Case 580 Super K (580SK) Construction King Backhoe Loader Service Manual, 1991–1997

Case factory service information for the 580 Super K (580SK) Construction King loader backhoe, P.I.N. JJG0160001 and after. The compiled manual includes Engine Removal and Installation, Section 2001, Form 8-17560.

PDF Search, Bookmarks and Diagram Detail

Navigation and fine print: PDF text search is not available. Section bookmarks are included, although some chapters have no separate bookmark. Small wiring labels require zooming; the reduced valve-seat dye-pattern chart has soft fine print.

ZIP download containing one printable English PDF with 1,195 pages, including one front cover, two general contents pages and two sealant-reference pages.

Engine, Powertrain and Hydraulic Workshop Coverage

The following is a selection of the covered work, not a complete contents list. Further topics include battery load testing and magnetic speed-sensor removal and installation.

• Engine and fuel system: Radiator and engine removal, torque-converter removal and installation, stall testing, cylinder-head and block overhaul, turbocharger service and failure analysis, injector testing and injection-pump timing.

• Powertrain: Transaxle and converter-housing removal, hydraulic PTO repair, rear axles and planetaries, transfer gearbox, differential lock, forward/reverse valve, charging pump, output shaft and internal transmission service.

• Steering and brakes: Eaton and Danfoss steering-control-valve repair, steering cylinders, 2WD and 4WD front axles, parking and disc brakes, master-cylinder repair and bleeding.

• Hydraulics: Fault isolation, relief-valve and pump-flow tests, system cleaning and water flushing; repair of pumps, loader/backhoe/three-point-hitch control valves, cylinders, swing sequence valve and double selector valve.

• Electrical diagnosis: Circuit test charts, cab/canopy harness data, starter and alternator repair, plus instrument-cluster, warning-lamp, gauge and tachometer checks.

• Air conditioning: Pressure diagnosis, leak testing, evacuation and charging, compressor service and component replacement.

• Mounted equipment: Return-to-dig and antirollback setup, loader-frame and backhoe-structure service, extendable dipper, ROPS, three-point hitch, standard and suspension seats, and seat belts.

This manual is suited to readers experienced in heavy-equipment repair and equipped for hydraulic flow testing and precision engine measurement.

Cylinder Head, Block and Fuel-System Repair

Step-by-step cylinder-head procedures cover disassembly, resurfacing checks, valve-guide and valve-seat replacement, valve refacing, rocker-arm service, installation, top-center location and valve-clearance adjustment.

The block chapter adds front and rear oil seals and wear sleeves, piston and rod inspection, cylinder-block reconditioning, main-bearing replacement without removing the crankshaft, crankshaft and camshaft service, flywheel and ring-gear work, and a crankcase-pressure test.

Engine configurations: Specifications distinguish naturally aspirated 4-390 and turbocharged 4T-390 applications. Cylinder-head data separate U.S.-built, Darlington-built and Neuss-built engines by injector configuration and engine serial break. Injector-identification guidance supports selection of matching replacement injectors and seals.

Injection equipment: Injector tests cover opening pressure, leakage and spray pattern. Separate CAV and Bosch pump sections address removal, installation, drive gears, timing, shutoff solenoids and primer pumps; Bosch timing includes dial-indicator checks. Internal injection-pump overhaul is outside these sections.

Lubrication and cooling procedures cover the oil pump, oil cooler, water pump, thermostat, fan pulley and belt tensioner. The cylinder-head chapter explains how machining marks relate to head-gasket selection and warns that an injector rotating in its bore can damage the head. Turbocharger failure analysis identifies bearing damage caused by inadequate lubrication during startup or loading.

Transmission Diagnosis, Axles and PTO

Transmission troubleshooting charts address a machine that will not move, loss of power, overheated transmission oil, rapid clutch or brake-disc wear, and pinion-shaft failure.

Related tests cover clutch pressure, charging-pump output, converter inlet and outlet pressure and flow, brake-cooling flow and lubrication flow. Together, these checks help trace a drive complaint before selecting the relevant internal repair procedure.

Internal repair: Gear-contact checks, bearing preload, end play and shift-linkage adjustment accompany the transmission procedures. PTO-equipped machines receive separate clutch, valve, shaft, pressure-test and removal information.

The 2WD front-axle section covers wheel bearings, kingpins and thrust bearings. The 4WD section adds planetary, swivel-housing and front-differential repair.

Hydraulic Fault Isolation and Valve Assembly

Troubleshooting separates problems affecting every circuit from faults isolated to one cylinder or control-valve section. These charts help determine whether testing should focus on the common supply or an individual cylinder or valve.

Loader control valve: Reassembly information identifies section numbering, inter-section O-rings and the original shim arrangement. Exploded views and cross sections cover the PTO clutch and valve, hydraulic pump, loader and backhoe valves, swing sequence valve, cylinders, loader frame, backhoe structures and three-point hitch.

Electrical Variants, A/C and Backhoe Structures

Electrical coverage separates standard and optional battery arrangements and the 65-amp and 95-amp alternator systems. A/C procedures extend to compressor clutch, seal, valve-plate and gasket replacement, as well as the evaporator and condenser.

Backhoe procedures cover swing-tower, boom, dipper and dipper-extension removal and installation, including wear-plate and shim selection for an extendable dipper. Bucket cutting-edge and tooth work, loader-frame installation and three-point-hitch installation are also included.

Schematics, Tools and Service References

Diagram examples include Starting, Charging and Instrument Cluster Circuits, Cab Harness and Canopy Harness layouts, the Schematic of Transmission Hydraulic System, Loader Backhoe Schematic and Loader Three Point Hitch Schematic. Steering has its own schematic and component views.

Workshop equipment: Engine work calls for the CAS-1690 rotation tool and CAS-2081 alignment tool; PTO and transmission work uses the CAS-1992 clutch spring compressor. Hydraulic testing identifies the CAS-1804/CAS-10111 pressure fitting kit and CAS-10280 flowmeter. Cleaning procedures specify the CAS-10162A portable filter and CAS-10508 fitting kit.

The ROPS chapter includes a dimensioned drawing for a shop-made steering-wheel puller. Reference pages provide standard and component-specific torque tables, approved fluids and capacities, pressure and flow specifications, wear limits, clearances, preload and end-play data, electrical test values, adjustment dimensions and tightening sequences.

Support raised loader or backhoe structures, relieve stored hydraulic pressure, keep clear of injector test spray, and follow the refrigerant-handling instructions before opening an A/C circuit. The ROPS chapter treats a damaged cab or canopy as a replacement item rather than a weld-or-straighten repair.

The content is factory service information for diagnosis and repair; it is not a parts catalog or operator's manual.

Examples of Pump-Flow and Alternator Test Data

Hydraulic specifications list 24 U.S. gpm for the rear pump section serving the loader and steering, and 9 U.S. gpm for the front section serving the backhoe. Both figures apply at 2,000 psi and 2,000 rpm; the flow-test procedures specify oil warmed to 125°F (52°C).

The 65-amp alternator section specifies rotor-winding resistance of 2.52–3.08 ohms for its slip-ring test.