Serv

ice

Man

ual

Service Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF J.I. CASE OR IT’S SUCCESSORS. J.I. CASE AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

580K Loader, Backhoe

Volume 1 of 3

CA-S-580K

580K Loader Backhoe TABLE OF CONTENTS

SERIES/SECTION SECTION NO.

1 GENERAL Safety Rules, Service Manual Introduction, and Torque

Specifications .................................................. 1001 General Engine Specifications .................................... 1010 Detailed Engine Specifications .................................... 1024 General Machine Specifications ................................... 1210 Maintenance and Lubrication ..................................... 1212

2 ENGINE

). 3

Removal and Installation of the Engine, Radiator, Power Shuttle, Torque Converter, and Front Engine Support ........................................................ 2000

Engine Accessories (Air Cleaning System, Spark Arresting Muffler, Ether Injection System Turbocharger Removal/Installation) ................ : .......................... 2001

Stall Tests ....................................................... 2002 Cylinder Head and Valve Train ..... '.' .............................. 24'15 Cylinder Block, Pistons, Rods, Camshaft, Main Bearings,

Oil Seals, and Flywheel ......................................... 2425 Lubrication System ..................... ; ......................... 2445 Cooling System ................................................... 2455 Turbocharger Disassembly/Assembly .............................. 2465 Turbocharger Failure Analysis .................................... 2565

FUEL SYSTEM Engine Controls, Fuel Lines, and Fuel Tank ; ....................... 3001 . Fuel System and Filters ........................................... 3410 Fuel Injection Pump and Drive Gear ............................... 3412 Fuel Injectors ................ : .................................... 3413

4 ELECTRICAL Removal and Installation of Electrical Components ................. 4000 Electrical Specifications and Troubleshooting ...................... 4002 Electrical Schematics ............................................. 4003 Instrument Cluster ............................................... 4004 Battery .......................................................... 4005 Starter and Starter Solenoid ....................................... 4006 Alternator ......... , ....................... " ..................... 4019

5 STEERING Removal and Installation of Steering Components .................. 5000 Optional Tilt and Telescoping Steering Column .................... 5001 Steering Specifications and Troubleshooting ....................... 5002 Steering Control Valve - Eaton .................................... 5007 Steering Control Valve - Danfoss .................................. 5008 Steering Cylinder ................................................. 5010 Front Axle - Two Wheel Drive ..................................... 5021 Front Axle - Four Wheel Drive ..................................... 5022

CASE Bur 8-71551 (Includes Revision Bur 8-66040R1)

FORM NO.

8-66910 8-28800 8-24161 8-66921 8-66931

8-67151

8-67160 8-67170 8-24171

8-24181 8-24191 8-24201 8-25550 9-78235

8-67180 8-24211 8-27080 8-24231

8-67190 8-67201 8-67211 8-67230 8-44360 8-42910 8-42851

8-67240 8-72800 8-67250 8-67261 8-71560 8-67271 8-67281 8-67291

Printed in U.S.A. Issued March 1987

Revised February 1988

SER I ES/SECTION SECTION NO. FORM NO.

6 POWER TRAIN Removal and Installation of Power Train Components .............. 6200 Maintenance ..................................................... 6201 Power Shuttle Operation and Troubleshooting ..................... 6202 Power Shuttle .................................................... 6210 Controls ......................................................... 6211 Transfer Gear Box ................................................ 6216 Transaxle and Differential Lock. Wet Brake ......................... 6217 Wheels and Tires ................................................. 6229

7 BRAKES Brakes (Brake Pedals to Transaxle) ................................ 7106 Differential Brakes. Wet Brakes .................................... 7125

8 HYDRAULICS Removal and Installation of Hydraulic Components ................. 8000 Maintenance ..................................................... 8001 Hydraulic Schematics. Specifications and Troubleshooting ......... 8002 Cleaning the Hydraulic System .................................... 8003 Hydraulic Pump - Sections fastened together with studs ............ 8005 Hydraulic Pump - Sections fasten together with cap screws ......... 8006 Loader Control Valite ............................................. 8007 Three Point Hitch Control Valve ................................... 8009 Cylinders ........................................................ 8090 Backhoe Control Valve ............ : ............................. 8107 Swing Sequence Valve ............................................ 8108

