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CASE Construction 580 Super R, 580SR, 590 Super R, 590SR, 695 Super M, 695SM, 695 Super R, 695SR Backhoe Loader Service Manual 9-91452 English

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Official Manual Overview

Take absolute command over your heavy-duty CASE 580SR, 590SR, 695SM, and 695SR Backhoe Loaders with this definitive OEM Service Manual. Covering both standard architectures and complex 4-Wheel Steer (4WS) configurations, this master blueprint delivers dealership-level teardown and calibration protocols for every core system. It provides exhaustive reconstruction data for the Carraro front axles and the electrically-controlled locking differential rear axles, enforcing massive factory fastening parameters (such as the 1000 Nm requirement for critical structural bolts). Moving beyond basic chassis repairs, the manual deeply integrates the mechanical overhaul procedures for the 95HP FAGE0454C and 110HP FAGE0484G powerplants, alongside precise pressure mapping and 2009–2065 rpm stall-speed metrics for both PowerShuttle and PowerShift transmissions. Complete with complex pin-by-pin electrical matrices (covering 23-pin AMP connectors to Central Unit relays) and 120 cc/rev Danfoss load-sensing hydraulic steering logic, this uncompromising guide eliminates diagnostic guesswork and restores absolute trenching and loading precision.

  • Brands: CASE Construction
  • Equipment Type: Backhoe Loader
  • Manuals Type: Service Manual
  • Machine Model: 580 Super R, 580SR, 590 Super R, 590SR, 695 Super M, 695SM, 695 Super R, 695SR
  • Serial Number: N/R
  • Region: N/R
  • Book Code: 9-91452
  • Issued: Printed in France, January 2005
  • Language: English
  • Pages: 996
  • File Format: PDF (Searchable)

Core Selling Points

  • Micro-Tolerance Drivetrain Assembly: Reconstruct the 4WD and 4WS drivetrains with uncompromising factory precision. The manual dictates exact structural fastening matrices, demanding 1000 Nm for critical front axle mounting hardware, 678 Nm for rear axle securing points, and 500 Nm for the loader control linkages. It thoroughly eliminates assembly guesswork by enforcing a strict 0.025 to 0.076 mm bearing end-float tolerance on the Four Wheel Drive shaft, utilizing highly specific shim increments ranging from 0.050 mm up to 0.508 mm.
  • Powershift Electronic Control Diagnostics: Master the transmission's digital logic without relying on expensive dealership scanners. This guide decodes the onboard 8-LED diagnostic matrix, allowing technicians to instantly translate light patterns (e.g., LED 2 Orange indicating a reverse solenoid open circuit) and specific fault codes (such as F11 "Start Up Fault Limp Home Selected" or F12 "Key Start ON") into actionable mechanical repairs, effectively bypassing the parts-cannon approach.
  • Comprehensive Pin-by-Pin Harness Schematics: Take total control over the machine's electrical nervous system. The literature features massive, high-resolution fold-out circuit diagrams covering the LVC Pilot Control, Cold Start network, and Cab Heating systems. It breaks down complex multi-pole AMP connections (like the XC1, XC2, and X16 fuse board harnesses) wire-by-wire, specifying exact voltage paths and ground points to trace severe shorts or severed communication lines.

Features & Highlights

  • Dynamic Hydraulic Benchmark Testing: Restore absolute breakout force and implement precise factory fluid calibrations. The text provides absolute pressure benchmarks, instructing technicians to verify the System Pressure Test port at 13.7 to 15.2 bar (198-220 psi), the Torque Converter relief valve at 10 bar, and the HPCO valves at up to 202 bar. It explicitly lists the required use of the proprietary Pressure Test Quick Release Coupler (Part No. 291924).
  • Proprietary OEM Tooling Registry: Equip your heavy machinery shop with the exact factory tool specifications required for complex, damage-free teardowns. The guide mandates specific service instruments, including the Danfoss No. SJ seal installer for steering control units and the SKF Induction Heater TIH 020 to properly expand and seat interference-fit taper roller bearings onto the axle half-shafts.
  • Specialized 4WS & Steering Motor Calibration: Navigate the complex geometry of the 4-Wheel Steer architecture with confidence. The documentation details the complete mechanical overhaul of the 120 cc/rev hydrostatic load-sensing steering motor and provides step-by-step troubleshooting charts to isolate front wheel surging directly to a leaking power cylinder, a stuck control valve spool, or a damaged metering element.

