Case cx240 crawler excavator service repair manual by 163757

CX210 - CX230 - CX240 Crawler Excavators Table of Contents DIVISION/SECTION

SECTION NÂ°

REFERENCE NÂ°

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

7-27690GB 7-29361GB

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

7-27724GB 7-27921GB 7-27933GB

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

7-27750GB 7-27772GB 7-27781GB 7-27803GB

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 (CX210 - CX230) ..............6004 Swing reduction gear, disassembly and assembly (CX240) ............................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 (CX210 - CX230) .................................8008 Swing motor, removal and installation (CX240) ...............................................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 valve .....................................................................................................8017 Hydraulic swivel, disassembly and assembly ..................................................8018 Swing motor, disassembly and assembly (CX210 - CX230)............................8019 Swing motor, disassembly and assembly (CX240) ..........................................8019 Hydraulic functions...........................................................................................8020

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7-27970GB

7-27952GB 7-27704GB 7-27990GB 7-27860GB 7-27890GB 7-27791GB 7-27811GB 7-28130GB 7-28071GB 7-28071GB 7-35490GB 9-36270GB 7-27902GB 7-28110GB 7-28210GB 7-27911GB 7-27942GB 7-29631GB 7-28080GB 7-28011GB 7-29760GB 7-28490GB

DIVISION/SECTION 9

SECTION NÂ°

REFERENCE NÂ°

UPPERSTRUCTURE Quick coupler ...................................................................................................9000 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: CNH Company reserves the right to make changes in the specification and design of the machine without prior notice and without 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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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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1001-7

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

Issued 09-00

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 ............................................................................................................................................................ 9 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 Boom foot/Undercarriage ....................................................................................................................................16 Boom cylinder foot/Undercarriage.......................................................................................................................17 Boom cylinder head/Boom ..................................................................................................................................17 Dipper cylinder foot/Boom...................................................................................................................................18 Boom/Dipper .......................................................................................................................................................18 Dipper cylinder head/Dipper................................................................................................................................18 Bucket cylinder foot/Dipper .................................................................................................................................19 Connecting rod/Dipper ........................................................................................................................................19 Compensator/Bucket...........................................................................................................................................19 Connecting rod/Compensator/Bucket cylinder head...........................................................................................20 Dipper/Bucket......................................................................................................................................................20 SPECIAL TORQUE SETTINGS ..............................................................................................................................21 MACHINE OVERALL DIMENSIONS.......................................................................................................................24

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 CT04D014

CT04A171

(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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1002-4

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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1002-5

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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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 on the gr ound and nev er keep them in 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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1002-7

SPECIFICATIONS Engine CX210/CX230

CX240

Make.............................................................................................. Isuzu ........................................................... Isuzu Model........................................................................................................................... BB-6BG1T 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............................................................................................................. 6 Bore and stroke ..........................................................................................................105x125 mm Displacement................................................................................................................ 6494 cm3 Operating conditions Idling ............................................................................................................................. 1000 rpm Max speed ..................................................................................1950 rpm ..................................................2150 rpm ECC 1289 power rating ........................................................ 105 kW (143 hp) ............................. 140,5 kW (190 hp) Max torque......................................................................... 532 Nm at 1600 rpm ....................... 676 Nm at 1800 rpm

Capacities Engine oil capacity..........................................................................................................24 litres Engine cooling system....................................................................................................27 litres Capacity of the radiator only........................................................ 12 litres .................................................. 12.2 litres Fuel tank..................................................................................... 265 litres .................................................. 340 litres Hydraulic fluid reservoir capacity...................................................................................120 litres Total hydraulic system capacity .................................................. 206 litres .................................................. 225 litres Capacity of the cooler only ..........................................................5.3 litres.................................................... 5.7 litres Travel reduction gear housing capacity ......................................................................... 4.7 litres Swing drive housing capacity ......................................................4.5 litres....................................................... 6 litres Idler wheel capacity ....................................................................................................... 180 cm3 Upper roller capacity...................................................................................................50 to 55 cm3 CX210

