Case cx160 crawler excavator service repair manual by 163757

CX160 Crawler Excavators Table of Contents SECTION NÂ°

REFERENCE NÂ°

GENERAL INFORMATION Safety, general information and standard torque data .....................................1001 General specifications and special torque setting............................................1002

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ENGINE Removal and installation of the engine ............................................................2000 Radiator and oil-cooler.....................................................................................2001 Engine specifications ............................................................................................. * Disassembly and assembly of the engine.............................................................. *

FUEL SYSTEM Fuel tank ..........................................................................................................3001 Fuel engine system................................................................................................ *

ELECTRICAL SYSTEM Electrical system, electrical and electronic troubleshooting .............................4001 Inspection and maintenance of batteries and connecting a booster battery ....4002 Main and engine electronic control boxes........................................................4003

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UNDERCARRIAGE Removal and installation of tracks ...................................................................5001 Rollers..............................................................................................................5003 Sprocket...........................................................................................................5004 Idler wheel and tension shock absorber ..........................................................5005

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DRIVE TRAIN Drive motor and final drive transmission removal and installation ...................6001 Drive motor and final drive transmission disassembly and assembly ..............6002 Swing reduction gear, removal and installation................................................6003 Swing reduction gear, disassembly and assembly ..........................................6004

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UNDERCARRIAGE HYDRAULICS

UPPERSTRUCTURE HYDRAULICS Depressurising and decontaminating the hydraulic system, use of the vacuum pump and bleeding the components ..............................................8000 Specifications, troubleshooting, checks and hydraulic pressure settings ........8001 Hydraulic reservoir removal and installation ....................................................8002 Main and pilot pumps, removal and installation ...............................................8003 Main hydraulic control valve, removal and installation.....................................8004 Attachment cylinders, removal and installation................................................8005 Hydraulic swivel, removal and installation .......................................................8006 Pilot blocs, removal and installation.................................................................8007 Swing motor, removal and installation .............................................................8008 Main hydraulic pump, disassembly and assembly...........................................8010 Main hydraulic control valve, disassembly and assembly................................8011 Attachment cylinders, disassembly and assembly...........................................8012 Hand control levers, disassembly and assembly .............................................8013 Foot control levers, disassembly and assembly ..............................................8014 Six-solenoid valves, disassembly and assembly .............................................8015 Caution valve, disassembly and assembly ......................................................8016 Safety vave ......................................................................................................8017 Hydraulic swivel, disassembly and assembly ..................................................8018 Swing motor, disassembly and assembly ........................................................8019 Hydraulic functions...........................................................................................8020

DIVISION/SECTION

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DIVISION/SECTION 9

SECTION N°

REFERENCE N°

UPPERSTRUCTURE Upperstructure, turntable and counterweight...................................................9002 Boom, dipper and bucket .................................................................................9003 Seat and seat belt ............................................................................................9004 Cab and cab equipment...................................................................................9005 Air conditioning troubleshooting.......................................................................9006 Air conditioning unit disassembly and assembly..............................................9007 Air conditioning servicing .................................................................................9008 Air conditioning components............................................................................9009 Large format hydraulic and electrical schematics .........................................Pocket

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* Consult the Engine Service Manual Sections to be distributed at a later date NOTE: CASE Company reserves the right to make changes in the specification and design of t he machine wit hout prior not ice and wit hout incurring any obligation to modify units previously sold. The description of the models shown in t his manual has been made in accordance wit h t he t echnical specif ications known a s of t he da te of design of this document.

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Edition 12-01

1001 SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS

Case

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1001

Section

1001-2

TABLE OF CONTENTS GENERAL INFORMATION .......................................................................................................................................3 SAFETY..................................................................................................................................................................... 4 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6

WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.

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1001-3

GENERAL INFORMATION Cleanning

Gears

Clean al l me tal parts except bearings, in a s uitable cleaning so lvent or by steam cl eaning. Do not us e caustic s oda fo r steam c leaning. After cl eaning, dry and put oil on al l pa rts. Clean oi l passages wi th compressed air. Clean bearings in a suitable cleaning solvent, dr y th e bea rings c ompletely an d put oil on the bearings.

Check all gears for wear and damage. Replace gears that have wear or damage.

Inspection Check all parts wh en the parts ar e di sassembled. Replace a ll par ts th at h ave wea r or dam age. S mall scoring o r gr ooves c an be removed wit h a hone or crocus c loth. Com plete a v isual i nspection for indications o f we ar, pitting an d th e r eplacement of parts necessary to prevent early failures.

Bearings Check bea rings for ea sy ac tion. If be arings have a loose fi t or r ough ac tion r eplace the b earing. W ash bearings wi th a su itable cl eaning s olvent and per mit to ai r dry . DO NOT DR Y BEARINGS WITH COMPRESSED AIR.

Needle bearings Before yo u pr ess nee dle bearings in a bore alw ays remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.

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Oil seals, O-rings and gaskets Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings.

Shafts Check a ll s hafts th at have wear or d amage. Check the be aring an d o il s eal s urfaces o f th e s hafts for damage.

Service parts Always i nstall genuine C ase s ervice parts. W hen ordering refer to the Parts Catalog for the correct part number of the genuine Cas e r eplacement ite ms. Failures due to the us e of othe r tha n gen uine Cas e replacement parts are not covered by warranty.

Lubrication Only u se the oils and lu bricants s pecified i n th e Operatorâ&#x20AC;&#x2122;s o r S ervice M anuals. F ailures due to th e use of n on-specified oils an d lu bricants ar e no t covered by warranty.

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1001-4

SAFETY

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.

To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Put the warning tag shown below on the key for the keyswitch when s ervicing or r epairing the ma chine. One w arning ta g i s s upplied wit h ea ch ma chine. Additional tags Part Number 331- 4614 ar e available from your service parts supplier

WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and f ol l ow ma nu fa c tu r er s i ns t ru c ti on s o n machine operation, service and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from your Case dealer.

WARNING: If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing.

WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution.

WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure.

WARNING: When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way.

WARNING: Read the operator’s manual to familiarize yourself with the correct control functions.

WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.

WARNING: This is a one man machine, no riders allowed.

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1001-5

WARNING: When servicing or repairing the machine, keep the shop floor and operatorâ&#x20AC;&#x2122;s compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use safe practices at all times.

WARNING: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual.

WARNING: Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area.

WARNING: When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

WARNING: Use insulated gloves or mittens when working with hot parts.

WARNING: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. WARNING: Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood.

WARNING: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer.

WARNING: When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors).

WARNING: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands.

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1001-6

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be ap plied evenly. The numbers in the figure below indicate the order of tightening.

JS00481A

Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or suitable cl eaning s olvent and dr ied. Ap ply 2- 3 d rops of Lo ctite t o the thr ead por tion of the c ap sc rew an d the n tighten.

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Torque table Tighten cap screws and nuts according to the table below if there are no other special instructions.

