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
4x1 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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