CX230/CX240

Lower roller capacity....................................................................210 cm3 .................................................... 250 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......................................................................................................... 40 A Battery Number of batteries required .......................................................................................... 2 Voltage of each battery ..............................................................................................12 volts Capacity ..................................................................................................................... 140 Ah Reserve ......................................................................................................................160 min Cold starting capacity at -17Â°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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Hydraulic system Main hydraulic pump CX210/CX230

CX240

Double, axial piston, variable flow pump. Max flow ................................................................................... 2x201 l/min ............................................ 2x212 l/min Displacement........................................................................... 2x101.5 cm3 ............................................2x97.2 cm3

Hydraulic pilot pump CX210 CX

230

CX240

Fixed flow pump. Max flow ...................................................................................... 22 l/min ..................... 20L/mn.....................22 l/min CX210/CX230 Displacement.................................................................................................................. 10 cm3

CX240

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) .......................................................373±5 bar Relief valves (boom, dipper and bucket) ......................................................................392±5 bar Relief valves (swing).................................................................. 279±4 bar ................................................290±4 bar Relief valves (travel) .....................................................................................................353±5 bar Safety valve (boom and dipper)....................................................................................392±5 bar

Cylinder Boom cylinder Barrel diameter ............................................................................ 120 mm .....................................................125 mm Rod diameter ................................................................................ 85 mm ........................................................90 mm Stroke ......................................................................................... 1255 mm .................................................. 1284 mm

Dipper cylinder Barrel diameter ............................................................................ 135 mm .....................................................145 mm Rod diameter ................................................................................ 95 mm ......................................................105 mm Stroke ......................................................................................... 1474 mm .................................................. 1627 mm

Bucket cylinder Barrel diameter ............................................................................ 115 mm .....................................................130 mm Rod diameter ................................................................................ 80 mm ........................................................90 mm Stroke ......................................................................................... 1012 mm .................................................. 1073 mm

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

Cylinder speeds (in mode S) Boom raising (open bucket on the floor)...................................3.5±0.6 sec. ........................................... 3.7±0.6 sec. Boom lowering (open bucket)...................................................2.9±0.6 sec. .............................................. 3±0.6 sec. Dipper extension.......................................................................2.7±0.6 sec. .............................................. 3±0.6 sec. Dipper retraction .......................................................................3.7±0.6 sec. ........................................... 4.2±0.6 sec. Bucket opening.........................................................................2.3±0.6 sec. ........................................... 2.8±0.6 sec. Bucket closing ........................................................................... 4±0.6 sec. ............................................... 5±0.6 sec. Cre 7-29361GB

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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.

Swing CX210/CX230

CX240

Fixed flow, axial piston motor. Automatic disc brake. Upperstructure swing speed.........................................................12 rpm .....................................................10,4 rpm Displacement...............................................................................151 cm3 .................................................... 146 cm3 Work output ................................................................................ 155 l/min .................................................. 182 l/min Reduction ratio ............................................................................. 16.757 ........................................................22.097 Braking torque.....................................................................................≥ 739 Nm .......................................................≥ 806 Nm Minimum brake pressure .................................................................................................29 bar Acceptable hydraulic motor leakage............................................ xx l/min.......................................................xx l/min

Travel CX210

CX230

CX240

Two-speed, axial piston motor. Automatic disc brake. Slow speed ................................................................................. 3.3 km/h ....................3,2 Km/h ..................3.4 km/h Fast speed.................................................................................. 5.7 km/h................... 5,3 Km/h .................5.5 km/h CX210/CX230

CX240

Incline that can be overcome........................................................................................ 70% (35°) CX210 C

X230

CX240

Tractive force ............................................................................ 18 340 daN ...................... daN ...............19 100 daN CX210