Cap Screw Name Size (Size) Spanner Cap Screw Tightening torque

Socket Head Cap Screw

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Spanner Tightening torque

M6 [mm]

M10

M12

M14

M16

M18

M20

[in.]

0.39

0.51

0.67

0.75

0.87

0.95

1.06

1.18

[Nm]

6.9

15.7

32.3

58.8

98.0

137.2

196.0

274.0

[lb-ft]

5.1

11.6

23.9

43.4

72.3

101.2

144.6

202.4

[mm]

[in.]

0.20

0.24

0.32

0.39

0.47

0.55

0.67

[Nm]

8.8

21.6

42.1

78.4

117.6

176.4

245.0

343.0

[lb-ft]

6.5

15.9

31.1

57.8

86.8

130.1

180.8

253.1

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1001-8

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1002 GENERAL SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

CNH

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1002

Section

1002-2

TABLE OF CONTENTS TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE ....................................................3 Machine.................................................................................................................................................................3 Engine ................................................................................................................................................................... 3 Component serial numbers ................................................................................................................................... 3 FLUIDS AND LUBRICANTS ..................................................................................................................................... 4 Hydraulic fluid....................................................................................................................................................... 4 Transmission component oil ................................................................................................................................ 4 Grease ................................................................................................................................................................. 4 Engine oil .............................................................................................................................................................. 5 Oil viscosity/Oil range............................................................................................................................................ 5 Fuel ...................................................................................................................................................................... 6 Anti-freeze/Anti-corrosion..................................................................................................................................... 6 Environment ......................................................................................................................................................... 6 Components made from plastic or resin .............................................................................................................. 6 SPECIFICATIONS..................................................................................................................................................... 7 Engine ................................................................................................................................................................... 7 Capacities ............................................................................................................................................................. 7 Electrical system ................................................................................................................................................... 7 Hydraulic system ................................................................................................................................................... 8 Cylinder .................................................................................................................................................................8 Control valve ......................................................................................................................................................... 9 Swing .................................................................................................................................................................... 9 Travel .................................................................................................................................................................... 9 Undercarriage ....................................................................................................................................................... 9 Attachment ..........................................................................................................................................................10 Weight of components ........................................................................................................................................10 DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS SET ............................................................11 Toothed wheel.....................................................................................................................................................11 Idler wheel...........................................................................................................................................................12 Upper roller .........................................................................................................................................................13 Lower roller .........................................................................................................................................................14 Track ...................................................................................................................................................................15 DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE MOBILE JOINTS OF THE ATTACHMENT................16 1. Boom foot/Undercarriage ................................................................................................................................16 2. Boom cylinder foot/Undercarriage...................................................................................................................17 3. Boom cylinder head/Boom ..............................................................................................................................17 4. Dipper cylinder foot/Boom ...............................................................................................................................18 5. Boom/Dipper ...................................................................................................................................................18 6. Dipper cylinder head/Dipper............................................................................................................................18 7. Bucket cylinder foot/Dipper .............................................................................................................................19 8. Connecting rod/Dipper ....................................................................................................................................19 9. Compensator/Bucket.......................................................................................................................................19 10. Connecting rod/Compensator/Bucket cylinder head.....................................................................................20 11. Dipper/Bucket................................................................................................................................................20 SPECIAL TORQUE SETTINGS ..............................................................................................................................21 MACHINE OVERALL DIMENSIONS CX130 CX160...............................................................................................24 MACHINE OVERALL DIMENSIONS CX180...........................................................................................................25

WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.

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1002-3

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE When placing a par ts order or making a r equest for information or assistance, always give you CASE Dealer the type and serial number of the machine concerned. Enter the required information on the lines below: Type, serial number, year of manufacture of the machine and the serial numbers of hydraulic and mechanical components.

Machine

2 CP98N006

CS01J532

(1) Type............................................................................. (2) Serial number.............................................................. (3) Year of manufacture....................................................

Engine Make and type ............................................................................................................................................................. Serial number ..............................................................................................................................................................

Component serial numbers Hydraulic pump............................................................................................................................................................ Swing reduction gear................................................................................................................................................... Travel reduction gears ................................................................................................................................................. Travel control valve...................................................................................................................................................... Attachment control valve ............................................................................................................................................. Swing control valve......................................................................................................................................................

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FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application.

WARNING: The conditions of use for individual fluids and lubricants must be respected.

Hydraulic fluid

Grease

CASE hy draulic f luid is s pecially designed for h igh pressure ap plications a nd for th e C ASE hydraulic system. The type of fluid to be used depends on th e ambient temperature.

The type of gr ease to us e depends on ambient temperature.

Temperate climates -20°C to +40°C Fluid type ISO VG 46 CASE reference: POHYDR

Hot climates 0°C to +60°C Fluid type ISO VG 100 CASE reference: POHYPC

Temperate and hot climates -20°C to +60°C Extreme pressure grease EP NLGI grade 2 with molybdenum disulphide.

Cold climates -40°C to +20°C Extreme pressure grease EP NLGI grade 0.

Cold climates -40°C to +20°C Fluid type ISO VG 22 CASE reference: POHYPF These v arious gr ades of fluid mu st be in co nformity with the CASE specification.

Transmission component oil Extreme pressure oi l us ed for tr ansmission components inside sealed housings. Extreme pressure oil TYPE API GL5 GRADE 80W90 or ISO VG 150.

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Engine oil CASE eng ine oi l No . 1 is r ecommended for yo ur engine. T his oil ensures correct lub rication of yo ur engine in all working conditions. If CA SE No. 1 Mu ltiperformance or Performance engine o il i s not av ailable, use o il c orresponding t o category API/CG/CF. NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out on CASE lubricants.

RD97F136

RD97F100

Oil viscosity/Oil range A 3 1

2 4 B

(A) FAHRENHEIT TEMPERATURE (2) WINTER (B) CELSIUS TEMPERATURE (3) TROPICAL (1) ALL SEASONS (4) ARCTIC (*) SHOWS THAT AN ENGINE OIL HEATER OR ENGINE COOLANT SOLUTION HEATER MUST BE USED

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CS98M561

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1002-6

Fuel

Environment

Use fuel that is to ASTM (American Society for Testing and Materials) D975 standard.

Before c arrying out an y s ervicing operation on this machine and before disposing of u sed fluids or lubricants, al ways thi nk of the environment. Never throw fluid or oil o n t he ground a nd never k eep them i n leaking receptacles.

Use Grade No. 2 fue l. The use of o ther types of fuel can result in a loss of power and may cause high fuel consumption. In c old wea ther, the us e of a mix ture of fu els No. 1 and No. 2 is temporarily permitted. Consult your fuel supplier. If th e te mperature f alls bel ow the fuel c loud p oint (point at whi ch wax begins to for m) the wax crystals will cause power loss or will prevent the engine from starting. IMPORTANT: In cold weather, fill the fuel tank at the end of the day’s work, in order to prevent the formation of condensation.