Problem Solver

  • Eradicates Paralyzing "Limp Home" Lockouts: Stop blindly replacing expensive transmission controllers. By utilizing the manual's internal switch logic procedures, mechanics can systematically test the directional modulation solenoids, verifying the exact 5.0-ohm resistance across the directional coils and 7.0-ohm resistance on the FWD valves to permanently cure 2nd-gear-only restrictions.
  • Resolves Severe Brake Drag & Overheating: Prevent premature wear of the wet-disc systems and binding hydrostatic travel. The guide walks builders through the precise mechanical adjustment of the brake disc and caliper assemblies, mandating an exact 0.5 mm clearance between the brake pads and disc, followed by a strict 4 to 5 click adjustment on the handbrake cable clevis.
  • Cures Unexplained Hydraulic Power Loss: Pinpoint elusive fluid drops within the main vehicle pump or HUSCO control valves. Technicians are provided with exhaustive flow-testing charts and visual leakage classifications (from Class 0 to Class 3), enabling them to isolate erratic loader responses to a fractured transmission drive rod, a sticking regulator valve, or a failed 4.3 bar filter bypass valve.

Important Pre-Purchase Advisories

  • Complete Heavy Equipment Blueprint: This expansive Service Manual serves as the ultimate diagnostic and structural reference for the entire machine, uniquely incorporating both the complete chassis systems (axles, Powershuttle/Powershift transmissions, loader/backhoe linkages) AND the deep mechanical overhaul instructions for the diesel engine. Furthermore, it strictly notes that any temporary wiring harness repairs must be executed using exclusively resin-cored solder to prevent chemical ingress during agricultural or spraying operations.

Table of Contents

  • SECTION 10 - ENGINE

    • Chapter 1 - Injection pump
      • Special tools
      • Removal
      • Installation

  • SECTION 17 - TORQUE CONVERTOR

    • Chapter 1 - With Powershuttle Transmission
      • Description Page
      • Specifications
      • Tightening Torques
      • Description and Operation
      • Overhaul
      • Control Valve
      • Transmission
      • Input shaft
      • Fault Finding
      • Differential Disassembly -- Powershuttle / Powershift

  • SECTION 21 - TRANSMISSIONS

    • CHAPTER 1 - 4x4 Compact Shuttle
      • Description Page
      • General Specifications
      • Description and Operation
      • Overhaul

  • SECTION 25 - FRONT AXLES

    • CHAPTER 1 - Front Axle for 2 and 4 Wheel Drive Only
      • Description Page
      • General Specifications
      • Overhaul
    • CHAPTER 2 - Front Axle for 4 Wheel Steer Only
      • Description Page
      • General Specifications
      • Overhaul

  • CHAPTER 3 - Front Axle

    • Description Page
    • Identification
    • Overhaul

  • CHAPTER 7 - Front Axle

    • Description Page
    • Identification
    • Overhaul

  • CHAPTER 10 - Front Axle

    • Description Page
    • Identification

  • SECTION 27 - REAR AXLES

    • CHAPTER 1 - Rear Axle with Foot Operated Diff Lock for 2 and 4 Wheel Drive Only
      • Description Page
      • General Specifications
      • Overhaul
    • CHAPTER 2 - Rear Axle with Electrically Operated Diff Lock for 2 and 4 Wheel Drive Only
      • Description Page
      • General Specifications
      • Overhaul
    • CHAPTER 3 - Rear Axle for 4 Wheel Steer Only
      • Description Page
      • General Specifications
      • Overhaul
    • CHAPTER 4 - Rear Axle
      • Description Page
      • Identification
      • Overhaul

  • SECTION 33 - BRAKE SYSTEMS

    • CHAPTER 1 - Brakes for 2 and 4 Wheel Drive Only
      • Description Page
      • General Specifications
      • Overhaul
    • CHAPTER 2 - Brakes for 4 Wheel Steer Only
      • Description Page
      • General Specifications
      • Overhaul

