Case 580SR User manual

580SR
580SR+
590SR
695SR
SERIES 3
580SR
580SR+
590SR
695SR
SERIES 3
Service manual
Service
manual
Print No. 87643852B
Print No. 87643852B
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7
SPICER OFF-HIGHWAY
AXLE DIVISION
21199
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TO READER
This manual has been printed for a skilful engineer
to supply necessary technical information to carry
out service operations on this machine.
Read carefully this manual to collect correct infor-
mation relevant to repair procedures.
For any question or remark, or in case of any error
relevant the contents of this manual, please con-
tact:
CNH ITALIA S.p.A.
Technical Information
Viale delle Nazioni, 55
41100 MODENA - Italy
REFERENCE
Beyond this Service Manual, also refer to docu-
ments hereunder listed:
ZOperator’s Manual
ZParts Catalogue
COMPLETE HANDBOOK FOR INSTRUCTIONS
AND REPAIRS
The complete Service Manual consists of two vol-
umes:
Z580SR / 580SR+ / 590SR / 695SR
Service Manual for “Loader backhoe”
Z580SR / 580SR+ / 590SR / 695SR
Service Manual “Engine”
The Service Manuals for “Loader backhoe” and “En-
gine” contain the necessary technical information to
carry out service and repair on machine and on en-
gine, necessary tools to carry out those operations
and information on service standard, on procedures
for connection, disconnection, disassembly and as-
sembly of parts.
The complete Service Manual which covers the
loader backhoe models 580SR / 580SR+ / 590SR /
695SR consists of the following volumes, which can
be identified through their print number as stated be-
low:
VOLUME MACHINE TYPE PRINT NUMBER
Service Manual - “Loader backhoe” 580SR / 580SR+ / 590SR / 695SR 87643852B
Service Manual - “Engine” 580SR / 580SR+ / 590SR / 695SR 87659057A
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PREVENT ACCIDENTS
The majority of accidents and injuries which occur in industry, on the farm, at home or on the
road, are caused by the failure of some individual to follow simple and fundamental safety rules
or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the
real cause and taking the necessary precautions, before the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be
conditions that cannot be completely safeguarded against, without interfering with reasonable
accessibility and efficient operation.
A careful operator and / or technician is the best insurance against accidents. The complete ob-
servance of one simple rule would prevent many thousands of serious injuries each year.
This rule is: never attempt to clean, lubricate or adjust a machine while it is in motion.
SWARNING
Before carrying out any maintenance operation, adjustment and or repair on machines equipped
with attachments, controlled hydraulically or mechanically, make sure that the attachment is low-
ered and safely set on the ground. If it is necessary to have the equipment partially or fully raised
to gain access to certain items, be sure the equipment is suitably supported by means other than
the hydraulic lift cylinders, cable and /or mechanical device used for controlling the equipment.
CNH ITALIA S.p.A.
Technical Information
Viale delle Nazioni, 55
41100 MODENA - Italy
All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.