Fuel storage Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

Consult yo ur local ec ological r ecycling ce ntre to obtain in formation on th e ap propriate m eans o f di sposing of these substances.

Components made from plastic or resin When c leaning pl astic par ts, the console, th e ins trument panel, the gauges, etc., do not use petrol (gasoline), paraffin ( kerosene), pa int s olvents, et c. Use only water, soap and a soft cloth. The u se of p etrol ( gasoline), p araffin ( kerosene), paint solvents, etc, will cause discoloration, cracking or deformation of these components.

The st orage tank mu st be pl aced outs ide and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

Anti-freeze/Anti-corrosion Use an ti-freeze i n a ll se asons to p rotect th e c ooling system from corrosion and all risk of freezing. In en vironments wi th a t emperature h igher tha n -36°C, us e a mi xture of 50 % ethy lene-glycol ba sed anti-freeze. For areas where the temperature is below -36°C, it is advisable to use a blend of 40% water and 60% antifreeze.

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SPECIFICATIONS CX130

CX160

CX180

Engine Make.............................................................................................. Isuzu ...............................← .................................... ← Model.................................................................................... BB-4BG1TRA-01DD-4BG1TRA-02← Type: F our st roke, wate r-cooled, ov erhead v alve, d irect i njection ( electronically co ntrolled), in- line eng ine wit h turbo-charger. Number of cylinders.......................................................................... 4...................................← ................................ ← Bore and stroke ....................................................................... 105x125mm .........................← .................................... ← Displacement.............................................................................. 4329cm3............................← .................................... ← Operating conditions Idling ..........................................................................................1000 tr/mn ..........................← .................................... ← Max speed .................................................................................2100 tr/mn ................ 2200 tr/mn ............................. ← ECC 1289 power rating ......................................................... 66,2 KW (89cv) ..........75KW (101cv).......................... ← Max torque at 1600 rpm .............................................................. 324 Nm .....................389 Nm ............................... ←

Capacities Engine oil capacity.......................................................................... 15L ................................← .................................... ← Engine cooling system.................................................................. 17.7 L ..............................← .................................... ← Capacity of the radiator only............................................................ 6 L .................................← .................................... ← Fuel tank........................................................................................ 250 L ...............................← .................................... ← Hydraulic fluid reservoir capacity.................................................... 73 L ................................← .................................... ← Total hydraulic system capacity ..................................................... 123 L ........................ 148 L ................................. ← Capacity of the cooler only ..............................................................7 L .................................← .................................... ← Travel reduction gear housing capacity ...........................................3 L .................................← .................................... ← Swing drive housing capacity ........................................................ 2.2 L........................... 5 L ................................... ← Idler wheel capacity ..................................................................... 160cm3 .....................180cm3 ............................... ← Upper roller capacity................................................................ 35 to 40 cm3 .............50 to 55 cm3 ........................... ← Lower roller capacity....................................................................190 cm3 .................... 210 cm3 ............................... ← NOTE: These capacities are only provided in an indicative manner. To check fluid levels, always use the oil dipstick, sight glasses or the filler cap.

Electrical system Type of system ...................................................................................................24 volts negative earth Alternator amperage......................................................................................................... 50 A Battery Number of batteries required .......................................................................................... 2 Voltage of each battery ..............................................................................................12 volts Capacity ..................................................................................................................... 120 Ah Reserve ......................................................................................................................160 min Cold starting capacity at -17°C.................................................................................... 800 A Load for load checking ................................................................................................ 400 A Starter motor Voltage .......................................................................................................................24 volts Power ......................................................................................................................... 4.5 kW Voltage regulator ..............................................................................................integrated, not adjustable

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1002-8 CX130

CX160

CX180

Hydraulic system Main hydraulic pump Double, axial piston, variable flow pump. Max flow ................................................................................... 2x123 l/min ...............2x137 l/min ............................← Displacement............................................................................ 2x57.6 cm3 ................ 2x64 cm3 ..............................←

Hydraulic pilot pump Fixed flow pump. Max flow ...................................................................................... 23 l/min .....................22 l/min ................................← Displacement.............................................................................. 10.7 cm3 ........................... ←.....................................←

Pressure settings Pilot circuit secondary relief valve ..............................................39 ±1 bar ........................... ←.....................................← Main relief valve (standard) ....................................................... 343±3 bar .......................... ←.....................................← Main relief valve (higher pressure - 2-stage relief) .................... 363±5 bar .......................... ←.....................................← Secondary relief valves (boom, dipper and bucket) .................. 383±5 bar .......................... ←.....................................← Secondary relief valves (swing)................................................. 279±4 bar .......................... ←.....................................← Secondary relief valves (travel) ................................................. 430±5 bar .................353±5 bar ..............................← Secondary relief valve (boom and dipper)................................. 383±5 bar .......................... ←.....................................←

Cylinder Boom cylinder Barrel diameter ............................................................................ 105 mm .....................115 mm................................← Rod diameter ................................................................................ 70 mm ...................... 80 mm ................................← Stroke .......................................................................................... 990 mm ....................1179 mm ..............................←

Dipper cylinder Barrel diameter ............................................................................ 115 mm .................... 125 mm ...............................← Rod diameter ................................................................................ 80 mm ...................... 90 mm ................................← Stroke ......................................................................................... 1108 mm .................. 1253 mm ..............................←

Bucket cylinder Barrel diameter ............................................................................. 95 mm ..................... 105 mm ...............................← Rod diameter ................................................................................ 65 mm ...................... 75 mm ................................← Stroke .......................................................................................... 881 mm .................... 985 mm ...............................←

Leaks on the cylinder - attachment lowering (without load) Boom cylinders (rod retracting) ....................................................≤ 3 mm/5 min ............. ≤ 5 mm/5 min...........................← Dipper cylinder (rod extension) .....................................................≤ 5 mm/5 min ............. ≤ 5 mm/5 min...........................← Bucket cylinder (rod extension) .................................................... ≤ 7 mm/5 min ............. ≤ 7 mm/5 min...........................← Full (at the end of the attachment) ............................................≤ 200 mm/10 min....... ≤ 200 mm/10 min .......................←

Cylinder speeds (in mode S) Boom raising (open bucket on the floor)...................................3.6±0.6 sec. .............. 3.8±0.6 sec. ............................← Boom lowering (open bucket)...................................................3.0±0.6 sec. .............. 3.6±0.6 sec. ............................← Dipper extension.......................................................................2.6±0.6 sec. .............. 3.0±0.6 sec. ............................← Dipper retraction .......................................................................3.2±0.6 sec. .............. 3.6±0.6 sec. ............................← Bucket opening.........................................................................2.3±0.6 sec. .............. 2.4±0.6 sec. ............................← Bucket closing ..........................................................................3.6±0.6 sec. .............. 4.2±0.6 sec. ............................←

