580L 580 Super L 590 Super L Series Service Manual PDF

Section
7003
7003
MASTER CYLINDER
CASE CORPORATION
700 STATE STREET
RACINE, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright © 1995 Case Corporation
3350 SOUTH SERVICE ROAD Bur 7-49490 Printed in U.S.A.
BURLINGTON, ON L7N 3M6 CANADA Issued May 1995
Template Name: SM_2_col Alt= to hide template information
Template Date: 1994_04_05 Alt+ to display template information
7003-2
TABLE OF CONTENTS
MASTER CYLINDER ..................................................................................................................................................................... 2
Disassembly ............................................................................................................................................................................. 2
Inspection ................................................................................................................................................................................. 4
Assembly .................................................................................................................................................................................. 4
NOTE: The Case Corporation reserves the right to make improvements in design or changes
in specifications at any time without incurring any obligation to install them on units previously
sold.
MASTER CYLINDER
Disassembly 12. Hit the open end of the master cylinder against a piece of
wood to move the piston assembly to the end of the
1. Clean the outside of the master cylinder. master cylinder.
2. Fasten the body (6) of the master cylinder is the vise. 13. Pull the piston assembly from the master cylinder.
3. Remove the flow valve adapter (1) from the master 14. There is a small tab in the spring seat (12) that holds the
cylinder. spring seat (12) on the piston (13). Use a screwdriver to
left up the tab.
4. Remove the flow valve (3) fro the master cylinder.
15. Remove the check valve assembly from the piston (13).
5. Remove the ball (5) from the master cylinder
16. Remove the seal (14) from the piston (13).
6. Remove the gasket (2) from the flow valve adapter (1).
17. Disconnect the check valve seat (10) from the spring seat
7. Remove the flow valve seal (4) fro the flow valve (3). (12).
8. Loosen the lock nut. Remove the clevis and lock nut from 18. Remove the spring (11) from the spring seat (12).
the push rod (15).
19. Remove the check valve seat (10) fro the check valve
9. Remove the boot (18) from the body (6). piston (8).
10. Remove the snap ring (17) from the body (6). 20. Remove the wave spring (9) from the check valve piston
(8).
11. Remove the push rod (15) and washer (16) from the body
(6). 21. Remove the check valve seal (7) from the check valve
piston (8).
Bur 7-49490 Issued 5-95 Printed in U.S.A.

7003-3
3
4
5 6
8
9
10
11
12
13
14
17 15
16
18
B9502283T
1. Flow Valve Adapter 6. Body 11. Spring 16. Washer

2. Gasket 7. Check Valve Seal 12. Spring Seat 17. Snap Ring
3. Flow Valve 8. Check Valve Piston 13. Piston 18. Boot
4. Flow Valve Seal 9. Wave Spring 14. Seal
5. Ball 10. Check Valve Seat 15. Push Rod
Master Cylinder

7003-4
Inspection 14. Lubricate the flow valve seal (4) and the flow valve (3)
with clean hydraulic oil. Install the flow valve (3) in the
1. Inspect the bores in the body (6) for scoring, pitting, or bore in the master cylinder. The flow valve (3) must be
other damage. If the bores in the body (6) are damaged a centered in the bore of the master cylinder.
new master cylinder must be used.
15. Install a new gasket (2) on the flow valve adapter (1).
2. Check the tab in the spring seat (12). Push the tab down
a small amount so that the tab will engage the end of the 16. Carefully start the flow valve adapter (1) into the bore in
piston (8). to hold the check valve assembly in place. If the master cylinder by hand. If the flow valve adapter (1)
the tab is broken, use a new master cylinder. cannot be turned into the master cylinder completely by
hand remove the flow valve adapter (1) from the master
3. Inspect the flow valve (3), ball (5). check valve piston (8), cylinder and make sure that the flow valve (3) is in the
piston (13), and the push rod (15) for scoring, pitting, or center of the bore in the master cylinder.
other damage. If the flow valve (3), ball (5), check valve
piston (8), piston (13) or the push rod (15) are damage a 17. Repeat step 16 until the flow valve adapter (1) can be
new master cylinder must be used. turned completely into the master cylinder by hand.
18. Tighten the flow adapter (1) to 30 to 40 pound-feet (41 to

Assembly 47 Nm).
1. Install the check valve seal (7) on the check valve piston 19. See Section 7002 and install the master cylinder on the
(8). machine.
2. Install the spring (11) on the spring seat (10). 20. Depress the brake pedal and allow the piston to return.
Adjust the push rod to piston clearance to 0.025 to 0.050
3. Instal the check valve assembly in the spring (11). inch (0.6 to 1.3 mm). Turn the clevis clockwise to shorten
Engage the stem of the check valve piston (8) in the or counterclockwise to lengthen. Tighten the lock nut
spring seat (12). against the clevis. See the illustration below.
4. Install the check valve assembly on the piston (13). Push
the check valve assembly onto the piston (13) until the
tab in the spring seat (12) engages the end of the piston
(13).
0.025 to 0.05 Inch
(0.6 to 1.3 mm)
5. Install the seal (14) on the piston (13).
6. Lubricate the bore of the body (6) with clean hydraulic

fluid.
7. Install the piston assembly into the bore of the body (6).
8. Push the piston assembly into the bore until the push rod
(15) and washer (16) can be installed. B870123R
9. Install the push rod (15) and washer (16).

1. 0.025 to 0.050 INCH (0.6 to 1.3 mm)
10. Install the snap ring (17).
11. Install the boot (18).
12. Install the lock nut and clevis on the push rod (15). Do not
tighten the lock nut on the push rod at this time.
13. Install the ball (5) in the body (6).

7003-5
3
4
5 6
8
9
10
11
12
13
14
17 15
16
18
B9502283T
1. Flow Valve Adapter 6. Body 11. Spring 16. Washer

2. Gasket 7. Check Valve Seal 12. Spring Seat 17. Snap Ring
3. Flow Valve 8. Check Valve Piston 13. Piston 18. Boot
4. Flow Valve Seal 9. Wave Spring 14. Seal
5. Ball 10. Check Valve Seat 15. Push Rod
Master Cylinder

Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM
CASE CORPORATION
700 STATE STREET
BURLINGTON, ON L7N 3M6 CANADA Issued May 1995
8003-2
TABLE OF CONTENTS
PORTABLE FILTER ..................................................................................................................................................... 3
GENERAL INFORMATION ............................................................................................................................................ 4
TYPES OF CONTAMINATION ....................................................................................................................................... 4
CLEANING THE HYDRAULIC SYSTEM .......................................................................................................................... 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM .................................................................................................... 7
NOTE: The Case Corporation reserves the right to make improvements in design or
changes in specifications at any time without incurring any obligation to install them on units
previously sold.
Bur 7-49640 Issued 5-95 Printed in U.S.A

8003-3
SPECIAL TOOLS
806128
The part number for the Fitting Kit is CAS-10508.
806127
The part number for the Portable Filter is CAS-10162A.

8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major cause of 1. Cylinder rod seals leak.
the malfunction of hydraulic components. Contamination is
any foreign material in the hydraulic oil. Contamination can 2. Control valve spools do not return to neutral.
enter the hydraulic system in several ways.
3. Movement of control valve spools is difficult.
1. When you drain the oil or disconnect any line.
4. Hydraulic oil becomes too hot.
2. When you disassemble a component.
5. Pump gears, housing, and other parts wear rapidly.
3. From normal wear of the hydraulic components.
6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals.
7. Quick failure of components that have been repaired.
5. From a damaged component in the hydraulic system.
8. Cycle times are slow; machine does not have enough
All hydraulic systems operate with some contamination. power.
The design of the components in this hydraulic system
per mits efficient operation with a small amount of If your machine has any of these problems, check the
contamination. An increase in this amount of contamination hydraulic oil for contamination. See Types of Contamination
can cause problems in the hydraulic system. The following list below. If you find contamination, use the Portable Filter to
includes some of these problems. clean the hydraulic system.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic and 3. Visible contamination is foreign material that can be
visible. found by sight, touch, or odor. Visible contamination can
cause a sudden failure of components. Examples of
1. Microscopic contamination occurs when very fine visible contamination:
particles of foreign material are in suspension in the
hydraulic oil. a. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. Microscopic b. Air in the oil.
contamination can be found by identification of the
following problems or by testing in a laboratory. Examples c. The oil is dark and thick.
of the problems:
d. The oil has the odor of burned oil.
a. Cylinder rod seal leak.
e. Water in the oil. See page 7.
b. Control valve spools do not return to NEUTRAL.
c. The hydraulic system has a high operating

temperature.

8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. See the fitting kit shown on page 3. Install the valve in the
following steps: hole for the drain plug. Make sure that the valve is closed.
a. Remove all the hydraulic oil from the inlet and outlet 9. Stop the vacuum pump.
hoses for the portable filter.
10. Connect the inlet hose for the portable filter to the valve
b. Remove the filter element from the portable filter. that is installed in the hole for the drain plug.
c. Remove all hydraulic oil from the portable filter. 11. Disconnect the vacuum pump from the filler cap opening
on the hydraulic reservoir.
d. Clean the inside of the housing for the filter
element. 12. Install the outlet hose for the portable filter in the
hydraulic reservoir.
2. You must know whether the contamination is microscopic
or visible. See Types of Contamination on page 4. 13. Open the valve that is installed in the hole for the drain
plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON position.
a. Check the maintenance schedule for the machine to Start and run the engine at 1500 rpm (r/min).
lear n if the hydraulic oil must be changed. If
needed, change the hydraulic oil. See Section 1002 15. Run the portable filter for 10 minutes.
for specifications. Change the hydraulic filter.
16. Continue to run the portable filter. Increase the engine
b. Do steps 6 through 38. s p e e d t o f u l l t h r o t t l e. H e a t t h e o i l t o o p e r a t i n g
temperature by doing the following steps:
4. If the contamination is visible:
a. Hold the bucket control lever in the ROLLBACK
a. Change the hydraulic oil and hydraulic filter. See position for 15 seconds.
Section 1002 for oil specifications.
b. Return the bucket control lever to NEUTRAL for 30
b. Do steps 5 through 38. seconds.
5. Check the amount of contamination in the hydraulic c. Repeat steps 17a through 18b until the oil in the
system by doing the following steps: hydraulic system is at operating temperature.
a. Disassemble one cylinder in two different circuits. 17. Continue to run the engine at full throttle. Continue to run
Check for damage to seals, scoring of the cylinder the portable filter.
wall, etc. Repair the cylinders as necessary.
18. Operate each hydraulic circuit to completely extend and
b. If, in your judgment, the damage to the cylinders retract the cylinders. Continue to operate each hydraulic
was caused by severe contamination and is not the circuit two times, one after the other, for 45 minutes.
result of normal wear, it is necessary to remove,
clean and repair valves, pump, lines, cylinders, 19. Decrease the engine speed to low idle.
hydraulic reservoir, etc. in the hydraulic system.
20. Continue to run the portable filter for 10 minutes.
6. Connect a vacuum pump to the hydraulic reservoir air
breather hose. Start the vacuum pump. 21. Stop the portable filter.
7. Loosen and remove the drain plug from the reservoir. 22. Stop the engine.
23. Remove the hose from the hydraulic reservoir.

8003-6
24. Close the valve that is installed in the hole for the drain 30. Stop the vacuum pump. Disconnect the vacuum pump
plug. from the hydraulic reservoir.
25. Disconnect the inlet hose for the portable filter from the 31. Remove the hydraulic filter element from the machine.
valve.
32. Install a new hydraulic filter element on the machine.
26. Connect a vacuum pump to the breather hose of the
hydraulic reservoir. 33. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
27. Start the vacuum pump.
34. Start the engine. Check for oil leakage around the new
28. Remove the valve from the hole for the drain plug. hydraulic filter.
29. Install the drain plug. 35. Stop the engine.

8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 9. Move each control lever in both directions to release
pressure in the hydraulic circuits.
2. Completely retract the cylinders of all attachments on the
machine. 10. Disconnect the line from the rod end and closed end of
each cylinder.
WARNING: If retracting the cylinder rods 11. Be sure all control levers are in the NEUTRAL position.
causes the attachment to be raised, block
! the attachment in place before proceeding to
the next step!
12. Start the engine and run the engine at low idle.
39-4 IMPORTANT: C h e ck t h e o i l l eve l i n t h e hy d ra u l i c

reser voir frequently while doing step 14. Have another
NOTE: Any attachment or part of an attachment that is person hold a container under the hydraulic lines while
raised must be supported with acceptable equipment to you do step 14.
prevent the attachment from falling.
13. Slowly move each control lever in both directions until oil
3. Loosen and remove the filler cap from the reservoir. begins to flow from the open line. Hold the control lever in
place until clean oil flows from the open line.
4. Drain the hydraulic oil from the reservoir.
14. Stop the engine.
a. The reservoir holds approximately 15 U.S. gallons
(56.8 litres) of hydraulic oil. NOTE: Any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
b. Have available acceptable equipment to drain the prevent the attachment from falling.
hydraulic oil.
15. Connect the line to the CLOSED end of each cylinder.
c. Remove the drain plug from the bottom of the
reservoir. 16. Start the engine and run the engine at low idle.
5. Remove the hydraulic oil filter from the machine. 17. Slowly and completely extend all cylinders. As the piston
rod comes out of the cylinder, oil will be pushed out of the
6. Install a new hydraulic oil filter on the machine. rod end of the cylinder.
7. Install the drain plug in the bottom of the reservoir. 18. Support the loader frame so that the loader frame will
stay in the RAISED position.
8. Fill the hydraulic reservoir with 14.4 U.S. gallons (54.5
litres) of Case TCH Fluid. 19. Stop the engine.
20. Connect the lines to the rod end of the cylinders.
21. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
22. Install the filler cap for the reservoir.

9002
Section
9002
AIR CONDITIONER TROUBLE SHOOTING
FOR SYSTEMS WITH R-134a REFRIGERANT
(Visual and Operating)
CASE CORPORATION
700 STATE STREET
BURLINGTON, ON L7N 3M6 CANADA Issued July 1995
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES .............................................................................................................................................. 3
SPECIAL TOOLS ........................................................................................................................................................ 4
TROUBLESHOOTING ............................................................................................................................................... 5-7
EXTERNAL COMPRESSOR CHECK ............................................................................................................................ 8,9
BLOWER MOTOR AND COMPRESSOR CLUTCH CHECK .......................................................................................... 10-13
CAB TEMPERATURE CHECK ................................................................................................................................. 14,15
VISUAL REFRIGERANT CHECK ................................................................................................................................. 16
CAB HEATER CHECK ............................................................................................................................................... 17
EVAPORATOR AND PLENUM CHECK ..................................................................................................................... 18,19
PRESSURE SWITCH CHECK ..................................................................................................................................... 20
AIR CONDITIONING CONTROL SWITCH CHECK .......................................................................................................... 21

Current Check ....................................................................................................................................................... 21
Sensing Line Check ............................................................................................................................................... 21
previously sold.

