Case cx460 tier 3 crawler excavator service repair manual by 163757

CX460 TIER 3 CRAWLER EXCAVATOR SERVICE MANUAL 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

7-27691EN SC4601002-0EN

ENGINE 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 Main and engine electronic control boxes ....................................................... 4003

SC4604001-0EN SM4604003-0EN

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

SM160B5001-0EN SM4605003-0EN SM160B5004-0EN SM4605005-0EN

DRIVE TRAIN Drive motor and final drive transmission removal and installation ................... 6001 Swing reduction gear, removal and installation ............................................... 6003 Swing reduction gear, disassembly and assembly .......................................... 6004 Travel reduction gear disassembly and assembly .......................................... 6005

SM4606001-0EN SM4606003-0EN SM4606004-0EN SM4606005-0EN

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 hydraulic 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 valves.................................................................................................... 8017 Hydraulic swivel, disassembly and assembly .................................................. 8018 Swing motor, disassembly and assembly ........................................................ 8019 Hydraulic functions .......................................................................................... 8020 Travel hydraulic motor, disassembly and assembly ......................................... 8021 Fan motor, removal and installation ................................................................. 8022 Fan motor, disassembly and assembly............................................................ 8023 Fan pump, removal, disassembly, assembly and installation........................... 8024 Hydraulic component functions........................................................................ 8030

SM4602001-0EN

SM4603001-0EN

SM4608000-0EN SC4608001-0EN SM4608002-0EN SM4608003-0EN SM4608004-0EN SM4608005-0EN SM4608006-0EN SM4608007-0EN SM4608008-0EN SM4608010-0EN SM4608011-0EN SM4608012-0EN SM4608013-0EN SM4608014-0EN SM4608015-0EN SM4608016-0EN SM4608017-0EN SM4608018-0EN SM4608019-0EN SC4608020-0EN SM4608021-0EN SM4608022-0EN SM4608023-0EN SM4608024-0EN SC4608030-0EN

DIVISION/SECTION 9

SECTION N°

UPPERSTRUCTURE Upperstructure, turntable and counterweight..................................................... 9002 Boom, dipper and bucket ................................................................................... 9003 Seat, removal and installation............................................................................ 9004 Cab and cab equipment..................................................................................... 9005 Air conditioning unit disassembly and assembly................................................ 9007 Large size hydraulic schematics ......................................................................Pocket Large size electrical schematics ......................................................................Pocket

REFERENCE N° SM4609002-0EN SM4609003-0EN SM4609004-0EN SM4609005-0EN SM4609007-0EN 87574463A 87574470A

* Consult the Engine Service Manual NOTE: CNH Company reserves the right to make changes in the specifica tion 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 this manual has been made in accordance with the technical specifications known as of the date of design of this document.

Lep SM460TOC-0EN

Issued 09-07

1001 SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS

CNH

Lep 7-27691EN

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.

Lep 7-27691EN

Issued 02-06

1001-3

GENERAL INFORMATION Cleanning

Gears

Clean all metal par ts except bear ings, in a suitab le cleaning so lvent or b y ste am clea ning. Do not use caustic sod a f or st eam clean ing. After clea ning, dry and put o il on al l pa rts. Clea n o il p assages with compressed air. Clean bearings in a suitable cleaning solvent, dry th e be arings completely an d pu t oil on the bearings.

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

Inspection Check a ll parts whe n th e pa rts ar e disassemb led. Replace a ll pa rts t hat h ave wear o r d amage. Small scoring or g rooves can be r emoved wit h a ho ne o r crocus clot h. Com plete a visual in spection for indications of w ear, p itting an d the r eplacement o f parts necessary to prevent early failures.

Bearings Check b earings f or easy actio n. If be arings ha ve a loose f it or ro ugh act ion r eplace t he bea ring. W ash bearings wit h a suitable cle aning solvent a nd p ermit to air dr y. DO NO T DR Y BEARIN GS WITH COMPRESSED AIR.

Needle bearings Before y ou pr ess nee dle bearings in a bore always 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.

Lep 7-27691EN

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 all shaf ts t hat ha ve w ear or dam age. Ch eck the bearing a nd oil seal surfaces of t he sha fts f or damage.

Service parts Always install gen uine Case ser vice par ts. When ordering refer to the Parts Catalog for the correct part number of t he g enuine Case r eplacement ite ms. Failures due to the use of other than ge nuine Ca se replacement parts are not covered by warranty.

Lubrication Only use t he o ils and lubr icants spe cified in t he Operatorâ&#x20AC;&#x2122;s or Service Ma nuals. Failures du e to th e use o f no n-specified o ils an d lub ricants are not covered by warranty.

Issued 02-06

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 injur y always follow the Warning, Caution and Danger notes in t his section and throughout the manual. Put th e warning t ag sh own be low on th e key for t he keyswitch w hen ser vicing or repairing the machine . One warning t ag is supplied with ea ch m achine. Additional ta gs Part Numb er 331-4614 are 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 o l l o w m a n u f a c tu r e r s i n s tr u c t i o n 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.

Lep 7-27691EN

Issued 02-06

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.

Lep 7-27691EN

Issued 02-06

1001-6

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be applied 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 cle aning solvent and dr ied. Apply 2- 3 d rops of Lo ctite t o t he th read p ortion o f th e cap screw an d t hen tighten.

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

Lep 7-27691EN

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

19.6

39.2

58.8

98.1

156.9

196.1

294.2

[lb-ft]

5.1

14.5

28.9

43.4

72.3

115.7

144.6

217

[mm]

[in.]

0.20

0.24

0.32

0.39

0.47

0.55

0.67

[Nm]

8.8

21.6

42.1

78.5

117.7

176.5

245.2

343.2

[lb-ft]

6.5

15.9

31.1

57.9

86.9

130.2

181

253.2

Issued 02-06

1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

CNH

Lep SC4601002-0EN

1002

Section

1002-2

TABLE OF CONTENTS

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.

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 5 Machine ....................................................................................................................................................................... 5 Engine .......................................................................................................................................................................... 5 Serial numbers of the components .............................................................................................................................. 5 FLUIDS AND LUBRICANTS ............................................................................................................................................ 6 Hydraulic fluid .............................................................................................................................................................. 6 Transmission component oil ........................................................................................................................................ 6 Grease ......................................................................................................................................................................... 6 Engine Oil .................................................................................................................................................................... 7 Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 8 Anti-freeze/Anti-corrosion........................................................................................................................................... 10 Environment ............................................................................................................................................................... 10 Plastic and resin parts................................................................................................................................................ 10 SPECIFICATIONS ......................................................................................................................................................... 11 Main data ................................................................................................................................................................... 11 Performance .............................................................................................................................................................. 11 Complete machine dimensions .................................................................................................................................. 11 Main body dimensions ............................................................................................................................................... 11 Engine ........................................................................................................................................................................ 12 Cooling system .......................................................................................................................................................... 12 Capacity of coolant and lubricants ............................................................................................................................. 12 Hydraulic oil filter........................................................................................................................................................ 12 Fuel filter .................................................................................................................................................................... 12 Operating devices ...................................................................................................................................................... 13 Hydraulic system........................................................................................................................................................ 14 Swing unit .................................................................................................................................................................. 16 Travel lower body....................................................................................................................................................... 16 Work Unit ................................................................................................................................................................... 17 Digging force (ISO 6015) ........................................................................................................................................... 18 COMPONENT WEIGHT................................................................................................................................................. 19 Major component weight ............................................................................................................................................ 19 Bucket weight............................................................................................................................................................. 20 Other component weight ............................................................................................................................................ 21 DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 22 Sprocket ..................................................................................................................................................................... 22 Idler wheel.................................................................................................................................................................. 23 Lep SC4601002-0EN

Issued 03-07

1002-3 Upper roller .................................................................................................................................................................24 Lower roller .................................................................................................................................................................25 Track...........................................................................................................................................................................26 DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..................................................................27 1. Boom foot/Frame ....................................................................................................................................................27 2. Boom cylinder foot/Frame.......................................................................................................................................28 3. Boom cylinder head/Boom......................................................................................................................................28 4. Arm cylinder foot/Boom ..........................................................................................................................................29 5. Boom/Arm...............................................................................................................................................................29 6. Arm cylinder head/Arm ...........................................................................................................................................29 7. Bucket cylinder foot/Arm.........................................................................................................................................30 8. Connecting rod/Arm................................................................................................................................................30 9. Compensator/Bucket ..............................................................................................................................................30 10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................31 11. Arm/Bucket ...........................................................................................................................................................31 SHIMS FOR ADJUSTING ATTACHMENT GAPS ..........................................................................................................32 For boom foot .............................................................................................................................................................32 SPECIAL TORQUE SETTINGS......................................................................................................................................33 MACHINE OVERALL DIMENSIONS ..............................................................................................................................36

Lep SC4601002-0EN

Issued 03-07

1002-5

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE For all part orders, request for information or assistance, always specify the type and the serial number of the machine to your Case dealer. Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the serial numbers of the hydraulic and mechanical components.