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LOADER BACKHOE MODELS
The complete range of Loader Backhoe models described in this manual are identified below:
580SR 580SR+ 590SR 695SR
Powershift / OO O
Powershuttle OOO /
Stabilizer sideshift OOO O
Stabilizer center pivot / / / O
Cab OOO O
Rops O// /
2WD O// /
4WD OOO O
4WS / / / O
Pilot control OOO O
Mechanical control OOO O
Engine 72 kW-97 HP model
F4GE948C*601 (mechanical) O// /
Engine 72 kW-97 HP model
F4HE0484C*J102 (electronic) /O//
Engine 82 kW-110 HP model
F4HE9484C*J102 (electronic) //
O/
Engine 82 kW-110 HP model
F4HE9484C*J103 - 4WS (electronic) /// O
Short dipper / / / /
Long dipper OOO O
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SECTION 00 - SAFETY PRECAUTIONS
SECTION 01 - MAINTENANCE
SECTION 02 - TECHNICAL SPECIFICATIONS
1. LOADER BACKHOE MODELS .................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. SPECIFICATIONS ........................................................................................................................................ 6
3.1 DIESEL ENGINE ................................................................................................................................... 6
3.2 TRANSMISSION.................................................................................................................................... 8
3.3 AXLES ................................................................................................................................................... 9
3.4 BRAKES ................................................................................................................................................ 9
3.5 STEERING........................................................................................................................................... 10
3.6 HYDRAULIC SYSTEM ........................................................................................................................ 10
3.7 FRONT COUNTERWEIGHT ............................................................................................................... 10
3.8 NOISE AND VIBRATION LEVELS ...................................................................................................... 11
3.9 BUCKETS ............................................................................................................................................ 11
3.10 TYRES ............................................................................................................................................... 12
4. DIMENSIONS AND PERFORMANCE........................................................................................................ 13
4.1 LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ....................................................... 13
4.2 DIMENSIONS AND PERFORMANCE OF LOADER ATTACHMENT WITH FORKS.......................... 19
4.3 BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE .................................................... 20
5. BACKHOE ATTACHMENT LIFTING CAPACITY ....................................................................................... 26
6. MAXIMUM LIFTING LOADS....................................................................................................................... 29
6.1 LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................ 29
6.2 BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ......................................................... 30
7. SUPPLY SUMMARY TABLE ...................................................................................................................... 31
SECTION 17 - TORQUE CONVERTERS
1. POWERSHUTTLE TORQUE CONVERTER ................................................................................................3
1.1 DESCRIPTION AND OPERATION........................................................................................................ 3
1.2 SPECIFICATIONS ................................................................................................................................. 4
1.3 OVERHAUL ........................................................................................................................................... 4
1.4 INSPECTION......................................................................................................................................... 4
1.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.6 STALL TEST.......................................................................................................................................... 5
1.7 FAULT FINDING.................................................................................................................................... 6
2. POWERSHIFT TORQUE CONVERTER ...................................................................................................... 7
2.1 DESCRIPTION AND OPERATION........................................................................................................ 7
2.2 SPECIFICATIONS ................................................................................................................................. 8
2.3 OVERHAUL ........................................................................................................................................... 8
2.4 INSPECTION......................................................................................................................................... 9
2.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 9
2.6 STALL TEST........................................................................................................................................ 11
2.7 FAULT FINDING.................................................................................................................................. 12
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SECTION 21 - TRANSMISSION
1. POWERSHUTTLE TRANSMISSION “TURNER MODEL COM-T4-2025”.................................................... 3
1.1 SPECIFICATIONS ................................................................................................................................. 3
1.2 MOUNTING SCREW TORQUE............................................................................................................. 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION ..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS ....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 2WD COMPONENTS .............................................................................................. 23
1.9 TRANSMISSION 4WD COMPONENTS .............................................................................................. 26
1.10 TRANSMISSION REMOVAL ............................................................................................................. 31
1.11 DISASSEMBLY AND ASSEMBLY..................................................................................................... 32
1.12 FAULT FINDING ................................................................................................................................ 90
1.13 SPECIAL TOOLS............................................................................................................................... 93
2. POWERSHIFT TRANSMISSION “DANA T16000” ..................................................................................... 94
2.1 SPECIFICATIONS ............................................................................................................................... 94
2.2 CONTROLS ......................................................................................................................................... 95
2.3 LUBRICATION ................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER................................................................................................................ 108
2.6 HYDRAULIC DIAGRAM..................................................................................................................... 109
2.7 OPERATION ...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION REMOVAL AND INSTALLATION ........................................................................ 133
2.11 TRANSMISSION COMPONENTS ................................................................................................... 137
2.12 DISASSEMBLY AND ASSEMBLY................................................................................................... 155
2.13 SPECIAL TOOLS............................................................................................................................. 264