9 MOUNTING EQUIPMENT Air Conditioning Troubleshooting ................................. 9002 Air Conditioning System .......................................... 9003 Loader .................................................... : ...... 9010 Three Point Hitch ................................................ 9033 RaPS Cab and RaPS Canopy ..................................... 9061 Seat and Seat Belts ............................................... 9064 Suspension Seat ................................................. 9065 Backhoe ......................................................... 9100

4002

ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING

TABLE OF CONTENTS

Specifications .......................... 4002-2 Checking Voltage at the Alternator Terminals .......................... 4002-8

Using Booster Batteries to Start the Engine ........................... 4002-4 Alternator and Voltage Regulator

Test ............................... 4002-9 Troubleshooting Charts ................ 4002-5

Troubleshooting the Starting Circuit .... 4002-10 Battery .............................. 4002-5

General Inspection .................. 4002-10 Alternator ............................ 4002-6

Starter and Starter Solenoid Test ..... 4002-10 Starter ............................... 4002-7

Troubleshooting the Return-To-Dig Troubleshooting the Charging Circuit ... 4002-8 Control ............................. 4002-12

General Inspection ................... 4002-8 Magnetic Detent Will Not Release the Control Lever ..................... 4002-12

Magnetic Detent Will Not Hold the Control Lever ..................... 4002-14

Bur 8-67201 Printed in U.S.A. Issued February 1988

5021-27

TOE-IN

Measuring Toe-In

STEP 1 Raise the front of the machine until the front wheels are free of the floor.

STEP 2 Hold a tool that has a sharp point against the cen­ter of the tire tread.

STEP 3 Hold the tool in one place and rotate the wheel to make a fine line around the tire. Repeat this proce­dure for the other front wheel.

STEP 4 Lower the front wheels to the floor.

STEPS Turn the steering wheel as needed to put the front wheels in the straight position.

STEP 6 Measure the distance between the marks at the front and rear of the tires .

STEP 7 The measurement at the rear of the tires must to 0 to 3/16 inch (0 to 5 mm) more than the measure­ment at the front of the tires.

Adjustment

STEP 1 Loosen the lock nut at each end of the piston rod for the steering cylinder.

STEP 2 Turn the piston rod as needed to increase or de­crease the toe-in.

STEP 3 When the toe-in is correct, tighten the lock nut nearest the flat on the piston rod first to 27 to 42 pound-feet (203 to 271 Nm). Then tighten the other lock nut to 27 to 42 pound-feet (203 to 271 Nm).

.----------------------------------B:--------------------------------~.l:

I.--------------------------------A--------------------------------.l 1. Mark Around Center of Tire 2. Steering Cylinder 3. Loosen Lock Nuts And Turn

Piston Rod As Required

Measurement B Must Be Equal To Or Up To 3/16 Inch (5 mm) Less Than Measurement A

861482

5022

FRONT AXLE - FOUR WHEEL DRIVE

TABLE OF CONTENTS

Specifications .......................... 5022-2 Planetary ............................. 5022-18

Special Tools .......................... 5022-3 Disassembly ........................ 5022-18

Toe-In ................................. 5022-4 Assembly ........................... 5022-23

Measuring Toe-In ..................... 5022-4 Swivel Housing and Axle Shaft ......... 5022-31

Adjustment .......................... 5022-4 Removal and Disassembly ........... 5022-31

Front Axle ............................. 5022-5 Replacing a Universal Joint .......... 5022-34

Removal ............................. 5022-5 Assembly and Installation ............ 5022-36

Installation ........................... 5022-7 Differential Carrier .................... 5022-42

Inspection ............................ 5022-11 Removal ............................ 5022-42

Exploded Views Installation . . . . . . . . . . . . . . . . . . . . . . . . .. 5022-43

