Professional Documents
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MR 580N PDF
MR 580N PDF
580SN-WT
580SN
590SN
Tractor Loader Backhoe
SERVICE MANUAL
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
SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.20.A
USER CONTROLS AND SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.A
USER CONTROLS AND SEAT Operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.32.C
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ENVIRONMENT CONTROL Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.40.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.
Failure to comply could result in death or serious injury.
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.
• 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.
RCPH10TLB046AAF 1
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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
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.
Failure to comply could result in death or serious injury.
W0006A
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
RCPH11TLB001AAM 2
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INTRODUCTION
RCPH11TLB002AAM 3
RCPH11TLB003AAM 4
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INTRODUCTION
RCPH10TLB437AAF 1
RCPH10TLB302AAF 2
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INTRODUCTION
RCPH10TLB159AAF 1
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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.
Failure to comply could result in death or serious injury.
W0230A
RCPH10TLB230AAF 1
RCPH10TLB221AAF 2
RCPH10TLB227AAF 3
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RCPH10TLB227AAF 4
RCPH10TLB231AAF 5
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Basic instructions
Open the hood:
1. Shut down the engine.
2. Turn the handle counter-clockwise to release the
hood latch.
RCPH10TLB166AAF 1
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
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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
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INTRODUCTION
Abbreviation Measurements
Typical applications Metric unit Imperial unit
Name Symbol Name Symbol
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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)
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)
Reservoir with filter change 47.1 l (12.45 US gal)
Reservoir without filter change 45.2 l (11.95 US gal)
580SN-WT
Total system 124.9 l (132 US qt)
Total system with Extendahoe 130.6 l (138.0 US qt)
Reservoir with filter change 47.1 l (12.45 US gal)
Reservoir without filter change 45.2 l (11.95 US gal)
590SN
Total system 132 l (139 US qt)
Total system with Extendahoe 137.7 l (145 US qt)
Reservoir with filter change 47.1 l (12.45 US gal)
Reservoir without filter change 45.2 l (11.95 US gal)
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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
Total system 18.0 l (19 US qt)
Refill (with or without filter change) 11.4 l (12 US qt)
580SN-WT, 590SN
Differential 8.6 l (9.1 US qt)
Each planetary hub 1.0 l (1.1 US qt)
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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.
RCPH10TLB244ACL 1
RCPH10TLB022FAL 2
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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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
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HYDRAULIC, PNEUMATIC, ELECTRICAL,
ELECTRONIC SYSTEMS - A
580N
580SN WT
580SN
590SN
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A.10.A / 1
Contents
TECHNICAL DATA
FUNCTIONAL DATA
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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
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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
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RCPH10TLB080AAM 1
DATAR
CAS10090 2
CAS-10090 Hand Pump
CAS10899 3
CAS-10899 Charging Kit
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RCIL10TLB016BAF 1
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RCPH10TLB005GAM 1
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RCPH10TLB007CAM 1
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RCPH10TLB003HAM 1
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RCPH10TLB005GAN 1
NOTE: Seal (6) must be pressed flush with face of recess with lip toward gear as shown.
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RCPH10TLB056FAM 1
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RCIL10TLB001GAF 1
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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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RCPH10TLB006GAM 1
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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RCPH10TBL001GAM 1
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RCPH10TLB040GAM 1
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RCPH10TLB039GAM 1
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RCPH10TLB041GAM 1
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RCPH10TLB042GAM 1
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RCPH10TLB006FAM 1
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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
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Relief valve - Drawing Single Stage Relief Valve, 580 Main Relief
with mechanical backhoe controls
RCPH10TLB008FAM 1
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Relief valve - Drawing Relief Valve, Main System Dual Stage for
580N with Pilot Controlled Backhoe
RCPH10TLB009FAM 1
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Relief valve - Drawing Load Sense Relief Valve, 580N with Pilot
Controlled Backhoe
RCPH10TLB057FAM 1
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RCPH10TLB011FAM 1
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RCPH10TLB043GAM 1
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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
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RCPH10TLB063FAM 1
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RCPH10TLB012FAM 1
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RCPH10TLB004GAM 1
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RCPH10TLB015FAL 1
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RCIL10TLB005GAF 1
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RCPH10TLB013GAM 1
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RCPH11TLB004GAM 1
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RCPH11TLB006FAM 1
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Control valve - Drawing Loader Valve, 2 Spool for 580N with pilot
controls
RCPH11TLB001FAL 1
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RCPH11TLB007FAM 1
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Control valve - Drawing Loader Valve, 3 Spool for 580N with pilot
controls
RCPH11TLB002FAL 1
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RCPH11TLB005GAM 1
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RCPH11TLB003GAM 1
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RCPH11TLB001HAM 1
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RCPH10TLB062FAM 1
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RCPH10TLB062FAM 1
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RCPH10TLB008CAM 1
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RCPH10TLB002HAN 1
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RCPH10TLB306ABL 1
RCPH10TLB454ABL 2
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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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:
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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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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.
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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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.
23. Stop the engine.
24. Disconnect the drain lines and connect the system
lines to the cylinders.
25. Check the oil level in the hydraulic reservoir. Add oil
as required.
26. Install the filler cap on the reservoir.
27. Remove the hydraulic filter elements from the ma-
chine.
28. Install new hydraulic filter elements on the machine.
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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RCPH10TLB371ABL 1
RCPH10TLB443ABL 2
RCPH10TLB372ABL 3
RCPH10TLB373ABL 4
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RCPH10TLB374ABL 5
RCPH10TLB376ABL 6
RCPH10TLB378ABL 7
RCPH10TLB381ABL 8
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RCPH10TLB382ABL 9
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RCPH10TLB383ABL 1
RCPH10TLB382ABL 2
RCPH10TLB384ABL 3
RCPH10TLB380ABL 4
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RCPH10TLB385ABL 5
RCPH10TLB386ABL 6
RCPH10TLB387ABL 7
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
RCPH10TLB388ABL 10
RCPH10TLB375ABL 11
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
RCPH10TLB391ABL 14
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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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Next operation:
PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, 580N Pilot machines (A.10.A).
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Prior operation:
PRIMARY HYDRAULIC POWER SYSTEM - Prepare - Machine Preparation, 580N Pilot machines (A.10.A).
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.
Test 3A
3. Hold loader on demand and open the load valve. Ad-
just engine speed to 2000 RPM.
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Test 3B
1. Continue to run engine at 2000 RPM. Slowly close
load valve until pressure is 138 bar (2001.0 psi).
2. Monitor flowmeter. Record results on Flowmeter
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).
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
Flowmeter Check Sheet.
Test 4C
1. Position loader approximately 45.7 cm (18 in) above
ground level. Hold bucket in rollback position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4D
1. Hold bucket in dump position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4E
1. Hold clam in open position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4F
1. Close clam and hold in closed position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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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.
3. Run engine at 2000 RPM. Increase pressure on
flowmeter to 138 bar (2001.0 psi).
Test 5A
1. Position backhoe to left side.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5B
1. Position backhoe to right side.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5C
1. If equipped with extend-a-hoe option, position out-
ward and hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5D
1. If equipped with extend-a-hoe option, retract and
hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5E
1. Raise left stabilizer. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5F
3. Raise right stabilizer. Hold in position.
4. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5G
NOTE: When lowering stabilizers, lower evenly to full stroke, then raise.
1. Lower left stabilizer. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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Test 5H
1. Lower right stabilizer. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5I
1. Roll backhoe bucket to dump position. Hold in posi-
tion.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5J
1. Roll backhoe bucket to dig position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5K
1. Position dipper in full extended position. Hold in po-
sition.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5L
1. Position dipper in full position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5M
1. Position boom in lower position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5N
1. Position boom in raised position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5P
1. Reverse direction on bi-directional valve.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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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
problem in circuit exists.
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
Flowmeter Check Sheet.
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.
3. Monitor flowmeter. When flow begins to decrease
by several l/min (gpm), record bar (psi) results on
Flowmeter Check Sheet.
Test 6E
1. Continue to slowly close flowmeter 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 - 193 bar (2349 - 2800 psi) is expected. If pressure is not to specification, adjust
quick coupler relief valve.
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Test 7A
1. Turn steering wheel to full right. Hold against stop.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 7B
1. Turn steering wheel to full left. Hold against stop.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
3. Extend backhoe bucket fully to dump position. Place
loader and backhoe bucket on ground.
Test 7C
1. Retract loader lock pins.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 7F
1. Extend backhoe bucket lock pins.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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.
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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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.
Notes:
Notes:
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Notes:
Notes:
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Notes:
Notes:
Notes:
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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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Next operation:
PRIMARY HYDRAULIC POWER SYSTEM - Test Pressure Test, 580N Mechanically Controlled machines
(A.10.A).
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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.
2. Slowly open flowmeter load valve until pressure
reads zero.
Test 1A
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 1B
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 1A are not within 10 percent
of 1B reading, replace relief valve.
Test 2A
3. Hold loader on demand and open the load valve. Ad-
just engine speed to 2000 RPM.
4. Monitor flowmeter. Record results on Flowmeter
Check Sheet.
Test 2B
1. Continue to run engine at 2000 RPM. Slowly close
load valve until pressure is 138 bar (2000 psi).
2. Monitor flowmeter. Record results on Flowmeter
Check Sheet.
3. Divide the flow reading at 138 bar (2000 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).
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Test 3A
5. Run engine at 2000 RPM. Increase pressure on
flowmeter to 138 bar (2000 psi).
1. Raise loader. Hold loader in raised position.
2. Monitor flowmeter. Record l/min (gpm) on Flowmeter
Check Sheet.
Test 3B
1. Lower loader. Hold loader in lower position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 3C
1. Position loader approximately 45.7 cm (18 in) above
ground level. Hold bucket in rollback position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 3D
1. Hold bucket in dump position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 3E
1. Hold clam in open position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 3F
1. Close clam and hold in closed position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
NOTE: Compare test results from Test 2B and Tests 3A thru 3F. If results vary more than 3.8 l/min (1 US gpm), a
problem in circuit exists.
3. Run engine at 2000 RPM. Increase pressure on
flowmeter to 138 bar (2001.0 psi).
Test 4A
1. Position backhoe to left side.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4B
1. Position backhoe to right side.
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Test 4C
1. If equipped with extend-a-hoe option, position out-
ward and hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4D
1. If equipped with extend-a-hoe option, retract and
hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4E
1. Raise left stabilizer. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4F
3. Raise right stabilizer. Hold in position.
4. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4G
NOTE: When lowering stabilizers, lower evenly to full stroke, then raise.
1. Lower left stabilizer. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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Test 4H
1. Lower right stabilizer. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4I
1. Roll backhoe bucket to dump position. Hold in posi-
tion.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4J
1. Roll backhoe bucket to dig position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4K
1. Position dipper in full extended position. Hold in po-
sition.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4L
1. Position dipper in full position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4M
1. Position boom in lower position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4N
1. Position boom in raised position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4P
1. Reverse direction on bi-directional valve.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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NOTE: Compare test results from Test 2B and Tests 4A thru 4P. If results vary more than 3.8 l/min (1 US gpm), a
problem in circuit exists.
Test 5A
1. Run engine at high idle. Close load valve on flowme-
ter.
2. Record bar (psi) results on Flowmeter Check Sheet.
Test 5B
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
Flowmeter Check Sheet.
Test 5C
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 5D
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.
3. Monitor flowmeter. When flow begins to decrease
by several l/min (gpm), record bar (psi) results on
Flowmeter Check Sheet.
Test 5E
1. Continue to slowly close flowmeter 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 - 193 bar (2349 - 2800 psi) is expected. If pressure is not to specification, adjust
quick coupler relief valve.
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Test 6A
1. Turn steering wheel to full right. Hold against stop.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 6B
1. Turn steering wheel to full left. Hold against stop.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
3. Extend backhoe bucket fully to dump position. Place
loader and backhoe bucket on ground.
Test 6C
1. Retract loader lock pins.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 6D
1. Extend loader lock pins.
2. Record l/min (gpm) results on Flowmeter Check
Sheet.
Test 6E
1. Retract backhoe bucket lock pins.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 6F
1. Extend backhoe bucket lock pins.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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.
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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.
Notes:
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Notes:
Notes:
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Notes:
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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.
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Prior operation:
PRIMARY HYDRAULIC POWER SYSTEM - Prepare Machine Preparation, All 580SN, 580SN WT and 590SN
machines (A.10.A).
Test 1A
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.
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 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 main relief valve. If readings from test 2A are not within 10 percent
of 2B reading, replace relief valve.
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RCPH11TLB002GAM 1
Test 2C
NOTE: If pressure is not in specification, adjust normal relief valve on Power Lift control valve.
4. Activate Power Lift.
5. Continue to close load valve on flowmeter.
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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.
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
2. Hold loader on demand and open the load valve. Ad-
just engine speed to 2000 RPM.
3. Monitor flowmeter. Record results on Flowmeter
Check Sheet.
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Test 3B
1. Continue to run engine at 2000 RPM. Slowly close
load valve until pressure is 138 bar (2000 psi).
2. Monitor flowmeter. Record results on Flowmeter
Check Sheet.
3. Divide the flow reading at 138 bar (2000 psi) by
recorded flow reading at 0 bar (0 psi).
NOTE: Pump efficiency is calculated by multiplying result by 100. If pump efficiency is greater than 80 percent, pump
is good. Continue to next test. If pump efficiency is less than 80 percent, repair or replace pump before continuing to
next test.
Test 4A
4. Run engine at 2000 RPM. Increase pressure on
flowmeter to 138 bar (2000 psi).
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
Flowmeter Check Sheet.
Test 4C
1. Position loader approximately 45.7 cm (18 in) above
ground level. Hold bucket in rollback position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4D
1. Hold bucket in dump position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4E
1. Hold clam in open position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 4F
1. Close clam and hold in closed position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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.
3. Run engine at 2000 RPM. Increase pressure on
flowmeter to 138 bar (2001.0 psi).
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Test 5A
1. Position backhoe to left side.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5B
1. Position backhoe to right side.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5C
1. If equipped with extend-a-hoe option, position out-
ward and hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5D
1. If equipped with extend-a-hoe option, retract and
hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5E
1. Raise left stabilizer. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5F
3. Raise right stabilizer. Hold in position.
4. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5G
NOTE: When lowering stabilizers, lower evenly to full stroke, then raise.
1. Lower left stabilizer. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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Test 5H
1. Lower right stabilizer. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5I
1. Roll backhoe bucket to dump position. Hold in posi-
tion.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5J
1. Roll backhoe bucket to dig position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5K
1. Position dipper in full extended position. Hold in po-
sition.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5L
1. Position dipper in full position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5M
1. Position boom in lower position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5N
1. Position boom in raised position. Hold in position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5O
1. If equipped with bi-directional auxiliary hydraulic, un-
hook quick disconnect couplers or cap lines. Hold
button in out position.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 5P
1. Reverse direction on bi-directional valve.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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
problem in circuit exists.
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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
Flowmeter Check Sheet.
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
3. Open flowmeter load valve to fully open position.
4. If equipped with front or rear hydraulic coupler, en-
gage. Slowly close flowmeter load valve.
5. Monitor flowmeter. When flow begins to decrease
by several l/min (gpm), record bar (psi) results on
Flowmeter Check Sheet.
Test 6E
1. Continue to slowly close flowmeter 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 - 193 bar (2349 - 2800 psi) is expected. If pressure is not to specification, adjust
quick coupler relief valve.
Test 7A
5. Turn steering wheel to full right. Hold against stop.
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Test 7B
7. Turn steering wheel to full left. Hold against stop.
8. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
9. Extend backhoe bucket fully to dump position. Place
loader and backhoe bucket on ground.
Test 7C
1. Retract loader lock pins.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
Test 7F
1. Extend backhoe bucket lock pins.
2. Monitor flowmeter. Record l/min (gpm) results on
Flowmeter Check Sheet.
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.
NOTE: For Pilot Controlled machines, replace the closed center plug in the backhoe valve with the standard flushing
valve components removed earlier.
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RCPH11TLB001GAM 3
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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, All 580SN, 580SN WT and 590SN
machines (A.10.A) for procedure.
Notes:
Notes:
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Notes:
Notes:
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Notes:
Notes:
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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
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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.
20. Start the engine and set engine speed to 2000 RPM.
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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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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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
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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.
26. Start the engine and set engine speed to 2000 RPM.
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.
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 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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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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RCPH10TLB334ABL 1
RCPH10TLB335ABL 2
RCPH10TLB336ABL 3
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RCPH10TLB337ABL 4
RCPH10TLB338ABL 5
RCPH10TLB332ABL 6
RCPH10TLB333ABL 7
Next operation:
Remote valve - Install (A.10.A)
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RCPH10TLB338ABL 1
RCPH10TLB339ABL 2
RCPH10TLB337ABL 3
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RCPH10TLB335ABL 4
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RCPH10TLB318ABL 1
5. Pull the floor mat away from the loader control cover.
RCPH10TLB076AAM 2
RCPH10TLB447ABL 3
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RCPH10TLB314ABL 4
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
RCPH10TLB001BAN 10
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RCPH10TLB428AAF 11
RCPH10TLB004GAN 12
RCPH10TLB077AAM 13
RCPH10TLB327ABL 14
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RCPH10TLB328ABL 15
RCPH10TLB045GAM 16
Next operation:
Remote valve - Install (A.10.A)
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RCPH10TLB045GAM 1
RCPH10TLB328ABL 2
RCPH10TLB075AAM 3
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RCPH10TLB326ABL 4
RCPH10TLB445ABL 5
RCPH10TLB428AAF 6
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RCPH10TLB001BAN 7
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
RCPH10TLB314ABL 11
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.
16. Lower the loader bucket to the floor and stop the
engine.
RCPH10TLB318ABL 13
17. Check for oil leakage at the loader control valve.
18. Check the oil level in the hydraulic reservoir. Add oil
as required. See Capacities () for specifications.
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RCPH10TLB004GAN 1
Next operation:
Remote valve - Install (A.10.A)
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RCPH10TLB040GAM 1
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RCPH10TLB331ABL 1
RCPH10TLB329ABL 2
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RCPH10TLB330ABL 3
Next operation:
Remote valve - Install (A.10.A)
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RCPH10TLB330ABL 1
RCPH10TLB329ABL 2
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RCPH10TLB316ABL 1
RCPH10TLB317ABL 2
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9. Pull the rubber boot (1) up and remove the rear cover
(3) and front cover (2).
RCPH10TLB315ABL 3
RCPH10TLB078GAL 4
Next operation:
Remote valve - Install (A.10.A)
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Prior operation:
Remote valve - Remove (A.10.A)
RCPH10TLB078GAL 1
RCPH10TLB317ABL 2
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RCPH10TLB316ABL 3
RCPH10TLB453ABL 4
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RCPH10TLB452ABL 1
RCPH10TLB428ABL 2
RCPH10TLB429ABL 3
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
RCPH10TLB432ABL 6
RCPH10TLB433ABL 7
RCPH10TLB434ABL 8
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RCPH10TLB435ABL 9
RCPH10TLB436ABL 10
11. Push down on the retainer cup and twist the plunger
out of the cup.
RCPH10TLB440ABL 11
RCPH10TLB441ABL 12
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RCPH10TLB442ABL 13
14. Turn control unit over in the vise and remove the
lower body.
RCPH10TLB437ABL 14
RCPH10TLB439ABL 15
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RCPH10TLB438ABL 16
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RCPH10TLB001CAM 1
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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
RCPH10TLB419ABL 2
RCPH10TLB420ABL 3
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RCPH10TLB421ABL 4
RCPH10TLB422ABL 5
RCPH10TLB423ABL 6
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RCPH10TLB424ABL 1
RCPH10TLB425ABL 2
RCPH10TLB426ABL 3
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.
1. Park the machine on a level surface. Put the back-
hoe in the transport position. Lower the loader
bucket to the floor.
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-
TRAL position for 15 seconds.
C. Repeat steps A and B until the tempera-
ture of the oil is 51 °C (124 °F) or the side
of the reservoir is very warm.
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)
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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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
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
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RCPH10TLB428AAF 1
RCPH10TLB320ABL 2
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RCPH10TLB323ABL 3
RCPH11TLB006GAM 4
RCPH10TLB325ABL 5
Next operation:
Hydraulic pump - Install (A.10.A)
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RCPH10TLB325ABL 1
RCPH10TLB323ABL 2
RCPH11TLB006GAM 3
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RCPH10TLB320ABL 4
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RCPH10TLB428AAF 1
RCPH10TLB013FAM 2
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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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RCPH10TLB013FAM 1
RCPH10TLB012BAM 2
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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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RCPH10TLB341ABL 1
RCPH10TLB342ABL 2
RCPH10TLB344ABL 3
Next operation:
Hydraulic pump - Inspect (A.10.A)
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RCPH10TLB345ABL 1
Next operation:
Hydraulic pump - Assemble (A.10.A)
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RCPH10TLB343ABL 1
RCPH10TLB342ABL 2
RCPH10TLB341ABL 3
Next operation:
Hydraulic pump - Disassemble (A.10.A)
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Next operation:
Pump Disassembly
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RCPH11TLB001BAL 1
RCPH11TLB002BAL 2
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RCPH11TLB003BAL 3
RCPH11TLB004BAL 4
RCPH10TLB349ABL 5
RCPH10TLB350ABL 6
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RCPH11TLB005BAL 7
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
RCPH10TLB364ABL 12
Next operation:
Hydraulic pump - Inspect (A.10.A)
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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
RCPH10TLB450ABL 2
RCPH10TLB449ABL 3
Next operation:
Hydraulic pump - Assemble (A.10.A)
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RCPH10TLB360ABL 1
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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RCPH10TLB363ABL 4
RCPH10TLB365ABL 5
RCPH11TLB007BAL 6
RCPH10TLB370ABL 7
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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
RCPH11TLB011BAL 10
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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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RCPH10CCH700BAO 1
RCPH10CCH699BAO 2
RCPH10CCH702BAO 3
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RCPH10TLB029BAM 4
RCPH10TLB030BAM 5
RCPH10CCH698BAO 6
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RCPH10CCH703BAO 7
RCPH10TLB024BAM 8
RCPH10TLB023BAM 9
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RCPH10TLB021BAM 10
RCPH10CCH704BAO 11
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
RCPH10CCH697BAO 14
RCPH10CCH696BAO 15
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RCPH10TLB027BAM 16
RCPH10TLB026BAM 17
RCPH10TLB025BAM 18
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RCPH10TLB022BAM 19
RCPH10TLB021BAM 20
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
RCPH10TLB018BAM 23
RCPH10TLB017BAM 24
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RCPH10TLB016BAM 25
RCPH10TLB015BAM 26
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Prior operation:
Hydraulic pump - Prepare Work Surface (A.10.A)
RCPH10TLB043GAM 1
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RCPH10TLB015BAM 2
RCPH10TLB018BAM 3
RCPH10TLB021BAM 4
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RCPH10CCH698BAO 5
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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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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RCIL10TLB016BAF 1
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Next operation:
Accumulator - Disassemble - Ride control (A.10.A)
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Next operation:
Accumulator - Inspect (A.10.A)
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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
Next operation:
Accumulator - Assemble (A.10.A)
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Accumulator - Assemble
Prior operation:
Accumulator - Inspect (A.10.A)
RCIL10TLB018BAF 1
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RCPH11TLB001BAM 2
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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RCPH10TLB008GAM 1
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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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CAS10899 1
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CAS10899 1
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RCPH10TLB392ABL 1
RCPH10TLB393ABL 2
RCPH10TLB394ABL 3
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RCPH10TLB395ABL 4
RCPH10TLB396ABL 5
RCPH10TLB397ABL 6
RCPH10TLB398ABL 7
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RCPH10TLB399ABL 8
RCPH10TLB400ABL 9
RCPH10TLB401ABL 10
RCPH10TLB402ABL 11
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RCPH10TLB403ABL 12
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RCPH10TLB404ABL 1
RCPH10TLB405ABL 2
RCPH10TLB406ABL 3
RCPH10TLB407ABL 4
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RCPH10TLB408ABL 5
RCPH10TLB409ABL 6
RCPH10TLB410ABL 7
RCPH10TLB411ABL 8
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RCPH10TLB412ABL 9
RCPH10TLB413ABL 10
RCPH10TLB414ABL 11
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RCPH10TLB415ABL 12
RCPH10TLB416ABL 13
RCPH10TLB417ABL 14
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RCPH10TLB392ABL 1
RCPH10TLB393ABL 2
RCPH10TLB394ABL 3
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RCPH10TLB395ABL 4
RCPH10TLB396ABL 5
RCPH10TLB398ABL 6
RCPH10TLB400ABL 7
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RCPH10TLB401ABL 8
RCPH10TLB402ABL 9
RCPH10TLB403ABL 10
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RCPH10TLB008CAM 1
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RCPH10TLB008CAM 1
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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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Index
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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
PRIMARY HYDRAULIC POWER SYSTEM - Prepare Machine Preparation, All 580SN, 580SN WT and 590SN
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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580N
580SN WT
580SN
590SN
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Contents
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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RCPH10TLB001AAL 1
RCPH10TLB017AAL 2
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RCPH10TLB004FAL 1
RCPH10TLB005FAL 2
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RCPH10TLB021AAL 3
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SYSTEM
RCPH10TLB012GAM 1
580SN, 590SN WT and 590 SN Extendahoe hose routing
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RCPH10TLB002AAL 1
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RCPH10TLB018AAL 1
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RCPH10TLB006FAL 1
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RCPH10TLB006FAL 1
Quick coupler cylinder
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RCPH10TLB003FAL 2
Coupler cylinder piston
RCPH10TLB020AAL 3
Coupler cylinder gland
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RCPH10TLB002FAL 1
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RCPH10TLB006CAM 1
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RCPH10TLB002HAM 1
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Next operation:
Coupler - Install (A.12.A)
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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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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
(10) from the piston.
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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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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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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RCPH10TLB006FAL 2
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RCPH10TLB003AAL 1
RCPH10TLB004AAL 2
RCPH10TLB005AAL 3
RCPH10TLB006AAL 4
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RCPH10TLB007AAL 5
RCPH10TLB008AAL 6
RCPH10TLB009AAL 7
RCPH10TLB010AAL 8
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RCPH10TLB011AAL 9
RCPH10TLB012AAL 10
Next operation:
Remote valve - Inspect (A.12.A)
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RCPH10TLB016AAL 1
1. Plug 3. Spring
2. O-ring 4. Crossover spool
RCPH10TLB014AAL 2
RCPH10TLB015AAL 3
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RCPH10TLB013AAL 4
Next operation:
Remote valve - Assemble (A.12.A)
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RCPH10TLB013AAL 1
RCPH10TLB012AAL 2
RCPH10TLB011AAL 3
RCPH10TLB015AAL 4
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RCPH10TLB010AAL 5
RCPH10TLB009AAL 6
RCPH10TLB014AAL 7
RCPH10TLB008AAL 8
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RCPH10TLB009AAL 9
RCPH10TLB016AAL 10
RCPH10TLB006AAL 11
RCPH10TLB005AAL 12
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RCPH10TLB004AAL 13
RCPH10TLB003AAL 14
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Index
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HYDRAULIC, PNEUMATIC, ELECTRICAL,
ELECTRONIC SYSTEMS - A
580N
580SN WT
580SN
590SN
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Contents
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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RCPH10TLB027AAM 1
X 6 connector
RCPH10TLB023AAM 2
RCPH10TLB025AAM 3
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X 12 connector
RCPH10TLB073AAM 4
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X 13 connector
RCPH10TLB073AAM 5
X 14 connector
RCPH10TLB073AAM 6
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X 16 connector
RCPH10TLB002BAM 7
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X 17 connector
RCPH10TLB002BAM 8
X 20 connector
RCPH10TLB033AAM 9
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X 21 connector
RCPH10TLB035AAM 10
X 22 connector
RCPH10TLB036AAM 11
X 23 connector
RCPH10TLB002AAM 12
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X 24 connector
RCPH10TLB002AAM 13
X 26 connector
RCPH10TLB002AAM 14
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X 27 connector
RCPH10TLB002AAM 15
X 28 connector
RCPH10TLB032AAM 16
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X 29 connector
RCPH10TLB031AAM 17
X 30 connector
RCPH10TLB058AAM 18
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X 33 connector
RCPH10TLB030AAM 19
X 34 connector
RCPH10TLB028AAM 20
X 35 connector
RCPH10TLB028AAM 21
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X 37 connector
RCPH10TLB002AAM 22
X 39 connector
RCPH10TLB018AAM 23
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X 51 connector
RCPH10TLB026AAM 24
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X 98 connector
RCPH10TLB002AAM 25
X 112 connector
RCPH10TLB002AAM 26
X 123 connector
RCPH10TLB074AAM 27
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X 143 connector
RCPH10TLB002AAM 28
X 181 connector
RCPH10TLB029AAM 29
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X 182 connector
RCPH10TLB029AAM 30
X 184 Connector
RCPH10TLB058AAM 31
X 186 connector
RCPH10TLB002AAM 32
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X 221 connector
RCPH10TLB034AAM 33
X 222 connector
RCPH10TLB034AAM 34
X 274 connector
RCPH10TLB002AAM 35
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X 300 connector
RCPH10TLB001BAM 36
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X 345 connector
RCPH10TLB022AAM 37
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RCPH10TLB072AAM 1
Connector 38
RCPH10TLB002AAM 2
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Connector 40
RCPH10TLB003AAM 3
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Connector 118
RCPH10TLB002AAM 4
Connector 132
RCPH10TLB002AAM 5
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Connector 133
RCPH10TLB005AAM 6
Connector 134
RCPH10TLB005AAM 7
Connector 137
RCPH10TLB002AAM 8
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Connector 138
RCPH10TLB006AAM 9
Connector 139
RCPH10TLB037AAM 10
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Connector 140
RCPH10TLB038AAM 11
Connector 141
RCPH10TLB038AAM 12
Connector 142
RCPH10TLB002AAM 13
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Connector 144
RCPH10TLB002AAM 14
Connector 145
RCPH10TLB002AAM 15
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Connector 146
RCPH10TLB001AAM 16
Connector 147
RCPH10TLB073AAM 17
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Connector 155
RCPH10TLB004AAM 18
Connector 342
RCPH10TLB002AAM 19
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RCPH10TLB062AAM 20
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RCPH10TLB003AAM 1
X 52 connector
RCPH10TLB018AAM 2
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X 53 connector
RCPH10TLB010AAM 3
X 54 connector
RCPH10TLB015AAM 4
X 55 connector
RCPH10TLB011AAM 5
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HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM
X 56 connector
RCPH10TLB018AAM 6
X 57 connector
RCPH10TLB010AAM 7
X 58connector
RCPH10TLB018AAM 8
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X 59 connector
RCPH10TLB019AAM 9
X 60connector
RCPH10TLB019AAM 10
X 61 connector
RCPH10TLB019AAM 11
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X 63 connector
RCPH10TLB009AAM 12
X 65 connector
RCPH10TLB020AAM 13
X 68 connector
RCPH10TLB008AAM 14
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RCPH10TLB007AAM 15
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X 76 connector
RCPH10TLB010AAM 16
X 77 connector
RCPH10TLB010AAM 17
X 78 connector
RCPH10TLB010AAM 18
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X 79 connector
RCPH10TLB010AAM 19
X 80 connector
RCPH10TLB010AAM 20
X 82 connector
RCPH10TLB014AAM 21
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X 83 connector
RCPH10TLB017AAM 22
X 86 connector
RCPH10TLB016AAM 23
X 93 connector
RCPH10TLB010AAM 24
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X 99 connector
RCPH10TLB013AAM 25
X 122 connector
RCPH10TLB021AAM 26
X 220 connector
RCPH10TLB012AAM 27
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X 275 connector
RCPH10TLB010AAM 28
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RCPH10TLB040AAM 1
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
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X 169 connector
RCPH10TLB020AAM 7
X 170 connector
RCPH10TLB011AAM 8
X 171 connector
RCPH10TLB011AAM 9
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HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM
X 173 connector
RCPH10TLB020AAM 10
X 174 connector
RCPH10TLB055AAM 11
X 176 connector
RCPH10TLB055AAM 12
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X 450 connector
RCPH10TLB010AAM 13
X 451 connector
RCPH10TLB010AAM 14
RCPH10TLB056AAM 15
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RCPH10TLB010AAM 1
Connector 178
RCPH10TLB010AAM 2
Connector 179
RCPH10TLB052AAM 3
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Connector 180
RCPH10TLB052AAM 4
Connector 188
RCPH10TLB052AAM 5
Connector 189
RCPH10TLB052AAM 6
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Connector 505
RCPH10TLB051AAM 7
RCPH10TLB056AAM 8
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RCPH10TLB013AAM 1
X 223 connector
RCPH10TLB056AAM 2
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RCPH10TLB022AAM 1
Connector 102
RCPH10TLB044AAM 2
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Connector 103
RCPH10TLB011AAM 3
Connector 104
RCPH10TLB041AAM 4
Connector 105
RCPH10TLB043AAM 5
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Connector 109
RCPH10TLB042AAM 6
Connector 110
RCPH10TLB045AAM 7
Connector 111
RCPH10TLB048AAM 8
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Connector 116
RCPH10TLB046AAM 9
Connector 117
RCPH10TLB047AAM 10
Connector 129
RCPH10TLB048AAM 11
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Connector 161
RCPH10TLB049AAM 12
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RCPH10TLB022AAM 1
Connector 501
RCPH10TLB049AAM 2
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RCPH10TLB057AAM 1
Connector 91
RCPH10TLB058AAM 2
Connector 432
RCPH10TLB018AAM 3
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Connector 433
RCPH10TLB018AAM 4
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RCPH10TLB054AAM 1
Connector 435
RCPH10TLB018AAM 2
Connector 446
RCPH10TLB015AAM 3
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Connector 447
RCPH10TLB057AAM 4
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RCPH10TLB058AAM 1
Connector 436
RCPH10TLB018AAM 2
Connector 442
RCPH10TLB057AAM 3
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RCPH10TLB018AAM 1
Connector 443
RCPH10TLB059AAM 2
Connector 441
RCPH10TLB010AAM 3
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RCPH10TLB060AAM 1
Connector 211
RCPH10TLB015AAM 2
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Connector 215
RCPH10TLB046AAM 3
Connector 216
RCPH10TLB047AAM 4
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RCPH10TLB060AAM 1
Connector 211
RCPH10TLB015AAM 2
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RCPH10TLB010AAM 1
Connector 453
RCPH10TLB010AAM 2
Connector 504
RCPH10TLB063AAM 3
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Connector 512
RCPH10TLB010AAM 4
Connector 515
RCPH10TLB010AAM 5
Connector 520
RCPH10TLB061AAM 6
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Connector 521
RCPH10TLB053AAM 7
Connector 522
RCPH10TLB061AAM 8
Connector 523
RCPH10TLB061AAM 9
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Connector 524
RCPH10TLB061AAM 10
Connector 525
RCPH10TLB061AAM 11
Connector 526
RCPH10TLB053AAM 12
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Connector 527
RCPH10TLB010AAM 13
Connector 528
RCPH10TLB061AAM 14
RCPH10TLB062AAM 15
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RCPH10TLB010AAM 1
Connector 453
RCPH10TLB010AAM 2
Connector 504
RCPH10TLB063AAM 3
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Connector 512
RCPH10TLB010AAM 4
Connector 513
RCPH10TLB010AAM 5
Connector 514
RCPH10TLB010AAM 6
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Connector 151
RCPH10TLB010AAM 7
Connector 520
RCPH10TLB061AAM 8
Connector 521
RCPH10TLB053AAM 9
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Connector 522
RCPH10TLB061AAM 10
Connector 523
RCPH10TLB061AAM 11
Connector 524
RCPH10TLB061AAM 12
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Connector 525
RCPH10TLB061AAM 13
Connector 526
RCPH10TLB053AAM 14
Connector 527
RCPH10TLB010AAM 15
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Connector 528
RCPH10TLB061AAM 16
RCPH10TLB062AAM 17
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RCPH10TLB069AAM 1
Connector 401
RCPH10TLB064AAM 2
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Connector 402
RCPH10TLB064AAM 3
Connector 403
RCPH10TLB064AAM 4
Connector 404
RCPH10TLB064AAM 5
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Connector 405
RCPH10TLB064AAM 6
Connector 407
RCPH10TLB064AAM 7
Connector 408
RCPH10TLB064AAM 8
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Connector 409
RCPH10TLB067AAM 9
Connector 410
RCPH10TLB010AAM 10
Connector 411
RCPH10TLB010AAM 11
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Connector 412
RCPH10TLB010AAM 12
Connector 413
RCPH10TLB010AAM 13
Connector 414
RCPH10TLB010AAM 14
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Connector 417
RCPH10TLB066AAM 15
Connector 418
RCPH10TLB066AAM 16
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Connector 419
RCPH10TLB068AAM 17
Connector 420
RCPH10TLB010AAM 18
Connector 421
RCPH10TLB010AAM 19
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Connector 422
RCPH10TLB065AAM 20
Connector 423
RCPH10TLB065AAM 21
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Connector 424
RCPH10TLB030AAM 22
Connector 425
RCPH10TLB030AAM 23
Connector 426
RCPH10TLB067AAM 24
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Connector 430
RCPH10TLB018AAM 25
Connector 455
RCPH10TLB057AAM 26
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RCPH10TLB010AAM 1
Connector 193
RCPH10TLB010AAM 2
Connector 194
RCPH10TLB010AAM 3
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Connector 195
RCPH10TLB010AAM 4
Connector 196
RCPH10TLB020AAM 5
Connector 201
RCPH10TLB020AAM 6
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Connector 213
RCPH10TLB051AAM 7
Connector G207
RCPH10TLB062AAM 8
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RCPH10TLB010AAM 1
Connector 178
RCPH10TLB010AAM 2
Connector 179
RCPH10TLB061AAM 3
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Connector 180
RCPH10TLB061AAM 4
Connector 188
RCPH10TLB061AAM 5
Connector 189
RCPH10TLB061AAM 6
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Connector 505
RCPH10TLB051AAM 7
Connector 530
RCPH10TLB010AAM 8
Connector 531
RCPH10TLB010AAM 9
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RCPH10TLB062AAM 10
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RCPH10TLB070AAM 1
Connector 357
RCPH10TLB071AAM 2
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Connector 374
RCPH10TLB033AAM 3
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RCPH10TLB027AAM 1
Connector 3
RCPH10TLB056AAM 2
Connector 5
RCPH10TLB056AAM 3
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Connector 6
RCPH10TLB023AAM 4
Connector 7
RCPH10TLB056AAM 5
Connector 9
RCPH10TLB025AAM 6
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Connector 12
RCPH10TLB073AAM 7
Connector 13
RCPH10TLB073AAM 8
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Connector 14
RCPH10TLB073AAM 9
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Connector 16
RCPH10TLB002BAM 10
Connector 17
RCPH10TLB002BAM 11
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Connector 20
RCPH10TLB033AAM 12
Connector 21
RCPH10TLB035AAM 13
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Connector 22
RCPH10TLB035AAM 14
Connector 23
RCPH10TLB002AAM 15
Connector 24
RCPH10TLB002AAM 16
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Connector 26
RCPH10TLB002AAM 17
Connector 27
RCPH10TLB002AAM 18
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Connector 28
RCPH10TLB032AAM 19
Connector 29
RCPH10TLB031AAM 20
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Connector 30
RCPH10TLB058AAM 21
Connector 33
RCPH10TLB030AAM 22
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Connector 34
RCPH10TLB028AAM 23
Connector 35
RCPH10TLB028AAM 24
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Connector 37
RCPH10TLB037AAM 25
Connector 39
RCPH10TLB018AAM 26
Connector 51
RCPH10TLB026AAM 27
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Connector 72
RCPH10TLB056AAM 28
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Connector 73
RCPH10TLB056AAM 29
Connector 98
RCPH10TLB002AAM 30
Connector 112
RCPH10TLB002AAM 31
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Connector 123
RCPH10TLB021AAM 32
Connector 143
RCPH10TLB002AAM 33
Connector 149
RCPH10TLB024AAM 34
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Connector 150
RCPH10TLB026AAM 35
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Connector 181
RCPH10TLB029AAM 36
Connector 182
RCPH10TLB029AAM 37
Connector 184
RCPH10TLB058AAM 38
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Connector 186
RCPH10TLB002AAM 39
Connector 221
RCPH10TLB034AAM 40
Connector 222
RCPH10TLB034AAM 41
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Connector 274
RCPH10TLB002AAM 42
Connector 300
RCPH10TLB001BAM 43
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Connector 345
RCPH10TLB022AAM 44
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RCPH10TLB062AAM 45
RCPH10TLB062AAM 46
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RCIL10TLB001JAM 1
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RCIL10TLB002JAM 1
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RCIL10TLB003JAM 1
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RCIL10TLB004JAM 1
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RCIL10TLB005JAM 1
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RCIL10TLB006JAM 1
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RCIL10TLB007JAM 1
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RCIL10TLB008JAM 1
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RCIL10TLB009JAM 1
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RCIL10TLB010JAM 1
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RCIL10TLB011JAM 1
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RCIL10TLB012JAM 1
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RCIL10TLB013JAM 1
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RCIL10TLB014JAM 1
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RCIL10TLB015JAM 1
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RCIL10TLB016JAM 1
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RCIL10TLB017JAM 1
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RCIL10TLB018JAM 1
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RCIL10TLB019JAM 1
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RCIL10TLB020JAM 1
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RCIL10TLB021JAM 1
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RCIL10TLB022JAM 1
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RCIL10TLB023JAM 1
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RCIL10TLB024JAM 1
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RCIL10TLB025JAM 1
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RCIL10TLB026JAM 1
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Alternator - Remove
RCPH10TLB227AAF 1
RCPH11TLB001AAM 2
RCPH11TLB002AAM 3
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RCPH10TLB429AAF 4
RCPH10TLB356AAF 5
RCPH10TLB231ABL 6
Next operation:
Alternator - Install (A.30.A)
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Alternator - Install
Prior operation:
Alternator - Remove (A.30.A)
RCPH10TLB231ABL 1
RCPH10TLB429AAF 2
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RCPH10TLB291AAF 1
RCPH11TLB080AAL 2
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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.
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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!
Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.
Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen
battery.
Failure to comply could result in death or serious injury.
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.
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.
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RCPH10TLB291AAF 1
RCPH11TLB080AAL 2
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Battery - Disconnect
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.
Failure to comply could result in death or serious injury.
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.
Failure to comply could result in death or serious injury.
W0006A
RCPH11TLB001AAM 1
RCPH11TLB002AAM 2
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RCPH11TLB003AAM 3
Next operation:
Battery - Connect (A.30.A)
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Battery - Connect
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.
Failure to comply could result in death or serious injury.
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.
Failure to comply could result in death or serious injury.
W0006A
RCPH11TLB003AAM 1
RCPH11TLB002AAM 2
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RCPH11TLB001AAM 3
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Index
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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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ELECTRONIC SYSTEMS - A
580N
580SN WT
580SN
590SN
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Contents
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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3068-Cylinder 3 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3069-Cylinder 3 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3070-Cylinder 3 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3071-Cylinder 3 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3076-Cylinder 2 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3077-Cylinder 2 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3078-Cylinder 2 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3079-Cylinder 2 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3080-Cylinder 4 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3081-Cylinder 4 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3082-Cylinder 4 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3083-Cylinder 4 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
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
3196-Cylinder 3 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3200-Cylinder 4 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
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
3230-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
3231-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3232-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3233-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
3234-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
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
3283-Sensor Supply Voltage 2 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
3284-Sensor Supply Voltage 2 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
3285-Sensor Supply Voltage 3 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
3286-Sensor Supply Voltage 3 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
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
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
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
9005-EEPROM checksum failure, hour meter location 2, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . 625
9006-EEPROM checksum failure, hour meter location 3, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . 626
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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Context:
General fault code identification and response.
Cause:
General fault code description.
Solution:
BD08E038-01 1
BD08E036-01 2
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BD08E037-01 3
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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.
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.
(1) Inspect the engine air filter. Replace the filter if needed.
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RCPH10TLB036AAF 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
(2) Turn the key switch on. Engine off. The Air Filter Restriction fault code should no longer be Active.
(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) 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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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.
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.
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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
RCPH10TLB046FAM 4
Schematic legend
(1) Coolant Temperature Sensor (3) Chassis Ground, (sensor is internally
grounded to chassis ground)
(2) Instrument Cluster
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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
(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.
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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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).
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 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.
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(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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B. NOT OK – The pressure is above 27.6 bar (400 psi). Repair or replace air conditioning system. Return
to Step 1 to confirm elimination of fault.
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
Step 1 to confirm elimination of fault.