Machine 1 2

CT04A171A

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

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

Serial numbers of the components Hydraulic pump ........................................................................................................................................................... Swing reduction gear .................................................................................................................................................. Travel reduction gears ................................................................................................................................................. Control valve ...............................................................................................................................................................

Lep SC4601002-0EN

Issued 03-07

1002-6

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 CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system. The type of fluid to be used depends on the ambient temperature. Temperate climates: -20°C to +40°C (-4° to 104° F) CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) Hot climates: 0°C to +50°C (32° to 122° F) CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP) Cold climates: -25°C to +20°C (-13° to 68° F) CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2) Biodegradable fluid: -30°C to +40°C (-22° to 104° F) This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit completely before refilling with this fluid. CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

Transmission component oil Extreme pressure oil used for enclosed transmission components. CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)

Grease CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide. CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and calcium. CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap.

Hydraulic breakers CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

Lep SC4601002-0EN

Issued 03-07

1002-7

Engine Oil THE CASE/AKCELA No. 1 engine oil is re commended for y our e ngine. Th is o il en sures p roper lubr ication of your engine for all operating conditions. If the CASE/AKCELA Multigrade "No. 1 EN GINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: ACEA E7. API CI-4.

CP02N001

Oil viscosity / Oil range

1 2 3 3

CT02M001

1) With mineral base (2) With semi-synthetic base (3) With synthetic base

Lep SC4601002-0EN

Issued 03-07

1002-8

Engine fuel, maintenance of fuel filters and fuel storage In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and they are to be used under high-pressure conditions. Therefore, the specified fuel must be used for the engine. As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it may invite a serious breakdown. In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the genuine filter is essential. The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel and the fuel elements.

Fuel to be applied Selection of fuel Following conditions must be met for the diesel engines, that is the one; 1 In which no dust even fine one is mixed, 2 With proper viscosity, 3 With high cetane rating, 4 With good flow properties in lower temperature, 5 With not much sulfur content, and 6 With less content of carbon residue Applicable standards for diesel fuel Applicable Standard

Recommendation

JIS (Japanese Industrial Standard)

NO.2

DIN (Deutsche Industrie Normen)

DIN 51601

SAE (Society of Automotive Engineers) Based on SAE-J-313C

NO. 2-D

BS (British Standard) Based on BS/2869-197

Class A-1

EN590 If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details. Requirements for diesel fuel Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big influence on its service durability and service life. Be sure to observe the following requirements for selecting fuel. Sulfur content............................................................................... 2500 ppm or less HFRR*.......................................................................................... 460 mm or less Water content............................................................................... 0.05 wt% or less * HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel. Sulfur content reacts to moisture to change into sulfuric acid after combustion. Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear. In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be worse which results in acceleration of wear of sliding portions. HFRR is an index that indicates lubricating property of a fuel. Large value of the index means poor lubrication so that seizure of the machine components may result if such a fuel is used. Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out. Lep SC4601002-0EN

Issued 03-07

1002-9 If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in acceleration of wear. Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter. IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation. This may also cause wear and seizure of the machine components. If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice allowing the fuel line to be clogged. IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria described above. IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine or an accident may be invited. Guarantee will not be given to a breakdown caused by the use of a improper fuel. Some fuels are used with engine oil or additives mixed together with diesel engine fuel. In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated. It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not meet the specifications and the requirements is used. Use the specified fuel for compliance of the exhaust gas control. IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to follow the items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns caused by not to follow these items. 1 Selection of engine oil Use API grade CF-4 or JASO grade DH-1. 2 Exchange the engine oil a nd engine oil f ilter element by the periodical interval reported on t he Operator’s Manual. 3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use. * EGR: Exhaust Gas Recircultion

Maintenance of fuel filters Be sure to use the genuine fuel filters. The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional filters to improve protection of machine equipment. If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine equipment can wear out in a short period of time. IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the use of a wrong filter. Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine. Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Manual. IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine. Time to replace filters may be advanced according to properties of the fuel being supplied. • Therefore, take measures to prevent dust or water from being entered in the fuel tank when supplying fuel. • When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply clean fuel standing above a precipitate. • If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel tank of the machine to supply clean fuel. Water drain cock is provided on the bottom side of the fuel tank. • Drain water before starting the engine every morning. • In addition, remove the cover under the tank once a year to clean up inside of the tank.

Lep SC4601002-0EN

Issued 03-07

1002-10

Fuel storage Long sto rage ca n le ad to t he accum ulation of im purities and cond ensation in t he f uel. Engine trouble can often be traced to the presence of water in the fuel. The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710) For areas where the temperature goes down to -38Â°C (-36.4Â°F), mix 50/50 with water. IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the system.

Environment Before carrying out a ny maintenance o peration on t his ma chine an d b efore disposing o f used f luids o r lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles. Contact your local ecological recycling ce ntre or your CASE Dealer to obtain information on the correct method of disposing of these lubricants.

Plastic and resin parts When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint solvents etc... Use only water, soap and a soft cloth. The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.

Lep SC4601002-0EN

Issued 03-07

1002-11

SPECIFICATIONS Main data Model name ............................................................................................................................CX460 Hydraulic Excavator Operating weight ............................................................................................................................. 46600 kg (102735 lbs) Engine output ....................................................................................................................................... 270 kW / 1950 rpm

Performance

Swing speed....................................................................................................................................................... 9.0 Tr/min. Travel speed Low Speed.................................................................................................................................... 3.1 km/h (1.93 mph) High Speed ................................................................................................................................... 5.3 km/h (3.30 mph) Maximum drawbar pull ..........................................................................................................................341 kN (76659.85) Grade ability ........................................................................................................................................................70% (35Â°) Ground pressure ............................................................................................... 80 kPa (600 mm (23.62 in) grouser shoe)

Complete machine dimensions Standard arm (3.40 m) (11 ft 1.85 in)

Short arm (2.55 m) (8 ft 4.39 in)

Length

11940 mm (470.07 in)

11990 mm (472.04 in)

Width

3350 mm (131.88 in)

Height

3600 mm (141.73 in)

3670 mm (144.48 in)

Main body dimensions

Main body width .............................................................................................................. See machine overall dimensions Main body length............................................................................................................. See machine overall dimensions Upper side swing body width ................................................................................................................. 3040 mm (120 in) Cab width ............................................................................................................................................ 1000 mm (39.37 in) Main body height............................................................................................................................... 3270 mm (128.73 in) Tail swing radius ................................................................................................................................ 3620 mm (142.51 in) Distance of rear swing body.............................................................................................................. 3600 mm (171.73 in) Ground clearance for upperstructure ...................................................................................................... 1330 mm (52.36) Center-to-center of wheels.................................................................................................................... 4400 mm (173.22) Overall track length ............................................................................................................................... 5450 mm (214.56) Maximum track width ........................................................................................................................ 3350 mm (131.88 in) Center-to-center for track ...................................................................................................................... 2750 mm (108.26) Width of track shoe .................................................................................600 mm (23.62 in) (Optional: 750 mm (29.52 in) Minimum ground clearance (To bottom of lower frame) ............................................................................ 540 mm (21.25)