2.14 FAULT FINDING .............................................................................................................................. 265
2.15 FAULT FINDING .............................................................................................................................. 267
SECTION 25 - FRONT AXLES
1. FRONT AXLE 2WD “CARRARO” ................................................................................................................. 3
1.1 SPECIFICATIONS ................................................................................................................................. 3
1.2 DISASSEMBLY AND ASSEMBLY......................................................................................................... 6
1.3 FAULT FINDING .................................................................................................................................. 24
2. FRONT AXLE 4WD “CARRARO” ............................................................................................................... 26
2.1 SPECIFICATIONS ............................................................................................................................... 26
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 31
2.3 FAULT FINDING .................................................................................................................................. 77
3. FRONT AXLE 4WS “CARRARO” ............................................................................................................... 80
3.1 SPECIFICATIONS ............................................................................................................................... 80
3.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 84
3.3 FAULT FINDING ................................................................................................................................ 137
4. SPECIAL TOOLS...................................................................................................................................... 140
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SECTION 27 - REAR AXLE
1. REAR AXLE 2WS ......................................................................................................................................... 3
1.1 DESCRIPTION AND OPERATION....................................................................................................... 3
1.2 SPECIFICATIONS ................................................................................................................................. 6
1.3 DISASSEMBLY AND ASSEMBLY......................................................................................................... 8
1.4 FAULT FINDING.................................................................................................................................. 27
2. REAR AXLE 4WS “CARRARO”.................................................................................................................. 28
2.1 SPECIFICATIONS ............................................................................................................................... 28
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 32
2.3 FAULT FINDING.................................................................................................................................. 81
3. SPECIAL TOOLS........................................................................................................................................ 84
SECTION 33 - BRAKES SYSTEM
1. SPECIFICATIONS ........................................................................................................................................ 3
2. PARKING BRAKE......................................................................................................................................... 6
2.1 PARKING BRAKE ADJUSTMENT ........................................................................................................ 7
3. BRAKE CYLINDERS .................................................................................................................................... 8
4. OIL BRAKE TANK ...................................................................................................................................... 13
5. BLEEDING PROCEDURE.......................................................................................................................... 13
SECTION 35 - HYDRAULIC SYSTEM
1. HYDRAULIC DIAGRAMS ............................................................................................................................. 3
1.1 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS................................................. 3
1.2 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .............................................................. 5
1.3 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS................................................. 7
1.4 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS .............................................................. 9
1.5 HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .................................................... 11
2. HYDRAULIC PUMP.................................................................................................................................... 13
2.1 DESCRIPTION AND OPERATION...................................................................................................... 13
2.2 SPECIFICATIONS ............................................................................................................................... 13
2.3 LOAD SENSING VALVE ..................................................................................................................... 16
2.4 REMOVAL ........................................................................................................................................... 18
2.5 COMPONENTS ................................................................................................................................... 19
2.6 DISASSEMBLY AND ASSEMBLY....................................................................................................... 20
3. CONTROL VALVES ................................................................................................................................... 24
3.1 CONTROL VALVES “REXROTH” (MECHANICAL MODELS) ............................................................ 24
3.2 “REXROTH” CONTROL VALVES (PILOT MODELS) ......................................................................... 40
3.3 SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE
(WITH HYDRAULIC CONTROL) .......................................................................................................... 49
3.4 RELIEF VALVES ................................................................................................................................. 52
3.5 ACCUMULATOR “GLIDE RIDE” PARKER.......................................................................................... 60
4. HYDRAULIC SWING SYSTEM .................................................................................................................. 63
4.1 DESCRIPTION AND OPERATION...................................................................................................... 63
4.2 HYDRAULIC OIL FLOW ...................................................................................................................... 64
5. HYDRAULIC CYLINDERS.......................................................................................................................... 66
5.1 LOADER ATTACHMENT BOOM CYLINDER ..................................................................................... 67
5.2 LOADER BUCKET CYLINDER ........................................................................................................... 72
5.3 4X1 LOADER BUCKET CYLINDER .................................................................................................... 76
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5.4 BACKHOE BOOM CYLINDER ............................................................................................................ 79
5.5 BACKHOE ATTACHMENT DIPPER CYLINDER ................................................................................ 83
5.6 BACKHOE BUCKET CYLINDER......................................................................................................... 87
5.7 TELESCOPIC CYLINDER ................................................................................................................... 91
