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  CASE 580 SUPER K LOADER BACKHOE SERVICE MANUAL for serial numbers JJG016001 and after hours and hours of deskewing and editing work done. 1300 PLUS PAGES IN ADOBE PDF FORM WITH SEARCHABLE BOOK MARKS 530MB CD many many hours of editing work done to create a perfect pdf file for you 100% satisfaction       DETAILS AND PICS BELOW: 1001 STANDARD TORQUE SPECIFICATIONS Torque Specifications - Decimal Torque Specifications - Steel Hydraulic Hardware Fittings Torque Specifications - Metric Hardware Torque Specifications - O-ring Face Seal Fittings Section 1002 FLUIDS AND LUBRICANTS 1002-2 CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change Type of oil Engine Cooling System Capacity without heater Capacity with heater Type of coolant Fuel Tank Capacity Capacity with auxiliary tank Type of fuel Hydraulic System Hydraulic reservoir refill capacity Type of oil Transmission Capacity Total System Capacity Type of oil Front Axle - Four Wheel Drive Capacity of center bowl Capacity of planetary (each) Type of oil Section 1024 SPECIFICATION DETAILS 1024-2 RUN-IN INSTRUCTIONS DENTIFICATION MARKS Crankshaft Cylinder Block Cylinder Head ENGINE SPECIFICATION DETAILS Cylinder Block Service Cylinder Sleeve Piston Piston Pin Piston Rings Cylinder Head Lifters Connecting Rod Crankshaft Camshaft Turbocharger Gear Train Rocker Arm Assembly Intake Valve Exhaust Valve Valve Springs Valve Seat Installation Dimensions SPECIAL TORQUES Section 2001 ENGINE REMOVAL AND INSTALLATION 2001-2 SPECIAL TOOLS RADIATOR REMOVAL ENGINE REMOVAL REMOVING AND INSTALLING THE TORQUE CONVERTER INSTALLING THE FRONT ENGINE SUPPORT Section 2402 SPECIFICATION DETAILS 4-390 Diesel Engine 2402-2 RUN-IN INSTRUCTIONS IDENTIFICATION MARKS Crankshaft Cylinder Block Cylinder Head ENGINE SPECIFICATION DETAILS Cylinder Block Service Cylinder Sleeve Piston Piston Pin Piston Rings Cylinder Head Lifters Connecting Rod Crankshaft Camshaft Turbocharger Gear Train Rocker Arm Assembly Intake Valve Exhaust Valve Valve Springs Valve Seat Installation Dimensions SPECIAL TORQUES Section 2415 CYLINDER HEAD AND VALVE TRAIN 4-390 Diesel Engine 2415-2 IDENTIFICATION MARKS SPECIFICATIONS SPECIAL TORQUES SPECIAL TOOLS CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLY CHECKING AND RESURFACING THE CYLINDER HEAD VALVE GUIDE REPLACEMENT 14 mm Replacement Valve Guides 11 mm Replacement Valve Guides INSPECTION OF THE VALVES AND VALVE SEATS VALVE SEAT INSTALLATION REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS CYLINDER HEAD ASSEMBLY ROCKER ARM DISASSEMBLY ROCKER ARM ASSEMBLY CYLINDER HEAD INSTALLATION LOCATING TOP CENTER ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE35-39 THERMOSTAT SERVICE Section 2425 CYLINDER BLOCK Crankshaft, Pistons, Rods, Sleeves, Camshaft, Bearings, Seals and