6. Check the A/C Relay
(2) Remove the A/C Relay K-008. Inspect the pins and wiring to the relay.
RCPH10TLB302AAF 5
(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. .
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 14 (A.30.A.88-C.20.E.14)
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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.
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.
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RCPH10TLB045AAF 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
(2) Instrument Cluster
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RCPH10TLB016GAM 5
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.
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.
Return to Step 1 to confirm elimination of fault.
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.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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Cause:
The Transmission Oil Temperature is above 115 °C (239 °F) for a period greater than 5 seconds.
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.
(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.
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.
BD08E063-01 4
NOTE: Power shift transmission. Bottom view of sensor look up.
(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.
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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
(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.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
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, the number of occurrences and engine hours of last
occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start the engine and actuate the throttle.
BD08E027-01 1
(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins and wiring for damage,
corrosion, abrasion or incorrect attachment.
(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.
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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
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
(2) Instrument Cluster
(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.
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.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(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.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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:
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, the number of occurrences and engine hours of last
occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
BD08E027-01 1
(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins.
(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.
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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 the throttle signal from the sensor.
RCPH10TLB017GAM 2
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) Breakout Tee
(2) Instrument Cluster
(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.
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.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(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.
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. 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.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
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, the number of occurrences and engine hours of last
occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
BD08E027-01 1
(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins.
(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.
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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 the throttle signal from the sensor.
RCPH10TLB017GAM 2
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) Breakout Tee
(2) Instrument Cluster
(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.
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 less than 0.5 volts at low idle. Replace the sensor and retest. Return to step 1 to
confirm elimination of fault.
4. Measure the throttle signal from the sensor to the Instrument Cluster.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(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.
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 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
elimination of fault.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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:
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, the number of occurrences and engine hours of last
occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
BD08E027-01 1
(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins.
(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.
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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. Measure the throttle signal from the sensor.
RCPH10TLB017GAM 2
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) Breakout Tee
(2) Instrument Cluster
(1) Connect the breakout 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. Wiggle the sensor harness
to reveal an intermittent condition.
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 there were voltage fluctuations or spikes as the throttle was moved. Replace the sensor. Return
to step 1 to confirm elimination of fault.
4. Measure the throttle signal from the sensor to the Instrument Cluster.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(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 throttle signal voltage changed from 0.55 volts to 4.2 volts. Temporarily replace the Instrument
Cluster and retest. Go to Step 1 to confirm elimination of the fault.
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 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
elimination of fault.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
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 code: Start and operate machine.
(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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B. NOT OK – The voltage is greater than 14.6 volts. Replace the alternator. Go to test Step 1 to confirm
elimination of fault.
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
elimination of fault.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
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 code: Start and operate machine.
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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.
B. NOT OK – The voltage is less than 11 volts. Replace the alternator.1 to confirm elimination of fault.
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 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
elimination of fault.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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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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.
3. Fault Code 1019 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 coolant temperature warning. Refer to the engine
troubleshooting guide for more information.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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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.
3. Fault Code 1020 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 transmission oil temperature warning. Refer to
the engine troubleshooting guide for more information.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
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Context:
Fuel temperature is greater than 82 °C (180 °F) for a period greater than 5 seconds. The Instrument Cluster will
Cause:
Fuel temperature is greater than 82 °C (180 °F) for a period greater than 5 seconds.
Solution:
1. Fault Code 1021 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 fuel temperature warning. Refer to the engine
troubleshooting guide for more information.
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
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:
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).
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.
RCPH10TLB048FAM 1
Schematic legend
(1) Foot Throttle (3) Dealer supplied breakout T
(2) Instrument Cluster
(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) 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
elimination of fault.
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.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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
system power up following the event.
Cause:
The Instrument Cluster detects a voltage less than 4.8 volts on the throttle 5 volt supply line (connector X-29, pin 18).
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 1024 is not recorded again. OK to return the machine to service.
RCPH10TLB048FAM 1
Schematic legend
(1) Foot Throttle (3) Dealer supplied breakout T
(2) Instrument Cluster
(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) 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
elimination of fault.
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.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
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, the number of occurrences and engine hours of last
occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
BD08E027-01 1
(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins.
(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.
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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 the throttle signal from the sensor.
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) Foot Throttle (3) Breakout Tee
(2) Instrument Cluster
(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 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.
4. Measure the throttle signal from the sensor to the Instrument Cluster.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(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.
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. 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.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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
3. Faulty reading from sensor.
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, the number of occurrences and engine hours of last
occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
BD08E027-01 1
(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins.
(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.
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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 the throttle signal from the sensor.
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) Foot Throttle (3) Breakout Tee
(2) Instrument Cluster
(1) Connect the breakout 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 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 less than 0.5 volts at low idle. Temporarily replace the sensor and retest. Return
to step 1 to confirm elimination of fault.
4. Measure the throttle signal from the sensor to the Instrument Cluster.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(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.
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 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
elimination of fault.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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).
Solution:
1. Verify that the fault code is still active. Cycle the key switch power. Refer to 0000 - Retrieving fault codes,
Backhoes.
BD08E041-01 1
(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.
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.
3. Measure the voltage at the hand throttle connector.
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RCPH10TLB050FAM 2
Schematic legend
(1) Hand Throttle (3) Dealer supplied breakout T
(2) Instrument Cluster
(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
confirm elimination of fault.
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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
replace the Instrument Cluster and retest. Go to 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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 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.
2. Failed Throttle sensor.
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.
BD08E041-01 1
(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 or 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.
3. Measure the voltage at the hand throttle connector.
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RCPH10TLB050FAM 2
Schematic legend
(1) Hand Throttle (3) Dealer supplied breakout T
(2) Instrument Cluster
(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. Temporarily replace the hand throttle and retest. Go to
Step 1 to confirm elimination of fault.
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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
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
replace the Instrument Cluster and retest. Go to 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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pin 17). 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 throttle signal less than 0.2 volts on the hand throttle signal line (connector X-29,
pin 17).
Solution:
1. Verify that the fault code is still active. Cycle the key switch power. Refer to 0000 - Retrieving fault codes,
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.
(2) Inspect the harness from the Instrument Cluster to the Hand Throttle. Verify that the harness is free of
damage, corrosion, abrasion or 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.
3. Measure the voltage at the hand throttle connector.
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RCPH10TLB050FAM 2
Schematic legend
(1) Hand Throttle (3) Dealer supplied breakout T
(2) Instrument Cluster
(3) Measure the voltage from pin A to pin C. The voltage should be approximately 5 volts.
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).
4. Measure the resistance of the signal wire.
(2) Disconnect the throttle sensor from the harness. Disconnect connector X-029 from the Instrument Cluster.
(3) Measure the resistance from X-029 pin 17 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(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.
5. Check the throttle signal from the sensor.
RCPH10TLB053FAM 3
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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RCPH10TLB050FAM 4
Schematic legend
(1) Hand Throttle (3) Breakout Tee
(2) Instrument Cluster
(1) Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pins 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.
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 less than 0.5 volts at low idle. Replace the sensor. Return to step 1 to confirm
elimination of fault.
6. Measure the throttle signal from the sensor to the Instrument Cluster.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(4) Turn the key switch ON, engine OFF. Measure the voltage from 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 approximately 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. Go to
Step 1 to confirm elimination of the fault.
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 less than 0.5 volts at low idle. 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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pin 17). 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 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.
2. Failed Throttle sensor.
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.
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.
(2) Inspect the harness from the Instrument Cluster to the Hand Throttle. Verify that the harness is free of
damage, corrosion, abrasion or 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.
3. Measure the voltage at the hand throttle connector.
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RCPH10TLB050FAM 2
Schematic legend
(1) Hand Throttle (3) Breakout Tee
(2) Instrument Cluster
(3) Measure the voltage from pin A to pin C. The voltage should be approximately 5 volts.
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).
4. Measure the resistance of the signal wire.
(2) Disconnect the throttle sensor from the harness. Disconnect connector X-029 from the Instrument Cluster.
(3) Measure the resistance from X-029 pin 17 to battery supply. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(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 battery supply. 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.
5. Check the throttle signal from the sensor.
RCPH10TLB053FAM 3
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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RCPH10TLB050FAM 4
Schematic legend
(1) Hand Throttle (3) Breakout Tee
(2) Instrument Cluster
(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).
(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.
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 less than 0.5 volts at low idle. Temporarily replace the sensor and retest. Return
to step 1 to confirm elimination of fault.
6. Measure the throttle signal from the sensor to the Instrument Cluster.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(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.
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 less than 0.5 volts at low idle. 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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pin 17).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 throttle signal less than 0.25 volts on the hand throttle signal line (connector X-29,
pin 17).
Solution:
1. Verify that the fault code is still active. Cycle the key switch power. Refer to 0000 - Retrieving fault codes,
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.
(2) Inspect the harness from the Instrument Cluster to the Hand Throttle. Verify that the harness is free of
damage, corrosion, abrasion or 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.
3. Measure the voltage at the hand throttle connector.
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RCPH10TLB050FAM 2
Schematic legend
(1) Hand Throttle (3) Breakout T
(2) Instrument Cluster
(3) Measure the voltage from pin A to pin C. The voltage should be approximately 5 volts.
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).
4. Measure the resistance of the signal wire.
(2) Disconnect the throttle sensor from the harness. Disconnect connector X-029 from the Instrument Cluster.
(3) Measure the resistance from X-029 pin 17 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(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.
5. Check the throttle signal from the sensor.
RCPH10TLB053FAM 3
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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RCPH10TLB050FAM 4
Schematic legend
(1) Hand Throttle (3) Dealer supplied breakout T
(2) Instrument Cluster
(1) Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pins 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 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 less than 0.5 volts at low idle. Replace the sensor. Return to step 1 to confirm
elimination of fault.
6. Measure the throttle signal from the sensor to the Instrument Cluster.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(4) Turn the key switch ON, engine OFF. Measure the voltage from 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 approximately 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.
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 less than 0.5 volts at low idle. 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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pin 17). 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 throttle signal less than 0.2 volts on the hand throttle signal line (connector X-29,
pin 17).
Solution:
1. Verify that the fault code is still active. Cycle the key switch power. Refer to 0000 - Retrieving fault codes,
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.
(2) Inspect the harness from the Instrument Cluster to the Hand Throttle. Verify that the harness is free of
damage, corrosion, abrasion or 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.
3. Measure the voltage at the hand throttle connector.
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RCPH10TLB050FAM 2
Schematic legend
(1) Hand Throttle (3) Breakout Tee
(2) Instrument Cluster
(3) Measure the voltage from pin A to pin C. The voltage should be approximately 5 volts.
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).
4. Measure the resistance of the signal wire.
(2) Disconnect the throttle sensor from the harness. Disconnect connector X-029 from the Instrument Cluster.
(3) Measure the resistance from X-029 pin 17 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(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.
(5) 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.
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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.
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.
C. NOT OK — The resistance measurement from step (5) 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.
5. Check the throttle signal from the sensor.
RCPH10TLB053FAM 3
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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RCPH10TLB050FAM 4
Schematic legend
(1) Hand Throttle (3) Dealer supplied breakout T
(2) Instrument Cluster
(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).
(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.
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 less than 0.5 volts at low idle. Replace the sensor. Return to step 1 to confirm
elimination of fault.
6. Measure the throttle signal from the sensor to the Instrument Cluster.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(4) Turn the key switch ON, engine OFF. Measure the voltage from 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 approximately 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.
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 less than 0.5 volts at low idle. 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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pin 17). 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 throttle signal less than 0.20 volts on the hand throttle signal line (connector X-29,
pin 17).
Solution:
1. Verify that the fault code is still active. Cycle the key switch power. Refer to 0000 - Retrieving fault codes,
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.
(2) Inspect the harness from the Instrument Cluster to the Hand Throttle. Verify that the harness is free of
damage, corrosion, abrasion or 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.
3. Measure the voltage at the hand throttle connector.
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RCPH10TLB050FAM 2
Schematic legend
(1) Hand Throttle (3) Breakout Tee
(2) Instrument Cluster
(3) Measure the voltage from pin A to pin C. The voltage should be approximately 5 volts.
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).
4. Measure the resistance of the signal wire.
(2) Disconnect the throttle sensor from the harness. Disconnect connector X-029 from the Instrument Cluster.
(3) Measure the resistance from X-029 pin 17 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(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.
5. Check the throttle signal from the sensor.
RCPH10TLB053FAM 3
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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RCPH10TLB050FAM 4
Schematic legend
(1) Hand Throttle (3) Dealer supplied breakout T
(2) Instrument Cluster
(1) Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pins 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.
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 less than 0.5 volts at low idle. Replace the sensor. Return to step 1 to confirm
elimination of fault.
6. Measure the throttle signal from the sensor to the Instrument Cluster.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(4) Turn the key switch ON, engine OFF. Measure the voltage from 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 approximately 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.
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 less than 0.5 volts at low idle. 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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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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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:
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.
Failure to comply could result in death or serious injury.
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
system power up following the event.
Cause:
The Instrument Cluster has detected the fuel sender resistance below 2 ohms for a period greater than 2 seconds.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
RCPH10TLB081AAM 1
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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
damage, corrosion, abrasion or 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.
3. Measure the resistance of the fuel level signal to chassis ground.
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.
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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(1). Tilt the cab and remove the fuel level sender from the tank.
(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.
Wiggle the harness during measurement to reveal an intermittent condition.
(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
Instrument Cluster and retest. Go to Step 1 to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
RCPH10TLB081AAM 1
(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
damage, corrosion, abrasion or 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.
3. Measure the resistance of the fuel level signal wire to chassis ground.
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.
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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(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.
Wiggle the harness during measurement to reveal an intermittent condition.
(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
Instrument Cluster and retest. Go to Step 1 to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
RCPH10TLB082AAM 1
(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.
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.
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RCPH10TLB052FAM 2
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.
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.
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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.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
1. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.
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
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 code: Start and operate machine.
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(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.
RCPH10TLB049FAM 4
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
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(1) Disconnect the Instrument Cluster Connector 2 (X 29). Inspect pins, wiring and connectors for damage,
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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
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(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(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
to reveal an intermittent condition.
(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.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive 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 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.
(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.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
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(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(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
to reveal an intermittent condition.
(3) Measure the resistance from pin 4 on connector X-029 to chassis ground. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive 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 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 and retest.
Go to Step 1.
(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.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
and the ECU. Repair or replace the harness 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.
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.
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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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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
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(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(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
to reveal an intermittent condition.
(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.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive 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 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.
(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.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
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(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(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
to reveal an intermittent condition.
(3) Measure the resistance from pin 4 on connector X-029 to chassis ground. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive 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 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 the 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 and retest.
Go to Step 1.
(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.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
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.
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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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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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:
CAN Data Link communications between the Instrument Cluster and the ECU have been lost. The Instrument Cluster
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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
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(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(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
to reveal an intermittent condition.
(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.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive 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 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 and retest.
Go to Step 1.
(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.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
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.
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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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with other CAN Data Link fault messages. The Instrument Cluster will illuminate the Danger Lamp and will
continually sound the audible alarm.
Cause:
CAN Data Link communications between the Instrument Cluster and the ECU have been lost. The Instrument Cluster
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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
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(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(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
to reveal an intermittent condition.
(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.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive 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 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 and retest.
Go to Step 1 to confirm elimination of the fault.
(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.
(2) Measure the resistance between pin 34 and pin 35 on the ECU. (Connector B). The resistance should be
between 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
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.
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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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:
CAN Data Link communications between the Instrument Cluster and the ECU have been lost. The Instrument Cluster
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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
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(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(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
to reveal an intermittent condition.
(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.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive 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 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 and retest.
Go to Step 1 to confirm elimination of the fault.
(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.
(2) Measure the resistance between pin 34 and pin 35 on the ECU. (Connector B). The resistance should be
between 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
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.
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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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with other CAN Data Link fault messages. The Instrument Cluster will illuminate the Danger Lamp and will
continually sound the audible alarm while the fault is active.
Cause:
CAN Data Link communications between the Instrument Cluster and the ECU have been lost. The Instrument Cluster
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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
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(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(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
to reveal an intermittent condition.
(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.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive 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 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 and retest.
Go to Step 1 to confirm elimination of the fault.
(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.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
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.
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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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 the fault.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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with other CAN Data Link fault messages. The Instrument Cluster will illuminate the Danger Lamp and will
continually sound the audible alarm while the fault is active.
Cause:
CAN Data Link communications between the Instrument Cluster and the ECU have been lost. The Instrument Cluster
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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
RCPH10TLB278AAF 1
RCPH10TLB138AAF 2
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
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(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 3
(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
to reveal an intermittent condition.
(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.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive 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 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 X-029 pin 3 and pin 4. 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 and retest.
Go to Step 1 to confirm elimination of the fault.
(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.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
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.
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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
The Coolant temp sensor signal to the ECU is either erratic or intermittent.
Solution:
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.
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.
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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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. Operation: Coolant temp sensor Test
Vehicle Status: Key Off Engine Off.
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.
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.
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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Cause:
The Coolant temperature sensor signal to the ECU is out of range of the upper threshold limit.
Solution:
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5. Short Circuit ECU engine connector 2 ECU engine connector 2 Open Circuit
(Pin: 15) (Pin: 26)
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.
A. If the resistance measurement does not approximately match the table, replace the sensor.
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.
A. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this
type, replace the ECU.
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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Cause:
The Coolant temperature sensor signal to the ECU is out of range of the lower threshold limit.
Solution:
A. If the resistance measurement does not approximately match the table, replace the sensor.
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.
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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.
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.
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 no other than normal display readings are indicated, erase the fault code and continue
operation.
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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.
3. Faulty ECU, supply voltages or grounds.
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.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace Boost Pressure sensor if damaged.
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.
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
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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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. Operation: Boost Pressure sensor Test
Vehicle Status: Key Off Engine Off.
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).
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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 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 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.
A. If the voltages and ground paths are correct and the Boost Pressure 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 Boost Pressure 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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Cause:
The Boost Pressure sensor signal to the ECU is out of range of the lower threshold limit.
1. Faulty sensor.
2. Faulty electrical wiring or connection.
3. Faulty ECU, supply voltages or grounds.
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.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace Boost Pressure sensor if damaged.
Remove LDFT 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.
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:
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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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. Operation: Boost Pressure sensor Test
Vehicle Status: Key Off Engine Off.
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).
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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 1 connector 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 DMM to the 1 connector. 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.
A. If the voltages and ground paths are correct and the Boost Pressure 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 Boost Pressure 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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Cause:
The Fuel temperature sensor signal to the ECU is out of the range of the upper threshold limit.
Solution:
A. If sensor resistance is within range leave connector KTF disconnected and continue with step 3.
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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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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Cause:
The Fuel temperature sensor signal to the ECU is out of the range of the lower threshold limit.
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.
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.
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
continuity measurements. See test table below.
Important Note:
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Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main
ECU connectors if this is not followed.
B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
5. Operation: Fuel temp sensor Test
Vehicle Status: Key Off Engine Off.
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.
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 6.
6. 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, 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:
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.
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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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).
7. 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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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.
3. Faulty ECU, supply voltages or grounds.
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.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace Boost Pressure sensor if damaged.
Remove LDFT 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.
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
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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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. 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 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 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.
A. If the voltages and ground paths are correct and the Boost Pressure 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 Boost Pressure 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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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.
2. Faulty electrical wiring or connection.
3. Faulty ECU with integrated APS, supply voltages or grounds.
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.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace Boost Pressure sensor if damaged.
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.
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
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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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. 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 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 DMM to the 1 connector. 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.
A. If the voltages and ground paths are correct and the Boost Press 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 Boost Pressure 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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Cause:
The Oil temp / press sensor pressure signal to the ECU is operating at the extreme low end of the signal range.
Solution:
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.
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.
Vehicle Status: Key On Engine Off.
Remove ODFT connector from the Oil temp / 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.
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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.
B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
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 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 DMM to 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.
A. If the voltages and ground paths are correct and the Oil temp / press 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 Oil temp / press sensor 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.
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.
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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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Cause:
The Oil temp / press sensor signal to the ECU is out of range of the upper threshold limit.
Solution:
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.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace OPS sensor if damaged.
Remove ODFT connector from the Oil temp / 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.
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.
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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. 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.
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.
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 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 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.
A. If the voltages and ground paths are correct and the Oil temp / press 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 Oil temp / press sensor 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.
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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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.
2. Faulty Oil temp / press sensor.
3. Faulty ECU, supply voltages or grounds.
Solution:
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.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace OPS sensor if damaged.
Remove ODFT connector from the Oil temp / 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.
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 the 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.
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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. 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 1 connector 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 DMM to 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.
A. If the voltages and ground paths are correct and the Oil temp / press 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 Oil temp / press sensor 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.
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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Cause:
The Oil temp / press sensor signal to the ECU is either erratic or intermittent.
Solution:
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.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace OPS sensor if damaged.
Remove ODFT connector from the Oil temp / 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.
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 the 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.
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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. 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 1 connector 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 DMM to the 1 connector. 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.
A. If the voltages and ground paths are correct and the Oil temp / press 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 Oil temp / press sensor 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.
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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Cause:
The Oil temp / press sensor signals to the ECU are both operating in the extreme upper portion of signal range.
Solution:
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.
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.
Vehicle Status: Key On Engine Off.
Remove ODFT connector from the Oil temp / 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.
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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.
B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
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 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 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.
A. If the voltages and ground paths are correct and the Oil temp / press 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 Oil temp / press sensor 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.
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.
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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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Cause:
The Oil temp / press and Coolant temp sensor signals to the ECU are out of range with respect to each other.
Solution:
A. If any of the errors exist, resolve the existing error. Then determine if this error has also been resolved.
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.
A. If damage is 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.
Remove ODFT connector from the Oil temp / 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.
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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.
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 Faulty Wiring.
Vehicle status: Key Off Engine Off.
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.
B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
6. 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 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 DMM to 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.
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A. If the voltages and ground paths are correct and the Oil temp / press 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 Oil temp / press sensor 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.
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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Cause:
The Oil temp / press sensor signal to the ECU is out of range of the upper threshold limit.
Solution:
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.
A. If damage is 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.
Remove ODFT connector from the Oil temp / 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.
Remove and perform continuity tests between connectors ODT 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.
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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. 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 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 DMM to 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.
A. If the voltages and ground paths are correct and the Oil temp / press 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 Oil temp / press sensor 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.
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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Cause:
The Oil temp / press sensor signal to the ECU is out of range of the lower threshold limit.
Solution:
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.
A. If damage is 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.
Remove ODFT connector from the Oil temp / 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.
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.
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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. 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 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 DMM to 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.
A. If the voltages and ground paths are correct and the Oil temp / press 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 Oil temp / press sensor 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.
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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Cause:
The Boost Pressure sensor signal to the ECU is out of range of the lower threshold limit.
1. Faulty sensor.
2. Faulty electrical wiring or connection.
3. Faulty ECU, supply voltages or grounds.
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.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace Boost Pressure sensor if damaged.
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.
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
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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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. 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 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 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.
A. If the voltages and ground paths are correct and the Boost Pressure 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 Boost Pressure 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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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.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for Active fault codes: Start and operate machine.
RCPH10TLB301AAF 1
A. NOT OK – Replace fuse. Return to Step 1 to confirm elimination of fault. If fuse blows again, go to Step 4
B. OK – Go to Step 4.
4. Check ground circuit.
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RCPH10TLB301AAF 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
the harness during measurement to reveal an intermittent condition.
A. NOT OK – Determine the break between connector and ground. Return to Step 1 to confirm elimination
of fault.
B. OK – Go to Step 5.
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 .
A. NOT OK – Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
B. OK – Go to Step 6.
6. Check circuit to Fuse Block.
RCPH10TLB302AAF 3
(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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
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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.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for Active fault codes: Start and operate machine.
BD08E024-01 1
A. NOT OK – Replace fuse. Return to Step 1 to confirm elimination of fault. If fuse blows again, go to Step 4
B. OK – Go to Step 4.
4. Check ground circuit.
BD08F241-01 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
the harness during measurement to reveal an intermittent condition.
A. NOT OK – Determine the break between connector and ground. Return to Step 1 to confirm elimination
of fault.
B. OK – Go to Step 5.
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 .
A. NOT OK – Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
B. OK – Go to Step 6.
6. Check circuit to Fuse Block.
BD08E024-01 3
(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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
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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:
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.
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.
(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.
B. OK – Go to Step 3.
3. Replace the engine control module.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
Solution:
1. Verify that fault code 3052 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.
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.
(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.
A. NOT OK – Check fuse F-001 and wiring to ECU. Return to Step 1 to confirm elimination of fault.
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B. OK – Go to Step 3.
3. Test alternator. Refer to Alternator - Malfunction (A.30.A).
B. OK – Go to Step 4.
4. Replace the engine control module.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
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.
(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.
A. NOT OK – Check fuse F-001 and wiring to ECU. Return to Step 1 to confirm elimination of fault.
B. OK – Go to Step 3.
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B. OK – Go to Step 4.
4. Replace the engine control module.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the injector output power driver
stage.
Solution:
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, 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.
3. 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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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.
Solution:
Inspect connector housing body/latch, pins and wiring harness for damage or corrosion.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection.
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.
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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.
A. If resistance test was not successful, repair wiring harness between ECU harness connector 3 and con-
nector VC1.
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.
A. If resistance test was successful, repair the internal harness between the Cylinder #1 injector and the
connector INJ1.
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.
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.
Vehicle Status: Key On Engine Off.
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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.
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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.
Failure to comply could result in death or serious injury.
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.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
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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,
abrasion, corrosion or incorrect attachment.
(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
(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.
(4) Measure the resistance from ECU connector A, pin 2, to injector connector pin 2. 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
NOTE: During installation of valve cover, tighten mounting nuts to a torque of 20 - 30 Nm (15 - 22 lb ft).
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
elimination of fault.
B. OK— Go to Step 4.
4. Check injector.
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(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.
B. OK— Go to Step 5.
5. Replace the engine control module.
Prior to changing the engine control module contact Technical Services Group for further assistance.
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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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
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 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
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
injector output power driver stage.
Solution:
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.
8. 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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Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the injector output power driver
stage.
Solution:
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, 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.
3. 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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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.
Solution:
Inspect connector housing body/latch, pins and wiring harness for damage or corrosion.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection.
Remove connector VC2 and perform an injector resistance test on the Cylinder #3/4 injector connector VC2.
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.
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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.
A. If resistance test was not successful, repair wiring harness between ECU harness connector 3 and con-
nector VC2.
Remove valve cover from the top of the head to allow access to the internal injector wiring harness. Remove the
Cylinder #3 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.
A. If resistance test was successful, repair the internal harness between the Cylinder #3 injector and the
connector INJ3.
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.
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.
Vehicle Status: Key On Engine Off.
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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.
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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.
Failure to comply could result in death or serious injury.
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.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
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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,
abrasion, corrosion or incorrect attachment.
(2) Disconnect injector connectors for cylinders 3 and 4. Inspect pins, wiring and connectors for damage, abra-
sion, corrosion or incorrect attachment.
BD08J014-01 2
(3) Check for open circuit from ECU connector A, pin 16 to injector connector pin 1. The resistance should be
less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Check for open circuit from ECU connector A, pin 1 to injector connector pin 2. The resistance should be
less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(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.
A. NOT OK— Determine the break or short 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 3.
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BD08J013-01 3
NOTE: During installation of valve cover, tighten mounting nuts to a torque of 20 - 30 Nm (15 - 22 lb ft).
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(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.
A. NOT OK— Determine the break or short between connectors and repair. Return to Step 1 to confirm
elimination of fault.
B. OK— Go to Step 4.
4. Check injector.
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(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.
A. NOT OK— Replace injector as needed. Return to Step 1 to confirm elimination of fault.
B. OK— Go to Step 5.
5. Replace the engine control module.
Prior to changing the engine control module contact Technical Services Group for further assistance.
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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Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 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 does not 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 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
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
injector output power driver stage.
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.
B. If the resistance was lower than range minimum, continue with step 5.
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.
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.
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
to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, leave connector VC2 disconnected and
continue with step 4.
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B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine
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.
A. If the resistance was within range, there is a short circuit condition in the engine injector harness between
connector VC2 and ECU harness connector 3, locate and repair the short circuit.
B. If the resistance was lower than range minimum, continue with step 6.
6. Remove the injector (valve) cover and disconnect the injector harness from the 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 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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Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the injector output power driver
stage.
Solution:
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, 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.
3. 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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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.
Solution:
Inspect connector housing body/latch, pins and wiring harness for damage or corrosion.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection.
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.
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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.
A. If resistance test was not successful, repair wiring harness between ECU harness connector 3 and con-
nector VC1.
Remove valve cover from the top of the head to allow access to the internal injector wiring harness. Remove the
Cylinder #2 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.
A. If resistance test was successful, repair the internal harness between the Cylinder #2 injector and the
connector INJ2 .
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.
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.
Vehicle Status: Key On Engine Off.
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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.
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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.
Failure to comply could result in death or serious injury.
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.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
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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,
abrasion, corrosion or incorrect attachment.
(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
(3) Measure the resistance from ECU connector A, pin 2 to injector connector pin 2. The resistance should be
less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from ECU connector A, pin 15 to injector connector pin 4. The resistance should be
less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance between ECU connector A pins 15 and 2. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK— Determine the break or short 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 2.
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BD08J013-01 3
NOTE: During installation of valve cover, tighten mounting nuts to a torque of 20 - 30 Nm (15 - 22 lb ft).
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(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
greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance between pins 3 and 4 of connector in rocker housing and ground (engine block).
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
A. NOT OK— Determine the break or short between connectors and repair. Return to Step 1 to confirm
elimination of fault.
B. OK— Go to Step 4.
4. Check injector.
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(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).
A. NOT OK— Replace injector as needed. Return to Step 1 to confirm elimination of fault.
B. OK— Go to Step 5.
5. Replace the engine control module.
Prior to changing the engine control module contact Technical Services Group for further assistance.
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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Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 2.
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 does not 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 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
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
injector output power driver stage.
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 6 and 11. 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.
B. If the resistance was lower than range minimum, continue with step 5.
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.
A. If there was continuity on either or both pins to chassis ground, continue with step 3.
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.
3. Disconnect the engine injector 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 1 to chassis ground and pin 2
to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, leave connector VC1 disconnected and
continue with step 4.
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B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine
injector harness between connector VC1 and ECU harness connector 3. Locate and repair the grounded
conductor.
4. Remove the injector (valve) cover and disconnect the injector harness from Cylinder #2 injector at connector
INJ2 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder #2 injector,
from terminal 1 to chassis ground. There should not be continuity.
A. If there is continuity, the Cylinder #2 injector solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in the Cylinder #2 injector circuit, between
connector VC1 and connector VC1. Locate and repair the grounded conductor.
5. Disconnect the engine injector harness from the injector cover at connector VC1 and use a multi-meter to check
the resistance on the injector cover side of connector VC1 between pins 1 and 2. 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
connector VC1 and ECU harness connector 3, locate and repair the short circuit.
B. If the resistance was lower than range minimum, continue with step 6.
6. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder #2 injector at connector
INJ2 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder #2 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 con-
nector INJ2 and connector VC1. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder #2 injector solenoid coil has failed. Replace
the injector.
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Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the injector output power driver
stage.
Solution:
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, 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.
3. 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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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.
Solution:
Inspect connector housing body/latch, pins and wiring harness for damage or corrosion.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection.
Remove connector VC2 and perform an injector resistance test on the Cylinder #3/4 injector connector VC2.
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.
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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.
A. If resistance test was not successful, repair wiring harness between ECU harness connector 3 and con-
nector VC2.
Remove valve cover from the top of the head to allow access to the internal injector wiring harness. Remove the
Cylinder #4 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.
A. If resistance test was successful, repair the internal harness between the Cylinder #4 injector and the
connector INJ4.
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.
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.
Vehicle Status: Key On Engine Off.
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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.
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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.
Failure to comply could result in death or serious injury.
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.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
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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,
abrasion, corrosion or incorrect attachment.
(2) Disconnect injector connectors for cylinders 3 and 4. Inspect pins, wiring and connectors for damage, abra-
sion, corrosion or incorrect attachment.
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.
(4) Measure the resistance from ECU connector A, pin 5, to injector connector pin 4. 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
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK— Determine the break or short 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 4.
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BD08J013-01 3
NOTE: During installation of valve cover, tighten mounting nuts to a torque of 20 - 30 Nm (15 - 22 lb ft).
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(3) Measure the resistance from injector 4 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
greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance between pins 3 and 4 of connector in rocker housing and ground (engine block).
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
A. NOT OK— Determine the break or short between connectors and repair. Return to Step 1 to confirm
elimination of fault.
B. OK— Go to Step 4.
4. Check injector.
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(2) Measure the resistance between terminals on number 4 injector, a reading of 0.5 - 1.0 Ω at 20 °C (68.0 °F) .
A. NOT OK— Replace injector as needed. Return to Step 1 to confirm elimination of fault.
B. OK— Go to Step 5.
5. Replace the engine control module.
Prior to changing the engine control module contact Technical Services Group for further assistance.
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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Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 4.
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 does not 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 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
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
injector output power driver stage.
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 3 and 14. 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.
B. If the resistance was lower than range minimum, continue with step 5.
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.
A. If there was continuity on either or both pins to chassis ground, continue with step 3.
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.
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 1 to chassis ground and pin 2
to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, leave connector VC2 disconnected and
continue with step 4.
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B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine
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 #4 injector at connector
INJ4 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder #4 injector,
from terminal 1 to chassis ground. There should not be continuity.
A. If there is continuity, the Cylinder #4 injector solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in the Cylinder #4 injector circuit, between
connector INJ4 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 1 and 2. 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
connector VC2 and ECU harness connector 3, locate and repair the short circuit.
B. If the resistance was lower than range minimum, continue with step 6.
6. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder #4 injector at connector
INJ4 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder #4 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 con-
nector INJ4 and connector VC2. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder #4 injector solenoid coil has failed. Replace
the injector.
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Cause:
The ECU has determined that there is no signal from the Crankshaft speed sensor. The engine is now operating in
BACKUP mode.
Solution:
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace Crankshaft speed sensor if damaged.
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.
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)
Vehicle Status: Key On Engine On (during test)
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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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.
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.
5. Operation: Check for Faulty Wiring.
Vehicle status: Key Off Engine Off.
Perform continuity tests between connector DG6 Incr and connector 2 on ECU engine 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 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.
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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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
6. 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.
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.
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.
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.
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 product schematics and determine root cause of
power and/or continuity problem(s).
7. 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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Cause:
The ECU has determined that there are errors in the signal from the Crankshaft speed sensor.
Solution:
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace Crankshaft speed sensor if damaged.
A. If the resistance is not within the specified range, replace the Crankshaft speed sensor.
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.
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
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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Cause:
The ECU has determined that there is no signal from the Camshaft speed sensor.
Solution:
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 if damaged.
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.
A. If the resistance test does not fall in the specified range, replace Camshaft 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 Camshaft speed sensor.
Vehicle Status: Key Off Engine Off (test setup)
Vehicle Status: Key On Engine On (during test)
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 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.
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.
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 of
this type, ensure the Camshaft speed sensor was properly installed.
D. If the voltage test was successful for the single ended connections and not for any of the in-line connec-
tions, proceed to step 5.
5. Operation: Check for Faulty Wiring.
Vehicle status: Key Off Engine Off.
Perform continuity tests between connector DG6 Segm and 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 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 connector 2. Make sure the multi-meter'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.
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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
6. 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.
Using the product schematics for a reference, remove connector 1 from the ECU and check for voltage and
continuity at the appropriate pins defined in the test table below. Use the 0.4 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.
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.
A. If the voltages and ground paths are correct and the Camshaft 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 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.
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 product schematics and determine root cause of
power and/or continuity problem(s).
7. 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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Cause:
The ECU has determined that there is no signal from the Camshaft speed sensor.
Solution:
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 if damaged.
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.
A. If the resistance test does not fall in the specified range, replace Camshaft 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 Camshaft speed sensor.
Vehicle Status: Key Off Engine Off (test setup)
Vehicle Status: Key On Engine On (during test)
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 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.
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.
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 of
this type, ensure the Camshaft speed sensor was properly installed.
D. If the voltage test was successful for the single ended connections and not for any of the in-line connec-
tions, proceed to step 5.
5. Operation: Check for Faulty Wiring.
Vehicle status: Key Off Engine Off.
Perform continuity tests between connector DG6 Segm and 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 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 connector 2. Make sure the multi-meter'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.
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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
6. 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.
Using the product schematics for a reference, remove connector 1 from the ECU and check for voltage and
continuity at the appropriate pins defined in the test table below. Use the 0.4 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.
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.
A. If the voltages and ground paths are correct and the Camshaft 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 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.
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 product schematics and determine root cause of
power and/or continuity problem(s).
7. 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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Cause:
The ECU has determined that there is a phase relationship error between the Crankshaft speed sensor and the
Camshaft speed sensor.
Solution:
B. If the error is no longer present or is in an inactive state, continue with step 15.
2. Operation: Electrical and Sensor Mounting Inspection.
Vehicle Status: Key Off Engine Off.
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.
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.
A. If the resistance test does not fall in the specified range, replace Camshaft speed sensor.
B. If the resistance test does fall in the specified range, proceed to step 4.
4. Operation: Resistance Test for Crankshaft speed sensor.
Vehicle Status: Key Off Engine Off
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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.
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.
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.
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.
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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3. Shorts ECU engine harness con- ECU engine harness con- Open Circuit
nector 2, (Pin: 23) nector 2, (Pin: 19)
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.
Vehicle Status: Key Off Engine Off.
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.
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.
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.
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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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.
Vehicle Status: Key Off Engine Off.
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.
Vehicle Status: Key Off Engine Off.
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.
A. If this fault code is still present and has not cleared, proceed to step 13.
10. Operation: Replace Crankshaft speed sensor.
Vehicle Status: Key Off Engine Off.
Replace the Crankshaft 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.
A. If this fault code is still present and has not cleared, proceed to step 11.
11. Operation: Swap the New Crankshaft speed sensor with the Old Camshaft speed sensor.
Vehicle Status: Key Off Engine Off.
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.
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
correct. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure
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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.
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.
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.
A. If the voltages and ground paths are correct, proceed to step 14.
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 .
Vehicle Status: Key On Engine Off.
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 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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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:
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection. Replace Crankshaft speed sensor if damaged.
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.
A. If the resistance test does not fall in the specified range, replace the 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)
Vehicle Status: Key On Engine On (during test)
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):
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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
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.
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 of
this type, ensure the 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.
5. Operation: Check for Faulty Wiring.
Vehicle status: Key Off Engine Off.
Perform continuity tests between connector DG6 Incr and 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 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 the connector 2. Make sure the multi-meter'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.
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B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
6. 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.
Using the product schematics for a reference, remove connector 1 from the ECU and check for voltage and
continuity at the appropriate pins defined in the test table below. Use the 0.4 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.
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.
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.
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 product schematics and determine root cause of
power and/or continuity problem(s).
7. 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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Cause:
The Rail Pressure sensor signal is too low.
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.
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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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 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.
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Solution:
1. Use the EST to flash the ECU with the appropriate data set.
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Solution:
1. Use the EST to flash the ECU with the appropriate data set.
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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.
2. Faulty ECU, hardware or software.
Solution:
A. If there is voltage, locate and repair the short to the voltage source.
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.
4. 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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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.
2. Faulty ECU, hardware or software.
Solution:
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.
4. 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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Cause:
The Rail Pressure sensor after-run signal is too high.
Solution:
A. If Rail Pressure sensor errors exist, follow troubleshooting procedure for existing Rail Pressure sensor
error.
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.
A. If there is continuity, leave the connectors disconnected and continue with step 4
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.
4. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector 2, pin 12 to the
Engine Sensor harness side of connector RDS4, pin 1. There should be continuity.
A. If there is continuity, leave the connectors disconnected and continue with step 5
B. If there is no continuity, there is an open circuit condition in the sensor signal wire. Locate and repair the
open circuit condition.
5. Visually inspect both connectors for electrical integrity.
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Cause:
The Rail Pressure sensor after-run signal is too low.
Solution:
A. If Rail Pressure sensor errors exist, follow troubleshooting procedure for existing Rail Pressure sensor
error.
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.
A. If there is continuity, leave the connectors disconnected and continue with step 4
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.
4. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector 2, pin 12 to the
Engine Sensor harness side of connector RDS4, pin 1. There should be continuity.
A. If there is continuity, leave the connectors disconnected and continue with step 5
B. If there is no continuity, there is an open circuit condition in the sensor signal wire. Locate and repair the
open circuit condition.
5. Visually inspect both connectors for electrical integrity.
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Cause:
The Fuel Pressure sensor signal is too high.
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.
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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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08F244-01 1
(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.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
(3) Measure the resistance from pin 2 on the grid heater relay to battery terminal and heater terminal studs.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
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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.
B. OK – Go to Step 3.
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
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance from grid heater relay connector 1 to ECU connector B pin 12. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from grid heater relay connector pin 2 to ECU connector B pin 75. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK – Determine the short circuit or break between connectors and repair. Return to Step 1 to confirm
elimination of fault.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08F244-01 1
(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.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
(3) Measure the resistance from pin 2 on the grid heater relay to battery terminal and heater terminal studs.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
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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.
B. OK – Go to Step 3.
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
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance from grid heater relay connector 1 to ECU connector B pin 12. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from grid heater relay connector pin 2 to ECU connector B pin 75. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK – Determine the short circuit or break between connectors and repair. Return to Step 1 to confirm
elimination of fault.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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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:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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.
B. OK – Go to Step 4.
3. Check circuit 1016-RD.
RCPH10TLB302AAF 2
(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
less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK – If circuit is open, check circuit SP-021 splice on front console harness. Repair or repalce the
harness as required. Return to Step 1 to confirm elimination of fault.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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NOTICE: Check alternator output voltage. 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:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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.
B. OK – Go to Step 4.
3. Check circuit 1016-RD.
RCPH10TLB302AAF 2
(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
less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK – If circuit is open, check circuit SP-021 splice on front console harness. Repair or repalce the
harness as required. Return to Step 1 to confirm elimination of fault.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08F244-01 1
(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.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
(3) Measure the resistance from pin 2 on the grid heater relay to battery terminal and heater terminal studs.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
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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.
B. OK – Go to Step 3.
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
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance from grid heater relay connector 1 to ECU connector B pin 12. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from grid heater relay connector pin 2 to ECU connector B pin 75. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK – Determine the short circuit or break between connectors and repair. Return to Step 1 to confirm
elimination of fault.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
Pump control valve circuit is open.
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.
A. If there is continuity, leave the connectors disconnected and continue with step 4
A. If there is continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
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Cause:
Fuel high pressure pump circuit is shorted.
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.
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 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.
4. Use a multi-meter to check for continuity from the Engine Injector harness side of connector ZME, pin 2 to the
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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3145-Terminal 15 - No 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.
Failure to comply could result in death or serious injury.
W0178A
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.
Failure to comply could result in death or serious injury.
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:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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BD08E032-01 1
(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.
The voltage should be approximately 12 V.
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.
B. OK – 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.
B. OK – Go to Step 4.
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.
B. OK – Go to Step 5.
5. Check circuit 3.
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RCPH10TLB302AAF 2
(1) Disconnect fuse block and inspect connections (F-025) and wiring for damage, abrasion, corrosion or incor-
rect attachment.
B. OK – Go to Step 6.
6. Replace ECU (Engine Control Unit).
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
The Oil temp / press sensor is reporting an abnormally high oil temperature to the ECU.
Solution:
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.
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.
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.
A. If damage is 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.
Remove ODFT connector from the Oil temp / 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.
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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.
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 6.
6. Operation: Check for Faulty Wiring.
Vehicle status: Key Off Engine Off.
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.
B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
7. 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.
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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 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 DMM to 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.
A. If the voltages and ground paths are correct and the Oil temp / press 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 Oil temp / press sensor 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.
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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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08F244-01 1
(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.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
(3) Measure the resistance from pin 2 on the grid heater relay to battery terminal and heater terminal studs.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
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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.
B. OK – Go to Step 3.
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
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance from grid heater relay connector 1 to ECU connector B pin 12. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from grid heater relay connector pin 2 to ECU connector B pin 75. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK – Determine the short circuit or break between connectors and repair. Return to Step 1 to confirm
elimination of fault.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08F244-01 1
(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.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
(3) Measure the resistance from pin 2 on the grid heater relay to battery terminal and heater terminal studs.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
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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.
