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580sr 590sr 695sr Series 3 Loader Backhoe Service Manual
Great Shop Repair Manual
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Manufacturers Specifications.
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This Great Manual
Includes the Following Sections
Section 00 Safety Precautions
Section 01 Maintenance
Section 02 Technical Specifications
Section 17 Torque Converters
Section 21 Transmission
Section 25 Front Axles
Section 27 Rear Axle
Section 33 Brakes System
Section 35 Hydraulic System
Section 39 Chassis
Section 41 Steering System
Section 50 Cab Heating and Air Conditioning
Section 55 Electrical System
Section 82 Loader
Section 84 Backhoe
SECTION 00 - SAFETY PRECAUTIONS
SECTION 01 - MAINTENANCE
SECTION 02 - TECHNICAL SPECIFICATIONS
1. LOADER BACKHOE MODELS .................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. SPECIFICATIONS....................................................................................................................................... 6
3.1 DIESEL ENGINE .................................................................................................................................. 6
3.2 TRANSMISSION................................................................................................................................... 8
3.3 AXLES .................................................................................................................................................. 9
3.4 BRAKES ............................................................................................................................................... 9
3.5 STEERING.......................................................................................................................................... 10
3.6 HYDRAULIC SYSTEM ........................................................................................................................ 10
3.7 FRONT COUNTERWEIGHT ............................................................................................................... 10
3.8 NOISE AND VIBRATION LEVELS ...................................................................................................... 11
3.9 BUCKETS........................................................................................................................................... 11
3.10 TYRES.............................................................................................................................................. 12
4. DIMENSIONS AND PERFORMANCE........................................................................................................ 13
4.1 LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ....................................................... 13
4.2 DIMENSIONS AND PERFORMANCE OF LOADER ATTACHMENT WITH FORKS.......................... 19
4.3 BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE .................................................... 20
5. BACKHOE ATTACHMENT LIFTING CAPACITY....................................................................................... 26
6. MAXIMUM LIFTING LOADS....................................................................................................................... 29
6.1 LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................ 29
6.2 BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ......................................................... 30
7. SUPPLY SUMMARY TABLE...................................................................................................................... 31
SECTION 17 - TORQUE CONVERTERS
1. POWERSHUTTLE TORQUE CONVERTER................................................................................................ 3
1.1 DESCRIPTION AND OPERATION........................................................................................................ 3
1.2 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 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 SPECIFICATIONS ................................................................................................................................ 3
1.2 MOUNTING SCREW TORQUE............................................................................................................. 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 SPECIFICATIONS ............................................................................................................................... 94
2.2 CONTROLS ........................................................................................................................................ 95
2.3 LUBRICATION.................................................................................................................................. 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER................................................................................................................ 108
2.6 HYDRAULIC DIAGRAM..................................................................................................................... 109
2.7 OPERATION..................................................................................................................................... 110
2.8 POWER FLOWS............................................................................................................................... 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION REMOVAL AND INSTALLATION........................................................................ 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 SPECIFICATIONS ................................................................................................................................ 3
1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 6
1.3 FAULT FINDING................................................................................................................................. 24
2. FRONT AXLE 4WD “CARRARO” ............................................................................................................... 26
2.1 SPECIFICATIONS ............................................................................................................................... 26
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 31
2.3 FAULT FINDING................................................................................................................................. 77
3. FRONT AXLE 4WS “CARRARO” ............................................................................................................... 80
3.1 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 SPECIFICATIONS................................................................................................................................ 6
1.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8
1.4 FAULT FINDING................................................................................................................................. 27
2. REAR AXLE 4WS “CARRARO”.................................................................................................................. 28
2.1 SPECIFICATIONS.............................................................................................................................. 28
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 32
2.3 FAULT FINDING................................................................................................................................. 81
3. SPECIAL TOOLS....................................................................................................................................... 84
SECTION 33 - BRAKES SYSTEM
1. SPECIFICATIONS....................................................................................................................................... 3
2. PARKING BRAKE........................................................................................................................................ 6
2.1 PARKING BRAKE ADJUSTMENT ........................................................................................................ 7
3. BRAKE CYLINDERS ................................................................................................................................... 8
4. OIL BRAKE TANK ..................................................................................................................................... 13
5. 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 SIDESHIFT PILOT MODELS.............................................................. 5
1.3 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS................................................. 7
1.4 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS.............................................................. 9
1.5 HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .................................................... 11
2. HYDRAULIC PUMP................................................................................................................................... 13
