Case 580T 580ST 590ST 695ST Backhoe Loaders Official Workshop Service Repair Manual

SECTION 00 – SAFETY RULES
FOREWORD………………………………………………………………………………………………………………………………….. 4
SAFETY INSTRUCTIONS……………………………………………………………………………………………………………….. 6
PREVENTION OF FIRE OR EXPLOSIONS……………………………………………………………………………………….. 8
PREVENTION OF BURNS………………………………………………………………………………………………………………. 9
PRECAUTIONS FOR WASTE DISPOSAL……………………………………………………………………………………….. 10
SECTION 01 – MAINTENANCE
SECTION 02 – TECHNICAL SPECIFICATIONS
MODELS……………………………………………………………………………………………………………………………………….. 3
IDENTIFICATION OF MAIN COMPONENTS……………………………………………………………………………………… 4
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………………….. 6
TRANSMISSION………………………………………………………………………………………………………………………… 6
AXLES ……………………………………………………………………………………………………………………………………… 7
BRAKES …………………………………………………………………………………………………………………………………… 8
STEERING………………………………………………………………………………………………………………………………… 8
HYDRAULIC SYSTEM ……………………………………………………………………………………………………………….. 9
FRONT COUNTERWEIGHT ……………………………………………………………………………………………………….. 9
NOISE AND VIBRATION LEVELS ……………………………………………………………………………………………… 10
BUCKETS……………………………………………………………………………………………………………………………….. 10
TYRES……………………………………………………………………………………………………………………………………. 11
DIMENSIONS AND PERFORMANCE……………………………………………………………………………………………… 12
DIMENSIONS – 2WS SIDESHIFT ………………………………………………………………………………………………. 12
DIMENSIONS – 2WS SIDESHIFT SLA (“STRAIGHT LOADER ARM”……………………………………………… 13
DIMENSIONS – 4WS SIDESHIFT ………………………………………………………………………………………………. 14
DIMENSIONS – 4WS CENTER PIVOT………………………………………………………………………………………… 15
LOADER ATTACHMENT PERFORMANCE…………………………………………………………………………………. 16
PERFORMANCE OF LOADER BUCKET WITH FORKS……………………………………………………………….. 19
BACKHOE ATTACHMENT PERFORMANCE………………………………………………………………………………. 21
MAXIMUM LIFTING LOADS…………………………………………………………………………………………………………… 24
LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE ………………………………………………………… 24
BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ……………………………………………………… 25
SUPPLY SUMMARY TABLE………………………………………………………………………………………………………….. 26
SECTION 10 – ENGINE
ENGINE INSTALLATION…………………………………………………………………………………………………………………. 3
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………………….. 4
72kW – HP ENGINE (580T) …………………………………………………………………………………………………………. 4
72kW – HP ENGINE (580ST)……………………………………………………………………………………………………….. 5
82kW – HP ENGINE (590ST – 695ST) …………………………………………………………………………………………… 6
SECTION 21 – TRANSMISSION
POWERSHUTTLE TRANSMISSION…………………………………………………………………………………………………. 3
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………… 4
CONTROLS ………………………………………………………………………………………………………………………………. 9
LUBRICATION…………………………………………………………………………………………………………………………. 13
GREASING ……………………………………………………………………………………………………………………………… 16
REMOVAL FROM MACHINE …………………………………………………………………………………………………….. 18
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………. 19
TROUBLESHOOTING…………………………………………………………………………………………………………….. 144
REPAIR TIMES………………………………………………………………………………………………………………………. 148
SPECIAL TOOLS……………………………………………………………………………………………………………………. 149
POWERSHIFT TRANSMISSION…………………………………………………………………………………………………… 150
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………….. 150
CONTROLS …………………………………………………………………………………………………………………………… 161
LUBRICATION……………………………………………………………………………………………………………………….. 163
GREASING ……………………………………………………………………………………………………………………………. 165
