Professional Documents
Culture Documents
Training Manual
From Serial Number:-
595 SLE - 9001
595 LSP – 10001
Example : SMFE44TC5X9EM9674
Key Changes
Notes
Backhoe Loader Improvements
New Cab
· Improved all round visibility
· Increased interior space
· Lower internal noise level
· Increased heater output
· Air re-circulation
· New seat with lumbar support
Transmission
· Gear ratios altered to give identical forward and reverse travel speeds
Hydraulic System
· Hydraulic oil flow increased to 160 litres/min for faster cycle times.
· Previously the secondary pump (with the unloader valve) oil flow was routed directly into the
backhoe valve block. It now combines with the main pump to supply the loader valve first prior to
both pumps feeding the backhoe valve. This is to ensure an even temperature in the valve blocks
to prevent valve stiction.
· Compensated check valve enables 100 litres/min flow into the auxiliary circuit without any
interaction from other services.
· The rockbreaker pressure and return line steel tubes are now rigidly located on the outside of the
boom structure.
Improved Hose Routing
· Hoses passing through and over castings are now constructed with a hardwearing polyethylene
outer cover, integral with the hose (known as armadillo).
· Swing casting incorporates a polypropylene wear strip.
Loader Changes
Loader beam pivot raised to increase arm breakout force along with other changes as follows:
· Lift capacity increased by 18% (std) 20% (7 in 1).
· Because the loader arm has been raised, the standard and 7 in 1 bucket dump stops have been
altered to achieve similar rotation angles as the previous loader. Although the previous buckets
will fit the new loader the bucket dump stops will need to be modified to prevent a foul condition.
Backhoe changes
4.5/4.9 Booms
All Models
· Larger valves
General Description
1004 40T (Engine Prefix AQ)
Fitted to 595 SLE / LSP
Number of Cylinders 4
Induction System Turbo Charged with Wastegate
Injection Fastram Direct
Bore 100mm (3.937in)
Stroke 127mm (5.00in)
Capacity 4 litres (243 ins )
³
Valve Guides
Fitted to both inlet and exhaust valves.
NOTE The guide for the exhaust valve is 1mm larger on the outer diameter than the guide for the
inlet valve, it is therefore important that the larger stem seal (coloured brown) is fitted to the
exhaust valve guide and the smaller stem seal (coloured green) is fitted to the inlet guide.
If any valve guides are replaced in service, the new guide must be reamed after fitting the
new special tool (27610030), which will also cut the valve seat at the same time ensuring
concentricity.
Valves
The inlet valve is larger than the exhaust. The angle of both inlet and exhaust valve faces is 45° or
30°. The angle of the valve seat is 46° or 31°.
NOTE Inlet and exhaust valves must not be lapped in.
Maximum Valve recession (Below face of cylinder head) AQ Engine
a) Production Inlet 1.40 – 1.70mm (0.055 – 0.067 ins)
Production Exhaust 1.50 – 1.80mm (0.059 – 0.071 ins)
b) Service Limit Inlet 1.95mm (0.077 ins)
Service Limit Exhaust 2.05mm (0.081 ins)
Valve Springs
Single valve springs fitted. No damper coils.
Cylinder Liners
Dry Type – Silicon Carbide Honed
Cast Iron – Flanged
Service Liner is pre-finished type with a transition fit of ± 0.03mm (± 0.001 ins).
Stand out of liner flange
0.10mm (0.004ins) above to 0.10mm (0.004ins) below the top face of the cylinder block.
Maximum permissible wear of liner bore – 0.25mm (0.010 ins).
Connecting Rods
‘H’ section, wedge shape small end.
NOTE The piston height is controlled by the length of the connecting rod. Six length grades (F tol)
may be fitted. The length is checked with the big end bearing removed and the original small
end bush fitted. To obtain the different grades the small bush is machined off centre to form
an eccentric bush. The amount the bush is off centre gives the different grades.
Grade Letter Colour Code Length (mm)
F Red 165.682/165.715
G Orange 165.728/165.761
H White 165.591/165.624
J Green 165.637/165.670
K Purple 165.499/165.532
L Blue 165.545/165.578
In Service three connecting rods are available to the correct length grade, or an unmatched small end
bush is available which must be reamed to the correct dimension after installation.
Pistons
The pistons have a ‘fastram’ combustion chamber in the top of the piston.
The pistons have two compression rings and an oil control ring. The groove for the top ring has a
metal insert to reduce wear of the groove. This piston skirt has a layer of graphite to improve the wear
characteristics. The gudgeon pin is off centre to reduce noise levels.
If with no. 1 cylinder on the top dead centre on the compression stroke it is not possible to insert the
timing pin fully, adjustment may have to be made by slackening the four torx screws and rotating the
fuel injection pump hub until the pin can be fully installed.
Powershuttle Transmission
Notes
General Description
The Powershuttle 2 Transmission has been revised to give the same road speeds in both forward and
reverse.
3 Spool Monoblock
On both electronic and mechanical machines the 3 spool valve is mechanically operated.
This contains the following functions:
Left hand Stabiliser. Contained within this circuit is a check valve in the pressure gallery and a load
sense valve. No shock valves are fitted.
Right hand Stabiliser. Contained within this circuit is a check valve in the pressure gallery and a load
sense valve. No shock valves are fitted.
Auxiliary. Contained within this circuit are two shock valves set at 190 bar, two anti-cavitation valves,
a compensated check valve in the pressure gallery and a load sense valve.
Note: If the auxiliary service is used for a hammer, the anti-cavitation valve in port ‘N’ must be
deleted. The return flow from the hammer returns to the tank via the return line filter. It does not pass
through the cooler.
If the auxiliary service is used for a patch planer the return oil from the planer must be connected to
port ‘P’ so that the returning oil returns to the tank via the cooler and the filter.
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Electrics
Notes
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Cab – Front Instrument Panel Layout
12
13
14
3 8 4 5
5 4 3 2 1 9 10
12 6 7 8 11
Cab – Side Instrument Panel
2 10
3 11
4 9 12 10 11
1
2 4 7 8 12
5
13
3
6 7 8
1 10 11
5 6 7 8 9 12 13
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P100T018
Fuses and Relays
Relays Fuses Rating
1 Headlight - Main 1 Headlight - Main – Left 7.5
2 Headlight - Dip 2 Headlight - Main – Right 7.5
3 Sidelights / Number Plate / 3 Headlight - Dip – Left 7.5
Illum Inst Pack 4 Headlight - Dip – Right 7.5
4 Brake Lights 5 Sidelights - Left/Number Plate 3
5 Hazard enable 6 Sidelights – Right 3
6 Indicator/hazard enable 7 Indicators 5
7 Front Wiper 8 Hazard 10
8 Rear Wiper 9 Worklights – Front 15
9 Front Washer 10 Worklights – Front 15
10 Rear Washer 11 Worklights – Rear 15
11 Front Horn / Rear Horn 12 Worklights – Rear 15
12 Indicators flasher unit 13 Rotating Beacon 15
13 Front Worklights 14 Brake Light – Left 3
14 Rear Worklights 15 Brake Light – Right 3
15 Rotating Beacon 16 Instrument Pack Illumination 3
16 Float enable relay 17 Difflock / 4WD 7.5
17 Clamp 18 Clamp / Q/A Digger / Q/A Loader 7.5
18 Digger Quick Attach 19 RTD / Unloader Valve 5
19 RTD 20 Fr Wiper / Rear Wiper /
20 Unloader Fr Wash / Rear Wash 15
21 Loader Quick Attach 21 Interior Loght / Radio 7.5
22 Ride Control Solenoids 22 Front Horn / Rear Horn 10
23 Gearbox - Forward 23 Ride Control Solenoids 10
24 Gearbox - Reverse 24 Gearbox - Forward/Reverse 5
25 4WD Switch 25 Fuel Solenoid / Fuel Enrich 7.5
26 Hose Burst 26 HMU 15
27 Gearbox – neutral 27 Air Conditioning Switch 7.5
28 Cigar Lighter 15
Main Fuses Rating 29 Heater 25
1 Alternator 125 30 Switch Pack & I Pack – Ignition 10
2 Cab (Ignition) 80 31 Switch Pack & I Pack – Vbattery 3
3 Cab (Battery) 80 32 Battery Relay Coils 5
4 Ignition Feed (Thermostart) 20 33 Ignition Relay Coils 5
5 Starter Relay and Solenoid 40
P100T020
Electronic System Overview
Electro-Hydraulics
On machines equipped with electro-hydraulic controls the spools which control the flow of oil to the
services are positioned by electrical signals and pilot supply oil rather than mechanical levers.
The electrical signals are generated by the hydraulic management unit (H.M.U.). This has complete
control of all the loader and backhoe services (slew, boom, dipperstick and bucket) plus the steerable
rear axle. The control signals take the form of a variable voltage in the range 25% to 75% of battery
voltage, ie 50% of battery voltage signals a spool to move to the mid position (neutral) –the no flow
position.
The electrical signals that control the hydraulic valve are generated by the H.M.U. in response to a
number of inputs. These include:-
· Two joysticks mounted on the seat.
· Switches on the seat that detect which direction the seat is facing.
Both the joysticks and the position transducers are based on potentiometers. These are devices
which produce a voltage that varies as the input shaft is rotated.
In its simplest form a potentiometer consists of a length of resistance wire connected between 12V
and 0V. A sliding contact moves along the wire as the input shaft rotates. At one end, the voltage on
the sliding contact is 12V. As the contact moves, the voltage on it gradually reduces until at the other
end of the wire it is 0V.
In practice, the voltage range is reduced to between say 1V to 11V. This provides a means of
detecting a broken wire, since if any wire should become open circuit, the voltage on the wiper will
become either 0V or 12V.
Safety Features
General Description
In addition to checking that the voltages from the joysticks are within range, the H.M.U. also checks
an auxiliary contact on each joystick. This contact is closed whenever the joystick is moved off the
neutral position. Therefore, before the H.M.U. activates a hydraulic service it checks the following
conditions:-
· The joystick signal is within range.
· The neutral switch is ON.
· The signal that controls the position of the spool must be adjusted in the range 3 to 9 volts,
assuming battery voltage is exactly 12V, ie. 25% to 75% of battery voltage.