Planetary ........................... 5022-12 Disassembly of Differential Carrier ... 5022-45

Swivel Housing ..................... 5022-13 Disassembly of Differential ........... 5022-49

Axle Housing and Axle Shaft ......... 5022-14 Assembly of Differential ............. 5022-51

Differential Carrier .................. 5022-15 Assembly of Differential Carrier ...... 5022-55

Pinion Gear Installation .............. 5022-16

Differential .......................... 5022-17

CASE CORPORATION Bur 8-67291 Printed in U.S.A. Issued February 1988

Clutch Cutout Actuated The clutch cutout function is used to disen­

gage the clutches without moving the direction control lever to NEUTRAL.

The clutch cutout solenoid is fastened to the control valve. The clutch cutout solenoid is spring loaded to hold the plunger and spool in position for normal operation of the power shuttle.

The clutch cutout solenoid is electrically actu­ated to actuate the clutch cutout function.

The clutch cutout solenoid can be actuated by:

1. PUMP FLOW 2. LUBRICATION OIL 3. STATIC OIL 4. RETURN OIL 5. SUCTION OIL

'i1

6. TO CHARGING PUMP 7 FROM CHARGING PUMP 8. CLUTCH CUTOUT

SOLENOID 9. PLUNGER

6202-7

1. Pushing the clutch cutout button on the tran­saxle shift lever.

2. Pushing the clutch cutout button on the loader control lever.

When the clutch cutout solenoid is actuated, the spring on the plunger moves the plunger away from the spool so that the spring for the spool can move the spool to stop the flow of oil to the clutch. At the same time, the spool connects the passage for the clutch to a return passage in the control valve to immediately relieve the pressure in the clutch.

10. SPOOL 11. PLUNGER (9) AND

SPOOL (10) MOVED IN THIS DIRECTION

12. TO TORQUE CONVERTER

7106

BRAKES, BRAKE PEDALS TO TRANSAXLE

TABLE OF CONTENTS

Specifications .......................... 7106-2 Parking Brake Adjustment .............. 7106-6

Brakes ................................. 7106-2 Illustration of Parking Brake Cable Installation ......................... 7106-7

Master Cylinder Fluid Level ........... 7106-2 Illustration of Parking Brake .......... 7106-8

Check the Warning Lamp for the Master Cylinder .................... 7106-2 Removing Air From the Brake System ... 7106-9

Brake Pedal Adjustment ................ 7106-3 Illustration of the Brake Hydraulic Installation .......................... 7106-10

Checking Brake Pedal Height ......... 7106-3 Master Cylinder ....................... 7106-11

Brake Pedal Height Adjustment ....... 7106-3 Removal ............................ 7106-11

Illustration of Brake Pedal Installation .. 7106-4 Installation .......................... 7106-13

Brake Adjustment ...................... 7106-5 Illustration of Master Cylinder ........ 7106-15

General Information .................. 7106-5 Disassembly ........................ 7106-16

Checking the Brake Adjustment ....... 7106-5 Inspection .......................... 7106-16

Adjustment Procedure ................ 7106-5 Assembly ........................... 7106-16

Bur 8-67351 Printed in U.S.A.

CASE CORPORATION Issued February 1988

9003

AIR CONDITIONING SYSTEM

TABLE OF CONTENTS

Specifications .......................... 9003-2 Compressor .......................... 9003-12

Special Tools .......................... 9003-3 Removal ............................ 9003-13

Adjustment of Drive Belt ................ 9003-4 Replacing the Coil or Clutch Assembly. 9003-13

Lubrication of Compressor . . . . . . . . . . . . .. 9003-5 Replacing the Seal .................. 9003-18

General Information .................. 9003-5 Replacing the Valve Plate or Gaskets .. 9003-23

Lubricant ............................ 9003-5 Replacing the Air Conditioning Control . . 9003-27

Oil Level Check ...................... 9003-5 Expansion Valve ...................... 9003-27

Oil Level for a New Compressor ......... 9003-6 Removal ............................ 9003-27