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1002-9

Control valve Five section control valve for dipper, boom acceleration, swing, option and RH travel. Four section control valve for dipper acceleration, bucket, boom and LH travel. Load holding valve for boom and dipper. CX130

CX160

CX180

Swing Fixed flow, axial piston motor. Automatic disc brake. Upperstructure swing speed....................................................... 13.4 rpm.................... 11.4 rpm .............................. ← Displacement................................................................................65 cm3 ..................... 151 cm3 ............................... ← Work output ................................................................................ 100 l/min ...................155 l/min .............................. ← Reduction ratio .............................................................................. 17.03 ........................ 13.34 ................................. ← Braking torque .....................................................................................≥ 294 Nm .................... ≥ 739 Nm.............................. ← Minimum brake release pressure ................................................. 29 bar ..............................← .................................... ← Acceptable hydraulic motor leakage............................................ xx l/min .............................← .................................... ←

Travel Two-speed, axial piston motor. Automatic disc brake. Slow speed ................................................................................. 3.6 km/h.................... 3.2 km/h ................. 2,4 km/h Fast speed.................................................................................. 5.5 km/h.................... 5,5 km/h .................... 4 km/h Incline that can be overcome..................................................... 70% (35°) ...........................← .................................... ← Tractive force ............................................................................ 11 000 daN ...............11 300 daN ........... 18340 daN Displacement............................................................................52.7/34 cm3 ................87/49 cm3 ........... 162/95 cm3 Work output ................................................................................ 121 l/min ...................140 l/min................. 137 l/mn Reduction ratio ................................................................................ 72............................ 57,5............................43,2 Braking torque (excluding reducer) ............................................. 145 Nm .....................135 Nm.................... 483Nm Number of turns at the sprockets (10 turns) Mode "S", fast speed ...............................................................13.4±0.6 sec. ............ 12.8±0.6 sec. ..... 19.6±0.6 sec. Mode "S", slow speed..............................................................20.6±0.7 sec. ............ 21.9±0.7 sec. ..... 33.4±0.7 sec. Permitted deviation in travel over a distance of 20 m Mode "H", full speed ....................................................................... 1 m ................................← .................................... ← Acceptable hydraulic motor leakage............................................ xx l/min .............................← .................................... ←

Undercarriage One-piece undercarriage with welded components. Lubricated rollers and idler wheels. Grease type track tension. Ground pressure with 500 mm track pads...............................................................0.39 bar .................... 0.47 bar with 600 mm track pads...............................................................0.33 bar .................... 0.40 bar ..................0,41 bar with 700 mm track pads...............................................................0.29 bar .................... 0.33 bar ..................0,36 bar With 800 mm track pads................................................................... X ...............................X ........................0,33 bar with rubber track pads .................................................................0.40 bar ..........................X .................................. X Tracks tension ........................................................................ 240 to 260mm .......... 260 to 280mm....280 to 300mm

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1002-10 CX130

CX160

CX180

Attachment Break-out force ...........................................................................9740 daN.................11 790 daN ............................← Penetration force 2.10 m dipper..............................................................................8020 daN 2.50 m dipper..............................................................................6740 daN 3.00 m dipper..............................................................................5610 daN 2.20 m dipper.................................................................................... X ........................ 9300 daN ..............................← 2.70 m dipper.................................................................................... X ........................ 8010 daN ..............................← 3.10 m dipper.................................................................................... X ........................ 7400 daN ..............................←

Weight of components Engine .......................................................................................... 361 kg ............................. ←.....................................← Hydraulic pump.............................................................................. 90 kg .............................. ←.....................................← Attachment control valve .............................................................. 140 kg ............................. ←.....................................← Swing motor/reduction gear assembly .......................................... 99 kg ........................221 kg .................................← Travel motor/reduction gear assembly ......................................... 204 kg .......................247 kg...................... 308 kg Boom cylinder............................................................................... 108 kg .......................157 kg .................................← Dipper cylinder.............................................................................. 157 kg .......................210 kg.................................← Bucket cylinder .............................................................................. 93 kg ........................117 kg .................................← Counterweight ............................................................................. 2300 kg .....................3330 kg ...............................← Cab ............................................................................................... 254 kg ............................. ←.....................................← Turnable bearing .......................................................................... 188 kg .......................244 kg...................... 263 kg Upperstructure............................................................................. 5820 kg .....................6780 kg.................... 7670kg Hydraulic swivel............................................................................. 27 kg .............................. ← ........................... 31 kg Undercarriage.............................................................................. 3880 kg .....................5760 kg................... 6570 kg Machine without attachment........................................................ 9830 kg ....................12 540kg................ 14240 kg Attachment .................................................................................. 2140 kg .....................3030 kg................... 3070 kg Boom ........................................................................................... 1200 kg .....................1470 kg................... 1780 kg Dipper ........................................................................................... 542 kg .......................729 kg...................... 805 kg Radiator and cooler set ................................................................. 48 kg .............................. ←.....................................← Fuel tank........................................................................................ 72 kg .............................. ←.....................................← Hydraulic tank............................................................................... 106 kg ............................. ←.....................................← Idler wheel ..................................................................................... 65 kg .........................82 kg ..................................← Upper roller.................................................................................... 13 kg .........................17 kg ..................................← Lower roller.................................................................................... 20 kg .........................36 kg ..................................← Shock absorber ............................................................................. 63 kg .........................85 kg....................... 126 kg Track 500 mm............................................................................... 728 kg ......................1016 kg Track 600 mm............................................................................... 816 kg ......................1164 kg................... 1257 kg Track 700 mm............................................................................... 970 kg ......................1374 kg................... 1460 kg Track 800 mm................................................................................... X ...............................X........................ 1593 kg

Cre 7-27714GB

Issued 03-03

1002-11

DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS SET Toothed wheel Dimensions a

Ød

Øb Øc

CS01B512

Dimension (mm) CX130 CX160 CX180

Marking a Øb Øc Ød P

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

59 53 584.48 578.5 652 646 635.48 --171.45 ---

66 60 582.5 576.5 659 653 644.6 --190 ---

Gauge

A B

E F N

H Q

P K

CS01D513

Cre 7-27714GB

A B C D E F G H I J K L M N O P Q R

CX130 200

CX160 CX180 220

171.5

190

60.48

69.58

35.61

4.23

4.6

---

0.52

21.46

26.2

30.6

72.9

84.7

Ø 652

R329.5

PDC 635.48

PDC 322.3

R66

R76.5

---

12.7°

R25.5

R29.6

---

R36

15.7°

17.1° Issued 03-03

1002-12

Idler wheel Dimensions Dimension (mm) CX160 CX130 CX180

Marking Øa

c Ø d (rod) Øa

Ø d (ring) e e

f f

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

510 506 17.5 --68 64 55 54.5 55 55.8 55 54.6 19.9 19.4

494 490 19 --84 80 65 64.5 65 65.8 69 68.6 12.4 11.9

Ød

CS01B514

Gauge

A B C D

H E G

I J

A B C D E F G H I J K L

CX130 135

CX160 CX180 159

10°

R37

R42

2-R4

2-R5

3.6

0.6

4-R3

26.5

17.5

160

180

CS01D514

Cre 7-27714GB

Issued 03-03

1002-13

Upper roller Dimensions g

Marking Øa b

Øa

Ød

Ø d (rod) Ø d (ring)