Flywheel 4-390 Diesel Engine 2425-2 SPECIFICATIONS Special Torques SPECIAL TOOLS FRONT OIL SEAL REPLACEMENT REAR OIL SEAL REPLACEMENT FONT OIL SEAL AND WEAR SLEEVE INSTALLATION REAR OIL SEAL AND WEAR SLEEVE INSTALLATION REMOVAL OF PISTONS AND RODS CYLINDER WALL INSPECTION RECONDITIONING THE ENGINE CYLINDER BLOCK Checking and Resurfacing the Cylinder Block Reconditioning the Cylinder Block for Oversize Pistons Reconditioning the Cylinder Block for Sleeves PISTON AND CONNECTING ROD DISASSEMBLY AND INSPECTION PISTON AND CONNECTING ROD ASSEMBLY AND INSTALLATION REPLACEMENT OF THE MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT CRANKSHAFT AND MAIN BEARINGS CRANKSHAFT GEAR REMOVAL CRANKSHAFT INSPECTION CRANKSHAFT RECONDITIONING Grinding a Crankshaft Crankshaft Rehardening CRANKSHAFT GEAR INSTALLATION CRANKSHAFT INSTALLATION Section 2445 LUBRICATION SYSTEM Oil Pan, Oil Pump, Oil Cooler and Oil Filter Housing 4-390 Diesel Engine 2445-2 SPECIFICATIONS SPECIAL TORQUES OIL PUMP Removal Disassembly and Assembly Installation OIL PRESSURE RELIEF VALVE OIL FILTER HOUSING AND OIL COOLER Removal Installation OIL PAN AND OIL INLET TUBE Removal and Installation 2445-3 SPECIAL TORQUES Section 2455 COOLING SYSTEM Thermostat, Water Pump, Fan Pulley and Belt Tensioner 4-390 Diesel Engine 2455-2 THERMOSTAT Removal Installation COOLING INLET MANIFOLD Removal Installation FAN PULLEY BRACKET Removal Installation BELT TENSIONER Removal Installation THERMOSTAT SERVICE SAFETY RULES SPECIAL TORQUES SPECIFICATIONS WATER PUMP Removal Installation Section 2465 TURBOCHARGER 2465-2 SPECIFICATIONS SPECIAL TORQUES SPECIAL TOOLS SERVICING THE TURBOCHARGER Removal Inspection Disassembly Inspection After Disassembly Assembly Installation SPECIFICATIONS Metric Value Turbine Wheel Horizontal Movement Section 2565 TURBOCHARGER FAILURE ANALYSIS 2565-2 CAUSES OF PREMATURE TURBOCHARGER FAILURE Section 3410 FUEL SYSTEM AND FILTERS Section 3413 FUEL INJECTORS 4-390 Diesel Engine 3413-2 SAFETY RULES SPECIFICATIONS SPECIAL TOOLS SPECIAL TORQUES GENERAL INFORMATION OPERATING PROCEDURES LOCATING FAULTY INJECTORS Locating Faulty Injectors at the Fuel Pump Locating Faulty Injectors at the Cylinder Head INJECTORS Removal Installation FUEL INJECTOR TESTER Nozzle Tester Preparation TESTING INJECTORS Checking Opening Pressure Checking Seat Leakage Spray Pattern INJECTOR Disassembly Cleaning and Inspection Assembly Adjustments INJECTOR SLEEVE (9 mm BORE TO 7 mm BORE) Installation Section 3414 CAV FUEL INJECTION PUMP Pump Drive Gear, Fuel ShutOff Primer Pump and Pump Timing 4-390 Diesel Engine 3414-2 SPECIAL TOOLS SPECIAL TORQUES TROUBLESHOOTING GUIDE FUEL INJECTION PUMP Removal Installation INJECTION PUMP GEAR Removal Installation FUEL INJECTION PUMP TIMING FUEL SHUT-OFF SOLENOID Removal and Disassembly Assembly and Installation PRIMER