9002-3
SAFETY PROCEDURES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS
!
SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS
AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY
OR DEATH. M171B
Refrigerant R-134a is the most stable, and easiest to work 3. Keep refrigerant containers in the correct upright position.
with of the refrigerants now used in air conditioner systems. Always keep refrigerant containers away from heat and
Refrigerant R-134a does not contain any chlorofluorocarbons sunlight. The pressure in a container will increase with
(CFC’s) which are harmful to the earth’s ozone layer. heat.
Safety procedures must be followed when working with 4. Always reclaim the refrigerant from the system if you are
Refrigerant R-134a to prevent possible personal injury. going to weld or steam clean near the air conditioner
system.
1. Always wear safety goggles when doing any service work
near an air conditioner system. Liquid refrigerant getting 5. Always check the temperature and pressure of the air
into the eyes can cause serious injury. Do the following if conditioner system before reclaiming refrigerant and
you get refrigerant in or near your eyes: when you test the system.
A. Flush your eyes with water for 15 minutes. 6. Dangerous gas can form when refrigerant comes in
contact with an open flame. Never permit fumes to be
B. See a family physician immediately inhaled.
2. A drop of liquid refrigerant on your skin may cause 7. Never leak test with compressed air or flame testers.
frostbite. Open the fitting carefully and slowly when it is Te s t s h a ve i n d i c a t e d t h a t , a t p r e s s u r e s a b o ve
necessary to service the air conditioner system. Your skin atmospheric, and with air concentrations greater than
must be treated for frostbite or a physician must be seen 60% by volume, R-134a can form a combustible gas.
if you get refrigerant on your skin.

9002-4
SPECIAL TOOLS
A22094 299L7B
REFRIGERANT RECOVERY, 9 INCH STEM TYPE THERMOMETER

RECYCLING AND CHARGING 0 TO 250° F CAS-10248
STATION OEM-1418
A22090
299L7A ELECTRONIC LEAK DETECTOR OEM-1437
SAFETY GOGGLES
CAS-10073-3
299L7C
BELT TENSION TOOL

CAS-10808

9002-5
TROUBLESHOOTING
1. Perform a visual inspection of the machine. Check the C. Are there any sharp bends or kinks in the hoses?
following and correct as necessary:
D. Are compressor clutch and pressure switch leads
A. Are the compressor and fan drive belts in place and plugged into the harness?
at the correct tension?
E. Are there heavy accumulations of oil or oily dust
B. Are grille screens, radiator, and condenser around the fittings, indicating refrigerant leakage?
unobstructed?
PROBLEM
NO COOLING
COMPRESSOR RUNS COMPRESSOR DOES NOT RUN
MECHANICAL
See External Compressor Check Page 8
ELECTRICAL
See Blower and Compressor

Clutch Check Page 10
REFRIGERANT
See Visual Refrigerant Check Page 16
INTERNAL SYSTEM PROBLEM
See Gauges and Testing Section 9003

9002-6
TROUBLESHOOTING
PROBLEM
NOT ENOUGH COOLING
MECHANICAL
ELECTRICAL
See Blower and Compressor

Clutch Check Page 10
REFRIGERANT
See Visual Refrigerant Check Page 16

9002-7
TROUBLESHOOTING
PROBLEM
INTERMITTENT COOLING
MECHANICAL
ELECTRICAL
See Blower Switch Check Page 11.

See Blower Motor Check Page 10.
See Compressor Clutch Check Page 10.
See Cutoff Relay Check Page 12.
PROBLEM
SYSTEM MAKES NOISE
MECHANICAL
See External Compressor Check Page 8.

See Blower Motor Check Page 10.
ELECTRICAL
See Compressor Clutch Check Page 10.

9002-8
EXTERNAL COMPRESSOR CHECK
Compressor
and Fan Loose or broken drive belts -
1 Belts Adjust the tension on a new
belt at 95 to 115 lbs (422 to 516
N) and at 90 to 110 lbs (400 to
489 N) after a minimum of ten
minutes run-in time on the belt.
Belt tension on a used belt
2 must be 90 to 110 lbs (400 to
489 N).
Too much belt wear - Replace a

BP9503119
worn belt, because a worn belt
1. Belt Tension Tool 2. Compressor Belt
will cause too much slip.
Compressor
Mounting Loose bracket mounting bolts -
Brackets Tighten the bolts to the correct
torque.
Brackets have breaks or cracks

- Replace the brackets.
BP9503114
Compressor The compressor belt will slip on

1 Clutch the compressor pulley if there
is a compressor seizure.
Remove the compressor for
service or replacement. See
Section 9005 of this ser vice
manual.
Remove the dust cover and

3 check the air gap on the
2 compressor clutch. The gap
BP9503115 between the front plate and
1. Belt 3. Compressor pulley assembly must be 0.41
2. Air Gap to 0.79 mm. See Section 9005
of this manual.
Use a socket wrench to slowly

rotate the compressor clock-
w is e. C om pres s or rot ati on
s h o ul d b e s m o ot h a n d no t
(Continued on next page) require much effort.

9002-9
(External Compressor Check Continued)
1 Pulley and Belt

Alignment The compressor pulley and the
fan pulley must be aligned
within 1/16 inch (1.6 mm) of
2 each other. Use a straight edge
to ch eck p ul ley al ig nme nt.
Adjust the compressor
mounting bracket if needed.
The drive belt should be
located in the forward clutch
groove.
BP9503115
1. Compressor Pulley 2. Fan Pulley

9002-10
BLOWER MOTOR AND COMPRESSOR CLUTCH CHECK
1 Keyed Power Turn on the ignition and the

Blower Fuse blower switch. Adjust the air
(25 Ampere) conditioner control to high.
2
Remove the cover panel at the
right-hand side of the loader
control console.
BP9504001
Check to see if the blower fuse
1. Cab Power Relay 2. Blower Fuse - 25 Amp is failed. Check the voltage at
the cab power relay. The cab
power relay is relay No. 2 on
the decal on the cover panel.
(Continued on next page)

9002-11
(Blower and compressor clutch check continued)
Blower Switch Check the switch operation.

The switch must give three
1 different blower speeds - Low
(I), Medium(II), and High(III).
BP9504002
1. Blower Switch
Check for loose connections or
The following is a list of the terminals on the blower switch. wires that have damage.
Repair or replace wires as
“B” Battery - power from fuse block. necessary.
“L” Low Speed - to blower motor resistor.
“M” Medium Speed - to blower motor resistor.
“H” High Speed - to blower motor.
“C” Compressor Clutch - to air conditioning switch.
The blower switch is connected
to the blower motor through a
resistor on low and medium
speed. See Section 4001 and
check the resistor if the blower
does not operate on low and
medium speed. The resistance
value for low speed is 0.504 to
0.616 ohms and for medium
speed the resistance value is
0.144 to 0.176 ohms.Test the
black wire harness if the blower
does not operate on high
speed. See Section 4001 in
A22091 this manual for blower switch
troubleshooting to test the high
speed switch position.

9002-12
Blower Motor Check the voltage at the blower

motor. Make repairs or replace
items as necessary.
A22101
Air Conditioner The compressor clutch must
Control Switch engage when the air
conditioner control switch is
tur ned fully on. The blower
1 switch must be on because
e le ct r i ca l pow er is c om in g
through the blower switch. See
Air Conditioner Control Switch
check in this section.
Test th e c irc ui ts of the ai r

conditioner control switch if the
BP9504003
compressor clutch does not
1. Air Conditioner Control Switch engage.
Cutoff Relay Check the relay for the

compressor clutch shutdown.
1 The clutch will not operate if
the system pr essure is too
2 high, above 385 PSI (2653
kPa), or too low, below 6 PSI
(41 kPa). The pres sure
indicator lamp will illuminate
when the relay is actuated. The
relay must be reset to operate
the compressor clutch if it has
been actuated. The power to
the relay must be interrupted to
BP9504002 reset the relay. Tur n the air
1. Air Conditioner Indicator Lamp conditioner control to the off
2. Air Conditioner Control Switch position to start the
compressor if the relay has

9002-13
High and Low Che ck the vo ltage at the

Pressure switches.
Switches
1. No voltage at switch -
break in wire from air
conditioner control switch.
2. Current through switch -

switch is ba d. See
Pressure Switch Check in
this section.
BP9503105 3. System pressure is too low

or too high.
Compressor The compressor clutch must

Clutch disengage when the wire lead
to the clutch is disconnected.
The current draw of the clutch

coil field must be 3.6 to 4.2
amperes at 12 volts. See
Section 9005 of this ser vice
manual.
BP9504004

9002-14
CAB TEMPERATURE CHECK
Air Louvers Close the recirculation louvers.
1
Make sure the cab discharge
louvers and defroster louvers
are open.
Make sure the blower control is

set on high and the air
BP9504005 conditioner temperature control
1. Air Discharge Louvers is on maximum.
BP9504006
1. Recirculation Louvers Air Conditioner Carefully feel the air
Hose Check conditioner hoses. The high
pressure hose must be warmer
than the low pressure hose.
2 If there is no temperature dif-

ference between the hoses -
1. The system is low on

refrigerant.
2. There is a restriction in the

system.
BP9504007
1. High Pressure Hose 2. Low Pressure Hose
3. The compressor is not
operating.

9002-15
(Cab temperature check continued)
Louver
Temperature Record the ambient tempera-
ture reading from a ther-
mometer placed in front of the
grille screen.
Put a thermometer in the

center air discharge louver and
r u n t h e c o m p r e s s or fo r 1 0
minutes to make sure the
system has stability.
BP9504008
C om p ar e t h e t he r m o me t er
reading and ambient
temperature reading to the
chart. If the reading is higher
than the values in the chart:
1. The system may need

refrigerant. Refer to
Section 9003.
2. There is restriction in the

system.
3. The compressor is not

operating.
4. The heater control valve is

leaking.
5. Evaporator air is by-

passing the core.
6. Evaporator core may be

plugged.
7. Expansion valve mal-

functioning.
AMBIENT TEMPERATURE CENTER LOUVER

TEMPERATURE
80°×F (27 °C).................................................55 to 63° F (13 to 17 °C)

90°×F (32 °C).................................................62 to 70° F (17 to 21 °C)
100°×F (38 °C)...............................................69 to 77° F (21 to 25 °C)
110°×F (43 °C)...............................................73 to 81×°F (23 to 27°C)
120°×F (49 °C)...............................................78 to 86×°F (26 to 30°C)

9002-16
VISUAL REFRIGERANT CHECK
Compressor Make sure that all hose

Hoses connections are tight.
C h e ck h o s e s fo r b e n d s o r
cracks. Replace all hoses that
have damage.
BP9504007
Leak Finding Stop the engine.

Check
1
WARNING: When refrigerant comes in

contact with an open flame, it can form
! dangerous gas. Never breathe these fumes.
SM109B
A22090
1. Electronic Leak Detector

Use electronic leak detector
OEM-1437 to inspect all
connections for leaking
refrigerant. The cab headliner
must be rem oved to detect
leaks around the expansion
valve.
NOTE: When checking the

compressor seal for a leak,
remove the dust cover and
rotate the clutch shaft
clockwise.
Repair all leaks and recharge

the system. See Section 9004.

9002-17
CAB HEATER CHECK
Heater Hoses Make sure the heater control is

in the off position. Feel the
heater hoses to see if they are
hot. The hoses may be hot due
1 to heat from air flow around the
2
engine.
The heater control valve in the

cab is not working if the hoses
are hot from engine coolant.
BP9410049
1. Heater Return Valve 2. Heater Hose
Heater Control Close the heater return valve at
Valve th e eng i ne. Tu r n th e va lve
clockwise to stop the flow of
coolant through the heater
core.
1
Check the temperature of the
cab heater hoses again.
Check the cab air louver

temperature.
BP9504009
1. Heater Control Valve
If it increases, check the
position of the heater control
valve. It should be completely
closed.
Replace the valve if the control

knob is at the OFF stop and
leakage is detected through the
valve.

9002-18
EVAPORATOR AND PLENUM CHECK
Evaporator Core R emove the h ead li ne r a nd

remove the evaporator core.
Check the fins on the evapora-

tor. All the fins that have bends
or damage must be made
straight.
BP9504010 Ke e p t h e eva p o r a t o r c o r e
1. Evaporator Core clean. If the core is dry, use
compressed air or a vacuum. If
the core is wet, flush the core
with water using a hose without
pressure.
If th e eva po ra to r c ore i s
ex t r e m e l y d i r t y, c h e ck t h e
condition of the air filter. Also
review the manner of operation
of the machine. Do not operate
the machine with doors and/or
windows open and with the
recirculation louver open. This
can allow dirt to be sucked into
the evaporator core and cause
it to become plugged.
Plenum Sealing Correct plenum sealing will

permit air through the
evaporator but not around the
evaporator.
1 See Section 9005 in this

manual for plenum sealing.
BP9504011
1. Plenum

9002-19
(Evaporator and plenum check continued)
Filters Keep the air filter elements

clean to provide maximum air
flow into the operator cab.
BP9504012
1. Filters

9002-20
PRESSURE SWITCH CHECK

The low pressure switch is located in the roof of the cab in the Normal operating conditions will see 26 to 51 PSI (180 to 355
low pressure tube to the evaporator.The high pressure switch kPa) on the low side of the system. The low pressure switch
is located at the front of the tractor and behind the grille. is open whenever the pressure is above 2 to 6 PSI (14 to 41
kPa). Below this the switch closes and sends a signal to the
relay to disengage the compressor clutch.
STEP 1
Check both terminals of the low pressure switch with a test
E ngin e O F F, key sw itc h O N, blowe r sw itc h O N, and lamp. If voltage is available at both terminals and pressure is
temperature control switch turned fully clockwise. not below 2 PSI (14 kPa), replace the switch.
NOTE: With the engine OFF, system pressure will
equalize on both sides of system to approximately 75 PSI STEP 3
(520 kPa) at room temperature.
Both pressure switches should remain in the open position.
To check system pressure, refer to Section 9003 in this

manual.
STEP 2
BP9503105
High pressure switch located at condenser.
Check for 12 VDC at high pressure switch. If no voltage,

check temperature control switch. Refer to Air Conditioner
Control Switch in this section.
Check both terminals of high pressure switch with a test

lamp. If voltage is present at both terminals and pressure is
BP9504013 not above 385 PSI (2 654 kPa), replace the switch.
Low pressure switch located in cab roof.
Check for 12 VDC at low pressure switch with a test lamp. If

no voltage, check temperature control switch. Refer to Air
Conditioner Control Switch Check in this section.

9002-21
AIR CONDITIONING CONTROL SWITCH CHECK

Current Check Sensing Line Check
The temperature control switch is located in the panel on the STEP 2
right-hand center cab post.
T h e t e m p e r a t u r e c o n t r o l sw i t c h s e n s e s eva p o ra t o r 2
temperature and controls current flow for compressor clutch
operation. 1
The switch interrupts current flow to the clutch at 33° F to 37°

F (0.6° C to 2.8° C) and will allow the clutch to energize at
42° to 70° F (5.6° C to 21° C) depending on switch position.
If the temperature control switch malfunctions, replace it.
STEP 1 T97352
1. Container of Ice and Water
2. Sensing Line
Engine OFF, key switch ON, and blower switch ON.

1
Turn temperature control switch fully clockwise. Remove
sensing tube from evaporator.
Place end of sensing tube in a container with ice and water

mixture.
STEP 3
BP9504003
1. Temperature Control Switch
Engine OFF, key switch ON, and blower switch ON.