  • SECTION 35 - HYDRAULIC SYSTEMS

    • CHAPTER 1 - Hydraulic Circuits and Components for HUSCO Only
      • Description Page
      • General Specifications
      • Hydraulic Valve Spool Seals
      • Stabliliser and Extendible Dipper Control Valves
      • Loader Control Valve
      • Backhoe Control Valve
    • CHAPTER 3 - Hydraulic Circuits and Components for REXROTH
      • Description Page
      • General Specifications
      • Description and Operation
      • Hydraulic Circuits
    • CHAPTER 5 - Control Valves for REXROTH with Mechanical or Hydraulic Control
      • Description Page
      • General Specifications
      • Overhaul
      • Disassembly
    • CHAPTER 6 - Swing System and Hydraulic Cylinders
      • Description Page
      • General Specifications
      • Swing System Description and Operation
      • Hydraulic Cylinders Description and Operation
      • Backhoe and Loader Cylinders - Removal and Installation
      • Backhoe and Loader Cylinder Overhaul
      • Swing Cylinder Removal and Overhaul
    • CHAPTER 7 - Hydraulic Pump
      • Description Page
      • General Specifications
      • Tightening torques
      • Description and Operation
      • Pump Overhaul
    • CHAPTER 8 - Rexroth Control Blocks
      • Description Page
      • General Specifications
      • Tightening torques
      • Exploded Wiew of the Lever
      • Overhaul of the Control Block

  • SECTION 39 - VEHICLE CHASSIS

    • CHAPTER 1 - CHASSIS COMPONENTS
      • Description Page
      • General Specifications
      • Overhaul

  • SECTION 41 - STEERING SYSTEMS

    • CHAPTER 1 - Steering for 2 and 4 Wheel Drive Only
      • Description Page
      • General Specifications
      • Fault Finding
      • Overhaul
    • CHAPTER 2 - Steering for 4 Wheel Steer Only
      • Description Page
      • General Specifications
      • Fault Finding
      • Overhaul

  • SECTION 50 - CAB HEATING AND AIR CONDITIONING

    • CHAPTER 1 - Cab Heating
      • Description Page
      • General Specifications
      • Fault Finding
      • Overhaul
    • CHAPTER 2 - Cab Air Conditioning
      • Description Page
      • General Specifications
      • Description & operation
      • Fault Finding
      • Overhaul

  • SECTION 55 - ELECTRICAL SYSTEM

    • CHAPTER 1 - System General
      • Description Page
      • Electrical equipment specifications
      • General Specifications
      • Tempory wiring harness repair
      • Electrical System General Fault Finding
    • CHAPTER 5 - Battery
      • Description Page
      • General Specifications
      • Removal and Installation
      • Battery Maintenance and Tests
    • CHAPTER 7 - Component Testing
      • Description Page
      • General Introduction
      • Component Testing
      • Component Earth Points
      • Key start and stop switch
      • Starter motor - starter relay
      • Safety start relais
      • Alternator
      • Transmissions
      • Cab
      • Steering control unit
      • Loader
      • Backhoe
    • (Schematics & Panels)
      • Lights (Schematic No. 4)
      • Lights - rear lights (Schematic No. 5)
      • Working lights (Schematic No. 6)
      • Windshield wiper & washer (Schematic No. 7) European model
      • Windshield wiper & washer (Schematic No. 7) NA model
      • Indicator switch & Beacon (Schematic N°7) N/America
      • Light switch & beacon (Schematic N°7) Europe
      • Heater (Schematic No. 8)
      • Optional Sear (Schematic N°8)
      • Cold start (Schematic No. 9) / Cold Start (Schematic N°9)
      • Side Instrument panel & Key Start
      • Front Instrument panel

  • SECTION 82 - LOADER

    • CHAPTER 1 - Loader Frame, Controls and Buckets for 2 and 4 Wheel Drive Only
      • Description Page
      • Tightening Torques
      • Special Tools
      • Specifications
      • General Specifications
      • Description and Operation
      • Overhaul
      • Overhaul -- Loader Controls
      • Return to Dig
    • CHAPTER 2 - Loader Frame, Controls and Buckets for 4 Wheel Steer Only
      • Description Page
      • General Specifications
      • Overhaul

  • SECTION 84 - BACKHOE

    • CHAPTER 1 - Backhoe, Boom and Dipperstick assembly
      • Description Page
      • General Specifications
      • Description and Operation
      • Backhoe Control Linkage Overhaul
      • Component Removal
      • Dipperstick and Boom--Complete Assembly
      • Dipperstick
      • Swing Post
      • Carriage Removal
      • Extendible Dipperstick Overhaul
      • Extendible Dipperstick--Overhaul and Wear Pad Adjustment