Lep SC4601002-0EN

Issued 03-07

1002-12

Engine

Name.............................................................................................................................................................ISUZU, 6UZ1 Type: ................................................................................ Water-cooled, 4-cycle diesel, 6-cylinder in line, direct injection .............................................................(electronic control), turbocharger with air cooled intercooler, without cooling fan. No. of cylinders - bore x stroke....................................................................................................6-dia. 120 mm x 145 mm Displacement........................................................................................................................................ 9.839 L (2.599 gal) Compression ratio ....................................................................................................................................................... 17.5 Rated output.......................................................................................................................................270 kW / 1950 min-1 Maximum torque................................................................................................................. 1435 Nm / apprex. 1500 min-1 Dry weight ........................................................................................................................................Approximately 840 kg Engine dimensions (LxWxH) ........................................................................ 1235x953x1272 mm (48.62x37.51x50.07 in) Oil pan ...................................................................................................................................... All direction 35°, inclinable Cooling fan ................................................... Remote (diameter 1016 mm (39.99 in) suction type-6 blades resin & steel) Oil pan capacity.................................................. Maximum: 36 L (9.51 gal) Minimum: 25 L (6.60 gal) (excluding oil filter) Direction of rotation ...................................................................................................................... Right (as seen from fan) Starter, reduction type ................................................................................................................................... .24 V, 5.5 kW Alternator, AC type ............................................................................................................................................. 24 V, 50 A Battery ............................................................................................................................................... 2 x 12V, 128 Ah/5 Hr

Cooling system

Fan drive system .........................................................................................................................................Hydraulic drive Fan type........................................................................................................... Ø 1016 mm (39.99 in), 6 blades, air intake Radiator Fin type .................................................................................................................................................................. wavy Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in) Oil cooler Fin type .................................................................................................................................................................. wavy Fin pitch ........................................................................................................................................... 1.75 mm (0.069 in) Inter-cooler Fin type ...............................................................................................................................................triangular straight Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in) Fuel cooler Fin type .................................................................................................................................................................. wavy Fin pitch ............................................................................................................................................. 2.0 mm (0.078 in)

Capacity of coolant and lubricants

Coolant ...................................................................................................................................................... 38 L (10.03 gal) Fuel ....................................................................................................................................................... 611 L (161.41 gal) Lubricant for engine..................................................................................................................................... 36 L (9.51 gal) Lubricant for travel reduction gear (per side)............................................................................................... 15 L (3.96 gal) Lubricant for swing reduction gear (per side) ........................................................................................... 10.5 L (2.77 gal) Hydraulic oil ........................................................................................................................................... 460 L (121.51 gal) Capacity of hydraulic oil tank................................................................................................................... 230 L (60.76 gal)

Hydraulic oil filter

Suction filter (inside tank) ....................................................................................................................................150 mesh Return filter (inside tank) .......................................................................................................................................... 10 µm Nephron filter (inside housing) ................................................................................................................................... 1 µm Pilot line filter (inside housing).................................................................................................................................. 10 µm

Fuel filter

Main filter.................................................................................................................................................................... 4 µm Pre-filter.................................................................................................................................................................... 10 µm

Lep SC4601002-0EN

Issued 03-07

1002-13

Operating devices

Operator's seat Location: left side Structure: KAB 555: Low frequency air suspension with helical springs and double acting hydraulic damper. Cab Smooth and round shape design cab, fabricated by press work Safety glass for all window. Levers and pedals For travel use: Levers and pedals (hydraulic pilot type) (x2) For operating machine use: Levers (hydraulic pilot type) (x2) Instruments and switches Work mode switchover: 4 modes (heavy digging, standard, finishing and auto) Travel speed switchover: Low-speed / high-speed switch One-touch idle: Knob switch type Monitor device Machine status display (full-dot liquid crystal) Travel speed selection status: Low Speed / High Speed Work mode selection status: H/S/L/A Auto idle selection status: ON/OFF Instruments (full-dot liquid crystal, except for hour meter) Fuel gauge: bar graph indicator Engine coolant temperature gauge: bar graph indicator Hydraulic oil temperature gauge: bar graph indicator Hour meter: digital type Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm Over heat* Battery charge* Faulty electrical system* Refill fuel*

Engine oil pressure*

Refill coolant*

Engine preheat

Auto warm-up

Air cleaner

Idling

Service interval

Digging power up

Lighting Working light

House:

24V, 70W (x1)

Boom:

24V, 70W (x1)

Cab:

24V, 70W (x2)

Interior light

24V, 10W (x1)

Horn: electric horn (x2) Other: Wiper with intermittent function. Window washer fluid. Air conditioner. Rear view mirror (left and right side). DC-DC converter.

Lep SC4601002-0EN

Issued 03-07

1002-14

Hydraulic system Hydraulic pump drive system, directly coupled to the engine (no transmission) Main pump Manufacturer............................................................................................................................................... Kawasaki Pump type .............................................................................................. double variable displacement piston pump Displacement volume ................................................................................................. 182 cm3 (11.11 cu in) x 2 /rev Rated operating pressure .......................................................................................................... 31.4 MPa (4554 psi) Maximum operating pressure .................................................................................................... 34.3 MPa (4975 psi) Input revolution speed......................................................................................................1980 min-1 (at 1980 rpm-1) Maximum discharge flow .................................................. 360 L/min (95.10 gpm) x 2 at 1980 min-1 (at 1980 rpm-1) Input horsepower ........................................................................................................................................ 221.6 kW Shaft input horsepower ................................................................................224.7 kW at 1980 min-1 (at 1980 rpm-1) Shaft input torque .............................................................................................. 1072.8 Nm (791 lb-ft) at 1980 min-1 Pilot pump Pump type ............................................................................................................................................... Gear pump Displacement volume ............................................................................................................ 15 cm3 (0.91 cu in)/rev Operating pressure ........................................................................................................................ 3.9 MPa (566 psi) Maximum flow ....................................................................... 29.7 L/min (7.84 gpm) (at 1980 min-1) (at 1980 rpm-1) Input horsepower ............................................................................................................................................ 3.1 kW Control characteristics Simultaneous output control of overall. Negative control. Electric horse power control. Control Valve Model; 4-spool section: integrated (1) or 5-spool section: integrated (1) Operation method: hydraulic pilot method: travel, swing and operating machine Maximum flow .......................................................................................................................... 360 L / min (95.10 gpm) Main relief set pressure.......................................................standard; 31.4 MPa (4554 psi) (at 340 L/min (89.81 gpm)) ...................................................................................... power boost; 34.3 MPa (4975 psi) (at 315 L/min (83.21 gpm)) Overload set pressure.............................................. when boom down; 24.5 MPa (3553 psi) (at 20 L/min (5.28 gpm)) ..................................................................................................... other: 36.3 MPa (5265 psi) (at 20 L/min (5.28 gpm)) Foot relief set pressure ......................................................................3.38 MPa (490.22 psi) (at 61 L/min (16.11 gpm)) Functions Straight travel circuit Boom up / 2-speed internal confluence for arm Boom/Arm load holding circuit Boom down regenerative circuit Arm in forced regenerative circuit Boom up override variable throttle valve Swing priority variable throttle valve Backup 2-speed confluence Hydraulic Cylinders Boom cylinder (x2) Cylinder bore .............................................................................................................................Ø170 mm (Ø6.69 in) Rod diametre .............................................................................................................................Ø115 mm (Ø4.52 in) Maximum retracted length .......................................................................................................... 2230 mm (87.79 in) Stroke ......................................................................................................................................... 1550 mm (61.02 in) Arm (dipper) cylinder Cylinder bore .............................................................................................................................Ø200 mm (Ø7.87 in) Rod diametre .............................................................................................................................Ø140 mm (Ø5.51 in) Maximum retracted length ........................................................................................................ 2588 mm (101.88 in) Stroke ......................................................................................................................................... 1820 mm (71.65 in) Bucket cylinder Cylinder bore .............................................................................................................................Ø165 mm (Ø6.49 in) Rod diametre .............................................................................................................................Ø115 mm (Ø4.52 in) Maximum retracted length .......................................................................................................... 1972 mm (77.63 in) Stroke ......................................................................................................................................... 1285 mm (50.59 in) Lep SC4601002-0EN