CX230/CX240

Displacement...........................................................................162.2/95 cm3 ................................... 168.9/100.3 cm3 Work output ................................................................................ 201 l/min .................................................. 212 l/min Reduction ratio ............................................................................................................... 43.246 Braking torque (including reducer) .............................................................................. 20 900 Nm Number of turns at the sprockets (10 turns) Mode "S", fast speed...........................................................14.2±0.6 sec. ........................................... 13±0.6 sec. Mode "S", slow speed .........................................................23.4±0.7 sec. ........................................ 21.4±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/mn ..................... xx l/mn .......................xx l/mn

Undercarriage CX210 CX

230

CX240

One-piece undercarriage with welded components. Lubricated rollers and idler wheels. Grease type track tension. Ground pressure with 550 mm track pads ................... .......................................................................... 0,54 Bar with 600 mm track pads ..........................................................0.41 bar .....................................................0.47 bar with 700 mm track pads ..........................................................0.36 bar .....................................................0.42 bar with 800 mm track pads ..........................................................0.33 bar .....................................................0.37 bar Track tension ............................................................................................................ 280 to 300 mm Cre 7-29361GB

Issued 05-05

1002-10

Attachment CX210/CX230

CX240

Break-out force ......................................................................... 14 110 daN ............................................ 17 300 daN Penetration force 1.90 m dipper............................................................................ 14 500 daN 2.40 m dipper............................................................................ 12 560 daN 3.00 m dipper............................................................................ 10 050 daN 2.50 m dipper............................................................................................................................................ 15 000 daN 3.10 m dipper............................................................................................................................................ 12 500 daN 3.50 m dipper.............................................................................................................................................11 400 daN

Weight of components CX210/CX230

CX240

Engine .............................................................................................................................512 kg Hydraulic pump................................................................................................................157 kg Attachment control valve .................................................................................................199 kg Swing motor/reduction gear assembly ......................................... 223 kg ........................................................ 345 kg Travel motor/reduction gear assembly ............................................................................308 kg Boom cylinder............................................................................... 169 kg ........................................................ 192 kg Dipper cylinder.............................................................................. 257 kg ........................................................ 327 kg Bucket cylinder ............................................................................. 151 kg ........................................................ 194 kg Counterweight ............................................................................. 4000 kg ..................................................... 5100 kg Cab ..................................................................................................................................254 kg Upperstructure attachment .......................................................... 8670 kg .................................................. 10 290 kg Machine without attachment.......................................................15 430 kg................................................. 18 110 kg Attachment .................................................................................. 3680 kg ..................................................... 4620 kg Boom attachment ........................................................................ 2110 kg ..................................................... 2620 kg Dipper attachment ........................................................................ 928 kg ...................................................... 1190 kg Radiator and cooler set ................................................................. 76 kg ........................................................... 84 kg Fuel tank...........................................................................................................................87 kg Hydraulic tank..................................................................................................................127 kg CX210

CX230/CX240

Turnable bearing .......................................................................... 263 kg ........................................................ 389 kg Undercarriage attachment ........................................................... 6570 kg ..................................................... 7610 kg Hydraulic swivel................................................................................................................31 kg Idler wheel ..................................................................................... 82 kg ........................................................... 91 kg Upper roller.......................................................................................................................17 kg Lower roller.................................................................................... 36 kg ........................................................... 40 kg Shock absorber ............................................................................ 126 kg ........................................................ 142 kg Track 550 mm.............................................................................................................................................................. Track 600 mm.............................................................................. 1263 kg ..................................................... 1365 kg Track 700 mm.............................................................................. 1470 kg ..................................................... 1502 kg Track 800 mm.............................................................................. 1599 kg ..................................................... 1633 kg

Cre 7-29361GB

Issued 05-05

1002-11

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

Øb Øc

Ød

CS01B512

Marking a Øb Øc Ød P

Dimension (mm) Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

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

Gauge

CS01B513

Cre 7-29361GB

Issued 05-05

1002-12

Idler wheel Dimensions Dimension (mm) CX230 CX210 CX240

Marking Øa

b c

b c Ø d (pin)