1
Turn temperature control switch fully clockwise.
Check voltage at temperature control switch terminal with

orange/green wire No. 85. If voltage is less than 5, check
blower switch.
Check Voltage at temperature control switch terminal with

orange/brown wire No. 60. If less than 5 volts, replace
BP9504003
temperature control switch.
1. Temperature Control Switch
When the sensing tube has cooled to the temperature of the

ice and water mixture, the temperature control switch should
interrupt the current flow to the compressor.
Check for current at temperature control switch terminal with

the No. 60 and No. 85 wires. Use a test lamp connected to a
good ground.
If current is not interrupted, replace the temperature control

switch.

9003
Section
9003
AIR CONDITIONER SYSTEM

GAUGES AND TESTING
CASE CORPORATION
700 STATE STREET
BURLINGTON, ON L7N 3M6 CANADA Issued July 1995
9003-2
TABLE OF CONTENTS
SPECIAL TOOLS ........................................................................................................................................................ 2
PRESSURE - TEMPERATURE CHART .......................................................................................................................... 4
A/C RECOVERY AND CHARGING STATION CONNECTIONS ........................................................................................... 5
PROBLEM - NO COOLING ....................................................................................................................................... 7-10
PROBLEM - NOT ENOUGH COOLING ..................................................................................................................... 11-19
PROBLEM - INTERMITTENT COOLING ................................................................................................................... 20,21
PROBLEM - NOISE IN SYSTEM .................................................................................................................................. 22
previously sold.
SPECIAL TOOLS
A22094
Refrigerant Recovery, Recycling and Charging Station OEM-1418

9003-3
SAFETY PROCEDURES

!
OR DEATH. M171B
Safety procedures must be followed when working with 4. Always reclaim the refrigerant from the system, if you are
system.
B. See a family physician immediately. inhaled.
2. A drop of liquid refrigerant on your skin may cause 7. Never leak test with compressed air or flame testers.

9003-4
PRESSURE - TEMPERATURE CHART
SOLID DRIVE FAN VISCOUS FAN
AMBIENT NORMAL LOW NORMAL HIGH NORMAL LOW NORMAL HIGH

TEMPERATURE SIDE PRESSURE SIDE PRESSURE SIDE PRESSUIRE SIDE PRESSURE
80×°F(27°C) 26 to 36 PSI 200 to 240 23 to 33 PSI 205 to 255 PSI

(180 to 250 kPa) (1 378 to 1 654 kPa) (158 to 227 kPa) (1 412 to 1 757 kPa)
90°F (32°C) 33 to 43 PSI 230 to 270 PSI 30 to 40 PSI 245 to 295 PSI
The pressure-temperature chart is based on the following

conditions:
1. Engine operating at 1500 RPM.
2. No engine load.
3. Fan speed control in High position.
4. Door open.
5. Thermostat on maximum setting ten minutes after

startup.
6. Maximum fresh air mode.
7. Side panels at hood installed.
8. Heater valve at engine shut off.

9003-5
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1
WARNING: Always wear safety goggles
when working with liquid refrigerant. Liquid
! re fr i ge ra nt in y ou r ey es c ou l d c au s e
blindness. SM0105A
STEP 3
BP9504007
Clean the external surfaces of the compressor and hoses.
Remove the caps from the service ports on the suction and
pressure hoses.
WARNING: Do not steam clean any air

conditioning parts while the system is Make sure the charging station manifold gauge valves are in
! charged. The heat will cause the refrigerant the closed position.
to rise to a pressure that could cause the
system to explode. SM104A
STEP 4
STEP 2
BP9505002
Start the and run the engine at 1500 RPM. Operate the air
BP9505001 conditioner system at maximum cooling setting and blower
Connect the hoses from the test gauges to the service ports. speed for 10 minutes with the cab door open. Observe the
test gauges and check the chart on page 4 against the gauge
Connect the hose from the low pressure gauge to the port on readings.
the suction hose.
Connect the hose from the high pressure gauge to the port on
the discharge hose.

9003-6
LOW PRESSURE HIGH PRESSURE SEE

PROBLEM GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 7
NO COOLING HIGH HIGH 8-10
NOT ENOUGH COOLING NORMAL TO SLIGHTLY HIGH NORMAL 11-12
NOT ENOUGH COOLING LOW LOW 13-15
NOT ENOUGH COOLING HIGH LOW 16
NOT ENOUGH COOLING HIGH HIGH 17-18
NOT ENOUGH COOLING LOW NORMAL 19
INTERMITTENT COOLING LOW HIGH 20
INTERMITTENT COOLING LOW LOW 21
NOISE IN SYSTEM NORMAL TO HIGH HIGH 22

9003-7
PROBLEM - NO COOLING
See pressure - temperature

VERY LOW VERY LOW chart on Page 4.
476L7
No Refrigerant - Indications: 1. Leak test the system. See Section 9002 in this manual.
A. Discharge air from evaporator warm. 2. Remove any remaining refrigerant from the system. See
Section 9004 in this manual.
B. Compressor does not run, or cycles off rapidly after
start up. 3. Repair system leaks as needed. Follow the given repair
procedure.
4. Check level of oil in the compressor - possible for

compressor to have an oil loss. See Section 9005 in this
manual.
5. Remove air and moisture from the system. See Section

9004 in this manual.
6. Charge the system with new refrigerant. See Section

7. Continue performance test for other possible problems.

9003-8
PROBLEM - NO COOLING

HIGH HIGH chart on Page 4.
476L7
Condenser Malfunctioning - Indications: 1. Check for loose or worn compressor belt and proper
engine fan operation.
A. Liquid line very hot.
2. Check to see that condenser, radiator, and grille screen
B. Discharge air from evaporator warm. are clean and that hood and radiator seals are in place.
3. Remove and check condenser for oil.
A. Remove refrigerant from the system. See Section

B. Check compressor for proper oil level.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See

4. Continue the performance test for other possible

problems.
(Continued on next page).

9003-9
(No
No Cooling - Continued
Continued)
Expansion Valve Malfunctioning - Indications: 1. Check the expansion valve. Remove the headliner.
Disconnect the low pressure cutout switch.
A. Discharge air from evaporator warm.
2. Test the expansion valve:
B. Much condensation on suction hose.
A. Remove insulation material from the top of the
C. Much condensation on evaporator outlet. valve. With engine running and air conditioner on
maximum cooling, cool the top of the valve with ice
and check for low pressure gauge decrease.
3. Allow the top of the expansion valve to warm. The valve

should open and the pressure should rise at the low
pressure gauge. Repeat Step 2. If there is little or no
decrease in the low pressure gauge, go to Step 5.
4. Replace all the expansion valve insulation material.
5. If the expansion valve did not operate correctly, remove

refrigerant from the system and remove the expansion
valve. See Section 9005 in this manual.
6. Install a new expansion valve, remove air and moisture

and charge the system. See Section 9004 in this manual.
7. Connect the low pressure cutout switch.

9003-10
(No Cooling - Continued)
Expansion Valve Malfunctioning - Indications: 1. Leak test system to see if it is possible that a leak has
permitted air to enter. See Section 9002 in this manual.
A. Suction line warm to your hand.
2. Remove refrigerant from the system. See Section 9004 in
B. Discharge air from evaporator only a little cool. this manual.
3. Repair leaks as needed.
4. Replace receiver-drier. The moisture removing material in

the receiver-drier could be full to capacity with moisture.
5. Check the oil level in the compressor - It is possible for

the compressor to lose oil. See Section 9005 in this
manual.



9003-11
PROBLEM - NOT ENOUGH COOLING
NORMAL TO See pressure - temperature

SLIGHTLY NORMAL chart on Page 4.
HIGH
476L7
Heater Control Valve not working - Indications: 1. The heater control valve is not closed if the hoses are hot.
A. Discharge air from evaporator only a little cool. 2. Shut off coolant flow to heater core.
B. Heater hoses to cab are warmer than ambient 3. Check air duct for temperature change.
temperature.
4. Inspect and repair heater control valve. See Section 9002
in this manual.
Air or moisture in the system - Indications: 1. Leak test the system to see if it is possible that a leak has
permitted air to enter. See Section 9002 of this manual.
A. Suction line warm to your hand.
2. Remove refrigerant from system. See Section 9004 of
B. Discharge air from the evaporator only a little cool. this manual.
3. Repair leaks as needed.
(Continued on next page) (Continued on next page)

9003-12
(Not Enough Cooling - Continued) (Air in the system - Continued)
4. Replace receiver-drier. The moisture removing material in

the receiver-drier could be full to capacity with moisture.
5. Check the oil level in the compressor - It is possible for

the compressor to lose oil. See Section 9005 in this
manual.


T he r m o st a t S en s i ng Tu b e L ow on C h ar ge o r o ut o f 1. Inspect and repair the thermostat sensing tube. See

Calibration - Indications: Section 9002 in this manual.
A. Excessive or incorrect compressor cycling.
B. Compressor clutch not engaging.

9003-13

LOW LOW chart on Page 4.
476L7
Not Enough Refrigerant- Indications: 1. Leak test the system to see if the system has a loss of
refrigerant.
A. Discharge air from the evaporator cool or warm - not
cold. A. If you find a leak, go to step 2.
B. If you do not find a leak, go to step 7.
2. Remove refrigerant from the system. See Section 9004 of

this manual.
3. Repair system leaks as needed.
4. Check oil level in the compressor. It is possible for the

compressor to lose oil. See Section 9005 in this manual.



problems.

9003-14
(Not Enough Cooling - Continued)
High Side Restrictions - Indications: 1. Remove the refrigerant from the system. The restriction in
the receiver-drier must be removed.
A. Discharge air from evaporator only a little cool.
2. Remove and replace part with restriction.
B. Condensation or frost on receiver-drier.
C. Liquid line to receiver-drier cool, with frost or 9004 in this manual.
condensation.
Expansion Valve not Operating - Indications: 1. Expansion valve inlet with condensation or frost is an
indication of a restriction in the expansion valve.
A. Discharge air from evaporator warm or cool - not
cold. A. Remove refrigerant from system. See Section 9004
in this manual.
B. Condensation or frost on expansion valve inlet.
B. Remove and replace expansion valve. See Section
C. Inlet end of expansion valve is warm. 9005 in this manual.
C. Remove air and moisture and charge the system.

See Section 9004 in this manual.
D. Continue performance test for possible other

problems.

9003-15
(Expansion Valve Not Operating - Continued)
2. Inlet end of expansion valve is cold - indication the valve

is not completely open.
A. Disconnect the low pressure cutout switch with the

engine running and the air conditioner on maximum
cooling. Cool the top of the valve with ice and check
for low pressure gauge decrease. The flow of air
from the blower motor must continue through the
evaporator core.
B. Allow the top of the expansion valve to warm. The

valve should open and the pressure should rise at
the low pressure gauge. Repeat step A.
C. If little or no decrease is shown in the low pressure

gauge reading, the expansion valve must be
replaced.
D. Remove refrigerant from the system, replace the

expansion valve, remove air and moisture and
charge the system. See Section 9004 in this
manual.
E. Connect the low pressure cutout switch. Replace all

the insulation material.
F. Continue performance test for other possible

problems.

9003-16

HIGH LOW chart on Page 4.
476L7
Compressor turning but not pumping properly - Indications: 1. Remove refrigerant from system. See Section 9004 in this
manual.
A. System is fully charged.
2. Before you start to repair the compressor, check and
B. Cool discharge air from evaporator. record the compressor oil level. See Section 9005 in this
manual.
3. Remove the compressor from the tractor because there is

indication of an internal leak in the compressor.
4. Repair or replace the compressor as necessary. See

5. Replace the receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more years.
C. Disassembly of compressor shows small particles

of moisture removing material (gold or brown
particles). See Section 9005 for receiver-drier
replacement.
6. Fill the compressor with new refrigerant oil as shown in

Section 9005 and install compressor in tractor.



problems.

9003-17

HIGH HIGH chart on Page 4.
476L7
Condenser Not Operating - Indications: 1. Check for loose or worn compressor belt and proper
engine fan operation.
A. Liquid line very hot.
2. Check to see that condenser, radiator, and grille screen
B. Discharge air from evaporator is warm. are clean and not damaged, and that hood and radiator
seals are in place.
3. Remove and inspect the condenser for oil collecting in the

tubes. See Section 9005 in this manual.
A. Remove refrigerant from system. See Section 9004

in this manual.
B. Check the compressor for proper oil level.
C. Replace receiver-drier. See Section 9005 in this

manual.
D. Remove air and moisture and charge the system.

See Section 9004 in this manual.

problems.

9003-18
(Not Enough Cooling - Continued)
Air in the System - Indications: 1. Remove the refrigerant from the system. See Section
A. Warm discharge air from the evaporator.
2. Replace the receiver-drier. The moisture removing
material could be full to capacity with moisture.



9003-19

LOW NORMAL chart on Page 4.
476L7
Thermostat Sensing Tube Not Functioning - Indications: 1. Check for proper positioning of sensing tube in the core.
A. Evaporator outlet cold or iced. 2. Sensing tube could be out of calibration. Replace the
sensing tube if necessary. See Section 9002 in this
B. Continuous Compressor operation. manual.
3. Check to see that evaporator seals are clean and

undamaged.

9003-20
PROBLEM - INTERMITTENT COOLING

LOW HIGH chart on Page 4.
476L7
Moisture in the system - Indications: 1. Remove refrigerant from the system. Too much moisture
gets into the expansion valve orifice and will freeze and
A. System cools well during cool part of the day, but stop the refrigerant flow. See Section 9004 in this manual.
does not cool during hot part of the day.
2. Replace receiver-drier. The moisture removing material
could be full to capacity with moisture. See Section 9005
in this manual.

9004 in this manual. The time needed to remove a large
amount of moisture will be two to three hours minimum.

5. Continue performance test for possible other problems.

9003-21
PROBLEM - INTERMITTENT COOLING

LOW LOW chart on Page 4.
476L7
Expansion Valve Not Operating - Indications: 1. Frost on outlet line of expansion valve may be an
indication of a restriction in the valve.
A. Discharge air from evaporator only cool.
A. Remove insulation material from the top of the
B. Condensation or frost on expansion valve outlet to valve. Disconnect the low pressure output switch
evaporator. with the engine running and the air conditioner on
maximum cooling. Cool the top of the valve with ice
and check for low pressure gauge decrease. The
flow of air from the blower motor must continue
through the evaporator core.
B. Allow the top of the expansion valve to warm. The

valve should open and the pressure should rise at
the low pressure gauge. Repeat Step A.
C. If there is little or no decrease shown on the low

pressure gauge, the expansion valve must be
replaced.
D. Remove refrigerant from the system, replace the

expansion valve, remove air and moisture, and
charge the system. See Sections 9004 and 9005 in
this manual.
E. Connect the low pressure cutout switch. Replace all

the insulation material.
F. Continue Performance test for possible other

problems.

9003-22
PROBLEM - NOISE IN SYSTEM
NORMAL See pressure - temperature

TO HIGH HIGH chart on Page 4.
476L7
To much Refrigerant in System - Indications: 1. Remove refrigerant from system. See Section 9004 in this
manual.
A. Cool discharge air from evaporator.
2. Remove moisture and charge system. See Section 9004
B. Compressor makes noise. in this manual.
3. Continue performance test for possible other problem.