REMOVAL FROM MACHINE …………………………………………………………………………………………………… 166
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………….. 167
TROUBLESHOOTING…………………………………………………………………………………………………………….. 331
REPAIR TIMES………………………………………………………………………………………………………………………. 335
SPECIAL TOOLS……………………………………………………………………………………………………………………. 336
SECTION 25 – FRONT AXLE
2WD – 2WS FRONT AXLE……………………………………………………………………………………………………………….. 3
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………… 3
LUBRICATION AND GREASING …………………………………………………………………………………………………. 4
REMOVAL FROM MACHINE ………………………………………………………………………………………………………. 6
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………… 7
TROUBLESHOOTING………………………………………………………………………………………………………………… 7
4WD – 2WS FRONT AXLE……………………………………………………………………………………………………………… 10
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………. 10
LUBRICATION AND GREASING ……………………………………………………………………………………………….. 11
REMOVAL FROM MACHINE …………………………………………………………………………………………………….. 13
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………. 14
TROUBLESHOOTING………………………………………………………………………………………………………………. 57
SPECIAL TOOLS……………………………………………………………………………………………………………………… 61
4WS FRONT AXLE……………………………………………………………………………………………………………………….. 62
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………. 62
LUBRICATION AND GREASING ……………………………………………………………………………………………….. 63
REMOVAL FROM MACHINE …………………………………………………………………………………………………….. 65
SECTION 27 – REAR AXLE
2WS REAR AXLE (580T – 580ST)…………………………………………………………………………………………………….. 3
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………… 3
LUBRICATION AND GREASING …………………………………………………………………………………………………. 5
REMOVAL FROM MACHINE ………………………………………………………………………………………………………. 7
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………… 8
TROUBLESHOOTING………………………………………………………………………………………………………………. 61
REPAIR TIMES………………………………………………………………………………………………………………………… 67
SPECIAL TOOLS……………………………………………………………………………………………………………………… 68
2WS REAR AXLE (590ST) …………………………………………………………………………………………………………….. 69
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………. 69
LUBRICATION AND GREASING ……………………………………………………………………………………………….. 71
REMOVAL FROM MACHINE …………………………………………………………………………………………………….. 73
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………. 74
TROUBLESHOOTING…………………………………………………………………………………………………………….. 127
REPAIR TIMES………………………………………………………………………………………………………………………. 133
SPECIAL TOOLS……………………………………………………………………………………………………………………. 134
4WS REAR AXLE (695ST) …………………………………………………………………………………………………………… 135
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………….. 135
LUBRICATION AND GREASING ……………………………………………………………………………………………… 138
REMOVAL FROM MACHINE …………………………………………………………………………………………………… 140
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………….. 141
TROUBLESHOOTING…………………………………………………………………………………………………………….. 219
REPAIR TIMES………………………………………………………………………………………………………………………. 225
SPECIAL TOOLS……………………………………………………………………………………………………………………. 227
SECTION 33 – BRAKE SYSTEM
PARKING BRAKE…………………………………………………………………………………………………………………………… 3
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………… 3
OPERATION……………………………………………………………………………………………………………………………… 3
ADJUSTMENT…………………………………………………………………………………………………………………………… 4
MECHANICAL PARKING BRAKE ADJUSTMENT PROCEDURE…………………………………………………….. 5
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………… 6
SERVICE BRAKE…………………………………………………………………………………………………………………………. 15