Watchdog Circuit
The enhanced safety checks provided by the H.M.U. are only sound if the H.M.U. itself is fail-safe.
This is achieved by having a second circuit within the HMU that monitors its operation. Should the
software fail to send a constant stream of pulses to this 'watchdog' it disables the outputs, thus
switching off power to the valve (PVE’s).
The Danfoss Valve
General Description
Proportional Type controllers are fitted to all the services of the Danfoss, loader and four spool
backhoe control valve.
The Danfoss valve is unique amongst mobile hydraulic equipment in having a servo within the valve
itself.
The spool is moved by HYDRAULIC pressure applied at either end of the spool and controlled by four
small poppet valves within the P.V.E. end cap. On proportional type controllers a small potentiometer
attached to the spool monitors its position and an electronic amplifier compares the actual spool
position with the demand signals and controls the poppet valves until the required spool position is
reached. Springs within the valve ensure the spool returns to the neutral position should electrical
power be removed or the signal voltage go open circuit.
KEY
1, 2, 3, 4 Poppet Valves
5 Potentiometer
6 Pilot Supply
7 Filter
A; B Feed lines to cylinder
T Tank line
25% to 75%
3 to 9 volts
(100 µA)
P100T028
P100TM035
Note 1
HMU automatically retains the language which was last used and also the machine type (model)
Note 2 – Monitor Steering
Steering Value Range
Straight Nominal 480 Allowed Range 280 – 680
Anti-clockwise (LH lock) Nominal 190 Allowed Range 20 – 400
Clockwise (RH lock) Nominal 650 Allowed Range 500 – 970
Allowable tolerance between left and right wheels
On front axle 90 – Difference straight
On rear axle 90 – Difference straight
Allowable tolerance between left and right wheels fully anti-clockwise (LH lock) and fully clockwise
(RH lock)
Front wheels 200
Rear wheels 200
Front Axle Rear Axle
Steering Straight -ahead Steering Straight -ahead
Steering Steering
Fully Anti-clockwise Fully Anti-clockwise
Steering Steering
Fully Clockwise Fully Clockwise
Shift ? Press Shift release and press ? if any of the following occur.
Once the diagnostic terminal is plugged into the 5 pin test point, in certain circumstances
the display screen may be blank. By pressing key Shift then ? it will initiate the terminal to
the front screen which displays the version of software present in the HMU and daughter
board.
Whilst at any stage of monitor or calibration pressing Shift then ? on the keyboard of the
diagnostic terminal will initiate the terminal to revert to the front screen.
Electro Hydraulic Test Equipment
Illuminated Voltage Monitor
The voltage monitor has an illuminated display which will indicate voltage of between 25% and 75% of
battery voltage in relation to joystick movement.
The monitor also has three colour coded sockets:
BLACK Ov Earth
RED V Batt Battery Voltage
WHITE Signal Signal Voltage
These three plugs give the added feature of being able to measure both battery and signal voltage
using the Multi-tester.
As An Example:-
If you used the slave joystick to test a service and you have diagnosed the problem as being
electrical, the illuminated voltage monitor can be used to carry out the following test on the output
signals from the H.M.U. to the P.V.E.’s on the Danfoss Control Valve.
1. Measure Battery Voltage.
2. Measure Neutral Voltage.
3. Measure output signal voltage range.
4. Test the smoothness of joystick operation. The voltage monitor can be connected to any of the
electrical P.V.E.’s on the Danfoss Control Valve.
Test Procedure
1. With the engine switched off, remove the Hirschmann plug from the P.V.E. of the affected service
on the Danfoss Control Valve.
2. Connect the double sided plug on the voltage monitor to the electrical P.V.E. on the Danfoss
Control Valve section.
3. Refit the Hirschmann plug to the top side of the double sided plug on the voltage monitor. The
voltage monitor is now connected into the signal path between the H.M.U. and the P.V.E. on the
Danfoss Valve section (See ST307).
4. Plug the Multi-tester leads into the earth (Black socket) and battery voltage (Red socket) (See
ST307) on the illuminated voltage monitor. Connect Multi-tester leads to the Multi-tester as shown
in ST252 and turn the range selector switch fully clockwise to 20 on the DC V scale.
5. DO NOT START THE ENGINE. Turn the ignition key switch to the + position and press the
hydraulic enable switch. If the affected service is the loader beam or loader bucket the seat must
be facing forward in which case only the right hand joystick is powered. If the affected service is
the Backhoe, Boom, Slew, Dipperstick or Bucket the seat must be in the digging position in which
case both joysticks are powered.
NOTE: When conducting these tests the operator must be SAT on the SEAT. ST252 shows the
Loader bucket section being tested, when the right hand joystick is moved off the neutral position
the Multi-tester should display the BATTERY VOLTAGE (Minimum Battery Voltage 11.8 Volts). No
battery voltage indicates either a faulty Hydraulic Enable Switch, Emergency overide button,
Loader (Backhoe) relay, a blown H.M.U. fuse or broken wire.
6. The next step is to measure the signal voltage. The signal voltage can be measured in two ways.
Firstly by means of the illuminated display on the monitor which will measure the signal voltage
from25% to 75% of the BATTERY VOLTAGE.
Additionally it can be measured by using the Multi-tester. When using this method the Multi-tester
leads must be plugged into the earth (BLACKSOCKET) and the SIGNAL (WHITESOCKET) of the
monitor.
NOTE:- When testing the loader beam and loader bucket sections the Hydraulic MODE switch
MUST be in the BUCKET mode and NOT in the fork mode.
7. When checking the loader BUCKET section the bucket must be FLAT on the ground (Return to
dig position) and the Loader beam lowered onto the ground.
8. When checking the loader BEAM section the bucket must be fully DUMPED and the beam
lowered to the ground.
NOTE:- Failure to carry out (7 & 8) may result in incorrect signal readings due to the
potentiometers fitted to the Loader Beam & Chassis.
9. Now move the appropriate joystick and note how the voltage changes and the limits it reaches.
On the illuminated display the signal voltage should range from between 25% & 75% of the
BATTERY VOLTAGE depending of the voltage change on the illuminated display when moving
the joystick.
As an example,
If you have a BATTERY VOLTAGE of12.8 volts, the expected Signal Voltage reading should be
as follows:-
· 25%= 3.2 volts with the joystick fully in one direction
· 50% = 6.4 volts with the joystick in neutral
· 75% = 9.6 volts with the joystick fully in the opposite direction
· On the Loader, the float function should come into operation at 65% =8.3 volts
See ST306 for an example of the Signal Voltage Test.
10. If the Signal readings are ERRATIC, this could be caused bya faulty joystick or bad connection. If
there is no signal voltage there could be a broken wire or bad connection.
Steering
All initial fault diagnosis/testing of the 4 wheel steer system must be carried out using the electronic
diagnostic unit as detailed in Bulletin 865/965/1300/01.
Slave Joystick Procedure:-
1. Lift the floor mat at the rear of the cab and remove both rear footplates between the seat
plinth and rear window.
2. Remove the screw retaining the Hirschmann plug which is connected to the controller of the
steering service and remove the plug.
3. The slave joystick has two leads, the lead fitted with the Hirschmann plug on the end
must be connected to the P.V.E. of the steering service and the other lead must be
plugged into the cigarette lighter socket (See ST317).
4. Using the two position switch select, the Fast mode on the slave joystick.
5. Select 2 W.S. on the steering mode selector switch.
6. Ensure no bystanders are in the vicinity of the rear wheels.
7. Start engine and raise rear wheels off the ground.
Erreur! Liaison
incorrecte.
8. Do not press the hydraulic enable switch.
9. Press and hold the yellow button, then move the joystick lever forward or backwards
to operate the service (See ST317).
10. If the service OPERATES NORMALLY under the control of the slave joystick, the problem is
in the ELECTRICAL SYSTEM. This could be caused by incorrect signals from the H.M.U. to
the Danfoss Control Valve.
11. If the service DOES NOT OPERATE NORMALLY, the problem is either hydraulic or with the
Proportional Electrical Controller on the Danfoss Control Valve.
Illuminated Voltage Monitor
Test Procedure:-
1. With the engine switched off, remove the Hirschmann plug from the electrical controller of the
steering service on the Danfoss Control Valve.
2. Connect the double sided plug on the voltage monitor to the electrical P.V.E. on the Danfoss
Control Valve steering section.
3. Refit the Hirschmann plug to the top side of the double sided plug on the voltage monitor.
The voltage monitor is now connected into the signal path between the H.M.U. and P.V.E. on
the Danfoss valve section (See ST307).
4. Plug the Multi-tester leads into the earth (BLACK SOCKET) and battery voltage (RED
SOCKET).
5. Ensure no bystanders are in the vicinity of the front or rear wheels.
6. Start engine, press hydraulic enable switch, raise all four wheels off the ground using
stabiliser legs and the loader assembly.
7. Set all four wheels to the straight ahead position, lower the rear wheels to the ground, the
front wheels are to REMAIN OFF THE GROUND.
8. Switch off engine.
9. Turn ignition switch to the “+” position, do NOT press hydraulic enable switch.
10. Slightly rotate steering wheel to check battery voltage. (Minimum voltage should be 11.8
volts).
11. Disconnect Multi-tester lead at monitor from red socket and reconnect to white socket to
measure signal voltage.
12. Rotating the steering wheel clockwise should increase voltage gradually to approximately 9
volts.
Steering Mode Selector
On 4WS machines a steering mode selector switch is fitted on the side console. The mode - 2WS,
4WS or crab - may be changed at any time whilst the engine is running. The rear wheels will
immediately turn to line-up according to the mode. If there is a lot of lock on the front wheels then a
significant amount of engine power may be required to turn the rear axle, particularly if the machine is
stationary. A prudent operator should raise the engine RPM a little before changing steering mode.
The steering mode switch should not be changed whilst the ignition is off. If it is, then on switch-on,
the H.M.U will detect that the position of the rear wheels does not agree with the switch and will sound
the buzzer to indicate steering error i.e. continuous beeps and the forward/reverse switch will be
inhibited. Normal operation is restored by changing the position of the steering mode switch.
In Cab Diagnostics
On the side control panel is a device which emits a “beep” sound. This alarm system operates when
the computer detects a fault which affects operation or safety.