5.8 4WS STABILIZER CYLINDER - CENTER PIVOT............................................................................... 95
5.9 STABILIZER CYLINDER - SIDESHIFT ............................................................................................... 99
5.10 SWING CYLINDER.......................................................................................................................... 103
5.11 BACKHOE ATTACHMENT SIDESHIFT CYLINDER - SIDESHIFT ................................................. 107
5.12 SPECIAL TOOLS............................................................................................................................. 108
6. HYDRAULIC CONTROL LEVERS............................................................................................................ 109
6.1 SPECIFICATIONS ............................................................................................................................. 109
6.2 DESCRIPTION AND OPERATION.................................................................................................... 110
6.3 DISASSEMBLY AND ASSEMBLY..................................................................................................... 113
6.4 CONTROL LEVER VALVE ................................................................................................................ 116
7. FAULT FINDING ....................................................................................................................................... 119
7.1 PRELIMINARY CHECKS................................................................................................................... 119
7.2 FAULT FINDING ................................................................................................................................ 120
SECTION 39 - CHASSIS
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. REMOVAL AND INSTALLATION COMPONENTS....................................................................................... 5
2.1 COMPONENTS WITHIN THE CHASSIS...............................................................................................5
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 6
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS ....................................................................... 8
2.4 COMPONENTS ATTACHED ON THE CHASSIS.................................................................................. 9
2.5 MOUNTING SCREW TORQUE........................................................................................................... 11
SECTION 41 - STEERING SYSTEM
1. STEERING SYSTEM 2WS ........................................................................................................................... 4
2. STEERING SYSTEM 4WS ........................................................................................................................... 7
3. POWER STEERING ................................................................................................................................... 12
3.1 SPECIFICATIONS ............................................................................................................................... 13
3.2 COMPONENTS ................................................................................................................................... 15
3.3 DISASSEMBLY AND ASSEMBLY....................................................................................................... 16
3.4 SPECIAL TOOLS................................................................................................................................. 33
3.5 FAULT FINDING .................................................................................................................................. 33
SECTION 50 - CAB HEATING AND AIR CONDITIONING
1. SPECIFICATIONS ........................................................................................................................................ 3
2. CAB HEATING.............................................................................................................................................. 5
2.1 DESCRIPTION AND OPERATION........................................................................................................ 5
3. AIR CONDITIONING................................................................................................................................... 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 16
3.3 CONTROLS AND OPERATION .......................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 26
3.5 FLUSHING THE SYSTEM ................................................................................................................... 44
3.6 EVACUATING THE SYSTEM.............................................................................................................. 46
3.7 CHARGING THE SYSTEM.................................................................................................................. 47
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3.8 COMPONENTS OVERHAUL .............................................................................................................. 48
3.9 COMPRESSOR................................................................................................................................... 53
3.10 SPECIAL TOOLS............................................................................................................................... 67
SECTION 55 - ELECTRICAL SYSTEM
1. GENERALITIES............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (580SR).......................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR)........................................................... 20
2.3 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (580SR)................................................................. 36
2.4 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR+/590SR) ............................................ 54
2.5 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (590SR)................................................................. 69
2.6 ELECTRICAL DIAGRAMS - 4WS POWERSHIFT CAB (695SR)........................................................ 84
3. CONTROLS AND INSTRUMENTS .......................................................................................................... 100
3.1 FRONT CONTROL PANELS (580SR / 590SR) ................................................................................ 100
3.2 FRONT CONTROL PANELS (695SR) .............................................................................................. 102
3.3 SIDE INSTRUMENT CLUSTER PANEL (580SR) ............................................................................. 104
3.4 SIDE INSTRUMENT CLUSTER PANEL (580SR+ / 590SR / 695SR)............................................... 106
3.5 SIDE INSTRUMENT CLUSTER (580SR).......................................................................................... 108
3.6 SIDE INSTRUMENT CLUSTER (580SR+ / 590SR / 695SR)............................................................ 110
3.7 IMMOBILISER CIRCUIT.................................................................................................................... 112
4. DIAGNOSTIC DISPLAY (580SR+ / 590SR / 695SR) ............................................................................... 113
4.1 SYMBOLS.......................................................................................................................................... 114
4.2 SETUP MENU ................................................................................................................................... 115
4.3 PROCEDURE ABOUT SELF TEST .................................................................................................. 116
4.4 ON BOARD ERROR CODE RETRIEVAL ......................................................................................... 117
4.5 BACKLIGHTING AND DIMMING....................................................................................................... 118
4.6 WORK HOURS.................................................................................................................................. 119
4.7 FUNCTIONAL DESCRIPTION .......................................................................................................... 120
4.8 WARNING SYSTEM.......................................................................................................................... 124
4.9 MAINTENANCE................................................................................................................................. 126