Section
9004
9004
AIR CONDITIONER SYSTEM SERVICE
Refrigerant Recovery,
Compressor Removal, And
System Evacuation and Recharging
CASE CORPORATION
700 STATE STREET
BURLINGTON, ON L7N 3M6 CANADA Issued July,1995
9004-2
TABLE OF CONTENTS
SPECIFICATIONS ....................................................................................................................................................... 2
SPECIAL TOOLS ........................................................................................................................................................ 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY ............................................................................................... 4
COMPRESSOR REMOVAL ........................................................................................................................................... 6
COMPRESSOR INSTALLATION .................................................................................................................................... 7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING ...................................................................................... 8
PRESSURE - TEMPERATURE CHART ........................................................................................................................ 11
sold.
SPECIFICATIONS
U.S. Standard Value Metric Value
Air Conditioning System Refrigerant Capacity ............................................................ 4 lbs 1.82 kg

9004-3
SAFETY PROCEDURES

!
OR DEATH. M171B
Safety procedures must be followed when working with 4. Always reclaim the refrigerant from the system, if you are
system.
B. See a family physician immediately. inhaled.
2. A drop of liquid refrigerant on your skin can cause 7. Never leak test with compressed air or flame testers.
SPECIAL TOOLS
A22094 299L7A
REFRIGERANT RECOVERY, RECYCLING AND SAFETY GOGGLES CAS-10073-3

RECHARGING STATION OEM-1418

9004-4
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refrigerant passes through an oil separator and a filter-drier before entering the refrigerant tank. The moisture
indicator will turn green when dry refrigerant passes over it.
If possible, run the air conditioning system for a few minutes before starting the recovery process. Turn the system off before
proceeding.
STEP 1 STEP 3
BP9504007 A22114
Clean the external surfaces of the compressor and hoses. Open the high and low valves.
Remove the caps from the service ports on the suction and
pressure hoses.
STEP 4
STEP 2
A22107
Make certain the refrigerant tank gas and liquid valves are
BP9505001 open.
With the charging station manifold gauge valves in the closed
position, connect the hoses from the test gauges to the
service ports.
Connect the hose from the low pressure gauge to the port on
the suction hose.
Connect the hose from the high pressure gauge to the port on
the discharge hose.

9004-5
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Move Slowly open the oil drain valve and drain the oil into the
the main power switch to the ON position and depress the reservoir. When the oil stops draining, close the oil drain
recovery start switch. valve completely.
The compressor will shut OFF automatically when recovery is

complete. Wait for 5 minutes and observe the manifold
STEP 8
pressure gauges for a pressure rise. If the pressure rises
above 0 PSI, depress the hold/cont switch then wait for the
compressor to automatically shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh oil equal to the amount in
the reservoir. See Section 9005.
STEP 9
A22108
Drain the oil separator of A/C system oil. Open the air purge
valve long enough to let some compressor discharge
pressure back into the separator.
BP9504007
Remove the hoses from the service ports and install the
caps.

9004-6
COMPRESSOR REMOVAL
STEP 10 STEP 13
BP9503118 BP9503114
Disconnect the low pressure line from the suction port and Push the compressor down toward the engine. Remove the
the high pressure line from the discharge por t on the compressor belt.
compressor. Immediately install protective caps on open
ports.
STEP 14
STEP 11
BP9503114
Remove the compressor pivot bolt, nut, washers, and lock
BP9504004 washer.
Disconnect the compressor clutch wire from the engine
harness assembly.
STEP 15
STEP 12 Remove the compressor from the tractor. See Section 9005 in
this manual to service the compressor.
BP9503116
Remove the compressor adjusting bolt, lock washer, and
washer.

9004-7
COMPRESSOR INSTALLATION
STEP 16 STEP 18
BP9503114 BP9503119
Install the compressor on the tractor. Install three washers on Adjust the belt tension. See Section 9005 in this service
the pivot bolt. Install the pivot bolt and washers into the rear manual.
of the compressor. Install a washer, lock washer, and nut on
the pivot bolt. Tighten the nut.
STEP 19
STEP 17
BP9504004
Connect the compressor clutch wire to the engine harness
BP9503113 assembly.
Install the drive belt on the tractor. Install the bolt, lock
washer, and washer into the compressor adjusting strap.

9004-8
STEP 20 STEP 21
BP9504007 BP9504007
Carefully remove the protective cap and connect the high Carefully remove the protective cap and connect the low
pressure line to the discharge port on the compressor. Make pressure line to the suction port on the compressor. Make
sure O-ring is in place. sure O-ring is in place.
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or more Connect the hose from the high pressure gauge to the port on
of the following conditions occurs before you remove the the discharge hose.
air and moisture from the system.
Removal of air and moisture from the system is necessary
1. The system has been opened for service before. after refrigerant has been removed from the system or after
2. Receiver-drier has operated two or more years. the system has been opened for maintenance. Air enters the
system when the system is opened. Air has moisture that
3. Disassembly of compressor shows small particles of must be removed to prevent damage to system components.
moisture removing material (gold or brown particles).
Air and moisture are removed from the system by a vacuum
4. Large system leak (broken hose, break in line). pump. A vacuum pump is the only equipment made to lower
5. Too much air or moisture in system. the pressure enough to change the moisture to vapor that can
be removed from the system.
6. Removal of compressor caused the system to be open
(uncapped) longer than 5 minutes. NOTE: Refer to the manufacturers user manual for
additional information.
STEP 22
STEP 23
BP9505001
With the charging station manifold gauge valves in the closed A22113
position, connect the hoses from the test gauges to the Connect the main power plug to a 115 volt AC outlet. Move
service ports. the main power switch to the ON position. If the Program and
Vacuum do not appear at the top of the display, press the
Connect the hose from the low pressure gauge to the port on Vacuum key. Program a minimum of 45 minutes and press the
the suction hose. Enter key. T he display will flash once indicating the
programmed data has been accepted.
9004-9
STEP 24 STEP 27
A22115 A22107
Press the Charge key. Program and Charge will appear on Open the red (vapor) and blue (liquid) valves on the tank.
the display.
STEP 28
STEP 25
A22123
A22113 Press the Vacuum key. Automatic will show on the display
Program 4.0 lbs and press the Enter key. The display will and after a slight delay, the vacuum pump will start. The
flash once indicating the programmed data has been display will show the amount of time programmed and begin a
accepted. countdown to zero.
When the programmed time has elapsed, an automatic hold

STEP 26 occurs. Check the low pressure gauge to see that the A/C
system maintains 28 to 29-1/2 inches of mercury (Hg). The
low pressure gauge must not increase faster than one inch of
mercury (Hg) in 15 minutes. If the system will not hold
vacuum, a leak exists that must be corrected before
recharging can begin. See Section 9002 in this manual for a
leak test.
A22114
Fully open the low and high pressure valves.

9004-10
STEP 29 STEP 31
A22116 BP9505002
Pr ess the Char ge key to begin refrigerant charging. Start the engine and run at 1500 RPM. Operate the air
Automatic and Charge will appear on the display. The display conditioner system at maximum cooling setting and blower
shows the programmed amount and counts down to zero as speed with the doors and windows open.
charging proceeds. When charging is completed, the display
shows CPL. NOTE: The compressor will not operate if the system
pressure is too low or too high. The pressure indicator
lamp will illuminate when the relay is actuated by low or
STEP 30 high pressure and the compressor clutch will disengage.
To restart the compressor, the air conditioner control or
blower switch must be turned to the OFF position and
then to the ON position.
STEP 32
A22117
Completely close the high and low pressure manifold valves.
A22117
Completely close the high and low pressure manifold valves.
Observe the pressure gauge readings to determine that the
correct amount of refrigerant has entered the system. See the
char t on page 9004-11 for temperature and pressure
variations.

9004-11
STEP 33 STEP 34
BP9505001 BP9504007
Stop the engine, close any open valves, and carefully remove Install the caps on the service por ts on the suction and
the manifold gauge hoses. discharge hoses.
PRESSURE - TEMPERATURE CHART

SOLID DRIVE FAN VISCOUS FAN
AMBIENT NORMAL LOW NORMAL HIGH NORMAL LOW NORMAL HIGH
TEMPERATURE SIDE PRESSURE SIDE PRESSURE SIDE PRESSURE SIDE PRESSURE
80×°F(27°C) 26 to 36 PSI 200 to 240 PSI 23 to 33 PSI 205 to 255 PSI
The pressure-temperature chart is based on the following 5. Thermostat on maximum setting ten minutes after
conditions: startup.
1. Engine operating at 1500 RPM. 6. Maximum fresh air mode.
2. No engine load. 7. Side panels at hood installed.
3. Fan speed control at High position. 8. Heater valve at engine shut off.
4. Door open.

Section
9005
9005
AIR CONDITIONER COMPONENT SERVICE
CASE CORPORATION
700 STATE STREET
BURLINGTON, ON L7N 3M6 CANADA Issued July,1995
9005-2
TABLE OF CONTENTS
SPECIAL TOOLS ........................................................................................................................................................ 4
COMPRESSOR BELT CHECK AND ADJUSTMENT .......................................................................................................... 5
COMPRESSOR OIL LEVEL CHECK ............................................................................................................................... 6
COMPRESSOR REPAIR .............................................................................................................................................. 8

Clutch Disassembly .................................................................................................................................................. 8
Clutch Assembly .................................................................................................................................................... 11
EXPANSION VALVE TESTING .................................................................................................................................... 15
EVAPORATOR AND EXPANSION VALVE .................................................................................................................... 16
CONDENSER, RECEIVER-DRIER, AND TUBES ............................................................................................................ 18
EVAPORATOR CORE REMOVAL ................................................................................................................................ 20
EVAPORATOR CORE INSTALLATION ......................................................................................................................... 22
sold.

9005-3
SAFETY PROCEDURES

!
OR DEATH. M171B
Safety procedures must be followed when working with
4. Always reclaim the refrigerant from the system, if you are
Refrigerant R-134a to prevent possible personal injury.
going to weld or steam clean near the air conditioner
system.
near an air conditioner system. Liquid refrigerant getting
5. Always check the temperature and pressure of the air
into the eyes can cause serious injury. Do the following if
conditioner system before reclaiming refrigerant and
you get refrigerant in or near your eyes:
when you test the system.
A. Flush your eyes with water for 15 minutes.
6. Dangerous gas can form when refrigerant comes in
B. See a family physician immediately
inhaled.
2. A drop of liquid refrigerant on your skin can cause
frostbite. Open the fitting carefully and slowly when it is
7. Never leak test with compressed air or flame testers.
necessary to service the air conditioner system. Your skin
Te s t s h a ve i n d i c a t e d t h a t , a t p r e s s u r e s a b o ve
must be treated for frostbite or a physician must be seen
atmospheric, and with air concentrations greater than
60% by volume, R-134a can form a combustible gas.

9005-4
SPECIAL TOOLS
299L7A T81574
SAFETY GOGGLES CAS-10073-3 COMPRESSOR SERVICE TOOL SET CAS10747A. ALSO

USE CAS2332 PULLER JAW SET.
A22094
REFRIGERANT RECOVERY, RECYCLING AND RECHARGE

OEM1418

9005-5
COMPRESSOR BELT CHECK AND ADJUSTMENT

Check interval ......................... Every 250 hours of operation
NOTE: Check the belt tension after the first 10 hours of

operation and then use the regular check interval.
BP9503113
To adjust the belt tension, loosen the compressor adjusting
bolts and pivot bolt. Apply pressure to the compressor until
the correct tension for the belt is reached. Tighten the
compressor adjusting bolts and pivot bolt.
BP9503119
Measure the compressor belt for correct tension using a belt
tension gage. Check the belt to the following specifications.
Belt Tension ................................ 45 to 55 lbs (200 to 245 N)
! WARNING: ** Rotating fan and belts. Contact can injure. Keep clear! ** M150A

9005-6
COMPRESSOR OIL LEVEL CHECK

Check the oil level in the compressor when any of the STEP 3
following has occurred:
A. Broken refrigerant hose.
B. Large refrigerant leak.
C. Compressor leak.
D. Damage to system components.
E. New compressor installed.
Use the following procedure to check the compressor oil
level.
STEP 1 7791288
Check the mounting angle of the compressor. Put the angle
gauge from the service tool set across the flat surfaces of the
two front mounting ears. Adjust the gauge so that the bubble
is between the center marks. Read the mounting angle to the
nearest degree mark. Make a note of the degree reading for
reference later.
STEP 4
BP9505002
Start the engine and run at 1500 RPM maximum. Operate the
air conditioner for 10 to 15 minutes at maximum cooling and
high blower speed.
STEP 2
BP9505113
Remove the oil filler plug.
BP9505001
Stop the engine. Connect the compres sor to the air
conditioner charging, recover y, and recycling station.
Discharge the system. See Section 9004 in this service
manual for complete instructions.
NOTE: Wear safety goggles when working with

refrigerant.

9005-7
STEP 5 STEP 7
Remove the dipstick. Count the oil level marks on the
dipstick. Use the following table to find the correct oil level for
the mounting angle of the compressor.
COMPRESSOR OIL LEVELS
MOUNTING ANGLE DIPSTICK

(DEGREES) READING
0 4 to 6
10 6 to 8
103L7 20 7 to 9
Remove the dust cover and use a wrench to rotate the clutch
clockwise until the internal parts are in the position shown 30 8 to 10
above. This will permit the dipstick to be inserted all the way.
40 9 to 11
50 9 to 11
STEP 6
60 9 to 12
90 9 to 12
STEP 8
If the oil level is not correct, add or subtract oil to the correct
level as shown in the above chart.
IMPORTANT: Use only SP-20 PAG oil.
STEP 9
85010
BP9505114
Put the dipstick in the oil filler hole to the stop position. Make
sure the dipstick is inserted all the way to the stop. Install a new O-ring on the oil filler plug. Install the plug and
tighten to a torque of 11 to 18 pound-feet (15 to 24 Nm).
NOTE: The illustration shows the front view of the
compressor with the dust cover removed.

9005-8
COMPRESSOR REPAIR
Clutch Disassembly
STEP 10 STEP 13
A21250 A21253
See Section 9004 in this service manual for compressor Remove the retaining nut for the front plate. Use the special
removal. Clean the external surfaces of the compressor spanner wrench from the service tool set to keep the plate
before doing any work on the compressor. and shaft from turning.
STEP 11 STEP 14
A21251 A21254
Remove the mounting bolts for the clutch dust cover. Install the special puller from the service tool set on the clutch
front plate.
STEP 12
STEP 15
A21252
Remove the clutch dust cover. A21255
Turn the center screw to pull the clutch front plate.

9005-9
STEP 16 STEP 19
A21256 A21260
Remove the shim(s) from the shaft. Remove the external snap ring for the bearing and pulley
assembly.
STEP 17
STEP 20
A21257
Remove the bearing dust cover. Be careful not to bend the A21261
dust cover. Install the special puller internal collars into the groove in the
pulley. Install the special tool onto the shaft. Tighten the
mounting screws finger tight.
STEP 18
STEP 21
A21258
Remove the key from the rotor shaft.
A21262
Turn the center screw on the puller.

