Case 580 590 695 Super R Backhoe Loader Official Workshop Service Repair Manual

SECTION 00 - SAFETY PRECAUTIONS
SECTION 01 - MAINTENANCE
SECTION 02 - TECHNICAL SPECIFICATIONS
1. LOADER BACKHOE MODELS .................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. TECHNICAL SPECIFICATIONS................................................................................................................... 5
4. LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ................................................................ 9
5. BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE ........................................................... 12
6. LIFTING CAPACITIES................................................................................................................................ 15
7. LOADER BUCKET WITH FORKS DIMENSIONS AND PERFORMANCE................................................. 18
8. FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS.............................................................. 19
SECTION 17 - TORQUE CONVERTERS
1. POWERSHUTTLE TORQUE CONVERTER ................................................................................................3
1.1 DESCRIPTION AND OPERATION........................................................................................................ 3
1.2 TECHNICAL SPECIFICATIONS............................................................................................................ 4
1.3 OVERHAUL ........................................................................................................................................... 4
1.4 INSPECTION ......................................................................................................................................... 4
1.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.6 STALL TEST.......................................................................................................................................... 5
1.7 FAULT FINDING.................................................................................................................................... 6
2. POWERSHIFT TORQUE CONVERTER ...................................................................................................... 7
2.1 DESCRIPTION AND OPERATION........................................................................................................ 7
2.2 TECHNICAL SPECIFICATIONS............................................................................................................ 8
2.3 OVERHAUL ........................................................................................................................................... 8
2.4 INSPECTION ......................................................................................................................................... 9
2.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 9
2.6 STALL TEST........................................................................................................................................ 11
2.7 FAULT FINDING.................................................................................................................................. 12
SECTION 21 - TRANSMISSION
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025” ................................................... 3
1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 TIGHTENING TORQUES ...................................................................................................................... 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 2WD COMPONENTS.............................................................................................. 23
1.9 TRANSMISSION 4WD COMPONENTS.............................................................................................. 26
1.10 TRANSMISSION REMOVAL ............................................................................................................. 31
1.11 DISASSEMBLY AND ASSEMBLY..................................................................................................... 32
1.12 FAULT FINDING................................................................................................................................ 90
1.13 SPECIAL TOOLS............................................................................................................................... 93
2. POWERSHIFT TRANSMISSION “DANA T16000” ..................................................................................... 94
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 94
2.2 TRANSMISSION CONTROLS............................................................................................................. 95
2.3 LUBRICATION ................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER................................................................................................................ 108
2.6 TRANSMISSION HYDRAULIC DIAGRAM ........................................................................................ 109
2.7 OPERATION ...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 134GEAR AND CLUTCH LAY OUT .................................................................................................. 132
2.10 TRANSMISSION / ENGINE REMOVAL FROM LOADER ............................................................... 133
2.11 TRANSMISSION COMPONENTS ................................................................................................... 137
2.12 DISASSEMBLY AND ASSEMBLY................................................................................................... 155
2.13 SPECIAL TOOLS............................................................................................................................. 264
2.14 FAULT FINDING .............................................................................................................................. 265
2.15 FAULT FINDING .............................................................................................................................. 267
SECTION 25 - FRONT AXLES
1. FRONT AXLE 2WD “CARRARO” ................................................................................................................. 3
1.1 TECHNICAL SPECIFICATIONS............................................................................................................ 3
1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.3 FAULT FINDING .................................................................................................................................. 23
2. FRONT AXLE 4WD “CARRARO” ............................................................................................................... 25
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 25
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 31
2.3 FAULT FINDING .................................................................................................................................. 77
3. FRONT AXLE 4WS “CARRARO” ............................................................................................................... 80
3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 80
3.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 84
3.3 FAULT FINDING ................................................................................................................................ 137
4. SPECIAL TOOLS...................................................................................................................................... 140
SECTION 27 - REAR AXLE
1. REAR AXLE 2WS ......................................................................................................................................... 3
1.1 DESCRIPTION AND OPERATION....................................................................................................... 3
1.2 TECHNICAL SPECIFICATIONS............................................................................................................ 6
1.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8
1.4 FAULT FINDING .................................................................................................................................. 27
2. REAR AXLE 4WS “CARRARO”.................................................................................................................. 28