Issued 03-07

1002-15 Rotating Joint Operating pressure High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi) Drain port (T) ................................................................................................................................. 1.0 MPa (145 psi) Pilot port (P) .................................................................................................................................. 3.9 MPa (566 psi) Hydrostatic test pressure High pressure passage (ABCD) ................................................................................................ 51.5 MPa (7469 psi) Drain port (T) ................................................................................................................................. 2.0 MPa (290 psi) Pilot port (P) .................................................................................................................................. 5.9 MPa (856 psi) Flow High pressure passage (ABCD) .......................................................................................... 360 L / min (95.10 gpm) Drain port (T) ......................................................................................................................... 40 L / min (10.56 gpm) Pilot port (P) ............................................................................................................................ 31 L / min (8.18 gpm) Number of revolutions...................................................................................................................... 15 min-1 (15 rpm-1) Torque; when pressurizing 2 ports..................................................................................................196 Nm (144.5 lb-ft) Port A; forward right ...................................................................................................................................................G1 Port B; forward left .....................................................................................................................................................G1 Port C; backward right ...............................................................................................................................................G1 Port D; backward left..................................................................................................................................................G1 Port E; drain port ....................................................................................................................................................G1/2 Port F; pilot port ..................................................................................................................................................... G1/4 Solenoid Valve Valve specifications Maximum flow...................................................................... P -> B: 20 L/min (5.28 gpm) Other: 5 L/min (1.32 gpm) Rated pressure ......................................................................................................................... 4.5 MPa (652.67 psi) Solenoid specifications Operating voltage ................................................................................................................................ DC 20 to 32 V Power consumption .................................................................................................................................. 17 W max. Hand control valve Manufacturer................................................................................................................................................... Kawasaki Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.06 to 419.15 psi) Operating angle Ports 1, 3 .............................................................................................................................................................. 19° Ports 2, 4 .............................................................................................................................................................. 25° Operating torque Port 1 ...................................................................................................................0.58 to 2.03 Nm (0.42 to 1.49 lb-ft) Port 3 ...................................................................................................................0.47 to 1.92 Nm (0.34 to 1.41 lb-ft) Ports 2, 4 .............................................................................................................0.71.to 2.30 Nm (0.52 to 1.69 lb-ft) Foot control valve Manufacturer................................................................................................................................................... Kawasaki Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.06 to 419.15 psi) Operating angle ..................................................................................................................................................... 12.4° Operating torque Valve................................................................................................................. 4.16 to 9.03 Nm (3.068 to 6.660 psi) Damper.........................................................................................4.90 Nm (at 0.0275 m/s) (3.614 psi (at 0.090 f/s))

Lep SC4601002-0EN

Issued 03-07

1002-16

Swing unit

Swing circle ......................................................................................................... Swing bearing type (with internal gears) Swing parking brake ................................................................................ Mechanical lock (operational lever linkage type) Swing lock .............................................................................................. Mechanical lock (swing lock switch linkage type) Swing hydraulic motor .....................................................................................................Fixed displacement piston motor Displacement ......................................................................................................................... 250 cm3 (15.26 cu in)/rev Operating pressure ........................................................................................................................ 29.4 MPa (4264 psi) Operating flow ............................................................................................................................. 360 L/min(95.10 gpm) Mechanical brake torque.....................................................................................................1288 Nm (949.97 lb-ft) min. Brake off pressure................................................................................................................ 2.9 MPa (420.60 psi) max. Relief valve set pressure....................................................................................................... 29.3 MPa (4249 psi) max. Reduction gear .................................................................................................. Planetary gear 2-stage reduction System Reduction ratio ........................................................................................................................................................ 27.143

Travel lower body

Travel hydraulic motor (x2) ......... Variable displacement piston motor, automatic 2-speed switch-over with parking brake Displacement .............................................................................................. 290.7/170.1 cm3 (17.74/10.38 cu in)/rev Operating pressure .................................................................................................................... 34.3 MPa (5192 psi) Operating flow..................................................................................................................... 360.4 L/min (95.20 gpm) Brake torque................................................................................ 71 KNm (52366 Ib-ft) min. (including reduction gear) Relief valve set pressure ............................................35.8 to 38.8 MPa (at 50L/min) (5192 to 5627 psi (at 13.20 gpm) Automatic 2-speed switch-over pressure ....................................................................................... 26.5 MPa (3843 psi) Reduction gear ...................................................................................................Planetary gear 3-stage reduction system Reduction ratio .................................................................................................................................................... 60.652 Travel brake .................................................................................................................................................. Hydraulic lock Parking brake ................................................................................................... Mechanical lock (travel lever linkage type) Track shoe Model ....................................................................................................................... Assembly-type triple grouser shoe Number of shoes (per side)........................................................................................................................................ 50 Shoe width Standard ....................................................................................................................................... 600 mm (23.62 in) Optional ....................................................................................................................................... 750 mm (29.52 in) Grouser height ...................................................................................................................................... 36 mm (1.41 in) Link pitch .......................................................................................................................................... 228.6 mm (8.99 in) Roller Number of upper rollers (per side) ............................................................................................................................... 2 Number of lower rollers (per side)................................................................................................................................ 9 Track belt tension adjuster............................................................................... Grease cylinder type (with cushion spring)

Lep SC4601002-0EN

Issued 03-07

1002-17

Work Unit

Model ................................................................................................................................................. Backhoe attachment Capacity / dimensions / working dimensions Bucket width.................................................................................................... 1400 mm (55.11 in) (without side cutter) Width of bucket with side cutter ....................................................................................................... 1510 mm (5944 in) Weight of bucket with side cutter ......................................................................................................1830 kg (4034 lbs) Boom 6980 mm (274.80 in)

Arm (dipper) length

Standard arm

Short arm

3380 mm (133.07 in)

2530 mm (99.60 in) 1840 mm 72.44 in

Bucket radius Bucket wrist angle

176Â°

Maximum digging radius

12000 mm 472.43 in

11230 mm 442.12 in

Maximum digging radius at ground line

11770 mm 463.38 in

10990 mm 432.67 in

Maximum digging depth

7720 mm 303.93 in

6870 mm 270.47 in

Maximum vertical straight wall digging depth

6570 mm 258.66 in

5670 mm 223.22 in

Maximum reach height

11140 mm 438.58 in

10820 mm 425.98 in

Maximum dump height

7740 mm 304.72 in

7420 mm 292.12 in

Minimum swing radius at front

4990 mm 196.45 in

5140 mm 202.36 in

Overall height with minimum swing radius at front

9250 mm 364.17 in

9320 mm 366.92 in

Lep SC4601002-0EN

Issued 03-07

1002-18

Digging force (ISO 6015) Arm (dipper) 3380 mm (133.07 in)

2530 mm (99.60 in)

Bucket digging force (standard)

247 kN (55527.8 lbf)

Bucket digging force (power boost)

270 kN (60698.4 lbf)

270 KN (60698.4 lbf)

209 kN (46985 lbf)

257 kN (57775.9 lbf)

229 kN (51481.2 lbf)

281 kN (63171.3 lbf)

Arm (dipper) digging force (standard) Arm (dipper) digging force (power boost)

Lep SC4601002-0EN

Issued 03-07

1002-19

COMPONENT WEIGHT Major component weight B

A C

G H

330.3.01.00.51A

Weight information is approximate A) Operating weight .................................................................................................................... 46600 kg (102735 lbs) B) Upper mechanism (including counterweight and turntable bearing) ........................................ 19700 kg (43431 lbs) C) Counterweight............................................................................................................................ 9200 kg (20282 lbs) D) Lower mechanism (with standard grouser shoe) .....................................................................16700 kg (36817 lbs) E) Main Unit Weighty ....................................................................................................................36400 kg (80248 lbs) F) Attachments .............................................................................................................................10000 kg (22046 lbs) G) Boom (including cylinders)......................................................................................................... 5540 kg (12213 lbs) H) Arm (dipper) (including cylinders and linkage).............................................................................2670 kg (5886 lbs)