Øa

Ø d (ring) e e

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

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

494 490 19 --84 80 70 69.5 70 70.8 74 73.6 15.9 15.5

Ød

CS01B514

Gauge

CS01B515

Cre 7-29361GB

Issued 05-05

1002-13

Upper roller Dimensions g

Marking

Øa b c

Øa

Ø d (pin)

Ød

Ø d (ring) e

f f

Dimension (mm) Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

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

CS01B516

Gauge

CS01B517

Cre 7-29361GB

Issued 05-05

1002-14

Lower roller Dimensions d

Øe

Øa

b CS01B518

Dimension (mm) CX230 CX210 CX240

Marking Øa b d Ø e (pin)

Standard Limit Standard Limit Standard Limit Standard Limit

150 142 15 --173 179 65 64.5

160 152 15 --173 179 70 69.5

Dimension (mm) CX230 CX210 CX240

Marking Ø e (ring) f g

Standard Limit Standard Limit Standard Limit

65 65.8 69 68.6 23.3 22.8

70 70.8 74 73.6 20.8 20.5

Gauge

CS01B519

Cre 7-29361GB

Issued 05-05

1002-15

Track c d

Øe

Øe Øf

Øf

Øg

Øg h

a CS01B520

Dimension (mm) CX230 CX210 CX240

Marking a b c d

Cre 7-29361GB

Standard Limit Standard Limit Standard Limit Standard Limit

34.5 21.5 106 101 37.985 36 19.95 16

36 23 106 101 37.985 36 17.95 16

Dimension (mm) CX230 CX210 CX240

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

Standard Limit Standard Limit Standard Limit Standard Limit

58.72 57.5 37.3 38.3 36.3 35.5 190 195

Issued 05-05

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) CX210 CX240 CX230

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

Cre 7-29361GB

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

682 692 681.5 679.5 0.5 to 3 Shims 90 89 90 91.5

696 706 695.5 693.5 0.5 to 3 Shims 100 99 100 101.5

Issued 05-05

1002-17

2. Boom cylinder foot/Undercarriage a

b Ød

CS01B523

Dimension (mm) CX210 CX240 CX230

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

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

106 112 105 103 1 to 2.5 Shims 80 79 80 81.5

109 115 108 106 1 to 2.5 Shims 90 89 90 91.5

3. Boom cylinder head/Boom a

Ød

CS01B524

Dimension (mm) CX210 CX240 CX230

Marking a b c (play) Ø d (pin) Ø d (ring) Cre 7-29361GB

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

100 98 525 512 1 to 2.5 Shims 85 84 85 86.5

108 106 528 522 1 to 2.5 Shims 90 89 90 91.5 Issued 05-05

1002-18

4. Dipper cylinder foot/Boom a

Dimension (mm) CX210 CX240 CX230

Marking

a b

Ød

c (a - b) Ø d (pin) CS01B525

Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

121 127 120 118 0.5 to 2 Shims 80 79 80 81.5

121 127 120 118 0.5 to 2 Shims 90 89 90 91.5

5. Boom/Dipper a

Dimension (mm) CX210 CX240 CX230

Marking a b

Ød

c (play) CS01B526

Ø d (pin) Ø d (dipper) Ø d (boom)

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

310 313.5 309.5 307.5 0.5 to 1.1 Shims 90 89 90 91.5 90 91.5

330 333.5 329.5 327.5 0.5 to 1.1 Shims 100 99 100 101.5 100 101.5

6. Dipper cylinder head/Dipper Dimension (mm) CX210 CX240 CX230

Marking a

Ød b a

b c (a - b)

c CS01B527

Ø d (pin) Ø d (ring)