B. OK – Go to Step 3.
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
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance from grid heater relay connector 1 to ECU connector B pin 12. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from grid heater relay connector pin 2 to ECU connector B pin 75. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK – Determine the short circuit or break between connectors and repair. Return to Step 1 to confirm
elimination of fault.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08F244-01 1
(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.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
(3) Measure the resistance from pin 2 on the grid heater relay to battery terminal and heater terminal studs.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
(4) Measure the resistance between pin 1 and pin 2 on grid heater relay. The resistance should be approximately
15 - 40 Ω.
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B. OK – Go to Step 3.
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
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance from grid heater relay connector 1 to ECU connector B pin 12. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from grid heater relay connector pin 2 to ECU connector B pin 75. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK – Determine the short circuit or break between connectors and repair. Return to Step 1 to confirm
elimination of fault.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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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.
Failure to comply could result in death or serious injury.
W0099A
NOTICE: When available use special tool 380040185 harness diagnostic/repair kit.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(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
confirm elimination of fault.
3. Check rail pressure sensor.
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BD08E030-01 1
(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.
B. NOT OK - Go to step 4.
4. Check voltage at fuel pressure sensor.
(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.
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.
(3) Measure the resistance from fuel pressure sensor connector pin 2 to ECU connector C, pin 14. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from fuel pressure sensor connector pin 3 to ECU connector C, pin 13. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - Go to Step 6.
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). Disconnect connector from fuel high pressure regulator. Inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment.
(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.
B. OK – Go to Step 7.
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
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3). Measure the resistance from high pressure regulator pin 1 to ECU connector A pin 9. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from high pressure regulator pin 2 to ECU connector A pin 10. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK - Determine the break or short between connectors or wiring and repair as required. Return to
Step 1 to confirm elimination of fault.
B. OK - Go to Step 8.
8. Replace the engine control unit.
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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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.
Failure to comply could result in death or serious injury.
W0099A
NOTICE: When available use special tool 380040185 harness diagnostic/repair kit.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(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
confirm elimination of fault.
3. Check rail pressure sensor.
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BD08E030-01 1
(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.
B. NOT OK - Go to step 4.
4. Check voltage at fuel pressure sensor.
(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.
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.
(3) Measure the resistance from fuel pressure sensor connector pin 2 to ECU connector C, pin 14. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from fuel pressure sensor connector pin 3 to ECU connector C, pin 13. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - Go to Step 6.
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). Disconnect connector from fuel high pressure regulator. Inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment.
(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.
B. OK – Go to Step 7.
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
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3). Measure the resistance from high pressure regulator pin 1 to ECU connector A pin 9. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from high pressure regulator pin 2 to ECU connector A pin 10. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK - Determine the break or short between connectors or wiring and repair as required. Return to
Step 1 to confirm elimination of fault.
B. OK - Go to Step 8.
8. Replace the engine control unit.
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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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.
Failure to comply could result in death or serious injury.
W0099A
NOTICE: When available use special tool 380040185 harness diagnostic/repair kit.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(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
confirm elimination of fault.
3. Check rail pressure sensor.
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BD08E030-01 1
(1) Disconnect rail pressure sensor connector. Inspect pins, wiring and connectors for damage, abrasion, cor-
rosion or incorrect attachment.
(1). Disconnect rail pressure sensor connector. Turn the key switch ON. The rail 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 Rail 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.
B. NOT OK - Go to step 4.
4. Check voltage at rail pressure sensor.
(3) Measure the voltage between Fuel Pressure connector pin 3 to pin 1 (ground). The voltage should be ap-
proximately 5 V.
A. NOT OK - Go to Step 5.
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,
abrasion, corrosion or incorrect attachment.
(2) Measure the resistance from Rail 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.
(3) Measure the resistance from Rail Pressure sensor connector pin 2 to ECU connector C pin 14. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from Rail Pressure sensor connector pin 3 to ECU connector C pin 13. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - Go to Step 6.
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). Disconnect connector from fuel high pressure regulator. Inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment.
(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.
B. OK – Go to Step 7.
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
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3). Measure the resistance from high pressure regulator pin 1 to ECU connector A pin 9. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from high pressure regulator pin 2 to ECU connector A pin 10. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK - Determine the break or short between connectors or wiring and repair as required. Return to
Step 1 to confirm elimination of fault.
B. OK - Go to Step 8.
8. Replace the engine control unit.
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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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.
Failure to comply could result in death or serious injury.
W0099A
NOTICE: When available use special tool 380040185 harness diagnostic/repair kit.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(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
confirm elimination of fault.
3. Check rail pressure sensor.
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BD08E030-01 1
(1) Disconnect rail pressure sensor connector. Inspect pins, wiring and connectors for damage, abrasion, cor-
rosion or incorrect attachment.
(1). Disconnect rail pressure sensor connector. Turn the key switch ON. The rail 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 Rail 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.
B. NOT OK - Go to step 4.
4. Check voltage at rail pressure sensor.
(3) Measure the voltage between Fuel Pressure connector pin 3 to pin 1 (ground). The voltage should be ap-
proximately 5 V.
A. NOT OK - Go to Step 5.
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,
abrasion, corrosion or incorrect attachment.
(2) Measure the resistance from Rail 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.
(3) Measure the resistance from Rail Pressure sensor connector pin 2 to ECU connector C pin 14. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from Rail Pressure sensor connector pin 3 to ECU connector C pin 13. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - Go to Step 6.
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). Disconnect connector from fuel high pressure regulator. Inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment.
(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.
B. OK – Go to Step 7.
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
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3). Measure the resistance from high pressure regulator pin 1 to ECU connector A pin 9. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from high pressure regulator pin 2 to ECU connector A pin 10. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK - Determine the break or short between connectors or wiring and repair as required. Return to
Step 1 to confirm elimination of fault.
B. OK - Go to Step 8.
8. Replace the engine control unit.
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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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.
Failure to comply could result in death or serious injury.
W0099A
NOTICE: When available use special tool 380040185 harness diagnostic/repair kit.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(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
confirm elimination of fault.
3. Check rail pressure sensor.
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BD08E030-01 1
(1) Disconnect rail pressure sensor connector. Inspect pins, wiring and connectors for damage, abrasion, cor-
rosion or incorrect attachment.
(1). Disconnect rail pressure sensor connector. Turn the key switch ON. The rail 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 Rail 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.
B. NOT OK - Go to step 4.
4. Check voltage at rail pressure sensor.
(3) Measure the voltage between Fuel Pressure connector pin 3 to pin 1 (ground). The voltage should be ap-
proximately 5 V.
A. NOT OK - Go to Step 5.
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,
abrasion, corrosion or incorrect attachment.
(2) Measure the resistance from Rail 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.
(3) Measure the resistance from Rail Pressure sensor connector pin 2 to ECU connector C pin 14. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from Rail Pressure sensor connector pin 3 to ECU connector C pin 13. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - Go to Step 6.
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). Disconnect connector from fuel high pressure regulator. Inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment.
(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.
B. OK – Go to Step 7.
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
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3). Measure the resistance from high pressure regulator pin 1 to ECU connector A pin 9. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from high pressure regulator pin 2 to ECU connector A pin 10. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK - Determine the break or short between connectors or wiring and repair as required. Return to
Step 1 to confirm elimination of fault.
B. OK - Go to Step 8.
8. Replace the engine control unit.
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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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.
Solution:
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.
B. If the resistance was significantly greater than maximum range, continue with step 4
4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 1 injector at connector
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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5. 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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Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the
Cylinder 2 injector output power driver stage.
Solution:
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 injector harness from the injector (valve) cover at connector VC1. Use a multi-meter to
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.
B. If the resistance was significantly greater than maximum range, continue with step 4
4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 2 injector at connector
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.
B. If the resistance was significantly greater than maximum range, the Cylinder 2 injector solenoid coil has
failed. Replace the injector.
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5. 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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Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the
Cylinder 3 injector output power driver stage.
Solution:
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 injector harness from the injector (valve) cover at connector VC2. Use a multi-meter to
check resistance on the injector (valve) cover side of connector VC2 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 injector harness between
connector 3 and connector VC2. Locate and repair the broken conductor.
B. If the resistance was significantly greater than maximum range, continue with step 4
4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 3 injector at connector
terminal 1 (high side ring terminal) Use a multi-meter to check resistance, on the Cylinder 3 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 3 and connector VC2. Locate and repair the broken conductor.
B. If the resistance was significantly greater than maximum range, the Cylinder 3 injector solenoid coil has
failed. Replace the injector.
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5. 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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Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the
Cylinder 4 injector output power driver stage.
Solution:
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 injector harness from the injector (valve) cover at connector VC2. Use a multi-meter to
check resistance on the injector (valve) cover side of connector VC2 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 VC2. Locate and repair the broken conductor.
B. If the resistance was significantly greater than maximum range, continue with step 4
4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 4 injector at connector
terminal 1 (high side ring terminal) Use a multi-meter to check resistance, on the Cylinder 4 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 VC2 and connector INJ4. Locate and repair the broken conductor.
B. If the resistance was significantly greater than maximum range, the Cylinder 4 injector solenoid coil has
failed. Replace the injector.
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5. 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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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.
Solution:
From:
1. Pin 4 to pin 13
2. Pin 11 to pin 6
3. Pin 5 to pin 12
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
chassis ground. There should not be continuity.
A. If there was continuity, record the pin number and continue to step 4.
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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
2. Connector VC1 pin 1, if recorded pin in Step 3 was pin 11, to chassis ground
3. Connector VC2 pin 4, if recorded pin in Step 3 was pin 5, to chassis ground.
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
3. Cylinder #3 injector at connector INJ3 if recorded pin in Step 3 was pin 5
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
A. If the resistance was within range, there is a short circuit condition in the engine injector harness between
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.
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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A. If the resistance was within range, there is a short circuit condition in the injector harness, between con-
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.
9. 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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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 in Bank 1.
Solution:
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.
4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder #1 injector at connector
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.
5. 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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Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the injector output power driver
stage in Bank 1.
Solution:
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, the ECU may have failed. Try reloading the ECU software and if the fault
reoccurs, replace the ECU.
3. 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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
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Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 2 (Group B, Cylinders
4, 5, & 6). 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 2.
Solution:
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
chassis ground. There should not be continuity.
A. If there was continuity, record the pin number and continue to step 4.
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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:
1. Connector VC3 pin 2, if recorded pin in Step 3 was pin 2, to chassis ground
2. Connector VC3 pin 3, if recorded pin in Step 3 was pin 1, to chassis ground
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.
5. Remove the injector (valve) cover and disconnect the injector harness from the injector:
For:
1. Cylinder #4 injector at connector INJ4 terminal 1 (high side ring terminal) if recorded pin in Step 3
was pin 3
2. Cylinder #5 injector at connector INJ5 if recorded pin in Step 3 was pin 1
3. Cylinder #6 injector at connector INJ6 if recorded pin in Step 3 was pin 2
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
VC3 pin 2 or 3 and ECU connector 3 pin 1 or 2
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
A. If the resistance was within range, there is a short circuit condition in the engine injector harness between
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.
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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A. If the resistance was within range, there is a short circuit condition in the injector harness, between con-
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.
9. 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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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 in Bank 2.
Solution:
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.
4. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder #4 injector at connector
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
VC3 pin 4 or 1 and ECU connector 3 pin 15 or 16
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.
5. 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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Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the injector output power driver
stage in Bank 2.
Solution:
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, the ECU may have failed. Try reloading the ECU software and if the fault
reoccurs, replace the ECU.
3. 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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
B. NOT OK - Go to Step 3.
3. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
B. NOT OK - Go to Step 3.
3. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
B. NOT OK - Go to Step 3.
3. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
B. NOT OK - Go to Step 3.
3. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
B. NOT OK - Go to Step 3.
3. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
B. NOT OK - Go to Step 3.
3. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(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.
B. OK - Go to Step 3.
3. Circuit E172-YE and E372-YE.
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
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from starter connector relay pin 86 to ECU connector B pin 37. 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. Go to Step 1 to confirm elimination of fault.
B. OK - Go to Step 4.
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.
B. OK - Go to Step 5.
5. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(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.
B. OK - Go to Step 3.
3. Circuit E172-YE and E372-YE.
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
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from starter connector relay pin 86 to ECU connector B pin 37. 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. Go to Step 1 to confirm elimination of fault.
B. OK - Go to Step 4.
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.
B. OK - Go to Step 5.
5. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(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.
B. OK - Go to Step 3.
3. Circuit E172-YE and E372-YE.
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
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from starter connector relay pin 86 to ECU connector B pin 37. 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. Go to Step 1 to confirm elimination of fault.
B. OK - Go to Step 4.
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.
B. OK - Go to Step 5.
5. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(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.
B. OK - Go to Step 3.
3. Circuit E172-YE and E372-YE.
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
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from starter connector relay pin 86 to ECU connector B pin 37. 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. Go to Step 1 to confirm elimination of fault.
B. OK - Go to Step 4.
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.
B. OK - Go to Step 5.
5. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
RCPH10TLB013BAM 1
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BD08F241-01 2
(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.
B. OK - Go to Step 3.
3. Circuit E172-YE and E372-YE.
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
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from starter connector relay pin 86 to ECU connector B pin 37. 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. Go to Step 1 to confirm elimination of fault.
B. OK - Go to Step 4.
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(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.
B. OK - Go to Step 5.
5. Replace ECU (Engine Control Unit).
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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3263-Busoff in CAN C
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
B. NOT OK - Go to Step 3.
3. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
BD08E032-01 1
RCPH10TLB084AAM 2
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(1) Connector C
(2) Connector A
(3) Connector B
(4) Fuse block
(5) Side console
(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.
(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.
A. NOT OK – Check fuse F-001 and wiring to ECU. Return to Step 1 to confirm elimination of fault.
B. OK – Go to Step 3.
3. Replace ECU (Engine Control Unit).
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
BD08E032-01 1
RCPH10TLB084AAM 2
(1) Connector C
(2) Connector A
(3) Connector B
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(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.
(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.
A. NOT OK – Check fuse F-001 and wiring to ECU. Return to Step 1 to confirm elimination of fault.
B. OK – Go to Step 3.
3. Replace ECU (Engine Control Unit).
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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.
(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 – 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
1 to confirm elimination of fault.
C. OK – Go to Step 3.
3. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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.
(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 – 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
1 to confirm elimination of fault.
C. OK – Go to Step 3.
3. Check circuit 1010-RD.
RCPH10TLB302AAF 2
(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.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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.
(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 – 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
1 to confirm elimination of fault.
C. OK – Go to Step 3.
3. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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.
(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 – 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
1 to confirm elimination of fault.
C. OK – Go to Step 3.
3. Check circuit 1010-RD.
RCPH10TLB302AAF 2
(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.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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.
(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 – 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
1 to confirm elimination of fault.
C. OK – Go to Step 3.
3. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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.
(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 – 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
1 to confirm elimination of fault.
C. OK – Go to Step 3.
3. Check circuit 1010-RD.
RCPH10TLB302AAF 2
(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.
B. OK – Go to Step 4.
4. Replace the engine control unit.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 03 (A.30.A.88-C.20.E.03)
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
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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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
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RCPH10TLB030FAM 1
(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
to reveal an intermittent condition.
(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.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive battery. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
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(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.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
RCPH10TLB085AAM 2
(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.
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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
2. Wiring or circuits open.
3. Wiring or circuits shorted.
4. Faulty Instrument Cluster
5. Faulty ECU
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
(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
Step 1 to confirm elimination of fault.
3. Measure harness resistance to chassis ground and positive battery.
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RCPH10TLB030FAM 1
(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
to reveal an intermittent condition.
(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.
(4) Disconnect the Instrument Cluster connector, X-029. Measure the resistance from pin 3 on connector X-29 to
positive battery. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
(5) Measure the resistance from pin 4 on connector X-29 to positive battery. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
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(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.
(2) Measure the resistance between pin 34 and 35 on the ECU. (Connector B). The resistance should be be-
tween 108 and 132 ohms.
A. OK - The resistance is between 108 and 132 ohms. There is an open circuit in the harness between X-001
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.
RCPH10TLB085AAM 2
(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.
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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
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.
(1). Use the Electronic Service Tool to clear all fault codes.
RCPH10TLB013BAM 1
RCPH10TLB084AAM 2
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(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.
B. OK - Go to Step 3.
3. Circuit E172-YE and E372-YE.
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
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4). Measure the resistance from starter connector relay pin 86 to ECU connector B pin 37. 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. Go to Step 1 to confirm elimination of fault.
B. OK - Go to Step 4.
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.
B. OK - Go to Step 5.
5. Replace ECU (Engine Control Unit).
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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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(1) Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
(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, contact Technical Services Group
for assistance.
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(1) Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
(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, contact Technical Services Group
for assistance.
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Cause:
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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. NOT OK – Repair fan or clear clogs from radiator. Return to Step 1 to confirm elimination of fault.
B. OK – Go to Step 3.
3. Check engine coolant temperature sensor.
BD08E033-01 1
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(1) Disconnect the coolant temperature sensor. Inspect pins, wiring and connectors for damage, abrasion, cor-
rosion or incorrect attachment.
(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.
B. OK – Go to Step 4.
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
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(2) Measure the resistance from coolant temperature sensor pin 1 to ECU connector C, pin 15. 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 5.
5. Replace the engine control unit.
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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3998-Unknown error
NOTICE: When available use special tool 380040185 harness diagnostic/repair kit.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
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.
(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.
A. NOT OK – Check fuse F-001 and wiring to ECU. Return to Step 1 to confirm elimination of fault.
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B. OK – Go to Step 3.
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
NOTICE: When available use special tool 380040185 harness diagnostic/repair kit.
NOTE: See engine repair manual for electrical schematic information.
Cause:
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.
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.
(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.
A. NOT OK – Check fuse F-001 and wiring to ECU. Return to Step 1 to confirm elimination of fault.
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B. OK – Go to Step 3.
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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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
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.
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.
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BD08E025-01 3
RCPH10TLB086AAM 4
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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.
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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.
B. NOT OK – Go to Step 7
4. Measure the resistance of the Forward and Reverse solenoid circuits.
(3) Measure the resistance from X-300 pin 3 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from X-300 pin 4 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(2) Measure the resistance from X-374 A3 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
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
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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
Step 1 to confirm elimination of fault.
7. Measure the voltage at the FNR Switch.
Use backprobes or a breakout harness to measure the voltage at the FNR switch.
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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.
(1) Measure the voltage from the FNR connector, pin 8 to ground (chassis ground). The voltage should be
approximately 12 volts.
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
(2) Measure the resistance from X-150 pin 13 to X-300 pin 2. 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. 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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
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.
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BD08E025-01 3
RCPH10TLB086AAM 4
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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,
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 harness is damaged. 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.
(3) Measure the voltage from X-300 pin 5 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.
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C. NOT OK – Go to Step 10
4. Measure the resistance of the S2 Solenoid and S3 Solenoid circuit to chassis ground.
(3) Measure the resistance from X-300 pin 6 to chassis ground. The resistance should be approximately 7.25
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from X-300 pin 7 to chassis ground. The resistance should be approximately 7.25
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(2) Measure the resistance from the solenoid to chassis ground. The resistance should be approximately 7.25
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance from X-374 A3 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 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
elimination of the fault.
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.
Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance X-300 pin 7 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 replace the Trax Control. 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 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.
(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.
(4) Measure the resistance between X-300 pin 7 and X-300 pin 41. The resistance should be approximately
7.25 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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(1) Measure the resistance from X-300 pin 6 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(2) Measure the resistance from X-300 pin 7 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 replace the TRAX Control. Go to Step 1
to confirm elimination of the fault.
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.
(2) Measure the between X-300 pin 6 and X-300 pin 13. The resistance should be greeter than 20,000 ohms.
Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the between X-300 pin 7 and X-300 pin 41. The resistance should be greeter than 20,000 ohms.
Wiggle the harness during measurement to reveal an intermittent condition.
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.
10. Measure the voltage at connector X-012
(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.
(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.
(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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
RCPH10TLB086AAM 2
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RCPH10TLB032FAM 3
Schematic legend
(1) Key Switch (3) Battery supply to key switch from fuse
F-025
(2) Trax 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,
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 harness is damaged. 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.
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(3) Measure the voltage from X-300 pin 8 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
elimination of the fault.
(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.
(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.
(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.
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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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
Cause:
Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 RPM.
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.
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BD08E025-01 3
RCPH10TLB086AAM 4
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RCPH10TLB032FAM 5
Schematic legend
(1) Key Switch (3) Battery to key switch from fuse F-025
(2) Trax 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,
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 harness is damaged. 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.
(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
elimination of the fault.
B. NOT OK – Go to Step 4
4. Measure the voltage at connector X-012
(1) Measure the voltage at X-012 pin 3 to chassis ground. The voltage should be approximately 12 volts.
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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-067. Repair as required. Go to Step 1 to confirm elimination of the
fault.
(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.
(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.
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.
Wiring harness - Electrical schematic frame 01 (A.30.A.88-C.20.E.01)
Wiring harness - Electrical schematic frame 02 (A.30.A.88-C.20.E.02)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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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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.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
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,
corrosion, abrasion and incorrect attachment.
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A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or harness has damage. Repair or replace harness or connectors as required.
Return to Step 1 to confirm elimination of fault.
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
the harness during measurement to reveal an intermittent condition.
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.
(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.
Go to Step 1 to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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4007-FWD input (Pin 12) current is too low with command present
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.
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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
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 and
tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Forward Solenoid. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
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A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or harness is damaged. Repair or replace harness or connectors as needed.
Return to Step 1 to confirm elimination of fault.
3. Measure the resistance through the wire.
(3) Measure the resistance from X-300 pin 3 to X-300 pin 12. The resistance should be approximately 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. 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.
4. Measure the resistance of the Forward Solenoid.
(3) Measure the resistance of the solenoid. The resistance should be approximately 7.25 ohms.
B. NOT OK – The resistance is greater than 8 ohms. The Forward Solenoid has an internal open circuit.
Replace the Forward Solenoid and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the wire.
(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.
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
to confirm elimination of the fault.
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
required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
The Trax Control is measuring an excessive current in the FWD input (Pin 12) feedback circuit when the Forward
Solenoid is ON.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
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 and
tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Forward Solenoid. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
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A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or harness is damaged. Repair or replace harness or connectors as needed.
Return to Step 1 to confirm elimination of fault.
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
the harness during measurement to reveal an intermittent condition.
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.
(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.
Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance was 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.
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
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 and
tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Forward Solenoid. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
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A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or harness is damaged. Repair or replace harness or connectors as needed.
Return to Step 1 to confirm elimination of fault.
3. Measure the resistance through the wire.
(3) Measure the resistance from X-300 pin 3 to X-300 pin 12. The resistance should be approximately 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. 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.
4. Measure the resistance of the Forward Solenoid.
(3) Measure the resistance of the solenoid. The resistance should be approximately 7.25 ohms.
B. NOT OK – The resistance is greater than 8 ohms. The Forward Solenoid has an internal open circuit.
Replace the Forward Solenoid and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the wire.
(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.
(3) Measure the resistance between X300 pin 3 and X-300 pin 12. 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. Temporarily replace the Trax Control and retest. Go to Step 1
to confirm elimination of the fault.
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
required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
RCPH10TLB036FAM 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) Reverse signal (input) to the Trax Control
(1) Inspect Trax connector X-300 and the Reverse 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 Reverse Solenoid. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
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A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or harness is damaged. Repair or replace harness or connectors as needed.
Return to Step 1 to confirm elimination of fault.
3. Measure the voltage on the solenoid return wire.
(2) Disconnect Trax connector X-300 and the Reverse Solenoid connector X-321.
(4) Measure the voltage from X-300 pin 40 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
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 40 to the Reverse Solenoid. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the Reverse 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.
Go to Step 1 to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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4012-RVS input (pin 40) current is too low with command present
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.
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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
RCPH10TLB036FAM 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) Reverse signal (input) to the Trax Control
(1) Inspect Trax connector X-300 and the Reverse 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 Reverse Solenoid. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
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A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or harness is damaged. Repair or replace harness or connectors as needed.
Return to Step 1 to confirm elimination of fault.
3. Measure the resistance through the wire.
(3) Measure the resistance from X-300 pin 3 to X-300 pin 12. The resistance should be approximately 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. 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.
4. Measure the resistance of the Reverse Solenoid.
(3) Measure the resistance of the solenoid. 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.
Replace the Reverse Solenoid and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the wire.
(2) Fabricate a 5 inch jumper wire with Deutsch pins on each end. Insert the jumper in connector X-321 pin 1
and X-321 pin 2.
(3) Measure the resistance between X300 pin 4 and X-300 pin 40. 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. Temporarily replace the Trax Control and retest. Go to Step 1
to confirm elimination of the fault.
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Reverse
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
The Trax Control is measuring an excessive current in the REV input (Pin 40) feedback circuit when the Reverse
Solenoid is ON.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
RCPH10TLB036FAM 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) Reverse signal (input) to the Trax Control
(1) Inspect Trax connector X-300 and the Reverse 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 Reverse Solenoid. Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
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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 is damaged. Repair or replace the harness or connectors as
needed. Return to Step 1 to confirm elimination of fault.
3. Measure the voltage on the solenoid return wire.
(2) Disconnect Trax connector X-300 and the Reverse Solenoid connector X-321.
(4) Measure the voltage from X-300 pin 40 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
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 Reverse Solenoid. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the Reverse 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.
Go to Step 1 to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
RCPH10TLB036FAM 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) Reverse signal (input) to the Trax Control
(1) Inspect Trax connector X-300 and the Reverse 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 Reverse Solenoid. 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.
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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.
3. Measure the resistance through the wire.
(3) Measure the resistance from X-300 pin 4 to X-300 pin 40. The resistance should be approximately 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. 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.
4. Measure the resistance of the Reverse Solenoid.
(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.
Replace the Reverse Solenoid and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the wire.
(2) Fabricate a 5 inch jumper wire with Deutsch pins on each end. Insert the jumper in connector X-321 pin 1
and X-320 pin 2.
(3) Measure the resistance between X300 pin 4 and X-300 pin 40. 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. Temporarily replace the Trax Control and retest. Go to Step 1
to confirm elimination of the fault.
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Reverse
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
H-Type transmission only. First and third shift modulation solenoid input (pin 13) feedback circuit is reading too much
current with command.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
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,
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 is damaged. Repair or replace the harness or connectors as
required. Return to Step 1 to confirm elimination of fault.
3. Measure the voltage on the solenoid return wire.
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(2) Disconnect Trax connector X-300 and the 1/3 Solenoid connector X-382.
(4) Measure the voltage from X-300 pin 13 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
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 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.
(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.
Go to Step 1 to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
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,
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 is damaged. Repair or replace the harness or connectors as
required. Return to Step 1 to confirm elimination of fault.
3. Measure the resistance through the wire.
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(3) Measure the resistance from X-300 pin 6 to X-300 pin 13. The resistance should be approximately 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. 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.
4. Measure the resistance of the 1/3 Solenoid.
(3) Measure the resistance of the solenoid. The resistance should be approximately 7.25 ohms.
B. NOT OK – The resistance is greater than 8 ohms. The 1/3 Solenoid has an internal open circuit. Replace
the 1/3 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the wire.
(2) Fabricate a 5 inch jumper wire with pins on each end. Insert the jumper in connector X-382 pin 1 and X-382
pin 2.
(3) Measure the resistance between X300 pin 6 and X-300 pin 13. 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. Temporarily replace the Trax Control and retest. Go to Step 1
to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
H-Type transmission only. First and third shift modulation solenoid input (pin 13) feedback circuit, current feedback is
too high with command.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
RCPH10TLB086AAM 2
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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, tight,
free of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Trax Control to the 1/3 Solenoid. 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 harness has damage. Repair or replace harness or connectors as required.
Return to Step 1 to confirm elimination of fault.
3. Measure the voltage on the solenoid return wire.
(2) Disconnect Trax connector X-300 and the 1/3 Solenoid connector X-382.
(4) Measure the voltage from X-300 pin 13 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
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 13 to the Forward Solenoid. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the 1/3 Solenoid.
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(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.
Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is 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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
H-Type transmission only. First and third shift modulation solenoid input (pin 13) feedback circuit, current feedback is
too low with the solenoid commanded to the On position.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
RCPH10TLB086AAM 2
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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, tight,
free of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Trax Control to the 1/3 Solenoid. 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 harness has damage. Repair or replace harness or connectors as required.
Return to Step 1 to confirm elimination of fault.
3. Measure the resistance through the wire.
(3) Measure the resistance from X-300 pin 6to X-300 pin 13. The resistance should be approximately 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. 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.
4. Measure the resistance of the 1/3 Solenoid.
(3) Measure the resistance of the solenoid. The resistance should be approximately 7.25 ohms.
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B. NOT OK – The resistance is greater than 8 ohms. The 1/3 Solenoid has an internal open circuit. Replace
the 1/3 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the wire.
(2) Fabricate a 5 inch jumper wire with Deutsch pins on each end. Insert the jumper in connector X-382 pin 1
and X-382 pin 2.
(3) Measure the resistance between X300 pin 6 and X-300 pin 13. 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. Temporarily replace the Trax Control and retest. Go to Step 1
to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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..
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
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 2/4 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 2/4 Solenoid. 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.
3. Measure the voltage on the solenoid return wire.
(2) Disconnect Trax connector X-300 and the 2/4 Solenoid connector X-383.
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(4) Measure the voltage from X-300 pin 41 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
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 41 to the 2/4 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the 2/4 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.
Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 6.5 ohms. The 2/4 Solenoid has an internal short circuit. Replace
the 2/4 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB086AAM 2
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 2/4 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 2/4 Solenoid. 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 is damaged. Repair or replace the harness or connectors as
required. Return to Step 1 to confirm elimination of fault.
3. Measure the resistance through the wire.
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(3) Measure the resistance from X-300 pin 7 to X-300 pin 41. The resistance should be approximately 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. 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.
4. Measure the resistance of the 2/4 Solenoid.
(3) Measure the resistance of the solenoid. The resistance should be approximately 7.25 ohms.
B. NOT OK – The resistance is greater than 8 ohms. The 2/4 Solenoid has an internal open circuit. Replace
the 2/4 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the wire.
(2) Fabricate a 5 inch jumper wire with Deutsch pins on each end. Insert the jumper in connector X-383 pin 1
and X-383 pin 2.
(3) Measure the resistance between X300 pin 7 and X-300 pin 41. 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. Temporarily replace the Trax Control and retest. Go to Step 1
to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
H-Type transmission only. Second and fourth shift modulation solenoid input (pin 41) feedback circuit, current feed-
back is too high with command.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
RCPH10TLB086AAM 2
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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 2/4 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 2/4 Solenoid. 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 harness has damage. Repair or replace harness or connectors as required.
Return to Step 1 to confirm elimination of fault.
3. Measure the voltage on the solenoid return wire.
(2) Disconnect Trax connector X-300 and the 2/4 Solenoid connector X-383.
(4) Measure the voltage from X-300 pin 41 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
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 41 to the 2/4 Solenoid. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the 2/4 Solenoid.
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(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.
Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 6.5 ohms. The 2/4 Solenoid has an internal short circuit. Replace
the 2/4 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
RCPH10TLB086AAM 2
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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 2/4 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 2/4 Solenoid. 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 harness has damage. Repair or replace the harness or connectors as
required. Return to Step 1 to confirm elimination of fault.
3. Measure the resistance through the wire.
(3) Measure the resistance from X-300 pin 7 to X-300 pin 41. The resistance should be approximately 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. 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.
4. Measure the resistance of the 2/4 Solenoid.
(3) Measure the resistance of the solenoid. The resistance should be approximately 7.25 ohms.
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B. NOT OK – The resistance is greater than 8 ohms. The 2/4 Solenoid has an internal open circuit. Replace
the 2/4 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the wire.
(2) Fabricate a 5 inch jumper wire with pins on each end. Insert the jumper in connector X-383 pin 1 and X-383
pin 2.
(3) Measure the resistance between X300 pin 7 and X-300 pin 41. 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. Temporarily replace the Trax Control and retest. Go to Step 1
to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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).
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB037FAM 2
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,
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.
3. Measure the resistance to chassis ground.
BC08A418 3
(1) Disconnect Trax connector X-300 and 1/3 solenoid connector 382.
(2) Measure the resistance from X-300 pin 6 to chassis ground. 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 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
greater than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace 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. Replace the 1/3 solenoid and retest. Return to Step
1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
H-Type Transmission Only - The 2/4 solenoid driver (output) is shorted to ground (chassis ground). The machine will
go into Limp Home Mode in second gear (without modulation).
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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RCPH10TLB037FAM 2
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 2/4 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 2/4 Solenoid. 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.
3. Measure the resistance to chassis ground.
BC08A418 3
(1) Disconnect Trax connector X-300 and 2/4 solenoid connector 383.
(2) Measure the resistance from X-300 pin 7 to chassis ground. 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 is less than 20,000 ohms. There is a short circuit to chassis ground in the 2/4
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 383 pin 1 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 and retest. Go to
Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 20,000 ohms. Replace the 2/4 solenoid and retest. Return to Step
1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
The Differential Lock solenoid driver (output) or the 4WD solenoid driver (output) is shorted to ground (chassis ground).
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E025-01 1
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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
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.
3. Measure the resistance to chassis ground.
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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).
(2) Measure the resistance from X-300 pin 39 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Measure the resistance from X-300 pin 11 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the
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.
4. Measure the resistance across the solenoid.
(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.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace 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. Replace the solenoid and retest. Return to Step 1 to
confirm elimination of fault.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
RCPH10TLB038FAM 2
Schematic legend
(1) FNR Switch (2) TRAX Controller
(1) Inspect Trax connector X-300 and the FNR Shift Lever 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 FNR Shift Lever. 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.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
vided
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(2) Measure the voltage from FNR connector pin 8 to chassis ground. The voltage should be approximately 12
volts.
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
voltage should be approximately 12 volts.
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
(X300-29). The voltage should be approximately 12 volts.
(4) Place the FNR switch in the Reverse position. Measure the voltage from X300 pin 46 to chassis ground
(X300-29). The voltage should be approximately 12 volts.
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
confirm elimination of fault.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
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RCPH10TLB038FAM 2
Schematic legend
(1) FNR Switch (2) TRAX Controller
(1) Inspect Trax connector X-300 and the FNR Shift Lever 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 FNR Shift Lever. 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.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
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
(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.
(3) Measure the resistance between X-300 pin 16 and X-300 pin 18. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
5. Measure the voltage at the Trax Control connector.
(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.
(5) Measure the voltage from X-300 pin 18 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
(6) Measure the voltage from X-300 pin 16 to chassis ground. The voltage should be approximately 12 volts.
Wiggle the harness during measurement to reveal an intermittent condition.
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
harness as required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. The Neutral and Reverse signal wires are shorted together.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
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RCPH10TLB038FAM 2
Schematic legend
(1) FNR Switch (2) TRAX Controller
(1) Inspect Trax connector X-300 and the FNR Shift Lever 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 FNR Shift Lever. 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.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
vided
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(2) Use a wire removal tool and remove wire pin 5 and pin 6 from the FNR connector.
RCPH10TLB026GAM 5
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (4) Remove wires from pin 5 and pin 6.
Switch
(2) Breakout Harness - Dealer pro- (5) Digital Volt Meter
vided
(3) Engine Harness (6) Chassis ground
(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 5 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 5 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 5 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.
(3) Measure the resistance between X-300 pin 16 and X-300 pin 46. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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 46. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
5. Measure the voltage at the Trax Control connector.
(1) Remove the breakout tee from the harness and FNR switch.
(2) Reinstall pin 5 and an pin 6 in the FNR connector. Reconnect the FNR harness connector to the FRN switch.
(5) Measure the voltage from X-300 pin 46 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
(6) Measure the voltage from X-300 pin 16 to chassis ground. The voltage should be approximately 12 volts.
Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage on pin 46 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 46 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 46 and X-300 pin 16. Repair or replace the
harness as required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. The Forward and Reverse signal wires are shorted together.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
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RCPH10TLB038FAM 2
Schematic legend
(1) FNR Switch (2) TRAX Controller
(1) Inspect Trax connector X-300 and the FNR Shift Lever 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 FNR Shift Lever. 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.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
vided
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(2) Use a wire removal tool and remove wire pin 5 and pin 7 from the FNR connector.
RCPH10TLB027GAM 5
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (4) Remove wires from pin 5 and pin 7.
Switch
(2) Breakout Harness - Dealer pro- (5) Digital Volt Meter
vided
(3) Engine Harness (6) Chassis ground
(5) Measure the voltage from pin 7 to chassis ground. The voltage should be approximately 12 volts.
(6) Measure the voltage from pin 5 to chassis ground. The voltage should be less than 0.5 volts.
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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B. NOT OK – The voltage on pin 7 is between 12 and 14.2 volts and the voltage on pin 5 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.
(3) Measure the resistance between X-300 pin 18 and X-300 pin 46. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit between X-300 pin 18 and
X-300 pin 46. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
5. Measure the voltage at the Trax Control connector.
(1) Remove the breakout tee from the harness and FNR switch.
(2) Reinstall pin 5 and an pin 7 in the FNR connector. Reconnect the FNR harness connector to the FNR switch.
(5) Measure the voltage from X-300 pin 18 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
(6) Measure the voltage from X-300 pin 46 to chassis ground. The voltage should be approximately 12 volts.
Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage on pin 18 is less than 0.5 volts and the voltage on pin 46 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 46 is between 12
and 14.2 volts. There is a short circuit between X-300 pin 18 and X-300 pin 46. Repair or replace the
harness as required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. The Forward and Reverse signal wires are shorted together.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
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RCPH10TLB038FAM 2
Schematic legend
(1) FNR Switch (2) TRAX Controller
(1) Inspect Trax connector X-300 and the FNR Shift Lever 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 FNR Shift Lever. 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.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
vided
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(2) Use a wire removal tool and remove wire pin 5 and pin 7 from the FNR connector.
RCPH10TLB027GAM 5
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (4) Remove wires from pin 5 and pin 7.
Switch
(2) Breakout Harness - Dealer pro- (5) Digital Volt Meter
vided
(3) Engine Harness (6) Chassis ground
(5) Measure the voltage from pin 7 to chassis ground. The voltage should be approximately 12 volts.
(6) Measure the voltage from pin 5 to chassis ground. The voltage should be less than 0.5 volts.
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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B. NOT OK – The voltage on pin 7 is between 12 and 14.2 volts and the voltage on pin 5 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.
(3) Measure the resistance between X-300 pin 18 and X-300 pin 46. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit between X-300 pin 18 and
X-300 pin 46. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
5. Measure the voltage at the Trax Control connector.
(1) Remove the breakout tee from the harness and FNR switch.
(2) Reinstall pin 5 and an pin 7 in the FNR connector. Reconnect the FNR harness connector to the FNR switch.
(5) Measure the voltage from X-300 pin 18 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
(6) Measure the voltage from X-300 pin 46 to chassis ground. The voltage should be approximately 12 volts.
Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage on pin 18 is less than 0.5 volts and the voltage on pin 46 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 46 is between 12
and 14.2 volts. There is a short circuit between X-300 pin 18 and X-300 pin 46. Repair or replace the
harness as required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. The Neutral and Forward signal wires are shorted together.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
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RCPH10TLB038FAM 2
Schematic legend
(1) FNR Switch (2) TRAX Controller
(1) Inspect Trax connector X-300 and the FNR Shift Lever connections. All connections should be secure, free
of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the FNR Shift Lever. 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.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
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
(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.
(3) Measure the resistance between X-300 pin 16 and X-300 pin 18. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
5. Measure the voltage at the Trax Control connector.
(1) Remove the breakout tee from the harness and FNR switch.
(2) Reinstall pin 6 and pin 7 in the FNR connector. Reconnect the FNR harness connector to the FNR switch.
(5) Measure the voltage from X-300 pin 18 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
(6) Measure the voltage from X-300 pin 16 to chassis ground. The voltage should be approximately 12 volts.
Wiggle the harness during measurement to reveal an intermittent condition.
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
harness as required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. The Neutral and Reverse signal wires are shorted together.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
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RCPH10TLB038FAM 2
Schematic legend
(1) FNR Switch (2) TRAX Controller
(1) Inspect Trax connector X-300 and the FNR Shift Lever 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 FNR Shift Lever. 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.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
vided
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(2) Use a wire removal tool and remove wire pin 5 and pin 6 from the FNR connector.
RCPH10TLB026GAM 5
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (4) Remove wires from pin 5 and pin 6.
Switch
(2) Breakout Harness - Dealer pro- (5) Digital Volt Meter
vided
(3) Engine Harness (6) Chassis ground
(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 5 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 5 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 5 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.
(3) Measure the resistance between X-300 pin 16 and X-300 pin 46. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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 46. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
5. Measure the voltage at the Trax Control connector.
(1) Remove the breakout tee from the harness and FNR switch.
(2) Reinstall pin 5 and an pin 6 in the FNR connector. Reconnect the FNR harness connector to the FNR switch.
(5) Measure the voltage from X-300 pin 46 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
(6) Measure the voltage from X-300 pin 16 to chassis ground. The voltage should be approximately 12 volts.
Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage on pin 46 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 46 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 46 and X-300 pin 16. Repair or replace the
harness as required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. Gear Command 1 and Gear Command 2 signal wires are shorted together.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
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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
(1) Inspect Trax connector X-300 and the FNR Shift Lever 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 FNR Shift Lever. 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.
3. Measure the voltage at the FNR Shift Lever in second gear.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
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
(1) FNR (Forward-Neutral-Reverse) (4) Remove wires from pin 2 and pin 3.
Switch
(2) Breakout Harness - Dealer pro- (5) Digital Volt Meter
vided
(3) Engine Harness (6) Chassis ground
(5) Measure the voltage from pin 2 to chassis ground. The voltage should be less than 0.5 volts.
(6) Measure the voltage from pin 3 to chassis ground. The voltage should be less than 0.5 volts.
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
14.2 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 third gear.
(3) Measure the voltage from pin 2 to chassis ground. The voltage should be less than 0.5 volts.
(4) Measure the voltage from pin 3 to chassis ground. The voltage should be approximately 12 volts
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 5.
B. NOT 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. Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of
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.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
During the shift from 1st gear to 2nd gear, the Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47)
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.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. Gear Command 2 signal wire shorted to a voltage source.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
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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
(1) Inspect Trax connector X-300 and the FNR Shift Lever 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 FNR Shift Lever. 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.
3. Measure the voltage at the FNR Shift Lever in first gear.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
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
(1) FNR (Forward-Neutral-Reverse) (4) Remove wires from pin 2 and pin 3.
Switch
(2) Breakout Harness - Dealer pro- (5) Digital Volt Meter
vided
(3) Engine Harness (6) Chassis ground
(5) Measure the voltage from pin 2 to chassis ground. The voltage should be approximately 12 volts.
(6) Measure the voltage from pin 3 to chassis ground. The voltage should be less than 0.5 volts.
A. 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. Go
to Step 4.
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B. NOT 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. 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 second gear.
(3) Measure the voltage from pin 2 to chassis ground. The voltage should be less than 0.5 volts.
(4) Measure the voltage from pin 3 to chassis ground. The voltage should be less than 0.5 volts.
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.
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.
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.
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.
Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
During the shift from 3rd gear to 4th gear, the Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47)
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.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. Gear Command 2 signal wire shorted to a voltage source.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
BD08E039-01 1
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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
(1) Inspect Trax connector X-300 and the FNR Shift Lever 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 FNR Shift Lever. 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.
3. Measure the voltage at the FNR Shift Lever in third gear.
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
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
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
(1) FNR (Forward-Neutral-Reverse) (4) Remove wires from pin 2 and pin 3.
Switch
(2) Breakout Harness - Dealer pro- (5) Digital Volt Meter
vided
(3) Engine Harness (6) Chassis ground
(5) Measure the voltage from pin 2 to chassis ground. The voltage should be less than 0.5 volts.
(6) Measure the voltage from pin 3 to chassis ground. The voltage should be approximately 12 volts.
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.
(3) Measure the voltage from pin 2 to chassis ground. The voltage should be approximately 12 volts.
(4) Measure the voltage from pin 3 to chassis ground. The voltage should be approximately 12 volts.
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.
5. Measure the resistance through the harness
RCPH10TLB014BAM 6
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (3) Jumper wire between pin 2 and pin
Switch 3.
(2) Engine 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 less than 10 ohms.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Controller and retest. Go to Step
1 to confirm elimination of the fault.
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.
Wiring harness - Electrical schematic frame 05 (A.30.A.88-C.20.E.05)
Wiring harness - Electrical schematic frame 19 (A.30.A.88-C.20.E.19)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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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Cause:
During the shift from 3rd gear to 4th gear, the Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47)
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.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. Gear Command 2 signal wire shorted to a voltage source.
3. Faulty FNR Shift Lever.
4. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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.
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.
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.
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.
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
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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).