Lep SC4601002-0EN

Issued 03-07

1002-20

Bucket weight Bucket capacity (m3)

Weight kg (lbs)

L1 mm (in)

L2 mm (in)

1.8

1430 (3153)

1384 (54.48)

1515 (59.64)

1.8 HD

1810 (3990)

1400 (55.11)

1508 (59.36)

2.0

1500 (3307)

1514 (59.60)

1645 (64.76)

2.0 HD

1910 (4211)

1530 (60.23)

1638 (64.48)

2.2

1510 (3329)

1825 (71.85)

1956 (77.00)

L1 L2

330.3.01.00.51BA

Lep SC4601002-0EN

Issued 03-07

1002-21

Other component weight Engine .....................................................................................................................................................840 kg (1852 lbs) Air cleaner ...............................................................................................................................................17.6 kg (38.8 lbs) Hydraulic pump ......................................................................................................................................... 245 kg (540 lbs) Attachment control valve ........................................................................................................................... 424 kg (935 lbs) Swing motor (excluding pinion) ...............................................................................................................565 kg (1245 lbs) Travel motor and reduction gear assembly .............................................................................................613 kg (1351 lbs) Rotary joint..................................................................................................................................................56 kg (123 lbs) Solenoid valve bank .................................................................................................................................. 7.0 kg (15.4 lbs) Hand control valve ......................................................................................................................................1.9 kg (4.2 lbs) Foot control valve ...................................................................................................................................... 7.8 kg (17.2 lbs) Standard boom......................................................................................................................................3540 kg (7804 lbs) Standard arm (dipper)...........................................................................................................................1690 kg (3726 lbs) Short arm (dipper).................................................................................................................................1490 kg (3285 lbs) Boom cylinder (one) .................................................................................................................................. 400 kg (882 lbs) Arm (dipper) cylinder...............................................................................................................................695 kg (1532 lbs) Bucket cylinder .......................................................................................................................................... 390 kg (860 lbs) Fuel tank ................................................................................................................................................... 243 kg (536 lbs) Hydraulic oil tank....................................................................................................................................... 229 kg (505 lbs) Turntable bearing ....................................................................................................................................656 kg (1446 lbs) Muffler ........................................................................................................................................................... 20 kg (44 lbs) Radiator total weight ................................................................................................................................. 208 kg (458 lbs) Oil cooler................................................................................................................................................... 34 kg (75 lbs) Radiator ..............................................................................................................................................23.3 kg (51.3 lbs) Air cooler................................................................................................................................................ 28.8 kg (63 lbs) Fuel cooler ............................................................................................................................................ 1.2 kg (2.64 lbs) Idler wheel................................................................................................................................................. 251 kg (553 lbs) Upper roller ................................................................................................................................................... 44 kg (97 lbs) Lower roller .................................................................................................................................................82 kg (181 lbs) Recoil spring ............................................................................................................................................. 343 kg (756 lbs) Recoil spring ...................................................................................................................................... 141 kg (310.8 lbs) Grease cylinder assembly ................................................................................................................ 62.3 kg (137.3 lbs) Threaded ..........................................................................................................................................68.8 kg (151.6 lbs) Yoke ..................................................................................................................................................66.8 kg (147.2 lbs) Track chains (per side) 600 mm (23.62 in).............................................................................................................................2580 kg (5688 lbs) 750 mm (29.52 in).............................................................................................................................2930 kg (6459 lbs)

Lep SC4601002-0EN

Issued 03-07

1002-22

DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY Sprocket Dimensions P

Øb

Ød

Øc

800.6.10.00.11A1

Dimension

Mark a Øb Øc Ød e P

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

90 78 773.6 761.6 867.5 854.5 847.3 43.5 48.5 229 -

3.54 3.07 30.45 29.98 34.15 33.64 33.35 1.71 1.90 9.01 -

Gauge

Unit in mm

300 228.6 44.8 5.4

3.1

117.8

99.6

37.9

R 3∼ 6

R 95 .6 R 36 .9

R 50 .7

24.5

90°

° 40.2

87.6

7 23. R4 .8 33 R4 CI01N501

Lep SC4601002-0EN

Issued 03-07

1002-23

Idler wheel Dimensions c

Dimension mm in

Mark Standard Limit Standard b Limit Standard c Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit Standard e (bushing) Limit Standard f Limit

676 665 22.5 102 92 95 94 95 96 100 99 15 -

Øa

e d

26.61 26.18 0.88 1.00 4.01 3.62 3.74 3.70 3.74 3.77 3.93 3.89 0.59 -

330.6.10.00.12B

Gauge

Unit in mm

250 204 102

42.5 22.5 15

R50

° 10

0.2

CI01N502

Lep SC4601002-0EN

Issued 03-07

1002-24

Upper roller Dimensions b

Dimension mm in

Mark Standard Limit Standard b Limit Standard c Limit Standard Ø d shaft Limit Standard Ø d bushing Limit Standard e bushing Limit Standard f Limit Standard g Limit

150 140 15 104 65 64 65 66 150 149 9 8.5 30 -

Øa

000.6.10.00.8C

5.90 5.51 0.59 4.09 2.55 2.51 2.55 2.59 5.90 5.86 0.35 0.33 1.18 -

Gauge

Unit in mm

210

104 97

° .1 13

125

120 245

CI01N503

Lep SC4601002-0EN

Issued 03-07

1002-25

Lower roller Dimensions d

000.6.10.00.08D

Dimension mm in

Mark Øa b d Ø e (Shaft)

Standard Limit Standard Limit Standard Limit Standard Limit

200 188 25 20 223 233 85 84

7.87 7.40 0.98 0.78 8.77 9.17 3.34 3.30

Dimension mm in

Mark Ø e (bushing) Øf g

Standard Limit Standard Limit Standard Limit

85 86 93 92 24.5 23.9

3.34 3.38 3.66 3.62 0.96 0.94

Gauge

Unit in mm

KTA1107X-C02

Lep SC4601002-0EN

Issued 03-07

1002-26

Track

c’

c d

d’

e’

f’ (4 pieces)

b a 800-6-10-00-11E-1

Mark Standard Limit Standard b Limit Standard Ø c (bushing) Limit Standard Ø d (bushing) Limit Standard Ø e (Pin) Limit Standard f Limit

Lep SC4601002-0EN

Dimension mm in 52 32 129 121 73.33 68.23 49.2 51.7 48.6 45.1 228.6 -

2.04 1.25 5.07 4.76 2.88 2.68 1.93 2.03 1.91 1.77 8.99 -

Mark Standard Limit Standard Ø d’ (bushing) Limit Standard Ø e’ (Pin) Limit Standard f’ (4 pieces) Limit

Ø c’ (bushing)

Dimension mm in 73.33 68.23 49.2 51.7 48.8 44.9 914.4 -

2.88 2.68 1.93 2.03 1.92 1.76 35.99 -

Issued 03-07

1002-27

DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS 4 7

6 1

10 3 5 2 8

CRIL06C002F

1. Boom foot/Frame a b

330.6.10.00.12C1

Dimension mm in

Mark a (frame) b (boom) c (clearance) Ø d (shaft) Ø e (bushing)

Lep SC4601002-0EN

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

874 34.40 882 34.72 871 34.29 868 34.17 3.5 to 5.5 0.13 to 0.21 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

Issued 03-07

1002-28

2. Boom cylinder foot/Frame a b

330.6.10.00.1.12C2

Dimension mm in

Mark a (boom) b (cylinder) c (clearance) Ø d (shaft) Ø e (bushing)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

126 4.96 132 5.19 125 4.92 122 4.80 1.5 to 3.5 0.05 to 0.13 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