PUMP Removal Installation SPECIAL TOOLS Section 4001 REMOVAL AND INSTALLATION OF ELECTRICAL COMPONENTS 4001-2 STARTER Removal Installation ALTERNATOR Removal Installation DRIVE BELT REPLACEMENT INSTRUMENT CLUSTER Removal Installation Replacing a Bulb Gauge, Voltmeter, or Tachometer Removal and Installation8 Circuit Board Section 4002 ELECTRICAL SPECIFICATIONS, TROUBLESHOOTING, AND SCHEMATICS 4002-2 SPECIFICATIONS3 Starting, Charging, and Instrument Cluster Circuits Warning Buzzer, Parking Brake, Backup Alarm, and Clutch Cutout Return-To-Dig, Cab Relay, Lamp Switches, Turn Signal and Flashers Flood Lamp Switch, High Pressure Switch, and Air Conditioning Compressor Clutch Cab Harness Canopy Harness Cab Harness (Continued) USING BOOSTER BATTERIES TO START THE ENGINE ALPHABETICAL INDEX OF COMPONENTS Section 4003 BATTERY(S) 4003-2 SPECIFICATIONSSee Section 4001 BOOSTER BATTERIESSee Section 4001 SAFETY RULES SPECIAL TOOLS MAINTENANCE Electrolyte Level Inspecting and Cleaning the Battery NONSPILL CAPS BATTERY TEST Visual Checks Specific Gravity Check Capacity (Load) Test CHARGING A BATTERY PREPARING A DRY CHARGED BATTERY FOR USE9 Section 4006 95 AMPERE ALTERNATOR 4006-2 SPECIFICATIONS DISASSEMBLY INSPECTION OF BRUSHES INSPECTION AND TESTING OF ROTOR INSPECTION AND TESTING OF STATOR TESTING THE CONDENSER TESTING THE RECTIFIER BRIDGE INSPECTION AND REPLACEMENT OF BEARINGS ASSEMBLY Section 4007 65 AMP ALTERNATOR A187873 4007-2 SPECIFICATIONS DISASSEMBLY INSPECTION OF BRUSHES INSPECTION AND TESTING OF ROTOR INSPECTION AND TESTING OF STATOR TESTING THE CONDENSER TESTING THE RECTIFIER BRIDGE ASSEMBLY Section 4008 INSTRUMENT CLUSTER 4008-2 INSTRUMENT CLUSTER4 Removal and Installation4 Replacing a Bulb4 Gauge or Tachometer Removal and Installation4 Circuit Board4 CHECKING THE WARNING LAMPS5 Engine Oil Pressure5 Alternator5 Hydraulic Filter and Air Filter5 CHECKING THE GAUGES6 Water Temperature, Oil Temperature, or Fuel Level6 Voltmeter6 CHECKING THE TACHOMETER7 Section 5002 SPECIFICATIONS, SCHEMATIC AND TROUBLESHOOTING SPECIFICATIONS SPECIAL TOOL TROUBLESHOOTING PROCEDURE CHECKING THE PRESSURE SETTING OF THE RELIEF VALVE ADJUSTING THE PRESSURE SETTING OF THE RELIEF VALVE CHECKING PISTON PACKING FOR THE STEERING CYLINDER SCHEMATIC Section 5006 STEERING CYLINDER REPAIR SPECIFICATIONS TWO WHEEL DRIVE STEERING CYLINDER4 Disassembly Inspection Assembly FOUR WHEEL DRIVE STEERING CYLINDER Disassembly Inspection Assembly Section 5007 FRONT AXLE, TWO WHEEL DRIVE MACHINES 5007-2 SPECIFICATIONS FRONT WHEEL BEARINGS Removal and Disassembly Inspection Assembly and Installation Wheel Bearing Adjustment SPLINDLE Removal Installation KiNGPIN BEARINGS AND THRUST BEARINGS Removal Installation TOE-IN Measuring Toe-In Adjustment Section 5008 FRONT AXLE - FOUR WHEEL DRIVE 5008-2 SPECIFICATIONS SPECIAL TOOLS MEASURING TOE-IN