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
elimination of the fault.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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
3. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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 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
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.
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
an intermittent condition.
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(3) Measure the resistance from Transmission Temperature Sensor 329 (H-Type Transmission 389) pin 2 to
X-300 pin 17. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal
an intermittent condition.
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
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
The transmission temperature signal input is shorted to ground.
1. Faulty wiring or connections from the Transmission Temperature Sensor to the Trax Control.
2. Faulty sensor
3. Faulty Trax control
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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 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 Temperature Sensor. 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.
3. Measure the resistance of the temperature signal wire to chassis ground.
(2) Measure the resistance from Transmission Temperature Sensor 329 (H-Type Transmission 389) pin 1 to
chassis ground. 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 is less than 20,000 ohms. There is an short circuit to chassis ground. Repair
or replace the harness as required. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the Temperature Sensor
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
The transmission temperature signal input has an open circuit or the signal wire is shorted to another voltage source.
1. Faulty wiring or connections from the Transmission Temperature Sensor to the Trax Control.
2. Faulty sensor
3. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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 Temperature Sensor connections. All connections
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
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.
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).
(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
an intermittent condition.
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(3) Measure the resistance from Transmission Temperature Sensor 329 (H-Type Transmission 389) pin 2 to
X-300 pin 17. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal
an intermittent condition.
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 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.
Wiggle the harness during measurement to reveal an intermittent condition.
B. NOT OK – The voltage is greater than 0.5 volts. There is a short circuit to another voltage source. Repair
or replace the harness as required. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance of the Temperature Sensor
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.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Faulty wiring or connections from the Transmission Temperature Sensor to the Trax Control.
2. Faulty Charge Pressure switch
3. Faulty Trax control
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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 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.
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.
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
connector 328 (390).
(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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(3) Measure the resistance from Transmission Pressure Sensor 328 (H-Type Transmission 390) pin 2 to X-300
pin 17. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
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. 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.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Controller and retest. Go to Step
1 to confirm elimination of the fault.
B. NOT OK – The resistance is greater than 10 ohms. The switch is faulty. Replace the pressure switch.
Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(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.
3. Verify that the wiring and connectors are free of damage.
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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 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.
A. OK – The connectors are secure and the harness is free of damage. Go to Step 4.
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. 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
connector 328 (390).
(2) Measure the resistance from Transmission Pressure Sensor 328 (H-Type Transmission 390) pin 1 to X-300
pin 44. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
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(3) Measure the resistance from Transmission Pressure Sensor 328 (H-Type Transmission 390) pin 2 to X-300
pin 17. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an
intermittent condition.
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.
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.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Controller and retest. Go to Step
1 to confirm elimination of the fault.
B. NOT OK – The resistance is greater than 10 ohms. The switch is faulty. Replace the pressure switch.
Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
1. Faulty wiring or connections from the Transmission Temperature Sensor to the Trax Control.
2. Faulty Charge Pressure switch
3. Faulty Trax control.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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 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.
A. OK – The connectors are secure and the harness is free of damage. Go to Step 4.
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.
3. Check Charge Pressure switch
(3) Measure the resistance between pin 1 and pin 2 on the Charge Pressure switch. The resistance should be
greater than 20,000 ohms.
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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.
4. 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
connector 328 (390).
(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.
Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
Wiring harness - Electrical schematic frame 21 (A.30.A.88-C.20.E.21)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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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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.
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
(2) Verify the connections to the ECU, Instrument Cluster, TRAX Controller and Diagnostic Connector are tight
and secure.
(3) Verify the CAN Data Link connections from the ECU to the TRAX Control are tight and secure.
(4) 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 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.
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.
4. Measure harness resistance to chassis ground and positive battery.
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RCPH10TLB030FAM 1
Schematic Legend
(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 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
an intermittent condition.
(3) Measure the resistance from pin 27 on connector X-300 to chassis ground. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from pin 55 on connector X-300 to positive battery. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance from pin 27 on connector X-300 to positive battery. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
5. Measure the resistance through the CAN Data Link circuit.
(1) Turn the key switch OFF. Disconnect Trax Control connector X-300.
(2) Measure the resistance between X-300 pin 27 and pin 55. The resistance should be between 54 and 66
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance is between 54 and 66 ohms. Temporarily replace the Trax Control and retest. Go to
Step 1 to confirm elimination of the fault.
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.
(3) Measure the resistance between X-300 pin 27 and X-300 pin 55. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
(2) Use the jumper wire to short (connect) X-029 pin 4 to pin 3.
RCPH10TLB042FAM 2
Schematic Legend
(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 (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.
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
(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 (8) Jumper wire to short pin 34 to pin 35
(2) 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. Temporarily replace the ECU and retest. Go to Step 1 to confirm
elimination of the fault code.
B. NOT OK - The resistance is greater than 10 ohms. There is an open circuit in the CAN Data Link to the
engine ECU. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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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.
(1) Use the Electronic Service Tool to clear all fault codes.
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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Cause:
The Trax Control 5 volt sensor output is shorted to another voltage source.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH10TLB032GAM 1
Schematic legend
(1) Gear Switch 1 (5) 27k ohm resistor
(2) Gear Switch 2 (6) 62k ohm resistor
(3) Gear Switch 3 (7) 12k 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,
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.
3. Measure the voltage from X-300 pin 15 to chassis ground.
(4) Measure the voltage from X-300 pin 15 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
the harness during measurement to reveal an intermittent condition.
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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
replace the harness as required. Go to Step 1 to confirm elimination of fault.
4. Measure the resistance through the harness and resistor network
(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.
(6) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 12.0k Ω
± 10%.
(7) Reconnect connector 360 and disconnect Gear Switch connector 362.
(8) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 11.0k Ω
± 10%.
(9) Reconnect connector 362 and disconnect Gear Switch connector 363.
(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.
(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.
(4) Use back probes or fabricate a breakout Tee and measure the voltage from X-300 pin 45 to chassis ground.
Refer to the table below for the prober gear switch positions and voltage measurements.
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Cause:
The Trax Control 5 volt sensor output is shorted to ground.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH10TLB032GAM 1
Schematic legend
(1) Gear Switch 1 (5) 27k ohm resistor
(2) Gear Switch 2 (6) 62k ohm resistor
(3) Gear Switch 3 (7) 12k 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,
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.
3. Measure the resistance from X-300 pin 15 to chassis ground.
(3) Measure the resistance from X-300 pin 15 to chassis ground. 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 is less than 20,000 ohms. The wire is shorted to chassis ground. Repair or
replace the harness as required. Go to Step 1 to confirm elimination of fault.
4. Measure the resistance through the harness and resistor newtork
(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.
(6) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 12.0k Ω
± 10%.
(7) Reconnect connector 360 and disconnect Gear Switch connector 362.
(8) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 11.0k Ω
± 10%.
(9) Reconnect connector 362 and disconnect Gear Switch connector 363.
(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.
(4) 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.
(5) Use back probes or fabricate a breakout Tee and measure the voltage from X-300 pin 45 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 with reference to chassis ground.
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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Cause:
S-Type Transmission Only - The S1 solenoid driver (output) is shorted to ground (chassis ground). The machine will
go into Limp Home Mode in second gear (without modulation).
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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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
and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the S1 Solenoid. 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.
3. Measure the resistance to chassis ground.
(2) Measure the resistance from X-300 pin 9 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the S1
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 to chassis ground..
(1) Measure the resistance from solenoid connector 324 pin 1 to chassis ground. The resistance should be
greater than 20,000 ohms.
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A. OK – The resistance is greater than 20,000 ohms. Temporarily replace 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. Replace the S1 solenoid and retest. Return to Step
1 to confirm elimination of fault.
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Cause:
S-Type Transmission Only - The S4 solenoid driver (output) is shorted to ground (chassis ground). The machine will
go into Limp Home Mode in second gear (without modulation).
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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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
and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the S4 Solenoid. 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.
3. Measure the resistance to chassis ground.
(2) Measure the resistance from X-300 pin 38 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the S4
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 to chassis ground.
(1) Measure the resistance from solenoid connector 324 pin 1 to chassis ground. The resistance should be
greater than 20,000 ohms.
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A. OK – The resistance is greater than 20,000 ohms. Temporarily replace 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. Replace the S4 solenoid and retest. Return to Step
1 to confirm elimination of fault.
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Cause:
The gear indicated by the shift rail position sensors is not consistent with the gear the Trax control is commanding.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH11TLB006FAL 1
Schematic legend
(1) Gear Switch 1 (8) Trax Control
(2) Gear Switch 2 (9) S1 Solenoid
(3) Gear Switch 3 (10) S2 Solenoid
(4) Gear Switch 4 (11) S3 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
(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,
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.
3. Monitor 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.
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.
(3) Disconnect S2 solenoid connector 360. Measure the resistance through the switch. The resistance should
be less than 10 ohms.
(4) Disconnect S3 solenoid connector 362. Measure the resistance through the switch. The resistance should
be less than 10 ohms.
(5) Disconnect S4 solenoid connector 363. Measure the resistance through the switch. The resistance should
be less than 10 ohms.
B. NOT OK – One or more resistance measurements are less than 10 ohms. Replace the faulty gear switch.
Return to Step 1 to confirm elimination of fault.
6. Measure the resistance through the harness and resistor network
(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.
(6) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 12.0k Ω
± 10%.
(7) Reconnect connector 360 and disconnect Gear Switch connector 362.
(8) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 11.0k Ω
± 10%.
(9) Reconnect connector 362 and disconnect Gear Switch connector 363.
(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.
7. Verify harness after repairs.
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(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.
(4) Use back probes or fabricate a breakout Tee and measure the voltage from X-300 pin 45 to chassis ground.
Refer to the table below for the prober gear switch positions and voltage measurements.
(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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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:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH11TLB006FAL 1
Schematic legend
(1) Gear Switch 1 (8) Trax Control
(2) Gear Switch 2 (9) S1 Solenoid
(3) Gear Switch 3 (10) S2 Solenoid
(4) Gear Switch 4 (11) S3 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
(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,
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.
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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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:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
RCPH11TLB006FAL 1
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Schematic legend
(1) Gear Switch 1 (8) Trax Control
(2) Gear Switch 2 (9) S1 Solenoid
(3) Gear Switch 3 (10) S2 Solenoid
(4) Gear Switch 4 (11) S3 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
(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,
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.
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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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:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH11TLB006FAL 1
Schematic legend
(1) Gear Switch 1 (8) Trax Control
(2) Gear Switch 2 (9) S1 Solenoid
(3) Gear Switch 3 (10) S2 Solenoid
(4) Gear Switch 4 (11) S3 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
(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,
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.
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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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:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH11TLB006FAL 1
Schematic legend
(1) Gear Switch 1 (8) Trax Control
(2) Gear Switch 2 (9) S1 Solenoid
(3) Gear Switch 3 (10) S2 Solenoid
(4) Gear Switch 4 (11) S3 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
(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,
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.
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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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:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH11TLB006FAL 1
Schematic legend
(1) Gear Switch 1 (8) Trax Control
(2) Gear Switch 2 (9) S1 Solenoid
(3) Gear Switch 3 (10) S2 Solenoid
(4) Gear Switch 4 (11) S3 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
(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,
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.
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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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:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH11TLB006FAL 1
Schematic legend
(1) Gear Switch 1 (8) Trax Control
(2) Gear Switch 2 (9) S1 Solenoid
(3) Gear Switch 3 (10) S2 Solenoid
(4) Gear Switch 4 (11) S3 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
(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,
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.
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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Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH10TLB032GAM 1
Schematic legend
(1) Gear Switch 1 (5) 27k ohm resistor
(2) Gear Switch 2 (6) 62k ohm resistor
(3) Gear Switch 3 (7) 12k 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,
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.
3. Measure the resistance between the signal wire and ground.
(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.
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.
4. Measure the resistance through the harness.
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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.
(4) Measure the resistance between X-300 pin 54 and X-300 pin 17. The resistance should be approximately
27,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is 27,000 ohms ±10 percent. Temporarily replace the Trax Controller and retest. Go
to Step 1 to confirm elimination of fault.
(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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Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH10TLB032GAM 1
Schematic legend
(1) Gear Switch 1 (5) 27k ohm resistor
(2) Gear Switch 2 (6) 62k ohm resistor
(3) Gear Switch 3 (7) 12k 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,
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.
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
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 battery supply.
Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
4. Measure the resistance through the harness.
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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.
(4) Measure the resistance between X-300 pin 54 and X-300 pin 15. The resistance should be approximately
74,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is 74,000 ohms ±10 percent. Temporarily replace the Trax Controller and retest. Go
to Step 1 to confirm elimination of fault.
(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 A8. The resistance should be approxi-
mately 74,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is 74,000 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 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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Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH10TLB032GAM 1
Schematic legend
(1) Gear Switch 1 (5) 27k ohm resistor
(2) Gear Switch 2 (6) 62k ohm resistor
(3) Gear Switch 3 (7) 12k 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,
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.
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.
Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
4. Measure the resistance through the harness.
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(2) Use a suitable wire to short Gear Switch 4 connector, pin 1 to pin 2. Disconnect Gear Switch 3 connector
362 pin 1. Verify that the wire from pin 1 does not short to chassis ground or to Gear Switch connector pin 2.
(4) Measure the resistance between X-300 pin 45 and X-300 pin 17. The resistance should be approximately
27,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is 27,000 ohms ±10 percent. Temporarily replace the Trax Controller and retest. Go
to Step 1 to confirm elimination of fault.
(1) Disconnect the Trax Controller harness X-300 from the Sub Harness X-344/X-345.
(2) Measure the resistance between Sub Harness connector B8 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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Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
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RCPH10TLB032GAM 1
Schematic legend
(1) Gear Switch 1 (5) 27k ohm resistor
(2) Gear Switch 2 (6) 62k ohm resistor
(3) Gear Switch 3 (7) 12k 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,
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.
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
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 battery supply.
Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
4. Measure the resistance through the harness.
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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.
(4) Measure the resistance between X-300 pin 45 and X-300 pin 15. The resistance should be approximately
74,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is 74,000 ohms ±10 percent. Temporarily replace the Trax Controller and retest. Go
to Step 1 to confirm elimination of fault.
(1) Disconnect the Trax Controller harness X-300 from the Sub Harness X-344/X-345.
(2) Measure the resistance between Sub Harness connector B8 and A8. The resistance should be approxi-
mately 74,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is 74,000 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, 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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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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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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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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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.
2. Power supply to the Trax Control.
3. CAN communication interrupted during normal operation.
4. Faulty wiring or CAN Data Link connections from the Instrument Cluster to the Trax Control.
5. Faulty Trax Control
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
B. NOT OK – The VCM is not programmed properly. Reprogram the VCM. Go to Step 1 to confirm elimination
of fault.
3. 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 CAN Data Link connections from the ECU to the TRAX Control are tight and secure.
(4) 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 4.
B. NOT OK - The harness or connectors have damage. Repair as required. Go to Step 1 to confirm elimi-
nation of fault.
4. Measure battery voltage at the Trax Control.
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(2) Measure the voltage at the Trax Connector X-300 pin 1 to X-300 pin 29. The voltage should be approximately
12 volts.
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.
5. Measure harness resistance to chassis ground and positive battery.
RCPH10TLB030FAM 1
Schematic Legend
(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 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
an intermittent condition.
(3) Measure the resistance from pin 27 on connector X-300 to chassis ground. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from pin 55 on connector X-300 to positive battery. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance from pin 27 on connector X-300 to positive battery. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
6. Measure the resistance through the CAN Data Link circuit.
(1) Turn the key switch OFF. Disconnect Trax Control connector X-300.
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(2) Measure the resistance between X-300 pin 27 and pin 55. The resistance should be between 54 and 66
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance is between 54 and 66 ohms. Temporarily replace the Trax Control and retest. Go to
Step 1 to confirm elimination of the fault.
B. NOT OK - The resistance is less than 54 ohms or the resistance is greater than 66 ohms, go to test Step 7.
7. Measure the resistance between CAN High and CAN Low wires.
(2) Disconnect the ECU and Instrument Cluster Data Link connectors.
(3) Measure the resistance between X-300 pin 27 and X-300 pin 55. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
8. Measure the resistance of the CAN Circuit to the Instrument Cluster.
(2) Use the jumper wire to short (connect) X-029 pin 4 to pin 3.
RCPH10TLB042FAM 2
Schematic Legend
(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 (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. Temporarily replace the Instrument Cluster and retest. Go to
Step 1 to confirm elimination of the fault code.
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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.
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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.
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 existing fault codes, number of occurrences, and engine hours at
last occurrence.
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
(2) Verify the connections to the ECU, Instrument Cluster, TRAX Controller and Diagnostic Connector are tight
and secure.
(3) Verify the CAN Data Link connections from the ECU to the TRAX Control are tight and secure.
(4) 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 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.
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.
4. Measure harness resistance to chassis ground and positive battery.
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RCPH10TLB030FAM 1
Schematic Legend
(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 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
an intermittent condition.
(3) Measure the resistance from pin 27 on connector X-300 to chassis ground. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Measure the resistance from pin 55 on connector X-300 to positive battery. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance from pin 27 on connector X-300 to positive battery. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
5. Measure the resistance through the CAN Data Link circuit.
(1) Turn the key switch OFF. Disconnect Trax Control connector X-300.
(2) Measure the resistance between X-300 pin 27 and pin 55. The resistance should be between 54 and 66
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance is between 54 and 66 ohms. Temporarily replace the Trax Control and retest. Go to
Step 1 to confirm elimination of the fault.
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.
(3) Measure the resistance between X-300 pin 27 and X-300 pin 55. The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
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.
(2) Use the jumper wire to short (connect) X-029 pin 4 to pin 3.
RCPH10TLB042FAM 2
Schematic Legend
(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 (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. Temporarily replace the Instrument Cluster and retest. Go to
Step 1 to confirm elimination of the fault code.
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.
Wiring harness - Electrical schematic frame 04 (A.30.A.88-C.20.E.04)
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
Wiring harness - Electrical schematic frame 22 (A.30.A.88-C.20.E.22)
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Cause:
The Instrument Cluster received and error message that it did not recognize. The Instrument Cluster will illuminate
the Amber warning lamp.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(1) Verify that the Instrument Cluster and Trax Control have the latest versions of software. Contact Technical
Services Group for assistance.
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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Cause:
The Instrument Cluster received and error message that it did not recognize. The Instrument Cluster will illuminate
the Red warning lamp.
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.
(1) Use the Electronic Service Tool to clear all fault codes.
(1) Verify that the Instrument Cluster and Trax Control have the latest versions of software. Contact Technical
Services Group for assistance.
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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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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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Solution:
1. Verify that 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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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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.
(1) Use the Electronic Service Tool to clear all fault codes.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance.
Wiring harness - Electrical schematic frame 11 (A.30.A.88-C.20.E.11)
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Index
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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
3068-Cylinder 3 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3069-Cylinder 3 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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3070-Cylinder 3 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3071-Cylinder 3 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3076-Cylinder 2 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3077-Cylinder 2 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3078-Cylinder 2 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3079-Cylinder 2 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3080-Cylinder 4 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3081-Cylinder 4 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3082-Cylinder 4 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3083-Cylinder 4 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
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
3196-Cylinder 3 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3200-Cylinder 4 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
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
3230-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
3231-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3232-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3233-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
3234-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
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
3283-Sensor Supply Voltage 2 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
3284-Sensor Supply Voltage 2 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
3285-Sensor Supply Voltage 3 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
3286-Sensor Supply Voltage 3 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
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
9005-EEPROM checksum failure, hour meter location 2, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
9006-EEPROM checksum failure, hour meter location 3, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
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
PRINTED IN U.S.A.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
580N , 580SN WT , 580SN , 590SN
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ENGINE AND PTO IN - 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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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
Function Engine RPM speed
Rated speed – full load 2200 RPM
Idle speed 900 - 1000 RPM
High idle– no load 2330 - 2430 RPM
Torque converter stall 2080 - 2260 RPM
Backhoe hydraulic stall 2160 - 2300 RPM
Loader hydraulic stall 2240 - 2335 RPM
Combined stall 1695 - 1930 RPM
Model 590SN
Function Engine RPM speed
Rated speed – full load 2200 RPM
Idle speed 900 - 1000 RPM
High idle– no load 2320 - 2430 RPM
Torque converter stall 2125 - 2290 RPM
Backhoe hydraulic stall 2190 - 2300 RPM
Loader hydraulic stall 2240 - 2335 RPM
Combined stall 1830 - 2010 RPM
Model 580SN WT
Function Engine RPM speed
Rated speed – full load 2200 RPM
Idle speed 900 - 1000 RPM
High idle– no load 2330 - 2430 RPM
Torque converter stall 2150 - 2295 RPM
Backhoe hydraulic stall 2330 - 2420 RPM
Loader hydraulic stall 2330 - 2420 RPM
Combined stall 2090 - 2270 RPM
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.
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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
2 2190 to 2300 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2125 to 2290 output of the hydraulic pump.
4 Below 1830
1 Above 2335
2 2190 to 2300 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2125 to 2290 output of the hydraulic pump. Check for leakage in the loader control valve.
4 Above 2010
1 2240 to 2335
2 Below 2190 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2125 to 2290 output of the hydraulic pump.
4 1830 to 2010
1 2240 to 2335
2 Below 2190 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2125 to 2290 output of the hydraulic pump.
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
Torque converter or transmission problems.
3 Below 2125
4 Below 1830
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ID RPM Results
1 Below 2330
2 2330 to 2420 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2150 to 2295 output of the hydraulic pump.
4 Below 2090
1 Above 2420
2 2330 to 2420 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2150 to 2295 output of the hydraulic pump. Check for leakage in the loader control valve.
4 Above 2270
1 2330 to 2420
2 Below 2330 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2150 to 2295 output of the hydraulic pump.
4 2090 to 2270
1 2330 to 2420
2 Below 2330 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2150 to 2295 output of the hydraulic pump.
4 2090 to 2270
1 2330 to 2420
2 2330 to 2420
Torque converter or transmission problems.
3 Above 2295
4 Above 2270
1 2330 to 2420
2 2330 to 2420
Torque converter or transmission problems.
3 Below 2150
4 Below 2090
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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.
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16. Disconnect the fuel return line (1) and the fuel input
line (2).
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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).
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12. Connect the fuel return line (1) and the fuel input line
(2).
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18. Install the fixed hood and air cleaner. Secure the
fixed hood to the uprights with flat washers and cap
screws.
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19. Attach the aspiration hose and the crank case venti-
lation hose.
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Next operation:
ENGINE - Install - 580SN, 580SN-WT, 590SN only (B.10.A).
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Next operation:
Radiator - Install - 580SN, 580SN-WT, 590SN only (B.50.A)
Next operation:
Engine hood - Install (E.20.A)
Next operation:
Battery - Connect (A.30.A)
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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.
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Next operation:
Balancer - Install (B.10.A)
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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
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580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
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
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RCPH10TLB720ABL 1
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RCPH10TLB005BAL 2
RCPH10TLB721ABL 3
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RCPH10TLB044GAL 1
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RCPH10TLB742ABL 1
RCPH10TLB743ABL 2
RCPH10TLB744ABL 3
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RCPH10TLB745ABL 4
RCPH10TLB746ABL 5
RCPH10TLB747ABL 6
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RCPH10TLB748ABL 7
RCPH10TLB749ABL 9
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RCPH10TLB726ABL 10
RCPH10TLB738ABL 11
RCPH10TLB739ABL 12
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RCPH10TLB733ABL 13
RCPH10TLB734ABL 14
RCPH10TLB735ABL 15
RCPH10TLB734ABL 16
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RCPH10TLB733ABL 17
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RCPH11TLB001AAM 1
RCPH10TLB429AAF 2
RCPH10TLB738ABL 3
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RCPH10TLB739ABL 4
RCPH10TLB736ABL 5
RCPH10TLB035AAL 6
RCPH10TLB038AAL 7
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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
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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RCPH10TLB727ABL 12
RCPH10TLB724ABL 13
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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RCPH10TLB730ABL 16
RCPH10TLB731ABL 17
RCPH10TLB732ABL 18
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RCPH10TLB733ABL 19
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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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
RCPH10TLB734ABL 2
RCPH10TLB733ABL 3
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RCPH10TLB732ABL 4
RCPH10TLB731ABL 5
RCPH10TLB730ABL 6
9. Install oil filler tube (3), mechanical fuel pump (2), and
fuel filter (1) on the engine.
RCPH10TLB737ABL 7
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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
RCPH10TLB725ABL 10
RCPH10TLB722ABL 11
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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
RCPH10TLB035AAL 14
RCPH10TLB040AAL 15
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20. Install air cleaner inlet hose and tighten the hose
clamp.
RCPH10TLB739ABL 16
RCPH10TLB738ABL 17
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RCPH11TLB148AAM 1
2. Remove hardware.
3. Lower tank slightly.
RCPH11TLB148AAM 2
RCPH11TLB149AAM 3
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RCPH11TLB149AAM 4
RCPH11TLB150AAM 5
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RCPH11TLB150AAM 1
RCPH11TLB149AAM 2
RCPH11TLB148AAM 3
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Index
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580N
580SN WT
580SN
590SN
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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
Remove - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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RCPH10TLB013FAL 1
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RCPH10TLB014FAL 1
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RCPH10TLB022AAL 1
RCPH10TLB031AAL 3
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RCPH10TLB023AAL 4
Next operation:
Exhaust manifold - Install (B.40.A)
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RCPH10TLB022AAL 1
RCPH10TLB024AAL 3
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RCPH10TLB031AAL 4
RCPH10TLB023AAL 5
Next operation:
Exhaust manifold - Install (B.40.A)
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Index
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580N
580SN WT
580SN
590SN
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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
Remove - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install - 580SN, 580SN-WT, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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RCPH10TLB031GAL 1
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RCPH10TLB030GAL 1
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RCPH10TLB022AAL 1
RCPH10TLB051AAL 2
RCPH10TLB356AAF 3
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RCPH10TLB046AAL 4
7. Drive the pivot tubes out of the hood pivot point. Re-
move the hood from the machine.
RCPH10TLB044AAL 5
RCPH10TLB050AAL 6
RCPH10TLB046AAL 7
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RCPH10TLB408ACL 8
12. Disconnect all four oil cooler hoses, two on each side
of the machine, from the oil cooler.
RCPH10TLB047AAL 9
RCPH10TLB053AAL 10
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
Next operation:
Radiator - Install - 580N only (B.50.A).
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Next operation:
Radiator - Assemble (B.50.A)
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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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RCPH10TLB048AAL 1
RCPH10TLB053AAL 2
RCPH10TLB047AAL 3
RCPH10TLB408ACL 4
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RCPH10TLB054AAL 5
RCPH10TLB044AAL 6
RCPH10TLB046AAL 7
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RCPH10TLB356AAF 8
RCPH10TLB051AAL 9
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RCPH11TLB009AAM 1
RCPH11TLB010AAM 2
RCPH11TLB032AAM 3
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RCPH11TLB011AAM 4
RCPH11TLB012AAM 5
RCPH11TLB013AAM 6
RCPH11TLB014AAM 7
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RCPH11TLB015AAM 8
RCPH11TLB016AAM 9
RCPH11TLB017AAM 10
RCPH11TLB018AAM 11
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RCPH11TLB019AAM 12
RCPH11TLB020AAM 13
13. Disconnect A/C receiver dryer lines and cap all open
ports.
RCPH11TLB021AAM 14
RCPH11TLB022AAM 15
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RCPH11TLB023AAM 16
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
RCPH11TLB027AAM 20
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RCPH11TLB028AAM 21
RCPH11TLB029AAM 22
RCPH11TLB029AAM 23
RCPH11TLB030AAM 24
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RCPH11TLB029AAM 25
RCPH11TLB031AAM 26
Next operation:
Radiator - Install - 580SN, 580SN-WT, 590SN only (B.50.A).
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Next operation:
Radiator - Assemble (B.50.A)
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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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RCPH11TLB031AAM 1
RCPH11TLB029AAM 2
RCPH11TLB030AAM 3
RCPH11TLB029AAM 4
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RCPH11TLB029AAM 5
RCPH11TLB028AAM 6
RCPH11TLB027AAM 7
8. Remove the caps and install the four oil cooler lines.
Left hand oil cooler lines Right hand oil cooler lines
RCPH11TLB026AAM 8 RCPH11TLB025AAM 9
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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
RCPH11TLB021AAM 13
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RCPH11TLB020AAM 14
RCPH11TLB019AAM 15
RCPH11TLB017AAM 16
RCPH11TLB016AAM 17
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RCPH11TLB015AAM 18
RCPH11TLB014AAM 19
RCPH11TLB013AAM 20
RCPH11TLB032AAM 21
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
RCPH11TLB010AAM 22
RCPH11TLB009AAM 23
RCPH10TLB032AAF 24
RCPH11TLB018AAM 25
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Index
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ENGINE AND PTO IN - B
580N
580SN WT
580SN
590SN
84516378 05/07/2011
B.80.A / 1
Contents
TECHNICAL DATA
STARTING SYSTEM
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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
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 AND PTO IN - STARTING SYSTEM
RCPH10TLB062GAL 1
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ENGINE AND PTO IN - STARTING SYSTEM
RCPH11TLB001AAM 1
RCPH10TLB429AAF 2
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ENGINE AND PTO IN - STARTING SYSTEM
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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ENGINE AND PTO IN - STARTING SYSTEM
RCPH10TLB230ABL 1
RCPH10TLB232ABL 2
RCPH10TLB429AAF 3
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ENGINE AND PTO IN - STARTING SYSTEM
RCPH11TLB002AAM 4
RCPH11TLB001AAM 5
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ENGINE AND PTO IN - STARTING SYSTEM
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
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RCPH10TLB221ABL 2
RCPH10TLB222ABL 3
RCPH10TLB223ABL 4
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RCPH10TLB224ABL 5
RCPH10TLB225ABL 6
RCPH10TLB226ABL 7
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ENGINE AND PTO IN - STARTING SYSTEM
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
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RCPH10TLB185ABL 1
RCPH10TLB186ABL 2
RCPH10TLB187ABL 3
RCPH10TLB188ABL 4
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ENGINE AND PTO IN - STARTING SYSTEM
RCPH10TLB189ABL 5
RCPH10TLB190ABL 6
RCPH10TLB191ABL 7
RCPH10TLB192ABL 8
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ENGINE AND PTO IN - STARTING SYSTEM
RCPH10TLB193ABL 9
RCPH10TLB194ABL 10
RCPH10TLB195ABL 11
12. Remove the steel ball from the starter drive. If nec-
essary, use a magnet.
RCPH10TLB196ABL 12
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RCPH10TLB171ABL 13
RCPH10TLB172ABL 14
RCPH10TLB173ABL 15
RCPH10TLB174ABL 16
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ENGINE AND PTO IN - STARTING SYSTEM
RCPH10TLB175ABL 17
18. Loosen and remove the screws that hold the cover.
RCPH10TLB176ABL 18
RCPH10TLB177ABL 19
RCPH10TLB178ABL 20
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RCPH10TLB179ABL 21
RCPH10TLB180ABL 22
Next operation:
Starter solenoid - Inspect (B.80.A)
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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.
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
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ENGINE AND PTO IN - STARTING SYSTEM
RCPH10TLB169ABL 3
Next operation:
Starter solenoid - Install (B.80.A)
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RCPH10TLB218ABL 1
RCPH10TLB219ABL 2
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RCPH10TLB179ABL 1
RCPH10TLB181ABL 2
RCPH10TLB178ABL 3
RCPH10TLB182ABL 4
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RCPH10TLB183ABL 5
RCPH10TLB184ABL 6
RCPH10TLB212ABL 7
RCPH10TLB213ABL 8
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RCPH10TLB214ABL 9
RCPH10TLB215ABL 10
RCPH10TLB216ABL 11
RCPH10TLB217ABL 12
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ENGINE AND PTO IN - STARTING SYSTEM
13. Start the starter drive into the starter drive housing.
RCPH10TLB197ABL 13
RCPH10TLB198ABL 14
RCPH10TLB199ABL 15
RCPH10TLB194ABL 16
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RCPH10TLB200ABL 17
RCPH10TLB201ABL 18
19. Fasten the starter solenoid in the vise and tighten the
screws that hold the starter drive housing.
RCPH10TLB193ABL 19
RCPH10TLB192ABL 20
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RCPH10TLB191ABL 21
RCPH10TLB202ABL 22
RCPH10TLB203ABL 23
RCPH10TLB204ABL 24
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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
RCPH10TLB207ABL 27
28. Install the cover and align the cover with the brush
holder.
RCPH10TLB208ABL 28
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29. Install and tighten the screws that hold the brush
holder.
RCPH10TLB209ABL 29
RCPH10TLB210ABL 30
RCPH10TLB211ABL 31
32. Install the cable, lock washer, and nut on the motor
terminal, and tighten the nut.
RCPH10TLB185ABL 32
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RCPH10TLB229ABL 1
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.
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Index
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CNH - Main 700 State Street Racine, Wisconsin United States 53404
PRINTED IN U.S.A.
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
TRANSMISSION, DRIVE AND PTO OUT
580N
580SN WT
580SN
590SN
84516378 05/07/2011
C
Contents
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C
TRANSMISSION, DRIVE AND PTO OUT - C
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
FUNCTIONAL DATA
SERVICE
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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
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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
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.
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.
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RCPH11TLB020BAL 1
RCPH11TLB021BAL 2
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RCPH11TLB022BAL 3
RCPH11TLB023BAL 4
CAS-10280 Flowmeter
RCPH11TLB024BAL 5
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RCPH10TLB828AAL 6
RCPH10TLB043ABL 7
RCPH10TLB045BL 8
RCPH10TLB044ABL 9
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RCPH10TLB688AAL 10
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RCPH10TLB5GAL 1
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RCPH10TLB020GAL 1
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RCPH10TLB021GAL 1
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RCPH11TLB001HAL 1
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RCPH11TLB002HAL 1
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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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Next operation:
TRANSMISSION Power Shuttle - Install (C.20.C)
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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).
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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).
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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.
1. Engage the parking brake.
2. Start the engine. The oil should be at normal operat-
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).
6. Monitor the gauge and record the values for full throt-
tle, see TRANSMISSION Power Shuttle - Pressure
test — 2 Wheel Drive, Test Two — Engine at 2200
rpm (C.20.C) or TRANSMISSION Power Shuttle -
Pressure test — 4 Wheel Drive, Test Two — En-
gine at 2200 rpm (C.20.C).
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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.
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 3 (A).
4. Move the direction control lever to forward.
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).
6. Monitor the gauge and record the values for full throt-
tle, see TRANSMISSION Power Shuttle - Pressure
test — 2 Wheel Drive, Test Two — Engine at 2200
rpm (C.20.C) or TRANSMISSION Power Shuttle -
Pressure test — 4 Wheel Drive, Test Two — En-
gine at 2200 rpm (C.20.C).
RCPH11TLB016BAL 1
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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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.
1. Verify that all test equipment is clean.
2. Engage the parking brake.
3. Start the engine. The oil should be at normal operat-
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.
6. 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).
7. Monitor the gauge and record the values for full throt-
tle, see TRANSMISSION Power Shuttle - Pressure
test — 2 Wheel Drive, Test Two — Engine at 2200
rpm (C.20.C) or TRANSMISSION Power Shuttle -
Pressure test — 4 Wheel Drive, Test Two — En-
gine at 2200 rpm (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.
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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.
1. Engage the parking brake.
2. Start the engine. The oil should be at normal operat-
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.
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).
6. Monitor the gauge and record the values for full throt-
tle, see TRANSMISSION Power Shuttle - Pressure
test — 2 Wheel Drive, Test Two — Engine at 2200
rpm (C.20.C) or TRANSMISSION Power Shuttle -
Pressure test — 4 Wheel Drive, Test Two — En-
gine at 2200 rpm (C.20.C).
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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.
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 9 (A).
4. Place the transmission 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).
6. Monitor the gauge and record the values for full throt-
tle, see TRANSMISSION Power Shuttle - Pressure
test — 2 Wheel Drive, Test Two — Engine at 2200
rpm (C.20.C) or TRANSMISSION Power Shuttle -
Pressure test — 4 Wheel Drive, Test Two — En-
gine at 2200 rpm (C.20.C).
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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.
1. Engage the parking brake.
2. Place the transmission in neutral.
3. Start the engine. The oil should be at normal operat-
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.
8. 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).
9. Monitor the gauge and record the values for full throt-
tle, see TRANSMISSION Power Shuttle - Pressure
test — 2 Wheel Drive, Test Two — Engine at 2200
rpm (C.20.C) or TRANSMISSION Power Shuttle -
Pressure test — 4 Wheel Drive, Test Two — En-
gine at 2200 rpm (C.20.C).
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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
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(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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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
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Next operation:
Control valve - Assemble (C.20.C)
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Next operation:
Control valve - Disassemble (C.20.C)
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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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RCPH10TLB006ABL 9
10. Pull the wire and the terminal from the connector.
RCPH10TLB007ABL 10
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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
RCPH10TLB010ABL 18
20. Remove the four Allen head bolts that fasten the
modulation cover to the control valve body.
RCPH10TLB754AAL 19
RCPH10TLB758AAL 20
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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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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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Next operation:
Control valve - Assemble (C.20.C)
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RCPH10TLB757AAL 9
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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
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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
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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
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RCPH10TLB745AAL 20
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RCPH10TLB743AAL 27
Next operation:
Control valve - Disassemble (C.20.C)
Next operation:
Control valve - Disassemble (C.20.C)
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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
down so that there is clearance between the snap
ring and the thrust plate. Remove the snap ring.
RCPH10TLB797AAL 12
RCPH10TLB798AAL 13
RCPH10TLB800AAL 14
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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
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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.
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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.
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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.
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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.
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28. Put the input shaft in the bottom piece of the CAS-
2379 special tool as shown so that the forward clutch
is up.
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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.
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37. Tap lightly on the end plate to move the end plate
down so that there is clearance between the snap
ring and the end plate.
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39. Use pry bars to lift the end plate evenly. Remove the
end plate.
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44. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS-2379 special tool.
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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.
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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.
50. Use compressed air in the port shown to remove the
piston.
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Next operation:
Shaft - Inspect (C.20.C)
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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.
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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.
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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.
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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.
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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.
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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.
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32. 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.
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37. 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.
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42. 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.
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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.
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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.
52. 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.
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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.
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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.
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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 43 through 61 must be performed before
installing the Teflon sealing ring on the input shaft.
62. Place the 380001429 spacer into the 380001428 ex-
pander/protector.
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66. 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.
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NOTE: The art shows a clutch pack without the PTO through shaft, the procedures for steps 68 and 69 are the same.
68. 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,
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
Next operation:
Shaft - Disassemble (C.20.C)
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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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27. Remove the steel ring (1) and the bronze ring (2)to-
gether.
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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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30. This photo shows the relationship of the balls (1), the
spring plates (2), the springs (3), and the hub (4).
RCPH10TLB949AAL 29
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Next operation:
Shaft - Inspect (C.20.C)
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Next operation:
Shaft - Assemble (C.20.C)
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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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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.
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Next operation:
Shaft - Adjust (C.20.C)
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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
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:
Shaft - Disassemble (C.20.C)
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Next operation:
Shaft - Inspect (C.20.C)
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Next operation:
Shaft - Assemble (C.20.C)
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Next operation:
Shaft - Disassemble (C.20.C)
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Next operation:
Shaft - Inspect (C.20.C)
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Next operation:
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Next operation:
Shaft - Disassemble (C.20.C)
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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.
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10. Remove the shaft for the small gear only if the shaft
is damaged. The shaft will probably be difficult to
remove.
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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.
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13. Remove the plug, the spring, and the ball for the
torque converter relief valve.
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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:
Shaft - Inspect (C.20.C)
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Next operation:
Shaft - Assemble (C.20.C)
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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.
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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.
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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.
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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.
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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.
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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.
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Next operation:
Shaft - Disassemble (C.20.C)
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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.
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Next operation:
Shaft - Inspect (C.20.C)
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Next operation:
Shaft - Assemble (C.20.C)
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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.
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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.
9. 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.
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12. 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.
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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).
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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.
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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.
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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.
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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.
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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.
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18. Remove the seven bolts that fasten the pump mount
to the rear housing.
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20. Use a plastic mallet and tap the through shaft out of
the transmission rear housing.
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28. Remove the three Allen head bolts that fasten the
shifter housing to the rear cover. Remove the shifter
assembly and the O-ring.
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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.
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33. Remove the brake disc flange from the output shaft.
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35. At the three prying points, use pry bars and loosen
the rear cover from the transmission.
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40. Remove the two Allen head bolts that hold the plate
between the two shift rods.
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42. Remove the two shift interlock balls from the groove
between the two shift rods.
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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.
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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.
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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.
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54. Remove the three bolts that fasten the cover to the
front housing.
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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.
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59. Remove the six bolts that fasten the oil pump in po-
sition.
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60. Use two pry bars to lift the oil pump evenly until the
oil pump can be removed.
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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.
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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.
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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.
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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.
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75. Remove the shift rod and fork assembly for first and
second gear from the rear housing.
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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-
mission, go to step 79.
77. Remove the four-wheel drive clutch gear.
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82. Remove the three Allen head bolts that fasten the
valve plate to the front housing.
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Next operation:
Shaft - Disassemble (C.20.C)
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Next operation:
Housing - Disassemble (C.20.C)
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Next operation:
Housing - Assemble (C.20.C)
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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.
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Next operation:
Control valve - Disassemble (C.20.C)
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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.
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4. Install the gasket for the valve plate on the front hous-
ing.
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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
NOTE: Steps 8 through 9 are for four-wheel drive transmissions only. If you are working on a two-wheel drive trans-
mission, go to step 10.
8. Put the bearing for the four-wheel drive shaft into
position in the rear housing.
RCPH10TLB917AAL 8
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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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21. Install the pins to fasten the shift collars to the shift
rods.
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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
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.
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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
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RCPH10TLB022ABL 34
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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).
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44. Pull the input shaft toward the front of the transmis-
sion to get clearance for the snap ring.
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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).
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66. 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.
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.
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NOTE: Steps 74 through 77 are for four-wheel drive transmissions only. If you are working on a two-wheel drive
transmission, go to step 78.
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
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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RCPH10TLB698AAL 75
NOTE: Steps 80 through 82 are for four-wheel drive transmissions only. If you are working on a two-wheel drive
transmission, go to step 83.
80. Install the gasket for the four-wheel drive valve.
RCPH10TLB905AAL 76
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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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
RCPH10TLB692AAL 81
RCPH10TLB691AAL 82
NOTE: The following photo shows the drain plug for four wheel drive machines.
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RCPH10TLB690AAL 83
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Index
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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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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
TRANSMISSION Powershift
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
TRANSMISSION Powershift
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
TRANSMISSION Powershift
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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Specifications
NOTE: All pressures and flows must be measured with an oil temperature of 80 °C (176 °F).
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RCPH11TLB020BAL 1
RCPH11TLB022BAL 2
CAS-10280 Flowmeter
RCPH11TLB024BAL 3
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RCPH10TLB145GAL 1
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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
RCPH10TLB828AAL 1
380002211 - Handle
RCPH10TLB059AAL 2
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RCPH10TLB080AAL 3
RCPH10TLB073AAL 4
RCPH10TLB074AAL 5
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RCPH10TLB072AAL 6
RCPH10TLB078AAL 7
RCPH10TLB079AAL 8
84516378 05/07/2011
C.20.E / 12
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB075AAL 9
RCPH10TLB076AAL 10
RCPH10TLB077AAL 11
84516378 05/07/2011
C.20.E / 13
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB043ABL 12
84516378 05/07/2011
C.20.E / 14
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB14GAL 1
84516378 05/07/2011
C.20.E / 15
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB15GAL 2
84516378 05/07/2011
C.20.E / 16
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB014FAL 1
Connector view from end of connector.
84516378 05/07/2011
C.20.E / 17
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 18
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 19
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 20
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB6GAL 1
84516378 05/07/2011
C.20.E / 21
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 22
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB17GAL 1
84516378 05/07/2011
C.20.E / 23
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 24
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB16GAL 1
84516378 05/07/2011
C.20.E / 25
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 26
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB152GAL 1
84516378 05/07/2011
C.20.E / 27
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 28
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB153GAL 1
84516378 05/07/2011
C.20.E / 29
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 30
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB154GAL 1
84516378 05/07/2011
C.20.E / 31
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 32
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB155GAL 1
84516378 05/07/2011
C.20.E / 33
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 34
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB156GAL 1
84516378 05/07/2011
C.20.E / 35
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 36
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB157GAL 1
84516378 05/07/2011
C.20.E / 37
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 38
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB158GAL 1
84516378 05/07/2011
C.20.E / 39
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 40
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB002GAN 1
84516378 05/07/2011
C.20.E / 41
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 42
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB160GAL 1
84516378 05/07/2011
C.20.E / 43
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 44
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB161GAL 1
84516378 05/07/2011
C.20.E / 45
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 46
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB162GAL 1
84516378 05/07/2011
C.20.E / 47
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 48
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
84516378 05/07/2011
C.20.E / 49
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 50
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 51
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 52
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB018GAL 1
84516378 05/07/2011
C.20.E / 53
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 54
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 55
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
• 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.