e f

Dimension (mm) CX160 CX130 CX180

f CS01B516

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

120 112 10 --68 62 40 39.5 40 40.8 63 62.6 5.5 5 22.5 22.5

120 112 10 --85 79 46 45.5 46 46.8 83 82.6 5.5 5 22.5 22

Gauge

G H

B C D E F

L M

K J

A B C D E F G H I J K L M N O P Q

CX130 130

CX160 CX180 156

78.6

11.3°

18°

11°

11.5°

20.5

17.5

6.5

5.5

4-R3

8-R3

50.5

150

175

CS01D515

Cre 7-27714GB

Issued 03-03

1002-14

Lower roller Dimensions d

Øe

Øa

b CS01B518

Dimension (mm) CX130 CX160 CX180

Marking Øa b d Ø e (rod)

Standard Limit Standard Limit Standard Limit Standard Limit

130 122 15 --142 148 50 49.5

150 142 15 --173 179 65 64.5

Dimension (mm) CX130 CX160 CX180

Marking Ø e (ring) f g

Standard Limit Standard Limit Standard Limit

50 50.8 53 52.6 24.3 23.8

65 65.8 69 68.6 23.3 22.8

Gauge

A B C D E I FGH

J V

P L M

O N

Q RS T U

CS010D516

Cre 7-27714GB

A B C D E F G H I J K L M N O P Q R S T U V

CX130

CX160 CX180

175

215

150.6

184.7

142

173

191

221

26.1

25.3

14.1

13.8

R10

R15

2-R10

5°

6R5

6-R5

1.5°

17°

23°

10°

4-R5

---

210

240 Issued 03-03

1002-15

Track c d

Øe

Øe Øf

Øf

Øg

Øg h

a CS01B520

Dimension (mm) CX130 CX160 CX180

Marking a b c d

Cre 7-27714GB

Standard Limit Standard Limit Standard Limit Standard Limit

28 18 89 84 17 15 10.7 9

34.5 21.5 106 101 37.985 36 17.95 16

Dimension (mm) CX130 CX160 CX180

Marking Ø e (ring) Ø f (ring) Ø g (rod) h

Standard Limit Standard Limit Standard Limit Standard Limit

50.6 49.5 34.1 35 33.25 32.5 171.45 175

58.72 57.5 37.3 38.3 36.3 35.5 190 195

Issued 03-03

1002-16

DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE MOBILE JOINTS OF THE ATTACHMENT 4

CS01B521

1. Boom foot/Undercarriage a

Ød

CS01B522

Dimension (mm) CX130 CX160 CX180

Marking a b c (a - b) Ø d (pin) Ø d (ring)

Cre 7-27714GB

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

569 579 568.5 566.5 0.5 to 3 Shims 75 76.5 75 74

632 642 631 629 0.5 à 3 Shims 80 79 80 81.5

Issued 03-03

1002-17

2. Boom cylinder foot/Undercarriage a

b Ød

CS01B523

Dimension (mm) CX130 CX160 CX180

Marking a b c (play) Ø d (pin) Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

83.5 89.5 82.5 80.5 1 to 2.5 Shims 70 69 70 71.5

111 117 110 108 1 to 2.5 Shims 70 69 70 71.5

3. Boom cylinder head/Boom a

Ød

CS01B524

Dimension (mm) CX130 CX160 CX180

Marking a b c (play) Ø d (pin) Ø d (ring)

Cre 7-27714GB

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

92 90 437 431 1 to 2.5 Shims 70 69 70 71.5

100 98 470 464 1 to 2.5 Shims 80 79 80 81.5

Issued 03-03

1002-18

4. Dipper cylinder foot/Boom a

Dimension (mm) CX130 CX160 CX180

Marking

a b c (a - b)

Ød

Ø d (pin) Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

99 105 98 96 0.5 to 2 Shims 70 69 70 71.5

111 117 110 108 0.5 to 2 Shims 80 79 80 81.5

CS01B525

5. Boom/Dipper a

Dimension (mm) CX130 CX160 CX180

Marking a b c (play)

Ød

Ø d (pin) CS01B526

Ø d (dipper) Ø d (boom)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

259 262 258.5 256.5 0.5 to 1.1 Shims 75 74 75 76.5 75 76.5

275 278 274.5 272.5 0.5 to 1.1 Shims 80 79 80 81.5 80 81.5

6. Dipper cylinder head/Dipper Dimension (mm) CX130 CX160 CX180

Marking a b

Ød b a

c (a - b) c

Ø d (pin) CS01B527

Cre 7-27714GB

Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

96.5 102.5 95.5 92.5 0.5 to 3 Shims 70 69 70 71.5

111 117 110 108 0.5 to 3 Shims 80 79 80 81.5

Issued 03-03

1002-19

7. Bucket cylinder foot/Dipper a b

Dimension (mm) CX130 CX160 CX180

Marking a Ød

b c (a - b) Ø d (pin) CS01B528

Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

88 94 87 85 0.5 to 3 Shims 65 64 65 66.5

101 107 100 98 0.5 to 3 Shims 65 64 65 66.5

8. Connecting rod/Dipper Dimension (mm) CX130 CX160 CX180

Marking c

a b

c (play) a

Ø d (pin)

Ød

Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

32 30 254 252 1 to 1.5 Shims 65 64 65 66.5

32 30 260 258 1 to 1.5 Shims 65 64 65 66.5

CS01B529

9. Compensator/Bucket Ød

Dimension (mm) CX130 CX160 CX180

Marking a

b b

c (play) Ø d (pin) Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

255 261 254 252 1 to 3.5 Shims 65 64 65 66.5

301 317 300 298 1 to 3.5 Shims 65 64 65 66.5

CS01B530

Cre 7-27714GB

Issued 03-03

1002-20

10. Connecting rod/Compensator/Bucket cylinder head Dimension (mm) CX130 CX160 CX180

Marking a f b

Standard Limit Standard b Limit Standard c (play) Limit Standard d Limit Standard e Limit Standard f (d - e) Limit Standard Ø g (pin) Limit Standard Øg (compensator) Limit

c Øg CS01B531

Ø g (cylinder)

Standard Limit

32 30 254 252 1 to 1.5 Shims 92 94 91 93 0.5 to 2 Shims 70 69 70 71.5

32 30 260 258 1 to 1.5 Shims 86 88 85 83 0.5 to 2 Shims 75 74 75 76.5

70 71.5

75 76.5

11. Dipper/Bucket Øe

a d a

b c (a - b)

d c

Ø e (pin) CS01B532

Ø e (dipper) Ø e (bucket)

Cre 7-27714GB

Dimension (mm) CX130 CX160 CX180

Marking Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

255 261 255 253 0 to 2.5 Shims 16 8 65 64 65 66.5 65 66.5

301 317 301 299 0 to 2.5 Shims 16 8 80 79 80 81.5 80 81.5

Issued 03-03

1002-21

SPECIAL TORQUE SETTINGS No.

