Case 580 D Backhoe Loader 1981 Service Manual

This PDF reproduces J.I. Case service information for the 1981 580D backhoe loader, covering naturally aspirated and turbocharged 207 diesel engines. It includes January 1981 sections and later revisions through August 1983; printed section references include 9-69270, 9-69271, and 9-69272. Starter and alternator sections are marked 9-69720.

Text Search, Section Bookmarks, and PDF Pages

Search and diagram detail: Text search works in parts of the manual, with gaps in specification and drivetrain sections. There are 72 section bookmarks. Small wiring labels require zooming, and some fine detail remains soft.

One printable, English-language PDF contains 1,732 pages, including 1,726 service pages and six additional cover and navigation pages.

Engine, Power Shuttle, and Backhoe Repair Coverage

These selected topics highlight the manual’s coverage. Other sections include battery load testing and hydraulic contamination removal with a portable filter.

• Diesel engine repair: Separate procedures for naturally aspirated and turbocharged 207 engines, from diagnosis and tune-up through internal inspection and reassembly.

• Engine removal and installation: Engine-to-drivetrain removal and installation, front engine support alignment, and torque converter flex plate positioning with tool CAS-1153.

• Power shuttle: Troubleshooting, clutch and cooling circuit pressure tests, forward and reverse clutch repair, and torque converter and hydraulic stall tests.

• Hydraulics and steering: Hydraulic pump diagnosis and overhaul, separate Parker-Hannifin and Hydreco loader control valve repair, and steering component service.

• Axles and driveline: Conventional front axle service and four-wheel-drive axle repair, covering planetary hubs, swivel housings, the differential, axle shafts, and transfer gearbox.

• Loader and backhoe: Attachment removal, swing tower service, pivot bushing replacement, and work on standard and extendable dippers.

• Electrical diagnosis: Chassis and cab wiring diagrams, starting-circuit tests, charging-system checks, and instrument troubleshooting.

The manual is suited to experienced service technicians equipped for precision measurement, hydraulic testing, and lifting major assemblies.

Engine Diagnostics, Maintenance, and Fuel Injection

Systematic engine diagnostics address hard starting, persistent misfires, overheating, power loss, excessive oil consumption, and low oil pressure. Maintenance information includes lubricant recommendations, filter service, and capacity data for engine oil, coolant, and hydraulic systems.

The tune-up sections cover compression testing, injector spray checks, valve adjustment, injection timing, and governed-speed adjustment. Engine accessory coverage distinguishes the air cleaners used with turbocharged and naturally aspirated engines and addresses the ether injection system, radiator, and turbocharger failure analysis.

Roosa Master Model DB injection pump: Coverage includes removal and installation, drive shaft service, pump gear backlash checks, inlet filter replacement, and speed adjustments.

Injector coverage extends to nozzle identification, test-stand checks, disassembly, cleaning, and adjustment. It identifies the M20322 test stand and M20520 injector tool kit.

Internal Engine Repair and Installation Cautions

Step-by-step procedures cover cylinder head, valve train, camshaft, crankshaft, cylinder sleeve, piston, connecting rod, and lubrication system work. The turbocharged engine sections also address the oil filter heat exchanger.

Inspection data includes piston ring end gaps, main bearing oil clearances, camshaft tolerances, sleeve protrusion, and component-specific torque tables, including oil pan drain plug and manifold fastener specifications.

The shared 188/207 engine material identifies an engine serial break at 2072089 affecting rocker arm lubrication and rear camshaft bushing installation. This identifies an engine component change, not a machine serial-number coverage range.

The front engine support installation section explains how misalignment can damage the hydraulic pump or its coupling.

Power Shuttle, Transaxle, and Brake Service

Shuttle repair covers the charging pump, control valve, and clutch cutout controls as well as the clutch components. Pressure-test interpretation helps distinguish clutch circuit leakage from charging or cooling circuit faults.

Separate transaxle and differential lock sections apply to naturally aspirated and turbocharged machines. They document shaft and gear work, shifter assembly repair, differential bearing preload, and ring gear-to-pinion backlash adjustment.

Self-adjusting differential brake procedures are likewise separated by engine configuration, with hydraulic brake cylinder service and pedal-to-transaxle linkage coverage.

Torque converter service is limited to diagnosis, removal, and replacement. A defective converter is replaced rather than internally overhauled.

Hydraulic Testing and Backhoe Configuration Differences

Six flowmeter tests cover loader and steering pump output, circuit leakage, and backhoe flow. Related procedures address main and secondary relief valves, neutral pressure, and the unloading valve. Equipment references include the CAS-10280 flowmeter and CAS-1205 relief-valve test block.

Steering diagnosis includes spool return-to-neutral checks and leakage tests, with repair sections for the pump, control valve, steering column, and cylinder.

The hydraulic sections distinguish standard and Super D backhoe valves, hand-swing and foot-swing controls, and machines with or without an extendable dipper. They also identify different boom and swing restrictor applications.

The Backhoe Hydraulic Circuit on Machines with Hand Swing and Steering System Diagram for Loader Backhoe Machines support circuit tracing. Separate sections cover stabilizer control valve and boom lock valve repair.

Cylinders, Loader Attachments, and Hitch Equipment

Cylinder service covers glands, pistons, seals, and bushings. Attachment repair extends to dipper extension wear strips and guide blocks, bucket cutting edges, and tooth replacement, supported by the Extendable Dipper illustration.

Loader procedures also cover return-to-dig and antirollback adjustment. Optional three-point-hitch coverage includes one-spool and four-spool control valves.

Wiring, Instruments, and Cab Equipment

Electrical troubleshooting includes starting-circuit voltage loss, starter and solenoid testing, alternator component tests, and instrument diagnosis. The Basic Wiring Diagram for Chassis and Cab and Air Conditioner Wiring Diagram accompany canopy lighting diagrams and instrument-cluster printed-circuit information.

Cab coverage includes air-conditioning fault diagnosis, pressure testing, compressor service, and refrigerant-system evacuation and charging procedures. ROPS cab and canopy, seat, seat belt, and noise-control sections round out the mounted-equipment coverage.

Review the factory safety procedures and torque standards before teardown, particularly where raised loader arms, hydraulic pressure, or heavy components are involved.

Preview of Valve Clearances and Hydraulic Test Data

For naturally aspirated and turbocharged 207 engines, the cold valve-tappet specifications give intake clearance as 0.012 inch (0.305 mm) and exhaust clearance as 0.014 inch (0.356 mm).

The hydraulic specifications list a main relief valve setting of 2,400–2,500 psi at full throttle, alongside circuit-specific pressure-test data for the loader and backhoe valves.