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
84516378 05/07/2011
C.20.E / 56
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
84516378 05/07/2011
C.20.E / 57
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB016GAL 1
84516378 05/07/2011
C.20.E / 58
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 59
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 60
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB019GAL 1
84516378 05/07/2011
C.20.E / 61
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 62
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB018GAL 1
84516378 05/07/2011
C.20.E / 63
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB013FAL 1
Transmission control connector locations
NOTE: Remove the floor plate to gain access to the transmission control connectors, J1 and J2.
84516378 05/07/2011
C.20.E / 64
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB028BAL 3
84516378 05/07/2011
C.20.E / 65
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB081AAL 1
RCPH10TLB082AAL 2
RCPH10TLB083AAL 3
84516378 05/07/2011
C.20.E / 66
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB249AAL 4
RCPH10TLB092AAL 5
Next operation:
TRANSMISSION Powershift - Assemble (C.20.E)
84516378 05/07/2011
C.20.E / 67
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB035ACL 1
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
84516378 05/07/2011
C.20.E / 68
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB082AAL 4
RCPH10TLB081AAL 5
Next operation:
TRANSMISSION Powershift - Disassemble (C.20.E)
84516378 05/07/2011
C.20.E / 69
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB094AAL 1
RCPH10TLB251AAL 2
RCPH10TLB252AAL 3
84516378 05/07/2011
C.20.E / 70
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB095AAL 4
RCPH10TLB096AAL 5
Next operation:
TRANSMISSION Powershift - Assemble (C.20.E)
84516378 05/07/2011
C.20.E / 71
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB014ACL 1
2. Install O-ring.
RCPH10TLB095AAL 2
RCPH10TLB098AAL 3
84516378 05/07/2011
C.20.E / 72
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB099AAL 4
RCPH10TLB099AAL 5
NOTE: Ensure the marks on the oil pump and bellhouse line up.
Next operation:
Electronic control - Disassemble (C.20.E)
84516378 05/07/2011
C.20.E / 73
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
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).
84516378 05/07/2011
C.20.E / 74
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB067AAL 6
84516378 05/07/2011
C.20.E / 75
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB167ABL 7
RCPH10TLB026AAL 8
84516378 05/07/2011
C.20.E / 76
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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:
84516378 05/07/2011
C.20.E / 77
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 78
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
84516378 05/07/2011
C.20.E / 79
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB081AAL 1
RCPH10TLB082AAL 2
RCPH10TLB083AAL 3
84516378 05/07/2011
C.20.E / 80
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB249AAL 4
RCPH10TLB092AAL 5
RCPH10TLB084AAL 6
RCPH10TLB085AAL 7
84516378 05/07/2011
C.20.E / 81
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB086AAL 8
RCPH10TLB087AAL 9
RCPH10TLB088AAL 10
RCPH10TLB089AAL 11
84516378 05/07/2011
C.20.E / 82
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB090AAL 12
RCPH10TLB091AAL 13
RCPH10TLB093AAL 14
RCPH10TLB094AAL 15
84516378 05/07/2011
C.20.E / 83
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
17. Loosen the pump from the transmission with two pry
bars.
RCPH10TLB251AAL 16
RCPH10TLB252AAL 17
RCPH10TLB095AAL 18
RCPH10TLB096AAL 19
84516378 05/07/2011
C.20.E / 84
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB254AAL 22
RCPH10TLB596AAL 23
84516378 05/07/2011
C.20.E / 85
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB102AAL 24
RCPH10TLB103AAL 25
Parking Brake
27. Loosen the flange bolt.
RCPH10TLB596AAL 26
RCPH10TLB868AAL 27
84516378 05/07/2011
C.20.E / 86
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB594AAL 30
NOTICE: The housing is under spring pressure, failure to follow these instructions could damage the transmission.
84516378 05/07/2011
C.20.E / 87
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB872AAL 31
RCPH10TLB873AAL 32
RCPH10TLB874AAL 33
RCPH10TLB875AAL 34
84516378 05/07/2011
C.20.E / 88
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB876AAL 35
RCPH10TLB877AAL 36
RCPH10TLB599AAL 37
RCPH10TLB600AAL 38
84516378 05/07/2011
C.20.E / 89
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB601AAL 39
RCPH10TLB602AAL 40
RCPH10TLB603AAL 41
RCPH10TLB604AAL 42
84516378 05/07/2011
C.20.E / 90
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB104AAL 46
84516378 05/07/2011
C.20.E / 91
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB256AAL 47
49. Remove the teflon seal ring from the PTO shaft.
RCPH10TLB105AAL 48
RCPH10TLB257AAL 49
RCPH10TLB106AAL 50
84516378 05/07/2011
C.20.E / 92
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB260AAL 53
55. Remove and discard the O-rings from the rear hous-
ing.
RCPH10TLB107AAL 54
84516378 05/07/2011
C.20.E / 93
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB109AAL 55
57. Remove the cap screws and the shield from the 4
wheel drive clutch pack.
RCPH10TLB144AAL 56
RCPH10TLB145AAL 57
Input shaft
59. Remove the teflon seal ring.
RCPH10TLB110AAL 58
84516378 05/07/2011
C.20.E / 94
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB111AAL 59
RCPH10TLB112AAL 60
RCPH10TLB113AAL 61
RCPH10TLB114AAL 62
84516378 05/07/2011
C.20.E / 95
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB115AAL 63
RCPH10TLB116AAL 64
RCPH10TLB262AAL 65
RCPH10TLB262AAL 66
84516378 05/07/2011
C.20.E / 96
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB117AAL 67
69. Use pry bars to lift and remove the thrust plate.
RCPH10TLB118AAL 68
RCPH10TLB119AAL 69
RCPH10TLB120AAL 70
84516378 05/07/2011
C.20.E / 97
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
75. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS2379 special tool (not shown).
RCPH10TLB121AAL 74
84516378 05/07/2011
C.20.E / 98
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB122AAL 75
RCPH10TLB265AAL 76
RCPH10TLB123AAL 77
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.
84516378 05/07/2011
C.20.E / 99
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB266AAL 78
80. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 79
RCPH10TLB267AAL 80
RCPH10TLB125AAL 81
84516378 05/07/2011
C.20.E / 100
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB126AAL 82
RCPH10TLB303AAL 83
RCPH10TLB127AAL 84
84516378 05/07/2011
C.20.E / 101
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
Reverse shaft
87. Insert a shaft protector between the puller and the
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
84516378 05/07/2011
C.20.E / 102
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB273AAL 88
RCPH10TLB146AAL 89
RCPH10TLB274AAL 90
RCPH10TLB147AAL 91
84516378 05/07/2011
C.20.E / 103
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB275AAL 92
RCPH10TLB148AAL 93
RCPH10TLB149AAL 94
RCPH10TLB150AAL 95
84516378 05/07/2011
C.20.E / 104
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
98. Drive the thrust plate down away from the lock ring.
RCPH10TLB276AAL 96
RCPH10TLB277AAL 97
RCPH10TLB151AAL 98
RCPH10TLB278AAL 99
84516378 05/07/2011
C.20.E / 105
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
102. Install the top piece of the CAS2379 special tool (not
shown). Use the three threaded rods and nuts to
fasten the two pieces together.
RCPH10TLB152AAL 100
RCPH10TLB279AAL 101
104. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS2379 special tool (not shown).
RCPH10TLB152AAL 102
RCPH10TLB153AAL 103
84516378 05/07/2011
C.20.E / 106
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB154AAL 104
107. Use compressed air and remove the piston from the
clutch pack.
RCPH10TLB155AAL 105
RCPH10TLB266AAL 106
RCPH10TLB156AAL 107
84516378 05/07/2011
C.20.E / 107
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
110. Use a puller and remove the bearing from the shaft.
RCPH10TLB157AAL 108
RCPH10TLB172AAL 109
RCPH10TLB173AAL 110
RCPH10TLB174AAL 111
84516378 05/07/2011
C.20.E / 108
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB284AAL 112
RCPH10TLB285AAL 113
RCPH10TLB175AAL 114
RCPH10TLB176AAL 115
84516378 05/07/2011
C.20.E / 109
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
118. Install the top piece of the CAS2379 special tool (not
shown). Use the three threaded rods and nuts to
fasten the two pieces together, remove the snap ring.
RCPH10TLB286AAL 116
119. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS2379 special tool (not shown).
RCPH10TLB177AAL 117
RCPH10TLB287AAL 118
121. Use compressed air and remove the piston from the
clutch pack.
RCPH10TLB304AAL 119
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB180AAL 122
RCPH10TLB181AAL 123
84516378 05/07/2011
C.20.E / 111
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB182AAL 124
RCPH10TLB183AAL 125
RCPH10TLB288AAL 126
RCPH10TLB184AAL 127
84516378 05/07/2011
C.20.E / 112
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB071AAL 128
RCPH10TLB310AAL 129
RCPH10TLB185AAL 130
RCPH10TLB289AAL 131
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB186AAL 132
RCPH10TLB187AAL 133
136. 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 134
RCPH10TLB264AAL 135
84516378 05/07/2011
C.20.E / 114
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
138. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS2379 special tool (not shown).
RCPH10TLB121AAL 136
RCPH10TLB188AAL 137
RCPH10TLB305AAL 138
141. Remove the piston and sleeve from the clutch hous-
ing.
RCPH10TLB189AAL 139
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB266AAL 140
143. Turn the shaft over and remove the teflon seal rings.
RCPH10TLB190AAL 141
RCPH10TLB191AAL 142
RCPH10TLB192AAL 143
84516378 05/07/2011
C.20.E / 116
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB193AAL 144
RCPH10TLB194AAL 145
RCPH10TLB290AAL 146
RCPH10TLB310AAL 147
84516378 05/07/2011
C.20.E / 117
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB185AAL 148
RCPH10TLB289AAL 149
RCPH10TLB186AAL 150
RCPH10TLB187AAL 151
84516378 05/07/2011
C.20.E / 118
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
154. 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 152
RCPH10TLB264AAL 153
156. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS2379 special tool (not shown).
RCPH10TLB121AAL 154
RCPH10TLB188AAL 155
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB305AAL 156
159. Remove the piston and sleeve from the clutch hous-
ing.
RCPH10TLB189AAL 157
RCPH10TLB195AAL 158
84516378 05/07/2011
C.20.E / 120
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB221AAL 159
RCPH10TLB297AAL 160
RCPH10TLB222AAL 161
RCPH10TLB298AAL 162
84516378 05/07/2011
C.20.E / 121
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB223AAL 163
RCPH10TLB299AAL 164
RCPH10TLB224AAL 165
168. Push down on the thrust plate and remove the lock
ring.
RCPH10TLB225AAL 166
84516378 05/07/2011
C.20.E / 122
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB226AAL 167
RCPH10TLB227AAL 168
RCPH10TLB228AAL 169
RCPH10TLB603AAL 170
84516378 05/07/2011
C.20.E / 123
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB229AAL 171
Next operation:
TRANSMISSION Powershift - Cleaning (C.20.E)
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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)
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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.
84516378 05/07/2011
C.20.E / 126
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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.
84516378 05/07/2011
C.20.E / 127
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 128
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB603AAL 1
RCPH10TLB229AAL 2
RCPH10TLB300AAL 3
RCPH10TLB301AAL 4
84516378 05/07/2011
C.20.E / 129
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB230AAL 5
RCPH10TLB231AAL 6
RCPH10TLB232AAL 7
RCPH10TLB233AAL 8
84516378 05/07/2011
C.20.E / 130
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB234AAL 9
RCPH10TLB235AAL 10
RCPH10TLB236AAL 11
RCPH10TLB237AAL 12
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
13. Turn the clutch pack over. Make sure that the disk/
counter disk pack and the piston are seated.
RCPH10TLB238AAL 13
RCPH10TLB239AAL 14
RCPH10TLB240AAL 15
RCPH10TLB241AAL 16
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB302AAL 19
20. Install the washer and the shim(s) that was deter-
mined in step 16.
RCPH10TLB244AAL 20
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB245AAL 21
RCPH10TLB246AAL 22
RCPH10TLB247AAL 23
RCPH10TLB248AAL 24
84516378 05/07/2011
C.20.E / 134
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB196AAL 25
RCPH10TLB197AAL 26
27. Install a new teflon seal ring and O-ring on the clutch
piston.
RCPH10TLB198AAL 27
RCPH10TLB291AAL 28
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB199AAL 29
RCPH10TLB177AAL 30
31. Install the snap ring, make sure the snap ring is prop-
erly seated.
RCPH10TLB286AAL 31
RCPH10TLB200AAL 32
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
84516378 05/07/2011
C.20.E / 137
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB266AAL 36
RCPH10TLB160AAL 37
RCPH10TLB280AAL 38
RCPH10TLB161AAL 39
84516378 05/07/2011
C.20.E / 138
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB203AAL 40
RCPH10TLB162AAL 41
42. Install the snap ring, make sure the snap ring is prop-
erly seated.
RCPH10TLB163AAL 42
RCPH10TLB162AAL 43
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB204AAL 44
RCPH10TLB292AAL 45
46. Align the slot in the thrust washer with the roll pin.
RCPH10TLB293AAL 46
RCPH10TLB205AAL 47
84516378 05/07/2011
C.20.E / 140
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB206AAL 48
49. Install the retaining ring, make sure the retaining ring
is properly seated.
RCPH10TLB207AAL 49
50. Apply air pressure to the clutch pack to seat the thrust
plate against the retaining ring and release the air
pressure. Align the clutch disc splines.
RCPH10TLB208AAL 50
RCPH10TLB209AAL 51
84516378 05/07/2011
C.20.E / 141
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
52. Install the clutch hub into the clutch pack, make sure
the clutch hub seats completely.
RCPH10TLB210AAL 52
RCPH10TLB294AAL 53
54. Put 1st gear clutch pack onto 1st gear clutch hub,
make sure the clutch hub seats completely.
RCPH10TLB174AAL 54
84516378 05/07/2011
C.20.E / 142
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB307AAL 57
RCPH10TLB308AAL 58
84516378 05/07/2011
C.20.E / 143
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
84516378 05/07/2011
C.20.E / 144
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB266AAL 62
RCPH10TLB160AAL 63
RCPH10TLB280AAL 64
RCPH10TLB216AAL 65
84516378 05/07/2011
C.20.E / 145
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB295AAL 66
RCPH10TLB162AAL 67
68. Install the snap ring, make sure the snap ring is prop-
erly seated.
RCPH10TLB163AAL 68
RCPH10TLB162AAL 69
84516378 05/07/2011
C.20.E / 146
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB296AAL 70
RCPH10TLB205AAL 71
RCPH10TLB206AAL 72
73. Install the retaining ring, make sure the retaining ring
is properly seated.
RCPH10TLB207AAL 73
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
74. Apply air pressure to the clutch pack to seat the thrust
plate against the retaining ring and release the air
pressure. Align the clutch disc splines.
RCPH10TLB281AAL 74
RCPH10TLB209AAL 75
RCPH10TLB217AAL 76
77. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB218AAL 77
84516378 05/07/2011
C.20.E / 148
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB158AAL 81
84516378 05/07/2011
C.20.E / 149
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
84516378 05/07/2011
C.20.E / 150
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB216AAL 86
RCPH10TLB295AAL 87
RCPH10TLB162AAL 88
89. Install the snap ring, make sure the snap ring is prop-
erly seated.
RCPH10TLB163AAL 89
84516378 05/07/2011
C.20.E / 151
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB162AAL 90
RCPH10TLB164AAL 91
RCPH10TLB165AAL 92
93. Align the slot on the thrust washer with the roll pin,
install the thrust washer and the needle bearing.
RCPH10TLB166AAL 93
84516378 05/07/2011
C.20.E / 152
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
94. Install the thrust plate and drive it down evenly to the
clutch disc.
RCPH10TLB167AAL 94
95. Install the retaining ring, make sure the retaining ring
is properly seated.
RCPH10TLB168AAL 95
96. Apply air pressure to the clutch pack to seat the thrust
plate against the retaining ring and release the air
pressure. Align the clutch disc splines.
RCPH10TLB281AAL 96
97. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB169AAL 97
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB170AAL 98
99. Align the slot on the thrust washer with the roll pin,
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
84516378 05/07/2011
C.20.E / 154
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
84516378 05/07/2011
C.20.E / 155
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB266AAL 105
RCPH10TLB160AAL 106
RCPH10TLB280AAL 107
RCPH10TLB216AAL 108
84516378 05/07/2011
C.20.E / 156
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB295AAL 109
RCPH10TLB162AAL 110
111. Install the snap ring, make sure the snap ring is prop-
erly seated.
RCPH10TLB163AAL 111
RCPH10TLB162AAL 112
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB129AAL 113
114. Align the slot on the thrust washer with the roll pin,
install the thrust washer.
RCPH10TLB130AAL 114
RCPH10TLB131AAL 115
RCPH10TLB132AAL 116
84516378 05/07/2011
C.20.E / 158
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB133AAL 117
RCPH10TLB134AAL 118
119. Install the retaining ring, make sure the retaining ring
is properly seated.
RCPH10TLB269AAL 119
RCPH10TLB114AAL 120
84516378 05/07/2011
C.20.E / 159
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB135AAL 121
RCPH10TLB136AAL 122
RCPH10TLB826AAL 123
RCPH10TLB829AAL 124
84516378 05/07/2011
C.20.E / 160
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB830AAL 125
RCPH10TLB840AAL 126
127. 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.
RCPH10TLB827AAL 127
RCPH10TLB137AAL 128
129. Turn the shaft over and repeat steps 104to 118and
assemble the other clutch pack.
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB821AAL 132
84516378 05/07/2011
C.20.E / 162
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB831AAL 133
RCPH10TLB838AAL 134
RCPH10TLB839AAL 135
137. 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 136
84516378 05/07/2011
C.20.E / 163
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB822AAL 137
RCPH10TLB832AAL 138
RCPH10TLB837AAL 139
RCPH10TLB839AAL 140
84516378 05/07/2011
C.20.E / 164
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
142. 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 141
RCPH10TLB823AAL 142
RCPH10TLB833AAL 143
RCPH10TLB836AAL 144
84516378 05/07/2011
C.20.E / 165
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB839AAL 145
147. 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 146
RCPH10TLB824AAL 147
RCPH10TLB834AAL 148
84516378 05/07/2011
C.20.E / 166
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB835AAL 149
RCPH10TLB839AAL 150
152. 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 151
Transmission Housings
153. Lubricate the bores of the transmission housing that
house teflon sealing rings.
RCPH10TLB143AAL 152
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB145AAL 153
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
84516378 05/07/2011
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB261AAL 157
RCPH10TLB107AAL 158
RCPH10TLB260AAL 159
NOTE: Do not bind the shafts to prevent damaging the teflon seal rings.
84516378 05/07/2011
C.20.E / 169
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB108AAL 160
RCPH10TLB258AAL 161
PTO Shaft
164. Slide the expander/protector onto the pump drive
shaft.
RCPH10TLB842AAL 162
RCPH10TLB843AAL 163
84516378 05/07/2011
C.20.E / 170
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB844AAL 164
RCPH10TLB845AAL 165
168. 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.
RCPH10TLB846AAL 166
169. Install the bearing and snap ring on the PTO shaft.
170. Put the PTO shaft into the transmission.
RCPH10TLB256AAL 167
84516378 05/07/2011
C.20.E / 171
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB104AAL 168
RCPH10TLB255AAL 169
Parking Brake
174. Install a new O-ring on the brake housing.
RCPH10TLB607AAL 170
84516378 05/07/2011
C.20.E / 172
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB595AAL 171
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
RCPH10TLB601AAL 174
NOTICE: Make sure the retainer is properly seated before removing spring compressor.
84516378 05/07/2011
C.20.E / 173
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB600AAL 175
RCPH10TLB599AAL 176
RCPH10TLB877AAL 177
RCPH10TLB876AAL 178
84516378 05/07/2011
C.20.E / 174
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB875AAL 179
RCPH10TLB874AAL 180
RCPH10TLB873AAL 181
RCPH10TLB872AAL 182
84516378 05/07/2011
C.20.E / 175
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB871AAL 183
RCPH10TLB869AAL 184
RCPH10TLB868AAL 185
RCPH10TLB870AAL 186
84516378 05/07/2011
C.20.E / 176
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB254AAL 187
Pump
192. Install a new O-ring.
RCPH10TLB095AAL 188
RCPH10TLB097AAL 189
84516378 05/07/2011
C.20.E / 177
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB098AAL 190
RCPH10TLB253AAL 191
RCPH10TLB099AAL 192
RCPH10TLB252AAL 193
84516378 05/07/2011
C.20.E / 178
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB094AAL 194
RCPH10TLB093AAL 195
RCPH10TLB250AAL 196
RCPH10TLB082AAL 197
84516378 05/07/2011
C.20.E / 179
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB081AAL 198
RCPH10TLB085AAL 199
RCPH10TLB090AAL 200
RCPH10TLB091AAL 201
84516378 05/07/2011
C.20.E / 180
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 181
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 182
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB007FAL 1
EST screen shot showing parameters being monitored.
84516378 05/07/2011
C.20.E / 183
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB006GAL 1
Left Side View
84516378 05/07/2011
C.20.E / 184
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB007GAL 2
Front View
84516378 05/07/2011
C.20.E / 185
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB008GAL 3
Right Side View
84516378 05/07/2011
C.20.E / 186
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
84516378 05/07/2011
C.20.E / 187
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB010GAL 5
Top View
84516378 05/07/2011
C.20.E / 188
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB014GAL 1
Top Right View
84516378 05/07/2011
C.20.E / 189
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB015GAL 2
Left Side View
84516378 05/07/2011
C.20.E / 190
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB012GAL 3
Right Side View
84516378 05/07/2011
C.20.E / 191
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB013GAL 4
Top Left View
84516378 05/07/2011
C.20.E / 192
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 193
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB081AAL 1
84516378 05/07/2011
C.20.E / 194
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB001GAL 1
84516378 05/07/2011
C.20.E / 195
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB011FAL 2
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
84516378 05/07/2011
C.20.E / 196
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH11TLB012GAL 1
Right Side View
84516378 05/07/2011
C.20.E / 197
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 198
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB152ACL 1
RCPH10TLB153ACL 2
4. Remove the screws (1) and the HDL and 4WD valves
(2).
RCPH10TLB154ACL 3
84516378 05/07/2011
C.20.E / 199
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB155ACL 4
RCPH10TLB040ACL 5
RCPH10TLB158ACL 6
RCPH10TLB154ACL 7
84516378 05/07/2011
C.20.E / 200
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB156ACL 8
RCPH10TLB041ACL 9
RCPH10TLB159ACL 10
RCPH10TLB160ACL 11
84516378 05/07/2011
C.20.E / 201
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB042ACL 12
RCPH10TLB192ACL 13
RCPH10TLB191ACL 14
RCPH10TLB190ACL 15
84516378 05/07/2011
C.20.E / 202
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB190ACL 16
RCPH10TLB189ACL 17
RCPH10TLB188ACL 18
RCPH10TLB187ACL 19
16. Remove the S1 (1st and 2nd gear) and S3 (3rd and
4th gear) solenoid valves.
84516378 05/07/2011
C.20.E / 203
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB252ACL 20
RCPH10TLB043ACL 21
RCPH10TLB186ACL 22
RCPH10TLB185ACL 23
84516378 05/07/2011
C.20.E / 204
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB184ACL 24
RCPH10TLB183ACL 25
RCPH10TLB182ACL 26
84516378 05/07/2011
C.20.E / 205
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB080ACL 27
84516378 05/07/2011
C.20.E / 206
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB080ACL 1
RCPH10TLB182ACL 2
RCPH10TLB183ACL 3
84516378 05/07/2011
C.20.E / 207
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB184ACL 4
RCPH10TLB185ACL 5
RCPH10TLB180ACL 6
RCPH10TLB187ACL 7
84516378 05/07/2011
C.20.E / 208
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB181ACL 8
RCPH10TLB189ACL 9
RCPH10TLB189ACL 10
RCPH10TLB190ACL 11
84516378 05/07/2011
C.20.E / 209
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB191ACL 12
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
84516378 05/07/2011
C.20.E / 210
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
20. Install the screws for the HDL, 4WD, REV and FWD
valves. Tighten the screws to specifications.
RCPH10TLB253ACL 16
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
Next operation:
Housing - Disassemble (C.20.E)
84516378 05/07/2011
C.20.E / 211
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB109AAL 1
RCPH10TLB045ACL 2
RCPH10TLB050ACL 3
84516378 05/07/2011
C.20.E / 212
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB049ACL 4
RCPH10TLB255ACL 5
RCPH10TLB256ACL 6
RCPH10TLB193ACL 7
84516378 05/07/2011
C.20.E / 213
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB105AAL 8
RCPH10TLB257AAL 9
RCPH10TLB106AAL 10
RCPH10TLB194ACL 11
84516378 05/07/2011
C.20.E / 214
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB145AAL 12
Next operation:
Shaft - Assemble (C.20.E)
84516378 05/07/2011
C.20.E / 215
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB719AAL 1
RCPH10TLB720AAL 2
RCPH10TLB732AAL 3
RCPH10TLB732AAL 4
84516378 05/07/2011
C.20.E / 216
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB257ACL 5
RCPH10TLB078ACL 6
RCPH10TLB257ACL 7
84516378 05/07/2011
C.20.E / 217
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB257AAL 8
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
RCPH10TLB256ACL 11
84516378 05/07/2011
C.20.E / 218
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
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
84516378 05/07/2011
C.20.E / 219
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB166ACL 16
RCPH10TLB167ACL 17
RCPH10TLB002AAN 18
RCPH10TLB001AAN 19
Next operation:
84516378 05/07/2011
C.20.E / 220
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 221
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB062ACL 1
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
84516378 05/07/2011
C.20.E / 222
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB251ACL 4
RCPH10TLB251ACL 5
RCPH10TLB064ACL 6
RCPH10TLB065ACL 7
84516378 05/07/2011
C.20.E / 223
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB058ACL 8
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
84516378 05/07/2011
C.20.E / 224
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB172ACL 11
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
84516378 05/07/2011
C.20.E / 225
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB217ACL 14
RCPH10TLB066ACL 15
RCPH10TLB061ACL 16
Next operation:
Shaft - Assemble (C.20.E)
84516378 05/07/2011
C.20.E / 226
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB233ACL 1
RCPH10TLB048ACL 2
RCPH10TLB234ACL 3
RCPH10TLB196ACL 4
84516378 05/07/2011
C.20.E / 227
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB197ACL 5
RCPH10TLB140ACL 6
RCPH10TLB233ACL 7
RCPH10TLB048ACL 8
84516378 05/07/2011
C.20.E / 228
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB234ACL 9
RCPH10TLB046ACL 10
RCPH10TLB266ACL 11
RCPH10TLB267ACL 12
84516378 05/07/2011
C.20.E / 229
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB067ACL 13
RCPH10TLB269ACL 14
RCPH10TLB270ACL 15
16. Engage the 3rd speed gear and check that the bush-
ing top is in range.
84516378 05/07/2011
C.20.E / 230
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB047ACL 16
RCPH10TLB146ACL 17
RCPH10TLB068ACL 18
RCPH10TLB147ACL 19
84516378 05/07/2011
C.20.E / 231
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
21. Engage the 4th speed gear and check that bushing
top is in the range as shown in next figure.
RCPH10TLB148ACL 20
RCPH10TLB066ACL 21
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
84516378 05/07/2011
C.20.E / 232
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB069ACL 24
RCPH10TLB236ACL 25
27. Push the piston into the seat using a soft tool mate-
rial. Remove the special tools.
RCPH10TLB237ACL 26
RCPH10TLB048ACL 27
84516378 05/07/2011
C.20.E / 233
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB196ACL 28
RCPH10TLB048ACL 29
RCPH10TLB196ACL 30
RCPH10TLB170ACL 31
84516378 05/07/2011
C.20.E / 234
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
33. Push the piston in your seat using a soft tool material.
Remove the special tool.
RCPH10TLB171ACL 32
RCPH10TLB070ACL 33
RCPH10TLB172ACL 34
RCPH10TLB172ACL 35
84516378 05/07/2011
C.20.E / 235
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB173ACL 36
RCPH10TLB065ACL 37
RCPH10TLB174ACL 38
RCPH10TLB144ACL 39
84516378 05/07/2011
C.20.E / 236
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB145ACL 40
RCPH10TLB062ACL 41
RCPH10TLB049ACL 42
Next operation:
Clutch and gear - Measure (C.20.E)
84516378 05/07/2011
C.20.E / 237
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB109AAL 1
RCPH10TLB110AAL 2
RCPH10TLB111AAL 3
RCPH10TLB112AAL 4
84516378 05/07/2011
C.20.E / 238
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB113AAL 5
RCPH10TLB117AAL 6
RCPH10TLB115AAL 7
RCPH10TLB116AAL 8
84516378 05/07/2011
C.20.E / 239
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB262AAL 9
RCPH10TLB262AAL 10
RCPH10TLB117AAL 11
12. Use pry bars to lift and to remove the thrust plate.
RCPH10TLB118AAL 12
84516378 05/07/2011
C.20.E / 240
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB119AAL 13
RCPH10TLB120AAL 14
15. Place a mark on each thrust plate and the lock ring.
RCPH10TLB263AAL 15
16. 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 16
84516378 05/07/2011
C.20.E / 241
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB264AAL 17
18. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS2379 special tool (not shown).
RCPH10TLB121AAL 18
RCPH10TLB122AAL 19
RCPH10TLB265AAL 20
84516378 05/07/2011
C.20.E / 242
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB123AAL 21
RCPH10TLB266AAL 22
23. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 23
RCPH10TLB267AAL 24
84516378 05/07/2011
C.20.E / 243
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB125AAL 25
RCPH10TLB126AAL 26
RCPH10TLB303AAL 27
RCPH10TLB127AAL 28
84516378 05/07/2011
C.20.E / 244
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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.
Use new parts as required.
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
84516378 05/07/2011
C.20.E / 245
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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:
Shaft - Assemble (C.20.E)
84516378 05/07/2011
C.20.E / 246
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB266AAL 1
RCPH10TLB198AAL 2
RCPH10TLB931AAL 3
4. Assemble sleeve.
RCPH10TLB116AAL 4
84516378 05/07/2011
C.20.E / 247
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB122AAL 5
6. Lower the lock spring cover. Insert lock ring Use tool
380100109 or CAS2379.
RCPH10TLB121AAL 6
7. Insert pin.
RCPH10TLB129AAL 7
RCPH10TLB130AAL 8
84516378 05/07/2011
C.20.E / 248
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB131AAL 9
RCPH10TLB132AAL 10
RCPH10TLB133AAL 11
RCPH10TLB134AAL 12
84516378 05/07/2011
C.20.E / 249
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB135AAL 13
RCPH10TLB135AAL 14
RCPH10TLB136AAL 15
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.
84516378 05/07/2011
C.20.E / 250
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB140AAL 16
RCPH10TLB826AAL 17
RCPH10TLB826AAL 18
RCPH10TLB830AAL 19
84516378 05/07/2011
C.20.E / 251
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB831AAL 20
21. Turn the seal compressor around and slide the end
with the narrow chamfer over the shaft and over the
seal ring. Leave the seal compressor in place for
15 minutes until the sealing ring has cooled and is
properly sized and seated in the groove. After the
seal ring has cooled, remove the seal compressor
from the shaft.
RCPH10TLB841AAL 21
RCPH10TLB170AAL 22
RCPH10TLB211AAL 23
84516378 05/07/2011
C.20.E / 252
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB897AAL 25
RCPH10TLB899AAL 26
RCPH10TLB902AAL 27
84516378 05/07/2011
C.20.E / 253
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB904AAL 28
30. Turn the seal compressor around and slide the end
with the narrow chamfer over the shaft and over the
seal ring. Leave the seal compressor in place for
15 minutes until the sealing ring has cooled and is
properly sized and seated in the groove. After the
seal ring has cooled, remove the seal compressor
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
84516378 05/07/2011
C.20.E / 254
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
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
RCPH10TLB125ACL 35
84516378 05/07/2011
C.20.E / 255
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB177ACL 36
RCPH10TLB136ACL 37
Next operation:
Shaft - Disassemble (C.20.E)
84516378 05/07/2011
C.20.E / 256
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB913AAL 1
RCPH10TLB915AAL 2
RCPH10TLB113AAL 3
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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RCPH10TLB076ACL 9
RCPH10TLB288AAL 10
RCPH10TLB184AAL 11
RCPH10TLB098ACL 12
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RCPH10TLB785AAL 13
RCPH10TLB137ACL 14
RCPH10TLB187AAL 15
RCPH10TLB193AAL 16
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RCPH10TLB101ACL 17
RCPH10TLB051ACL 18
RCPH10TLB052ACL 19
RCPH10TLB053ACL 20
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RCPH10TLB054ACL 21
22. Remove the steel ring (1)and the sintered ring (2).
RCPH10TLB055ACL 22
RCPH10TLB056ACL 23
RCPH10TLB079ACL-2 24
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RCPH10TLB079ACL-2 25
RCPH10TLB102ACL 26
RCPH10TLB103ACL 27
RCPH10TLB104ACL 28
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RCPH10TLB105ACL 29
RCPH10TLB080ACL-2 30
Next operation:
Shaft - Assemble (C.20.E)
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RCPH10TLB105ACL 1
RCPH10TLB104ACL 2
RCPH10TLB103ACL 3
RCPH10TLB102ACL 4
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RCPH10TLB951AAL 5
RCPH10TLB952AAL 6
RCPH10TLB056ACL 7
RCPH10TLB946AAL 8
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RCPH10TLB945AAL 9
RCPH10TLB947AAL 10
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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
RCPH10TLB100ACL 13
RCPH10TLB099ACL 14
RCPH10TLB107ACL 15
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RCPH10TLB081ACL-2 16
RCPH10TLB108ACL 17
RCPH10TLB137ACL 18
RCPH10TLB082ACL 19
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RCPH10TLB097ACL 20
RCPH10TLB135ACL 21
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
RCPH10TLB106ACL 26
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RCPH10TLB084ACL 27
RCPH10TLB085ACL 28
RCPH10TLB086ACL 29
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
RCPH10TLB178ACL 32
RCPH10TLB164ACL 33
Next operation:
Shaft - Disassemble (C.20.E)
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RCPH10TLB719AAL 1
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
RCPH10TLB890AAL 6
RCPH10TLB027ABL 7
Next operation:
Shaft - Assemble (C.20.E)
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RCPH10TLB090ACL 1
2. Assemble sleeve.
RCPH10TLB129ACL 2
3. Assemble springs.
RCPH10TLB128ACL 3
4. Install spacer.
RCPH10TLB127ACL 4
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RCPH10TLB092ACL 5
RCPH10TLB091ACL 6
RCPH10TLB093ACL 7
RCPH10TLB094ACL 8
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RCPH10TLB095ACL 9
10. 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.
RCPH10TLB095ACL 10
RCPH10TLB096ACL 11
RCPH10TLB164GAL 12
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB124ACL 13
RCPH10TLB123ACL 14
RCPH10TLB122ACL 15
RCPH10TLB130ACL 16
Next operation:
Shaft - Disassemble (C.20.E)
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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
RCPH10TLB198ACL 4
Next operation:
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RCPH10TLB141ACL 1
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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RCPH10TLB075ACL 4
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
RCPH10TLB178ACL 10
RCPH10TLB164ACL 11
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RCPH10TLB213ACL 1
RCPH10TLB242ACL 2
RCPH10TLB241ACL 3
RCPH10TLB263ACL 4
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB258ACL 5
RCPH10TLB259ACL 6
RCPH10TLB260ACL 7
RCPH10TLB261ACL 8
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB262ACL 9
RCPH10TLB026ACL 10
RCPH10TLB264ACL 11
RCPH10TLB265ACL 12
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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
RCPH10TLB268ACL 15
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:
Clutch and gear - Measure (C.20.E)
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RCPH10TLB210ACL 1
RCPH10TLB243ACL 2
RCPH10TLB210ACL 3
RCPH10TLB027ACL 4
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB264ACL 5
RCPH10TLB265ACL 6
RCPH10TLB016ACL 7
RCPH10TLB211ACL 8
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB212ACL 9
RCPH10TLB213ACL 10
RCPH10TLB214ACL 11
Next operation:
Clutch and gear - Measure (C.20.E)
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB244ACL 1
RCPH10TLB215ACL 2
RCPH10TLB028ACL 3
4. D(2) measurement.
RCPH10TLB216ACL 4
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RCPH10TLB029ACL 5
Next operation:
Clutch and gear - Measure (C.20.E)
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB219ACL 1
RCPH10TLB247ACL 2
RCPH10TLB247ACL 3
RCPH10TLB218ACL 4
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB030ACL 5
RCPH10TLB031ACL 6
RCPH10TLB032ACL 7
RCPH10TLB245ACL 8
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB219ACL 9
RCPH10TLB248ACL 10
RCPH10TLB243ACL 11
RCPH10TLB208ACL 12
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RCPH10TLB209ACL 13
RCPH10TLB015ACL 14
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
RCPH10TLB220ACL 2
RCPH10TLB221ACL 3
RCPH10TLB222ACL 4
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB151ACL 5
RCPH10TLB223ACL 6
RCPH10TLB224ACL 7
RCPH10TLB018ACL 8
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB225ACL 9
RCPH10TLB024ACL 10
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
RCPH10TLB227ACL 14
RCPH10TLB227ACL 15
RCPH10TLB231ACL 16
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RCPH10TLB229ACL 17
RCPH10TLB230ACL 18
RCPH10TLB019ACL 19
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
RCPH10TLB018ACL 22
RCPH10TLB230ACL 23
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RCPH10TLB022ACL 24
RCPH10TLB230ACL 25
RCPH10TLB021ACL 26
RCPH10TLB230ACL 27
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB020ACL 28
RCPH10TLB230ACL 29
RCPH10TLB018ACL 30
RCPH10TLB230ACL 31
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RCPH10TLB022ACL 32
RCPH10TLB230ACL 33
RCPH10TLB022ACL 34
RCPH10TLB230ACL 35
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RCPH10TLB230ACL 36
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
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Next operation:
Shaft - Disassemble (C.20.E)
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RCPH10TLB258AAL 1
RCPH10TLB176ACL 2
RCPH10TLB110ACL 3
4. Remove washer.
RCPH10TLB111ACL 4
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RCPH10TLB112ACL 5
RCPH10TLB113ACL 6
RCPH10TLB114ACL 7
RCPH10TLB115ACL 8
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RCPH10TLB116ACL 9
RCPH10TLB132ACL 10
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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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
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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RCPH10TLB118ACL 17
18. Remove the input shaft (1). Remove the idler shaft
(2).
RCPH10TLB177ACL 18
RCPH10TLB044ACL 19
RCPH10TLB249ACL 20
Next operation:
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB161ACL 1
2. Remove all the old sealant from the rear housing cou-
pling surface with a suitable tool.
RCPH10TLB202ACL 2
RCPH10TLB201ACL 3
RCPH10TLB203ACL 4
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB204ACL 5
RCPH10TLB162ACL 6
RCPH10TLB205ACL 7
RCPH10TLB254ACL 8
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RCPH10TLB254ACL 9
RCPH10TLB719AAL 10
RCPH10TLB250ACL 11
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
RCPH10TLB259AAL 14
RCPH10TLB258AAL 15
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
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
RCPH10TLB115ACL 20
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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
RCPH10TLB112ACL 23
RCPH10TLB121ACL 24
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RCPH10TLB111ACL 25
RCPH10TLB110ACL 26
RCPH10TLB176ACL 27
RCPH10TLB175ACL 28
Next operation:
Shaft - Disassemble (C.20.E)
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RCPH10TLB131ACL 1
RCPH10TLB036ACL 2
RCPH10TLB037ACL 3
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB038ACL 4
RCPH10TLB242ACL 5
RCPH10TLB241ACL 6
Next operation:
Electronic control - Assemble (C.20.E)
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RCPH10TLB003BAN 1
RCPH10TLB038ACL 2
RCPH10TLB151ACL 3
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TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
RCPH10TLB157ACL 4
RCPH10TLB242ACL 5
RCPH10TLB037ACL 6
RCPH10TLB036ACL 7
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RCPH10TLB131ACL 8
Next operation:
Control valve - Disassemble (C.20.E)
84516378 05/07/2011
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84516378 05/07/2011
C.20.E / 328
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 329
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 330
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 331
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 332
TRANSMISSION, DRIVE AND PTO OUT - TRANSMISSION Powershift
84516378 05/07/2011
C.20.E / 333
Index
84516378 05/07/2011
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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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CNH - Main 700 State Street Racine, Wisconsin United States 53404
PRINTED IN U.S.A.
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
AXLES, BRAKES AND STEERING
580N
580SN WT
580SN
590SN
84516378 05/07/2011
D
Contents
84516378 05/07/2011
D
AXLES, BRAKES AND STEERING - D
580N
580SN WT
580SN
590SN
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Contents
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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FRONT AXLE - Special tools - Carraro Front axle two wheel drive
CAS-1842 Wheel stud removal and installation
RCPH10TLB466ABL 1
RCPH10TLB235ABL 2
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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
RCPH10TLB235ABL 2
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Capacities
Differential 7.7 l (8.1 US qt) or bottom of fill hole.
Planetary 0.5 l (0.5 US qt) or fill to line.
Type of Fluid Wet Brake/Transmission Lubricant - SAE 80W140
(MAT3510)
Lubricant Kluberplus 84279121
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.
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AXLES, BRAKES AND STEERING - FRONT AXLE
Specifications
Planet pin screw 95 - 105 N·m (70.1 - 77.4 lb ft)
Planetary 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 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
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 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
RCPH10TLB638ABL 2
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RCPH10TLB684ABL 3
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380100092 Wrench to loosen and tighten tie rods for steering cylinder.
RCPH10TLB235ABL 4
RCPH10TLB635ABL 5
RCPH10TLB025FAL 6
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RCPH10TLB026FAL 7
RCPH10TLB027FAL 8
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RCPH10TLB033FAL 9
RCPH10TLB029FAL 10
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RCPH10TLB030FAL 11
RCPH10TLB261ACL 12
RCPH10TLB260ACL 13
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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)
Bolts for steering cylinder 120 N·m (88.5 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 bearing caps 266 N·m (196.2 lb ft)
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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RCPH10TLB461ABL 1
RCPH10TLB468ABL 2
RCPH10TLB465ABL 3
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RCPH10TLB467ABL 4
RCPH10TLB466ABL 5
RCPH10TLB469ABL 6
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380100091 for all two wheel drive and the 580N, 580SN
four wheel drive front axle
RCPH10TLB235ABL 7
CAS10468 - Puller
Lubricant - 580SN
Capacity - center bowl 6.3 l (6.7 US qt)
Capacity - each wheel end 0.59 l (0.6 US qt)
Type of fluid Wet brake/transmission lubricant - SAE 80W140
MAT3510
Lubricant - 590SN
Capacity - center bowl 6.7 l (7.1 US qt)
Capacity - each wheel end 0.65 l (0.7 US qt)
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)
Bolts for steering cylinder 120 N·m (88.5 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 bearing caps 266 N·m (196.2 lb ft)
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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RCPH10TLB461ABL 1
RCPH10TLB633ABL 2
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RCPH10TLB637ABL 3
RCPH10TLB638ABL 4
RCPH10TLB683ABL 5
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RCPH10TLB684ABL 6
RCPH10TLB235ABL 7
RCPH10TLB636ABL 8
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RCPH10TLB635ABL 9
RCPH10TLB634ABL 10
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RCPH10TLB388ACL 1
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RCPH10TLB001FAL 1
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RCPB10TLB002HAL 1
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RCPB10TLB002HAL 1
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RCPH10TLB004GAL 1
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RCPH10TLB171GAL 1
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RCPH10TLB001GAL 1
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RCPH10TLB182GAL 1
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RCPH10TLB001HAL 1
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RCPH10TLB002GAL 1
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RCPH10TLB003GAL 1
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RCPH10TLB180GAL 1
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RCPH11TLB136AAM 1
RCPH11TLB146AAM 2
RCPH11TLB139AAM 3
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RCPH11TLB140AAM 4
RCPH11TLB141AAM 5
RCPH11TLB142AAM 6
RCPH11TLB143AAM 7
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RCPH11TLB144AAM 8
RCPH11TLB145AAM 9
Next operation:
FRONT AXLE - Install (D.10.A)
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RCPH11TLB140AAM 1
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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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
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RCPH10TLB129GAL 6
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RCPH10TLB388ACL 1
RCPH11TLB136AAM 2
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RCPH11TLB146AAM 3
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
RCPH11TLB145AAM 9
Next operation:
FRONT AXLE - Install (D.10.A)
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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
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RCPH11TLB139AAM 3
12. Loosen and remove the plugs from the hoses and the
caps from the fittings for the steering cylinder.
