Case 580T 580ST 590ST 695ST Backhoe Loader Official Workshop Service Repair Manual
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This is the COMPLETE Official Service Repair Manual for the Case 580T 580ST 590ST 695ST Backhoe Loader.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Backhoe Loader.
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
This Manual contains information and data to this model. has specs, diagrams, and actual real photo illustrations, and schemes,
which give you complete step by step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine.
this manual offers full information you need for repair your machine.
the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service.
all pages are printable, so run off what you need and take it with you into the garage or workshop.
which give you complete step by step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine.
this manual offers full information you need for repair your machine.
the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service.
all pages are printable, so run off what you need and take it with you into the garage or workshop.
Models & Serials Covered:
84428671B
Table of Contents:
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
DIESEL ENGINE ……………………………………………………………………………………………………………………….. 6
TRANSMISSION………………………………………………………………………………………………………………………… 9
AXLES ……………………………………………………………………………………………………………………………………. 10
BRAKES …………………………………………………………………………………………………………………………………. 11
STEERING………………………………………………………………………………………………………………………………. 11
HYDRAULIC SYSTEM ……………………………………………………………………………………………………………… 12
FRONT COUNTERWEIGHT ……………………………………………………………………………………………………… 12
NOISE AND VIBRATION LEVELS ……………………………………………………………………………………………… 13
BUCKETS……………………………………………………………………………………………………………………………….. 13
TYRES……………………………………………………………………………………………………………………………………. 14
DIMENSIONS AND PERFORMANCE……………………………………………………………………………………………… 15
DIMENSIONS – 2WS SIDESHIFT ………………………………………………………………………………………………. 15
DIMENSIONS – 2WS SIDESHIFT (“STRAIGHT LOADER ARM” models) ………………………………………… 16
DIMENSIONS – 4WS SIDESHIFT ………………………………………………………………………………………………. 17
DIMENSIONS – 4WS CENTER PIVOT………………………………………………………………………………………… 18
LOADER ATTACHMENT PERFORMANCE…………………………………………………………………………………. 19
PERFORMANCE OF LOADER BUCKET WITH FORKS ……………………………………………………………….. 22
BACKHOE ATTACHMENT PERFORMANCE………………………………………………………………………………. 24
MAXIMUM LIFTING LOADS…………………………………………………………………………………………………………… 27
LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE ………………………………………………………… 27
BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ……………………………………………………… 28
SUPPLY SUMMARY TABLE ………………………………………………………………………………………………………….. 29
SECTION 21 – TRANSMISSION
POWERSHUTTLE TRANSMISSION…………………………………………………………………………………………………. 3
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………… 4
HYDRAULIC DIAGRAM………………………………………………………………………………………………………………. 7
CONTROLS …………………………………………………………………………………………………………………………….. 13
LUBRICATION …………………………………………………………………………………………………………………………. 17
GREASING ……………………………………………………………………………………………………………………………… 20
REMOVAL FROM MACHINE …………………………………………………………………………………………………….. 22
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………. 23
TROUBLESHOOTING …………………………………………………………………………………………………………….. 148
REPAIR TIMES………………………………………………………………………………………………………………………. 152
SPECIAL TOOLS……………………………………………………………………………………………………………………. 153
POWERSHIFT TRANSMISSION…………………………………………………………………………………………………… 154
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………….. 154
CONTROLS …………………………………………………………………………………………………………………………… 165
LUBRICATION ……………………………………………………………………………………………………………………….. 167
GREASING ……………………………………………………………………………………………………………………………. 169
REMOVAL FROM MACHINE …………………………………………………………………………………………………… 170
DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………….. 171
TROUBLESHOOTING …………………………………………………………………………………………………………….. 335
REPAIR TIMES………………………………………………………………………………………………………………………. 339
SPECIAL TOOLS……………………………………………………………………………………………………………………. 340
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
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………. 66
TROUBLESHOOTING …………………………………………………………………………………………………………….. 131
REPAIR TIMES………………………………………………………………………………………………………………………. 137
SPECIAL TOOLS……………………………………………………………………………………………………………………. 138
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
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………… 5
SERVICE BRAKE …………………………………………………………………………………………………………………………. 14
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………. 14
OPERATION……………………………………………………………………………………………………………………………. 14
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…………………………………………….. 13
HYDRAULIC DIAGRAM – 4WS SIDESHIFT PILOT MODELS ………………………………………………………… 15
HYDRAULIC DIAGRAM – 4WS CENTER PIVOT PILOT MODELS …………………………………………………. 17
HYDRAULIC PUMP………………………………………………………………………………………………………………………. 19
HYDRAULIC FIXED-FLOW-RATE GEAR PUMP………………………………………………………………………….. 19
HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP…………………………………………………………………. 30
CONTROL VALVES………………………………………………………………………………………………………………………. 44
LOADER CONTROL VALVE ……………………………………………………………………………………………………… 53
BACKHOE ATTACHMENT CONTROL VALVE…………………………………………………………………………….. 57
RELIEF VALVES………………………………………………………………………………………………………………………. 69
BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE ………………………………………….. 78
ACCUMULATOR “GLIDE RIDE” PARKER……………………………………………………………………………………….. 81
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………. 81
MAINTENANCE ……………………………………………………………………………………………………………………….. 81
SAFETY ………………………………………………………………………………………………………………………………….. 81
CHECKING AND ADJUSTING THE PRECHARGE PRESSURE ……………………………………………………. 82
HYDRAULIC SWING SYSTEM ………………………………………………………………………………………………………. 84
OPERATION……………………………………………………………………………………………………………………………. 84
HYDRAULIC CYLINDERS……………………………………………………………………………………………………………… 87
LOADER ATTACHMENT BOOM CYLINDER……………………………………………………………………………….. 88
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…………………………………………………………………………. 5
COMPONENTS WITHIN THE CHASSIS……………………………………………………………………………………….. 5
COMPONENTS OF THE LOWER PART OF THE CHASSIS …………………………………………………………… 6
COMPONENTS ATTACHED OUTSIDE THE CHASSIS ………………………………………………………………… 10
COMPONENTS OF THE UPPER PART ……………………………………………………………………………………… 11
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…………………………………………………………………………………………………………. 44
DRAINING THE SYSTEM …………………………………………………………………………………………………………. 46
CHARGING THE SYSTEM………………………………………………………………………………………………………… 47
OVERHAUL …………………………………………………………………………………………………………………………….. 48
COMPRESSOR ……………………………………………………………………………………………………………………………. 53
TECHNICAL SPECIFICATIONS…………………………………………………………………………………………………. 53
REMOVAL AND INSTALLATION ……………………………………………………………………………………………….. 54
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………. 57
TROUBLESHOOTING………………………………………………………………………………………………………………. 66
SECTION 55 – ELECTRIC SYSTEM
ELECTRIC DIAGRAMS …………………………………………………………………………………………………………………… 3
ELECTRIC DIAGRAMS – POWERSHUTTLE ROPS (580T mechanical engine) …………………………………. 3
ELECTRIC DIAGRAMS – POWERSHUTTLE CAB (580T mechanical engine)………………………………….. 18
ELECTRIC DIAGRAMS – POWERSHUTTLE CAB (580ST – 590ST electronic engine) ……………………… 36
ELECTRIC DIAGRAMS – POWERSHIFT CAB (2WS) …………………………………………………………………… 54
ELECTRIC DIAGRAMS – POWERSHIFT CAB (4WS) …………………………………………………………………… 73
CONTROLS AND INSTRUMENTS …………………………………………………………………………………………………. 92
FRONT CONTROL PANELS (580T – 580ST – 590ST)…………………………………………………………………… 92
FRONT CONTROL PANELS (695ST)…………………………………………………………………………………………. 94
CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580T mechanical engine)………………………… 96
CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580ST – 590ST – 695ST electronic engine)… 98
SIDE INSTRUMENT CLUSTER (580T)……………………………………………………………………………………… 100
SIDE INSTRUMENT CLUSTER (580ST – 590ST – 695ST)…………………………………………………………… 102
ANTI-START SYSTEM ……………………………………………………………………………………………………………. 104
DIAGNOSTIC DISPLAY (580ST – 590ST – 695ST) ………………………………………………………………………….. 105
SYMBOLS……………………………………………………………………………………………………………………………… 107
SETUP MENU………………………………………………………………………………………………………………………… 108
PROCEDURE ABOUT SELF TEST…………………………………………………………………………………………… 109
ON BOARD ERROR CODE RETRIEVAL…………………………………………………………………………………… 110
BACKLIGHTING AND DIMMING………………………………………………………………………………………………. 111
WORK HOURS ………………………………………………………………………………………………………………………. 112
OPERATION………………………………………………………………………………………………………………………….. 113
WARNING SYSTEM ……………………………………………………………………………………………………………….. 117
MAINTENANCE ……………………………………………………………………………………………………………………… 118
WARNING MESSAGES…………………………………………………………………………………………………………… 119
STARTING SYSTEM …………………………………………………………………………………………………………………… 126
OPERATION………………………………………………………………………………………………………………………….. 126
STARTER MOTOR …………………………………………………………………………………………………………………. 129
TROUBLESHOOTING …………………………………………………………………………………………………………….. 134
ALTERNATOR ……………………………………………………………………………………………………………………………. 136
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………….. 136
OPERATION………………………………………………………………………………………………………………………….. 137
TROUBLESHOOTING …………………………………………………………………………………………………………….. 138
BATTERY…………………………………………………………………………………………………………………………………… 139
TECHNICAL SPECIFICATIONS……………………………………………………………………………………………….. 139
OPERATION………………………………………………………………………………………………………………………….. 139
REPLACEMENT …………………………………………………………………………………………………………………….. 140
CHARGE AND ELECTROLYTE LEVEL CHECK ………………………………………………………………………… 141
CONNECTING A BOOSTER BATTERY ……………………………………………………………………………………. 142
BATTERY MASTER SWITCH ………………………………………………………………………………………………….. 142
TROUBLESHOOTING …………………………………………………………………………………………………………………. 143
SECTION 82 – LOADER ATTACHMENT
LOADER ATTACHMENT CONTROLS………………………………………………………………………………………………. 4
LOADER ATTACHMENT OPERATION…………………………………………………………………………………………. 4
4×1 LOADER BUCKET CONTROL (Optional)………………………………………………………………………………… 7
LOADER ATTACHMENT CONTROL LOCK (Specific to certain countries) ………………………………………… 8
LOADER BUCKET SELF-LEVELLING ………………………………………………………………………………………………. 9
580T – 590ST “STRAIGHT LOADER ARM” MODELS……………………………………………………………………… 9
“RETURN TO DIG” SYSTEM LOADER BUCKET ……………………………………………………………………………… 10
580T – 590ST “STRAIGHT LOADER ARM” MODELS……………………………………………………………………. 10
580T – 580ST – 590ST – 695ST EXCEPT FOR “STRAIGHT LOADER ARM” MODELS ……………………… 11
LOADER ATTACHMENT SAFETY STRUT………………………………………………………………………………………. 12
LOADER ATTACHMENT SAFETY STRUT (2WS)………………………………………………………………………… 12
LOADER ATTACHMENT SAFETY STRUT (2WS – “STRAIGHT LOADER ARM”) ……………………………. 13
LOADER ATTACHMENT SAFETY STRUT (4WS) ……………………………………………………………………….. 15
REMOVAL AND INSTALLATION OF LOADER BUCKET…………………………………………………………………… 16
STANDARD LOADER BUCKET…………………………………………………………………………………………………. 16
LOADER BUCKET WITH FORKS (Optional) ……………………………………………………………………………….. 17
BUCKET TEETH REPLACEMENT……………………………………………………………………………………………… 18
LOADER REMOVAL……………………………………………………………………………………………………………………… 19
LOADER ATTACHMENT (2WS – “STRAIGHT LOADER ARM”)……………………………………………………… 19
LOADER ATTACHMENT (2WS – 4WS) ………………………………………………………………………………………. 22
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
HANDLING CYLINDER …………………………………………………………………………………………………………….. 32
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………. 33
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