2.1 DESCRIPTION AND OPERATION...................................................................................................... 13
2.2 SPECIFICATIONS.............................................................................................................................. 13
2.3 LOAD SENSING VALVE ..................................................................................................................... 16
2.4 REMOVAL .......................................................................................................................................... 18
2.5 COMPONENTS .................................................................................................................................. 19
2.6 DISASSEMBLY AND ASSEMBLY....................................................................................................... 20
3. CONTROL VALVES .................................................................................................................................. 24
3.1 CONTROL VALVES “REXROTH” (MECHANICAL MODELS) ............................................................ 24
3.2 “REXROTH” CONTROL VALVES (PILOT MODELS) ......................................................................... 40
3.3 SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE
(WITH HYDRAULIC CONTROL) .......................................................................................................... 49
3.4 RELIEF VALVES ................................................................................................................................ 52
3.5 ACCUMULATOR “GLIDE RIDE” PARKER.......................................................................................... 60
4. HYDRAULIC SWING SYSTEM .................................................................................................................. 63
4.1 DESCRIPTION AND OPERATION...................................................................................................... 63
4.2 HYDRAULIC OIL FLOW...................................................................................................................... 64
5. HYDRAULIC CYLINDERS......................................................................................................................... 66
5.1 LOADER ATTACHMENT BOOM CYLINDER ..................................................................................... 67
5.2 LOADER BUCKET CYLINDER ........................................................................................................... 72
5.3 4X1 LOADER BUCKET CYLINDER.................................................................................................... 76
5.4 BACKHOE BOOM CYLINDER ............................................................................................................ 79
5.5 BACKHOE ATTACHMENT DIPPER CYLINDER ................................................................................ 83
5.6 BACKHOE BUCKET CYLINDER......................................................................................................... 87
5.7 TELESCOPIC CYLINDER ................................................................................................................... 91
5.8 4WS STABILIZER CYLINDER - CENTER PIVOT............................................................................... 95
5.9 STABILIZER CYLINDER - SIDESHIFT ............................................................................................... 99
5.10 SWING CYLINDER......................................................................................................................... 103
5.11 BACKHOE ATTACHMENT SIDESHIFT CYLINDER - SIDESHIFT................................................. 107
5.12 SPECIAL TOOLS............................................................................................................................ 108
6. HYDRAULIC CONTROL LEVERS............................................................................................................ 109
6.1 SPECIFICATIONS ............................................................................................................................. 109
6.2 DESCRIPTION AND OPERATION.................................................................................................... 110
6.3 DISASSEMBLY AND ASSEMBLY..................................................................................................... 113
6.4 CONTROL LEVER VALVE ................................................................................................................ 116
7. FAULT FINDING...................................................................................................................................... 119
7.1 PRELIMINARY CHECKS................................................................................................................... 119
7.2 FAULT FINDING............................................................................................................................... 120
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 ON THE CHASSIS.................................................................................. 9
2.5 MOUNTING SCREW TORQUE........................................................................................................... 11
SECTION 41 - STEERING SYSTEM
1. STEERING SYSTEM 2WS ........................................................................................................................... 4
2. STEERING SYSTEM 4WS ........................................................................................................................... 7
3. POWER STEERING .................................................................................................................................. 12
3.1 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. 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 CONTROLS AND OPERATION .......................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 26
3.5 FLUSHING THE SYSTEM................................................................................................................... 44
3.6 EVACUATING THE SYSTEM.............................................................................................................. 46
3.7 CHARGING THE SYSTEM.................................................................................................................. 47
3.8 COMPONENTS OVERHAUL .............................................................................................................. 48
3.9 COMPRESSOR.................................................................................................................................. 53
3.10 SPECIAL TOOLS.............................................................................................................................. 67
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 ROPS (580SR).......................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR)........................................................... 20
2.3 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (580SR)................................................................. 36
2.4 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR+/590SR) ............................................ 54
2.5 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (590SR)................................................................. 69
2.6 ELECTRICAL DIAGRAMS - 4WS POWERSHIFT CAB (695SR)........................................................ 84
3. CONTROLS AND INSTRUMENTS .......................................................................................................... 100
3.1 FRONT CONTROL PANELS (580SR / 590SR) ................................................................................ 100
3.2 FRONT CONTROL PANELS (695SR) .............................................................................................. 102
3.3 SIDE INSTRUMENT CLUSTER PANEL (580SR)............................................................................. 104
3.4 SIDE INSTRUMENT CLUSTER PANEL (580SR+ / 590SR / 695SR)............................................... 106
3.5 SIDE INSTRUMENT CLUSTER (580SR).......................................................................................... 108
3.6 SIDE INSTRUMENT CLUSTER (580SR+ / 590SR / 695SR)............................................................ 110
3.7 IMMOBILISER CIRCUIT.................................................................................................................... 112
4. DIAGNOSTIC DISPLAY (580SR+ / 590SR / 695SR) ............................................................................... 113
4.1 SYMBOLS......................................................................................................................................... 114
4.2 SETUP MENU .................................................................................................................................. 115
4.3 PROCEDURE ABOUT SELF TEST .................................................................................................. 116