2.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 28
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 32
2.3 FAULT FINDING .................................................................................................................................. 81
3. SPECIAL TOOLS........................................................................................................................................ 84
SECTION 33 - BRAKES SYSTEM
1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. HAND BRAKE............................................................................................................................................... 6
2.1 HAND BRAKE ADJUSTMENT............................................................................................................... 7
3. BRAKE MASTER CYLINDERS .................................................................................................................... 8
3.1 BRAKE TANK ...................................................................................................................................... 13
3.2 BRAKE BLEEDING PROCEDURE...................................................................................................... 13
SECTION 35 - HYDRAULIC SYSTEM
1. HYDRAULIC DIAGRAMS ............................................................................................................................. 3
1.1 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS................................................. 3
1.2 HYDRAULIC DIAGRAM - 2WS CENTRE PIVOT PILOT MODELS ...................................................... 5
1.3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .............................................................. 8
1.4 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT MECHANICAL MODELS ....................................... 11
1.5 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS............................................... 13
1.6 HYDRAULIC DIAGRAM - 4WS CENTRE PIVOT PILOT MODELS .................................................... 15
1.7 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODEL .............................................................. 18
2. HYDRAULIC PUMP.................................................................................................................................... 21
2.1 DESCRIPTION AND OPERATION...................................................................................................... 21
2.2 TECHNICAL SPECIFICATIONS.......................................................................................................... 22
2.3 LOAD SENSING VALVE ..................................................................................................................... 24
2.4 REMOVAL ........................................................................................................................................... 26
2.5 COMPONENTS ................................................................................................................................... 27
2.6 DISASSEMBLY AND ASSEMBLY....................................................................................................... 28
3. CONTROL VALVES ................................................................................................................................... 32
3.1 CONTROL VALVES “REXROTH” (MECHANICAL MODELS) ............................................................ 32
3.2 CONTROL VALVES “REXROTH” (PILOT MODELS) ......................................................................... 48
4. HYDRAULIC SWING SYSTEM .................................................................................................................. 71
4.1 DESCRIPTION AND OPERATION...................................................................................................... 71
4.2 HYDRAULIC OIL FLOW ...................................................................................................................... 72
4.3 PRECISION SWING CONTROL ......................................................................................................... 74
5. HYDRAULIC CYLINDERS.......................................................................................................................... 77
5.1 LOADER CYLINDER ........................................................................................................................... 78
5.2 LOADER BUCKET CYLINDER ........................................................................................................... 83
5.3 4X1 BUCKET CYLINDER.................................................................................................................... 87
5.4 BACKHOE BOOM CYLINDER ............................................................................................................ 90
5.5 BACKHOE CROWD CYLINDER ......................................................................................................... 94
5.6 BACKHOE BUCKET CYLINDER......................................................................................................... 98
5.7 SHORT AND LONG TELESCOPIC CYLINDER................................................................................ 102
5.8 STABILIZER CYLINDER (CENTRE PIVOT - 4WS) .......................................................................... 106
5.9 STABILIZER CYLINDER (SIDESHIFT) ............................................................................................. 110
5.10 SWING CYLINDER.......................................................................................................................... 114
5.11 SIDESHIFT CARRIAGE CYLINDER (SIDESHIFT) ......................................................................... 118
5.12 SPECIAL TOOLS............................................................................................................................. 120
6. PILOT HYDRAULIC CONTROL LEVERS ................................................................................................ 121
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 121
6.2 DESCRIPTION AND OPERATION.................................................................................................... 122
6.3 DISASSEMBLY AND ASSEMBLY..................................................................................................... 125
6.4 PILOT HYDRAULIC CONTROL VALVE............................................................................................ 128
7. FAULT FINDING AND FLOW TESTING .................................................................................................. 131
7.1 PRELIMINARY CHECKS................................................................................................................... 131
7.2 FAULT FINDING................................................................................................................................ 132
7.3 PRESSURE TESTING....................................................................................................................... 136
SECTION 39 - CHASSIS
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. REMOVAL AND INSTALLATION COMPONENTS....................................................................................... 5
2.1 COMPONENTS WITHIN THE CHASSIS...............................................................................................5
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 6
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS ....................................................................... 8
2.4 COMPONENTS ATTACHED ABOVE THE CHASSIS........................................................................... 9
2.5 TIGHTENING TORQUES .................................................................................................................... 11
SECTION 41 - STEERING SYSTEM
1. STEERING SYSTEM 2WS ........................................................................................................................... 4
2. STEERING SYSTEM 4WS ........................................................................................................................... 7
3. STEERING MOTOR ................................................................................................................................... 12