OPERATION……………………………………………………………………………………………………………………………. 15
BRAKE BLEEDING PROCEDURE……………………………………………………………………………………………… 16
BRAKE PEDALS FUNCTIONALITY CHECK ……………………………………………………………………………….. 17
SECTION 35 – HYDRAULIC SYSTEM
HYDRAULIC DIAGRAMS ………………………………………………………………………………………………………………… 3
HYDRAULIC DIAGRAM – 2WS SIDESHIFT MECHANICAL MODELS………………………………………………. 3
HYDRAULIC DIAGRAM – 2WS SIDESHIFT PILOT MODELS ………………………………………………………….. 9
HYDRAULIC DIAGRAM – 4WS SIDESHIFT MECHANICAL MODELS…………………………………………….. 11
HYDRAULIC DIAGRAM – 4WS SIDESHIFT PILOT MODELS ………………………………………………………… 13
HYDRAULIC DIAGRAM – 4WS CENTER PIVOT PILOT MODELS …………………………………………………. 15
HYDRAULIC PUMP………………………………………………………………………………………………………………………. 17
HYDRAULIC FIXED-FLOW-RATE GEAR PUMP………………………………………………………………………….. 17
HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP…………………………………………………………………. 28
CONTROL VALVES………………………………………………………………………………………………………………………. 43
LOADER CONTROL VALVE ……………………………………………………………………………………………………… 52
BACKHOE ATTACHMENT CONTROL VALVE…………………………………………………………………………….. 56
RELIEF VALVES………………………………………………………………………………………………………………………. 68
BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE ………………………………………….. 77
ACCUMULATOR “GLIDE RIDE” PARKER……………………………………………………………………………………….. 80
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………. 80
MAINTENANCE……………………………………………………………………………………………………………………….. 80
SAFETY ………………………………………………………………………………………………………………………………….. 80
CHECKING AND ADJUSTING THE PRECHARGE PRESSURE ……………………………………………………. 81
HYDRAULIC SWING SYSTEM ………………………………………………………………………………………………………. 83
OPERATION……………………………………………………………………………………………………………………………. 83
HYDRAULIC CYLINDERS……………………………………………………………………………………………………………… 86
LOADER ATTACHMENT BOOM CYLINDER……………………………………………………………………………….. 87
LOADER BUCKET CYLINDER…………………………………………………………………………………………………… 93
4X1 LOADER BUCKET CYLINDER……………………………………………………………………………………………. 97
BACKHOE BOOM CYLINDER …………………………………………………………………………………………………. 100
BACKHOE ATTACHMENT DIPPER CYLINDER ………………………………………………………………………… 104
BACKHOE BUCKET CYLINDER………………………………………………………………………………………………. 108
TELESCOPIC CYLINDER……………………………………………………………………………………………………….. 112
STABILIZER CYLINDER – CENTER PIVOT (695ST)…………………………………………………………………… 115
STABILIZER CYLINDER – SIDESHIFT ……………………………………………………………………………………… 119
SWING CYLINDER…………………………………………………………………………………………………………………. 123
BACKHOE ATTACHMENT LOCK CYLINDER – SIDESHIFT ………………………………………………………… 127
SPECIAL TOOLS……………………………………………………………………………………………………………………. 128
HYDRAULIC CONTROL LEVERS…………………………………………………………………………………………………. 129
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………….. 129
CONTROLS AND OPERATION ……………………………………………………………………………………………….. 130
COMPONENTS ……………………………………………………………………………………………………………………… 131
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………….. 133
CONTROL LEVER VALVE ………………………………………………………………………………………………………. 136
TROUBLESHOOTING …………………………………………………………………………………………………………………. 138
PRELIMINARY CHECKS…………………………………………………………………………………………………………. 138
TROUBLESHOOTING (WITH “REXROTH” CONTROL VALVES)…………………………………………………. 139
SWING………………………………………………………………………………………………………………………………….. 141
HYDRAULIC PUMP………………………………………………………………………………………………………………… 142
SECTION 39 – CHASSIS
DESCRIPTION ………………………………………………………………………………………………………………………………. 3
REMOVAL AND INSTALLATION OF COMPONENTS ………………………………………………………………………… 6