3. Boom cylinder head/Boom c

330.6.10.00.12D1

Mark a (boom) a (cylinder) c (clearance) Ø d (shaft) Ø d (bushing)

Lep SC4601002-0EN

mm Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

Dimension

140 5.51 137 5.39 679 26.73 675 26.57 1.5 to 3.0 0.05 to 0.11 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

Issued 03-07

1002-29

4. Arm cylinder foot/Boom a

Mark

Standard Limit Standard b (cylinder) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

a (boom)

Dimension mm in 156 6.14 162 6.37 155 6.10 153 6.02 1.0 to 3.0 0.03 to 0.11 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

330.6.10.00.12D2

5. Boom/Arm g

a b

Mark

330.6.10.00.12E1

Standard Limit Standard b (arm) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit Standard g Limit

a (boom)

Dimension mm in 437 17.20 440 17.32 432.7 17.03 429.7 16.91 4.5 to 5.5 0.17 to 0.21 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78 98 3.85 96 3.77

6. Arm cylinder head/Arm a b

Mark Standard Limit Standard b (cylinder) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

a (arm)

Dimension mm in 156 6.14 161 6.33 155 6.10 153 6.02 1.0 to 3.0 0.039 to 0.11 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

330.6.10.00.12F1

Lep SC4601002-0EN

Issued 03-07

1002-30

7. Bucket cylinder foot/Arm a

Mark

Standard Limit Standard b (cylinder) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

a (arm)

c d

330.6.10.00.12F2

Dimension mm in 141 5.55 146 5.74 140 5.51 138 5.43 1.0 to 3.0 0.039 to 0.11 Shim adjustment 110 4.33 109 4.29 110 4.33 111.5 4.38

8. Connecting rod/Arm c

Mark

Standard Limit Standard b Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

e a d

Dimension mm in 50 1.96 47 1.85 441 17.36 437 17.20 1.5 to 2.0 0.059 to 0.078 Shim adjustment 95 3.74 94 3.70 95 3.74 96.5 3.79

330.6.10.00.12G1

9. Compensator/Bucket c

Mark Standard Limit Standard b (link) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

a (bucket)

b a e

Dimension mm in 480 18.89 485 19.09 479 18.85 476 18.74 1.5 to 3.5 0.059 to 0.13 Shim adjustment 100 3.93 99 3.89 100 3.93 101.5 3.99

330.6.10.00.12G2

Lep SC4601002-0EN

Issued 03-07

1002-31

10. Connecting rod/Compensator/Bucket cylinder head c

Mark

f d e

Standard Limit Standard b Limit Standard c (clearance) Limit Standard d (link) Limit Standard e (cylinder) Limit Standard f (clearance) Limit Standard Ø g (shaft) Limit Standard Ø h (bushing) Limit Standard Ø i (bushing) Limit

h a g 330.6.10.00.12H1

Dimension mm in 50 1.96 48 1.88 441 17.36 436 17.16 1.5 to 2.5 0.059 to 0.098 Shim adjustment 141 5.55 143 5.62 140 5.51 138 5.43 1.5 to 2.0 0.059 to 0.078 Shim adjustment 110 4.33 109 4.29 110 4.33 111.5 4.38 110 4.33 111.5 4.38

11. Arm/Bucket c d

Mark

g f

a b

e 330.6.10.00.12I1

Lep SC4601002-0EN

Standard Limit Standard b (arm) Limit Standard c (clearance) Limit Standard d Limit Standard Ø e (shaft) Limit Standard Ø f (bushing) Limit Standard Ø g (bushing) Limit

a (bucket)

Dimension mm in 480 18.89 479 18.85 476 18.74 1.5 to 4.0 0.059 to 0.15 Shim adjustment 16 0.62 10 0.39 100 3.93 99 3.89 100 3.93 101.5 3.99 100 3.93 101.5 3.99

Issued 03-07

1002-32

SHIMS FOR ADJUSTING ATTACHMENT GAPS For boom foot

R O.D I.D

000-6-10-02-02A

Part No.

I.D.

O.D.

Shim Thickness

Material

KNV1132

160

100

1.2

SPHC

KRV2390

190

115

1.2

SPHC

KBV1441

101

220

130

1.2

SPHC

KBV1748

101

230

135

1.2

SPHC

KSV1805

111

240

140

1.2

SPHC

R O.D

I.D

000-6-10-02-02B

Part No.

I.D.

O.D.

Shim Thickness

Material

KSV1930

111

240

140

1.0

Urethone

KSV11380

111

240

140

2.0

Urethone

KSV1931

116

240

140

1.0

Urethone

KSV11390

116

240

140

2.0

Urethone

KTV10730

121

245

150

2.0

Urethone

KTV10740

121

245

150

1.0

Urethone

KTV10750

121

260

150

2.0

Urethone

KTV10760

121

260

150

1.0

Urethone

KWV0097

141

280

160

1.0

Urethone

KWV10510

141

280

160

2.0

Urethone

KWV0096

141

300

180

1.0

Urethone

KWV10500

141

300

180

2.0

Urethone

KUV10150

141

300

170

1.0

Urethone

KUV10160

141

300

170

2.0

Urethone

KUV10130

151

300

170

1.0

Urethone

KUV10140

151

300

170

2.0

Urethone

Lep SC4601002-0EN

Issued 03-07

1002-33

SPECIAL TORQUE SETTINGS No.

Component

Screw

Wrench (mm)

M24

Torque setting

Travel motor and reduction gear assembly

Drive sprocket

M24

900-1052 Nm (664-776 lb-ft)

Take-up Roller

M16

267-312 Nm (197-230 lb-ft)

Upper roller

M24

521-608 Nm (385-448 lb-ft)

Lower roller

M24

902-1049 Nm (665-774 lb-ft)

900-1052 Nm (664-776 lb-ft)

Track guard

M24

902-1049 Nm (665-774 lb-ft)

Shoe bolt

M24

1236-1510 Nm (912-1114 lb-ft)

Counterweight

M30

1765-2010 Nm (1302-1482 lb-ft)

Turntable bearing

M24

952-1050 Nm (702-774 lb-ft)

10 *

Swing equipement

11 * 12 *

Engine

13 * 14 *

M24

900-1050 Nm (664-774 lb-ft)

Mount

M20

324-373 Nm (239-275 lb-ft)

Front bracket

M10

64-73 Nm (47-54 lb-ft)

Rear bracket

M16

147-176 Nm (108-130 lb-ft)

Radiator

M16

147-176 Nm (108-130 lb-ft)

Frange

M12

88-108 Nm (65-79 lb-ft)

Pump

M20

367-496 Nm (271-366 lb-ft)

15 * 16 *

Hydraulic pump

17 *

Hydraulic reservoir

M16

226-265 Nm (167-195 lb-ft)

18 *

Fuel reservoir

M16

226-265 Nm (167-195 lb-ft)

19 *

Control valve

M20

333-392 Nm (245-289 lb-ft)

Lock bar

M16

267-312 Nm (197-230 lb-ft)

Joint

M12

54-64 Nm (40-47 lb-ft)

20 * 21 * 22 23 * 24

Rotating joint Cab Battery

Floor

M16

78-80 Nm (57-59 lb-ft)

Mount

M10

35-42 Nm (26-31 lb-ft)

M10

20-29 Nm (15-21 lb-ft)

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

Lep SC4601002-0EN

Issued 03-07

1002-34

17 18

15, 16

11, 12, 13 8

14 24 20, 21

7 1, 2 9

22, 23

7 4 3

TORQUE_1

Lep SC4601002-0EN

Issued 03-07

1002-35

17 20

TORQUE_2

Lep SC4601002-0EN

Issued 03-07

1002-36

MACHINE OVERALL DIMENSIONS NOTE: Numbers are subject to change without notice due to design change or other reasons. The figures give values that include the shoe lug height (36 mm (1.41 in))

Standard arm (3380 mm (133.07 in)) * : with catwalks - (option)

* BKTU6001_338M

Short arm (2530 mm (99.60 in)) * : with catwalks - (option)

* BKTU6001_253M

Lep SC4601002-0EN

Issued 03-07

2001 FUEL-COOLER, ENGINE INTER-COOLER, RADIATOR AND OIL-COOLER

CNH

Lep SM4602001-0EN

2001

Section

2001-2

TABLE OF CONTENTS SPECIFICATIONS ..... .................................................................................................................................................... 2 RADIATOR, OIL-COOLER, INTER COOLER AND FUEL COOLER ............................................................................. 3 Removal . .................................................................................................................................................................... 3 Installation . ................................................................................................................................................................. 3 ENGINE .......................................................................................................................................................................... 4 Removal . .................................................................................................................................................................... 4 Installation . ................................................................................................................................................................. 4 ENGINE AND RADIATOR - FIGURE 1 .......................................................................................................................... 6

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 See Section 1002

Lep SM4602001-0EN

Issued 09-07

2001-3

RADIATOR, OIL-COOLER, INTER COOLER AND FUEL 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 Operator’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.