RCPH11TLB146AAM 4
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RCPH10TLB603ABL 1
RCPH10TLB716ABL 2
RCPH10TLB604ABL 3
RCPH10TLB605ABL 4
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RCPH10TLB606ABL 5
RCPH10TLB607ABL 6
RCPH10TLB608ABL 7
RCPH10TLB609ABL 8
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RCPH10TLB610ABL 9
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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Next operation:
FRONT AXLE - Assemble (D.10.A)
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RCPH10TLB612ABL 1
RCPH10TLB611ABL 2
RCPH10TLB610ABL 3
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RCPH10TLB609ABL 4
RCPH10TLB608ABL 5
RCPH10TLB607ABL 6
RCPH10TLB613ABL 7
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RCPH10TLB614ABL 8
RCPH10TLB615ABL 9
RCPH10TLB616ABL 10
RCPH10TLB717ABL 11
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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
RCPH10TLB718ABL 17
18. Snug the jam nuts for the tie rods and recheck toe-in.
RCPH10TLB620ABL 18
RCPH10TLB621ABL 19
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RCPH10TLB303ACL 1
3. Loosen and remove the tie rod ends from the swivel
housings.
RCPH10TLB951ABL 2
RCPH10TLB240ACL 3
RCPH10TLB311ACL 4
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RCPH10TLB605ABL 5
RCPH10TLB606ABL 6
RCPH10TLB607ABL 7
RCPH10TLB954ABL 8
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RCPH10TLB956ABL 9
RCPH10TLB699ABL 10
RCPH10TLB926ABL 11
13. If required, remove the front and rear pivot seals and
bushings.
RCPH10TLB612ABL 12
Next operation:
FRONT AXLE - Inspect (D.10.A)
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Next operation:
FRONT AXLE - Assemble (D.10.A)
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RCPH10TLB612ABL 1
RCPH10TLB926ABL 2
RCPH10TLB699ABL 3
RCPH10TLB269ACL 4
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RCPH10TLB002ACL 5
RCPH10TLB607ABL 6
RCPH10TLB613ABL 7
RCPH10TLB614ABL 8
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RCPH10TLB311ACL 9
RCPH10TLB616ABL 10
RCPH10TLB240ACL 11
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
RCPH10TLB718ABL 16
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17. Snug the jam nuts for the tie rods and recheck toe-in.
RCPH10TLB620ABL 17
RCPH10TLB621ABL 18
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1. Drain oil.
RCPH10TLB276ACL 1
RCPH10TLB957ABL 2
RCPH10TLB958ABL 3
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RCPH10TLB255ACL 4
Next operation:
Differential - Disassemble (D.10.A)
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RCPH10TLB962ABL 1
RCPH10TLB963ABL 2
RCPH10TLB964ABL 3
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RCPH10TLB964ABL 4
RCPH10TLB964ABL 5
RCPH10TLB966ABL 6
RCPH10TLB989ABL 7
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RCPH10TLB972ABL 8
RCPH10TLB512ABL 9
RCPH10TLB263ACL 10
RCPH10TLB976ABL 11
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14. Use a press and drive the pinion shaft out of the outer
bearing.
RCPH10TLB977ABL 12
RCPH10TLB978ABL 13
RCPH10TLB979ABL 14
RCPH10TLB535ABL 15
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RCPH10TLB531ABL 16
RCPH10TLB713ABL 17
RCPH10TLB974ABL 18
Next operation:
Differential - Disassemble (D.10.A)
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RCPH10TLB967ABL 1
RCPH10TLB968ABL 2
RCPH10TLB970ABL 3
RCPH10TLB928ABL 4
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RCPH10TLB930ABL 5
RCPH10TLB931ABL 6
Next operation:
Differential - Inspect (D.10.A)
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Next operation:
Differential - Assemble (D.10.A)
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RCPH10TLB931ABL 1
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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RCPH10TLB970ABL 4
RCPH10TLB987ABL 5
RCPH10TLB988ABL 6
Next operation:
Differential - Assemble (D.10.A)
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RCPH10TLB532ABL 1
RCPH10TLB535ABL 2
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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RCPH10TLB533ABL 5
RCPH10TLB982ABL 6
RCPH10TLB983ABL 7
RCPH10TLB984ABL 8
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RCPH10TLB263ACL 9
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
RCPH10TLB985ABL 11
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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
RCPH10TLB715ABL 15
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RCPH10TLB991ABL 16
RCPH10TLB992ABL 17
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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
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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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.
RCPH10TLB991ABL 22
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RCPH10TLB992ABL 23
RCPH10TLB992ABL 24
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.
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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
RCPH10TLB264ACL 29
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RCPH10TLB995ABL 30
RCPH10TLB996ABL 31
RCPH10TLB997ABL 32
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RCPH10TLB693ABL 1
RCPH10TLB692ABL 2
RCPH10TLB484ABL 3
5. Loosen and remove the bolts that hold the top king
pin.
RCPH10TLB695ABL 4
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RCPH10TLB697ABL 5
RCPH10TLB698ABL 6
RCPH10TLB502ABL 7
10. Remove the fitting from the closed end of the steering
cylinder.
11. Remove the bolts.
RCPH10TLB639ABL 8
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RCPH10TLB287ABL 9
RCPH10TLB288ABL 10
RCPH10TLB508ABL 11
RCPH10TLB509ABL 12
Next operation:
Differential - Disassemble (D.10.A)
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RCPH10TLB462ABL 1
RCPH10TLB701ABL 2
RCPH10TLB702ABL 3
RCPH10TLB703ABL 4
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RCPH10TLB704ABL 5
RCPH10TLB715ABL 6
RCPH10TLB706ABL 7
RCPH10TLB707ABL 8
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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
RCPH10TLB533ABL 14
RCPH10TLB534ABL 15
RCPH10TLB535ABL 16
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RCPH10TLB531ABL 17
RCPH10TLB713ABL 18
RCPH10TLB691ABL 19
Next operation:
Differential - Disassemble (D.10.A)
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RCPH10TLB513ABL 1
RCPH10TLB514ABL 2
RCPH10TLB515ABL 3
RCPH10TLB516ABL 4
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RCPH10TLB518ABL 5
RCPH10TLB520ABL 6
RCPH10TLB521ABL 7
RCPH10TLB522ABL 8
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RCPH10TLB464ABL 9
Next operation:
Differential - Inspect (D.10.A)
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Next operation:
Differential - Assemble (D.10.A)
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RCPH10TLB463ABL 1
2. Find the case half that has the threaded holes. Make
sure that the threads are free of lubricant.
RCPH10TLB523ABL 2
RCPH10TLB524ABL 3
RCPH10TLB521ABL 4
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RCPH10TLB520ABL 5
RCPH10TLB525ABL 6
RCPH10TLB519ABL 7
RCPH10TLB518ABL 8
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RCPH10TLB526ABL 9
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
RCPH10TLB528ABL 14
Next operation:
Differential - Assemble (D.10.A)
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RCPH10TLB532ABL 1
RCPH10TLB537ABL 2
RCPH10TLB538ABL 3
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RCPH10TLB539ABL 4
RCPH10TLB540ABL 5
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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RCPH10TLB541ABL 7
RCPH10TLB535ABL 8
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
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
RCPH10TLB547ABL 17
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RCPH10TLB691ABL 18
22. Use a suitable driver and drive a new seal into the
cover.
RCPH10TLB714ABL 19
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
differential carrier. Do not overtighten the bolts. The
bearings must be able to rotate.
RCPH10TLB704ABL 24
RCPH10TLB715ABL 25
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RCPH10TLB715ABL 26
RCPH10TLB555ABL 27
RCPH10TLB701ABL 28
35. If the original ring gear and pinion gear are being
used, the backlash must be equal to the measure-
ment made during disassembly.
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)
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RCPH10TLB715ABL 29
RCPH10TLB557ABL 30
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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RCPH10TLB559ABL 33
RCPH10TLB560ABL 34
RCPH10TLB508ABL 35
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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RCPH10TLB498ABL 40
RCPH10TLB694ABL 41
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RCPH10TLB482ABL 1
RCPH10TLB483ABL 2
RCPH10TLB484ABL 3
RCPH10TLB711ABL 4
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RCPH10TLB500ABL 5
RCPH10TLB712ABL 6
RCPH10TLB502ABL 7
10. Remove the fitting from the closed end of the steering
cylinder.
11. Remove the bolts.
RCPH10TLB505ABL 8
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RCPH10TLB506ABL 9
RCPH10TLB508ABL 10
RCPH10TLB509ABL 11
Next operation:
Differential - Disassemble (D.10.A)
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RCPH10TLB462ABL 1
RCPH10TLB701ABL 2
RCPH10TLB702ABL 3
RCPH10TLB703ABL 4
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RCPH10TLB704ABL 5
RCPH10TLB715ABL 6
RCPH10TLB706ABL 7
RCPH10TLB707ABL 8
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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 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
RCPH10TLB533ABL 14
RCPH10TLB534ABL 15
RCPH10TLB535ABL 16
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RCPH10TLB531ABL 17
RCPH10TLB713ABL 18
RCPH10TLB691ABL 19
Next operation:
Differential - Disassemble (D.10.A)
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RCPH10TLB513ABL 1
RCPH10TLB514ABL 2
RCPH10TLB515ABL 3
RCPH10TLB516ABL 4
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RCPH10TLB518ABL 5
RCPH10TLB520ABL 6
RCPH10TLB521ABL 7
RCPH10TLB632ABL 8
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RCPH10TLB631ABL 9
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
RCPH10TLB463ABL 12
Next operation:
Differential - Inspect (D.10.A)
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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:
Differential - Assemble (D.10.A)
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RCPH10TLB463ABL 1
2. Find the case half that has the threaded holes. Make
sure that the threads are free of lubricant.
RCPH10TLB523ABL 2
RCPH10TLB524ABL 3
RCPH10TLB629ABL 4
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RCPH10TLB628ABL 5
RCPH10TLB627ABL 6
RCPH10TLB632ABL 7
RCPH10TLB521ABL 8
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RCPH10TLB520ABL 9
RCPH10TLB525ABL 10
RCPH10TLB519ABL 11
RCPH10TLB518ABL 12
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RCPH10TLB526ABL 13
RCPH10TLB517ABL 14
15. Install the other thrust washer in the other case half.
RCPH10TLB527ABL 15
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
RCPH10TLB528ABL 18
Next operation:
Differential - Assemble (D.10.A)
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RCPH10TLB532ABL 1
RCPH10TLB537ABL 2
RCPH10TLB538ABL 3
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RCPH10TLB539ABL 4
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
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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RCPH10TLB541ABL 7
RCPH10TLB535ABL 8
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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RCPH10TLB470ABL 15
RCPH10TLB546ABL 16
RCPH10TLB547ABL 17
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RCPH10TLB691ABL 18
RCPH10TLB714ABL 19
RCPH10TLB709ABL 20
24. Lubricate the O-ring and the seal with clean oil. In-
stall the cover.
RCPH10TLB710ABL 21
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RCPH10TLB548ABL 22
RCPH10TLB549ABL 23
RCPH10TLB550ABL 24
RCPH10TLB551ABL 25
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RCPH10TLB552ABL 26
RCPH10TLB553ABL 27
RCPH10TLB555ABL 28
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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
36. If the original ring gear and pinion gear are being
used, the backlash must be equal to the measure-
ment made during disassembly.
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
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
RCPH10TLB559ABL 34
RCPH10TLB560ABL 35
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RCPH10TLB508ABL 36
RCPH10TLB507ABL 37
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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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
Nm (140 pound-feet).
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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RCPH10TLB951ABL 1
RCPH10TLB952ABL 2
RCPH10TLB484ABL 3
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RCPH10TLB390ACL 4
RCPH10TLB391ACL 5
RCPH10TLB405ACL 6
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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RCPH10TLB699ABL 8
RCPH10TLB926ABL 9
RCPH10TLB959ABL 10
RCPH10TLB492ABL 11
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RCPH10TLB459ABL 12
RCPH10TLB472ABL 13
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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RCPH10TLB593ABL 16
21. Remove the long axle shaft (or short axle shaft) from
the coupling.
RCPH10TLB594ABL 17
RCPH10TLB596ABL 18
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
RCPH10TLB477ABL 22
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
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
RCPH10TLB590ABL 29
RCPH10TLB591ABL 30
RCPH10TLB592ABL 31
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RCPH10TLB595ABL 32
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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RCPH10TLB994ABL 1
RCPH10TLB490ABL 2
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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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
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
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RCPH10TLB693ABL 1
RCPH10TLB692ABL 2
RCPH10TLB695ABL 3
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RCPH10TLB697ABL 4
RCPH10TLB698ABL 5
RCPH10TLB699ABL 6
RCPH10TLB640ABL 7
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RCPH10TLB489ABL 8
RCPH10TLB491ABL 9
RCPH10TLB492ABL 10
RCPH10TLB456ABL 11
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RCPH10TLB457ABL 12
RCPH10TLB459ABL 13
RCPH10TLB460ABL 14
RCPH10TLB472ABL 15
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RCPH10TLB599ABL 16
19. Fasten the bearing cap in a vise and drive the cou-
pling off the bearing cap.
RCPH10TLB473ABL 17
RCPH10TLB593ABL 18
21. Remove the long axle shaft (or short axle shaft) from
the coupling.
RCPH10TLB594ABL 19
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RCPH10TLB596ABL 20
RCPH10TLB474ABL 21
24. Remove the yoke from the bearing cap. DO NOT hit
the axle shaft in the seal area.
RCPH10TLB475ABL 22
25. Press the other bearing cap out of the yoke as far as
possible.
RCPH10TLB476ABL 23
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RCPH10TLB477ABL 24
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.
the cross is in both bearing caps.
RCPH10TLB588ABL 29
32. Hold the cross and press the bearing caps into the
yoke.
RCPH10TLB589ABL 30
RCPH10TLB590ABL 31
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RCPH10TLB591ABL 32
RCPH10TLB592ABL 33
RCPH10TLB595ABL 34
RCPH10TLB597ABL 35
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39. Carefully raise the cross into the top bearing cap so
that the cross is in both bearing caps.
RCPH10TLB598ABL 36
40. Hold the cross and press the bearing cap into the
coupling so that a snap ring can be installed.
RCPH10TLB600ABL 37
RCPH10TLB601ABL 38
Next operation:
Housing - Assemble (D.10.A)
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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
RCPH10TLB698ABL 3
RCPH10TLB696ABL 4
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RCPH10TLB497ABL 5
RCPH10TLB498ABL 6
RCPH10TLB693ABL 7
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RCPH10TLB482ABL 1
RCPH10TLB483ABL 2
3. Remove the nut and remove the ball joint from the
swivel housing.
RCPH10TLB484ABL 3
RCPH10TLB486ABL 4
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RCPH10TLB487ABL 5
RCPH10TLB488ABL 6
RCPH10TLB640ABL 7
RCPH10TLB488ABL 8
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RCPH10TLB489ABL 9
RCPH10TLB491ABL 10
RCPH10TLB492ABL 11
RCPH10TLB456ABL 12
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RCPH10TLB457ABL 13
RCPH10TLB459ABL 14
RCPH10TLB460ABL 15
RCPH10TLB472ABL 16
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RCPH10TLB599ABL 17
RCPH10TLB473ABL 18
RCPH10TLB593ABL 19
21. Remove the long axle shaft (or short axle shaft) from
the coupling.
RCPH10TLB594ABL 20
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RCPH10TLB596ABL 21
RCPH10TLB474ABL 22
RCPH10TLB475ABL 23
25. Press the other bearing cap out of the yoke as far as
possible.
RCPH10TLB476ABL 24
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RCPH10TLB477ABL 25
RCPH10TLB478ABL 26
28. Press a bearing cap into the yoke 6mm (1/4 inch)
from the top of the yoke.
RCPH10TLB585ABL 27
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
the cross is in both bearing caps.
RCPH10TLB588ABL 30
32. Hold the cross and press the bearing caps into the
yoke.
RCPH10TLB589ABL 31
RCPH10TLB590ABL 32
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RCPH10TLB591ABL 33
RCPH10TLB592ABL 34
RCPH10TLB595ABL 35
RCPH10TLB597ABL 36
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39. Carefully raise the cross into the top bearing cap so
that the cross is in both bearing caps.
RCPH10TLB598ABL 37
40. Hold the cross and press the bearing cap into the
coupling so that a snap ring can be installed.
RCPH10TLB600ABL 38
RCPH10TLB601ABL 39
Next operation:
Housing - Assemble (D.10.A)
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RCPH10TLB493ABL 1
RCPH10TLB490ABL 2
RCPH10TLB494ABL 3
RCPH10TLB488ABL 4
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RCPH10TLB495ABL 5
RCPH10TLB485ABL 6
RCPH10TLB496ABL 7
RCPH10TLB497ABL 8
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RCPH10TLB498ABL 9
RCPH10TLB499ABL 10
Next operation:
Differential - Remove (D.10.A)
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Planetary and hub - Disassemble - CNH Front Axle Four Wheel Drive
Prior operation:
FRONT AXLE - Remove (D.10.A)
NOTE: The following procedures show the axle already removed from the machine for ease of explanation.
2. Raise the wheel(s) off the floor and use acceptable
supports to hold the machine in position.
3. Remove the nuts and hardened washers and remove
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
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
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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RCPH10TLB360ACL 7
RCPH10TLB361ACL 8
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
RCPH10TLB365ACL 12
RCPH10TLB366ACL 13
RCPH10TLB367ACL 14
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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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RCPH10TLB961ABL 18
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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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
RCPH10TLB290ACL 24
RCPH10TLB625ABL 25
NOTE: Manufacturer recommends replacement of T-dowels if they are pressed out of the hub.
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RCPH10TLB299ACL 26
RCPH10TLB300ACL 27
RCPH10TLB301ACL 28
RCPH10TLB302ACL 29
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RCPH10TLB400ACL 30
RCPH10TLB401ACL 31
RCPH10TLB261ACL-2 32
RCPH10TLB260ACL-2 33
Next operation:
Planetary and hub - Inspect (D.10.A)
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Planetary and hub - Inspect - CNH Front Axle Four Wheel Drive
1. Clean all parts in cleaning solvent.
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
RCPH10TLB371ACL 2
RCPH10TLB372ACL 3
RCPH10TLB374ACL 4
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RCPH10TLB375ACL 5
RCPH10TLB376ACL 6
RCPH10TLB402ACL 7
RCPH10TLB378ACL 8
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RCPH10TLB380ACL 9
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
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
RCPH10TLB624ABL 13
RCPH10TLB998ABL 14
RCPH10TLB400ACL 15
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RCPH10TLB387ACL 16
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).
RCPH10TLB261ACL-2 18
RCPH10TLB285ACL 19
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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
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
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RCPH10TLB561ABL 1
RCPH10TLB562ABL 2
RCPH10TLB563ABL 3
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RCPH10TLB564ABL 4
RCPH10TLB565ABL 5
RCPH10TLB566ABL 6
RCPH10TLB567ABL 7
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RCPH10TLB568ABL 8
RCPH10TLB569ABL 9
RCPH10TLB570ABL 10
RCPH10TLB571ABL 11
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RCPH10TLB572ABL 12
RCPH10TLB660ABL 13
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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RCPH10TLB573ABL 16
RCPH10TLB574ABL 17
RCPH10TLB575ABL 18
RCPH10TLB576ABL 19
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RCPH10TLB577ABL 20
Next operation:
Planetary and hub - Inspect (D.10.A)
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Next operation:
Planetary and hub - Assemble (D.10.A)
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RCPH10TLB578ABL 1
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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RCPH10TLB480ABL 4
RCPH10TLB481ABL 5
RCPH10TLB575ABL 6
RCPH10TLB574ABL 7
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RCPH10TLB573ABL 8
RCPH10TLB626ABL 9
RCPH10TLB624ABL 10
RCPH10TLB623ABL 11
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RCPH10TLB579ABL 12
RCPH10TLB580ABL 13
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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RCPH10TLB567ABL 16
RCPH10TLB566ABL 17
RCPH10TLB565ABL 18
RCPH10TLB564ABL 19
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RCPH10TLB583ABL 20
RCPH10TLB584ABL 21
RCPH10TLB561ABL 22
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RCPH10TLB642ABL 1
RCPH10TLB641ABL 2
5. Remove the two allen head bolts that hold the carrier.
RCPH10TLB643ABL 3
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RCPH10TLB645ABL 4
RCPH10TLB646ABL 5
8. Discard O-ring.
RCPH10TLB680ABL 6
RCPH10TLB647ABL 7
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RCPH10TLB648ABL 8
RCPH10TLB649ABL 9
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
RCPH10TLB654ABL 13
RCPH10TLB655ABL 14
RCPH10TLB656ABL 15
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RCPH10TLB657ABL 16
RCPH10TLB660ABL 17
RCPH10TLB662ABL 18
21. Press the busings from the hub only if new bushing(s)
are needed or a new hub is installed.
RCPH10TLB670ABL 19
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RCPH10TLB688ABL 20
RCPH10TLB689ABL 21
RCPH10TLB690ABL 22
RCPH10TLB665ABL 23
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RCPH10TLB664ABL 24
RCPH10TLB669ABL 25
28. Press the pinion shafts out of the carrier if new ones
are to be installed.
RCPH10TLB672ABL 26
RCPH10TLB674ABL 27
Next operation:
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Next operation:
Planetary and hub - Assemble (D.10.A)
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RCPH10TLB682ABL 1
RCPH10TLB675ABL 2
RCPH10TLB673ABL 3
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RCPH10TLB676ABL 4
RCPH10TLB685ABL 5
RCPH10TLB686ABL 6
RCPH10TLB687ABL 7
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RCPH10TLB690ABL 8
RCPH10TLB689ABL 9
RCPH10TLB688ABL 10
RCPH10TLB666ABL 11
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RCPH10TLB667ABL 12
RCPH10TLB668ABL 13
RCPH10TLB679ABL 14
RCPH10TLB664ABL 15
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RCPH10TLB665ABL 16
RCPH10TLB671ABL 17
RCPH10TLB663ABL 18
RCPH10TLB661ABL 19
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RCPH10TLB658ABL 20
RCPH10TLB659ABL 21
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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RCPH10TLB656ABL 24
RCPH10TLB655ABL 25
27. Align the holes in the hub with the holes in the swivel
housing and install the ring gear.
RCPH10TLB677ABL 26
RCPH10TLB651ABL 27
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29. Ensure shaft is all the way out prior to installing thrust
washers and snap ring.
RCPH10TLB649ABL 28
RCPH10TLB649ABL 29
RCPH10TLB648ABL 30
RCPH10TLB647ABL 31
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RCPH10TLB680ABL 32
RCPH10TLB646ABL 33
RCPH10TLB644ABL 34
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RCPH10TLB642ABL 35
Next operation:
Housing - Disassemble (D.10.A)
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Index
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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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AXLES, BRAKES AND STEERING - D
580N
580SN WT
580SN
590SN
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Contents
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
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)
Backlash for ring gear 0.2 - 0.29 mm (0.008 - 0.011 in)
RCPH10TLB379AAL 1
RCPH10TLB380AAL 2
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RCPH10TLB484AAL 3
RCPH07SPT024AAA 4
RCPH10TLB378AAL 5
RCPH10TLB377AAL 6
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RCPH10TLB381AAL 7
RCPH10TLB590AAL 8
RCPH10TLB584AAL 9
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)
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AXLES, BRAKES AND STEERING - REAR AXLE
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)
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 (without seal) 2.6 - 3.3 N·m (23.0 - 29.2 lb in)
Backlash for ring gear 0.2 - 0.29 mm (0.008 - 0.011 in)
RCPH10TLB379AAL 1
RCPH10TLB380AAL 2
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RCPH10TLB637ABL 3
RCPH10TLB484AAL 4
RCPH10TLB485AAL 5
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RCPH10TLB638ABL 6
RCPH10TLB378AAL 7
RCPH10TLB377AAL 8
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RCPH10TLB635ABL 9
RCPH10TLB381AAL 10
RCPH10TLB636ABL 11
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RCPH10TLB634ABL 12
RCPH10TLB633ABL 13
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RCPH10TLB9GAL 1
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RCPH10TLB10GAL 1
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB11GAL 1
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB13GAL 1
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AXLES, BRAKES AND STEERING - REAR AXLE
(1) Vent
(2) Axle housing
(3) Plugs
(4) Pin D15x35
(5) Bolt M6x25
(6) Differential support
(7) Bolt M12x100
(8) Bolt M12x1.75
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RCPH10TLB7GAL 1
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB12GAL 1
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH11TLB121AAM 1 RCPH11TLB120AAM 2
RCPH11TLB122AAM 3
RCPH11TLB123AAM 4
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH11TLB124AAM 5
RCPH11TLB123AAM 6
RCPH11TLB125AAM 7
RCPH11TLB076AAL 8
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RCPH11TLB125AAM 9
RCPH11TLB124AAM 10
RCPH11TLB126AAM 11
RCPH11TLB127AAM 12
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH11TLB128AAM 13
RCPH11TLB129AAM 14
RCPH11TLB130AAM 15
Next operation:
REAR AXLE - Install (D.12.A)
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RCPH11TLB130AAM 1
RCPH11TLB129AAM 2
RCPH11TLB128AAM 3
RCPH11TLB127AAM 4
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AXLES, BRAKES AND STEERING - REAR AXLE
5. Install the left hand and right hand brake hose guard
hardware.
RCPH11TLB126AAM 5
RCPH11TLB124AAM 6
RCPH11TLB125AAM 7
RCPH11TLB123AAM 8
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RCPH11TLB120AAM 9
RCPH11TLB121AAM 10
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RCPH10TLB373AAL 1
RCPH10TLB374AAL 2
RCPH10TLB370AAL 3
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RCPH10TLB371AAL 4
RCPH10TLB369AAL 5
Next operation:
Differential - Disassemble (D.12.A)
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RCPH10TLB364AAL 1
RCPH10TLB362AAL 2
RCPH10TLB432AAL 3
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RCPH10TLB433AAL 4
RCPH10TLB434AAL 5
RCPH10TLB435AAL 6
RCPH10TLB436AAL 7
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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.
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB444AAL 14
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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
NOTE: Do not remove the pin at this time, leave the pin in far enough to support the spider gear and thrust washer.
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AXLES, BRAKES AND STEERING - REAR AXLE
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
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB359AAL 22
RCPH10TLB340AAL 23
25. The pinion gear nut is staked into place on the pinion
shaft.
RCPH10TLB341AAL 24
RCPH10TLB342AAL 25
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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
RCPH10TLB345AAL 28
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB346AAL 29
RCPH10TLB347AAL 30
RCPH10TLB348AAL 31
Next operation:
Differential - Remove (D.12.A)
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RCPH10TLB349AAL 1
RCPH10TLB350AAL 2
RCPH10TLB351AAL 3
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RCPH10TLB352AAL 4
RCPH10TLB353AAL 5
RCPH10TLB354AAL 6
RCPH10TLB355AAL 7
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RCPH10TLB356AAL 8
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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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB459AAL 1
Next operation:
Differential - Install (D.12.A)
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RCPH10TLB461AAL 1
RCPH10TLB460AAL 2
RCPH10TLB357AAL 3
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RCPH10TLB356AAL 4
RCPH10TLB355AAL 5
RCPH10TLB351AAL 6
RCPH10TLB352AAL 7
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB353AAL 8
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
RCPH10TLB360AAL 11
Next operation:
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RCPH10TLB481AAL 1
RCPH10TLB358AAL 2
RCPH10TLB452AAL 3
RCPH10TLB451AAL 4
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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
NOTE: Push the pin in just far enough to hold the thrust washer and spider.
7. Install the spacer as shown, push the pins into the
spacer.
RCPH10TLB448AAL 7
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AXLES, BRAKES AND STEERING - REAR AXLE
8. Make sure to install the pin so that the dowel pin hole
aligns with the dowel pin hole in the housing.
RCPH10TLB445AAL 8
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.
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AXLES, BRAKES AND STEERING - REAR AXLE
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
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
RCPH10TLB457AAL 14
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB435AAL 16
RCPH10TLB453AAL 17
19. Install the cover into the housing, install the locking
ring.
RCPH10TLB434AAL 18
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB491AAL 19
RCPH10TLB458AAL 20
RCPH10TLB454AAL 21
RCPH10TLB455AAL 22
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RCPH10TLB390AAL 23
RCPH10TLB389AAL 24
RCPH10TLB391AAL 25
RCPH10TLB392AAL 26
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RCPH10TLB388AAL 27
RCPH10TLB387AAL 28
RCPH10TLB386AAL 29
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31. Find the number on the end of the pinion shaft. Write
this number on line “d” of the worksheet.
RCPH10TLB480AAL 30
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
RCPH10TLB482AAL 31
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RCPH10TLB483AAL 32
RCPH10TLB483AAL 33
RCPH10TLB462AAL 34
RCPH10TLB463AAL 35
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RCPH10TLB464AAL 36
RCPH10TLB465AAL 37
RCPH10TLB466AAL 38
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.
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB467AAL 39
RCPH10TLB466AAL 40
46. Stake the lip on the pinion nut into the slot in the
pinion shaft.
RCPH10TLB468AAL 41
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RCPH10TLB456AAL 42
RCPH10TLB362AAL 43
Next operation:
Differential - Adjust (D.12.A)
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AXLES, BRAKES AND STEERING - REAR AXLE
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:
Differential - Adjust (D.12.A)
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RCPH10TLB469AAL 1
RCPH10TLB362AAL 2
RCPH10TLB363AAL 3
Next operation:
Differential - Install (D.12.A)
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RCPH10TLB366AAL 1
RCPH10TLB365AAL 2
RCPH10TLB367AAL 3
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4. Lubricate the O-ring and the seal with clean oil. In-
stall the cover on the center section.
RCPH10TLB368AAL 4
Next operation:
Differential - Install (D.12.A)
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RCPH10TLB470AAL 1
RCPH10TLB369AAL 2
RCPH10TLB372AAL 3
Next operation:
Differential - Check (D.12.A)
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NOTE: Make sure the air is removed from the brake system when the axle is installed on the machine.
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RCPH10TLB532AAL 1
RCPH10TLB531AAL 2
RCPH10TLB530AAL 3
Next operation:
Differential - Disassemble (D.12.A)
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RCPH10TLB535AAL 1
RCPH10TLB362AAL 2
RCPH10TLB552AAL 3
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RCPH10TLB545AAL 4
RCPH10TLB544AAL 5
RCPH10TLB546AAL 6
RCPH10TLB547AAL 7
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RCPH10TLB550AAL 8
RCPH10TLB548AAL 9
RCPH10TLB549AAL 10
RCPH10TLB551AAL 11
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14. Remove the three pins securing the spider pins in the
differential.
RCPH10TLB553AAL 12
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.
17. Remove the spider gear and thrust washer.
RCPH10TLB511AAL 15
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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
NOTE: Do not remove the pin at this time, leave the pin in far enough to support the spider gear and thrust washer.
21. Push the other short spider pin out of the spacer by
pushing it through the hole in the spacer.
RCPH10TLB586AAL 19
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AXLES, BRAKES AND STEERING - REAR AXLE
NOTE: Do not remove the pin at this time, leave the pin in far enough to support the spider gear and thrust washer.
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
RCPH10TLB504AAL 23
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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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RCPH10TLB538AAL 27
30. The pinion gear nut is staked into place on the pinion
shaft.
RCPH10TLB539AAL 28
RCPH10TLB540AAL 29
RCPH10TLB541AAL 30
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB575AAL 33
RCPH10TLB576AAL 34
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RCPH10TLB580AAL 35
RCPH10TLB579AAL 36
Next operation:
Differential - Remove (D.12.A)
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RCPH10TLB562AAL 1
RCPH10TLB563AAL 2
RCPH10TLB564AAL 3
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RCPH10TLB566AAL 4
RCPH10TLB567AAL 5
RCPH10TLB570AAL 6
RCPH10TLB572AAL 7
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RCPH10TLB573AAL 8
RCPH10TLB574AAL 9
Next operation:
Differential - Install (D.12.A)
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RCPH10TLB574AAL 1
RCPH10TLB573AAL 2
3. Install the fork onto the shaft with collar of fork to-
wards the retaining ring.
RCPH10TLB572AAL 3
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RCPH10TLB571AAL 4
RCPH10TLB569AAL 5
RCPH10TLB568AAL 6
RCPH10TLB567AAL 7
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB566AAL 8
RCPH10TLB565AAL 9
RCPH10TLB563AAL 10
RCPH10TLB562AAL 11
Next operation:
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RCPH10TLB494AAL 1
RCPH10TLB496AAL 2
RCPH10TLB497AAL 3
RCPH10TLB498AAL 4
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RCPH10TLB499AAL 5
RCPH10TLB500AAL 6
RCPH10TLB501AAL 7
RCPH10TLB493AAL 8
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RCPH10TLB503AAL 9
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
RCPH10TLB505AAL 12
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AXLES, BRAKES AND STEERING - REAR AXLE
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
NOTE: Push the pin in just far enough to hold the thrust washer and spider.
16. Place the spacer between the spider gears as
shown.
RCPH10TLB510AAL 16
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AXLES, BRAKES AND STEERING - REAR AXLE
17. Make sure to install the pin so that the pin hole (1),
aligns with the pin hole in the housing.
RCPH10TLB513AAL 17
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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RCPH10TLB516AAL 21
RCPH10TLB517AAL 22
RCPH10TLB518AAL 23
RCPH10TLB519AAL 24
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RCPH10TLB588AAL 25
RCPH10TLB550AAL 26
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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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB521AAL 29
RCPH10TLB522AAL 30
RCPH10TLB524AAL 31
RCPH10TLB581AAL 32
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB487AAL 35
RCPH10TLB583AAL 36
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RCPH10TLB488AAL 37
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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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB487AAL 41
RCPH10TLB577AAL 42
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AXLES, BRAKES AND STEERING - REAR AXLE
43. Use a suitable driver and press the bearing onto the
shaft.
RCPH10TLB578AAL 43
RCPH10TLB561AAL 44
RCPH10TLB560AAL 45
RCPH10TLB558AAL 46
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RCPH10TLB557AAL 47
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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RCPH10TLB542AAL 51
54. Stake the lip on the pinion nut into the slot in the
pinion shaft.
RCPH10TLB539AAL 52
RCPH10TLB362AAL 53
Next operation:
Differential - Adjust (D.12.A)
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB362AAL 3
Next operation:
Differential - Adjust (D.12.A)
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RCPH10TLB528AAL 1
RCPH10TLB587AAL 2
RCPH10TLB362AAL 3
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB527AAL 4
Next operation:
Differential - Install (D.12.A)
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RCPH10TLB366AAL 1
RCPH10TLB365AAL 2
RCPH10TLB536AAL 3
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AXLES, BRAKES AND STEERING - REAR AXLE
4. Lubricate the O-ring and the seal with clean oil. In-
stall the cover on the center section.
RCPH10TLB543AAL 4
RCPH10TLB537AAL 5
Next operation:
Differential - Install (D.12.A)
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RCPH10TLB534AAL 1
RCPH10TLB529AAL 2
RCPH10TLB530AAL 3
RCPH10TLB533AAL 4
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AXLES, BRAKES AND STEERING - REAR AXLE
Next operation:
Differential - Check (D.12.A)
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AXLES, BRAKES AND STEERING - REAR AXLE
NOTE: Make sure the air is removed from the brake system when the axle is installed on the machine.
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB385AAL 2
RCPH10TLB376AAL 3
RCPH10TLB382AAL 4
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB393AAL 5
RCPH10TLB394AAL 6
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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AXLES, BRAKES AND STEERING - REAR AXLE
9. Pull the half shaft out with the hub and brakes.
RCPH10TLB397AAL 9
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
RCPH10TLB311AAL 12
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB312AAL 14
RCPH10TLB401AAL 15
RCPH10TLB314AAL 16
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB406AAL 20
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AXLES, BRAKES AND STEERING - REAR AXLE
21. Use two acceptable flat bars and evenly pry the brake
piston up from the hub.
RCPH10TLB316AAL 21
RCPH10TLB317AAL 22
RCPH10TLB421AAL 23
RCPH10TLB318AAL 24
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AXLES, BRAKES AND STEERING - REAR AXLE
25. If the machine has high work hours, remove and dis-
card the outer brake piston O-ring.
RCPH10TLB415AAL 25
26. If the machine has high work hours, remove and dis-
card the inner brake piston O-ring.
RCPH10TLB416AAL 26
27. If the machine has high work hours, remove and dis-
card the brake cylinder O-ring.
RCPH10TLB418AAL 27
RCPH10TLB319AAL 28
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB322AAL 32
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB423AAL 36
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RCPH10TLB329AAL 37
RCPH10TLB330AAL 38
RCPH10TLB331AAL 39
RCPH10TLB332AAL 40
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RCPH10TLB425AAL 41
RCPH10TLB426AAL 42
RCPH10TLB429AAL 43
RCPH10TLB431AAL 44
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB430AAL 45
Next operation:
Hub - Inspect (D.12.A)
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AXLES, BRAKES AND STEERING - REAR AXLE
Hub - Inspect - Wheel hub and brakes - 580N and 580SN only
1. Clean all parts in cleaning solvent.
2. Discard all seals and O-rings.
3. Inspect the bearing cups and the rollers in the wheel
bearings for flat areas, pitting, scoring, and other
damage. Also check the inner race for damage. If
you find any of these defects, you must install new
wheel bearings and bearing cups.
4. Inspect the planetary shafts for wear and damage.
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
other damage. Use new parts as required.
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.
Use new parts as required.
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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AXLES, BRAKES AND STEERING - REAR AXLE
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.
RCPH10TLB427AAL 1
RCPH10TLB428AAL 2
RCPH10TLB333AAL 3
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RCPH10TLB430AAL 4
RCPH10TLB431AAL 5
RCPH10TLB332AAL 6
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB423AAL 7
RCPH10TLB328AAL 8
RCPH10TLB324AAL 9
RCPH10TLB325AAL 10
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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
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RCPH10TLB336AAL 14
RCPH10TLB419AAL 15
RCPH10TLB420AAL 16
RCPH10TLB422AAL 17
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RCPH10TLB337AAL 18
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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RCPH10TLB408AAL 22
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
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27. Place the third adjuster ring onto aligning tool with
the slot at 180° from the slot of the first ring.
RCPH10TLB411AAL 25
28. Place the fourth adjuster ring onto aligning tool with
the slot at 270° from the slot of the first ring.
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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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
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RCPH10TLB400AAL 33
RCPH10TLB402AAL 34
RCPH10TLB313AAL 35
38. Put the half shaft (1) and brake separator plate pins
(2) into the axle housing.
RCPH10TLB473AAL 36
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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
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42. Place the outer brake disc onto the half shaft, do not
damage any of the splines or teeth.
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
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RCPH10TLB478AAL 43
RCPH10TLB479AAL 44
RCPH10TLB383AAL 45
Next operation:
Differential - Remove (D.12.A)
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RCPH10TLB384AAL 1
RCPH10TLB385AAL 2
RCPH10TLB376AAL 3
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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
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RCPH10TLB395AAL 7
8. Slowly pull hub away from axle, make sure that the
brake disks and plates stay with the hub.
RCPH10TLB396AAL 8
9. Pull the half shaft out with the hub and brakes.
RCPH10TLB397AAL 9
RCPH10TLB398AAL 10
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AXLES, BRAKES AND STEERING - REAR AXLE
11. Stand the hub up, mark the reaction plat that was
against the axle housing. Remove the reaction and
brake disks.
RCPH10TLB399AAL 11
NOTE: Keep brake surfaces in same relationship to each other if being reused.
12. Remove the half shaft from the planetary gears.
RCPH10TLB311AAL 12
13. Left hand shaft is 807 mm (31.7 in) long and the right
hand shaft is 701 mm (27.5 in) long.
RCPH10TLB375AAL 13
RCPH10TLB312AAL 14
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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.
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RCPH10TLB404AAL 18
RCPH10TLB405AAL 19
RCPH10TLB406AAL 20
21. Use an acceptable flat bars and pry the brake piston
up from the hub.
RCPH10TLB316AAL 21
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RCPH10TLB317AAL 22
RCPH10TLB421AAL 23
24. The cylinder may remain in the housing, use pry bar
and remove the cylinder.
RCPH10TLB318AAL 24
RCPH10TLB415AAL 25
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RCPH10TLB416AAL 26
RCPH10TLB418AAL 27
RCPH10TLB319AAL 28
RCPH10TLB320AAL 29
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB322AAL 32
RCPH10TLB323AAL 33
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AXLES, BRAKES AND STEERING - REAR AXLE
35. Place the wheel end in a press and lock the wheel
hub so it can not turn.
RCPH10TLB326AAL 34
RCPH10TLB327AAL 35
RCPH10TLB423AAL 36
RCPH10TLB329AAL 37
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RCPH10TLB330AAL 38
RCPH10TLB331AAL 39
RCPH10TLB332AAL 40
RCPH10TLB425AAL 41
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RCPH10TLB426AAL 42
RCPH10TLB429AAL 43
RCPH10TLB431AAL 44
RCPH10TLB430AAL 45
Next operation:
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AXLES, BRAKES AND STEERING - REAR AXLE
Hub - Inspect - Wheel hub and brakes - 580SN-WT and 590SN only
1. Clean all parts in cleaning solvent.
2. Discard all seals and O-rings.
3. Inspect the bearing cups and the rollers in the wheel
bearings for flat areas, pitting, scoring, and other
damage. Also check the inner race for damage. If
you find any of these defects, you must install new
wheel bearings and bearing cups.
4. Inspect the planetary shafts for wear and damage.
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
other damage. Use new parts as required.
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.
Use new parts as required.
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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AXLES, BRAKES AND STEERING - REAR AXLE
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
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RCPH10TLB430AAL 4
RCPH10TLB431AAL 5
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.
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AXLES, BRAKES AND STEERING - REAR AXLE
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
RCPH10TLB324AAL 9
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AXLES, BRAKES AND STEERING - REAR AXLE
RCPH10TLB325AAL 10
RCPH10TLB424AAL 11
14. Hold the snap ring open and lower the planetary as-
sembly into position.
RCPH10TLB334AAL 12
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AXLES, BRAKES AND STEERING - REAR AXLE
15. Make sure that the snap ring is fully closed, two tips
touch, remove lifting equipment.
RCPH10TLB335AAL 13
RCPH10TLB336AAL 14
RCPH10TLB419AAL 15
RCPH10TLB420AAL 16
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RCPH10TLB422AAL 17
RCPH10TLB337AAL 18
21. Place the brake piston and cylinder onto the hub.
RCPH10TLB417AAL 19
RCPH10TLB339AAL 20
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RCPH10TLB407AAL 21
RCPH10TLB408AAL 22
RCPH10TLB409AAL 23
NOTE: For ease of installation, look at the inside of the adjuster ring, place tapered end down.
26. Place the second adjuster ring onto aligning tool with
the slot at 90° from the slot of the first ring.
RCPH10TLB410AAL 24
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AXLES, BRAKES AND STEERING - REAR AXLE
27. Place the third adjuster ring onto aligning tool with
the slot at 180° from the slot of the first ring.
RCPH10TLB411AAL 25
28. Place the fourth adjuster ring onto aligning tool with
the slot at 270° from the slot of the first ring.
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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AXLES, BRAKES AND STEERING - REAR AXLE
31. Insert the adjuster into the brake piston, make sure
that the chaffered side is up.
RCPH10TLB403AAL 29
32. Make sure the tips 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 grove in
the brake piston.
RCPH10TLB338AAL 32
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RCPH10TLB400AAL 33
RCPH10TLB402AAL 34
RCPH10TLB313AAL 35
38. Put the half shaft and brake separator plate pins into
the axle housing.
RCPH10TLB473AAL 36
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RCPH10TLB474AAL 37
RCPH10TLB475AAL 38
NOTE: For the 580N there is only one brake disk, for all Super N models there are two brake disks.
41. Install the second brake separator, SN models only.
RCPH10TLB476AAL 39
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AXLES, BRAKES AND STEERING - REAR AXLE
42. Place the outer brake disk onto the half shaft, do not
damage any of the splines or teeth.