4.4 ON BOARD ERROR CODE RETRIEVAL ......................................................................................... 117
4.5 BACKLIGHTING AND DIMMING....................................................................................................... 118
4.6 WORK HOURS................................................................................................................................. 119
4.7 FUNCTIONAL DESCRIPTION .......................................................................................................... 120
4.8 WARNING SYSTEM......................................................................................................................... 124
4.9 MAINTENANCE................................................................................................................................ 126
4.10 WARNING MESSAGES .................................................................................................................. 127
5. STARTING SYSTEM............................................................................................................................... 134
5.1 DESCRIPTION AND OPERATION.................................................................................................... 134
5.2 FAULT FINDING............................................................................................................................... 135
5.3 STARTER MOTOR........................................................................................................................... 138
6. ALTERNATOR......................................................................................................................................... 144
6.1 SPECIFICATIONS............................................................................................................................ 144
6.2 DESCRIPTION AND OPERATION.................................................................................................... 144
6.3 COMPONENTS ................................................................................................................................ 146
6.4 REMOVAL ........................................................................................................................................ 147
6.5 PRELIMINARY CHECK AND TESTS................................................................................................ 148
6.6 FAULT FINDING............................................................................................................................... 157
7. BATTERY ................................................................................................................................................ 158
7.1 SPECIFICATIONS............................................................................................................................ 158
7.2 DESCRIPTION AND OPERATION.................................................................................................... 158
7.3 BATTERY REPLACEMENT .............................................................................................................. 159
7.4 MAINTENANCE................................................................................................................................ 161
7.5 TESTS .............................................................................................................................................. 163
7.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 165
7.7 BATTERY MASTER SWITCH ........................................................................................................... 165
8. COMPONENT TESTING .......................................................................................................................... 166
8.1 GENERAL INTRODUCTION ............................................................................................................. 166
8.2 COMPONENT TESTING................................................................................................................... 167
8.3 GROUND POINTS............................................................................................................................ 167
8.4 ALTERNATOR.................................................................................................................................. 170
8.5 TRANSMISSIONS ............................................................................................................................. 170
8.6 PARKING BRAKE SWITCH............................................................................................................... 174
8.7 CAB................................................................................................................................................... 175
8.8 4WD SWITCH................................................................................................................................... 180
8.9 BRAKE PEDAL SWITCHES .............................................................................................................. 180
8.10 BRAKE OIL LEVEL WARNING LAMP............................................................................................. 181
8.11 FRONT WORK LAMP SWITCH (1) - REAR WORK LAMP SWITCH (2) MAIN LIGHT SWITCH.... 181
8.12 HAZARD SWITCH ........................................................................................................................... 182
8.13 HAZARD WARNING LIGHT RELAY................................................................................................ 182
8.14 MULTI FUNCTION SWITCH............................................................................................................ 183
8.15 FRONT WINDSHIELD WIPER MOTOR (1) - REAR WINDSHIELD WIPER MOTOR (2) ............... 183
8.16 4WS - STEERING SELECTOR SWITCH ........................................................................................ 184
8.17 STEERING CONTROL UNIT........................................................................................................... 185
8.18 4WS REAR AXLE STEERING SENSOR......................................................................................... 187
8.19 4WS FRONT AXLE STEERING SENSOR ...................................................................................... 187
8.20 STEERING SOLENOID VALVE....................................................................................................... 188
8.21 DIFFERENTIAL LOCK SWITCH (1) ................................................................................................ 189
8.22 LOADER ......................................................................................................................................... 190
8.23 BACKHOE....................................................................................................................................... 193
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 3
1.1 LOADER ATTACHMENT OPERATION................................................................................................. 3
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 6
3. LOADER ATTACHMENT SAFETY STRUT.................................................................................................. 7
4. LOADER BUCKET REMOVAL ..................................................................................................................... 8
5. LOADER REMOVAL.................................................................................................................................. 11
SECTION 84 - BACKHOE
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION ............................................................ 6
3. BACKHOE ATTACHMENT HYDRAULIC CONTROLS .............................................................................. 15
4. REMOVAL AND INSTALLATION ............................................................................................................... 17
4.1 CENTER PIVOT BACKHOE ATTACHMENT DISASSEMBLY............................................................ 17
4.2 BACKHOE ATTACHMENT DISASSEMBLY - SIDESHIFT.................................................................. 20
4.3 BACKHOE BUCKET REMOVAL ......................................................................................................... 23
4.4 BUCKET TEETH REPLACEMENT...................................................................................................... 23
4.5 DIPPER REMOVE.............................................................................................................................. 24
5. TELESCOPIC DIPPER REVISION............................................................................................................. 27
6. TELESCOPIC DIPPER REVISION............................................................................................................. 27
7. REVISIONE DEL BRACCIO TELESCOPICO............................................................................................. 27