9005-10
STEP 22 STEP 25
A21263 A21266
Remove the pulley and bearing assembly. Remove the clutch coil assembly.
STEP 23 STEP 26
A21265 A21267
Remove the snap ring for the clutch coil assembly. Remove the internal snap ring and remove the bearing from
the pulley.
STEP 24
A21264
Disconnect the clip for the lead wire.

9005-11
Clutch Assembly
1016L93
STEP 27 STEP 28
102L7 A21266
Use an ammeter, voltmeter, and a 12 volt battery to check the Install the clutch coil assembly. Align the detent ball and
amperage of the clutch coil. The current draw must be 3.6 to socket on the coil and housing.
4.2 amperes at 12 volts.
A reading of more than 4.2 amperes indicates a short within
the coil.
No amperage reading indicates an open circuit in the coil.
Replace the clutch coil if the amperage reading is not correct.

9005-12
STEP 29 STEP 32
A21264 A21268
Install the clip for the coil lead wire. Put the pulley and the bearing assembly on the front housing
hub. Install a driver on the pulley assembly. Make sure that
the tool is on the inner race of the bearing.
STEP 30
STEP 33
A21265
Install the snap ring for the clutch coil assembly.
A21268
Support the compressor on the four mounting ears at the
STEP 31 compressor rear. Use a a hammer to tap the pulley assembly
onto the front housing hub. As the pulley is tapped onto the
hub you can hear the difference in sound when the pulley is
fully installed. Make sure the bearing is against the bottom of
the hub.
A21267
Install the bearing in the pulley and install the internal snap
ring.

9005-13
STEP 34 STEP 37
A21260 A21270
Install the external snap ring on the front housing hub. Gently tap the dust cover until it is seated.
STEP 35 STEP 38
A21259 A21256
Install the key in the rotor shaft. Install the shim(s) on the rotor shaft.
STEP 36 STEP 39
A21269 A21271
Place the bearing dust cover in the bore. Place the driver Install the front plate on the rotor shaft. Make sure the keyway
from the special tool kit over the dust cover. in the plate is aligned with the key in the shaft. Install the
driver over the shaft.

9005-14
STEP 40 STEP 42
A21272 T97256
Use a hammer to tap the plate onto the shaft. Make sure the Use a feeler gauge to measure the gap between the front
plate is against the clutch shims. As the plate is tapped onto plate and pulley assembly. The gap must be 0.016 to 0.031
the shaft you can hear the difference in the sound when the inch (0.41 to 0.79 mm). The gap must be even all the way
plate is fully installed. around the plate. If necessary , lightly lift , or push down on
the plate to make the gap even.
STEP 41 NOTE: If the gap does not meet the above

specifications, remove the front plate and add or subtract
clutch shims as required.
STEP 43
A21253
Install the nut on the rotor shaft. Use the spanner wrench and
a torque wrench to tighten the nut to a torque of 11 to 15
pound-feet (15 to 20 Nm).
A21252
Install the dust cover.
STEP 44
A21251
I ns t a ll t he s i x b o l ts t ha t ho l d t h e d u st c over to t he
compressor. Tighten to 5 to 8 pound-feet (7 to 11 Nm).
9005-15
EXPANSION VALVE TESTING

The following test is to be made with the expansion valve STEP 48
mounted in the system. No repair, cleaning or adjustment is
recommended for the valve.
STEP 45
BP95F001
Watch the low pressure gauge as ice is applied onto the cap
of the expansion valve.
The pressure must start to lower. When the pressure reaches
BP9504011 4 PSI (28 kPa), the low pressure indicator will illuminate and
Remove headliner. the compressor will stop. The relay must be reset after the
compressor has stopped before the system will operate. To
reset the relay, turn the air conditioner to the OFF position
STEP 46 and then back to the desired temperature setting.
STEP 49
Warm the expansion valve and watch the low pressure
gauge.
Within minutes, the expansion valve will open and the
pressure must rise at the low pressure gauge. The pressure
will rise to a range of 45 to 75 PSI (310 to 520 kPa).
STEP 50
If the pressure does not rise per step 49, the valve is not
BP95F002 operating. Replace the valve.
Install low pressure hose from OEM-1418 to the low pressure
service port. Close both manifold valves.
STEP 47
Make sure the flow of air continues through the evaporator
core. Start the engine and run at 1500 RPM.Turn the Blower
Switch to the HIGH position, and with the temperature control
valve turned fully clockwise, check the low pressure gauge
reading.
The low pressure reading will range from 26 to 51 PSI (180 to
355 kPa) when the compressor is operating

9005-16
EVAPORATOR AND EXPANSION VALVE

The refrigerant must be reclaimed from the system and all the Connect the suction hose to the evaporator outlet. Install an
black insulation must be removed from the fittings and O-ring between the fittings.
expansion valve before the evaporator core or the expansion
valve are replaced. NOTE: Tighten all the connections. Use two wrenches
to prevent damage to the parts when tightening tubes
The expansion valve must be installed with the sensor toward
and hoses. Always replace O-rings and put clean
the top of the tractor. The port nearest to the IN mark must
refrigerant oil on the O-rings.
point away from the evaporator core. Connect the evaporator
core fittings to the expansion valve. Install O-rings between
NOTE: SP-20 PAG OIL must be added whenever a
the evaporator core and the expansion valve.
component is replaced. Refer to the chart below for
Connect the expansion valve to the evaporator inlet tube. recommended quantities.
Install an O-ring between the expansion valve inlet and the
pressure hose from the receiver-drier. COMPONENT OIL AMOUNT
FL OZ CC
Evaporator 1.5 to 1.7 45 to 50
Condenser 1.2 to 1.3 35 to 40
Receiver-Drier 0.7 to 0.8 20 to 25
Hoses (Normal Length) 0.3 to 0.7 10 to 20

9005-17
BT95F024
3
1
6
5
7 4
2
8
5
9
11
10
BT95F024
BT95F024
1. Evaporator Core 5. O-Ring 9. Cap

2. Expansion Valve 6. Suction Hose 10. A/C Control Switch and
3. O-Ring 7. Pressure Hose Sensing Line
4. O-Ring 8. Low Pressure Switch 11. Left-Hand Air Duct

9005-18
CONDENSER, RECEIVER-DRIER, AND TUBES

C. When the expansion valve is replaced (because of
WARNING: ** Do not steam clean any air corrosion caused by moisture in the system).
conditioner system parts while the system is
charged. The heat will cause the refrigerant D. When the receiver-drier or inlet and outlet lines feel
! to rise to a pressure that could cause the cool to your hand when the system is operating.
system to explode.** This condition is an indication of too much moisture
SM104A in the system.
The receiver-drier must be installed with the inlet connected
Keep the condenser fins clean and straight to make sure to the hose from the condenser and the outlet connected to
there is maximum flow through the condenser and radiator at the tube going to the evaporator. Always install new O-rings
all times. Use compressed air or a rigid brush to clean the when you connect the receiver-drier to the system.
condenser. Also check and clean the grille screen and
radiator. Maximum air flow will prevent the engine from Use the two hand, two wrench method to prevent damage to
getting too hot and will give the most efficient operation of the the tubes and fittings when you loosen or tighten the tube
air conditioner system. connections.
Always replace the O-rings when you separate connections to
IMPORTANT: Because the condenser fins bend easily, make sure you get a good tight seal when you make the
be careful when you clean the condenser. connections again. Apply clean refrigerant oil onto the O-
Replace the receiver-drier every other time the system is rings.
opened for repair or service. Replace the receiver-drier each
time the system is opened under the following conditions:
A. In an area where there is high moisture content in
the air.
B. If the system has been open for a long period of
time because of a leak (broken hoses, loose
connections) that has permitted air and moisture to
enter the system.

9005-19
5
3
8
1
7
6
BT95F023
BT95F023
1. Condenser 5. Receiver-Drier
2. High Pressure Switch 6. Hose - Compressor to Cab
3. Hose - Receiver-Drier to Cab 7. Hose - Compressor to Condenser
4. Hose - Condenser to Receiver-Drier 8. Compressor

9005-20
EVAPORATOR CORE REMOVAL

STEP 51 STEP 54
Carefully remove the four nuts that hold the housing to the
roof of the cab and lower the housing including the blower,
heater core, and air conditioner evaporator to the front dash
and steering wheel area.
NOTE: Be careful not to kink the the air conditioner

lines, as this could cause premature failure of the hoses.
STEP 55
BP9504009
Remove the screws that hold the cover on the right-hand
center post. Then remove the cover and the control panel.
STEP 52
1
BP95F001
If the insulation (1) has not been removed, remove it now
from the expansion valve and the evaporator lines.
To test the valve see Expansion Valve Testing in this section.
Discharge the A/C system to remove the evaporator core.
See Section 9004 of this manual.
BP9504011 STEP 56
Remove headliner
STEP 53
1
4
1
2
3 BP95F001
Disconnect the air conditioner suction and discharge lines (1)
at the expansion valve. Remove and discard the O-rings. Cap
1 and plug the lines to prevent dirt and moisture from entering
BP95F002
the system.
Remove the hose clamps (1) and disconnect the four drain
hoses (2) at the housing. Disconnect the low pressure switch
(3). Remove the bolts (4) retaining the air ducts and remove
the air ducts. Disconnect the blower.

9005-21
STEP 57 STEP 58
3 Remove the evaporator core from the housing and put the
evaporator on a clean bench. Remove the expansion valve
from the evaporator core. It can be necessary to use a back-
up wrench to prevent damage to the tubes. Remove and
2 discard the O-rings from between the expansion valve and
4 the evaporator core lines.
1
BT95F129
1. 2 inches (50 mm)
2. 4 inches (100 mm)
3. 2 inches (50 mm)
4. 12 inches (300 mm)
Remove the thermostat probe for the air conditioner control

that is put into the evaporator core.

9005-22
EVAPORATOR CORE INSTALLATION

STEP 59 STEP 64
Put new O-rings on the evaporator core lines. Lubricate the
O-rings with clean refrigerant oil.
STEP 60
BP95F001
1 Connect the air conditioner discharge and suction lines to the
expansion valve. Wrap the valve and the lines with insulation.
BP95F001
STEP 65
Install the expansion valve (1). Tighten the fittings to a torque
Install the evaporator core in the housing with the heater
of 18 to 25 lb ft (25 to 34 Nm). It can be necessary to use a
core. Be sure the foam insulation strips are in place to seal
backup wrench to prevent damage to the evaporator tubes.
the plenum around the evaporator so air is forced through the
evaporator and the heater core.
STEP 61
Install the evaporator core in the housing
STEP 66
STEP 62 Raise the housing into place, including the blower, heater
core and air conditioner evaporator. Fasten with four nuts to
3 the roof. Be sure the top insulation strip is in place.
2
STEP 67
4
1
1
4
2
3
BT95F129
1. 2 inches (50 mm) 1
BP95F002I
BP95F002
2. 4 inches (100 mm)
3. 2 inches (50 mm) Connect the blower. Install the hose clamps (1) and the air
4. 12 inches (300 mm) ducts using bolts (4). Make sure the seals on the air ducts are
in place. Connect the low pressure switch (3). Connect the
Install the thermostat probe for the air conditioner. four drain hoses (2) to the housing and tape in place to the air
ducts. Connect the blower. Make sure the seals are in place
when installing air ducts.
STEP 63
Install new O-rings on the discharge and suction lines at the
expansion valve. Lubricate the O-rings with clean refrigerant
oil.
9005-23
STEP 68 STEP 69
BP9504006 BP9504002
Install headliner. Install the control panel and the cover on the center post