Component

Screw (Ă&#x2DC;)

Key (mm)

Torque setting (Nm) CX130

CX160 CX180

Travel motor/reduction gear assembly

M16

267-312

Sprocket

M16

267-312

Idler wheel

M16

267-312

Upper roller

M16

267-312

---

M20

---

521-608

Lower roller

M16

267-312

---

M18

---

371-432

Chain guide

M18

---

380-443

Track pad

M16

392-430

---

M20

---

468-545

Counterweight

M27

844-980

1058-1235

Turntable (undercarriage)

M16

280-322

---

M20

---

468-545

Turntable (upperstructure)

11 *

Swing motor/reduction gear assembly

12 * 13 *

M16

280-322

---

M20

---

468-545

M16

280-322

---

M20

---

521-608

Engine

M16

265-313

Engine support

M10

64-73

Radiator

M12

64-73

15 *

Hydraulic pump

M10

63-72

16 *

Hydraulic reservoir

M16

206-247

17 *

Fuel tank

M16

206-247

18 *

Control valve

M16

267-312

M12

19 *

Hydraulic swivel

M12

109-127

Cab

M16

78-80

Battery

M10

20-29

M12

---

88-111

88-107

---

NOTE: Use Loctite 262 or an equivalent on retaining screws of components marked with an asterisk (*).

Cre 7-27714GB

Issued 03-03

1002-22

16 18

12 13

21 7 19

1 9 10

6 20

4 CS00E507

2 CS00E508

CS00E509

7 4

5 8 CS00E510

Cre 7-27714GB

CS00E511

Issued 03-03

1002-23

13 12

10 CS00E513

CS00E512

15 14

CS00E516 CS00E515

18 16

CS00E518

CS00E519

CS00E520

21 20

CS00E522

Cre 7-27714GB

CS00E523

CS00E524

Issued 03-03

1002-24

MACHINE OVERALL DIMENSIONS CX130 CX160 E

J L

H D CS01B533

Only on CX130 machines with 3 m dipper C

Point B Point A

Point A: Working position Point B: Transport position

IMPORTANT: For the transport of CX130 machines with 3 m dipper, it is imperative that the dipper cylinder head/dipper linkage is positioned at point B. NOTE: Never work with the pin in this position.

A A F

I H

WARNING: When the dipper cylinder is placed in position B (transport), take care not to damage the cab, there can be interference between the bucket and the cab.

C CS00E527

CX130

CX160

Dippers 2.10 m

2.50 m

Dippers

3.00 m (A) 3.00 m (B)

2.20 m

2.70 m

3.10 m

2.92 m

3.09 m

2.88 m

A....................................................

2.74 m

3.26 m

2.78 m

B....................................................

2.74 m

C....................................................

7.49 m

7.38 m

7.54 m

8.40 m

8.44 m

D....................................................

3.81 m

4.32 m

E....................................................

2.52 m

2.54 m

F ....................................................

0.89 m

1.02 m

G ...................................................

2.05 m

2.37 m

H....................................................

3.50 m

3.90 m

I .....................................................

2.78 m

3.09 m

J ....................................................

1.99 m

K (standard track pads)..............

0.60 m

L (with 500 mm track pads) ........

2.49 m

L (with 600 mm track pads) ........

2.59 m

L (with 700 mm track pads) ........

2.69 m

M ...................................................

0.44 m

N....................................................

5.44 m

5.34 m

5.50 m

6.03 m

6.07 m

Cre 7-27714GB

2.88 m

Issued 03-03

1002-25

MACHINE OVERALL DIMENSIONS CX180 E

J L

H D

CS01B533

CX180 Dippers A ...................................................

2.20 m

2.70 m

3.05 m (A)

2.53 m

2.92 m

3.09 m 2.89 m

B ...................................................

2.89 m

C ...................................................

8.41 m

8.39 m

8.44 m

D ...................................................

4.45 m

E ...................................................

2.54 m

F....................................................

1.04 m

G ...................................................

2.37 m

H ...................................................

4.15 m

I .....................................................

3.37 m

J....................................................

2.20 m

K (standard track pads)..............

0.60 m

0.60 m 2.80 m

L (with 500 mm track pads)........

2.80 m

L (with 600 mm track pads)........

2.90 m

L (with 700 mm track pads)........

3.00 m

M...................................................

0.46 m

Cre 7-27714GB

Issued 03-03

1002-26

Cre 7-27714GB

Issued 03-03

Section 2000

Case

Cre 7-28220GB

2000

REMOVAL AND INSTALLATION OF THE ENGINE

2000-2

SPECIFICATIONS Weight of engine............................................................................................................................. See Section 1002

SPECIAL TORQUE SETTINGS Engine retaining screws ................................................................................................................. See Section 1002

Cre 7-28220GB

Issued 09-00

2000-3

ENGINE Removal and installation

STEP 6

STEP 1

CD00J024

Remove the engine throttle control. JS00163A

Park the mac hine on hard, flat gr ound. Low er the attachment to the ground.

STEP 7

STEP 2 Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000).

STEP 3

2 2

CD00J025

Disconnect the fuel supply pipe (1) and the fuel return pipe (2) and plug them.

STEP 8

1 JD00375A

Remove the battery c over ( 1) a nd di sconnect th e earth cable (-) (2) from the battery.

STEP 4

1 2

Refer to Section 8003 and remove the hy draulic pump.

STEP 5 Refer to Section 20 01 an d r emove th e r adiator an d oil-cleaner assembly.

CD00J026

Remove the hoses (1) and (2) from the heater system and plug them.

Cre 7-28220GB

Issued 09-00

2000-4

STEP 9

STEP 12

1 1 CD00J027

CD00J030

Label and di sconnect th e e lectrical c onnection fr om the water temperature sensor (1).

Label and d isconnect th e el ectrical sup ply ( 1) to th e pre-heating plugs.

STEP 10

STEP 13

1 1

CD00J028

Label and di sconnect th e e lectrical c onnection fr om the fuel temperature sensor (1).

STEP 11

CD00J031

Label an d di sconnect the starter m otor e lectrical connections. Remove the earth braid cable (1) at the engine end.

2 CD00J029

Label and di sconnect th e e lectrical c onnection fr om the oil pressure d etector ( 1) and the en gine s peed detector (2).

Cre 7-28220GB

Issued 09-00

2000-5

STEP 14

STEP 16

CD00J032

Label an d d isconnect th e c onnectors f or th e electronic r egulator an d dis connect the fue l flo w regulating resistance.