DISASSEMBLY OF PLANETARY INSPECTION OF PLANETARY PARTS ASSEMBLY OF PLANETARY REMOVAL AND DISASSEMBLY OF SWIVEL HOUSING REPLACING A UNIVERSAL JOINT ASSEMBLY AND INSTALLATION OF SWIVEL HOUSING REMOVAL OF DIFFERENTIAL CARRIER DISASSEMBLY OF DIFFERENTIAL CARRIER DISASSEMBLY OF DIFFERENTIAL INSPECTION OF DIFFERENTIAL PARTS ASSEMBLY OF DIFFERENTIAL ASSEMBLY OF DIFFERENTIAL CARRIER INSTALLATION OF DIFFERENTIAL CARRIER SECTION INDEX - POWER TRAIN Section Title Section Number Removal and Installation o* Power Train Components6001 Transmission Specifications and Schematic6002 Wheels and Tires6003 PTO6019 Rear Axles and Planetaries6201 Transfer Gearbox6202 Differential and Differential Lock6203 Forward/Reverse Valve6204 Torque Converter Charging Pump, Output Shaft, And Converter Housing6205 Transmission6206 Section 6001 REMOVAL AND INSTALLATION OF POWER TRAIN COMPONENTS 6001-2 SPECIFICATIONS SPECIAL TOOLS REMOVING THE TORQUE CONVERTER HOUSING AND TORQUE CONVERTER INSTALLING THE TORQUE CONVERTER AND TORQUE CONVERTER HOUSING REMOVING THE TRANSAXLE INSTALLING THE TRANSAXLE REPLACING A UNIVERSAL JOINT Section 6002 SPECIFICATIONS, SCHEMATIC AND TROUBLESHOOTING 6002-2 SPECIFICATIONS SPECIAL TOOLS SCHEMATIC OF TRANSMISSION HYDRAULIC SYSTEM TROUBLESHOOTING Problem: Machine Will Not Move Problem: Loss of Power Problem: Oil in Transmission Too Hot Problem: Clutch Discs Wear Too Fast or Are Burned Problem: Brake Discs Wear Too Fast Problem: Pinion Shaft Failure CHECKING CLUTCH PRESSURE CHECKING OUTPUT OF CHARGING PUMP AND SETTING OF CHARGE PRESSURE RELIEF VALVE CHECKING CONVERTER IN PRESSURE AND FLOW CHECKING CONVERTER OUT PRESSURE AND FLOW CHECKING BRAKE COOLING FLOW CHECKING LUBRICATION FLOW AND PRESSURE FOR CLUTCHES CHECKING LUBRICATION FLOW FOR PINION SHAFT Section 6003 WHEELS AND TIRES 6003-2 WHEEL BOLTS AND NUTS Section 6019 HYDRAULIC PTO SPECIFICATIONS SPECIAL TORQUES SPECIAL TOOLS SHOP EQUIPMENT TOOLS PTO HOUSING Removal Installation PTO INPUT SHAFT (PRIMARY) Removal and Disassembly Assembly and Installation PTO CLUTCH Removal Disassembly Inspection Assembly Cross Sectional Drawing of the PTO Clutch Installation PTO VALVE Removal Disassembly Assembly Cross Sectional Drawing of the PTO Valve Installation INPUT AND OUTPUT SHAFTS Removal Installation Section 6201 REAR AXLES AND PLANETARIES 6201-2 SPECIFICATIONS SPECIAL TORQUES SPECIAL TOOLS SHOP EQUIPMENT TOOLS TOOLS TO BE MADE SERVICING THE REAR AXLES AND PLANETARIES Removal Disassembly Inspection Assembly Installation Section 6202 TRANSFER GEARBOX 6202-2 SPECIAL TORQUES SHOP EQUIPMENT TOOLS TRANSFER GEARBOX Removal Disassembly Inspection Assembly Installation Section 6203 DIFFERENTIAL AND DIFFERENTIAL LOCK 6203-2 SPECIFICATIONS SPECIAL TORQUES SHOP EQUIPMENT TOOLS SERVICING THE DIFFERENTIAL AND DIFFERENTIAL LOCK Removal Disassembly Inspection Assembly