Cre 7-29361GB

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

121 127 120 118 0.5 to 3 Shims 80 79 80 81.5

121 127 120 118 0.5 to 3 Shims 90 89 90 91.5

Issued 05-05

1002-19

7. Bucket cylinder foot/Dipper a b

Dimension (mm) CX210 CX240 CX230

Marking Ød

a b c (a - b) CS01B528

Ø d (pin) Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

101 107 100 98 0.5 to 3 Shims 75 74 75 76.5

116 122 105 103 0.5 to 3 Shims 80 79 80 81.5

8. Connecting rod/Dipper Dimension (mm) CX210 CX240 CX230

Marking

b c (play)

Ø d (pin)

Ød CS01B529

Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

32 30 296 294 1 to 1.5 Shims 75 74 75 76.5

40 38 316 314 1 to 1.5 Shims 80 79 80 81.5

9. Compensator/Bucket Dimension (mm) CX210 CX240 CX230

Ød Marking c a b

b c (play) Ø d (pin) CS01B530

Cre 7-29361GB

Ø d (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

307 313 306 304 1 to 3.5 Shims 80 79 80 81.5

317 323 316 314 1 to 3.5 Shims 90 89 90 91.5

Issued 05-05

1002-20

10. Connecting rod/Compensator/Bucket cylinder head Dimension (mm) CX210 CX240 CX230

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 30 296 294 1 to 1.5 Shims 96 98 95 93 0.5 to 2 Shims 80 79 80 81.5

40 38 316 314 1 to 1.5 Shims 106 108 105 103 0.5 to 2 Shims 90 89 90 91.5

80 81.5

90 91.5

11. Dipper/Bucket Øe

Marking

d a

a b

c (a - b) d

Ø e (pin) CS01B532

Ø e (dipper) Ø e (bucket)

Cre 7-29361GB

Dimension (mm) CX210 CX240 CX230 Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

307 313 306 304 1 to 3.5 Shims 16 8 80 79 80 81.5 80 81.5

326 332 325 323 1 to 3.5 Shims 16 8 90 89 90 91.5 90 91.5

Issued 05-05

1002-21

SPECIAL TORQUE SETTINGS No.

Component

Screw (Ø)

Key (mm)

Torque setting (Nm)

Travel motor/reduction gear assembly

M16

267-312

Sprocket

M16

267-312

Idler wheel

M16

267-312

Upper roller

M20

521-608

Lower roller

M18

371-432

Chain guide

M18

380-443

Track pad

M20

300 + 120°

M27

1058-1235

M30

1333-1549

M20

468-545

M24

783-913

M20

468-545

M24

783-913

M20

521-608

Counterweight

Turntable (undercarriage)

Turntable (upperstructure)