STEP 15

Label and di sconnect the al connections.

ternator

CD00J035

electrical

NOTE: If the machine is equipped with air conditioning, remove the compressor retaining hardware and move the compressor away from the engine.

STEP 17 Remove all the clips, etc. which attach the electrical harnesses to the engine an d mov e the m out of the way.

STEP 18

CD00J033

Remove the hos e wh ich c onnects th e tur bo-charger to the air filter.

CD00J036

Install a s uitable l ifting dev ice on t he e ngine lifting rings (for the weight of the engine, see Section 1002).

Cre 7-28220GB

Issued 09-00

2000-6

STEP 19

STEP 20

Remove the engine retaining hardware.

When n othing i nterferes wi th th e r emoval of th e engine, r aise the eng ine ca refully an d i nstall i t on a suitable repair bench.

NOTE: When installing, check visually the condition of the rubber flexible mountings and change them if necessary. Tighten the engine retaining screws to the torque specified in Section 1002.

NOTE: To install the engine, proceed in the reverse order from that of removal.

Before using the machine carry out the following operations: -

Bleed and prime the fuel system (see Operatorâ&#x20AC;&#x2122;s Manual). Fill and bleed the engine cooling system (see Operatorâ&#x20AC;&#x2122;s Manual). Check the hydraulic system, fuel system and cooling system for leaks. Check the level of fluid in the hydraulic reservoir. Top up if necessary.

Cre 7-28220GB

Issued 09-00

2001 Section 2001 RADIATOR AND OIL-COOLER

Case

Cre 7-28040GB

2001-2

WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.

SPECIFICATIONS Coolant solution.............................................................................................................................. See Section 1002 Total capacity of coolant solution system .................................................................................................... 17.7 litres Thermostat opening range Starts to open..................................................................................................................................................82°C Completely opened .........................................................................................................................................95°C Hydraulic fluid ................................................................................................................................. See Section 1002

Cre 7-28040GB

Issued 09-00

2001-3

RADIATOR AND OIL-COOLER Before performing any operation on the machine, carry out the following operations in the order shown: -

Park the machine on hard, flat ground. Lower the attachment to the ground. Shut down the engine. Remove the starter switch key. Make sure that all pressure in the hydraulic system has been released (see Operatorâ&#x20AC;&#x2122;s Manual).

WARNING: The components of the engine and the hydraulic pump reach high temperatures when the machine is operating. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow the machine to cool down before starting any servicing operation.

Removing the radiator and oilcooler assembly

STEP 6 3

STEP 1 Remove the engine lower cover plate.

STEP 2 2

1 1 3

2 CD00G022

Disconnect and plug the hoses (1) and (2) of the oil cooler (3) an d dr ain the oi l c ooler in to a c lean receptacle.

STEP 7

5 CD00G021

Remove the eng ine upp er hoo d ( 1), th e up per gr ille (2) and the air filter (3). Remove the air conditioning (4) heat ex changer, wi thout di sconnecting i t, an d place it on the battery hood (5).

STEP 3

Remove the expansion reservoir cap. IMPORTANT: Do not remove the cap when the engine is hot, since the system would still be under pressure and you would run the risk of being scalded.

STEP 4 Drain the cooling system (see Operatorâ&#x20AC;&#x2122;s Manual).

STEP 5

4 CD00G023

Disconnect the expansion reservoir hose (2) from the radiator ( 1). Dis connect the wate r pu mp r eturn hose (3) and inlet hose (4) from the engine.

Release pressure i n th e h ydraulic r eservoir to al low installation of the vacuum pump (see Section 8000).

Cre 7-28040GB

Issued 09-00

2001-4

STEP 8

STEP 11 2 1 1

CD00G024

Remove the four lower retaining screws (1) from the radiator and oil-cooler bracket (2).

STEP 9 CS00G513

Pass a s uitable s ling ar ound the r adiator and oi lcooler assembly, then, using a suitable lifting device, remove the radiator and oil-cooler assembly.

NOTE: During the lifting operation, push the radiator and oil-cooler assembly back to avoid the engine cooling fan.

Installation When installing, proceed in the reverse order to that of removal. CD00G025

Disassemble t he t wo re taining screws (1) a nd remove the rear retaining tie-rod (2) from the radiator and oil-cooler assembly bracket (3).

Before operating the machine:

STEP 10

- Check the h ydraulic circuit coo ling s ystem for leaks.

- Check the level of oil in the hydraulic reservoir. Top up if necessary.

- Fill and bleed the eng ine cooling sy stem ( see Operatorâ&#x20AC;&#x2122;s Manual).

- Check the engine cooling system for leaks.

CD00G026

Disassemble t he t wo re taining screws (1) a nd remove the f ront an gle br acket ( 2) fr om the r adiator and oil-cooler assembly bracket (3).

Cre 7-28040GB

Issued 09-00

2001-5

CHANGING THE RADIATOR AND OIL-COOLER Disassembly and assembly NOTE: The parts are numbered in order of disassembly. Assembly is carried out in the reverse numerical order.

6 8 10

9 13 12

14 2 1

4 1 2 3 4 5 6 7

INTAKE SHROUD RETAINING SCREWS INTAKE SHROUD RADIATOR UPPER MOUNTING RADIATOR LOWER MOUNTING RADIATOR COVER MOUNTING COVER

Cre 7-28040GB

11 8 9 10 11 12 13 14

FILTER MOUNTING FILTER OIL-COOLER UPPER MOUNTING OIL-COOLER LOWER MOUNTING OIL-COOLER BRACKET BRACKET

CI00G505

Issued 09-00

2001-6

Cre 7-28040GB

Issued 09-00

3001 Section 3001 REMOVAL AND INSTALLATION OF THE FUEL RESERVOIR

Case

Cre 7-27970GB

3001-2

3 3 4 5

SPECIFICATIONS See Section 1002

Cre 7-27970GB

Issued 04-01

3001-3

FUEL RESERVOIR Removal STEP 1

STEP 9 Remove t he screws ( 8) a nd the protective pl ate ( 9) from on top of the fuel reservoir (1).

STEP 10 Loosen the two screws (10) lo cated un derneath the machine. O pen the s ide p ortion of t he m achine an d remove the two screws (11) located on the RH side of the fuel reservoir (1). Remove the protective plate of the reservoir (12).

STEP 11 Park the mac hine on hard, flat gr ound. Low er the attachment to the ground.

Remove the two screws (13) that hold the fuel oil filter (14). Attach ta gs to the two ho ses (15) a nd (16). Remove th e fu el oi l f ilter ( 14) b y removing th e tw o hoses (15) and (16) and the circlips (17) and (18).

STEP 2

STEP 12

Reduce the engine speed to idle for 30 seconds, then shut down the engine.

Shift the pl astic pr otection ( 19) from t he f uel pr obe (20). Remove the retaining screws (21) then the fuel probe (20) as well as the seal (22).