Fault condition Problem Corrective action
1 short “beep” The seat is not properly Move the seat forwards slightly. When properly
(595 LSP only) locked in an operating positioned the seat should not swivel. If the seat
position. is locked in position and the warning continues,
check the seat position switches. All hydraulic
services will be inoperable while this fault
occurs.
1 long “beep” Emergency stop button is Unlock emergency stop button.
Non repeating locked off.
2 short “beeps” There is a fault in the loader Visually check for damage to the potentiometers
beam levelling system. on the loader pivot. Also inspect the wiring and
connectors for damage. The machine requires
IMMEDIATE attention from your Case Dealer
and must not be operated until the fault is
corrected.
1 short and 1 There is a fault in the loader Visually check for damage to the potentiometers
long “beeps” bucket levelling system. on the bucket linkage pivot. Also inspect the
wiring and connectors for damage. The machine
requires IMMEDIATE attention from your Case
Dealer and must not be operated until the fault
is corrected.
3 short “beeps” Faulty control lever signal – It is dangerous to operate the machine with this
right-hand. fault as erratic movements may occur. The
machine requires IMMEDIATE attention from
your Case Dealer and must not be operated
until the fault is corrected.
2 short and 1 Faulty control lever signal – It is dangerous to operate the machine with this
long “beeps” left-hand. fault as erratic movements may occur. The
(595 LSP only) machine requires IMMEDIATE attention from
your Case Dealer and must not be operated
until the fault is corrected.
4 short “beeps” Steering error : This Select the correct steering mode corresponding
warning sounds during to the position of the machine’s wheels. The
start-up, if the steering audible alarm will cease sounding.
wheel position does not
agree with the mode
selected.
The alarm sounds during The fault is in the harness or the steering mode
work or will not clear with switch. The machine requires IMMEDIATE
changing the steering mode attention from your Case Dealer and must not
as described above. be operated until the fault is corrected.
3 short and 1 long Front and rear axles steering The steering will remain in the selected
“beeps” potentiometer fault, 4WS and mode (4WS/crab) until the wheels are
crab mode only. steered to the straight ahead position.
The rear wheels will remain in 2WS
mode until the fault is rectified. The
machine requires IMMEDIATE attention
from your Case Dealer and must not be
operated until the fault is corrected.
5 short “beeps” Rear axle steering Visually check for damage to the
potentiometer fault, 2WS potentiometers on the rear axle. Also
mode only. inspect the wiring and connectors for
damage. The machine requires
IMMEDIATE attention from your Case
Dealer and must not be operated until
the fault is corrected.
4 short and 1 long Front axle steering Visually check for damage to the
“beeps” potentiometer fault, 2WS potentiometers on the rear axle. Also
mode only. inspect the wiring and connectors for
damage. The machine requires
IMMEDIATE attention from your Case
Dealer and must not be operated until
the fault is corrected..
6 short “beeps” Rear wheels mis-aligned, The rear wheels will self correct them
2WS mode only. selves very slowly in half degree steps.
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Lubricants and Service Intervals
Notes
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liO DW4 liO DW2 retliF LR reniart S liO retli F liO retliF RP reniartS & liO
knaT ceS .mirP liO
tnalooC leuF retliF leuF retliF riA elx A tnor F sciluardy H enign E elx A raeR x obraeG
PSL 595 & ELS 595
snoitacificepS liO/slavretnI ecivreS/seiticapaC/stnemelE
4001
Section
4001
ELECTRICAL SCHEMATIC
TABLE OF CONTENTS
SCHEMATIC SYMBOLS ......................................................................................................................................... 3
RELAY FUSE BOARD AND CONNECTOR............................................................................................................ 4
RELAY FUSE BOARD AND CONNECTOR............................................................................................................ 4
RELAY FUSE BOARD AND CONNECTOR............................................................................................................ 5
INSTRUMENTS AND CONTROLS FRONT CONSOLE ......................................................................................... 6
INSTRUMENTS AND CONTROLS FRONT CONSOLE ......................................................................................... 7
INSTRUMENTS AND CONTROLS SIDE CONSOLE 595SLE ............................................................................... 8
INSTRUMENTS AND CONTROLS SIDE CONSOLE 595LSP ............................................................................... 9
INSTRUMENTS AND CONTROLS SIDE CONSOLE ........................................................................................... 10
WIRING DIAGRAM (PLATE A) ............................................................................................................................. 12
WIRING DIAGRAM (PLATE B) ............................................................................................................................. 14
WIRING DIAGRAM (PLATE C) ............................................................................................................................. 16
WIRING DIAGRAM (PLATE D) ............................................................................................................................. 18
WIRING DIAGRAM (PLATE E) ............................................................................................................................. 20
WIRING DIAGRAM (PLATE F) ............................................................................................................................. 22
WIRING DIAGRAM (PLATE G)............................................................................................................................. 24
WIRING DIAGRAM (PLATE H) ............................................................................................................................. 26
WIRING DIAGRAM (PLATE J).............................................................................................................................. 28
WIRING DIAGRAM (PLATE K) ............................................................................................................................. 30
WIRING DIAGRAM (PLATE L).............................................................................................................................. 32
ENGINE HARNESS WIRING ................................................................................................................................ 34
POWER WIRING HARNESS AND CABLE (SINGLE BATTERY)......................................................................... 36
POWER WIRING HARNESS AND CABLE (TWIN BATTERY)............................................................................. 37
CHASSIS HARNESS WIRING .............................................................................................................................. 38
FRONT CONSOLE HARNESS, SIDE CONSOLE HARNESS AND CAB HARNESS WIRING ............................ 40
SEAT HARNESS WIRING (595LSP) .................................................................................................................... 42
ALPHABETICAL INDEX........................................................................................................................................ 43
SCHEMATIC SYMBOLS
A (n) Radio/C.B
B (n) Indicator/pressure switch/loud speakers/pressure limit switch/detectors/temperature sender/gauge
E (n) Lighting components
F (n) Fuses
G (n) Electrical supply generators
H (n) Warning devices
K (n) Relays
M (n) Motors
P (n) Instruments
R (n) Heating elements/heater plugs
S (n) Switches/master switch
V (n) Diodes
X (n) Supply line connections
Y (n) Solenoid valves, solenoids
NOTE: The (n) gives the identiÞcation number of the components.
Example: K2 is relay N °2.
Wire color
Refer to the chart below regarding the wire color when testing during troubleshooting (for connector numbers, refer
to the following pages).
Wire color table
Symbol B W Br P V G O
Symbol R Y Lg Sb L Gr
RELAY FUSE BOARD AND CONNECTOR RELAY FUSE BOARD AND CONNECTOR
Fuses Relays
F1 7.5A, Left main headlight K1 RL1 Main headlight relay
F2 7.5A, Right main headlight K2 RL2 Dip headlight relay
F3 7.5A, Left dip headlight K3 RL3 Side lights/number platI/illumination instrument pack relay
F4 7.5A, Right dip headlight K4 RL4 Brake light relay
F5 3A, Left sidelight/number plate K5 RL5 Hazard enable relay
F6 3A, Right side light K6 RL6 Indicator/hazard relay
F7 5A, Indicator light K7 RL7 Front wiper relay
F8 10A, Hazard light K8 RL8 Rear wiper relay
F9 15A, Front worklight K9 RL9 Front washer relay
F10 15A, Front worklight K10 RL10 Rear washer relay
F11 15A, Rear worklight K11 RL11 Front horn/rear horn relay
F12 15A, Rear worklight K12 RL12 Indicators ßasher unit
F13 15A, Rotating beacon K13 RL13 Front worklight relay
F14 3A, Left brake light K14 RL14 Rear worklight relay
F15 3A, Right brake light K15 RL15 Rotating beacon relay
F16 3A, Instrument pack illumination K16 RL16 Float enable relay
F17 7.5A, Differential lock/4WD K17 RL17 Clamp relay
F18 7.5A, Clamp/Quick attach digger/Quick attach loader K18 RL18 Digger quick attach relay
F19 5A, Return to dig/Unloader valve K19 RL19 Not used
F20 15A, Front wiper/Rear wiper/Front washer/Rear washer K20 RL20 Unloader relay
F21 7.5A, Interior light/radio K21 RL21 Loader quick attach relay
F22 10A, Front horn/Rear horn K22 RL22 Ride control solenoid relay
F23 10A, Ride control solenoid K23 RL23 Forward gearbox relay
F24 5A, Forward/Reverse gearbox K24 RL24 Reverse gearbox relay
F25 7.5A, Fuel solenoid/Enrich solenoid K25 RL25 4WD switch relay
F26 15A, HMU K26 RL26 Hose-burst relay