4.10 WARNING MESSAGES .................................................................................................................. 127
5. STARTING SYSTEM ................................................................................................................................ 134
5.1 DESCRIPTION AND OPERATION.................................................................................................... 134
5.2 FAULT FINDING................................................................................................................................ 135
5.3 STARTER MOTOR............................................................................................................................ 138
6. ALTERNATOR.......................................................................................................................................... 144
6.1 SPECIFICATIONS ............................................................................................................................. 144
6.2 DESCRIPTION AND OPERATION.................................................................................................... 144
6.3 COMPONENTS ................................................................................................................................. 146
6.4 REMOVAL ......................................................................................................................................... 147
6.5 PRELIMINARY CHECK AND TESTS................................................................................................ 148
6.6 FAULT FINDING................................................................................................................................ 157
7. BATTERY ................................................................................................................................................. 158
7.1 SPECIFICATIONS ............................................................................................................................. 158
7.2 DESCRIPTION AND OPERATION.................................................................................................... 158
7.3 BATTERY REPLACEMENT .............................................................................................................. 159
7.4 MAINTENANCE................................................................................................................................. 161
7.5 TESTS ............................................................................................................................................... 163
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7.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 165
7.7 BATTERY MASTER SWITCH ........................................................................................................... 165
8. COMPONENT TESTING .......................................................................................................................... 166
8.1 GENERAL INTRODUCTION ............................................................................................................. 166
8.2 COMPONENT TESTING ................................................................................................................... 167
8.3 GROUND POINTS............................................................................................................................. 167
8.4 ALTERNATOR ................................................................................................................................... 170
8.5 TRANSMISSIONS ............................................................................................................................. 170
8.6 PARKING BRAKE SWITCH............................................................................................................... 174
8.7 CAB.................................................................................................................................................... 175
8.8 4WD SWITCH .................................................................................................................................... 180
8.9 BRAKE PEDAL SWITCHES .............................................................................................................. 180
8.10 BRAKE OIL LEVEL WARNING LAMP............................................................................................. 181
8.11 FRONT WORK LAMP SWITCH (1) - REAR WORK LAMP SWITCH (2) MAIN LIGHT SWITCH.... 181
8.12 HAZARD SWITCH ........................................................................................................................... 182
8.13 HAZARD WARNING LIGHT RELAY................................................................................................ 182
8.14 MULTI FUNCTION SWITCH............................................................................................................ 183
8.15 FRONT WINDSHIELD WIPER MOTOR (1) - REAR WINDSHIELD WIPER MOTOR (2) ............... 183
8.16 4WS - STEERING SELECTOR SWITCH ........................................................................................ 184
8.17 STEERING CONTROL UNIT........................................................................................................... 185
8.18 4WS REAR AXLE STEERING SENSOR......................................................................................... 187
8.19 4WS FRONT AXLE STEERING SENSOR ...................................................................................... 187
8.20 STEERING SOLENOID VALVE....................................................................................................... 188
8.21 DIFFERENTIAL LOCK SWITCH (1) ................................................................................................ 189
8.22 LOADER .......................................................................................................................................... 190
8.23 BACKHOE........................................................................................................................................ 193
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 3
1.1 LOADER ATTACHMENT OPERATION.................................................................................................3
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 6
3. LOADER ATTACHMENT SAFETY STRUT.................................................................................................. 7
4. LOADER BUCKET REMOVAL ..................................................................................................................... 8
5. LOADER REMOVAL................................................................................................................................... 11
SECTION 84 - BACKHOE
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION ............................................................ 6
3. BACKHOE ATTACHMENT HYDRAULIC CONTROLS .............................................................................. 15
4. REMOVAL AND INSTALLATION ............................................................................................................... 17
4.1 CENTER PIVOT BACKHOE ATTACHMENT DISASSEMBLY ............................................................ 17
4.2 BACKHOE ATTACHMENT DISASSEMBLY - SIDESHIFT.................................................................. 20
4.3 BACKHOE BUCKET REMOVAL ......................................................................................................... 23
4.4 BUCKET TEETH REPLACEMENT...................................................................................................... 23
4.5 DIPPER REMOVE ............................................................................................................................... 24
5. TELESCOPIC DIPPER REVISION............................................................................................................. 27
6. TELESCOPIC DIPPER REVISION............................................................................................................. 27
7. REVISIONE DEL BRACCIO TELESCOPICO............................................................................................. 27
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580SR
580SR+
590SR
695SR
SECTION 00 - SAFETY PRECAUTIONS
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2 SECTION 00 - SAFETY PRECAUTIONS
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SECTION 00 - SAFETY PRECAUTIONS 3
This warning symbol points out important messages
involving personal safety.