COMPONENTS WITHIN THE CHASSIS ………………………………………………………………………………………. 9
COMPONENTS OF THE LOWER PART OF THE CHASSIS …………………………………………………………… 7
COMPONENTS ATTACHED OUTSIDE THE CHASSIS………………………………………………………………… 11
COMPONENTS OF THE UPPER PART……………………………………………………………………………………… 12
SECTION 41 – STEERING SYSTEM
DESCRIPTION ………………………………………………………………………………………………………………………………. 3
2WS STEERING SYSTEM………………………………………………………………………………………………………………. 4
4WS STEERING SYSTEM………………………………………………………………………………………………………………. 7
POWER STEERING……………………………………………………………………………………………………………………… 11
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………. 11
COMPONENTS ……………………………………………………………………………………………………………………….. 13
DISASSEMBLY………………………………………………………………………………………………………………………… 15
ASSEMBLY……………………………………………………………………………………………………………………………… 18
SECTION 50 – CAB HEATING AND AIR CONDITIONING
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………………….. 3
GENERAL…………………………………………………………………………………………………………………………………. 3
CAB HEATING……………………………………………………………………………………………………………………………….. 5
CONTROLS………………………………………………………………………………………………………………………………. 5
OPERATION……………………………………………………………………………………………………………………………… 6
AIR FLOW DIFFUSERS ……………………………………………………………………………………………………………… 7
OVERHAUL ………………………………………………………………………………………………………………………………. 9
TROUBLESHOOTING………………………………………………………………………………………………………………. 11
AIR CONDITIONING …………………………………………………………………………………………………………………….. 12
PRINCIPLES OF AIR CONDITIONING……………………………………………………………………………………….. 12
CONTROLS…………………………………………………………………………………………………………………………….. 17
OPERATION……………………………………………………………………………………………………………………………. 18
TROUBLESHOOTING AND TESTING………………………………………………………………………………………… 25
FLUSHING THE SYSTEM…………………………………………………………………………………………………………. 43
DRAINING THE SYSTEM …………………………………………………………………………………………………………. 45
CHARGING THE SYSTEM………………………………………………………………………………………………………… 46
OVERHAUL …………………………………………………………………………………………………………………………….. 47
COMPRESSOR……………………………………………………………………………………………………………………………. 52
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………. 52
REMOVAL AND INSTALLATION……………………………………………………………………………………………….. 53
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………. 56
TROUBLESHOOTING………………………………………………………………………………………………………………. 65
SECTION 55 – ELECTRIC SYSTEM
ELECTRIC DIAGRAMS …………………………………………………………………………………………………………………… 3
ELECTRIC DIAGRAMS – POWERSHUTTLE ROPS (580T mechanical engine) …………………………………. 3
ELECTRIC DIAGRAMS – POWERSHUTTLE CAB (580T – 580T SLA mechanical engine)…………………. 18
ELECTRIC DIAGRAMS – POWERSHUTTLE CAB (580ST – 590ST electronic engine)………………………. 36
ELECTRIC DIAGRAMS – POWERSHIFT CAB (580ST – 590ST electronic engine) – 2WS…………………. 53
ELECTRIC DIAGRAMS – POWERSHIFT CAB (695ST) – 4WS……………………………………………………….. 72
CONTROLS AND INSTRUMENTS………………………………………………………………………………………………….. 91
FRONT CONTROL PANELS (580T – 580ST – 590ST)…………………………………………………………………… 91
FRONT CONTROL PANELS (695ST)…………………………………………………………………………………………. 93
CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580T mechanical engine)………………………… 95
CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580ST – 590ST – 695ST electronic engine) ……….97
SIDE INSTRUMENT CLUSTER (580T)……………………………………………………………………………………….. 99
SIDE INSTRUMENT CLUSTER (580ST – 590ST – 695ST)…………………………………………………………… 101
ANTI-START SYSTEM ……………………………………………………………………………………………………………. 103
DIAGNOSTIC DISPLAY (580ST – 590ST – 695ST) ………………………………………………………………………….. 104