1 HYDRAULIC RESERVOIR 37
BREATHER 35 REGENERATION
VALVE SOLENOID VALVE FOR
6 STEERING AUXILIARY HYDRAULICS
CYLINDER
5 HYDRAULIC
PUMP EXTENDAHOE
SPOOL
33
30
36
2 CONTROL VALVE FOR
34 AUXILIARY HYDRAULICS
HYDRAULIC
RESERVOIR EXTENDAHOE
7 BUCKET CYLINDER
STEERING SPOOL 4
CONTROL 31 37
32
VALVE SOLENOID VALVE FOR
BUCKET AUXILIARY HYDRAULICS 5 16
4 OIL 13 CYLINDER
COOLER
3 CIRCUIT
HYDRAULIC RELIEF
FILTER DIPPER VALVES
SPOOL 7
30 8
8 29
3
STEERING DIPPER
RELIEF CYLINDER
VALVE 13 CIRCUIT
RELIEF 32
VALVES
RIGHT
STABILIZER
SPOOL 27 36
37
28
RIGHT
STABILIZER 17
BUCKET SPOOL LIFT SPOOL CLAM SPOOL CYLINDER
LEFT
12 14 15 STABILIZER
SPOOL 25 6
9 19 26 1
LOADER MAIN RELIEF LEFT 2 38 39 40
CONTROL VALVE STABILIZER
VALVE CYLINDER
24
BOOM 13 CIRCUIT
SPOOL RELIEF 22 B9610032T
11 VALVES 26
23
FLOW CONTROL 9 10 11 12
VALVE 13 14 15 19
38
ACCUMULATOR 13 20 21 23 25
FOR RIDE 27 29 31 33 35
CONTROL
10 24
RELIEF VALVE FOR BOOM CYLINDER
BACKHOE AUXILIARY
1. HYDRAULIC RESERVOIR BREATHER 13. CIRCUIT RELIEF VALVES 27. RIGHT STABILIZER SPOOL
HYDRAULICS 2. HYDRAULIC RESERVOIR 14. LIFT SPOOL 29. DIPPER SPOOL
3. HYDRAULIC FILTER 15. CLAM SPOOL 30. DIPPER CYLINDER
39 4. OIL COOLER 16. BUCKET CYLINDERS 31. BUCKET SPOOL
13 RIGHT SOLENOID 5. HYDRAULIC PUMP 17. LIFT CYLINDERS 32. BUCKET CYLINDER
13 6. STEERING CYLINDER 33. EXTENDAHOE SPOOL
VALVE FOR RIDE 19. MAIN RELIEF VALVE
CIRCUIT RELIEF CIRCUIT 7. STEERING CONTROL VALVE 20. BACKHOE CONTROL VALVE 35. REGENERATION VALVE
VALVES CONTROL RELIEF 8. STEERING RELIEF VALVE 21. SWING SPOOL 36. CONTROL VALVE FOR AUXILIARY HYDRAULICS
VALVES 9. LOADER CONTROL VALVE 22. SWING CYLINDERS 37. SOLENOID VALVES FOR AUXILIARY HYDRAULICS
21 10. RELIEF VALVE FOR BACKHOE 23. BOOM SPOOL 38. ACCUMULATOR FOR RIDE CONTROL
AUXILIARY HYDRAULICS 24. BOOM CYLINDER 39. RIGHT SOLENIOD VALVE FOR RIDE CONTROL
SWING 11. FLOW CONTROL VALVE 25. LEFT STABILIZER SPOOL
20 SPOOL 40. LEFT SOLENIOD VALVE FOR RIDE CONTROL
12. BUCKET SPOOL 26. LEFT STABILIZER CYLINDER
BACKHOE
CONTROL
VALVE
40
LEFT SOLENOID
VALVE FOR RIDE
"L" SERIES LOADER BACKHOE FAMILY
CONTROL
HYDRAULIC SCHEMATIC (580L)
22 SWING
CYLINDERS
Additional copies of this hydraulic and electrical schematic can be ordered through
16 17 18 BT96C131 Technical Publications Distribution System. The part number is 7-48712.
BUCKET LIFT CLAM
CYLINDERS CYLINDERS CYLINDERS
CHARGING CRANKING AND KEYSWITCH POWER RELAY ETHER START AND START RELAY FUSE BLOCK
1D 1D 1D NO. GA. COLOR FROM: TO: NO. GA. COLOR FROM: TO:
1
3 19E
20
23F
19B
0 ST (None) Battery Ground 36P 16 Yellow/Brown Instrument Cluster T3 Park Brake Switch & Diode
34 34
31S 31S 19
19B
11
19B
1 0 Red Battery Starter Battery Terminal 36R 16 Yellow/Gray Alarm Relay #1 T87 Seat Position Switch (NC) &
POWER RELAYS
4 12B 3 57
16
61
14 1A 8 Red Starter Battery Terminal Alternator Diode
34 85 86 #1
16
12A 19E 23F
BATTERY
12A 12C 12C 14 FUSE 19C 19K
1B 6 Red Starter Battery Terminal Power Junction Post 37 16 Yellow/White Warning Alarm (-), Wire Coolant Temperature Switch
5
FUEL SHUTOFF BLOCK 1D 2D 3D 4D 5D 6D 7D 8D 9D 10D 11D 12D 13D 14D
39B
1 31S 1
30 87
87A
SOLENOID 19E
10A 10A 20A 10A 1C 12 Red Power Junction Post Starter Relay T30
19E 8
11 3 38 16 Yellow/Blue Instrument Cluster T8 Air Filter Restriction Switch &
12B
85 86 #2 25 NEUTRAL START 12C 1D 12 Red/Lt Blue Power Junction Post Ignition Switch (Batt) Fuse
85 86 8
SWITCH 1C 2C 3C 4C 5C 6C 7C 8C 9C 10C 11C 12C 13C 14C Diode
25A
Block 2B, 4B, 6B, 8B
3 6 KEY F 8
12B
15A 15A 25A
39A 16 Purple/Yellow Diode & Wire 23G Warning Alarm (+)
87A 21
30 87 SWITCH
30 87
87A
N R 25B 8 12A 1E 12 Red Power Junction Post Power Relays 1, 2, 3, T30
2 39B 16 Purple/White Warning Alarm (-) Alarm Relay #1 T30, Diode &
85 86 #3 CLUTCH CUTOUT ETHER 1D
ALTERNATOR 1D 8 6 8 31S 10A 10A 10A
Wire # 37
RELAY 21C INJECTION
10
12 1B 2B 3B 4B 5B 6B 7B 8B 9B 10B 11B 12B 13B 14B
87A
86 85 86 85 SOLENOID 34 40A 12 Black Front Driving, Work, Turn Ground
30 87
4 20
12A 15A 10A 10A 15A 10A
3 12 Orange/White Ignition Switch (Ignition) Fuel Solenoid (Hold In), Fuse Lamps, Front Wiper,
4 22
10
87A
87 30
87A
87 30
21A 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12A 13A 14A
Block 2D, 4D Blower
1E
1A 1B 1C 1C
9
NEUTRAL 63 25C 19D 19A 19F 3C 16 Gray/Black RH Speaker Ground at Radio 40B 12 Black/White Rear Work, Tail, Turn Ground
START 16 13 9
10
0
21B
POWER RELAY 56
17
64A 49 4 14 Orange/Black Ignition Switch (ACC.) Power Relays 1, 2, 3, T85 Lamps, Rear Wiper Stop
JUNCTION 21A 21A 28 B 19 15 12
STARTER 4D 16 Gray RH Speaker Radio (Right Output) Switch & AC Indicator
3 STARTER AND 10 ETHER START 10 THERMO 34 34
STARTER SOLENOID
10 7 RELAY BUTTON (OPT.) 13 31S 31S 5E 16 Gray/Black LH Speaker Ground at Radio Lamp
SWITCH
10 10
CHASSIS 10 10
6F 16 Gray LH Speaker Radio (Left Output) 41 14 Pink Front Driving Lamp Front Driving, Tail, Cluster -
GROUND 30 30 30 30
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND Switch T12
8 16 Yellow/White Ignition Switch Momen- Diodes
1 2 3 4 42C 12 Dk Blue/Orange Rear Work Lamp Relay Rear Work Lamps
tary Ground
INSTRUMENT CLUSTER SENDER AND SWITCHES T87
15 INSTRUMENT CLUSTER WARNING ALARM 10 16 Black/Orange Accessories Ground
41 13 42F 16 Dark Blue Front Work Lamp Switch Front Work Lamps
31T 31T 12A 12 Red/Black Power Relay 1, T87 Fuse Block 2A, 4A, 6A, 8A,
32T 32T 24 and 10A 44 14 Tan Brake Switch Brake Lamps
36F 36F
36H 36H WARNING 45L 16 Dark Brown/Yellow Flasher Relay T5 Left Turn Signal Lamps
ALARM 12B 12 Red/Orange Power Relay 2, T87 Fuse Block 2C, 4C, 6C, and
20
25 8C 45R 16 Dark Brown/Green Flasher Relay T7 Right Turn Signal Lamps
10 11 12 13 14 15 16 17 18 19 TRANS
17 18 TEMP ENGINE
46 16 Dark Brown Flasher Switch Flasher Relay T1
19B
2
FUEL OIL
AIR FILTER SENDER 22 39A
TEMPERATURE
12C 12 Red Power Relay 3, T87 Fuse Block 6D, 8D, 10D, and
DASH 36H RESTRICTION 39B
LAMPS TRANS
OIL
FILTER 10
LEVEL PRESS
SWITCH
REAR
AXLE
SWITCH 12D 47L 16 Lt Brown/Yellow Turn Signal Switch (Left) Left Turn Indicator, Flash Re-
OIL
V0LTAGE SENDER SWITCH
23F P
TEMP 37
19A 14 Red Fuse Block 7A Driving Light Switch lay T6
P SWITCH ALARM
V T 27 47R 16 Lt Brown/Green Turn Signal Switch (Right) Right Turn Indicator, Flash
ENGINE FUEL
T
23 RELAY #2 19B 12 Red/Black Fuse Block 3C Alternator Lamp, Turn Signal
TEMP 8
PARKING BRAKE 26 85 86
Switch, Brake Switch, Hazard Relay T3
SWITCHES 8 52
ENGINE
21 ALARM Switch, Flasher Relay T2 48 16 Lt Brown/White Beacon Switch Beacon
PARK
#1 #2
OIL BRAKE TACH ENGINE RELAY #1 24 87A
BRAKE
10 16 TEMP 30 87 19C 12 Red/White Fuse Block 5D Rear Work Lamp Switch and 49 16 Gray Fuse Block 5B Dome Lamp
AIR ALT 33T 85 86
HYD SENDER
DIODE FILTER
.
30
23G
10
Relay T30 51A 16 Red/Yellow Wire 27 & Diode Backup Alarm (+)
9 8 DIODE RES. NC
7 6 5 4 3 2 1
SWITCH
39B
30 87
87A
36R
19D 16 Red/Yellow Fuse Block 5A Rotating Beacon Switch 52 16 Blue/Red Diodes Alarm Relay #2 T85
34 36P 23F
38 30 DIODE DIODE 19E 16 Red/Blue Fuse Block 1D Clutch Relay T85 and T30, 53 16 Purple/Red Loader Valve RTD Sole- RTD Limit Switch (NC)
31S 31S 30 28 Forward and Reverse Relays
38
36P 36P 36R
SEAT
noid
30
31P 31P 31P 31P 31P
DIODE T30
19B 23F 33T 33T POSITION 56 16 Red/Gray Fuse Block 1B Optional Radio or C.B.
38 38 SWITCH 19F 16 Red/Green Fuse Block 9A Loader Valve RTD Solenoid
23F 23F 23F 23F 57 16 Orange/Yellow Fuse Block 1C Optional Radio or C.B. and
10 10 10 10 10 10 19H 16 Red/Purple Rear Work Lamp Switch Rear Work Lamp and Relay Optional Rear Auxiliary Hy-
30 30 30 30 30 30 T85 draulic Switch
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND
5 7 19K 16 Red/Brown Fuse Block 7D Front Work Lamp Switch 59 16 Red Optional Rear Auxiliary Optional Rear Auxiliary Hy-
6
WIPERS (CAB) BLOWER AND A/C (CAB) 20 16 Black Ignition Switch Body Ground Hydraulic Switch draulic Solenoid
TRANSMISSION CONTROLS RETURN-TO-DIG REAR WIPER
39 PARK SWITCH 40
REAR WIPER
BLOWER 21 16 White/Green Clutch Relay T87a Forward/Neutral/Reverse Le- 60 16 Orange/Brown A/C Thermostat A/C Relay T30, A/C High/Low
29 30 MOTOR 46 AIR COMPRESSOR 45
CLUTCH SWITCH
MOTOR ver (+) Pressure Switches
CLUTCH 88 M 40A
CUTOUT SWITCH
CUTOUT
SWITCH
21A 16 White/Red Ignition Switch (Start) Ether Start Button and Neu- 60A 16 Orange/Black A/C Relay T86 & T87 A/C/ Low/High Pressure
H
(SHIFT HANDLE) 38 H 47 tral Relay T30
(LOADER
L
80 L Switch,
HANDLE) FRONT RESISTOR
3 25
WIPER BOARD AND 21B 12 White Starter Relay T87 Starter Solenoid A/C Indicator Lamp
36 63 63
31 FORWARD RELAY
30 MOTOR 67 THERMAL 48 A/C LOW
P 60B
21C 16 White/Yellow Forward/Neutral/Reverse Neutral Relay T85 60B 16 Orange/Green A/C Relay T87a A/C Compressor Clutch
RETURN-TO-DIG
66
42 82
FUSE
PRESSURE SWITCH
85 86
10 LIMIT SWITCH 69 REAR WIPER 88 Lever (-) 61 14 Gray/White Fuse Block 5C Blower Switch (+)
3 25A 40A SWITCH (CAB) 81 86
49
32 FORWARD SOLENOID
4 52 A/C HIGH
P 22 16 White/Purple Neutral Relay T87 Starter Relay T85 61B 16 Gray/Black Dome Lamp Dome Lamp Switch
87A NC 87
3 30
87
26
63
41 BLOWER PRESSURE SWITCH 60A 23F 16 White/Orange Fuse Block 3D Instrument Cluster T2, T9, 62 16 Orange/Gray Windshield Washer Front Windshield Washer
C NO SWITCH
25B 34 10
53 FRONT WIPER 40B
Tach, Diode Switch Pump
DIODE 40B M
REVERSE SOLENOID SWITCH (CAB) H 40A
85 86
10 37 63 WINDSHIELD WASHER 4 L
50 85 86 23G 16 White/Blue Diode & Wire 39A Alarn Relay #1 T85 63 14 Orange/Purple Fuse Block 1A Front/Rear Wiper Switches,
44 PUMP OPT.
A/C
3 19E 87A
LOADER 4 43 INDICATOR
87A
24 16 White/Brown Alarn Relay #1 T86 Alarn Relay #2 T30 Motors,
27 VALVE WINDSHIELD
30 87
SOLENOID 63 WASHER
OFF LAMP 10 30 87
25 16 White/Gray Clutch Relay T86 Clutch Cutout Switches Windshield Washer Switch
F R M M 61 60
33
51A
35 DIODE 53 19F
SWITCH OPT.
A/C
53 25A 16 White/Black Forward/Neutral/Reverse Forward Relay T85 & Diode 64A 16 Orange/Blue Fuse Block 3B Horn Switch
REVERSE T
65 51 RELAY
RELAY BACKUP
30 30
A/C 85 Lever (FOR) 64B 16 Green/Red Horn Switch Horn
ALARM 62 TEMP SWITCH
30
7 52 40B 40B 25B 16 White/Orange Forward/Neutral/Reverse Reverse Relay T85 & Diode 65 16 Orange/Brown Windshield Washer Rear Windshield Washer
40A 40A
10 10 10 10 Lever (REV) Switch Pump
30 30 30 30 30 25C 16 Orange/Yellow Fuse Block 3A 4WD Engage Switch 66 16 Green Front Wiper Switch - Low Front Wiper - Low
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND
25E 16 Orange/White 4WD Engage Switch 4WD Solenoid 67 16 Red Front Wiper Switch - High Front Wiper - High
8 9 10 11 26 16 Orange/Gray Forward Relay T87 Forward Solenoid & Diode 69 16 Yellow Front Wiper Switch - Front Wiper - Brake
27 16 Orange/Red Reverse Relay T87 Reverse Solenoid, Wire Brake
DOME LAMPS (CAB) HORN ROTATING BEACON AND WORK LAMPS
FRONT AND REAR LAMPS (STANDARD) FLASHER, TURN SIGNAL, AND BRAKE LAMP SWITCHES #51A, & Diode 70 16 Black Optional Rear Auxiliary Ground
59 60 RIGHT
61 67 HORN 69 28 16 Gray/Orange Ether Start Button Ether Injection Solenoid Hydraulic Solenoid
ROTATING
LEFT REAR
LEFT FRONT
63 HORN 4
ROTATING 70 BEACON (OPT.)
57 REAR REAR L R TURN
TURN LAMP
TURN
68 BUTTON BEACON SWITCH 30 16 Black/Yellow Accessories Ground 71 16 Red/Black Aux Hyd Foot Switch “N/ Aux Hydraulic Solenoid
4
56 FRONT TAIL TURN LAMP 62 SIGNAL SWITCH 73 31P 16 Yellow/Black Instrument Cluster T7 Oil Pressure Switch & Diode O”
LAMPS LAMP L R RIGHT FRONT
ROAD 45R
LAMPS TURN LAMP 19D 10 FRONT
31S 16 Yellow/Red Alternator Tach Output Instrument Cluster Tachome- 75 16 Red Ride Control Engage Ride Control Solenoids
45L 45L 48 42F WORK
45R LAMPS ter Switch
44 FRONT WORK
55 45R 71
DOME 41
47L 4 LAMP SWITCH 90
31T 16 Yellow Instrument Cluster T10 Coolant Temperature Sender 80 14 Black Wiper (Ground) Rear Wiper Motor Stop
LAMP SWITCH
41 47R Switch
44
64B
74
REAR WORK 32T 16 Yellow/Green Instrument Cluster T11 Transmission Temperature
40A 40B 65
FLASHER LAMPS 81 16 Gray Rear Wiper Switch - Low Rear Wiper - Low
64 RELAY (BOTTOM
19K Sender
45L 4 42F
41 5 OF SOCKET)
66 30 64A 40A
33T 16 Yellow/Pink Instrument Cluster T1 Rear Axle Temperature 82 16 White Rear Wiper Switch - High Rear Wiper - High
4 54 DRIVING LAMP 40A
BRAKE
72
DOME 58 SWITCH
LAMP 40A
FLASHER SWITCH REAR WORK 10 75 Switch 85 14 Orange/Green Blower Switch A/C Thermostat
LAMP (L.H.) SWITCH 4 LAMP SWITCH
7 REAR WORK
49
61B 19B
LAMP RELAY 34 16 Yellow/Dk Blue Alternator Instrument Cluster T5 86 14 Light Blue Blower Switch - Low Resistor Board - Low
4
40B 6 5 4 64A
3 2 1
46 85 86 36F 16 Yellow/Orange Instrument Cluster T14 Fuel Level Sender 87 14 Blue Blower Switch - Medium Resistor Board - Medium
30 19C 19H
49 61B
41 10 10 30 87A 42C 36H 16 Yellow/Purple Instrument Cluster T18 Hydraulic Filter Restriction 88 14 Lt Blue/White Blower Switch - High Resistor Board - High/Blower
19B 19B 19C
30 87 Switch & Diode
19A
40B 90 16 Black Rotating Beacon Ground
90
40B 40B 40B 40B 40B
40A 40A 40A 40A 40A
10 10 10 10 10 10
30 30 30 30 30
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND
8 Indicates circuit continued on block shown.