Carefully read the safety rules contained herein and
follow advised precautions to avoid potential haz-
ards and safeguard your safety and personal integ-
rity.
In this manual you will find this symbol together with
the following keywords:
WARNING - it gives warning about improper repair
operations and deriving potential consequences af-
fecting the service technician’s personal safety.
DANGER - it gives specific warning about potential
dangers for personal safety of the operator or other
persons directly or indirectly involved.
TO PREVENT ACCIDENTS
Most accidents and personal injuries that occur in the work site or on the road, are caused by the failure of
some individual to follow simple and fundamental safety rules or precautions.
For this reason, MOST ACCIDENTS CAN BE PREVENTED: by recognizing the real cause and taking the nec-
essary precautions, before the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be conditions that
cannot be completely safeguarded against, without interfering with reasonable accessibility and efficient oper-
ation.
A careful operator or technician is the best precaution against accidents. The complete observance of one sim-
ple rule would prevent many thousands of serious injuries each year.
This rule is: never attempt to clean, lubricate or adjust a machine while it is in motion.
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4 SECTION 00 - SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
ZCarefully follow specified repair and maintenance
procedures.
ZDo not wear rings, wristwatches, jewels, unbut-
toned or flapping clothing such as: ties, torn
clothes, scarves, open jackets or shirts with open
zips which could get hold into moving parts.
We advise to use approved safety clothing such
as: anti-slipping footwear, gloves, safety goggles,
helmets, etc.
ZNever carry out any repair on the machine if some-
one is sitting on the operator’s seat, except if they are
certified operators to assist in the operation to be car-
ried out.
ZNever operate the machine or use attachments
from a place other than sitting at the operator’s
seat.
ZNever carry out any operation on the machine
when the engine is running, except when specifi-
cally indicated.
ZStop the engine and ensure that all pressure is re-
lieved from hydraulic circuits before removing
caps, covers, valves, etc.
ZAll repair and maintenance operations should be
carried out with the greatest care and attention.
ZService stairs and platforms used in a workshop or
in the field should be built in compliance with the
safety rules in force.
ZDisconnect the batteries and label all controls to
warn that the Machine is being serviced. Block the
machine and all equipment which should be
raised.
ZNever check or fill fuel tanks and accumulator batter-
ies, nor use starting liquid if you are smoking or near
open flames as such fluids are flammable.
ZBrakes are inoperative when they are manually re-
leased for maintenance purposes. In such cases,
the machine should be kept constantly under con-
trol using blocks or similar devices.
ZThe fuel filling gun should remain always in contact
with the filler neck.
Maintain this contact until the fuel stops flowing
into the tank to avoid possible sparks due to static
electricity buildup.
ZUse exclusively specified towing points for towing
the machine. Connect parts carefully. Ensure that
foreseen pins and/or locks are steadily fixed before
applying traction.
Do not stop near towing bars, cables or chains
working under load.
ZTo transfer a failed machine, use a trailer or a low
loading platform trolley if available.
ZTo load and unload the machine from the transpor-
tation mean, select a flat area providing a firm sup-
port to the trailer or truck wheels. Firmly tie the
machine to the truck or trailer platform and block
wheels as required by the forwarder.