RCPH10TLB477AAL 40
43. Make sure the slots of the inner and outer brake disks
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
RCPH10TLB478AAL 43
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AXLES, BRAKES AND STEERING - REAR AXLE
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
Next operation:
Differential - Remove (D.12.A)
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Index
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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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AXLES, BRAKES AND STEERING - D
580N
580SN WT
580SN
590SN
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D.20.C / 1
Contents
TECHNICAL DATA
STEERING Hydraulic
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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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D.20.C / 2
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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RCPH10TLB077GAL 1
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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RCPH10TLB234ABL 1
RCPH10TLB233ABL 1
RCPH10TLB284ABL 2
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RCPH10TLB001HAM 1
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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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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB071GAL 1
Steering Control Valve Hydraulic Installation 580N, 580SN and 590SN
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RCPH10TLB072GAL 1
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RCPH10TLB073GAL 1
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RCPH10TLB076GAL 1
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RCPH10TLB001HAM 1
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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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RCPH10TLB068GAL 1
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RCPH10TLB128GAL 1
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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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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB074GAL 1
Canopy Models
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RCPH10TLB025AAL 1
RCPH10TLB024AAL 2
RCPH10TLB023AAL 3
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB240ABL 4
RCPH10TLB289ABL 5
RCPH10TLB066GAL 6
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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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RCPH10TLB289ABL 1
RCPH10TLB240ABL 2
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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
RCPH10TLB025AAL 5
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB241ABL 1
RCPH10TLB242ABL 2
RCPH10TLB243ABL 3
RCPH10TLB244ABL 4
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB245ABL 5
RCPH10TLB246ABL 6
RCPH10TLB247ABL 7
RCPH10TLB248ABL 8
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB249ABL 9
RCPH10TLB250ABL 10
RCPH10TLB251ABL 11
12. Use a punch to push the pin out of the sleeve and
spool.
RCPH10TLB252ABL 12
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
13. Remove the drive shaft from the sleeve and spool.
RCPH10TLB253ABL 13
RCPH10TLB254ABL 14
RCPH10TLB255ABL 15
RCPH10TLB256ABL 16
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RCPH10TLB257ABL 17
RCPH10TLB258ABL 18
RCPH10TLB259ABL 19
RCPH10TLB260ABL 20
Next operation:
Control valve - Inspect (D.20.C)
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RCPH10TLB064GAL 1
RCPH10TLB065GAL 2
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RCPH10TLB283ABL 3
Next operation:
Control valve - Assemble (D.20.C)
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB261ABL 1
2. Put the “O” ring of the two piece seal on the recessed
tip of the plunger.
RCPH10TLB262ABL 2
RCPH10TLB263ABL 3
RCPH10TLB264ABL 4
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB265ABL 5
RCPH10TLB266ABL 6
RCPH10TLB267ABL 7
RCPH10TLB268ABL 8
NOTE: Seal and “O” ring must both be within shaft seal counterbore of the housing.
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB269ABL 9
RCPH10TLB071ABL 10
RCPH10TLB258ABL 11
RCPH10TLB270ABL 12
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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
RCPH10TLB274ABL 16
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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
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.
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB279ABL 21
24. Align the timing mark on the drive shaft with a valley
of the gerotor.
RCPH10TLB280ABL 22
RCPH10TLB281ABL 23
RCPH10TLB282ABL 24
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RCPH10TLB003BAM 25
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB014FAM 1
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB238ABL 1
RCPH10TLB237ABL 2
Next operation:
Steering cylinder - Install (D.20.C)
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB301ABL 1
RCPH10TLB302ABL 2
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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
RCPH10TLB287ABL 5
RCPH10TLB288ABL 6
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
Next operation:
Steering cylinder - Install (D.20.C)
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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
RCPH10TLB302ABL 3
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB068GAL 1
Next operation:
Steering cylinder - Inspect (D.20.C)
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RCPH10TLB068GAL 1
Next operation:
Steering cylinder - Assemble (D.20.C)
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RCPH10TLB068GAL 1
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RCPH10TLB290ABL 1
RCPH10TLB291ABL 2
RCPH10TLB292ABL 3
RCPH10TLB293ABL 4
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
RCPH10TLB294ABL 5
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
RCPH10TLB297ABL 8
Next operation:
Steering cylinder - Inspect (D.20.C)
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
Next operation:
Steering cylinder - Assemble (D.20.C)
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RCPH10TLB299ABL 1
RCPH10TLB297ABL 2
RCPH10TLB298ABL 3
RCPH10TLB294ABL 4
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
Next operation:
Steering column - Install (D.20.C)
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AXLES, BRAKES AND STEERING - STEERING Hydraulic
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.
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Index
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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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AXLES, BRAKES AND STEERING - D
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
FUNCTIONAL DATA
SERVICE
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
580SN-WT, 590SN
Capacity - center bowl 18.6 l (19.7 US qt)
Type of Fluid. Wet Brake/Transmission Lubricant - SAE 80W140
MAT3510
RCPH10TLB378AAL 1
Self adjusting brake tools 380002435
NOTE: Part of rear axle service tools.
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB043ABL 2
CAS-2379 input shaft holder and spring compressor
NOTE: Part of transmission service tools.
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB033GAL 1
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB033GAL 1
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
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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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB8GAL 1
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB591AAL 1
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB024AAL 1
RCPH10TLB023AAL 2
RCPH10TLB240ABL 3
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
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
Next operation:
Master cylinder - Install (D.30.C)
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB593AAL 1
RCPH10TLB167ABL 2
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB592AAL 3
RCPH10TLB240ABL 4
RCPH10TLB023AAL 5
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
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
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB591AAL 1
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
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
RCPH10TLB384AAL 2
RCPH10TLB385AAL 3
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB376AAL 4
RCPH10TLB382AAL 5
RCPH10TLB393AAL 6
RCPH10TLB394AAL 7
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB395AAL 8
12. Slowly pull hub away from axle, make sure that the
brake disks and plates stay with the hub.
RCPH10TLB396AAL 9
13. Pull the half shaft out with the hub and brakes.
RCPH10TLB397AAL 10
RCPH10TLB398AAL 11
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
15. 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 12
RCPH10TLB311AAL 13
17. Left hand shaft is 807 mm (31.8 in) long and the right
hand shaft is 701 mm (27.6 in) long.
RCPH10TLB375AAL 14
RCPH10TLB312AAL 15
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB401AAL 16
RCPH10TLB314AAL 17
RCPH10TLB315AAL 18
RCPH10TLB404AAL 19
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
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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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB421AAL 24
28. The cylinder may remain in the housing, use pry bar
and remove the cylinder.
RCPH10TLB318AAL 25
RCPH10TLB415AAL 26
RCPH10TLB416AAL 27
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB418AAL 28
RCPH10TLB319AAL 29
Next operation:
Brake - Inspect (D.30.C)
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
Brake - Inspect
Prior operation:
Brake - Disassemble (D.30.C)
Next operation:
Brake - Assemble (D.30.C)
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
Brake - Assemble
Prior operation:
Brake - Inspect (D.30.C).
RCPH10TLB336AAL 1
RCPH10TLB419AAL 2
RCPH10TLB420AAL 3
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB422AAL 4
RCPH10TLB337AAL 5
RCPH10TLB417AAL 6
RCPH10TLB339AAL 7
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB407AAL 8
RCPH10TLB408AAL 9
RCPH10TLB409AAL 10
11. Place the second adjuster ring onto aligning tool with
the slot at 90° from the slot of the first ring.
RCPH10TLB410AAL 11
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AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
12. Place the third adjuster ring onto aligning tool with
the slot at 180° from the slot of the first ring.
RCPH10TLB411AAL 12
13. Place the fourth adjuster ring onto aligning tool with
the slot at 270° from the slot of the first ring.
RCPH10TLB412AAL 13
14. Place driver tool onto aligning tool, driver part of tool
kit 380002435.
RCPH10TLB413AAL 14
15. Drive the rings onto the adjuster until they are seated
against the depth setting tool.
RCPH10TLB414AAL 15
84516378 05/07/2011
D.30.C / 30
AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
16. Insert the adjuster into the brake piston, make sure
that the chaffered side is up.
RCPH10TLB403AAL 16
17. Make sure the tips of the snap ring face the adjuster
during installation.
RCPH10TLB490AAL 17
18. Install the snap ring into the self adjuster bore.
RCPH10TLB314AAL 18
19. Make sure the snap ring fully engages the grove in
the brake piston.
RCPH10TLB338AAL 19
84516378 05/07/2011
D.30.C / 31
AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB400AAL 20
RCPH10TLB402AAL 21
RCPH10TLB313AAL 22
23. Put the half shaft and brake separator plate pins into
the axle housing.
RCPH10TLB473AAL 23
84516378 05/07/2011
D.30.C / 32
AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB474AAL 24
25. Place the inner brake disk onto the half shaft, do not
damage any of the splines or teeth.
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
damage any of the splines or teeth.
RCPH10TLB477AAL 27
84516378 05/07/2011
D.30.C / 33
AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
28. Make sure the slots of the inner and outer brake disks
are aligned with each other.
RCPH10TLB471AAL 28
29. Install dowel rods into axle housing, two short rods
for bench repair, three long for in vehicle repair.
RCPH10TLB472AAL 29
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
84516378 05/07/2011
D.30.C / 34
AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
RCPH10TLB383AAL 32
RCPH10TLB066AAL 33
RCPH10TLB306AAL 34
84516378 05/07/2011
D.30.C / 35
AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
Brake - Test
Vehicle Brakes
84516378 05/07/2011
D.30.C / 36
AXLES, BRAKES AND STEERING - SERVICE BRAKE Hydraulic
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.
9. Lock the brake pedals with the brake pedal locking
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
84516378 05/07/2011
D.30.C / 38
AXLES, BRAKES AND STEERING - D
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
RCPH10TLB596AAL 1
RCPH10TLB868AAL 2
RCPH10TLB869AAL 3
84516378 05/07/2011
D.32.B / 3
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
RCPH10TLB871AAL 4
RCPH10TLB594AAL 5
RCPH10TLB872AAL 6
RCPH10TLB873AAL 7
84516378 05/07/2011
D.32.B / 4
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
RCPH10TLB874AAL 8
RCPH10TLB875AAL 9
RCPH10TLB876AAL 10
RCPH10TLB877AAL 11
84516378 05/07/2011
D.32.B / 5
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
RCPH10TLB599AAL 12
RCPH10TLB600AAL 13
RCPH10TLB601AAL 14
RCPH10TLB602AAL 15
84516378 05/07/2011
D.32.B / 6
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
RCPH10TLB603AAL 16
RCPH10TLB604AAL 17
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
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
Brake - Inspect
Prior operation:
Brake - Disassemble (D.32.B)
Next operation:
Brake - Assemble (D.32.B)
84516378 05/07/2011
D.32.B / 8
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
Brake - Assemble
Prior operation:
Brake - Inspect (D.32.B)
NOTE: Some of the following images may not represent your transmission, the procedures are the same.
1. Install a new O-ring on the brake housing.
RCPH10TLB607AAL 1
RCPH10TLB595AAL 2
RCPH10TLB608AAL 3
NOTE: Make sure that the seal ring does not twist during installation.
84516378 05/07/2011
D.32.B / 9
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
RCPH10TLB602AAL 4
RCPH10TLB601AAL 5
RCPH10TLB600AAL 6
RCPH10TLB599AAL 7
84516378 05/07/2011
D.32.B / 10
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
RCPH10TLB877AAL 8
RCPH10TLB876AAL 9
RCPH10TLB875AAL 10
RCPH10TLB874AAL 11
84516378 05/07/2011
D.32.B / 11
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
RCPH10TLB873AAL 12
RCPH10TLB872AAL 13
RCPH10TLB871AAL 14
RCPH10TLB869AAL 15
84516378 05/07/2011
D.32.B / 12
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
RCPH10TLB868AAL 16
RCPH10TLB870AAL 17
84516378 05/07/2011
D.32.B / 13
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
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
RCPH10TLB598AAL 2
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
AXLES, BRAKES AND STEERING - PARKING BRAKE Mechanical
Brake - Test
Parking brake
1. Apply the parking brake.
2. Lock the brake pedals with the brake pedal locking
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
84516378 05/07/2011
D.32.B / 16
AXLES, BRAKES AND STEERING - D
580N
580SN WT
580SN
590SN
84516378 05/07/2011
D.50.C / 1
Contents
TECHNICAL DATA
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
84516378 05/07/2011
D.50.C / 3
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels
RCPH10TLB610AAL 1
84516378 05/07/2011
D.50.C / 4
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels
RCPH10TLB611AAL 1
84516378 05/07/2011
D.50.C / 5
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels
RCPH11TLB119AAM 1
2. Remove hardware.
RCPH11TLB135AAM 2
RCPH11TLB136AAM 3
84516378 05/07/2011
D.50.C / 6
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels
RCPH11TLB135AAM 1
RCPH10TLB074AAF 2
84516378 05/07/2011
D.50.C / 7
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels
RCPH11TLB138AAM 1
2. Remove hardware.
RCPH11TLB138AAM 2
RCPH11TLB120AAM 3
84516378 05/07/2011
D.50.C / 8
AXLES, BRAKES AND STEERING - WHEELS AND TRACKS Wheels
RCPH11TLB138AAM 1
84516378 05/07/2011
D.50.C / 9
Index
84516378 05/07/2011
D.50.C / 10
84516378 05/07/2011
D.50.C / 11
CNH - Main 700 State Street Racine, Wisconsin United States 53404
PRINTED IN U.S.A.
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
FRAME AND CAB
580N
580SN WT
580SN
590SN
84516378 05/07/2011
E
Contents
SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.20.A
580N , 580SN WT , 580SN , 590SN
84516378 05/07/2011
E
FRAME AND CAB - E
580N
580SN WT
580SN
590SN
84516378 05/07/2011
E.10.B / 1
Contents
SERVICE
Front
Remove - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
84516378 05/07/2011
E.10.B / 2
FRAME AND CAB - FRAME Primary frame
RCPH11TLB098AAM 1
RCPH11TLB099AAM 2
RCPH11TLB100AAM 3
RCPH11TLB101AAM 4
84516378 05/07/2011
E.10.B / 3
FRAME AND CAB - FRAME Primary frame
RCPH11TLB102AAM 5
RCPH11TLB103AAM 6
RCPH11TLB104AAM 7
RCPH11TLB105AAM 8
84516378 05/07/2011
E.10.B / 4
FRAME AND CAB - FRAME Primary frame
RCPH11TLB106AAM 9
RCPH11TLB107AAM 10
RCPH11TLB108AAM 11
RCPH11TLB109AAM 12
84516378 05/07/2011
E.10.B / 5
FRAME AND CAB - FRAME Primary frame
RCPH11TLB110AAM 13
RCPH11TLB111AAM 14
RCPH11TLB112AAM 15
RCPH11TLB113AAM 16
84516378 05/07/2011
E.10.B / 6
FRAME AND CAB - FRAME Primary frame
RCPH11TLB114AAM 17
RCPH11TLB115AAM 18
RCPH11TLB116AAM 19
RCPH11TLB117AAM 20
84516378 05/07/2011
E.10.B / 7
FRAME AND CAB - FRAME Primary frame
RCPH11TLB118AAM 21
84516378 05/07/2011
E.10.B / 8
FRAME AND CAB - FRAME Primary frame
RCPH11TLB118AAM 1
RCPH11TLB117AAM 2
RCPH11TLB116AAM 3
RCPH11TLB114AAM 4
84516378 05/07/2011
E.10.B / 9
FRAME AND CAB - FRAME Primary frame
RCPH11TLB113AAM 5
RCPH11TLB112AAM 6
RCPH11TLB111AAM 7
RCPH11TLB110AAM 8
84516378 05/07/2011
E.10.B / 10
FRAME AND CAB - FRAME Primary frame
RCPH11TLB108AAM 9
RCPH11TLB107AAM 10
RCPH11TLB105AAM 11
RCPH11TLB104AAM 12
84516378 05/07/2011
E.10.B / 11
FRAME AND CAB - FRAME Primary frame
RCPH11TLB103AAM 13
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
RCPH11TLB100AAM 16
84516378 05/07/2011
E.10.B / 12
FRAME AND CAB - FRAME Primary frame
RCPH11TLB099AAM 17
84516378 05/07/2011
E.10.B / 13
Index
84516378 05/07/2011
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
SHIELD - 20.A
SERVICE
Engine hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84516378 05/07/2011
E.20.A / 2
FRAME AND CAB - SHIELD
RCPH11TLB001AAM 1
RCPH11TLB002AAM 2
RCPH11TLB002AAM 3
RCPH11TLB004AAM 4
84516378 05/07/2011
E.20.A / 3
FRAME AND CAB - SHIELD
RCPH11TLB005AAM 5
RCPH11TLB006AAM 6
7. Remove hood.
RCPH11TLB008AAM 7
84516378 05/07/2011
E.20.A / 4
FRAME AND CAB - SHIELD
RCPH11TLB008AAM 1
RCPH11TLB006AAM 2
RCPH11TLB005AAM 3
RCPH11TLB004AAM 4
84516378 05/07/2011
E.20.A / 5
FRAME AND CAB - SHIELD
RCPH11TLB002AAM 5
RCPH11TLB002AAM 6
RCPH11TLB001AAM 7
84516378 05/07/2011
E.20.A / 6
Index
SHIELD - 20.A
Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84516378 05/07/2011
E.20.A / 7
84516378 05/07/2011
E.20.A / 8
FRAME AND CAB - E
580N
580SN WT
580SN
590SN
84516378 05/07/2011
E.32.A / 1
Contents
FUNCTIONAL DATA
SERVICE
84516378 05/07/2011
E.32.A / 2
FRAME AND CAB - USER CONTROLS AND SEAT
RCPH10TLB095GAL 1
84516378 05/07/2011
E.32.A / 3
FRAME AND CAB - USER CONTROLS AND SEAT
RCPH10TLB096GAL 1
84516378 05/07/2011
E.32.A / 4
FRAME AND CAB - USER CONTROLS AND SEAT
RCPH10TLB094GAL 1
(Right Side Shown)
84516378 05/07/2011
E.32.A / 5
FRAME AND CAB - USER CONTROLS AND SEAT
RCPH10TLB858ABL 1
RCPH10TLB922ABL 2
RCPH10TLB924ABL 3
RCPH10TLB923ABL 4
84516378 05/07/2011
E.32.A / 6
FRAME AND CAB - USER CONTROLS AND SEAT
RCPH10TLB923ABL 5
RCPH10TLB857ABL 6
RCPH10TLB856ABL 7
RCPH10TLB859ABL 8
84516378 05/07/2011
E.32.A / 7
FRAME AND CAB - USER CONTROLS AND SEAT
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
E.32.A / 8
FRAME AND CAB - USER CONTROLS AND SEAT
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
84516378 05/07/2011
E.32.A / 9
FRAME AND CAB - USER CONTROLS AND SEAT
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
RCPH10TLB872ABL 19
RCPH10TLB871ABL 20
84516378 05/07/2011
E.32.A / 10
FRAME AND CAB - USER CONTROLS AND SEAT
RCPH10TLB873ABL 21
RCPH10TLB874ABL 22
23. Loosen and remove the 4 bolts from the lateral iso-
lator plate.
RCPH10TLB875ABL 23
RCPH10TLB876ABL 24
84516378 05/07/2011
E.32.A / 11
FRAME AND CAB - USER CONTROLS AND SEAT
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
RCPH10TLB912ABL 28
84516378 05/07/2011
E.32.A / 12
FRAME AND CAB - USER CONTROLS AND SEAT
RCPH10TLB913ABL 29
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
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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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RCPH10TLB885ABL 45
RCPH10TLB908ABL 46
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
RCPH10TLB887ABL 50
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
RCPH10TLB891ABL 54
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
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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RCPH10TLB906ABL 61
62. Use acceptable tools and remove the shaft from the
lower housing assembly.
RCPH10TLB905ABL 62
RCPH10TLB903ABL 63
RCPH10TLB899ABL 64
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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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Next operation:
USER CONTROLS AND SEAT - Assemble (E.32.A)
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RCPH10TLB901ABL 1
RCPH10TLB902ABL 2
RCPH10TLB899ABL 3
RCPH10TLB903ABL 4
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RCPH10TLB904ABL 5
RCPH10TLB906ABL 6
RCPH10TLB898ABL 7
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
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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RCPH10TLB891ABL 13
RCPH10TLB890ABL 14
15. Install the air line into the fitting on the air spring.
Tighten the fitting nut.
RCPH10TLB889ABL 15
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
RCPH10TLB885ABL 18
RCPH10TLB907ABL 19
RCPH10TLB884ABL 20
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RCPH10TLB883ABL 21
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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RCPH10TLB879ABL 25
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
RCPH10TLB914ABL 30
RCPH10TLB913ABL 31
RCPH10TLB912ABL 32
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RCPH10TLB911ABL 33
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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RCPH10TLB874ABL 37
RCPH10TLB873ABL 38
RCPH10TLB871ABL 39
RCPH10TLB872ABL 40
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RCPH10TLB870ABL 41
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
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
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
RCPH10TLB921ABL 56
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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
RCPH10TLB753ABL 59
RCPH10TLB754ABL 60
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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)
in this Manual for complete troubleshoot-
ing procedure for the instrument cluster.
Configuration mode
NOTE: This procedure can also be used for diagnostic pur-
poses.
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Prior operation:
Instrument panel - Visual inspection (E.32.A)
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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.
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RCPH10TLB339AAF 1
Next operation:
Instrument panel - Disassemble (E.32.A)
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Prior operation:
Instrument panel - Remove (E.32.A)
Next operation:
Instrument panel - Assemble (E.32.A)
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Next operation:
Instrument panel - Install (E.32.A)
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RCPH10TLB339AAF 1
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Index
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FRAME AND CAB - E
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
SERVICE
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RCIL10TLB002GAF 1
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB009HAL 1
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB776ABL 1
RCPH10TLB777ABL 2
RCPH10TLB777ABL 3
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RCPH10TLB776ABL 4
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB832ABL 1
RCPH10TLB833ABL 2
Slide
1. Remove the slide bushings from the left side of the
slide assembly.
RCPH10TLB836ABL 3
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB837ABL 4
Swivel
1. Remove the cotter pin from the swivel bolt.
RCPH10TLB838ABL 5
RCPH10TLB839ABL 6
RCPH10TLB841ABL 7
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
RCPH10TLB846ABL 10
RCPH10TLB848ABL 11
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB849ABL 12
RCPH10TLB850ABL 13
RCPH10TLB851ABL 14
RCPH10TLB852ABL 15
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB855ABL 16
RCPH10TLB853ABL 17
RCPH10TLB854ABL 18
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
Slide
1. Check the position locking teeth for damage.
RCPH10TLB835ABL 1
RCPH10TLB834ABL 2
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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.
5. Repair or replace as needed.
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
Pedestal
1. Place the height adjustment plunger and the spring
into the pedestal shaft.
RCPH10TLB854ABL 1
RCPH10TLB853ABL 2
RCPH10TLB855ABL 3
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB852ABL 4
RCPH10TLB851ABL 5
RCPH10TLB850ABL 6
RCPH10TLB848ABL 7
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
RCPH10TLB775ABL 13
RCPH10TLB829ABL 14
Seat
1. Install the seat.
2. Install and tighten the seat stop.
RCPH10TLB832ABL 15
Next operation:
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB755ABL 1
RCPH10TLB756ABL 2
3. Pull forward and lift the back cushion off of the mount-
ing tabs to remove.
RCPH10TLB757ABL 3
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
Lumber adjustment
1. Drive the roll pin out of the lumbar adjustment knob.
RCPH10TLB759ABL 4
RCPH10TLB758ABL 5
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
RCPH10TLB816ABL 10
RCPH10TLB815ABL 11
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB814ABL 12
RCPH10TLB813ABL 13
10. Remove the spring for the recliner handle from the
arm rest bracket.
RCPH10TLB801ABL 14
RCPH10TLB810ABL 15
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB809ABL 16
RCPH10TLB808ABL 17
RCPH10TLB807ABL 18
RCPH10TLB802ABL 19
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
16. Remove the two bolts from the recliner bracket, re-
move the bracket.
RCPH10TLB803ABL 20
RCPH10TLB804ABL 21
Slide
1. Remove the slide bushings from the left side of the
slide assembly.
RCPH10TLB763ABL 22
RCPH10TLB764ABL 23
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
Swivel
1. Remove the cotter pin from the swivel bolt.
RCPH10TLB766ABL 24
RCPH10TLB767ABL 25
RCPH10TLB768ABL 26
RCPH10TLB769ABL 27
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB770ABL 28
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
RCPH10TLB783ABL 31
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB784ABL 32
RCPH10TLB787ABL 33
RCPH10TLB785ABL 34
RCPH10TLB781ABL 35
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB786ABL 36
RCPH10TLB828ABL 37
RCPH10TLB788ABL 38
RCPH10TLB789ABL 39
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
RCPH10TLB792ABL 43
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB797ABL 44
RCPH10TLB797ABL 45
RCPH10TLB798ABL 46
18. Remove the lower pivot bolt for the lower plate of the
suspension assembly.
RCPH10TLB794ABL 47
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RCPH10TLB795ABL 48
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Slide
1. Check the position locking teeth for damage.
RCPH10TLB765ABL 1
RCPH10TLB831ABL 2
Swivel
1. Inspect the bearing tracks, the bearings, and the
bearing separator plate for wear or damage.
2. Repair or replace as needed.
RCPH10TLB772ABL 3
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
Suspension
1. Inspect the slider blocks and the bushings for wear
and damage.
RCPH10TLB796ABL 4
RCPH10TLB797ABL 5
RCPH10TLB798ABL 6
RCPH10TLB799ABL 7
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RCPH10TLB007ACL 8
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
Suspension
1. Install the slider blocks on the lower plate as shown.
NOTE: Do not lubricate the slider blocks.
RCPH10TLB818ABL 1
RCPH10TLB795ABL 2
RCPH10TLB819ABL 3
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB821ABL 4
RCPH10TLB822ABL 5
RCPH10TLB797ABL 6
RCPH10TLB792ABL 7
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB824ABL 8
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
RCPH10TLB826ABL 11
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RCPH10TLB827ABL 12
RCPH10TLB785ABL 13
RCPH10TLB787ABL 14
Swivel
1. Place the bearing separator plate onto the lower por-
tion of the swivel.
RCPH10TLB773ABL 15
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RCPH10TLB774ABL 16
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB775ABL 20
RCPH10TLB829ABL 21
RCPH10TLB784ABL 22
RCPH10TLB782ABL 23
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB783ABL 24
Seat
1. Install the seat.
2. Install the seat stop.
RCPH10TLB762ABL 25
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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RCPH10TLB803ABL 28
RCPH10TLB802ABL 29
RCPH10TLB806ABL 30
RCPH10TLB807ABL 31
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB808ABL 32
RCPH10TLB809ABL 33
RCPH10TLB810ABL 34
11. Install the handle return spring into the mounting hole
in the arm rest.
RCPH10TLB811ABL 35
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RCPH10TLB812ABL 36
RCPH10TLB813ABL 37
14. Place the spring onto the pivot pin and hook the
spring onto the seat back.
RCPH10TLB814ABL 38
RCPH10TLB815ABL 39
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB816ABL 40
RCPH10TLB817ABL 41
RCPH10TLB779ABL 42
RCPH10TLB778ABL 43
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
Lumbar
1. Place the lumbar assembly into position on the seat
back and install new rivets.
RCPH10TLB761ABL 44
RCPH10TLB758ABL 45
RCPH10TLB760ABL 46
Cushion
1. Install the back seat cushion by aligning the retaining
tabs with the slots.
RCPH10TLB830ABL 47
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RCPH10TLB756ABL 48
3. Align the retaining tabs with the slots and push the
seat bottom into position.
RCPH10TLB755ABL 49
Next operation:
Seat belt - Install (E.32.C)
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RCPH10TLB858ABL 1
RCPH10TLB922ABL 2
RCPH10TLB924ABL 3
RCPH10TLB923ABL 4
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB923ABL 5
RCPH10TLB857ABL 6
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
16. Use acceptable tools and remove the roll pin and
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
19. Use acceptable tools and remove the roll pin and
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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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
RCPH10TLB872ABL 19
RCPH10TLB871ABL 20
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
30. Remove the two bolts from the mounting bracket for
the height adjustment switch.
31. Remove the height adjustment switch assembly.
RCPH10TLB873ABL 21
RCPH10TLB874ABL 22
34. Loosen and remove the four bolts from the lateral
isolator plate.
RCPH10TLB875ABL 23
RCPH10TLB876ABL 24
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
RCPH10TLB912ABL 28
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB913ABL 29
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
RCPH10TLB885ABL 44
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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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RCPH10TLB887ABL 49
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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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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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
RCPH10TLB906ABL 60
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
83. Use acceptable tools and remove the shaft from the
lower housing assembly.
RCPH10TLB905ABL 61
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
RCPH10TLB900ABL 64
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RCPH10TLB901ABL 65
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RCPH10TLB901ABL 1
RCPH10TLB902ABL 2
RCPH10TLB899ABL 3
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB903ABL 4
RCPH10TLB904ABL 5
RCPH10TLB906ABL 6
RCPH10TLB898ABL 7
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
10. Install the plastic pins into the lower mounting holes
of the rubber boot.
RCPH10TLB919ABL 8
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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RCPH10TLB894ABL 12
RCPH10TLB891ABL 13
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB888ABL 16
23. Install three wire ties for the wiring harness on the
lower housing assembly.
RCPH10TLB918ABL 17
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB907ABL 20
RCPH10TLB884ABL 21
RCPH10TLB883ABL 22
RCPH10TLB882ABL 23
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
RCPH10TLB878ABL 27
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB914ABL 32
RCPH10TLB913ABL 33
RCPH10TLB912ABL 34
53. Install the rubber insulator and top washer onto the
shock.
RCPH10TLB911ABL 35
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB910ABL 36
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB874ABL 40
RCPH10TLB873ABL 41
RCPH10TLB871ABL 42
RCPH10TLB872ABL 43
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB870ABL 44
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
RCPH10TLB864ABL 51
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
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
RCPH10TLB860ABL 54
82. Install and tighten the two Allen head bolts in the seat
stop.
RCPH10TLB859ABL 55
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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB856ABL 56
RCPH10TLB857ABL 57
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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FRAME AND CAB - USER CONTROLS AND SEAT Operator seat
RCPH10TLB921ABL 60
RCPH10TLB858ABL 61
94. After the seat has been assembled, adjust the slide
pucks to the desired lateral movement of the seat.
RCPH10TLB862ABL 62
Next operation:
Seat belt - Install (E.32.C)
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RCPH10TLB753ABL 1
RCPH10TLB439AAF 2
RCPH10TLB440AAF 3
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Index
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FRAME AND CAB - E
580N
580SN WT
580SN
590SN
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Contents
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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RCPH10TLB020FAL 1
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RCPH10TLB001GAD 1
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RCPH10TLB001HAD 1
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RCPH10TLB003GAD 1
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RCPH10TLB004GAD 2
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RCPH11TLB063AAM 1
RCPH11TLB001AAM 2
RCPH11TLB064AAM 3
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RCPH11TLB065AAM 4
RCPH11TLB066AAM 5
RCPH11TLB067AAM 6
RCPH11TLB068AAM 7
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RCPH11TLB069AAM 8
RCPH11TLB070AAM 9
RCPH11TLB075AAL 10
RCPH11TLB071AAM 11
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RCPH11TLB072AAM 12
RCPH11TLB073AAM 13
RCPH11TLB074AAM 14
RCPH11TLB074AAM 15
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RCPH11TLB075AAM 16
17. Identify, tag and remove the bolts securing the loader
control rods.
RCPH11TLB076AAM 17
RCPH11TLB077AAM 18
RCPH11TLB078AAM 19
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RCPH11TLB079AAM 20
RCPH11TLB080AAM 21
RCPH11TLB081AAM 22
RCPH11TLB082AAM 23 RCPH11TLB083AAM 24
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RCPH11TLB084AAM 25
RCPH11TLB009AAL 26
RCPH11TLB085AAM 27
RCPH11TLB085AAM 28
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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
RCPH11TLB089AAM 32
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32. Remove air cleaner to turbo tube. Cap all open ports.
RCPH11TLB036AAM 33
RCPH11TLB037AAM 34
RCPH11TLB038AAM 35
RCPH11TLB039AAM 36
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RCPH11TLB040AAM 37
RCPH10TLB031AAL 38
RCPH11TLB090AAM 39
RCPH11TLB091AAM 40
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RCPH11TLB092AAM 41
RCPH11TLB093AAM 42
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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RCPH10TLB624AAL 1
RCPH11TLB096AAM 2
3. Install the right hand rear wheel well inner mud flap.
RCPH11TLB095AAM 3
RCPH11TLB094AAM 4
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RCPH11TLB093AAM 5
RCPH11TLB092AAM 6
RCPH11TLB091AAM 7
RCPH11TLB090AAM 8
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RCPH10TLB031AAL 9
RCPH11TLB039AAM 10
RCPH11TLB040AAM 11
RCPH11TLB038AAM 12
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RCPH11TLB037AAM 13
RCPH11TLB036AAM 14
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
RCPH11TLB086AAM 18
RCPH11TLB085AAM 19
RCPH11TLB085AAM 20
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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.
RCPH11TLB082AAM 23 RCPH11TLB083AAM 24
RCPH11TLB081AAM 25
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RCPH11TLB080AAM 26
RCPH11TLB079AAM 27
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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RCPH11TLB076AAM 30
RCPH11TLB075AAM 31
RCPH11TLB074AAM 32
RCPH11TLB074AAM 33
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RCPH11TLB073AAM 34
34. Secure the floor plate to the floor with the existing
hardware.
RCPH11TLB072AAM 35
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
RCPH11TLB069AAM 39
RCPH11TLB068AAM 40
RCPH11TLB067AAM 41
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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:
Battery - Connect (A.30.A)
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RCPH10TLB030AAL 1
8. Remove the screws from the right hand side and the
left hand side of the front floor mat.
RCPH10TLB318ABL 2
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
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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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
RCPH10TLB615AAL 10
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
RCPH10TLB621AAL 14
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
RCPH10TLB067AAL 17
RCPH10TLB050AAL 18
RCPH10TLB626AAL 19
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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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RCPH10TLB035AAL 23
RCPH10TLB034AAL 24
34. Tag and disconnect the wires for the air filter restric-
tion switch.
RCPH10TLB025AAL 25
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
37. Push the wires for the air restriction switch through
the hole in the curtain. Remove the bolts from the
rubber curtain on the firewall and remove the curtain.
RCPH10TLB240ABL 28
RCPH10TLB622AAL 29
RCPH10TLB625AAL 30
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RCPH10TLB167ABL 31
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.
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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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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
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RCPH10TLB066GAL 2
1. Spacer 6. Bolt
2. Mount 7. Control valve
3. Control valve 8. Washer
4. Mount 9. Bolt
5. Washer
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
RCPH10TLB622AAL 5
16. Push the wires for the air restriction switch through
the hole the curtain. Install the curtain and bolts on
the fire wall.
RCPH10TLB240ABL 6
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
RCPH10TLB025AAL 9
RCPH10TLB034AAL 10
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
RCPH10TLB067AAL 16
RCPH10TLB617AAL 17
28. Install the rear floor plate. If equipped install the rear
floor mat.
RCPH10TLB614AAL 18
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RCPH10TLB079GAL 19
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
RCPH10TLB619AAL 23
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
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
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RCPH10TLB001CAD 1
RCPH10TLB126AAF 2
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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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Prior operation:
Door, window and windscreen - Remove - Rear window - top (E.34.A)
RCPH10TLB004AAD 1
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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RCPH10TLB126AAF 4
RCPH10TLB001CAD 5
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RCPH10TLB001CAD 1
RCPH10TLB002CAD 2
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RCPH10TLB003CAD 3
NOTICE: Forcing the window to bend during removal may cause damage to the window.
7. Remove the middle window from the frame.
Next operation:
Door, window and windscreen - Install (E.34.A)
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Prior operation:
Door, window and windscreen - Remove (E.34.A)
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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RCPH10TLB003CAD 3
RCPH10TLB003CAD 4
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RCPH10TLB002CAD 5
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RCPH10TLB349AAF 1
RCPH10TLB342AAF 2
NOTICE: Forcing the window to bend during removal may cause damage to the window.
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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RCPH10TLB012AAD 1
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Index
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FRAME AND CAB - E
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
FUNCTIONAL DATA
SERVICE
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
299L7C 1
Phone: 1-800-533-0492
RCPH07SPT081AAA 2
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH07SPT096AAA 3
RCPH10TLB677AAL 4
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB001EAL 1
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB036GAL 1
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB663AAL 2
RCPH10TLB661AAL 3
RCPH10TLB662AAL 4
RCPH10TLB656AAL 5
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB661AAL 7
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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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB042AAL 11
RCPH10TLB662AAL 12
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB656AAL 13
RCPH10TLB660AAL 14
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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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB659AAL 17
RCPH10TLB042AAL 18
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB655AAL 2
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FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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
27 °C (80.6 °F) 1.24 - 1.37 bar (18 - 20 psi) 15.1 - 16.5 bar (219 - 239 psi) 12 °C (53.6 °F)
32 °C (89.6 °F) 1.72 - 1.86 bar (25 - 27 psi) 18.9 - 20.3 bar (274 - 294 psi) 17 °C (62.6 °F)
35 °C (95.0 °F) 1.80 - 1.99 bar (26 - 29 psi) 21.0 - 22.4 bar (305 - 325 psi) 17 °C (62.6 °F)
38 °C (100.4 °F) 1.86 - 2.06 bar (27 - 30 psi) 22.0 - 23.4 bar (319 - 339 psi) 18 °C (64.4 °F)
41 °C (105.8 °F) 1.93 - 2.13 bar (28 - 31 psi) 23.4 - 24.8 bar (339 - 360 psi) 18 °C (64.4 °F)
43 °C (109.4 °F) 2.06 - 2.20 bar (30 - 32 psi) 24.4 - 25.8 bar (354 - 374 psi) 19 °C (66.2 °F)
Next operation:
ENVIRONMENT CONTROL Air-conditioning system - Check (E.40.C)
84516378 05/07/2011
E.40.C / 20
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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
RCPH10TLB669AAL 2
Next operation:
ENVIRONMENT CONTROL Air-conditioning system - Check (E.40.C)
84516378 05/07/2011
E.40.C / 21
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB668AAL 1
RCPH10TLB680AAL 2
84516378 05/07/2011
E.40.C / 22
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB668AAL 3
84516378 05/07/2011
E.40.C / 23
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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
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
84516378 05/07/2011
E.40.C / 24
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB630AAL 1
RCPH10TLB675AAL 2
84516378 05/07/2011
E.40.C / 25
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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
84516378 05/07/2011
E.40.C / 26
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB676AAL 5
84516378 05/07/2011
E.40.C / 27
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB631AAL 1
RCPH10TLB632AAL 2
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
84516378 05/07/2011
E.40.C / 28
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB635AAL 5
RCPH10TLB636AAL 6
RCPH10TLB637AAL 7
RCPH10TLB638AAL 8
84516378 05/07/2011
E.40.C / 29
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB639AAL 9
10. Remove the external snap ring for the bearing and
pulley assembly.
RCPH10TLB641AAL 10
RCPH10TLB642AAL 11
RCPH10TLB643AAL 12
84516378 05/07/2011
E.40.C / 30
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB644AAL 13
14. Remove the snap ring for the clutch coil assembly.
RCPH10TLB646AAL 14
RCPH10TLB645AAL 15
RCPH10TLB647AAL 16
84516378 05/07/2011
E.40.C / 31
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
17. Remove the internal snap ring and remove the bear-
ing from the pulley.
RCPH10TLB648AAL 17
Next operation:
Compressor - Assemble (E.40.C)
84516378 05/07/2011
E.40.C / 32
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB933ABL 1
RCPH10TLB647AAL 2
RCPH10TLB645AAL 3
RCPH10TLB646AAL 4
84516378 05/07/2011
E.40.C / 33
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB648AAL 5
RCPH10TLB649AAL 6
RCPH10TLB649AAL 7
RCPH10TLB641AAL 8
84516378 05/07/2011
E.40.C / 34
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB640AAL 9
10. Place the bearing dust cover in the bore. Place driver
from special tool kit over the dust cover.
RCPH10TLB650AAL 10
RCPH10TLB651AAL 11
RCPH10TLB637AAL 12
84516378 05/07/2011
E.40.C / 35
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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
RCPH10TLB679AAL 16
84516378 05/07/2011
E.40.C / 36
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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
84516378 05/07/2011
E.40.C / 37
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
84516378 05/07/2011
E.40.C / 38
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
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
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB674AAL 1
RCPH10TLB666AAL 3
Next operation:
Evaporator - Install (E.40.C)
84516378 05/07/2011
E.40.C / 40
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
Evaporator - Install
Prior operation:
Evaporator - Remove (E.40.C)
RCPH10TLB037GAL 1
84516378 05/07/2011
E.40.C / 41
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB671AAL 3
RCPH10TLB673AAL 4
84516378 05/07/2011
E.40.C / 42
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
RCPH10TLB674AAL 1
RCPH10TLB666AAL 2
84516378 05/07/2011
E.40.C / 43
FRAME AND CAB - ENVIRONMENT CONTROL Air-conditioning system
84516378 05/07/2011
E.40.C / 44
Index
84516378 05/07/2011
E.40.C / 45
CNH - Main 700 State Street Racine, Wisconsin United States 53404
PRINTED IN U.S.A.
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
FRAME POSITIONING
580N
580SN WT
580SN
590SN
84516378 05/07/2011
F
Contents
FRAME POSITIONING - F
84516378 05/07/2011
F
FRAME POSITIONING - F
580N
580SN WT
580SN
590SN
84516378 05/07/2011
F.20.D / 1
Contents
FRAME POSITIONING - F
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
84516378 05/07/2011
F.20.D / 3
FRAME POSITIONING - STABILISING Working stabilising
84516378 05/07/2011
F.20.D / 4
FRAME POSITIONING - STABILISING Working stabilising
RCPH11TLB021HAN 1
84516378 05/07/2011
F.20.D / 5
Index
FRAME POSITIONING - F
84516378 05/07/2011
F.20.D / 6
84516378 05/07/2011
F.20.D / 7
CNH - Main 700 State Street Racine, Wisconsin United States 53404
PRINTED IN U.S.A.
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
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
TOOL POSITIONING - G
LIFTING - 10.A
580N
580SN WT
580SN
590SN
84516378 05/07/2011
G.10.A / 1
Contents
TOOL POSITIONING - G
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
RCPH11TLB158AAM 1
RCPH11TLB159AAM 2
RCPH11TLB160AAM 3
84516378 05/07/2011
G.10.A / 3
TOOL POSITIONING - LIFTING
RCPH11TLB161AAM 4
RCPH11TLB162AAM 5
RCPH11TLB163AAM 6
RCPH11TLB164AAM 7
84516378 05/07/2011
G.10.A / 4
TOOL POSITIONING - LIFTING
8. Remove pin.
RCPH11TLB165AAM 8
RCPH11TLB166AAM 9
10. Carefully lift and remove the cylinder from the ma-
chine.
RCPH11TLB164AAM 10
84516378 05/07/2011
G.10.A / 5
TOOL POSITIONING - LIFTING
RCPH11TLB164AAM 1
RCPH11TLB163AAM 2
RCPH11TLB165AAM 3
84516378 05/07/2011
G.10.A / 6
TOOL POSITIONING - LIFTING
RCPH11TLB163AAM 4
RCPH11TLB162AAM 5
RCPH11TLB161AAM 6
RCPH11TLB160AAM 7
84516378 05/07/2011
G.10.A / 7
TOOL POSITIONING - LIFTING
RCPH11TLB159AAM 8
RCPH11TLB158AAM 9
84516378 05/07/2011
G.10.A / 8
TOOL POSITIONING - LIFTING
RCPH11TLB167AAM 1
RCPH11TLB168AAM 2 RCPH11TLB169AAM 3
3. Remove pin.
RCPH11TLB170AAM 4
84516378 05/07/2011
G.10.A / 9
TOOL POSITIONING - LIFTING
4. Remove link.
RCPH11TLB171AAM 5
RCPH11TLB172AAM 6
RCPH11TLB173AAM 7
7. Support cylinder.
RCPH11TLB174AAM 8
84516378 05/07/2011
G.10.A / 10
TOOL POSITIONING - LIFTING
RCPH11TLB175AAM 9
RCPH11TLB176AAM 10
RCPH11TLB177AAM 11
RCPH11TLB163AAM 12
84516378 05/07/2011
G.10.A / 11
TOOL POSITIONING - LIFTING
RCPH11TLB178AAM 13
RCPH11TLB179AAM 14
84516378 05/07/2011
G.10.A / 12
TOOL POSITIONING - LIFTING
RCPH11TLB179AAM 1
RCPH11TLB178AAM 2
RCPH11TLB163AAM 3
RCPH11TLB177AAM 4
84516378 05/07/2011
G.10.A / 13
TOOL POSITIONING - LIFTING
RCPH11TLB176AAM 5
RCPH11TLB175AAM 6
RCPH11TLB173AAM 7
RCPH11TLB172AAM 8
84516378 05/07/2011
G.10.A / 14
TOOL POSITIONING - LIFTING
RCPH11TLB171AAM 9
RCPH11TLB170AAM 10
RCPH11TLB168AAM 11 RCPH11TLB169AAM 12
RCPH11TLB167AAM 13
84516378 05/07/2011
G.10.A / 15
Index
TOOL POSITIONING - G
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
CNH - Main 700 State Street Racine, Wisconsin United States 53404
PRINTED IN U.S.A.