SYMBOLS……………………………………………………………………………………………………………………………… 106
SETUP MENU………………………………………………………………………………………………………………………… 107
PROCEDURE ABOUT SELF TEST…………………………………………………………………………………………… 108
ON BOARD ERROR CODE RETRIEVAL…………………………………………………………………………………… 109
BACKLIGHTING AND DIMMING………………………………………………………………………………………………. 110
WORK HOURS………………………………………………………………………………………………………………………. 111
OPERATION………………………………………………………………………………………………………………………….. 112
WARNING SYSTEM……………………………………………………………………………………………………………….. 116
MAINTENANCE……………………………………………………………………………………………………………………… 117
WARNING MESSAGES…………………………………………………………………………………………………………… 118
STARTING SYSTEM …………………………………………………………………………………………………………………… 124
OPERATION………………………………………………………………………………………………………………………….. 124
STARTER MOTOR…………………………………………………………………………………………………………………. 127
TROUBLESHOOTING…………………………………………………………………………………………………………….. 132
ALTERNATOR……………………………………………………………………………………………………………………………. 134
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………….. 134
OPERATION………………………………………………………………………………………………………………………….. 135
TROUBLESHOOTING…………………………………………………………………………………………………………….. 136
BATTERY…………………………………………………………………………………………………………………………………… 137
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………….. 137
OPERATION………………………………………………………………………………………………………………………….. 137
REPLACEMENT …………………………………………………………………………………………………………………….. 138
CHARGE AND ELECTROLYTE LEVEL CHECK ………………………………………………………………………… 139
CONNECTING A BOOSTER BATTERY ……………………………………………………………………………………. 140
BATTERY MASTER SWITCH ………………………………………………………………………………………………….. 140
TROUBLESHOOTING …………………………………………………………………………………………………………………. 141
SECTION 82 – LOADER ATTACHMENT
LOADER ATTACHMENT CONTROLS………………………………………………………………………………………………. 3
LOADER ATTACHMENT OPERATION ………………………………………………………………………………………… 3
4×1 LOADER BUCKET CONTROL (Optional) ……………………………………………………………………………….. 6
LOADER ATTACHMENT CONTROL LOCK (Specific to certain countries)………………………………………… 7
BUCKET SELF-LEVELLING…………………………………………………………………………………………………………….. 8
LOADER ATTACHMENT SAFETY STRUT………………………………………………………………………………………. 12
LOADER ATTACHMENT SAFETY STRUT (2WS) ……………………………………………………………………….. 12
LOADER ATTACHMENT SAFETY STRUT (4WS) ……………………………………………………………………….. 13
REMOVAL AND INSTALLATION OF LOADER BUCKET…………………………………………………………………… 14
STANDARD LOADER BUCKET…………………………………………………………………………………………………. 14
LOADER BUCKET WITH FORKS (Optional) ……………………………………………………………………………….. 15
BUCKET TEETH REPLACEMENT……………………………………………………………………………………………… 16
LOADER REMOVAL……………………………………………………………………………………………………………………… 17
SECTION 84 – BACKHOE ATTACHMENT
DESCRIPTION AND OPERATION……………………………………………………………………………………………………. 3
BACKHOE ATTACHMENT CONTROLS……………………………………………………………………………………………. 6
BACKHOE ATTACHMENT MECHANICAL CONTROLS …………………………………………………………………. 7
BACKHOE ATTACHMENT HYDRAULIC CONTROLS………………………………………………………………….. 18
BACKHOE ATTACHMENT SIDESHIFT (Sideshift version) ……………………………………………………………. 24
BACKHOE ATTACHMENT DISASSEMBLY …………………………………………………………………………………….. 26
BACKHOE BUCKET REPLACEMENT………………………………………………………………………………………… 28
BACKHOE BUCKET…………………………………………………………………………………………………………………. 29
BACKHOE ATTACHMENT HYDRAULIC HANDLING ……………………………………………………………………….. 30
CONTROLS…………………………………………………………………………………………………………………………….. 30
HYDRAULIC DIAGRAM ……………………………………………………………………………………………………………. 31
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………. 32

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