ZFor electrical heaters, battery-chargers and similar
equipment use exclusive auxiliary power supplies
with a efficient ground to avoid electrical shock
hazard.
ZAlways use lifting equipment and similar of appro-
priate capacity to lift or move heavy components.
ZPay special attention to bystanders.
ZNever pour gasoline or diesel oil into open, wide
and low containers.
ZNever use gasoline, diesel oil or other flammable
liquids as cleaning agents. Use non-flammable
non-toxic proprietary solvents.
ZWear protection goggles with side guards when
cleaning parts using compressed air.
ZDo not exceed a pressure of 2.1 bar, in accordance
with local regulations.
ZDo not run the engine in a closed building without
proper ventilation.
ZDo not smoke, use open flames, cause sparks in
the nearby area when filling fuel or handling highly
flammable liquids.
ZDo not use flames as light sources when working
on a machine or checking for leaks.
ZMove with caution when working under a Machine,
and also on or near a Machine. Wear proper safety
accessories:
helmets, goggles and special footwear.
ZDuring checks which should be carried out with the
engine running, ask an assistant to sit at the oper-
ator’s seat and keep the service technician under
visual control at any moment. In case of operations
outside the workshop, drive the machine to a flat
area and block it. If working on an incline cannot be
avoided, first block the Machine carefully. Move it
to a flat area as soon as possible with a certain ex-
tent of safety.
ZRuined or plied cables and chains are unreliable.
Do not use them for lifting or trailing. Always han-
dle them wearing gloves of proper thickness.
ZChains should always be safely fastened. Ensure
that fastening device is strong enough to hold the
load foreseen. No persons should stop near the
fastening point, trailing chains or cables.
ZThe working area should be always kept CLEAN
and DRY. Immediately clean any spillage of water
or oil.
ZDo not pile up grease or oil soaked rags: they consti-
tute a great fire hazard. Always place them into a met-
al container. Before starting the Machine or its
attachments, check, adjust and block the operator’s
seat. Also ensure that there are no persons within the
Machine or attachment operating range.
ZDo not keep in your pockets any object which might fall
unobserved into the Machine’s inner compartments.
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SECTION 00 - SAFETY PRECAUTIONS 5
ZWhenever there is the possibility of being reached
by ejected metal parts or similar, use protection
eye mask or goggles with side guards, helmets,
special footwear and heavy gloves. Whenever it is
necessary to carry out welding operations, it is
necessary to wear suitable personal protective de-
vices: tinted eye protection, helmets, special cloth-
ing, gloves and safety shoes. All persons standing
in the vicinity of the welding process should wear
tinted eye protection. NEVER LOOK AT THE
WELDING ARC IF YOUR EYES ARE NOT SUIT-
ABLY PROTECTED.
ZMetal cables with the use get frayed. Always wear
adequate protections (heavy gloves, eye protec-
tion, etc.).
ZHandle all parts with the greatest caution. Keep
your hands and fingers far from gaps, moving
gears and similar. Always use approved protective
equipment, such as eye protection, heavy gloves
and protective footwear.
START UP
ZNever run the engine in confined spaces which are
not equipped with adequate ventilation for exhaust
gas extraction.
ZNever bring your head, body, arms, legs, feet,
hands, fingers near fans or rotating belts.
ENGINE
ZAlways loosen the radiator cap very slowly before
removing it to allow pressure in the system to dis-
sipate. Coolant should be topped up only when the
engine is stopped or idle if hot.
ZDo not fill up fuel tank when the engine is running,
mainly if it is hot, to avoid ignition of fires in case of
fuel spilling.
ZNever check or adjust the fan belt tension when the
engine is running. Never adjust the fuel injection
pump when the machine is moving.
ZNever lubricate the machine when the engine is
running.
ELECTRICAL SYSTEMS
ZIf it is necessary to use auxiliary batteries, cables
must be connected at both sides as follows: (+) to
(+) and (-) to (-). Avoid short-circuiting the termi-
nals. GAS RELEASED FROM BATTERIES IS
HIGHLY FLAMMABLE. During charging, leave the
battery compartment uncovered to improve venti-
lation. Avoid checking the battery charge by
means of “jumpers” made by placing metallic ob-
jects across the terminals. Avoid sparks or flames
near the battery area. Do not smoke to prevent ex-
plosion hazards.