Removal

Installation

NOTE: For the removal refer to the figure 1, page 6.

NOTE: For the installation refer to the figure 1, page 6, proceed in the reverse order from that of removal.

STEP 1 Drain the cooling system (see Operator’s Manual).

STEP 2 Release pressure in the hydraulic reservoir to allow the vacuum pump to be mounted (see Section 8000).

1) Coat the thread of reference (37) and (13) with loctite or equivalent after removing any oil film and fasten by tightening torque . 2) Apply packing liquid (69) to the connection of radiator hose after removing any oil film and fasten by tightening torque. 3) Tighten up the hose band from the direction schown on the D.W.G. Before operating the machine: - Check the oil level in the hydraulic reservoir. Top up if necessary. - Check the hydraulic fluid cooling circuit for leaks. - Fill and bleed the engine cooling system (see Operator’s Manual). - Check the engine cooling system for leaks.

Lep SM4602001-0EN

Issued 09-07

2001-4

ENGINE Removal

STEP 7

NOTE: For the removal refer to the figure 1, page 6.

Remove the engine retaining hardware.

STEP 1

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.

STEP 8 When there is n othing int erfering wit h t he re moval o f the engine, raise the engine carefully and install it on a suitable repair bench.

STEP 9 Refer to Section 8003 and remove the hydraulic pump.

Installation JS00163A

Park t he ma chine on h ard, fl at g round. Lower t he attachment to the ground.

STEP 2 Release p ressure in th e h ydraulic sy stem an d in th e hydraulic reservoir (see Section 8000).

STEP 3

NOTE: For the installation refer to the figure 1, page 6, proceed in the reverse order from that of removal. 1) Coat the thread of reference (11), (35), (37), (41), (43) and (49) with loctite or equivalent after removing any oil film and fasten by tightening torque . 2) The elastic rubbers of reference (46) and (74) should be assembled after confirming the discrimination color. Before operating t he machin e, carr y out the f ollowing operations: - Bleed and prime th e f uel sy stem (s ee O peratorâ&#x20AC;&#x2122;s Manual). - Fill and bleed the engine cooling system (see Operatorâ&#x20AC;&#x2122;s Manual). - Check t he h ydraulic, fu el a nd coo ling syste ms f or leaks. - Check the oil level in the hydraulic reservoir. Top up if necessary.

CT07A009

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

STEP 4 Label and disconnect all the electrical connections from the engine.

STEP 5 NOTE: For the removal refer to the figure 1, page 6. Remove all the clips, etc. which at tach th e electrical harnesses to the engine and move out of the way.

STEP 6 Install a suitable lifting device on the engine lifting rings (for the weight of the engine, see Section 1002).

Lep SM4602001-0EN

Issued 09-07

2001-6

ENGINE AND RADIATOR - FIGURE 1

330-5-02-02-24

Lep SM4602001-0EN

Issued 09-07

2001-7 1 - SPL BOLT 2 - BUCKET 3 - ELBOW 4 - HYDRAULIC HOSE 5 - HYDRAULIC HOSE 6 - ELBOW 7 - GEAR PUMP 8 - HIGH STRENGTH BOLT 9 - HIGH STRENGTH WASHER 10 - BRACKET; MUFFLER 11 - HIGH STRENGTH BOLT 12 - HIGH STRENGTH WASHER 13 - BOND 14 - NUT; FLANGED 15 - BOLT; U 16 - MUFFLER 20 - SEAL CLAMP 22 - EXHAUST PIPE 24 - PLUG 25 - HOSE ADAPTER 26 - HOSE CLAMP 27 - AIR HOSE 28 - HOSE CLAMP 30 - BRACKET 31 - AIR-INLET PIPE 32 - BRACKET 33 - AIR HOSE 34 - AIR-INLET PIPE 35 - HIGH STRENGTH BOLT 36 - HIGH STRENGTH WASHER 37 - SEMS BOLT 38 - RADIATOR STAY 39 - HOSE BAND 40 - TUBE 41 - SEMS BOLT 42 - ENGINE SUPPORT REAR 43 - HIGH STRENGTH BOLT 44 - HIGH STRENGTH WASHER 45 - PLATE 46 - ELASTIC RUBBER 47 - SPL NUT 48 - SEMS BOLT 49 - ENGINE SUPPORT REAR 50 - HOSE BAND 51 - VINYL HOSE 52 - HOLDER 53 - SEMS BOLT 54 - RESERVE TANK 55 - BRACKET 56 - VACUUM SENSOR

Lep SM4602001-0EN

57 - ELBOW 58 - SPL JOINT 59 - HIGH STRENGTH NUT 60 - RUBBER HOSE 61 - ELBOW 62 - JUBILEE CLIP 63 - JUBILEE CLIP 64 - AIR-INLET HOSE 65 - ELBOW 66 - CLAMP 67 - SPL BOLT 68 - HOSE CLAMP 69 - LIQUID PACKING 70 - RADIATOR HOSE 71 - CLAMP 72 - BRACKET 73 - ENGINE SUPPORT FRONT 74 - ELASTIC RUBBER 75 - HYDRAULIC HOSE 76 - HYDRAULIC HOSE 77 - HYDRAULIC HOSE 78 - ENGINE SUPPORT FRONT 79 - BRACKET 80 - HOSE BAND 81 - BRACKET 82 - RADIATOR (STD) ASSY 83 - SPL LABEL 84 - AIR CLEANER 85 - AIR HOSE 86 - HARNESS BAND 87 - JUBILEE CLIP 88 - CLAMP 89 - ELBOW 90 - DIESEL ENGINE 91 - BRACKET 92 - HIGH STRENGTH BOLT 93 - HOSE CLAMP 94 - AIR HOSE 95 - HOSE CLAMP 96 - RADIATOR HOSE (IN) 97 - AIR-INLET PIPE 98 - RADIATOR STAY REAR 99 - HIGH STRENGTH BOLT 100 - HIGH STRENGTH BOLT 102 - BRACKET 103 - HOSE CLAMP 104 - CLAMP 105 - LIQUID PACKING 106 - BRACKET 107 - SEMS BOLT 108 - ENGINE; DIESEL 109 - SEMS BOLT 110 - HOSE CLAMP 111 - HIGH STRENGTH BOLT

Issued 09-07

2001-8

NOTES ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ........................................................................................................................................................................................... ...........................................................................................................................................................................................

Lep SM4602001-0EN

Issued 09-07

3001 REMOVAL AND INSTALLATION OF THE FUEL TANK

CNH

Lep SM4603001-0EN

3001

Section

3001-2

SPECIFICATIONS See Section 1002.

Lep SM4603001-0EN

Issued 09-07

3001-3

FUEL TANK Removal STEP 1

STEP 9 Remove the screws (8) and the protective plate (9).

STEP 10 Remove th e sc rews ( 21) a nd t he protective plate (22).

STEP 11 Loosen t he t wo screws ( 10) located un der t he machine. O pen t he side portion o f the machine and remove the two screws (11) located on the RH side of the fuel re servoir (1 ). Remove th e pr otective plate (12) of the reservoir. JS00163A1

Park th e ma chine o n ha rd, f lat g round. L ower th e attachment to the ground.