F27 7.5A, Air conditioning switch K27 RL27 Neutral gearbox relay
F28 15A, Cigar lighter K28 - Battery relay (ignition)
F29 25A, Heater K29 - Start relay
F30 10A, Switch pack & illumination pack - ignition
F31 3A, Switch pack & illumination pack - battery
F32 5A, Battery relay coils
F33 5A, Ignition relay coils
F 12
F 13
F 20
F 21
F 11
X1 J1 20 way Relay fuse board ® Forward/Reverse - indicator switch - right front console K8 K1 5
switch pack K7
X2 J2 12 way Relay fuse board ® Right and left headlight
X7
X3 J3 16 way Relay fuse board ® Front control panel - handbrake switch - stop light switch - F22
differential lock switch F32
K1 3 K1 1 K1 4 X4
X4 J4 20 way Relay fuse board ® Side console switch pack F8
X5A J5A 18 way Relay fuse board ® Left lights (stop/indicator/light) - right lights (stop/indicator/
light) - number plate - reverse alarm - rear horn F30
F31 X1
X5B J5B 12 way Relay fuse board ® Differential lock solenoid - side shift clamp solenoid - quick K6 F7
K1 2
attach - return to dig solenoid (mech) - brake pressure switch - return to dig F17
switch (mech) X12 X3
X6A J6A 18 way Relay fuse board ® Rear wiper - right rear worklight - left rear worklight - rotating
beacon - front wiper - right front worklight - left front worklight K2 5 K5
F1
X6B J6B 12 way Relay fuse board ® Right front worklight - left front worklight - radio
F2
X2
X7 J7 8 way Relay fuse board ® Side control panel K1 0
K1 F4
X8 J8 20 way Relay fuse board ® Loader valve solenoid - front horn - quick attach - front
washer - rear washer - ride control solenoid - forward solenoid - reverse F3
X8
solenoid - 4WD solenoid K9
F16
K2
X9 J9 20 way Relay fuse board ® Engine speed sensor - engine stop solenoid - enrichment F28
X 10
solenoid - hose burst solenoid - ßoat switch (mech.) - air conditioning compres-
K2 1 F6
sor switch - de-clutch transmission switch (loader lever) - de-clutch transmission
K3 F5
switch (gearbox lever) - loader valve switch - HMU
X10 J10 12 way Relay fuse board ® Key switch - cigar lighter K2 3
X11 J11 7 way Relay fuse board ® Air conditioning switch and thermostat - heater K2 2 K4
X12 J12 1 way +Battery (F36) ® Relay fuse board X15
K2 4
X13 J13 1 way Masse ® Relay fuse board K2 6 K1 6
X14 J14 1 way +Battery (F35 - K28) ® Relay fuse board
X15 J15 1 way Masse ® Relay fuse board K2 0 X14
F24 F23 K2 7
A2 Relay fuse board F19
K1 9 F29
F18
F27 F 26
F 15
F 25
F 33
F 14
K1 8 K1 7
X5A X5B X9
K2 9
K2 8
CM99E002
S8
22
1 2 3 4
CI99E514
S2 4
H1 4 H1 5
1
S7
S8
CI98J533
S3 7
A2
S4
S4 1
X1 9
1 X2 2 A6 E9
CI99E510
S3 7
A2
S4
E9
CI99E513
CI98J539
G1 - S1
X29 - X30
G2 G1 B5
CS99F501
CM99F040
E3
E11 - E14
CS99F501
MAIN HEADLIGHT RELAY LEFT MAIN BEAM INDICA- DIP HEADLIGHT RELAY LEFT SIDE LIGHT/REGISTRATION/ILLUMINATION RELAY
INDICATORS SWITCH
AND RIGHT BEAM LIGHT TOR LAMP AND RIGHT DIP BEAM LIGHT LEFT SIDE LIGHT LEFT REAR LIGHT REGISTRATION PLATE LIGHT
BAT. + BAT. +
B A T . + R L Y C O IL B A T . + R L Y C O IL
IG N . R L Y O P + IG N . R L Y O P +
IG N . R L Y C O IL S IG N . R L Y C O IL S
WG1 WG1
30 85 30 85 30 85
K1 K2 K3
87A 87 86 87A 87 86 87A 87 86
X 1 /1 9 X 1/16
UW0,35F4 UK0,35
X 1/1
RO 0,35
F6
X 26
X 3 /1 5
F1 F2 F3 F4 F5
7 ,5 A 7 ,5 A 7,5A 7,5A 3A
UW0,35F3
S7
X 2 /2 X 2 /3 X 2/5 X 2/4 X 2/7 X 5A 17 X 5A /12
RW1C1
UW1F2 UW1F1 X 2 5 /1 1 UK1F2 UK1F1 RB0,5 RB1
RW1C3 RW1C1
P2
E11 E15 B0,35F9 E 10 E 14 E 12 E3 E7 E8
H43
GND GND
B10 B10
CM99F041
B6
CS99F501
BAT. + BAT. +
B A T . + R L Y C O IL B A T . + R L Y C O IL
IG N . R L Y O P + IG N . R L Y O P +
IG N . R L Y C O IL S IG N . R L Y C O IL S
WG1 WG1
F 20
15A
K9
30 85
V3
X 25/3
BW0,35
F5 K7
87A 87 86
P2
F6 F 16
3A 3A
P 10 P 14
X 6A /15 X 6A /6 X 6A /16 X 1/12
X 2 7 /7 X 1 7 /1 6 X 2 5 /1 8 X 28/18 S 10 H 10
E 16 E6 X 9/10 X 9/11
S24 S20 P2 P3 X 27/5
BW1 BY1
X 1 /2 0 X 4 /2 0 X 3 /8 X 7/4
GND GND
B10 B10
CM99F042
M2
H2
H1
CS99F501
BAT. + BAT. +
B A T . + R L Y C O IL B A T . + R L Y C O IL
IG N . R L Y O P + IG N . R L Y O P +
IG N . R L Y C O IL S IG N . R L Y C O IL S
WG1 WG1
F22
10A
F20
30 85 30 85 30 85 30 85
V4 V5 V6 V16
K8 K9 K 10 K 11
87A 87 86 87A 87 86 87A 87 86 87A 87 86
X 6 A /1 4 X 6A /5 X 6A /4 X 4/17 X 8/16 X 1 /1 1 X 8 /1 8 X 4 /1 2 X 8 /1 2 X 5 A /6 X 4 /5 X 1 /4
X 1 7 /1 1 X 2 7 /2 X 1 7 /1 2
X 7 /5 X 26/
S 20 S24 S20
H1 H2 S20 S7
M3
M4
M M
M5
S 28 H28 S9 H9 S29 H 29 S34
X 1 7 /7 X 2 7 /5 X 1 7 /7 X 1 7 /7 X 26/
GND GND
B10 B10
CM99F043
X17
CS99F501
BAT. + BAT. +
B A T . + R L Y C O IL B A T . + R L Y C O IL
IG N . R L Y O P + IG N . R L Y O P +
IG N . R L Y C O IL S IG N . R L Y C O IL S
WG1 WG1
F13
15A
30 85 30 85 30 85
V 17 V18 V19
K13 K 14 K 15
87A 87 86 87A 87 86 87A 87 86
F9 F 10 F11 F12
15A 15A 15A 15A
X 4/1 4 X 4 /1 6 X 4 /1 5
GN0,5 PK0,5
UG0,5
X 6A /18 X 6A /17 X 6A /8 X 6A /7 X 1 7 /1 X 6 A /1 1 X 6 A /1 0 X 6 A /1 3 X 6 A /1 2 X 1 7 /1 0 X 6 A /1 X 6 A /9 X 1 7 /9
S20 S20 S 20
UG1R2 UG1R1 UY1R1 UY1R2 PS1R1 PS1R2 GN1R2 GN1R1 PK1R2 PK1R1
S 25 H 25 S27 H 27 S26 H 26
E 20 E 18 E 21 E 19 E25 E27 E26 E28
X 1 7 /7 X 1 7 /7 X 1 7 /7
E22 E23
X 6B /6 X 6B /5 X 4/2 0 X 6 B /4 X 6 A /3 X 6 B /3 X 6 A /2 X 4 /2 0 X 6 B /2 X 6 B /1 X 4 /2 0
GND GND
B10 B10
CM99F044
Y11 - Y12
B11
B7 Y4
CS99F501
AIR CONDITIONING SWITCH CLAMP RELAY BUCKET QUICK ATTACH RELAY LOADER QUICK ATTACH RELAY UNLOADER RELAY
AIR CONDITIONING PRESSURE BACKHOES BOOM BUCKET QUICK AT- LOADER QUICK AT-
COMPRESSOR MAGNETIC SIDE SHIFT CLAMP BUCKET QUICK AT- LOADER QUICK AT- LOADER VALVE SOLE-
UNLOCKING TACH SWITCH/ TACH SWITCH LOADER VALVE SWITCH/LAMP
CLUTCH SOLENOID TACH SOLENOID TACH SOLENOID NOID
SWITCH LAMP LAMP LAMP
BAT. + BAT. +
B A T . + R L Y C O IL B A T . + R L Y C O IL
IG N . R L Y O P + IG N . R L Y O P +
IG N . R L Y C O IL S IG N . R L Y C O IL S
WG1 WG1
X 1 1 /3
PR1 30 85 30 85 30 85 30 85
PG1
X 5 A /5 X 4 /1 9 X 5 A /7 X 4 /2 X 8 /1 4 X 1 /1 5 X 8 /1 0 X 4 /4
Y11 Y12 Y4 Y3
X 9 /1 7
S30 H30 S31 H31 S15 H15 S33 H33
PB1 X 1 7 /7 X 1 7 /7 X 2 7 /5 X 1 7 /7
P
B11 B1C28 B0,5 B1C3
B0,5F7 B1C1 B0,5
B1C27 B0,5
X 5 B /7 X 4 /2 0 X 5 B /8 X 4 /2 0 X 8 /1 3 X 1 /2 0 X 8 /9 X 4 /2 0
Y 10
GND
B10
CM99K016
E13 E2
Y5 - Y6
CS99F501
RIDE CONTROL RELAY HOSE BURST RELAY DIRECTION HAZARD ENABLE RELAY LEFT INDICATOR/HAZARD RELAY
INDICATORS FLASHER UNIT
RIDE CONTROL RIDE CONTROL HOSE BURST SOLENOID INDICATOR FLOAT ENABLE RELAY TURN INDICATOR FRONT RIGHT TURN INDICATOR HAZARD WARNING
INDICATORS SWITCH
SOLENOIDS SWITCH/LAMP HOSE BURST PRESSURE SWITCH LAMP AND REAR LIGHT FRONT AND REAR LIGHT SWITCH/LAMP
CM99F046
S8
Y7 - Y8 - Y14 H3
Y9
CS99F501
CM99K017
A4
E31
X29
CS99F501
BAT. + BAT. +
IG N . R L Y O P + IG N . R L Y O P +
H 41
R0,5
X 25/6 RK1 G0,5F1 G0,5 G0,5S3 G0,5F2
GU2,5
BO0,35 X 17/6
NK0,5 R2
X 3/9 RP1 KO2 X 17/8
NK0,5
1 S 40
S 20 X 27/1
X 5B /3 X 17/7 A4
2 3 4
X 25/4 X 28/4
S 24
X 25/1 X 28/1
GR2 GS2
A5 E9 X 27/5
P2 P3
B8
X 25/20 X 28/20
E 24
B1R5
B2 B2
GY2
B0,5F3 B0,5S1 B0,5 B0,5F7
B1C39 B1R4
E 31
X 5B /11 X 6 B /1 0 X 6 B /9 X 1 0 /1 0 X 3/8 X 7/4 X 4/20 X 1/20 X9
B2,5
CM99F048
A3 - S43 - X21
B9 - S17 - S18
CS99F501
BAT+
W S2
R2
X 1 0 /4 X 9/16 R B0,5
A2
R S 0,5
R3
X 9 /2 0 X 4 /7 X 4 /8 X 3 /3
P2 X 20/2
WB0,5 KR0,5 H 48
X 25/12
YG0,5 X 20/1
WS2 B2 X 1 8 /1 X 1 8 /2
S 19 A6
B9 S 17 S 18
W2 A1
S 42 S 41
X 16
S 37
A3
S 43
R1
B2
K 29 C o il
CM99C001
P9
P1 P7 A4
CS99F501
POTENTIOMETERS SOLENOIDS
EMERGENCY
SLEW BUCKET DIPPER
SWITCH LEFT FRONT LEFT REAR
RETURN TO DIG LOADER ARMS RIGHT REAR WHEEL BOOM
RIGHT FRONT WHEEL WHEEL
CLAM LOADER BEAM LOADER BUCKET
WHEEL
W S2 Y 20 Y 19 Y 22 Y 21
R2
S 38
R B0,5
R S 0,5
S R 0,5 U B0,5 B0,5C 31 S O 0,5 U S 0,5 B0,5C 33
U Y 0,5 B0,5C 32 S U 0,5 U K0,5 B0,5C 34 S W 0,5
X 23/36 X 23/33 X 23/34 X 23/35 X 23/32 X 24/3 X 24/4 X 24/14 X 24/7 X 24/8 X 24/16
A4
X 23/25 X 23/27 X 23/29 X 23/16 X 23/18 X 23/14 X 23/22 X 23/24 X 23/20 X 23/7 X 23/8 X 23/11 X 23/3 X 23/4 X 23/9
X 23/26 X 23/28 X 23/30 X 23/17 X 23/13 X 23/15 X 23/23 X 23/19 X 23/21 X 23/12 X 23/5 X 23/6 X 23/10 X 23/1 X 23/2
PW 1 KY 1 B1 C 1 6 KG 0 ,5 BN 0 ,5 B0,5C 41 KLG 0,5 BW 0,5C 1 B0,5C 43 S B0,5 U G 0,5 B0,5C 37 S LG 0,5 U W 0,5 B0,5C 35
KW 1 B1 C 1 5 SP1 BG 0 ,5 B0 ,5 C 4 0 KN 0,5 BLG 0,5 B0,5C 42 KS 0,5 U O 0,5 B0,5C 38 S Y 0,5 U LG 0,5 B0,5C 36 S K0,5
Y 15 Y 16 Y 17 Y 18
P1 P5 P6 P7 P8 P9
B2
CM99G002
B1
Y2
X2 9
R1
1
X3 0
G2
M1
G2 B3
Y1
B1 0 B2
Y1 0
CI98G515
F3 5
M1
F3 7
G1
S1
3
CI98J500
F3 5
G1
F3 7
M1
S1
3
CI98G526
X2 0 A1
X3 3
S1 9
S3 8 X1 2 X1 3 X1 4 X1 5
X5 B X8
A2
E6 E7 E8
E5
X5 A E4 Y1 9
Y1 2 Y1 1 Y2 0
X9
Y2 1
B8
Y2 2
K2 8
Y5 Y6
K2 9 Y7
M4 Y2 3 Y2 4 P5 P4
S2 2 Y8
M5 B5
G2
P8
A4
B4 2
H3 E1 E2 E3
X2 3
Y3 Y1 8
P9
Y1 7 H2
Y1 5 Y1 6 Y1 4
X3 1
P6 4
F3 5 F3 6 F3 7 F3 8
F3 4
X2 9 Y9
H1
1 X3 0 B6 P1 Y4 X3 2
P7
CI99E508
P2 S2 4 S7 S6 S1 9
E1 8
E2 4
E1 9
E1 0 E1 1 S5
1 E2 1
E1 2 E1 3 E9
E2 0
2 E1 4 E1 5
M2
E2 2 4
E1 6 E1 7
A5
3
E2 3
S2 1
2
X1 0
S2 0 A1
E2 5 S4
E2 6
X3 3
X3
X1 X2 8
E2 7 X2
3
P3
X4
E2 8 A2
X6 B X6 A X1 1 A2
X7
A2 5
M3 S4 0
X1 7 S2 0
S3 6 6
S3 7 X1 6 X1 8 A1
M3
CI99E509
B9
X19 - 8 way Daughter board ® Left hand joystick - or right (595SLE)
S1 7
X20 - 6 way Daughter board ® HMU
X21 - - Left hand joystick ® Daughter board - Pressure pad switch - seat
X22 - - Right hand joystick ® Left hand joystick or daughter board (595SLE)
S4 3 A1
X1 9
X2 1
S1 8
3
CI99E511
ALPHABETICAL INDEX
Numerics C
4WD switch relay......................................................4 Clamp relay.................................................. 4, 22, 23
Compressor magnetic clutch ................................. 23
A
Connector daughter board ..................................... 30
Air conditioning .......................................................40 Connector engine harness............................... 12, 28
Air conditioning compressor magnetic clutch ...22, 34 Connector front control panel......... 14, 16, 24, 28, 30
Air conditioning pressure ........................................23 Connector indicator switch............................... 14, 24
Air conditioning pressure switch .............................22 Connector left-hand joystick................................... 30
Air conditioning switch ............................4, 22, 23, 40 Connector relay fuse board........... 12, 14, 16, 18, 20,