11 *

Swing motor/reduction gear assembly

M24

783-913

12 *

Engine

M16

265-313

13 *

Engine support

M10

64-74

Radiator

M16

147-176

15 *

Hydraulic pump

M10

64-74

M20

367-496

16 *

Hydraulic reservoir

M16

232-276

17 *

Fuel tank

M16

232-276

18 *

Control valve

M16

267-312

19 *

Hydraulic swivel

M12

109-127

Cab

M16

78-80

Battery

M10

20-29

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

Cre 7-29361GB

Issued 05-05

1002-22

16 18

12 13

21 7 19

1 9 10

6 20

4 CS00E507

6 1

2 CS00E508

CS00E509

7 4 6 3

5 8 CS00E510

Cre 7-29361GB

CS00E511

Issued 05-05

1002-23

13 12

CS00E512

CS00E514

15 14

CS00E517 CS00E515

CS00E518

CS00E519

CS00E521

21 20

CS00E522

Cre 7-29361GB

CS00E523

CS00E525

Issued 05-05

1002-24

MACHINE OVERALL DIMENSIONS E

M J L

I H D

CS01B533

1.90 m A B

2.88 m

CX210

CX230

CX240

Dippers

2.40 m

3.00 m

2.50 m

3.10 m

3.50 m

2.50 m

3.10 m

3.50 m

3.07 m

2.91 m

3.04 m

3.10 m

2,92 m

3.31 m

3.08 m

3.30 m

2.88 m

2.95 m

2.96 m

9.47 m

9.39 m

9.59 m

9.58 m

9.48 m

9.95 m

9.88 m

9.91 m

4.95 m

4,95 m

5.22 m

2.75 m

2.50 m

2.75 m

1.04 m

1.09 m

1.10 m

2.72 m

2.83 m

2.91 m

4.46 m

4.24 m

4.64 m

3.66 m

3.46 m

3.83 m

3.84 m

2.39 m

1,99 m

2.59 m

K (standard track pads)

0.60 m

0.55 m

0.60 m

2,54 m

L (with 600 mm track pads)

2.99 m

3.19 m

L (with 700 mm track pads)

3.09 m

3.29 m

L (with 800 mm track pads)

3.19 m

3.39 m

0.49 m

0.46 m

L (standard track pads)

Cre 7-29361GB

0.48 m

Issued 05-05

Section 2000

Case

Cre 7-28230GB

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 7-28230GB

Issued 09-00

2000-3

ENGINE Removal and installation

STEP 6

STEP 1

CD00J037

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

CD00J038

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

STEP 8

CD00F091

Disconnect the earth cable from the battery (1) (-).

STEP 4 Refer to Section 8003 and remove the hy draulic pump.

1 2

STEP 5 Refer to Section 20 01 an d r emove th e r adiator an d oil-cooler assembly. CD00J039

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

Cre 7-28230GB

Issued 09-00

2000-4

STEP 9

STEP 12

1 CD00J044

CD00J047

Label and disconnect the ele ctrical connections from 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

CD00J045

Label and disconnect the ele ctrical connections from the fuel temperature sensor (1).

STEP 11

CD00J048

Label an d disconnect th e e lectrical connections t o the starter motor. Remove the earth cable (1) at the engine end.

CD00J046

Label and disconnect the ele ctrical connections from the oil pressure d etector ( 1) and the en gine s peed detector (2).

Cre 7-28230GB

Issued 09-00

2000-5

STEP 14

STEP 16

CD00J040

Label and disconnect the connectors to the electronic regulator and disconnect the fuel fl ow r egulation resistance.

STEP 15

CD00J042

Label an d disconnect th e e lectrical connections t o the alternator. NOTE: If the machine is equipped with air conditioning, remove the compressor mounting hardware and move the compressor away from the engine.

STEP 17 Remove all the clips, etc, which fasten the electrical harnesses to the engine and move the harnesses out of the way.

STEP 18

CD00J041

Remove the hose connecting the turbo-charger to the air filter.

CD00J043

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 7-28230GB

Issued 09-00

2000-6

STEP 19

STEP 20

Remove the engine retaining hardware.

When there is nothing interfering with the removal of the engine, raise the engine carefully and install it on a suitable repair bench.

NOTE: When installing, make a visual inspection of 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: When installing the engine in the machine, proceed in the reverse order from removal.

Before operating 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, fuel and cooling systems for leaks. Check the oil level in the hydraulic reservoir. Top up if necessary.

Cre 7-28230GB

Issued 09-00

2001 Section 2001 RADIATOR AND OIL-COOLER

Case

Cre 7-28050GB

2001-2

3 3 3 4 6

CHANGING THE RADIATOR OR THE OIL-COOLER............................................................................................. 7 Disassembly and assembly.................................................................................................................................. 7

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 cooling system capacity ...................................................................................................................... 26.4 litres Thermostat opening range Starts to open..................................................................................................................................................82°C Completely open .............................................................................................................................................95°C Hydraulic fluid ................................................................................................................................. See Section 1002

Cre 7-28050GB

Issued 09-00

2001-3

RADIATOR AND OIL-COOLER Before carrying out any operation on the machine, perform 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 pressure in the hydraulic system has been completely released (see Operatorâ&#x20AC;&#x2122;s Manual).