ZPrior to any service, check for fuel or coolant leaks.
Remove these leaks before going on with the work.
Do not charge batteries in confined spaces. En-
sure that ventilation is appropriate to prevent acci-
dental explosion hazard due to build-up of gasses
relieved during charging.
ZAlways disconnect the batteries before performing
any type of service on the electrical system.
HYDRAULIC SYSTEMS
ZSome fluid slowly coming out from a very small
port can be almost invisible and be strong enough
to penetrate the skin. For this reason, use a piece
of cardboard or a piece of wood for checking. NEV-
ER USE YOUR HANDS. If any fluid is injected into
the skin, seek medical aid immediately. Lack of im-
mediate medical attention, serious infections or
dermatitis may result.
ZAlways take system pressure readings using the
appropriate gauges.
WHEELS AND TYRES
ZCheck that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodi-
cally check possible damages to the rims and
tyres.
ZKeep off and stay at the tyre side when correcting
the inflation pressure.
ZCheck the pressure only when the machine is un-
loaded and tyres are cold to avoid wrong readings
due to over-pressure. Do not reuse parts of recov-
ered wheels as improper welding, brazing or heat-
ing may weaken the wheel and make it fail.
ZNever cut, nor weld a rim with the inflated tyre as-
sembled.
ZTo remove the wheels, block both front and rear
Machine wheels. Raise the Machine and install
safe and stable supports under the Machine in ac-
cordance with regulations in force.
ZDeflate the tyre before removing any object caught
into the tyre tread.
ZNever inflate tyres using flammable gases as they
may originate explosions and cause injuries to by-
standers.
REMOVAL AND INSTALLATION
ZLift and handle all heavy components using lifting
equipment of adequate capacity. Ensure that parts
are supported by appropriate slings and hooks.
Use lifting eyes provided to this purpose. Take
care of the persons near the loads to be lifted.
ZHandle all parts with great care. Do not place your
hands or fingers between two parts. Wear ap-
proved protective clothing such as safety goggles,
gloves and footwear.
ZDo not twist chains or metal cables. Always wear
protection gloves to handle cables or chains.
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6 SECTION 00 - SAFETY PRECAUTIONS
IMPORTANT ECOLOGICAL CONSIDERATIONS
The following are recommendations which may be
of assistance:
ZBecome acquainted with and ensure that you un-
derstand the relative legislation applicable to your
country.
ZWhere no legislation exists, obtain information
from suppliers of oils, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and
nature and how to safely store, use and dispose of
these substances.
Helpful hints
ZAvoid filling tanks using jerry cans or inappropriate
pressurized fuel delivery systems which may
cause considerable spillage.
ZIn general, avoid skin contact with all fuels, oils, ac-
ids, solvents, etc.
Most of them contain substances which can be
harmful to your health.
ZModern oils contain additives. Do not burn contam-
inated fuels and/or waste oils in ordinary heating
systems.
ZAvoid spillage when draining off used engine cool-
ant mixtures, engine, transmission and hydraulic
oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubri-
cants. Store them safely until they can be disposed
of in a proper way to comply with local legislation
and available resources.
ZModern coolant mixtures, i.e. antifreeze and other
additives, should be replaced every two years.
They should not be allowed to get into the soil but
should be collected and disposed of safely.
ZDo not open the Air-Conditioning system yourself.
It may contain gases which should not be released
into the atmosphere. Your air conditioning special-
ist has special equipment for discharging and
charging the system.
ZRepair any leaks or defects in the engine cooling or
hydraulic system immediately.
ZDo not increase the pressure in a pressurized sys-
tem as this may lead to a catastrophic failure of the
system components.
ZProtect hoses during welding as penetrating weld
chips may burn a hole or weaken them, causing
the loss of oils, coolant, etc.
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580SR
580SR+
590SR
695SR
SECTION 01 - MAINTENANCE
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2 SECTION 01 - MAINTENANCE
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