Air filter pressure ....................................................13 22, 24, 26, 28, 30
Alternator ..............................................12, 13, 34, 38 Connector right front console
Alternator charging .................................................13 switch pack ............................................ 16, 18, 28
Alternator charging warning lamp...........................10 Connector right-hand joystick ................................ 30
Connector side console panel................................ 28
B
Connector side console
Backhoes boom unlocking indicator lamp ........10, 22 switch pack .......................... 16, 18, 20, 22, 24, 28
Backhoes boom unlocking switch.....................10, 22 Connector side control panel ........................... 12, 16
Backhoes quick attach indicator lamp ....................10 Connectors............................................................... 5
Backhoes quick attach switch...........................10, 22
D
Backhoes switch...............................................30, 42
Battery ........................................................12, 36, 37 Daughter board ................ 8, 9, 24, 30, 31, 38, 40, 42
Battery cable negative ......................................36, 37 De-clutch transmission............................................. 8
Battery cable positive .......................................36, 37 De-clutch transmission switch.......... 6, 26, 30, 38, 42
Battery ignition relay ...............................................38 Differential lock solenoid ........................................ 38
Battery master switch .................................13, 36, 37 Differential lock switch ..................................... 27, 40
Battery relay .......................................................4, 12 Differential lock/4WD ............................................... 4
Battery relay coils .....................................................4 Differential locking pedal.......................................... 6
Battery relay ignition engine fault lamp...................13 Differential look solenoid........................................ 26
battery/ignition ........................................................29 Differential solenoid ............................................... 27
Boom ......................................................................33 Digger quick attach ................................................ 22
Boom solenoid..................................................32, 38 Digger quick attach relay ......................................... 4
Brake light relay............................................4, 26, 27 Diode........................................ 16, 18, 20, 22, 24, 26
Brake pedal ..............................................................6 Dip headlight relay ............................................. 4, 14
Brake pressure switch ......................................28, 38 Dip headlight relay left and right dip beam light ..... 15
Bucket.....................................................................33 Dipper .................................................................... 33
Bucket quick attach indicator lamp .........................22 Dipper solenoid ................................................ 32, 38
Bucket quick attach relay........................................23 Direction indicator lamp ............................... 7, 24, 25
Bucket quick attach solenoid ............................22, 38
E
Bucket solenoid ................................................32, 38
Earth strap ................................................. 36, 37, 38
C
Emergency............................................................... 9
Cab earth stud ........................................................37 Emergency stop switch ...................... 8, 9, 10, 32, 38
Cab harness ...........................................................40 Emergency switch.................................................. 33
Cab interior light .........................................28, 29, 40 Engine accelerator pedal ......................................... 6
Chassis harness ...............................................36, 37 Engine air filter pressure switch ....................... 12, 34
Chassis harness wiring...........................................38 Engine air filter pressure warning lamp.................. 10
Chassis/valve block harness ..................................38 Engine coolant maxi temperature .......................... 13
Cigar lighter ..............................4, 8, 9, 10, 28, 29, 40 Engine coolant temperature................................... 13
Cigar lighter harness ..............................................40 Engine coolant temperature gauge........................ 10
Clam .......................................................................33 Engine coolant warning lamp................................. 10
Clam solenoid...................................................32, 38 Engine fault warning lamp.................................. 7, 12
Clam switch ............................................................30 Engine harness ................................................ 34, 38
Clam valve switch...............................................8, 42 Engine harness wiring............................................ 34
Clamp .......................................................................4 Engine oil pressure ................................................ 13
Engine oil pressure switch ............................... 12, 34
Cre 7-26620GB Issued 10-99
4001-44
E F
Engine oil pressure warning lamp ..........................10 Fuse box .......................................................... 36, 37
Engine speed sensor........................................16, 38 Fuses ................. 4, 12, 14, 16, 18, 20, 22, 24, 26, 28
Engine stop solenoid ..................................12, 13, 34
G
Engine tachometer ...........................................10, 13
Engine water maxi temperature switch.............12, 34 Gear change lever ................................................... 6
Engine water temperature sensor ..........................34
H
Engine water temperature switch ...........................12
Enrich solenoid .........................................................4 Handbrake switch .................................... 8, 9, 27, 40
Enrichment solenoid ...................................12, 13, 34 Hazard enable relay................................................. 4
Hazard enable relay left turn indicator
F
front and rear light ............................................. 25
Float enable relay .........................................4, 24, 25 Hazard fusible relay ............................................... 24
Forward gearbox relay..................................4, 26, 27 Hazard light.............................................................. 4
Forward solenoid ..............................................26, 38 Hazard relay........................................................... 24
Forward/Reverse gearbox ........................................4 Hazard warning indicator lamp ........................ 10, 24
Forward/Reverse switch ...........................................6 Hazard warning switch..................................... 10, 24
Forward/reverse switch ......................................7, 26 Headlight harness .................................................. 40
Front and rear horn relay........................................19 Heater .......................................................... 4, 28, 40
Front and rear horn switch......................................19 Heater switch ................................................. 8, 9, 40
Front console............................................................7 Heater switch heater .............................................. 29
Front console harness ............................................40 HMU................................................. 4, 28, 29, 32, 38
Front console harness, side console Hose burst pressure switch.............................. 24, 25
harness and cab harness wiring ........................40 Hose burst relay............................................... 24, 25
Front console panel ............................6, 7, 14, 16, 28 Hose burst solenoid ......................................... 24, 25
Front console panel illumination .............................16 Hose-burst relay....................................................... 4
Front control panel..........................12, 24, 26, 30, 40 Hose-burts solenoid ............................................... 38
Front control panel Vbattery/ignition.......................29 Hourmeter .................................................... 7, 16, 17
Front drive axle indicator lamp .................................7 Hydraulic enable indicator lamp............................. 10
Front drive axle switch..............................................7 Hydraulic enable switch ......................................... 10
Front horn .....................................................4, 18, 38 Hydraulic oil filter pressure switch.................... 12, 38
Front horn relay ......................................................18 Hydraulic oil filter restriction ................................... 13
Front horn/rear horn relay.........................................4 Hydraulic oil filter warning lamp ............................. 10
Front light indicator lamp ........................................10 Hydraulic pump flow indicator lamp ....................... 10
Front screen wash indicator lamp.............................7 Hydraulic pump flow switch.............................. 10, 22
Front screen wiper indicator lamp ............................7
I
Front washer.............................................................4
Front washer indicator lamp ...................................18 Ignition relay coils .................................................... 4
Front washer pump motor ................................18, 38 Illumination instrument pack relay...................... 4, 14