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
HITCH AND WORKING TOOL
580N
580SN WT
580SN
590SN
84516378 05/07/2011
H
Contents
84516378 05/07/2011
H
HITCH AND WORKING TOOL - H
580N
580SN WT
580SN
590SN
84516378 05/07/2011
H.20.B / 1
Contents
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
84516378 05/07/2011
H.20.B / 2
HITCH AND WORKING TOOL - BOOM Lift
590SN
Cylinder piston bolt 2830 - 3210 N·m (2087 - 2368 lb ft)
Cylinder gland 135 - 542 N·m (100 - 400 lb ft)
Cylinder lock screw 2.3 N·m (20 lb in)
84516378 05/07/2011
H.20.B / 3
HITCH AND WORKING TOOL - BOOM Lift
84516378 05/07/2011
H.20.B / 4
HITCH AND WORKING TOOL - BOOM Lift
RCPH11TLB019HAN 1
84516378 05/07/2011
H.20.B / 5
HITCH AND WORKING TOOL - BOOM Lift
84516378 05/07/2011
H.20.B / 6
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB006HAD 1
84516378 05/07/2011
H.20.B / 7
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB057GAL 1
84516378 05/07/2011
H.20.B / 8
HITCH AND WORKING TOOL - BOOM Lift
84516378 05/07/2011
H.20.B / 9
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB779AAD 1
RCPH10TLB586AAD 2
RCPH10TLB585AAD 3
RCPH10TLB588AAD 4
84516378 05/07/2011
H.20.B / 10
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB584AAD 5
RCPH10TLB589AAD 6
RCPH10TLB778AAD 7
Next operation:
Cylinder - Disassemble - Boom cylinder (H.20.B)
84516378 05/07/2011
H.20.B / 11
HITCH AND WORKING TOOL - BOOM Lift
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)
84516378 05/07/2011
H.20.B / 12
HITCH AND WORKING TOOL - BOOM Lift
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)
84516378 05/07/2011
H.20.B / 13
HITCH AND WORKING TOOL - BOOM Lift
Prior operation:
Cylinder - Assemble - Boom cylinder (H.20.B)
84516378 05/07/2011
H.20.B / 14
HITCH AND WORKING TOOL - BOOM Lift
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
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB778AAD 1
RCPH10TLB779AAD 2
RCPH10TLB589AAD 3
RCPH10TLB584AAD 4
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H.20.B / 16
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB588AAD 5
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H.20.B / 17
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB777AAD 1
RCPH10TLB129AAD 2
RCPH10TLB586AAD 3
RCPH10TLB018AAD 4
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H.20.B / 18
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB584AAD 5
RCPH10TLB101AAD 6
RCPH10TLB777AAD 7
RCPH10TLB100AAD 8
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HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB098AAD 9
Next operation:
Arm - Install - Boom (H.20.B)
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H.20.B / 20
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB777AAD 1
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
HITCH AND WORKING TOOL - BOOM Lift
RCPH10TLB018AAD 4
RCPH10TLB129AAD 5
Next operation:
Arm - Install Backhoe Boom (H.25.B) or DIPPER Extension - Install (H.25.F)
84516378 05/07/2011
H.20.B / 22
Index
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H.20.B / 23
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H.20.B / 24
HITCH AND WORKING TOOL - H
580N
580SN WT
580SN
590SN
84516378 05/07/2011
H.20.D / 1
Contents
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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H.20.D / 2
HITCH AND WORKING TOOL - BOOM Swing
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H.20.D / 3
HITCH AND WORKING TOOL - BOOM Swing
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H.20.D / 4
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB003HAD 1
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H.20.D / 5
HITCH AND WORKING TOOL - BOOM Swing
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H.20.D / 6
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB143GAL 1
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H.20.D / 7
HITCH AND WORKING TOOL - BOOM Swing
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H.20.D / 8
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB002HAD 1
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H.20.D / 9
HITCH AND WORKING TOOL - BOOM Swing
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H.20.D / 10
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB006HAD 1
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H.20.D / 11
HITCH AND WORKING TOOL - BOOM Swing
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H.20.D / 12
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB097GAL 1
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H.20.D / 13
HITCH AND WORKING TOOL - BOOM Swing
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H.20.D / 14
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB103GAL 1
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H.20.D / 15
HITCH AND WORKING TOOL - BOOM Swing
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H.20.D / 16
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB008GAD 1
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H.20.D / 17
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB057GAL 1
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H.20.D / 18
HITCH AND WORKING TOOL - BOOM Swing
84516378 05/07/2011
H.20.D / 19
HITCH AND WORKING TOOL - BOOM Swing
When disconnecting hydraulic components be prepared to cap and plug hoses and ports. Direct the flow of oil into a
suitable container.
RCPH10TLB061AAD 1
RCPH10TLB069AAD 2
RCPH10TLB055AAD 3
84516378 05/07/2011
H.20.D / 20
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB059AAD 4
RCPH10TLB063AAD 5
RCPH10TLB057AAD 6
RCPH10TLB094AAD 7
84516378 05/07/2011
H.20.D / 21
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB054AAD 8
RCPH10TLB051AAD 9
Next operation:
Cylinder - Disassemble - Swing cylinders (all models) (H.20.D)
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HITCH AND WORKING TOOL - BOOM Swing
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-
ment. Be careful to prevent damage to the tube (23).
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
HITCH AND WORKING TOOL - BOOM Swing
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
HITCH AND WORKING TOOL - BOOM Swing
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
HITCH AND WORKING TOOL - BOOM Swing
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-
ment. Be careful to prevent damage to the tube (23).
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
torque value of 2.3 N·m (20 lb in).
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
torque of 2.3 N·m (20 lb in).
Next operation:
Cylinder - Install - Swing cylinders (all models) (H.20.D)
84516378 05/07/2011
H.20.D / 26
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB051AAD 1
RCPH10TLB054AAD 2
RCPH10TLB090AAD 3
RCPH10TLB057AAD 4
84516378 05/07/2011
H.20.D / 27
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB063AAD 5
RCPH10TLB059AAD 6
RCPH10TLB055AAD 7
RCPH10TLB069AAD 8
84516378 05/07/2011
H.20.D / 28
HITCH AND WORKING TOOL - BOOM Swing
Prior operation:
Arm - Remove - Boom (H.20.B)
RCPH10TLB094AAD 1
RCPH11TLB036AAL 2
RCPH10TLB088AAD 3
84516378 05/07/2011
H.20.D / 29
HITCH AND WORKING TOOL - BOOM Swing
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
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
84516378 05/07/2011
H.20.D / 30
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB783AAD 8
RCPH10TLB079AAD 9
RCPH10TLB086AAD 10
RCPH10TLB073AAD 11
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.
84516378 05/07/2011
H.20.D / 31
HITCH AND WORKING TOOL - BOOM Swing
11. Remove the shims and washers from the lower pin
locations on the swing tower.
RCPH10TLB072AAD 12
RCPH10TLB071AAD 13
RCPH10TLB070AAD 14
Next operation:
Swing tower - Install (H.20.D)
84516378 05/07/2011
H.20.D / 32
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB081AAD 1
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.
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
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
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB017AAD 4
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
84516378 05/07/2011
H.20.D / 34
HITCH AND WORKING TOOL - BOOM Swing
RCPH10TLB054AAD 8
RCPH10TLB776AAD 9
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
84516378 05/07/2011
H.20.D / 36
HITCH AND WORKING TOOL - H
580N
580SN WT
580SN
590SN
84516378 05/07/2011
H.25.B / 1
Contents
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
590SN
Cylinder piston bolt 2830 - 3210 N·m (2087 - 2368 lb ft)
Cylinder gland 135 - 542 N·m (100 - 400 lb ft)
Cylinder lock screw 2.3 N·m (20 lb in)
84516378 05/07/2011
H.25.B / 3
HITCH AND WORKING TOOL - DIPPER Lift
84516378 05/07/2011
H.25.B / 4
HITCH AND WORKING TOOL - DIPPER Lift
RCPH11TLB018HAN 1
84516378 05/07/2011
H.25.B / 5
HITCH AND WORKING TOOL - DIPPER Lift
RCPH10TLB057GAL 1
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H.25.B / 6
HITCH AND WORKING TOOL - DIPPER Lift
84516378 05/07/2011
H.25.B / 7
HITCH AND WORKING TOOL - DIPPER Lift
Prior operation:
Cylinder - Remove - Boom cylinder (H.20.B)
RCPH10TLB576AAD 1
RCPH10TLB577AAD 2
RCPH10TLB579AAD 3
84516378 05/07/2011
H.25.B / 8
HITCH AND WORKING TOOL - DIPPER Lift
RCPH10TLB572AAD 4
RCPH10TLB571AAD 5
RCPH10TLB581AAD 6
RCPH10TLB580AAD 7
84516378 05/07/2011
H.25.B / 9
HITCH AND WORKING TOOL - DIPPER Lift
RCPH10TLB569AAD 8
Next operation:
Cylinder - Disassemble - Dipper cylinder (H.25.B)
84516378 05/07/2011
H.25.B / 10
HITCH AND WORKING TOOL - DIPPER Lift
Next operation:
Cylinder - Overhaul - Dipper cylinder (H.25.B)
84516378 05/07/2011
H.25.B / 11
HITCH AND WORKING TOOL - DIPPER Lift
Next operation:
Cylinder - Assemble - Dipper cylinder (H.25.B)
84516378 05/07/2011
H.25.B / 12
HITCH AND WORKING TOOL - DIPPER Lift
84516378 05/07/2011
H.25.B / 13
HITCH AND WORKING TOOL - DIPPER Lift
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
torque value of 2.3 N·m (20 lb in).
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
torque of 2.3 N·m (20 lb in).
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)
84516378 05/07/2011
H.25.B / 14
HITCH AND WORKING TOOL - DIPPER Lift
Prior operation:
Cylinder - Assemble - Dipper cylinder (H.25.B)
RCPH10TLB569AAD 1
RCPH10TLB580AAD 2
RCPH10TLB581AAD 3
84516378 05/07/2011
H.25.B / 15
HITCH AND WORKING TOOL - DIPPER Lift
RCPH10TLB577AAD 4
RCPH10TLB579AAD 5
RCPH10TLB576AAD 6
RCPH10TLB572AAD 7
Next operation:
Cylinder - Install - Boom cylinder (H.20.B)
84516378 05/07/2011
H.25.B / 16
HITCH AND WORKING TOOL - DIPPER Lift
Prior operation:
DIPPER Extension - Remove Dipper Arm (H.25.F)
RCPH11TLB050AAL 1
RCPH11TLB051AAL 2
RCPH11TLB052AAL 3
84516378 05/07/2011
H.25.B / 17
HITCH AND WORKING TOOL - DIPPER Lift
5. Remove pin.
RCPH11TLB053AAL 4
RCPH11TLB054AAL 5
RCPH11TLB056AAL 6
RCPH11TLB050AAL 7
84516378 05/07/2011
H.25.B / 18
HITCH AND WORKING TOOL - DIPPER Lift
RCPH11TLB055AAL 8
RCPH11TLB057AAL 9
RCPH11TLB058AAL 10
84516378 05/07/2011
H.25.B / 19
HITCH AND WORKING TOOL - DIPPER Lift
RCPH11TLB058AAL 1
RCPH11TLB058AAL 2
RCPH11TLB057AAL 3
RCPH11TLB055AAL 4
84516378 05/07/2011
H.25.B / 20
HITCH AND WORKING TOOL - DIPPER Lift
RCPH11TLB050AAL 5
RCPH11TLB056AAL 6
RCPH11TLB053AAL 7
RCPH11TLB052AAL 8
84516378 05/07/2011
H.25.B / 21
HITCH AND WORKING TOOL - DIPPER Lift
RCPH10TLB784AAD 9
84516378 05/07/2011
H.25.B / 22
Index
84516378 05/07/2011
H.25.B / 23
84516378 05/07/2011
H.25.B / 24
HITCH AND WORKING TOOL - H
580N
580SN WT
580SN
590SN
84516378 05/07/2011
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
84516378 05/07/2011
H.25.F / 2
HITCH AND WORKING TOOL - DIPPER Extension
84516378 05/07/2011
H.25.F / 3
HITCH AND WORKING TOOL - DIPPER Extension
RCPH10TLB126GAL 1
84516378 05/07/2011
H.25.F / 4
HITCH AND WORKING TOOL - DIPPER Extension
RCPH10TLB127GAL 1
84516378 05/07/2011
H.25.F / 5
HITCH AND WORKING TOOL - DIPPER Extension
RCPH10TLB119GAL 1
84516378 05/07/2011
H.25.F / 6
HITCH AND WORKING TOOL - DIPPER Extension
84516378 05/07/2011
H.25.F / 7
HITCH AND WORKING TOOL - DIPPER Extension
84516378 05/07/2011
H.25.F / 8
HITCH AND WORKING TOOL - DIPPER Extension
RCPH11TLB020HAN 1
84516378 05/07/2011
H.25.F / 9
HITCH AND WORKING TOOL - DIPPER Extension
RCPH11TLB074AAL 1
RCPH11TLB077AAL 2
RCPH11TLB078AAL 3
84516378 05/07/2011
H.25.F / 10
HITCH AND WORKING TOOL - DIPPER Extension
RCPH11TLB079AAL 4
RCPH11TLB059AAL 5
RCPH11TLB060AAL 6
RCPH11TLB061AAL 7
84516378 05/07/2011
H.25.F / 11
HITCH AND WORKING TOOL - DIPPER Extension
RCPH11TLB062AAL 8
RCPH11TLB063AAL 9
RCPH11TLB064AAL 10
RCPH11TLB065AAL 11
84516378 05/07/2011
H.25.F / 12
HITCH AND WORKING TOOL - DIPPER Extension
RCPH11TLB066AAL 12
RCPH11TLB067AAL 13
Next operation:
DIPPER Extension - Install (H.25.F)
84516378 05/07/2011
H.25.F / 13
HITCH AND WORKING TOOL - DIPPER Extension
RCPH11TLB066AAL 1
RCPH11TLB065AAL 2
RCPH11TLB064AAL 3
84516378 05/07/2011
H.25.F / 14
HITCH AND WORKING TOOL - DIPPER Extension
RCPH11TLB063AAL 4
RCPH11TLB062AAL 5
RCPH11TLB061AAL 6
RCPH11TLB060AAL 7
84516378 05/07/2011
H.25.F / 15
HITCH AND WORKING TOOL - DIPPER Extension
RCPH11TLB059AAL 8
RCPH11TLB078AAL 9
84516378 05/07/2011
H.25.F / 16
HITCH AND WORKING TOOL - DIPPER Extension
84516378 05/07/2011
H.25.F / 17
HITCH AND WORKING TOOL - DIPPER Extension
84516378 05/07/2011
H.25.F / 18
Index
84516378 05/07/2011
H.25.F / 19
84516378 05/07/2011
H.25.F / 20
HITCH AND WORKING TOOL - H
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
84516378 05/07/2011
H.30.C / 3
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
84516378 05/07/2011
H.30.C / 4
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
RCPH11TLB017HAN 1
84516378 05/07/2011
H.30.C / 5
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
RCPH10TLB057GAL 1
84516378 05/07/2011
H.30.C / 6
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
84516378 05/07/2011
H.30.C / 7
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
RCPH11TLB025AAL 1
RCPH11TLB026AAL 2
RCPH11TLB027AAL 3
RCPH11TLB028AAL 4
84516378 05/07/2011
H.30.C / 8
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
RCPH11TLB029AAL 5
RCPH11TLB030AAL 6
RCPH11TLB031AAL 7
RCPH11TLB032AAL 8
84516378 05/07/2011
H.30.C / 9
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
RCPH11TLB033AAL 9
RCPH11TLB032AAL 10
RCPH11TLB034AAL 11
Next operation:
Cylinder - Install Backhoe Dipper Cylinder (H.30.C)
84516378 05/07/2011
H.30.C / 10
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
RCPH10TLB608AAD 1
RCPH10TLB610AAD 2
RCPH11TLB033AAL 3
RCPH11TLB032AAL 4
84516378 05/07/2011
H.30.C / 11
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
RCPH10TLB611AAD 5
RCPH11TLB030AAL 6
RCPH11TLB028AAL 7
RCPH11TLB027AAL 8
84516378 05/07/2011
H.30.C / 12
HITCH AND WORKING TOOL - ARM TOOL ATTACHMENT Tilt
10. Remove the supports from the boom and dipper arm.
RCPH11TLB025AAL 9
84516378 05/07/2011
H.30.C / 13
Index
84516378 05/07/2011
H.30.C / 14
84516378 05/07/2011
H.30.C / 15
CNH - Main 700 State Street Racine, Wisconsin United States 53404
PRINTED IN U.S.A.
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
EXCAVATING AND LANDSCAPING
580N
580SN WT
580SN
590SN
84516378 05/07/2011
J
Contents
84516378 05/07/2011
J
EXCAVATING AND LANDSCAPING - J
580N
580SN WT
580SN
590SN
84516378 05/07/2011
J.20.B / 1
Contents
TECHNICAL DATA
Bucket
General specification - Weld specifications for standard bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
SERVICE
84516378 05/07/2011
J.20.B / 2
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
84516378 05/07/2011
J.20.B / 3
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB681AAL 1
RCPH10TLB682AAL 2
RCPH10TLB683AAL 3
84516378 05/07/2011
J.20.B / 4
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB038GAL 1
84516378 05/07/2011
J.20.B / 5
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB053GAL 1
84516378 05/07/2011
J.20.B / 6
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB039GAL 1
NOTE: Adjust length and offset of bucket control rod (20) and lift control rod (30) using clevis (27).
84516378 05/07/2011
J.20.B / 7
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB040GAL 1
84516378 05/07/2011
J.20.B / 8
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB043GAL 1
Loader frame
84516378 05/07/2011
J.20.B / 9
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB041GAL 1
Bucket frame
84516378 05/07/2011
J.20.B / 10
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB004HAL 1
Lift cylinder hydraulic installation
84516378 05/07/2011
J.20.B / 11
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB003HAL 1
Bucket cylinder hydraulic installation
84516378 05/07/2011
J.20.B / 12
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB042GAL 1
Clam cylinder circuit
84516378 05/07/2011
J.20.B / 13
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB047GAL 1
Clam cylinder hydraulic installation
84516378 05/07/2011
J.20.B / 14
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB936ABL 1
Antirollback linkage
84516378 05/07/2011
J.20.B / 15
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB084GAL 1
84516378 05/07/2011
J.20.B / 16
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB045GAL 1
84516378 05/07/2011
J.20.B / 17
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB046GAL 1
1. Control lever
84516378 05/07/2011
J.20.B / 18
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB144GAL 1
84516378 05/07/2011
J.20.B / 19
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
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.
84516378 05/07/2011
J.20.B / 20
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB005CAM 1
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.
84516378 05/07/2011
J.20.B / 21
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
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.
84516378 05/07/2011
J.20.B / 22
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
84516378 05/07/2011
J.20.B / 23
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB681AAL 1
RCPH10TLB935ABL 2
84516378 05/07/2011
J.20.B / 24
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
84516378 05/07/2011
J.20.B / 25
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB003GAN 1
84516378 05/07/2011
J.20.B / 26
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH10TLB011BAL 1
84516378 05/07/2011
J.20.B / 27
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
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.
84516378 05/07/2011
J.20.B / 28
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
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.
84516378 05/07/2011
J.20.B / 29
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
84516378 05/07/2011
J.20.B / 30
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
Next operation:
Bucket - Install (J.20.B)
84516378 05/07/2011
J.20.B / 31
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
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.
14. Install the snap ring.
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
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
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
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH11TLB151AAM 1
RCPH11TLB152AAM 2
RCPH11TLB153AAM 3 RCPH11TLB154AAM 4
84516378 05/07/2011
J.20.B / 34
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH11TLB155AAM 5 RCPH11TLB156AAM 6
5. Remove bucket.
RCPH11TLB157AAM 7
84516378 05/07/2011
J.20.B / 35
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH11TLB157AAM 1
RCPH11TLB155AAM 2 RCPH11TLB156AAM 3
RCPH11TLB153AAM 4 RCPH11TLB154AAM 5
84516378 05/07/2011
J.20.B / 36
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH11TLB151AAM 6
84516378 05/07/2011
J.20.B / 37
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH11TLB131AAM 1
RCPH11TLB132AAM 2
RCPH11TLB133AAM 3
RCPH11TLB134AAM 4
84516378 05/07/2011
J.20.B / 38
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
RCPH11TLB132AAM 1
RCPH11TLB133AAM 2
RCPH11TLB132AAM 3
84516378 05/07/2011
J.20.B / 39
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
NOTICE: When you remove the bottom weld at the rear of the bottom cutting edge, do not cut through the bottom of
the bucket.
2. Use carbon arc rod or an acetylene cutting torch to
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
84516378 05/07/2011
J.20.B / 40
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
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.
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J.20.B / 41
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
84516378 05/07/2011
J.20.B / 42
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
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
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
84516378 05/07/2011
J.20.B / 44
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
84516378 05/07/2011
J.20.B / 45
EXCAVATING AND LANDSCAPING - DIGGING Non-articulated digging tools
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.
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
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
EXCAVATING AND LANDSCAPING - J
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
Exploded view - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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
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EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
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
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EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
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
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EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
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
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EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB059GAL 1
Valve cut away view
RCPH10TLB007FAL 2
Valve schematic
84516378 05/07/2011
J.50.C / 6
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB009FAL 1
Circuit relief valve
84516378 05/07/2011
J.50.C / 7
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB060GAL 1
84516378 05/07/2011
J.50.C / 8
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB162ABL 1
RCPH10TLB161ABL 2
84516378 05/07/2011
J.50.C / 9
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB010FAL 1
RCPH10TLB003FAL 2
84516378 05/07/2011
J.50.C / 10
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB020AAL 3
84516378 05/07/2011
J.50.C / 11
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
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)
84516378 05/07/2011
J.50.C / 12
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
84516378 05/07/2011
J.50.C / 13
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB102ABL 1
RCPH10TLB103ABL 2
RCPH10TLB105ABL 3
84516378 05/07/2011
J.50.C / 14
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB107ABL 4
RCPH10TLB108ABL 5
RCPH10TLB110ABL 6
RCPH10TLB111ABL 7
84516378 05/07/2011
J.50.C / 15
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB112ABL 8
RCPH10TLB113ABL 9
RCPH10TLB114ABL 10
RCPH10TLB115ABL 11
84516378 05/07/2011
J.50.C / 16
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB117ABL 12
RCPH10TLB121ABL 13
RCPH10TLB123ABL 14
RCPH10TLB124ABL 15
84516378 05/07/2011
J.50.C / 17
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB126ABL 16
RCPH10TLB127ABL 17
RCPH10TLB128ABL 18
22. Loosen the cap screws for the centering spring cover.
RCPH10TLB130ABL 19
84516378 05/07/2011
J.50.C / 18
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB131ABL 20
RCPH10TLB132ABL 21
RCPH10TLB133ABL 22
RCPH10TLB134ABL 23
84516378 05/07/2011
J.50.C / 19
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB138ABL 24
RCPH10TLB137ABL 25
RCPH10TLB136ABL 26
RCPH10TLB141ABL 27
84516378 05/07/2011
J.50.C / 20
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
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
RCPH10TLB140ABL 30
RCPH10TLB139ABL 31
84516378 05/07/2011
J.50.C / 21
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB138ABL 32
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
84516378 05/07/2011
J.50.C / 22
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
41. Remove the cap screws for the seal retaining plate.
RCPH10TLB143ABL 36
RCPH10TLB144ABL 37
RCPH10TLB145ABL 38
RCPH10TLB146ABL 39
84516378 05/07/2011
J.50.C / 23
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB147ABL 1
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
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB074ABL 4
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
RCPH10TLB149ABL 7
84516378 05/07/2011
J.50.C / 25
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
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
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB150ABL 12
14. Remove the plug, spacer, spring, and valve from the
valve body.
RCPH10TLB152ABL 13
RCPH10TLB153ABL 14
RCPH10TLB154ABL 15
84516378 05/07/2011
J.50.C / 27
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB155ABL 16
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
RCPH10TLB130ABL 19
84516378 05/07/2011
J.50.C / 28
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB126ABL 20
RCPH10TLB123ABL 21
RCPH10TLB120ABL 22
RCPH10TLB119ABL 23
84516378 05/07/2011
J.50.C / 29
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
RCPH10TLB117ABL 24
RCPH10TLB116ABL 25
RCPH10TLB115ABL 26
RCPH10TLB114ABL 27
84516378 05/07/2011
J.50.C / 30
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
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
RCPH10TLB110ABL 30
RCPH10TLB108ABL 31
84516378 05/07/2011
J.50.C / 31
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
33. Install and torque the plug to 65 N·m +/- 6.7 (48 lb ft
+/- 5).
RCPH10TLB107ABL 32
RCPH10TLB105ABL 33
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
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
Next operation:
Cylinder - Inspect (J.50.C)
84516378 05/07/2011
J.50.C / 33
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
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 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
EXCAVATING AND LANDSCAPING - CARRYING Articulated tools
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
84516378 05/07/2011
J.50.C / 36
84516378 05/07/2011
J.50.C / 37
CNH - Main 700 State Street Racine, Wisconsin United States 53404
PRINTED IN U.S.A.
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
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 3006-Coolant Temperature Sensor - Signal Not Plausible A.50.A / 143
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3006-Coolant Temperature Sensor - Signal Not Plausible A.50.A / 144
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3006-Coolant Temperature Sensor - Signal Not Plausible A.50.A / 144
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3007-Coolant temperature signal - signal above range A.50.A / 145
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3007-Coolant temperature signal - signal above range A.50.A / 145
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3007-Coolant temperature signal - signal above range A.50.A / 146
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3007-Coolant temperature signal - signal above range A.50.A / 146
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3008-Coolant Temperature Signal - Signal Below Range Minimum A.50.A / 147
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3008-Coolant Temperature Signal - Signal Below Range Minimum A.50.A / 147
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3008-Coolant Temperature Signal - Signal Below Range Minimum A.50.A / 147
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3008-Coolant Temperature Signal - Signal Below Range Minimum A.50.A / 148
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3010-Air intake temperature sensor signal above maximum range A.50.A / 149
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3010-Air intake temperature sensor signal above maximum range A.50.A / 149
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3010-Air intake temperature sensor signal above maximum range A.50.A / 150
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3010-Air intake temperature sensor signal above maximum range A.50.A / 151
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3011-Air intake temperature sensor signal below minimum range A.50.A / 152
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3011-Air intake temperature sensor signal below minimum range A.50.A / 152
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3011-Air intake temperature sensor signal below minimum range A.50.A / 153
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3011-Air intake temperature sensor signal below minimum range A.50.A / 154
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3016-Fuel Temperature Sensor - Signal Below Range Minimum A.50.A / 157
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3016-Fuel Temperature Sensor - Signal Below Range Minimum A.50.A / 157
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3016-Fuel Temperature Sensor - Signal Below Range Minimum A.50.A / 158
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3016-Fuel Temperature Sensor - Signal Below Range Minimum A.50.A / 158
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3019-Boost Pressure Sensor - Signal Above Range Maximum A.50.A / 160
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3019-Boost Pressure Sensor - Signal Above Range Maximum A.50.A / 160
Diagnostic /Repair Kit (NEF)]
05/07/2011
39
Genuine IU PAGE
380040185 [Harness 3019-Boost Pressure Sensor - Signal Above Range Maximum A.50.A / 161
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3022-Boost Pressure Sensor - Signal Not Plausible A.50.A / 162
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3022-Boost Pressure Sensor - Signal Not Plausible A.50.A / 162
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3022-Boost Pressure Sensor - Signal Not Plausible A.50.A / 163
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3028-Oil pressure too low A.50.A / 167
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3028-Oil pressure too low A.50.A / 168
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3028-Oil pressure too low A.50.A / 168
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3029-Oil Pressure Sensor - Short Circuit To Battery A.50.A / 170
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3029-Oil Pressure Sensor - Short Circuit To Battery A.50.A / 170
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3029-Oil Pressure Sensor - Short Circuit To Battery A.50.A / 171
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3030-Oil Pressure Sensor - Short Circuit To Ground A.50.A / 172
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3030-Oil Pressure Sensor - Short Circuit To Ground A.50.A / 172
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3030-Oil Pressure Sensor - Short Circuit To Ground A.50.A / 173
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3031-Oil pressure sensor - hardware error A.50.A / 174
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3031-Oil pressure sensor - hardware error A.50.A / 174
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3031-Oil pressure sensor - hardware error A.50.A / 175
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3032-Oil Pressure Sensor - Value Too High A.50.A / 176
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3032-Oil Pressure Sensor - Value Too High A.50.A / 177
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3032-Oil Pressure Sensor - Value Too High A.50.A / 177
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3033-Oil Temperature Sensor - Signal Not Plausible A.50.A / 179
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3033-Oil Temperature Sensor - Signal Not Plausible A.50.A / 180
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3033-Oil Temperature Sensor - Signal Not Plausible A.50.A / 180
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3033-Oil Temperature Sensor - Signal Not Plausible A.50.A / 180
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3034-Oil Temperature Sensor - Signal Above Range Maximum A.50.A / 182
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3034-Oil Temperature Sensor - Signal Above Range Maximum A.50.A / 182
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3034-Oil Temperature Sensor - Signal Above Range Maximum A.50.A / 183
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3035-Oil Temperature Sensor - Signal Below Range Minimum A.50.A / 184
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3035-Oil Temperature Sensor - Signal Below Range Minimum A.50.A / 184
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3035-Oil Temperature Sensor - Signal Below Range Minimum A.50.A / 185
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3037-Boost Pressure Sensor - Signal Low A.50.A / 186
Diagnostic /Repair Kit (NEF)]
05/07/2011
40
Genuine IU PAGE
380040185 [Harness 3037-Boost Pressure Sensor - Signal Low A.50.A / 186
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3037-Boost Pressure Sensor - Signal Low A.50.A / 187
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3061-Cylinder 1 - Injector Cable Short Circuit A.50.A / 201
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3061-Cylinder 1 - Injector Cable Short Circuit A.50.A / 201
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3069-Cylinder 3 - Injector Cable Short Circuit A.50.A / 210
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3069-Cylinder 3 - Injector Cable Short Circuit A.50.A / 210
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3077-Cylinder 2 - Injector Cable Short Circuit A.50.A / 219
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3077-Cylinder 2 - Injector Cable Short Circuit A.50.A / 219
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3081-Cylinder 4 - Injector Cable Short Circuit A.50.A / 228
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3081-Cylinder 4 - Injector Cable Short Circuit A.50.A / 228
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3088-Crankshaft sensor lost synchronization A.50.A / 235
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3088-Crankshaft sensor lost synchronization A.50.A / 235
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3088-Crankshaft sensor lost synchronization A.50.A / 236
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3088-Crankshaft sensor lost synchronization A.50.A / 237
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3089-Crankshaft Sensor - Invalid Signal A.50.A / 238
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3089-Crankshaft Sensor - Invalid Signal A.50.A / 238
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3090-Phase defect of camshaft speed sensor signal detected A.50.A / 240
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3090-Phase defect of camshaft speed sensor signal detected A.50.A / 240
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3090-Phase defect of camshaft speed sensor signal detected A.50.A / 241
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3090-Phase defect of camshaft speed sensor signal detected A.50.A / 242
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3091-Camshaft sensor phase synchronization failure A.50.A / 243
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3091-Camshaft sensor phase synchronization failure A.50.A / 243
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3091-Camshaft sensor phase synchronization failure A.50.A / 244
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3091-Camshaft sensor phase synchronization failure A.50.A / 245
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3093-Offset Between Camshaft And Crankshaft - Outside A.50.A / 246
Diagnostic /Repair Kit (NEF)] Boundaries
380040185 [Harness 3093-Offset Between Camshaft And Crankshaft - Outside A.50.A / 247
Diagnostic /Repair Kit (NEF)] Boundaries
380040185 [Harness 3093-Offset Between Camshaft And Crankshaft - Outside A.50.A / 247
Diagnostic /Repair Kit (NEF)] Boundaries
380040185 [Harness 3093-Offset Between Camshaft And Crankshaft - Outside A.50.A / 247
Diagnostic /Repair Kit (NEF)] Boundaries
380040185 [Harness 3093-Offset Between Camshaft And Crankshaft - Outside A.50.A / 248
Diagnostic /Repair Kit (NEF)] Boundaries
380040185 [Harness 3093-Offset Between Camshaft And Crankshaft - Outside A.50.A / 248
Diagnostic /Repair Kit (NEF)] Boundaries
05/07/2011
41
Genuine IU PAGE
380040185 [Harness 3093-Offset Between Camshaft And Crankshaft - Outside A.50.A / 250
Diagnostic /Repair Kit (NEF)] Boundaries
380040185 [Harness 3095-Operating With Camshaft Sensor Only - Backup Mode A.50.A / 251
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3095-Operating With Camshaft Sensor Only - Backup Mode A.50.A / 251
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3095-Operating With Camshaft Sensor Only - Backup Mode A.50.A / 252
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3095-Operating With Camshaft Sensor Only - Backup Mode A.50.A / 253
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3147-Oil Temperature Too High A.50.A / 280
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3147-Oil Temperature Too High A.50.A / 281
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3147-Oil Temperature Too High A.50.A / 281
Diagnostic /Repair Kit (NEF)]
380040185 [Harness 3147-Oil Temperature Too High A.50.A / 282
Diagnostic /Repair Kit (NEF)]
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
CNH - Main 700 State Street Racine, Wisconsin United States 53404
PRINTED IN U.S.A.
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
CRANK SIGNAL
ALTERNATOR
TO CLUSTER
INSTRUMENT CLUSTER
STARTER
KEY ON
FRONT WIPER
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
13 ACC TO GROUND
F&R
SAHR BRAKE
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
FRONT WASHER
PUMP GROUND
FRONT LIGHTS
SIGNAL LIGHTS CAB GROUND
KEY ON
DOME LIGHT B+
TURN SIGNAL
INDICATOR GROUND
HAZARD LIGHTS
SWITCH GROUND
REAR WIPER
MOTOR GROUND
INSTRUMENT CLUSTER B+
ELECTRICAL SCHEMATIC
POWER POINT B+ HPCR ENGINE
SPS/PS TRANSMISSION
GROUND
DECLUTCH TO TRAX
V P T
LEVER HAND FOOT TEMPERATURE
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
S.P.S.T. S.P.D.T. D.P.S.T. D.P.D.T.
MAINTAINED
MISCELLANEOUS SYMBOLS VARIABLE RESISTOR RESISTOR
HVAC BLOWER
KEY ON BLOWER MOTOR GROUND
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
ROTATING BEACON
KEY ON
ROTATING BEACON
SWITCH LAMP GROUND
RIDE CONTROL TANK
SOLENOID GROUND
HYDRAULIC POWER
LIFT SWITCH
POWER LIFT REQUEST
TO CLUSTER
POWER LIFT
RELAY
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
LEGEND
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
SIDE LIGHTS
INSTALLER TAP
WIRE BREAKOUT
ALT TACH TO TRAX
4WD/RC
DIFF LOCK, KD, DC, CO BUTTONS
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
FRONT LIGHTS
CAB GROUND
SIGNAL LIGHTS
KEY ON
DOME LIGHT B+
TAIL LIGHTS
SAHR BRAKE
SOLENOID GROUND
POWER POINT B+
LEGEND
REAR WORK LIGHTS BACKLIGHT
INSTRUMENT CLUSTER
KEY ON
SEAT POSITION
SWITCH GROUND
INDICATES CONSTANT POWER
POWER POINT 2 GROUND
DECLUTCH TO TRAX
INSTRUMENT CLUSTER GROUND
SAHR BRAKE RELAY GROUND
HOUSINGS ACTUATORS
ABBREVIATION-------COLOR ABBREVIATION------COLOR
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
CONTACTS
MOMENTARY
S.P.S.T. S.P.D.T. D.P.S.T. D.P.D.T.
MAINTAINED
MISCELLANEOUS SYMBOLS VARIABLE RESISTOR RESISTOR
CIRCUIT 1 CIRCUIT 1
CIRCUIT 2 WIRE BUNDLE CIRCUIT 2
CIRCUIT 3 CIRCUIT 3
CIRCUIT 4 CIRCUIT 4
WIRE BREAKOUT
COLOR
WIRE ID SPLICE
HVAC BLOWER
WIRE SIZE KEY ON
BLOWER MOTOR GROUND
WB - WIRE BREAKOUT
FB - FUSE BREAKOUT
GB - GROUND 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
CS POWER RELAY
KEY ON POWER COIL GROUND
CS SOLENOID
GROUND
RIDE CONTROL
ACCUMULATOR
SOLENOID GROUND
HORN GROUND
RIDE CONTROL
TANK SOLENOID
GROUND
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
C B
CANOPY EXTERIOR LIGHTS 20 MECH. ENGINE GRID HEATER 21 TRAX SPS CONTROLLER 22 PILOT CONTROLS INPUT 23
LEGEND
RAC84470422S1S2
COMBO HYDRAULICS 24 FUSE DIAGRAMS
ST FROM IGNITION SWITCH
INSTRUMENT CLUSTER
FRONT WIPER
FRONT WORK
LIGHT ALT/ECU
FLASHER
IGNITION SW B+
ABBREVIATION-------COLOR ABBREVIATION------COLOR
V P T R----------------------------RED OR-------------- ----------ORANGE INDICATES CIRCUIT CONNECTION
BRAKE LIGHTS
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/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
REAR LIGHTS
CAB B+ POWER
B+ FROM STARTER
SIDE LIGHTS
INSTALLER TAP
WIRE BREAKOUT 3 3
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+
RADIO KEY ON
EH CLAM GROUND
EHOE RETRACT
FRONT LIGHTS
RIGHT HAND STABILIZER PRESSURE SWITCH
CAB GROUND
SIGNAL LIGHTS
BI-DIR AUX FORWARD KEY ON
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
FRONT WIPER MOTOR GROUND
FRONT WORK LIGHT BACKLIGHT
TAIL LIGHTS
CLUSTER B+
POWERSHUTTLE TRANSMISSION
POWER POINT B+
RAC 84470423
DRIVING LIGHTS BACKLIGHT
POWER POINT 1 GROUND
FRONT WORK LIGHT BACKLIGHT
88-1 S-012
LEGEND
BRAKE LIGHTS TO CLUSTER
INSTRUMENT CLUSTER
KEY ON
SEAT POSITION
INDICATES CONSTANT POWER
SWITCH GROUND
RAC84470423S1S1
INSTRUMENT CLUSTER 11 POWER POINTS 12 SAHR PARK BRAKE 13
RADIO B+
HOUSINGS ACTUATORS
ABBREVIATION-------COLOR ABBREVIATION------COLOR
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
CONTACT CONFIGURATIONS BK -------------------------BLACK LU------------------------LIGHT BLUE
S ---------------------------GRAY DG------------------------DARK GREEN
RADIO GROUND
BK/W----------------------BLACK/WHITE LG------------------------LIGHT GREEN INDICATES INTERNALLY
LIQUID LEVER FLOAT PRESSURE COIL DIODE GROUNDED UNITS
CONTACTS
MOMENTARY
S.P.S.T. S.P.D.T. D.P.S.T. D.P.D.T.
MAINTAINED
MISCELLANEOUS SYMBOLS VARIABLE RESISTOR RESISTOR
CIRCUIT 1 CIRCUIT 1
CIRCUIT 2 WIRE BUNDLE CIRCUIT 2
CIRCUIT 3 CIRCUIT 3
CIRCUIT 4 CIRCUIT 4
WIRE BREAKOUT
COLOR
WIRE ID SPLICE HVAC BLOWER
WIRE SIZE KEY ON
BLOWER MOTOR GROUND
WB - WIRE BREAKOUT
FB - FUSE BREAKOUT
GB - GROUND BREAKOUT
HVAC 14 AUDIO 15
HORN B+
HORN GROUND
HYDRAULIC POWER
LIFT SWITCH S-012
HYDRAULIC OPTIONS 20 PILOT CONTROL INPUTS 21 COMBO / AUX / UNI HYDRAULICS 22 CANOPY EXTERIOR LIGHTS 23
LEGEND
RD - RED
FRONT WORK
LIGHTS
BATTERY SOCKET CONTACT
GRID HEATER
FLASHER
ACC. FROM IGNITION
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
DIRECTION OF 1 2
SOLENOID
TO NEUTRAL RELAY
ALT. SIGNAL TO
STARTER
STARTER INSTALLER
TAP
TN - TAN HVAC
BLOWER
STARTER RELAY COIL
COMFORT
STEER
PILOT LOADER CONTROL HARNESS
CONTROL
MOTOR
KEY ON
FNR KEY ON FROM
SPEAKER
CLUTCH RELAY
INSTALLER TAP
KEY ON
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
RIGHT-HAND STABILIZER
EHOE RETRACT
FROT WASHER
PUMP GROUND
EHOE EXTEND
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
TAIL LIGHTS
FRONT DRIVING
LIGHTS KEY ON
PILOT CONTROLS 7 FRONT EXTERIOR LIGHTS 8 INTERIOR LIGHTING 9 WIPERS AND WASHERS 10
AIR FILTER
ELECTRICAL SCHEMATIC
REAR WORK LIGHTS BACKLIGHT
ALT TACH
POWER POINT B+
SAHR BRAKE
RELAY GROUND
INSTRUMENT CLUSTER GROUND
RAC84470424S1S1
INSTRUMENT CLUSTER 11 POWER POINTS 12 SAHR PARK BRAKE 13
RADIO B+
RESISTOR
PIN CONTACT
RD - RED BATTERY SOCKET CONTACT
BK - BLACK DIODE
WIRE ID
YE - YELLOW WIRE COLOR CONNECTOR
RADIO KEY ON
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
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
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
GRID HEATER
ON INDICATOR
TO CLUSTER
EHOE EXTEND
EHOE RETRACT
RH STABILIZER
PILOT CONTROLS
MODULE GROUND
HORN B+
LH STABILIZER
HORN OUTPUT
PILOT CONTROL INPUTS 20 COMBO/ AUX/ UNI HYDRAULICS 21 CANOPY EXTERIOR LIGHTS 22 FUSE DIAGRAM 23
LEGEND
RAC
RAC
580N MECHANICAL
RAC 84390774
LEGEND
RAC 84390776S1S1
CONNECTIONS BETWEEN THE JOYSTICKS, BACKHOE VALVE AND MULTI-FUNCTION
PRERSSURE REDUCING VALVE ARE SHOWN ON SHEET 2.
580N
PILOT HYDRAULICS
RAC 84390777
RAC 84390777S1S2
580SN, 580SN-WT AND 590SN RAC 84390776
HYRDAULIC VVOC WITH BOOST (HEAVYLIFT)
VARIABLE PISTON PUMP SUPPLY STEERING PRIORITY
VARIABLE PISTON PUMP SUPPLY LOADER VALVE SUPPLY
VARIABLE PISTON SUPPLY BACKHOE VALVE SUPPLY
RETURN TO TANK/SUMP
RAC 84390776S1S2
NOTES ON PAGE 2.
580SN, 580SN-WT AND 590SN
HYDRAULIC VVCC RAC 84390778
GEAR PUMP SUPPLY STEERING UNIT
GEAR PUMP SUPPLY TO CONTROLS
RETURN TO TANK/SUMP
RAC 84390778S1S1
580SN, 580SN-WT AND 590SN
HYDRAULIC VVCC RAC 84390778
GEAR PUMP SUPPLY STEERING UNIT
GEAR PUMP SUPPLY TO CONTROLS
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