Discharging the Air Conditiong System .. 9003-7 Installation .......................... 9003-28

Removing Air and Moisture from the Inspection .......................... 9003-29 Air Conditioning System .............. 9003-8

Testing and Adjusting ............... 9003-30 Charging the Air Conditioning System ... 9003-9

Replacing the Evaporator .............. 9003-32 General Information .................. 9003-9

Condensor . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9003-35 Charging Procdure ................... 9003-9

Removal ........................... ' 9003-36

Installation .......................... 9003-36

8-67470 Printed in U,S.A. Issued March 1987

9010

LOADER

TABLE OF CONTENTS

Standard Bucket ....................... 9010-2 Adjustment for Return-To-Dig . ......... 9010-11

Replacement of Cutting Edge ......... 9010-2 Adjustment of Antirollback ............. 9010-12

Clam Bucket ........................... 9010-4 Illustration of Loader Controls Installation . ......................... 9010-14

Replacement of Cutting Edge for Clam .............................. 9010-4 Illustration of Lift Cylinder Hydraulic

Installation .......................... 9010-15 Replacement of Cutting Edge for

Blade .............................. 9010-5 Illustration of Bucket Cylinder Hydraulic Installation .......................... 9010-16

Bucket Teeth .......................... 9010-6 Illustration of Front Counterweight ..... 9010-17

Replacement of Tooth Shank ......... 9010-6 Illustration of Rear Counterweight and

Replacement of Tooth Point .......... 9010-6 Drawbar ............................ 9010-18

Loader Frame . ......................... 9010-7 Illustration of Loader Clam Cylinder Hydraulic Circuit .................... 9010-19

Removal ............................. 9010-7 Illustration of Loader Clam Cylinder

Illustration of Loader Frame ........... 9010-9 Hydraulic Circuit .................... 9010-20

Insta"ation .......................... 9010-10

8-67480 Printed in U.S.A.

CASE CORPORATION Issued March 1987

9100

BACKHOE

TABLE OF CONTENTS

Swing Tower ............. .............. 9100-2 Stabilizer Cylinder Hydraulic Installation ........................ 9100-19

Removal ............................. 9100-2 Swing Tower and Swing Cylinder

Installation ........................... 9100-3 Installation ........................ 9100-20

Boom ................................. 9100-5 Sequence Valve Linkage ............. 9100-21

Removal ............................. 9100-5 Swing Cylinder Hydraulic Installation .9100-22

Installation ........................... 9100-6 Boom Latch Installation ............. 9100-23

Dipper . ................................ 9100-8 Boom and Dipper Installation ........ 9100-24

Removal ............................. 9100-8 Boom Cylinder Hydraulic Installation .9100-25

Installation ........................... 9100-8 Dipper Cylinder Hydraulic Installation ........................ 9100-26

Dipper Extension ...................... 9100-10 Quick Coupler and Bucket

Removal ............................ 9100-10 Installation ........................ 9100-27

Installation .......................... 9100-10 Bucket Cylinder Installation Without

Replacing Wear Plates for the Dipper. 9100-11 Extendable Dipper ................ 9100-28

Cutting Edges ......................... 9100-12 Extendable Dipper .................. 9100-29

Heavy Duty Buckets ................. 9100-12 Extension Cylinder Hydraulic

Installation ........................ 9100-30

Bucket Teeth ......................... 9100-14 Bucket Cylinder Hydraulic Installation With Extendable Dipper ............ 9100-31

Replacing a Tooth Shank ............ 9100-14 Backhoe Controls With Foot Swing ... 9100-32

Replacing a Tooth Point ............. 9100-16

Optional Backhoe controls with Exploded Views ....................... 9100-17 Foot Swing ....................... 9100-33

Supply and Return Lines ............. 9100-17 Backhoe Controls with Hand Swing .. 9100-34

9100-18 Swing Section Valve Adjustment .............. See Section 8000

CASE CORPORATION Bur 8-67531 Printed in U.S.A. Issued February 1988