Front washer relay........................................4, 18, 19 Illumination relay .................................................... 15
Front washer switch............................................7, 18 Indicator ................................................................. 14
Front wiper..........................................................4, 17 Indicator light............................................................ 4
Front wiper indicator lamp ......................................16 Indicator relay ........................................................ 25
Front wiper motor ...................................................40 Indicator switch ........................................ 6, 7, 24, 40
Front wiper relay.................................................4, 16 Indicator switch (4WD)........................................... 26
Front wiper switch...............................................7, 16 Indicator/hazard relay .............................................. 4
Front worklight ....................................................4, 21 Indicators flasher unit................................... 4, 24, 25
Front worklight indicator lamp.................................20 Indicators relay....................................................... 24
Front worklight relay ...........................................4, 20 Indicators switch ........................................ 15, 18, 25
Front worklight switch .......................................10, 20 Instrument pack illumination .............................. 4, 17
Fuel.........................................................................10 Instruments and controls front console ................ 6, 7
Fuel level ................................................................13 Instruments and controls side console........... 8, 9, 10
Fuel level gauge .....................................................10 Interior light .............................................................. 4
Fuel sender.......................................................12, 38
Fuel solenoid ............................................................4
Fuse........................................................................20
4008
TABLE OF CONTENTS
SPECIAL TOOLS ......................................................................................................................................................2
CALIBRATION...........................................................................................................................................................3
Mode type calibration ............................................................................................................................................3
Steering calibration ...............................................................................................................................................4
Loader calibration..................................................................................................................................................5
Loader bucket calibration ......................................................................................................................................6
Setup backhoe (Fermec 965 or Case 595LSP only).............................................................................................8
DIAGNOSIS...............................................................................................................................................................9
FLOW CHART FOR TEST CALIBRATION OF ELECTRONIC MACHINES...........................................................13
SPECIAL TOOLS
CD99G084
Diagnostic terminal (Part Nû 3621167M2)
O® Key on the diagnostic tester will abort any monitor mode and proceed to the next step
Shift ? Press Shift release and press ? if any of the following occur.
Once the diagnostic terminal is plugged into the 5 pin test point, in certain circumstances the display
screen may be blank. By pressing key Shift then ? it will initiate the terminal to the front screen which
displays the version of sofware present in the HMU and daughter board.
Whilst at any stage of monitor or calibration pressing Shift then ? on the keyboard of the diagnostic ter-
minal will initiate the terminal to revert to the front screen.
CALIBRATION
Mode type calibration 10. The terminal display will show :
Calibrate ?
ÒYÓ or ÒNÓ
NOTE : If N is selected, the diagnostic terminal will go
to monitor steering, see page 9.
Press Y on the diagnostic terminal.
Steering calibration
1. Carry out steps 1 to 12 on page 3. 7. The terminal display will show :
2. The terminal display will show : Use RH joystick
CAL.Steering & steer wheel to
ÒYÓ or ÒNÓ set axles RIGHT
type ÒYÓ or ÒNÓ
NOTE : If N is selected, the diagnostic terminal will
go to Calibrate loader, see page 5. NOTE : If N is selected, the diagnostic terminal will
go to Calibrate loader, see page 5.
Press Y on the diagnostic terminal.
Use the right joystick to turn the rear wheels and
3. The terminal display will show : the steering wheel to turn the front wheels com-
Make sure that pletely to the right. Hold the controls in this posi-
steer mode is tion. Press Y on the diagnostic terminal.
set to 2WS & 8. The terminal display will show :
HYD Enable is ON
NOTE : This display will only appear on the screen if
Place the steering mode selector in 2WS mode. there is a problem in the steering circuit.
Parameters saved
in HMU
Loader calibration
1. Carry out steps 1 to 12 on page 3. 5. The terminal display will show :
2. The terminal display will show : Set Loader to
CAL. Steering max height
ÒYÓ or ÒNÓ type ÒYÓ or ÒNÓ
NOTE : If Y is selected, the diagnostic terminal will go NOTE : If N is selected, the diagnostic terminal will
to Calibrate steering, see page 4. go to Calibrate bucket, see page 6.
Press N on the diagnostic terminal. Use the right joystick to raise the loader arm to
maximum raised position. Press Y on the diagnos-
3. The terminal display will show : tic terminal.
CAL. Loader 6. The terminal display will show :
ÒYÓ or ÒNÓ
Set Loader to
NOTE : If N is selected, the diagnostic terminal will go max depth posn
to Calibrate bucket, see page 6. type ÒYÓ or ÒNÓ
Press Y on the diagnostic terminal. NOTE : If Y or N are selected, the diagnostic terminal
4. The terminal display will show : will go to Calibrate bucket, see page 6.
Right joystick Use the right joystick to lower the loader arm to
is neutral ? maximum lowered position. Press Y on the diag-
type ÒYÓ or ÒNÓ nostic terminal, the loader calibration is completed.
MOVING
Front bucket
To start type Y
& WAIT !!
NOTE : If Y is selected, the diagnostic terminal will go With the left joystick in neutral position, press Y on
to Calibrate steering, see page 4. the diagnostic terminal.
8. The terminal display will show :
Press N on the diagnostic terminal.
3. The terminal display will show : ISO Backhoe ?
type
CAL. Loader ÒYÓ or ÒNÓ
ÒYÓ or ÒNÓ
European community (EEC) conÞguration, Press Y
NOTE : If Y is selected, the diagnostic terminal will go on the diagnostic terminal.
to Calibrate loader, see page 5.
Non-European community (Non-EEC) conÞgura-
Press N on the diagnostic terminal. tion, Press N on the diagnostic terminal.
4. The terminal display will show : 9. the terminal display will show :
CAL. Bucket Save Backhoe ?
ÒYÓ or ÒNÓ type
ÒYÓ or ÒNÓ
NOTE : If Y is selected, the diagnostic terminal will go
to Calibrate loader bucket, see page 6. NOTE : If N is selected, the diagnostic terminal will
Press N on the diagnostic terminal. return to Calibrate, see page 3.
5. If the loader bucket is calibrated, the terminal Press Y on the diagnostic terminal.
display will show : 10. The terminal display will show :
Save Loader Cal ? Parameters saved
type in HMU
ÒYÓ or ÒNÓ
After 3 beeps, the setup calibration procedure is
NOTE : If Y is selected, the diagnostic terminal will completed.
save the parameters in the HMU, see page 7, Step
11.
Press N on the diagnostic terminal.
6. The monitor display will show :
SETUP Backhoe ?
ÒYÓ or ÒNÓ
DIAGNOSIS
1. Carry out steps 1 to 12 on page 3. Monitor loader diagnosis
2. The terminal display will show : 5. The terminal display will show :
Calibrate ? Monitor
ÒYÓ or ÒNÓ LOADER
ÒYÓ or ÒNÓ
NOTE : If Y is selected, the diagnostic terminal will go
to Calibrate, see page 3, Step 9. NOTE : If N is selected and :
Press N on the diagnostic terminal. - the model is a Fermec 965 or Case 595LSP,
the terminal will go to Monitor left joystick
Monitor steering diagnosis diagnosis, see Step 7.
3. The terminal display will show : - The model is a Fermec 960 or Case
595SLE, the terminal will go to Monitor right
Monitor joystick diagnosis, see Step 9.
STEERING
Press the hydraulic enable switch and press Y on
ÒYÓ or ÒNÓ
the diagnostic terminal.
NOTE : If N is selected, the diagnostic terminal will go 6. The terminal display will show :
to Monitor loader diagnosis, see Step 5.
/ 620
Press the hydraulic enable switch and press Y on 413/
the diagnostic terminal. / ÷
4. The terminal display will show :
NOTE : Change these values, using the right joystick
2WS Steer mode and check that the data displayed corresponds to the
480 I I 480 values given in note 2 on page 12.
480 I I 480 If this is not the case:
- Calibrate the loader arm, if this has not
NOTE : Change these values, using the steering already been done, see page 5.
wheel and the steering mode selector and check that - If loader arm calibration has already been
the date displayed corresponds to the values given in carried out, repair or replace the defective
note 1 on page 11. component(s) in the circuit concerned.
If this is not the case: Calibrate once the circuit is operative.
- Calibrate the steering, if this has not already
been done, see page 4. Key :
- If steering calibration has already been
< Bucket level ^ Bucket mode
carried out, repair or replace the defective
component(s) in the circuit concerned. = Fork mode ÷ Float
Calibrate once the circuit is operative.