Installation Section 6204 FORWARD/REVERSE VALVE 6204-2 SPECIFICATIONS SPECIAL TORQUES SHOP EQUIPMENT TOOLS FORWARD/REVERSE VALVE Disassembly Inspection Assembly Section 6205 TORQUE CONVERTER CHARGING PUMP, OUTPUT SHAFT, AND CONVERTER HOUSING 6205-2 SPECIAL TORQUES SHOP EQUIPMENT TOOLS SERVICING THE CHARGING PUMP Removal Disassembly Inspection Assembly Installation SERVICING THE OUTPUT SHAFT Removal Inspection Installation SERVICING THE TORQUE CONVERTER HOUSING Section 6206 TRANSMISSION 6206-2 SPECIFICATIONS SPECIAL TORQUES SPECIAL TOOLS SHOP EQUIPMENT TOOLS TRANSMISSION END COVER Removal Installation SERVICING THE INTERMEDIATE SHAFT Removal Disassembly Inspection Assembly Installation SERVICING THE SHUTTLE SHAFT Removal Disassembly Inspection Assembly Installation SERVICING THE PINION SHAFT Disassembly Inspection Assembly Checking Ring Gear and Pinion Tooth Contact SERVICING THE GEAR SHIFTERS Removal Disassembly Inspection Assembly Installation Adjustment REMOVAL AND INSTALLATION OF THE MAGNETIC SPEED SENSOR INSTALLATION OF TRANSAXLE REAR COVER45 Section 7000 PARKING BRAKE 7000-2 SPECIFICATIONS SPECIAL TORQUES SHOP EQUIPMENT TOOLS SERVICING THE PARKING BRAKE Removal Disassembly Inspection Assembly Installation Section 7002 REMOVAL AND INSTALLATION OF BRAKE COMPONENTS 7002-2 MASTER CYLINDER Removal Installation REMOVING AIR FROM THE BRAKE SYSTEM PARKING BRAKE See Section 7000 DISC BRAKE See Section 7001 Section 7003 MASTER CYLINDER 7003-2 REMOVING AIR FROM THE BRAKE SYSTEMSee Section 7002 MASTER CYLINDER Removal and InstallationSee Section 7002 Disassembly Inspection Assembly Section 8001 REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS 8001-2 OIL COOLER Removal Installation HYDRAULIC PUMP Removal Installation LOADER CONTROL VALVE Removal Installation BACKHOE CONTROL VALVE Removal Installation SWING SEQUENCE VALVE Removal Installation SWING SEQUENCE VALVE ADJUSTMENT THREE-POINT HITCH CONTROL VALVE Removal Installation Section 8002 HYDRAULIC SCHEMATICS, SPECIFICATIONS AND TROUBLESHOOTING 8002-2 SPECIFICATIONS SPECIAL TOOLS TROUBLESHOOTING PROCEDURE FOR PROBLEM IN ALL CIRCUITS TROUBLESHOOTING PROCEDURE FOR PROBLEM IN A SINGLE CIRCUIT MAIN RELIEF VALVE CHECKING OUTPUT OF PUMP WITH FLOWMETER CIRCUIT RELIEF VALVES FOR LOADER AND BACKHOE CONTROL VALVES CIRCUIT RELIEF VALVE FOR THE THREE POINT HITCH CONTROL VALVE ADJUSTING THE MAIN RELIEF VALVE OR A CIRCUIT RELIEF VALVE CROSS-SECTION DRAWINGS Pump Loader Control Valve Steering Control Valve Filter Backhoe Control Valve Three Point Hitch Control Valve Swing Sequence Valve LOADER BACKHOE SCHEMATIC LOADER THREE POINT HITCH SCHEMATIC Section 8004 HYDRAULIC PUMP SPECIFICATIONS DISASSEMBLY INSPECTION ASSEMBLY Section 8005 LOADER CONTROL VALVE 8005-2 SPECIFICATIONS SPECIAL TOOLS SEPARATING THE VALVE SECTIONS5 ASSEMBLING THE VALVE SECTIONS6 