WARNING: When the machine is working, the engine components and the hydraulic pump reach a high temperature. 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 oil-cooler

STEP 4 2

STEP 1

2 CD00G013

CD00G009

Remove th e upp er g rille ( 1), th en r emove the air conditioning heat exchanger (2) without disconnecting it.

STEP 2 Release pressure i n th e h ydraulic r eservoir to al low the vacuum pump to be mounted (see Section 8000).

STEP 3

Disassemble the fou r r etaining screws ( 1) fr om th e oil-cooler (2) and remove the oil-cooler.

Installing the oil-cooler When installing, p roceed i n the reverse order f rom that of removal. Before using the machine, check the level of oil in the hydraulic r eservoir. Top u p i f ne cessary. Che ck th e hydraulic fluid cooling circuit for leaks.

1 3 2

4 CD00G010

Disconnect and plug the hoses (1) and (2). Drain the oil fr om the o il-cooler ( 3) in to a c lean r eceptacle. Disassemble th e four s crews ( 4) from the oi l-cooler bracket (3). Cre 7-28050GB

Issued 09-00

2001-4

Removing the radiator

STEP 4

STEP 1

3 4

2 CD00G014

CD00G009

Remove the upper grille (1).

STEP 2

Disassemble the retaining screws (1) from the hinges (2) of the oil-cooler bracket (3) at the radiator bracket end (4). The oi l-cooler br acket ( 3) is then sep arated from the radiator bracket (4).

STEP 5 Remove the cap from the expansion reservoir. IMPORTANT: Do not remove the cap when the engine is hot, since the system would still be under pressure and you could be scalded.

STEP 6 Drain the cooling system (see Operatorâ&#x20AC;&#x2122;s Manual).

STEP 7

CD00G012

Disassemble the fou r retaining screws ( 1) fr om th e oil-cooler bracket (2).

STEP 3 3

CD00G015

Disconnect the expansion reservoir hose (2) and the return hose (3) from the radiator (1).

1 CD00G152

Pivot t he oil-cooler br acket assembly (1) to th e maximum opened position. Wedge the a ssembly (1) into position.

Cre 7-28050GB

Issued 09-00

2001-5

STEP 8

STEP 11

CD00G016

CD00G019

Disconnect the water pump intake hose (4) from the radiator (1).

Disassemble t he two re taining screws (1 ) and remove the rear tie-rod (2).

STEP 9

STEP 12

1 2

3 CD00G017

Loosen the retaining band (1) as far as possible, then slide th e r etaining ban d ( 1) a nd th e r ubber s kirt ( 2) onto the shroud (3).

STEP 10

CD00G020

Disassemble t he two re taining screws (1 ) and remove the front mounting angle bracket (2).

STEP 13

1 1

CD00G018

Remove t he lo wer re taining sc rews (1 ) f rom t he radiator bracket.

CS00G513

Pass a s uitable s ling r ight ar ound the r adiator an d support assembly and, using a suitable lifting device, remove the radiator and support assembly. Cre 7-28050GB

Issued 09-00

2001-6

Installing the radiator When installing, pr oceed i n t he reverse order fr om that of removal. Before op erating the mac hine, fill and ble ed th e engine coo ling s ystem ( see Operatorâ&#x20AC;&#x2122;s M anual) and check the engine cooling system for leaks.

Cre 7-28050GB

Issued 09-00

2001-7

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

9 6 8

1 11 12

4 5

1 2 3 4 5 6 7 8 9

INTAKE SHROUD RETAINING SCREWS INTAKE SHROUD RADIATOR UPPER RETAINING SCREWS RADIATOR LOWER RETAINING SCREWS RADIATOR OIL-COOLER BRACKET RETAINING SCREWS OIL-COOLER OIL-COOLER BRACKET FILTER RETAINING SCREWS

Cre 7-28050GB

13 10 11 12 13

FILTER GUARD RETAINING HARDWARE GUARD RADIATOR SUPPORT

CI00G506

Issued 09-00

2001-8

Cre 7-28050GB

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 7-27724GB

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 7-27724GB

Issued 05-05

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 7-27724GB

Issued 05-05

4001-4

SPECIFICATIONS See section 1002.