Press button O ®
Press button O ® to go to Monitor loader diagno-
If the model is a Fermec 960 or Case 595LE, the
sis.
diagnostic terminal will display ÒMonitor left joy-
stickÓ, see step 7.
If the model is a Fermec 965 or Case 595LSP, the
diagnostic terminal will display ÒMonitor right joy-
stickÓ, see step 9.
CS99G515 CS99G515
Steering Steering
Fully Anti-clockwise Fully Anti-clockwise
CS99G517 CS99G517
Steering Steering
Fully clockwise Fully clockwise
CS99G516 CS99G516
70
Y min
70
Y min
Y float
100
950 X min
X max 70 920
X rtd
X max X min
950 70
Y max Y max
950 950
CS99G518 CS99G519
LH JOYSTICK RH JOYSTICK
X MIN = 70 Y MIN = 70 X MIN = 70 Y MIN = 70
NEUTRAL = 72 NEUTRAL = 512 +/- 20 X RTD = 920 NEUTRAL = 512 +/- 20
X MAX = 950 Y MAX = 950 NEUTRAL = 512 Y FLOAT = 100
X MAX = 950 Y MAX = 950
TOLERANCE - 20 VALUES UNLESS OTHERWISE STATED
512
70 950
CS99G520
CLAM MIN = 70
CLAM MAX = 950
IF LOADER Y
ONLY
ENGLISH FRAN‚AIS DEUTSCH ESPANOL ITALIANO DANISH
? N ? N ? N ? N ? N ? N
ÒYÓ or ÒNÓ ÒOÓ or ÒNÓ ÒJÓ or ÒNeingebenÓ ÒSÓ o ÒNÓ ÒSÓ o ÒNÓ ÒSÓ o ÒNÓ
USE RH JOYSTICK & SET LOADER TO MAX SET BUCKET TO MAX KEY
N N KEY
STEER WHEEL TO SET HEIGHT POSN THEN DUMP POSN TYPE (*) T X DUMP
MACHINE IS N ÒYÓ or ÒNÓ KEY > SEAT FORWÕD
AXLES LEFT THEN TYPE # NEUTRAL SWITCH
N FERMEC 965 ÒYÓ or ÒNÓ < BUCKET LEVEL L SEAT DOWN
Y TYPE ACTIVE
ÒYÓ or ÒNÓ = FORK MODE < SEAT BACKWÕD
ÒYÓ or ÒNÓ Y ^ BUCKET MODE ^ SEAT UP
Y
Y
SET BUCKET TO MAX
N
LEFT JOYSTICK IS
CENTRAL TYPE
÷ FLOAT * OVERRIDE
# NEUTRAL SWITCH
Waiting for SET LOADER TO MAX CROWD POSN TYPE
Y N ÒYÓ or ÒNÓ ACTIVE
HMU DEPTH POSN THEN ÒYÓ or ÒNÓ
USE RH JOYSTICK & TYPE Y N
N STEER WHEEL TO SET ÒYÓ or ÒNÓ
AXLES RIGHT THEN Y
N Checking HMU is set to TYPE ISO BACKHOE ? SAVE BACKHOE
SET BUCKET TO LEVEL N
correct machine ÒYÓ or ÒNÓ TYPE ÒYÓ or ÒNÓ
Y POSN TYPE
ÒYÓ or ÒNÓ ÒYÓ or ÒNÓ
Y
Y Y Y
Y
USE RH JOYSTICK &
STEER WHEEL TO MOVING FRONT PARAMETERS SAVED
N
ALIGN F/R WHEELS BUCKET TO START N IN HMU (3 BEEPS)
THEN TYPE TYPE
ÒYÓ or ÒNÓ ÒYÓ & WAIT !!
NOTE : Calibration of the loader (and rear wheel steering of electronic machines) must be
Y Y carried out with the engine running (1200 rpm). The loader requires raising to maximum
N SAVE STEERING TYPE WAIT FOR HMU
height. Ensure that there is sufÞcient headroom and that it is safe to operate the loader
ÒYÓ or ÒNÓ (3 BEEPS) before starting the engine.
Y Y
Y
PARAMETERS SAVED
IN HMU (3 BEEPS)
8 002
8002
TABLE OF CONTENTS
SPECIFICATIONS .............................................................................................................................................. 3
SPECIAL TOOLS................................................................................................................................................ 3
TROUBLESHOOTING PROCEDURES ............................................................................................................. 4
General .......................................................................................................................................................... 4
Fault warning alarms ................................................................................................................................... 6
Loader or backhoe service does not work ................................................................................................ 8
Loader or backhoe service operates slowly ............................................................................................. 9
Controls operate slowly ............................................................................................................................ 10
Accumulator loses pressure rapidly when the engine is switched off................................................. 10
Return to dig function does not work ...................................................................................................... 10
Loader bucket self-level malfunction ...................................................................................................... 11
DECOMPRESSING THE HYDRAULIC SYSTEM (on the control valves) ..................................................... 12
DECOMPRESSING THE HYDRAULIC SYSTEM (using the control levers) ................................................. 13
595SLE type ................................................................................................................................................ 13
595LSP type ................................................................................................................................................ 13
RELIEF VALVE TESTS .................................................................................................................................... 15
PUMP TEST ..................................................................................................................................................... 17
BACK PRESSURE VALVE PRESSURE TEST............................................................................................... 18
CHECKING THE SYSTEM FOR OPTIONAL RIDE CONTROL ...................................................................... 19
HYDRAULIC PUMP.......................................................................................................................................... 21
STEERING CONTROL VALVE ....................................................................................................................... 22
LOADER CONTROL VALVE .......................................................................................................................... 23
BACKHOE CONTROL VALVE ....................................................................................................................... 24
595SLE ....................................................................................................................................................... 24
BACKHOE CONTROL VALVE ...................................................................................................................... 25
595LSP ...................................................................................................................................................... 25
HYDRAULIC CIRCUIT DESCRIPTION .......................................................................................................... 26
595SLE-595LSP BACKHOE LOADER HYDRAULIC SCHEMATIC............................................................. 27
SPECIFICATIONS
All machines
Hydraulic oil speciÞcation ...........................................................................................................................DIN 51524
Hydraulic oil viscosity
- below 30 °C (86 °C ).......................................................................................................................System ISO VG46
- above 30 °C (86 °C) .........................................................................................................................................ISO 68
Hydraulic reservoir capacity ........................................................................................................................... 45 litres
Hydraulic pump outlet pressure
- outer section ( 80 l/mn)..................................................................................................................................190 bar
- inner section (80 l /mn)..................................................................................................................................225 bar
Brake booster pump
- Engine idling....................................................................................................................................................12 bar
- Engine at 2200 rpm .........................................................................................................................................16 bar
All machines
Unloader valve operating pressure.......................................................................................................207 to 214 bar
Back pressure valve pressure
- engine idling ...........................................................................................................................................34 to 35 bar
- engine at 2200 rpm ................................................................................................................................49 to 50 bar
Electrica calibration of the machine (see section 4008)
Brake booster pump (see section 7000)
SPECIAL TOOLS
Pressure gauge 0 to 50 bar.
Pressure gauge 0 to 100 bar.
Pressure gauge 0 to 300 bar .
Adaptator to replace a circuit relief valve
Flow meter
Gate valve and hose
Slave joystick
Elektron diagnostic terminal
TROUBLESHOOTING PROCEDURES
General
Check the machine for oil leaks and damaged or missing parts. Repair as required.
(595LSP and 595SLE)
With all controls in neutral, does the engine seem Continue with the procedure.
slightly loaded ? NO
YES
With a fully charged battery and single pump Continue with the procedure.
operation selected does the starter motor lack
power ? NO
YES
With the machine idling, is the hydraulic oil hotter Continue with the procedure.
than expected ? NO
YES
Is the oil cooler free from external obstructions ? Remove the obstructions.
NO
YES
With all the controls in neutral, can the main relief Troubleshooting procedure complete.
valve be heard operating ? NO
YES
With the bucket empty, raise the loader. Does the Troubleshooting procedure complete.
relief valve stop operating until maximum height
is reached ? NO
YES
The load sensing valve is stuck in the closed Fill the hydraulic reservoir with the oil
position and Òdead heads Ó the pump whenever speciÞed in section 1002.
NO
the spools are in neutral. Replace the load
sensing valve. Is the oil in the hydraulic reservoir
at the correct level ?
YES
Are the hydraulic hoses connected correctly ? Connect hoses in accordance with the
NO hydraulic schematic.
YES
Has the emergency stop button been reset ? Twist the emergency stop button to
NO reset the hydraulic system.
YES
Has the hydraulics enable switch been set to on ? Set the hydraulics enable switch to on.
NO
YES
Did the green light in the hydraulics enable switch Replace the bulb in the hydraulics
come on ? enable switch.
NO
YES
(595LSP only)
Is the green light in the hydraulics enable switch Continue with the procedure.
ßashing twice per second ? NO
YES
Is the driver sat in the seat ? The warning is given if the driver is
NO not seated.
YES
Has the light stopped ßashing ? Replace the seat pressure switch.
NO
YES
YES
Do the input signal test as detailed in this section. Do the calibration procedures
Are the input signals correct ? NO detailed in this section
YES
Did the fault warning alarm give a single Continue with the procedure.
ÒbeepÓ ? NO
YES
The seat is not properly locked in an operating Replace the seat position switches.
position. Move the seat forward until it locks. NO
The seat shoult not swivel. Has the single
ÒbeepÓ fault warning alarm stopped ?
YES
There is a fault in the loader bucket levelling Call your Service department
system. Check the wiring, the connectors and NO immediately and describe the symptoms
the potentiometers on the bucket linkage and that you have found. The machine must
the beam pivot, for damage. Are any of the not be operated until the fault has been
components damaged ? corrected.
YES
Did the fault warning alarm give three ÒbeepÓ ? Continue with the procedure.
NO
YES
(595SLE only)
There is faulty joystick signal. It is dangerous to Do not operate the machine.
operate the machine with this fault. Call your NO
Service department immediately and describe
the symptoms that you have found. The
machine must not be operated until the fault
has been corrected. Has the fault been
corrected ?
YES
The fault is in the left joystick. Call your Do not operate the machine
Service department immediately and NO
describe the symptoms that you have found.