OUTLET SECTION Disassembly Exploded View Assembly Cross Section INLET SECTION Disassembly Inspection Exploded View Assembly Cross Section BUCKET SECTION Disassembly Exploded View Inspection Assembly Cross Section LIFT SECTION Disassembly Exploded View Inspection Assembly Cross Section CLAM SECTION Disassembly Exploded View Inspection Assembly Cross Section CIRCUIT RELIEF VALVE Dissasembly Inspection Assembly 8006 CYLINDERS Specifications Special Tools Loader Bucket and Lift Backhoe Extension Bucket Swing, Clam Stabilizer and Dipper Cylinders Disassembly Inspection Assembly Boom Cylinder Disassembly Inspection Assembly Lift Cylinder for the Three-Point Hitch Disassembly Inspection Assembly Tilt Cylinder for the Three-Point Hitch Disassembly Inspection Assembly Pitch Cylinder for the Three-Point Hitch Disassembly Inspection Assembly Section 8007 BACKHOE CONTROL VALVE 8007-2 SPECIFICATIONS SPECIAL TOOLS EXPLODED VIEW OF BACKHOE CONTROL VALVE SEPARATING THE VALVE SECTIONS ASSEMBLING THE VALVE SECTIONS INLET SECTION Disassembly Assembly OUTLET SECTION Disassembly Assembly SWING AND BOOM SECTION Disassembly Assembly STABILIZER SECTION Disassembly Assembly BUCKET, DIPPER, AND EXTENDABLE DIPPER SECTIONS Disassembly Assembly CIRCUIT RELIEF VALVE Disassembly Inspection Assembly INSPECTION Section 8008 SWING SEQUENCE VALVE 8008-2 SPECIFICATIONS DISASSEMBLY INSPECTION EXPLODED VIEW OF SWING SEQUENCE VALVE ASSEMBLY CROSS SECTION VIEW OF SWING SEQUENCE VALVE 8009 THREE-POINT HITCH CONTROL VALVE Specifications 8009-2 Exploded View Special Tools 8009-2 Assembly Separating the Valve Sections 8009-3 Inlet/Outlet and Auxiliary Section Assembling the Valve Sections 8009-5 Disassembly Lift Section 8009-6 Exploded View Disassembly 8009-6 Assembly Exploded View 8009-10 Inspection Assembly 8009-11 Relief Valves Tilt and Pitch Sections 8009-15 Disassembly Disassembly 8009-15 Inspection Assembly Section 8011 DOUBLE SELECTOR VALVE SPECIFICATIONS DOUBLE SELECTOR VALVE Disassembly Inspection Assembly Section 9005 ROPS CAB AND ROPS CANOPY SPECIAL TOOL TORQUE SPECIFICATIONS POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY ILLUSTRATION OF ROPS CANOPY INSTALLATION4 ILLUSTRATION OF SEAT INSTALLATION REMOVAL AND INSTALLATION OF ROPS CAB REMOVAL AND INSTALLATION OF ROPS CANOPY REMOVAL AND INSTALLATION OF HEATER REMOVAL AND INSTALLATION OF TEMPERATURE CONTROL Section 9008 THREE-POINT HITCH 9008-2 REMOVING THE THREE POINT HITCH INSTALLING THE THREE POINT HITCH EXPLODED VIEWS Three Point Hitch Cylinder Hydraulic Installation Three Point Hitch Control Valve and Control Lever Installation              THANKS FOR LOOKING!!  On Jun-29-09 at 11:03:40 PDT, seller added the following information: |
Shipping and handling Item location: DDG, Canada Shipping to: Worldwide
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