12 13 14 FUSE AND RELAY LOCATION
15 16
* STARTING & * INSTRUMENTS * REAR WORK * FRONT WORK SPARE SPARE
4WD ELECTRICAL CIRCUIT REAR AUXILIARY HYDRAULICS RIDE CONTROL (OPT.) 74 TRANSMISSION CONT. & ALARM SYS. LAMPS LAMPS
RADIO AND C.B. (OPT.) 8 7
30 9
RIDE CONTROL 85
RIGHT RIDE CONTROL RADIO & RIDE CONTROL * SIGNAL LAMPS ** BLOWER SPARE
84 SOLENOID (ACCUMULATOR) REAR AUXILIARY
4 ENGAGE SWITCH
4WD ENGAGE HYDRAULIC (OPT)
76
F O R WA R D
REVERSE
SWITCH 78
S TA R T E R
* HORN ** DOME LAMP
*
RADIO & C.B., (BATT+) SPARE
*
*
*
LAMPS
REAR
RELAY
RELAY
RELAY
RELAY
FOOT OPERATED 79 32
4 4 81
4
4
REAR AUXILIARY
HYD. SWITCH
REAR AUXILIARY
HYDRAULICS SOLENOID RADIO (OPT.)
64 * WIPERS 4WD (OPT) ROTATING * DRIVING LAMPS * RETURN
BEACON (OPT) TO DIG
NEUTRAL
CLUTCH
ALARM
* ALARM
NC B+ GRD 4D 6F 57 75
*
*
*
RELAY
RELAY
RELAY
ACC + 3C 5E
RELAY
25C 25E 59
LEFT 25 *STANDARD EQUIPMENT
#2
NO 6F
#1
C 82
77 5E SPEAKER
**STANDARD EQUIPMENT W/CAB
FLASHER
POWERRE
56
POW ER
POW ER
*
4D
WA R N I N G
4WD SOLENOID RIGHT
83
*
*
*
RELAY
RELAY
RELAY
26
RELAY
(OPT)
3C SPEAKER
A/C
(DISENGAGES 4WD 59
RELAY
LAY
#2
#3
#1
WHEN ENGERIZED) 57
TO
57 86
C.B.
30 10 LEFT RIDE CONTROL
10 70 FEED
SOLENOID (TANK) 10A 10A 20A 10A SPARE SPARE
70 52

15A 15A 25A SPARE
80
AUXILIARY 10 10A 10A 10A SPARE
HYDRAULICS 15A 10A 10A 15A 10A

SWITCH
4 Junction
Block
ELECTRICAL SCHEMATIC
10
30
10 10 10
(580L, 580 Super L and 590 Super L)
20 14
17 18 19 181635A1 Technical Publications Distribution System. The part number is 7-48712.
BT96C025
1 HYDRAULIC RESERVOIR 39
BREATHER SOLENOID VALVE FOR
REGENERATION
37 AUXILIARY HYDRAULICS
VALVE
STEERING
8
CYLINDER
EXTENDAHOE
HYDRAULIC CYLINDER
5
PUMP
36
6 FRONT
SECTION
2 38
HYDRAULIC
REAR CONTROL VALVE FOR
CIRCUIT
RESERVOIR 7 SECTION AUXILIARY HYDRAULICS
RELIEF
35 VALVES
9 EXTENDAHOE
34
SPOOL 15 BUCKET 39
STEERING
CYLINDER SOLENOID VALVE FOR
CONTROL
VALVE AUXILIARY HYDRAULICS
3 4
OIL COOLER
HYDRAULIC 33
FILTER
BUCKET
DIPPER SPOOL 32
SPOOL 31
10 DIPPER
CYLINDER
STEERING
RELIEF
VALVE
15
CIRCUIT
RELIEF
VALVES 32
30
29
RIGHT STABILIZER 34
LIFT CLAM
RIGHT CYLINDER 4
BUCKET STABILIZER
11 SPOOL SPOOL SPOOL SPOOL
LOADER 14 16 17 18
CONTROL
VALVE 21 MAIN
RELIEF 28
VALVE
LEFT STABILIZER
CYLINDER
3 9
13 27
FLOW LEFT 15 CIRCUIT 10
CONTROL 25 STABILIZER RELIEF
VALVE SPOOL VALVES
BOOM
SPOOL
40 38
ACCUMULATOR
FOR RIDE 39
CONTROL
8
5 6 7
12
SWING 19
RELIEF
VALVE 41 1 2
RIGHT SOLENOID 26
15 VALVE FOR RIDE 15 26 40 41 42
CONTROL
CIRCUIT
RELIEF CIRCUIT BOOM
RELIEF CYLINDER
VALVES
VALVES
28
11 12 13 14
23
22 24 15 16 17 21
SWING B9410025T
BACKHOE SPOOL
CONTROL 15 22 23 25 27 29
VALVE
31 33 35 37
42 1. HYDRAULIC RESERVOIR BREATHER 14. BUCKET SPOOL 28. LEFT STABILIZER CYLINDER
LEFT SOLENOID 2. HYDRAULIC RESERVOIR 15. CIRCUIT RELIEF VALVES 29. RIGHT STABILIZER SPOOL
VALVE FOR RIDE 3. HYDRAULIC FILTER 16. LIFT SPOOL 31. DIPPER SPOOL
CONTROL 4. OIL COOLER 17. CLAM SPOOL 32. DIPPER CYLINDER
5. HYDRAULIC PUMP 18. BUCKET CYLINDERS 33. BUCKET SPOOL
6. FRONT SECTION 19. LIFT CYLINDERS 34. BUCKET CYLINDER
7. REAR SECTION 21. MAIN RELIEF VALVE 35. EXTENDAHOE SPOOL
18 19 20 22. BACKHOE CONTROL VALVE 37. REGENERATION VALVE
8. STEERING CYLINDER
CLAM 9. STEERING CONTROL VALVE 23. SWING SPOOL 38. CONTROL VALVE FOR AUXILIARY HYDRAULICS
BUCKET LIFT 24. SWING CYLINDERS
CYLINDERS 10. STEERING RELIEF VALVE 39. SOLENIOD VALVES FOR AUXILIARY HYDRAULICS
CYLINDERS CYLINDERS
11. LOADER CONTROL VALVE 25. BOOM SPOOL 40. ACCUMULATOR FOR RIDE CONTROL
12. SWING RELIEF VALVE 26. BOOM CYLINDER 41. RIGHT SOLENIOD VALVE FOR RIDE CONTROL (ACCUMULATOR)
24 13. FLOW CONTROL VALVE 27. LEFT STABILIZER SPOOL 42. LEFT SOLENIOD VALVE FOR RIDE CONTROL (TANK)
SWING
CYLINDERS

HYDRAULIC SCHEMATIC
(580 SUPER L and 590 SUPER L)
Technical Publications Distribution System. The part number is 7-48722.
Copyright © 2006. CNH America, LLC. All Rights Reserved. 7-48722-Schematic
CHARGING CRANKING AND KEYSWITCH POWER RELAY ETHER START AND START RELAY FUSE BLOCK
1D 1D 1D NO. GA. COLOR FROM: TO: NO. GA. COLOR FROM: TO:
1
3 19E
20
23F
19B
0 ST (None) Battery Ground 36P 16 Yellow/Brown Instrument Cluster T3 Park Brake Switch & Diode
34 34
31S 31S 19
19B
11
19B
1 0 Red Battery Starter Battery Terminal 36R 16 Yellow/Gray Alarm Relay #1 T87 Seat Position Switch (NC) &
POWER RELAYS
4 12B 3 57
16
61
14 1A 8 Red Starter Battery Terminal Alternator Diode
34 85 86 #1
16
12A 19E 23F
BATTERY 12C 12C 14 FUSE 19C 19K
1B 6 Red Starter Battery Terminal Power Junction Post 37 16 Yellow/White Warning Alarm (-), Wire Coolant Temperature Switch
12A
5
FUEL SHUTOFF BLOCK 1D 2D 3D 4D 5D 6D 7D 8D 9D 10D 11D 12D 13D 14D
39B
1 31S 1
30 87
87A
SOLENOID 19E
10A 20A 10A 1C 12 Red Power Junction Post Starter Relay T30
19E 8
11 3
10A
38 16 Yellow/Blue Instrument Cluster T8 Air Filter Restriction Switch &

