Case 580 Super K Loader Backhoe Service Manual, 1992–1996

Case Corporation’s 580 Super K Loader Backhoe service publication 8-17551, printed August 1992, covers machines with P.I.N. JJG0160001 and after. General and engine index forms 8-17141 and 8-17161 organize the service sections, including optional PTO, three-point-hitch equipment, and ROPS cab or canopy installations.

PDF Search, Diagram Detail, and Page Count

Search and drawing detail: An embedded OCR layer supports text searches across the service chapters, but some diagram labels are missing or garbled in search results. There are no embedded PDF bookmarks. Small wiring and hydraulic schematic labels require zooming.

The manual is supplied as one printable, English-language PDF with 1,248 pages, including the cover page, nine tab dividers, and 46 blank pages. Original indexes and reference charts are also included in that total.

Engine, Power-Shuttle, and Loader-Backhoe Service

The following selected service topics summarize the coverage rather than reproduce the full contents. Other sections provide wheel-and-tire specifications and suspension-seat repair procedures.

• Engine and fuel systems: Engine removal, cylinder-head and block repair, cooling and lubrication service, turbocharger diagnosis, injector overhaul, and injection-pump timing.

• Power train: Torque-converter and transaxle removal, power-shuttle hydraulic diagnosis, clutch-pack repair, transmission adjustment, and PTO service.

• Axles, brakes, and steering: Rear axle and planetary repair, differential-lock service, brake repair, and separate steering and front-axle procedures for two- and four-wheel-drive machines.

• Hydraulics: Pressure and flow tests, pump overhaul, loader and backhoe control-valve repair, cylinder service, and circuit schematics.

• Electrical troubleshooting: Circuit-specific fault isolation, wiring diagrams, harness drawings, starter and alternator service, and instrument-cluster tests.

• Mounted equipment: Loader-frame and backhoe component removal, extendable-dipper wear-plate work, ROPS service, heater repair, and air-conditioning diagnosis and component service.

This manual is suited to mechanics familiar with internal engine and transaxle work and equipped for hydraulic flow testing, precision measurement, and heavy-component handling.

Engine Inspection and Internal Repair

Factory step-by-step procedures cover radiator and engine removal, torque-converter separation, and front engine-support alignment. The stall-test check sheet helps distinguish engine performance problems from hydraulic or torque-converter/transmission faults before more focused testing.

Cylinder-head work includes resurfacing inspection, 11 mm and 14 mm valve-guide replacement, valve-seat installation and refacing, rocker-arm service, valve-clearance adjustment, and thermostat service.

The block chapters cover cylinder-wall inspection, machining for oversize pistons or service sleeves, piston and connecting-rod work, crankshaft and main bearings, camshaft service, front and rear seals and wear sleeves, flywheel service, and crankcase blow-by testing. Separate lubrication, cooling, turbocharger, and turbocharger-failure sections provide related procedures and inspection limits.

The manual warns that front-support misalignment can damage the hydraulic pump, while an injector rotating in its cylinder-head bore can damage the head.

Injector Repair and Pump Timing

Injector coverage includes fault isolation, opening-pressure and seat-leakage tests, spray-pattern assessment, disassembly, cleaning, reassembly, pressure adjustment, and nozzle-bore conversion sleeves. CAS-1694 and CAS-2155 bore cleaners are identified for the different injector configurations.

For North American engines, the cylinder-head and injector chapters give conflicting nozzle-changeover serial numbers; the installed nozzle configuration needs to be identified before replacement parts are selected.

The main contents distinguish the CAV pump section for the 4-390 from the Bosch section for the 4T-390. Both cover machine-side pump removal and installation, drive-gear service, timing, fuel-shutoff-solenoid work, and primer-pump procedures. These sections do not provide internal injection-pump overhaul or bench-calibration instructions.

Power Shuttle, Axles, Brakes, and Steering

Transmission diagnosis addresses a machine that will not move, loss of power, overheating, premature clutch or brake-disc wear, and pinion-shaft failure. The transmission hydraulic schematic accompanies clutch-pressure, charging-pump-output, converter inlet/outlet, brake-cooling, and lubrication-flow checks.

Internal repair sections cover the forward/reverse valve, charging pump, output shaft, converter housing, shuttle clutch packs, transmission shafts and synchronizers, pinion preload and end play, and crown-wheel tooth-contact patterns. PTO, rear axle and planetary, transfer-gearbox, and differential-lock procedures are included.

The transaxle removal section warns that moving its levers with the control rods disconnected can release the detents and require transmission disassembly.

Brake coverage includes parking and disc brakes, component removal and installation, master-cylinder repair, and bleeding. Steering sections distinguish Eaton and Danfoss valves, with separate cylinder and front-axle procedures for two- and four-wheel-drive machines, including toe-in and four-wheel-drive planetary service.

Hydraulic Testing and Valve Overhaul

Hydraulic troubleshooting separates faults affecting all circuits from problems in a single circuit. Procedures cover flowmeter testing, main and circuit relief-valve checks and adjustment, system cleaning and flushing, and pump inspection.

Component sections extend to the loader and backhoe valves, cylinders, swing sequence valve, three-point-hitch control valve, and double selector valve. Cross-section drawings complement the Loader Backhoe Schematic and Loader Three Point Hitch Schematic.

Hydraulic work involves raised equipment and trapped pressure; follow the manual’s equipment-support, pressure-relief, and contamination-control precautions.

Electrical Circuits and Harness Drawings

The Starting, Charging, and Instrument Cluster Circuits support power-supply and starting diagnosis. Separate charts address the warning buzzer, parking brake, backup alarm, and clutch cutout.

Return-to-dig, cab-relay, lamp-switch, turn-signal, and flasher circuits are covered alongside the Cab Harness and Canopy Harness drawings. Component chapters cover batteries, the starter and solenoid, 65-amp and 95-amp alternators, and instrument-cluster warning-lamp, gauge, and tachometer checks.

Loader, Backhoe, Cab, and Air Conditioning

Mounted-equipment procedures cover loader-frame removal, bucket cutting edges and teeth, and integral-backhoe swing-tower, boom, dipper, extendable-dipper, and wear-plate work. Quick-coupler and auxiliary-hydraulic installation drawings accompany three-point-hitch removal and ROPS cab, canopy, and heater service.

Air-conditioning coverage extends beyond pressure checks to evacuation and charging, compressor removal, clutch and seal replacement, and valve-plate service.

Workshop Tools and Reference Tables

Tool references include the CAS-1690 engine rotating tool, CAS-2162 torque-angle gauge, CAS-1692A blow-by manometer, CAS-2018 torque-converter alignment tool, CAS-10280 hydraulic flowmeter, and CAS-1989 transmission tool kit with clutch-spring and seal-compression tooling. A dimensioned axle-bearing preload-tool drawing supports workshop tool fabrication.

Reference data include decimal and metric fastener charts, 37-degree flare and O-ring face-seal fitting torques, component torque tables, fluid capacities and lubricants, wear limits, clearances, backlash, preload, and hydraulic and electrical test specifications.

Examples of Valve and Loader Adjustment Data

The cylinder-head section specifies cold rocker-arm-to-valve clearances of 0.254 mm for intake valves and 0.508 mm for exhaust valves, alongside the illustrated adjustment procedures.

For the loader’s return-to-dig adjustment, the pedal-and-lever section gives a switch-to-inner-bucket-link clearance of 0.3–0.7 mm. This is an adjustment specification for that linkage, separate from the hydraulic pressure-test data.