JS00163A

STEP 3 Turn the ig nition ke y t o "O N" wi thout s tarting th e engine.

STEP 4 Attach a "DO NOT OPERATE" tag to th e ignition key in the cab.

STEP 13 Remove the four screws (23) from the fuel reservoir (1), as well as the shims (24).

STEP 14 Remove the fuel reservoir (1) using a hoist.

STEP 5

STEP 15

NOTE: The numbers in brackets refer to the figures on pages 5 and 6.

See the operatorâ&#x20AC;&#x2122;s manual for removing the fuel filter.

Remove the ac cess pan el un der the fu el r eservoir (1).

STEP 6 Open the filling plug of the r eservoir ( 2). Em pty th e reservoir using the valve (3) then remove the latter.

STEP 7 Lift the hood of the front boot. Remove the retaining screw (4) of the access ramp (5). Remove the access ramp (5).

STEP 8 Remove the s crews ( 6) on top and the n in side th e front boot, then remove the protective housing (7).

Cre 7-27970GB

Issued 04-01

3001-4

Installation NOTE: The numbers in brackets refer to the figures on pages 5 and 6.

STEP 1 Using a hoist, position the fuel r eservoir ( 1) on th e machine.

STEP 2 Install the shims (24) as well as the four screws (23), tighten th e s crews t o a torque, s ee s pecifications. Install the v alve ( 3) and tighten the va lve ( 3) to a torque of 14.7 Nm.

STEP 3 Install a new seal (22), then the fuel probe (20) using the five screws (21), reposition the plastic protection correctly (19).

STEP 7 Install th e protective housing ( 7) on top of the front boot us ing the screws ( 6) the n p ut b ack t he s crew mask.

STEP 8 Install t he ac cess r amp ( 5) us ing s crews ( 4). Cl ose the front boot.

STEP 9 Fill the fuel reservoir (see the operatorâ&#x20AC;&#x2122;s manual) and make sure that there are no leaks.

STEP 10 Reinstall the protective plate on top of the machine.

STEP 4 Install the fuel o il fi lter (14) o n th e r eservoir using screws ( 13). I nstall th e two ho ses ( 15) and ( 16) taking help of the tags ins talled dur ing r emoval. Tighten using circlips (18) and (17).

STEP 5 Install the reservoir protection (12) using screws (10) and (11). Tighten the screws (10) and (11).

STEP 6 Install the protective pl ate (9) on top reservoir (1). Tighten the screws (8).

Cre 7-27970GB

of the fuel

Issued 04-01

3001-5

Description Location 5

4 7

11 6

CS00F539

8 4 5 6 7 8 9

SCREW ACCESS RAMP SCREW PROTECTIVE HOUSING SCREW FUEL RESERVOIR PROTECTIVE PLATE

Cre 7-27970GB

4 10 SCREW 11 SCREW 12 RESERVOIR PROTECTIVE PLATE

CS00F540

Issued 04-01

3001-6

Fuel reservoir 2

20 22 21

17 18

24 23

1 2 3 13 14 15 16

FUEL RESERVOIR PLUG VALVE SCREW FUEL OIL FILTER HOSE HOSE

Cre 7-27970GB

17 18 20 21 22 23 24

CIRCLIP CIRCLIP FUEL PROBE SCREW SEAL SCREW SCREW

CI00F506

Issued 04-01

4001 Section 4001 ELECTRICAL AND ELECTRONIC CIRCUIT AND TROUBLESHOOTING

CNH

Cre 7-27723GB

4001-2

TABLE OF CONTENTS SPECIFICATIONS ....................................................................................................................................................4 SPECIAL TOOLS ..................................................................................................................................................... 4 LOCATION OF COMPONENTS .............................................................................................................................. 6 General location of the components (outside the cab) ......................................................................................... 6 General location of the components (outside the cab) ......................................................................................... 8 Relay and main fuses (battery compartment) ....................................................................................................10 General location of the components (inside the cab) .........................................................................................12 Fuse box ............................................................................................................................................................14 Instrument panel ................................................................................................................................................15 OPERATING PRINCIPLES ....................................................................................................................................16 Engine checks ....................................................................................................................................................16 Work mode selection ..........................................................................................................................................18 H/S/L mode checking .........................................................................................................................................20 Auto mode checking ...........................................................................................................................................21 Acceleration checking ........................................................................................................................................22 Engine idle checking (automatic/manual) ..........................................................................................................23 Breaker mode checking .....................................................................................................................................24 Automatic engine preheat ..................................................................................................................................25 Auto engine warm-up .........................................................................................................................................28 Idle checking using the battery voltage and the coolant temperature ................................................................30 Engine emergency stop .....................................................................................................................................32 Back-up mode ....................................................................................................................................................34 Function locking .................................................................................................................................................36 Power boost .......................................................................................................................................................37 Swing brake .......................................................................................................................................................38 Travel mode .......................................................................................................................................................40 Supply cut-off delayed ........................................................................................................................................43 Protection by power transistor ............................................................................................................................44 Coolant temperature indicator ............................................................................................................................44 Hydraulic oil temperature indicator .....................................................................................................................46 Fuel level ............................................................................................................................................................47 Engine fuel injection pump electronic regulator .................................................................................................48

Cre 7-27723GB

Issued 03-03

4001-3 ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode) ...........................................................50 Access to monitor displays .................................................................................................................................50 Machine condition ..............................................................................................................................................51 Diagnostic code ..................................................................................................................................................54 Machine history ..................................................................................................................................................57 Re-initialisation . ..................................................................................................................................................60 WARNING MESSAGES .........................................................................................................................................63 Message display ................................................................................................................................................63 EXCAVATOR MODEL SELECTION PROCEDURE ..............................................................................................64 Changing the language code .............................................................................................................................65 CHANGING THE ACCESS CODE FOR THE ANTI-THEFT SYSTEM ..................................................................66 TROUBLESHOOTING ...... .....................................................................................................................................67 Prior inspections .................................................................................................................................................67 Reading the organisation charts ........................................................................................................................68 Procedures . ........................................................................................................................................................69 Low fuel ..............................................................................................................................................................70 Add coolant solution ...........................................................................................................................................71 Low engine oil pressure .....................................................................................................................................72 Overheating ........................................................................................................................................................73 Defective battery charge circuit ..........................................................................................................................76 Electrical system troubleshooting .......................................................................................................................78 Travel .. ...............................................................................................................................................................82 ELECTRICAL INSPECTION OF COMPONENTS ..................................................................................................83 Inspection equipment .........................................................................................................................................83 Proportional solenoid .........................................................................................................................................85 Engine emergency stop motor ...........................................................................................................................86 6 solenoid valve block ........................................................................................................................................86 Engine rpm sensor .............................................................................................................................................87 Engine coolant and hydraulic oil temperature sensor ........................................................................................88 Pressure sensor .................................................................................................................................................89

Cre 7-27723GB

Issued 03-03

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