12B
85 86 #2 25 NEUTRAL START 12C 1D 12 Red/Lt Blue Power Junction Post Ignition Switch (Batt) Fuse
85 86 8
SWITCH 1C 2C 4C 5C 6C 7C 8C 9C 10C 11C 12C 13C 14C Diode
Block 2B, 4B, 6B, 8B
3C
KEY F 25A
87A
3 6 21
8
12B
15A 15A 25A
39A 16 Purple/Yellow Diode & Wire 23G Warning Alarm (+)
30 87 SWITCH 87
87A
N R 25B 8 12A 1E 12 Red Power Junction Post Power Relays 1, 2, 3, T30
2 30
39B 16 Purple/White Warning Alarm (-) Alarm Relay #1 T30, Diode &
85 86 #3 CLUTCH CUTOUT ETHER 1D
ALTERNATOR 1D 8 6 8 31S 10A 10A 10A
Wire # 37
RELAY 21C INJECTION
10
12 1B 2B 3B 4B 5B 6B 7B 8B 9B 10B 11B 12B 13B 14B
87A
86 85 86 85 SOLENOID 34 40A 12 Black Front Driving, Work, Turn Ground
30 87
4 20
12A 15A 10A 10A 15A 10A
3 12 Orange/White Ignition Switch (Ignition) Fuel Solenoid (Hold In), Fuse Lamps, Front Wiper,
4 22
10
87A
87 30
87A
87 30
21A 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A 11A 12A 13A 14A
Block 2D, 4D Blower
1E
1A 1B 1C 1C
9
NEUTRAL 63 25C 19D 19A 19F 3C 16 Gray/Black RH Speaker Ground at Radio 40B 12 Black/White Rear Work, Tail, Turn Ground
START 16 13 9
10
0
21B
POWER RELAY 56
17
64A 49 4 14 Orange/Black Ignition Switch (ACC.) Power Relays 1, 2, 3, T85 Lamps, Rear Wiper Stop
JUNCTION 21A 21A 28 B 19 15 12
STARTER 4D 16 Gray RH Speaker Radio (Right Output) Switch & AC Indicator
3 STARTER AND 10 ETHER START 10 THERMO 34 34
STARTER SOLENOID
10 7 RELAY BUTTON (OPT.) 13
SWITCH 31S 31S 5E 16 Gray/Black LH Speaker Ground at Radio Lamp
10
CHASSIS 10 10 10
6F 16 Gray LH Speaker Radio (Left Output) 41 14 Pink Front Driving Lamp Front Driving, Tail, Cluster -
GROUND 30 30 30 30
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND Switch T12
8 16 Yellow/White Ignition Switch Momen- Diodes
1 2 3 4 42C 12 Dk Blue/Orange Rear Work Lamp Relay Rear Work Lamps
tary Ground
INSTRUMENT CLUSTER SENDER AND SWITCHES T87
15 INSTRUMENT CLUSTER WARNING ALARM 10 16 Black/Orange Accessories Ground
41 13 42F 16 Dark Blue Front Work Lamp Switch Front Work Lamps
31T 31T 12A 12 Red/Black Power Relay 1, T87 Fuse Block 2A, 4A, 6A, 8A,
32T 32T 24 and 10A 44 14 Tan Brake Switch Brake Lamps
36F 36F
36H 36H
WARNING 45L 16 Dark Brown/Yellow Flasher Relay T5 Left Turn Signal Lamps
ALARM 12B 12 Red/Orange Power Relay 2, T87 Fuse Block 2C, 4C, 6C, and
20
25 8C 45R 16 Dark Brown/Green Flasher Relay T7 Right Turn Signal Lamps
10 11 12 13 14 15 16 17 18 19 TRANS
17 18 TEMP ENGINE
46 16 Dark Brown Flasher Switch Flasher Relay T1
19B
2
FUEL OIL
AIR FILTER SENDER 22 39A
TEMPERATURE
12C 12 Red Power Relay 3, T87 Fuse Block 6D, 8D, 10D, and
DASH 36H RESTRICTION 39B
LAMPS TRANS
OIL
FILTER 10
LEVEL PRESS
SWITCH
REAR
AXLE
SWITCH 12D 47L 16 Lt Brown/Yellow Turn Signal Switch (Left) Left Turn Indicator, Flash Re-
OIL
V0LTAGE SENDER SWITCH
23F P
TEMP
SWITCH
37
19A 14 Red Fuse Block 7A Driving Light Switch lay T6
P ALARM
V T 27 47R 16 Lt Brown/Green Turn Signal Switch (Right) Right Turn Indicator, Flash
ENGINE FUEL
T
23 RELAY #2 19B 12 Red/Black Fuse Block 3C Alte rnator Lamp, Turn Signal
TEMP 8
PARKING BRAKE 26 85 86
Switch, Brake Switch, Hazard Relay T3
SWITCHES 8 52
ENGINE
21 ALARM Switch, Flasher Relay T2 48 16 Lt Brown/White Beacon Switch Beacon
PARK
#1 #2
OIL BRAKE TACH ENGINE RELAY #1 24 87A
BRAKE
10 16 TEMP 30 87 19C 12 Red/White Fuse Block 5D Rear Work Lamp Switch and 49 16 Gray Fuse Block 5B Dome Lamp
AIR ALT 33T 85 86
HYD SENDER
DIODE FILTER
.
30
23G
10
Relay T30 51A 16 Red/Yellow Wire 27 & Diode Backup Alarm (+)
9 DIODE RES. NC
8 7 6 5 4 3 2 1
SWITCH
39B
30 87
87A
36R
19D 16 Red/Yellow Fuse Block 5A Rotating Beacon Switch 52 16 Blue/Red Diodes Alarm Relay #2 T85
34 36P 23F
38 30 DIODE DIODE 19E 16 Red/Blue Fuse Block 1D Clutch Relay T85 and T30, 53 16 Purple/Red Loader Valve RTD Sole- RTD Limit Switch (NC)
31S 31S 30 28 Forward and Reverse Relays
38
36P 36P 36R
SEAT
noid
30
31P 31P 31P 31P 31P
DIODE T30
19B 23F 33T 33T POSITION 56 16 Red/Gray Fuse Block 1B Optional Radio or C.B.
38 38 SWITCH 19F 16 Red/Green Fuse Block 9A Loader Valve RTD Solenoid
23F 23F 23F 23F 57 16 Orange/Yellow Fuse Block 1C Optional Radio or C.B. and
10 10 10 10 10 10 19H 16 Red/Purple Rear Work Lamp Switch Rear Work Lamp and Relay Optional Rear Auxiliary Hy-
CHASSIS GROUND
30 30 30 30 30 30 T85 draulic Switch
CHASSIS GROUND CHASSIS GROUND
5 7 19K 16 Red/Brown Fuse Block 7D Front Work Lamp Switch 59 16 Red Optional Rear Auxiliary Optional Rear Auxiliary Hy-
6
WIPERS (CAB) BLOWER AND A/C (CAB) 20 16 Black Ignition Switch Body Ground Hydraulic Switch draulic Solenoid
TRANSMISSION CONTROLS RETURN-TO-DIG REAR WIPER
39 PARK SWITCH 40
REAR WIPER
BLOWER 21 16 White/Green Clutch Relay T87a Forward/Neutral/Reverse Le- 60 16 Orange/Brown A/C Thermostat A/C Relay T30, A/C High/Low
29 30 MOTOR 46 AIR COMPRESSOR 45
CLUTCH SWITCH
MOTOR ver (+) Pressure Switches
CLUTCH 88 M 40A
CUTOUT SWITCH
CUTOUT
SWITCH
21A 16 White/Red Ignition Switch (Start) Ether Start Button and Neu- 60A 16 Orange/Black A/C Relay T86 & T87 A/C/ Low/High Pressure
H
(SHIFT HANDLE) 38 H 47 tral Relay T30
(LOADER
L
80 L Switch,
HANDLE) FRONT RESISTOR
3 25
WIPER BOARD AND 21B 12 White Starter Relay T87 Starter Solenoid A/C Indicator Lamp
36 63 63
31 FORWARD RELAY
30 MOTOR 67 THERMAL 48 A/C LOW
P 60B
21C 16 White/Yellow Forward/Neutral/Reverse Neutral Relay T85 60B 16 Orange/Green A/C Relay T87a A/C Compressor Clutch
RETURN-TO-DIG
66
42 82
FUSE
PRESSURE SWITCH
85 86
10 LIMIT SWITCH 69 REAR WIPER 88 Lever (-) 61 14 Gray/White Fuse Block 5C Blower Switch (+)
3 25A 40A 81 86
SWITCH (CAB) 49
32 FORWARD SOLENOID
4 52 A/C HIGH
P 22 16 White/Purple Neutral Relay T87 Starter Relay T85 61B 16 Gray/Black Dome Lamp Dome Lamp Switch
87A NC 87
3 30
87
26
63
41 BLOWER PRESSURE SWITCH 60A 23F 16 White/Orange Fuse Block 3D Instrument Cluster T2, T9, 62 16 Orange/Gray Windshield Washer Front Windshield Washer
C NO SWITCH
25B 34 10
53 FRONT WIPER 40B
Tach, Diode Switch Pump
DIODE 40B M
REVERSE SOLENOID SWITCH (CAB) H 40A
85 86
10 37 63 WINDSHIELD WASHER 4 L
50 85 86 23G 16 White/Blue Diode & Wire 39A Alarn Relay #1 T85 63 14 Orange/Purple Fuse Block 1A Front/Rear Wiper Switches,
44 PUMP OPT.
A/C
3 19E 87A
LOADER 4 43 INDICATOR
87A
24 16 White/Brown Alarn Relay #1 T86 Alarn Relay #2 T30 Motors,
27 VALVE WINDSHIELD
30 87
SOLENOID 63 WASHER
OFF LAMP 10 30 87
25 16 White/Gray Clutch Relay T86 Clutch Cutout Switches Windshield Washer Switch
F R M M 61 60
33
51A
35 DIODE 53 19F
SWITCH OPT.
A/C
53 25A 16 White/Black Forward/Neutral/Reverse Forward Relay T85 & Diode 64A 16 Orange/Blue Fuse Block 3B Horn Switch
REVERSE T
RELAY BACKUP
65
A/C 51 RELAY
Lever (FOR) 64B 16 Green/Red Horn Switch Horn
30 30 85
ALARM 62 TEMP SWITCH
7 52 30
40B 40B 25B 16 White/Orange Forward/Neutral/Reverse Reverse Relay T85 & Diode 65 16 Orange/Brown Windshield Washer Rear Windshield Washer
40A 40A
10 10 10 10 Lever (REV) Switch Pump
30 30 30 30 30 25C 16 Orange/Yellow Fuse Block 3A 4WD Engage Switch 66 16 Green Front Wiper Switch - Low Front Wiper - Low
25E 16 Orange/White 4WD Engage Switch 4WD Solenoid 67 16 Red Front Wiper Switch - High Front Wiper - High
8 9 10 11 26 16 Orange/Gray Forward Relay T87 Forward Solenoid & Diode 69 16 Yellow Front Wiper Switch - Front Wiper - Brake
27 16 Orange/Red Reverse Relay T87 Reverse Solenoid, Wire Brake
DOME LAMPS (CAB) HORN ROTATING BEACON AND WORK LAMPS
FRONT AND REAR LAMPS (STANDARD) FLASHER, TURN SIGNAL, AND BRAKE LAMP SWITCHES #51A, & Diode 70 16 Black Optional Rear Auxiliary Ground
59 60 RIGHT
61 67 HORN 69 28 16 Gray/Orange Ether Start Button Ether Injection Solenoid Hydraulic Solenoid
ROTATING
LEFT REAR
LEFT FRONT
63 HORN 4
ROTATING 70 BEACON (OPT.)
57 REAR REAR L R TURN
TURN LAMP
TURN
68 BUTTON BEACON SWITCH 30 16 Black/Yellow Accessories Ground 71 16 Red/Black Aux Hyd Foot Switch “N/ Aux Hydraulic Solenoid
4
56 FRONT TAIL TURN LAMP 62 SIGNAL SWITCH 73 31P 16 Yellow/Black Instrument Cluster T7 Oil Pressure Switch & Diode O”
LAMPS LAMP L R RIGHT FRONT
ROAD 45R
LAMPS TURN LAMP 19D 10 FRONT
31S 16 Yellow/Red Alternator Tach Output Instrument Cluster Tachome- 75 16 Red Ride Control Engage Ride Control Solenoids
45L 45L 48 42F WORK
45R LAMPS ter Switch
44 FRONT WORK
55 45R 71
DOME 41
47L 4 LAMP SWITCH 90
31T 16 Yellow Instrument Cluster T10 Coolant Temperature Sender 80 14 Black ear Wiper MWotiopreSrt(oGpround) R
LAMP SWITCH
41 47R Switch
44
64B
74
REAR WORK 32T 16 Yellow/Green Instrument Clus ter T11 Transmission Temperature
40A 40B 65
FLASHER LAMPS 81 16 Gray Rear Wiper Switch - Low Rear Wiper - Low
64 RELAY (BOTTOM
19K Sender
45L 4 42F
41 5 OF SOCKET)
66 30 64A 40A
33T 16 Yellow/Pink Instrument Cluster T1 Rear Axle Temperature 82 16 White Rear Wiper Switch - High Rear Wiper - High
4 54 DRIVING LAMP 40A
BRAKE
72
DOME 58 SWITCH
LAMP 40A
FLASHER SWITCH REAR WORK 10 75 Switch 85 14 Orange/Green Blower Switch A/C Thermostat
LAMP (L.H.) SWITCH 4 LAMP SWITCH
7 REAR WORK
49
61B 19B
LAMP RELAY 34 16 Yellow/Dk Blue Alternator Instrument Cluster T5 86 14 Light Blue Blower Switch - Low Resistor Board - Low
4
40B 6 5 4 64A
3 2 1
46 85 86 36F 16 Yellow/Orange Instrument Cluster T14 Fuel Level Sender 87 14 Blue Blower Switch - Medium Resistor Board - Medium
30 19C 19H
49 61B
41 10 10 30 87A 42C 36H 16 Yellow/Purple Instrument Cluster T18 Hydraulic Filter Restriction 88 14 Lt Blue/White Blower Switch - High Resistor Board - High/Blower
19B 19B 19C
30 87 Switch & Diode
19A
40B 90 16 Black Rotating Beacon Ground
90
40B 40B 40B 40B 40B
40A 40A 40A 40A 40A
10 10 10 10 10 10
30 30 30 30 30
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND
12 13 14
15 16
4WD ELECTRICAL CIRCUIT REAR AUXILIARY HYDRAULICS RADIO AND C.B. (OPT.) RIDE CONTROL (OPT.) FUSE AND RELAY LOCATION
74
8 7
84
RIDE CONTROL 85 RIGHT RIDE CONTROL
SOLENOID (ACCUMULATOR)
30 9 * STARTING & * INSTRUMENTS * REAR WORK * FRONT WORK SPARE SPARE
ENGAGE SWITCH TRANSMISSION CONT. & ALARM SYS. LAMPS LAMPS
4
4WD ENGAGE
76 SWITCH 78 RADIO & RIDE CONTROL * SIGNAL LAMPS ** BLOWER SPARE
F ORWAR D
REVERSE
S TA R T E R
FOOT OPERATED REAR AUXILIARY
*
79 4 4 81
*
*
LAMPS
*
REAR
RELAY
HYDRAULIC (OPT)
RELAY
RELAY
RELAY
REAR AUXILIARY
REAR AUXILIARY 32
4 HYD. SWITCH 4
HYDRAULICS SOLENOID RADIO (OPT.)
B+ GRD 4D 6F 57 75
64 RADIO & C.B., (BATT+) * HORN ** DOME LAMP SPARE
NEUTRAL
NC
CLUTCH
ACC + 3C 5E
AL ARM
AL ARM
*
25C 25E 59
* WIPERS * DRIVING LAMPS * RETURN
*
*
*
RELAY
RELAY
LEFT
RELAY
NO 6F
RELAY
C 82 25 4WD (OPT) ROTATING
#2
SPEAKER
#1
5E BEACON (OPT) TO DIG
77
56 4D RIGHT
FL ASHER
4WD SOLENOID 83 *STANDARD EQUIPMENT
POWERRE
POWER
POWER
*
WAR NI N G
3C SPEAKER
*
(DISENGAGES 4WD 59
*
*
RELAY
RELAY
RELAY
26
RELAY
(OPT)
**STANDARD EQUIPMENT W/CAB
A/C
WHEN ENGERIZED)
LAY
RELAY
57
#2
#3
#1
TO
57 86
C.B.
30 10 LEFT RIDE CONTROL
10 70 FEED
SOLENOID (TANK)
70 SPARE SPARE
10A 10A 20A 10A
80 52
15A 15A 25A SPARE
AUXILIARY 10
10A 10A 10A SPARE
HYDRAULICS
SWITCH 15A 10A 10A 15A 10A
Junction
4
Block
10 10 10 10
30
CHASSIS GROUND CHASSIS GROUND CHASSIS GROUND

ELECTRICAL SCHEMATIC
CHASSIS GROUND
20 14
17 18 19 BT96C025
8 Indicates circuit continued on block shown. 181635A1 (580L, 580 Super L and 590 Super L)
Technical Publications Distribution System. The part number is 7-48722.
Copyright © 2006. CNH America, LLC. All Rights Reserved. 7-48722-Schematic

580L 580 Super L 590 Super L Series Service Manual PDF

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580L 580 Super L 590 Super L Series Service Manual PDF

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Section

Bur 7-49490 Issued 5-95 Printed in U.S.A.

1. Flow Valve Adapter 6. Body 11. Spring 16. Washer

Bur 7-49490 Issued 5-95 Printed in U.S.A.

18. Tighten the flow adapter (1) to 30 to 40 pound-feet (41 to

6. Lubricate the bore of the body (6) with clean hydraulic

9. Install the push rod (15) and washer (16).

11. Install the boot (18).

13. Install the ball (5) in the body (6).

Bur 7-49490 Issued 5-95 Printed in U.S.A.

1. Flow Valve Adapter 6. Body 11. Spring 16. Washer

Bur 7-49490 Issued 5-95 Printed in U.S.A.

CLEANING THE HYDRAULIC SYSTEM

GENERAL INFORMATION ............................................................................................................................................ 4

TYPES OF CONTAMINATION ....................................................................................................................................... 4

CLEANING THE HYDRAULIC SYSTEM .......................................................................................................................... 5

FLUSHING WATER FROM THE HYDRAULIC SYSTEM .................................................................................................... 7

Bur 7-49640 Issued 5-95 Printed in U.S.A

The part number for the Fitting Kit is CAS-10508.

The part number for the Portable Filter is CAS-10162A.

Bur 7-49640 Issued 5-95 Printed in U.S.A.

c. The hydraulic system has a high operating

Bur 7-49640 Issued 5-95 Printed in U.S.A.

CLEANING THE HYDRAULIC SYSTEM

23. Remove the hose from the hydraulic reservoir.

Bur 7-49640 Issued 5-95 Printed in U.S.A.

29. Install the drain plug. 35. Stop the engine.

Bur 7-49640 Issued 5-95 Printed in U.S.A.

FLUSHING WATER FROM THE HYDRAULIC SYSTEM

39-4 IMPORTANT: C h e ck t h e o i l l eve l i n t h e hy d ra u l i c

20. Connect the lines to the rod end of the cylinders.

22. Install the filler cap for the reservoir.

Bur 7-49640 Issued 5-95 Printed in U.S.A.

AIR CONDITIONER TROUBLE SHOOTING

FOR SYSTEMS WITH R-134a REFRIGERANT

(Visual and Operating)

SPECIAL TOOLS ........................................................................................................................................................ 4

TROUBLESHOOTING ............................................................................................................................................... 5-7

EXTERNAL COMPRESSOR CHECK ............................................................................................................................ 8,9

BLOWER MOTOR AND COMPRESSOR CLUTCH CHECK .......................................................................................... 10-13

CAB TEMPERATURE CHECK ................................................................................................................................. 14,15

VISUAL REFRIGERANT CHECK ................................................................................................................................. 16

CAB HEATER CHECK ............................................................................................................................................... 17

EVAPORATOR AND PLENUM CHECK ..................................................................................................................... 18,19

PRESSURE SWITCH CHECK ..................................................................................................................................... 20

AIR CONDITIONING CONTROL SWITCH CHECK .......................................................................................................... 21

Bur 7-50091 Issued 7-95 Printed in U.S.A

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

Bur 7-50091 Issued 7-95 Printed in U.S.A.

REFRIGERANT RECOVERY, 9 INCH STEM TYPE THERMOMETER

BELT TENSION TOOL

Bur 7-50091 Issued 7-95 Printed in U.S.A.

COMPRESSOR RUNS COMPRESSOR DOES NOT RUN

See External Compressor Check Page 8

See Blower and Compressor

See Visual Refrigerant Check Page 16

INTERNAL SYSTEM PROBLEM

See Gauges and Testing Section 9003

Bur 7-50091 Issued 7-95 Printed in U.S.A.

See External Compressor Check Page 8

See Blower and Compressor

See Visual Refrigerant Check Page 16

INTERNAL SYSTEM PROBLEM