The machine must be operated until the fault
has been corrected. Has the fault been
corrected ?
YES
Did the fault warning alarm give Þve ÒbeepsÓ ? Continue with the procedure.
NO
YES
There is a fault in the steering harness. Refer to Call your Service department
the troubleshooting procedures contained in NO immediately and describe the
Section 5001 of this manuel. Has the Þve ÒbeepÓ symptoms that you have found. The
fault warning alarm stopped ? machine must not be operated until the
fault has been corrected.
YES
Did the blue warning light on the side console Continue with the procedure.
come on ? NO
YES
The loader bucket is in ßoat mode. De-select ßoat Remove the loader valve assembly
mode, has the blue warning light gone out ? NO and replace the bucket spool.
YES
(595LSP only)
Did the fault warning alarm give a continuous Continue with the procedure
ÒbeepÓ ? NO
YES
The manual override switch is selected. Replace or repair the manuel override
Release the manual override switch. Has the NO switch
continuous ÒbeepÓ stopped ?
YES
Stop the engine and use the manual operation Remove the loader valve assembly or
lever to move the spool of the non-functioning NO the backhoe valve assembly and
service. Does the spool move freely without replace the non-functioning spool.
ÒjammingÓ.
YES
Start the engine and use the manual operation Operate the loader bucket at the
lever to move the spool of the non-functioning NO same time as the non-functioning
service. Does the service work using the manual service. Does the service work ?
operation lever ?
NO
NO
Fit the slave joystick to the spool of the non- The fault is hydraulic. Do the servo
functioning service and do the signal path test as NO pressure test as detailed in this
detailed in this section. Does the service work using section. Does the service work ?
the slave joystick ?
NO
The fault is electrical. Do the output signal test Check the wiring and the connectors to
as detailed in this section. is there a signal NO the spool of the non-functioning service.
voltage ?
YES
Do the input signal test as detailed in this Do the calibration procedures as detailed
section. Are the input signals correct ? NO in Section 4008.
YES
YES
Do the unloader valve pressure test as detailed in Replace the unloader valve as
this section. Is the unloader valve serviceable ? NO detailed in the Service Manual.
YES
YES
Operate the dipperstick, the bucket and the Continue with the procedure.
boom together. Is the delay longer ? NO
YES
The accumulator check valve is partially closed. Service the servo valve as detailed
Do the servo pressure test as detailed in this NO in the Service Manual.
section. Does the service operate correctly ?
YES
YES
Do the input signal test as detailed in this Continue with the procedure.
section. Do the signals need calibrating ? NO
YES
YES
Do the back pressure valve pressure test as Replace or repair the back pressure valve
detailed in this section. Is the back pressure NO as detailed in the Service Manual.
valve serviceable ?
YES
Does the return to dig function work correctly ? Call your Service department
NO immediately and describe the symptoms
that you have found. The machine must
YES
not be operated untill the fault has been
corrected.
Troubleshooting procedure complete.
YES
Does self-levelling begin when the loader bucket Continue with the procedure.
is higher than 1,2 m from the ground ? NO
YES
Recalibrate or replace the potentiometer. Is the Call your Service department immediatly
self-level function operating correctly ? NO and describe the symptoms that you have
found. The machine must not be operated
YES until the fault has been corrected.
Does the material spill backwards out of the Continue with the procedure.
bucket as it is raised ? NO
YES
Does the self-levelling begin when the loader Continue with the procedure.
bucket is lower than 1.2 m from the ground ? NO
YES
Recalibrate or replace the potentiometer. Is the Call your Service department immediately
NO
self-level funtion operating correctly ? and describe the symptoms that you have
found. The machine must not be operated
YES until the fault has been corrected.
3
CI98J518
CS98J538
CD99E021 CP99D009
Turn the starter switch key to "On" position and press Turn the starter switch key to "On" position and press
the hydraulic enable switch to enable the system. the hydraulic enable switch.
Place the loader control lever in ßoat position, then
operate the lever from left to right several times to STEP 4
release the hydraulic pressure.
STEP 4
CK99E013
STEP 5
With backhoe attachment
CK99E010
CP99E004
CS98J539
CS98J540
Cre 7-26630GB Issued 10-99
8002-16
To adjust the pilot valve, remove the black plastic cap, 17. Partially select the boom lever to raise the boom
and using a 6 mm Allen key, adjust the pressure. to to maximum height. It will be found that the
increase the pressure turn the Allen key clockwise, to pressure registered on the gauge will gradually
reduce the pressure, turn the Allen key anti- increase until a point is reached where the gauge
clockwise. needle drops to zero. This point is where the
unloader valve operates.
NOTE : If the pressure cannot be adjusted to 225 bar
it indicates that the inlet compensator housed in the 18. The correct operating pressure of the unloader
inlet module is not allowing full pressure to build up in valve is 207 ± 7 bar.
0
the cylinder. Any such cases should be notiÞed to the 19. If the unloader valve operates outside the above
Service Department. Having carried out steps 2 to 7 limits, the unloader relief valve capsule must be
the inner pump, the inlet compensator and the main replaced.
relief valve for the hydraulic system have been
20. Having checked the unloader valve, the engine
checked.
must be stopped, the gauge, hose and adaptor
9. Stop the engine, relieve hydraulic pressure, removed and the blanking plug fitted.
remove the pressure checking gauge, hose and
21. Refit the pump guard, start the engine and lift the
adaptor and refit the seal, union and feed pipe for
loader to maximum height and remove the safety
the backhoe clamp, (Sideshift machines) and the
support strut.
plug (Centermount machines).
10. Start the engine, raise the loader to maximum
height and fit the safety support strut.
11. Remove the pump guard.
12. With the engine stopped, fit adaptor from the
pressure test kit into the unloader valve pressure
checking point closest to the pump body.
13. Attach the hydraulic test hose and 0-400 bar
pressure gauge to the adaptor.
14. Start the engine and set the RPM at 1800 on the
hand throttle.
15. Select fast mode (dual pump flow) on the side
console switch.
16. Raise the backhoe boom to within 15 cm of
cylinder rod, from itÕs maximum height.
PUMP TEST
1. Park the machine on a level surface. 14. Connect the pressure gauge to the test port (5)
2. Work the machine until the temperature of the M10x100 on the underside of the unloader valve
hydraulic oil is 50 °C. (6) fitted on the pump (2).
3. Raise the loader beam and install the safety strut 15. Start the engine and run it at 2200 rpm.
and stop the engine. 16. Check that the pump outlet pressure and flow
4. Depressurize the hydraulic system. are correct. Refer to page 3.
5. Remove the pump guard. 17. If the pump flow rate is less than the minimum
flow rate specified, replace the pump.
6. Connect the flow meter to the outlet port (1) of
the inner (80 l/mn) section of the hydraulic pump. 18. Slowly raise the loader beam against the cylinder
internal cushioning. This will raise the system
7. Connect the pressure gauge to the test point pressure until the unloader valve operates.
M10x100 (3) in the pump outlet piping.
19. Record the unloader valve operating pressure.
8. Start the engine and run it at 2200 rpm.
20. When the unloader valve operates, check that
9. Check that the pump outlet pressure and flow the pump outlet pressure is 0 to 5 bar and that
are correct. Refer to page 3. the outlet flow is 0 litre/min.
10. If the pump flow rate is lees than the minimum 21. Check that the unloader valve operating
flow rate specified, replace the pump. pressure is correct. Refer to page 3.
11. Stop the engine and depressurize the system. 22. If the unloader valve operating pressure is
12. Remove the pressure gauge and the flow meter outside the specified limits, replace the unloader
from the inner section of the pump. valve.
13. Connect the flow meter to the outlet port (4) of 23. Slowly increase the pressure to 175 bar and
the outer (80 l/mn) section of the hydraulic pump. check that the minimum flow rate for the outer
section of the pump has been restored. Refer to
page 3.
24. Install the pump guard.
6 2
4
2
5
6
CI98J522
2
1
CI98G504
1. Backhoe valve
2. Pressure gauge
3. Tee
1
2
5
3
CI99G505
HYDRAULIC PUMP
1. Rear section
2. Front section
3 6 3 2
3. Outlet
4. Inlet
5. Drive shaft
6. Coupling
1
4
CS98J543
4
2
3
2
1
8
2
7
6
5
CI99G503
LS
T P
3
R L
CM99G007
T2 A B C D E F G H
4
PP
7
2 T1
L.S.
3 1
P
5
CM99G004
3 2
L.S. P2
155b
190b
240b
P
*
N
190b
M
L
K
J
280b
CM99G008
H
280b
G
1. Inlet
265b
2. Anticavitation valve
F
280b
3. Circuit relief valve
E
4. Regeneration valve
310b 5. Full flow relief valve
6. Relief valve pilote valve
D
240b
C
7. Compensation valve
240b
A-B. To slew cylinders
C-D. To boom cylinder
B
240b
A
PP
G-H. To bucket cylinder
J-K. To stabilizer cylinder
L-M. To stabilizer cylinder
N-P. To hammer or auxilliary cylinder
1
T2 * Remove the forced feed valve when using the
hydraulic hammer option.
16b 225b 5 50b
NOTE : For correct identiÞcation and in the interests
7 6 4 of safety the corresponding pressure setting is
CM99G005
engraved on the side of each valve.
L.S. P2
155b
190b
P
* 240b
N
190b
M
L
K
J
280b
CM99G008
1. Inlet
H
280b
G
2. Anticavitation valve
265b 3. Circuit relief valve
4. Regeneration valve
F
280b
E
7. Compensation valve
D
240b
8. Pilot pressure valve
C
240b
E-F. To dipper cylinder
A
Legend
38 33
LS
P T P
43 ∆ N
22
D B
M
P HPCO
9 L
C A 23
D B 2
10
K 31 M
J
5
C A 34
24 11
44 ∆
R L
1
37
16 H
G
25
17
F
32
18 12 13 14 8
E N2
26
3
C V
A B C D E F G H
D T2
C
∆ 27
PP
45
S
6 B
7
PP 30
PP
P 28 29 35
21 * 20
P T1
P T
46 * C T1 L.S.
P2
T2 P
T
C 47 39 40 41 42
CM99E004