.

Grade 8 bolts, nuts, and studs

NOTE: Use thick nuts with Grade 8 bolts.

Grade 10.9 bolts, nuts and studs

Grade 12.9 bolts, nuts, and studs

Steel hydraulic fittings

Straight threads with O-ring

Split flange mounting bolts

O-ring face seal end

O-ring boss end fitting or lock nut

Area (Land area)

Typical applications Metric unit Imperial unit

Temperature (other than Thermodynamic)

580SN, 580SN-WT, 590SN

Front drive axle - Two wheel drive

Front drive axle - Four wheel drive

Rear axle (differential)

Brake master cylinder

If the recommended engine oil is not available in multi-

Refer to the chart for recommended viscosity at ambient

Dye and black light procedure for detecting oil leaks

Kit part number 380040182 consisting of:

1. Prior to adding dye, connect the black light to the

• Casting surfaces can hold residual oil.

HYDRAULIC, PNEUMATIC, ELECTRICAL,

PRIMARY HYDRAULIC POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.A

SECONDARY HYDRAULIC POWER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.12.A

ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.50.A

PRIMARY HYDRAULIC POWER SYSTEM - 10.A