3.1 TECHNICAL SPECIFICATIONS.......................................................................................................... 13
3.2 COMPONENTS ................................................................................................................................... 15
3.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 16
3.4 SPECIAL TOOLS................................................................................................................................. 33
3.5 FAULT FINDING .................................................................................................................................. 33
SECTION 50 - CAB HEATING AND AIR CONDITIONING
1. TECHNICAL SPECIFICATIONS................................................................................................................... 3
2. CAB HEATING.............................................................................................................................................. 5
2.1 DESCRIPTION AND OPERATION........................................................................................................ 5
3. AIR CONDITIONING................................................................................................................................... 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 16
3.3 DESCRIPTION AND OPERATION...................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 25
3.5 FLUSHING THE SYSTEM ................................................................................................................... 43
3.6 EVACUATING THE SYSTEM.............................................................................................................. 45
3.7 CHARGING THE SYSTEM.................................................................................................................. 46
3.8 COMPONENTS OVERHAUL............................................................................................................... 47
3.9 COMPRESSOR ................................................................................................................................... 51
3.10 SPECIAL TOOLS............................................................................................................................... 65
SECTION 55 - ELECTRICAL SYSTEM
1. GENERALITIES ............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING .................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB ........................................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHIFT CAB ............................................................................... 25
2.3 ELECTRICAL DIAGRAMS - 4WS........................................................................................................ 45
2.4 ELECTRICAL DIAGRAMS - ROPS ..................................................................................................... 65
3. CONTROLS AND INSTRUMENTS............................................................................................................. 81
3.1 FRONT INSTRUMENT PANEL (580 Super R - 590 Super R) ............................................................ 81
3.2 SIDE INSTRUMENT PANEL (695 Super R)........................................................................................ 83
3.3 SIDE PANEL........................................................................................................................................ 85
3.4 DIAGNOSTIC SIGNALING .................................................................................................................. 88
3.5 CALIBRATION OF SPEEDOMETER ..................................................................................................90
3.6 IMMOBILISER CIRCUIT...................................................................................................................... 91
4. STARTING SYSTEM .................................................................................................................................. 92
4.1 DESCRIPTION AND OPERATION...................................................................................................... 92
4.2 FAULT FINDING.................................................................................................................................. 93
4.3 STARTER MOTOR.............................................................................................................................. 96
5. ALTERNATOR.......................................................................................................................................... 102
5.1 TECHNICAL SPECIFICATIONS........................................................................................................ 102
5.2 DESCRIPTION AND OPERATION.................................................................................................... 102
5.3 COMPONENTS ................................................................................................................................. 104
5.4 REMOVAL ......................................................................................................................................... 105
5.5 PRELIMINARY CHECK AND TESTS................................................................................................ 106
5.6 FAULT FINDING................................................................................................................................ 115
6. BATTERY ................................................................................................................................................. 116
6.1 TECHNICAL SPECIFICATIONS........................................................................................................ 116
6.2 DESCRIPTION AND OPERATION.................................................................................................... 116
6.3 REMOVAL AND INSTALLATION ...................................................................................................... 117
6.4 MAINTENANCE................................................................................................................................. 119
6.5 TESTS ............................................................................................................................................... 121
6.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 123
6.7 BATTERY MASTER SWITCH ........................................................................................................... 123
7. COMPONENT TESTING .......................................................................................................................... 124
7.1 GENERAL INTRODUCTION ............................................................................................................. 124
7.2 COMPONENT TESTING ................................................................................................................... 125
7.3 GROUND POINTS............................................................................................................................. 125
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 3
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 6
3. LOADER ATTACHMENT SAFETY STRUT.................................................................................................. 7
4. LOADER BUCKET REMOVAL ..................................................................................................................... 9
5. LOADER ARM REMOVAL.......................................................................................................................... 11
SECTION 84 - BACKHOE
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. BACKHOE ATTACHMENT MECHANICAL CONTROL VERSION .............................................................. 6
3. BACKHOE ATTACHMENT PILOT CONTROL VERSION.......................................................................... 13
4. REMOVAL AND INSTALLATION ............................................................................................................... 15
5. TELESCOPIC DIPPER REVISION............................................................................................................. 25

========================================