SPECIAL TOOLS

BS98G045

1 Service connector kit CAS-30039 2 Multimeter CAS-1559

Cre 7-27724GB

Issued 05-05

4001-6

LOCATION OF COMPONENTS General location of the components (outside the cab) CX130/CX160/CX180 Model E2

B45

B81

B26

M4 X1

R5 B27 B41

F25

B21 B22

S52

M2 52

S55 G1

B43 F25 B44

F24 F23 F22 K7

G2 Y8

R2 A3

B42 CM02H001

Cre 7-27724GB

Issued 05-05

4001-7 52 A3 B1 B2 B21 B22 B26 B27 B41 B42 B43 B44 B45 B81 E1 E2 E3 F22 F23 F24 F25 G1 G2 K7 M1 M2 M4 R1 R2 R5 S52 S55 X1 X2 Y7 Y8

6 solenoid valve bank Electronic acceleration Coolant temperature sensor Hydraulic oil temperature sensor Engine oil pressure switch Swing pilot pressure switch Upper pilot pressure switch Travel pilot pressure switch Engine rpm sensor Pump pressure sensor P1 Pressure sensor (nega-cont) Pump pressure sensor P2 (yellow band) Overload indicator pressure switch Horn Working light (upperstructure) Working light (attachment) Working light (cab) Fuse 20 A; main fuse for circuits F11 and F12 Fuse 65 A; main fuse for circuits F3 to F10 and F13 to F20 Fuse 20 A; main fuse for circuit F2 Fuse 20 A; main fuse for circuit F1 Batteries Alternator Relay battery Starter motor Engine emergency stop motor Washer motor Glow plugs Fuel flow adjustment resistor Fuel sensor Air conditioning compressor clutch switch Minimum coolant solution level switch Fuel filler pump connector Rotary light connector Main pump proportional solenoid Air conditioner magnet clutch

Cre 7-27724GB

Issued 05-05

4001-8

General location of the components (outside the cab) CX210/CX230/CX240 Model E2

B45 B81 E1

E3 M4 X1

R5 B26 B27

B22

B41 G1

B21

F25 F24

F23

F22

B42

B44

S55 Y7

S52

R2 A3

B43

B2 CM02H002

Cre 7-27724GB

Issued 05-05

4001-9 52 A3 B1 B2 B21 B22 B26 B27 B41 B42 B43 B44 B45 B81 E1 E2 E3 F22 F23 F24 F25 G1 G2 K7 M1 M2 M4 R1 R2 R5 S52 S55 X1 X2 Y7 Y8

Cre 7-27724GB

Issued 05-05

4001-10

Relay and main fuses (battery compartment)

F24

F23

F25 F22

1 F22 F23 F24 F25 K7

Battery cables Fuse 20 A; main fuse for circuits F11 and F12 Fuse 65 A; main fuse for circuits F3 to F10 and F13 to F20 Fuse 20 A; main fuse for circuit F2 Fuse 20 A; main fuse for circuit F1 Relay battery

Cre 7-27724GB

CI00E501

Issued 05-05

4001-11

CX210/CX230/CX240 Model

F23

F22

F24

F25

1. 2. 3. 4. 5. 6.

Relay battery Fuse 65 A: for F3 to F10 and F13 to F20A circuits Fuse 20 A: for F11 and F12 circuits (before contact) Fuse 20 A: for F1 circuits Fuse 20 A: for F2 circuits Battery cables

Cre 7-27724GB

CI00E502

Issued 05-05

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