STEP 2 Reduce the engine speed to idle for 30 seconds, then shut down the engine.

STEP 3 Turn t he ig nition k ey t o "O N" without starting the engine.

STEP 4 Attach a "D O NOT OPERATE" tag to the ignition key in the cab.

STEP 5

STEP 12 Attach labels on th e hose s. Remo ve th e hose s and the retaining clips.

STEP 13 Shift the plast ic p rotection (13) f rom the fu el se nsor (14). Remove the retaining screws (15) then the fuel sensor (14) as well as the seal (16).

STEP 14 Remove the screws (17) and (20) from the fuel tank (1), and the shims (18).

STEP 15 Remove the fuel tank (1) using a hoist.

NOTE: The numbers within brackets refer to the figures on pages 5 and 6. Remove the access panel under the fuel reservoir (1).

STEP 6 Open the filling plug (2) of the tank (1). B leed the remaining fu el using the v alve (3 ) t hen rem ove th e latter. Remove the filter (19) and the fuel gauge.

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 th e sc rews (6) on top an d th en ins ide the front boot, then remove the protective housing (7).

Lep SM4603001-0EN

Issued 09-07

3001-4

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

STEP 1 Using a ho ist, posit ion t he fuel reservoir (1) on th e machine.

STEP 2 Install the shims (18) as well as the screws (17) and (20), tig hten th e scr ews (17) to a to rque o f 22 5.6 to 264.8 Nm (1 66.39 t o 1 95.31 lb f-ft). In stall t he valve (3) and tighten the valve (3) to a to rque of 14.7 Nm (10.80 lbf-ft).

STEP 8 Install t he pr otective ho using (7 ) on top o f the f ront boot using th e screws (6 ) th en put ba ck th e screw mask.

STEP 9 Install th e ac cess r amp (5) usin g screws (4 ). Close the front boot.

STEP 10 Fill the fuel reservoir (see the operator's manual) and make sure that there are no leaks.

STEP 3

STEP 11

Install a new seal (16), then the fuel probe (14) using the five screws (15), reposition the plastic protection correctly (13).

Reinstall the protective plate on top of the machine.

STEP 4 Install the hoses by taking help of the labels attached during removal. Tighten using retaining clips.

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

STEP 6 Install the protective plate (9). Tighten the screws (8).

STEP 7 Install t he p rotective plate (22). T ighten t he scr ews (21).

Lep SM4603001-0EN

Issued 09-07

3001-5

Description Location 6

7 6

21 22

20 4 5 6 7 8 9 10 11 12 20 21 22

SCREW ACCESS RAMP SCREW PROTECTIVE HOUSING SCREW SKID PLATE SCREW SCREW SKID PLATE SCREW SCREW SKID PLATE

Lep SM4603001-0EN

Issued 09-07

3001-6

Fuel tank

2 19

16 15

18 17 3

1 2 3 13 14

FUEL ESERVOIR R PLUG VALVE PLASTIC PROTECTION FUEL PROBE

Lep SM4603001-0EN

15 16 17 18 19

SCREW SEAL SCREW SHIM FILTER

Issued 09-07

4001 ELECTRICAL AND ELECTRONIC CIRCUIT AND TROUBLESHOOTING

CNH

Lep SC4604001-0EN

4001

Section

4001-2

TABLE OF CONTENTS ELECTRIC CIRCUITS OPERATION EXPLANATION ................................................................................................... 4 System Chart of Function .......................................................................................................................................... 4 ENGINE CONTROL ....................................................................................................................................................... 7 Fuel Injection Control (Common rail type) ................................................................................................................. 7 GENERAL LOCATION OF THE COMPONENTS (INSIDE THE CAB)........................................................................ 12 RELAYS AND MAIN FUSES (battery compartment) ................................................................................................... 13 FUSE BOX ................................................................................................................................................................... 14 WORK MODE SELECTION ......................................................................................................................................... 15 THROTTLE CONTROL................................................................................................................................................ 22 IDLING CONTROL (AUTO/ONE-TOUCH)................................................................................................................... 25 BREAKER MODE ........................................................................................................................................................ 27 AUTO PREHEAD (GLOW CONTROL) ........................................................................................................................ 28 AUTO WARM UP ......................................................................................................................................................... 31 OVERHEAT PROTECTION ......................................................................................................................................... 32 ATMOSPHERIC PRESSURE COMPENSATION ........................................................................................................ 33 CONTROL WHEN STARTING ENGINE...................................................................................................................... 34 CONTROL WHEN STOPPING ENGINE ..................................................................................................................... 35 EMERGENCY STOP OF THE ENGINE ...................................................................................................................... 35 ENGINE PROTECTION FUNCTION (EPF) ................................................................................................................. 36 FUNCTION LOCKING.................................................................................................................................................. 38 POWER BOOST .......................................................................................................................................................... 39 SWING BRAKE ............................................................................................................................................................ 40 TRAVEL MODE............................................................................................................................................................ 42 TRAVEL ALARM .......................................................................................................................................................... 43 POWER SHUT-OFF DELAY........................................................................................................................................ 44 CONTROL OF HYDRAULIC DRIVEN FAN ................................................................................................................. 45 FUEL SUPPLY PUMP CONTROL (AUTOMATIC STOP) OPTION............................................................................. 54 POWER TRANSISTOR PROTECTION ....................................................................................................................... 56 MONITOR DISPLAY .................................................................................................................................................... 57 Normal Display ......................................................................................................................................................... 57 Message Display ...................................................................................................................................................... 60 Lep SC4604001-0EN

Issued 03-07

4001-3 ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode) ................................................................. 61 Access to monitor displays .......................................................................................................................................61 Machine condition .....................................................................................................................................................62 Diagnostic code ........................................................................................................................................................65 Machine history .........................................................................................................................................................70 Resetting ...................................................................................................................................................................73 MACHINE INFORMATION ........................................................................................................................................... 77 Setting of machine model .........................................................................................................................................77 Changing the language code ....................................................................................................................................79 Display of engine information ...................................................................................................................................79 Re-setting of engine information ...............................................................................................................................79 Selection of injector ..................................................................................................................................................80 TROUBLESHOOTING .................................................................................................................................................. 83 Prior inspections .......................................................................................................................................................83 Reading the organisation charts ...............................................................................................................................84 Procedures ... ............................................................................................................................................................85 Fuel ...........................................................................................................................................................................86 Add coolant solution .................................................................................................................................................87 Low engine oil pressure ............................................................................................................................................88 Overheating .. ............................................................................................................................................................89 Defective battery charge circuit ................................................................................................................................92 Electrical system troubleshooting .............................................................................................................................94 ELECTRICAL INSPECTION OF COMPONENTS ........................................................................................................ 96 Main pump proportional solenoid ............................................................................................................................100 6 solenoid valve bank .............................................................................................................................................100 Hydraulic oil temperature sensor ............................................................................................................................101 Pressure sensor ......................................................................................................................................................101

Lep SC4604001-0EN

Issued 03-07

4001-4

ELECTRIC CIRCUITS OPERATION EXPLANATION System Chart of Function ITEM

FUNCTION

Engine control

Work mode selection a) H/S/L mode

METHOD Electronic control (common-rail)

Maximum e ngine speed, p ump cu rrent, and pr essurizing so lenoid v alve ar e co nMachine set ting can be selected ac cordtrolled accor ding to t he sele cted work ing to co nditions su ch as of w orkload o r mode. fuel efficiency preference, and lifting operation. b) Auto-mode Suitable w ork mode is automatically selected.

c) Load prefectch control Pump c urrent is k ept at 0 mA while machine is not being operated.

Selection of auto-mode allows the load to be calcula ted with p ressure of n egative control P1 and P2 which in tur n w ork mode is switched. Pump cu rrent a nd en gine co ntroller ar e controlled by signal from pressure switch.

Throttle control

Engine ca n be controlled con tinuously Engine spe ed is adju sted b y cont rol of from idling to high idling speed by opera- throttle valve. tor's instruction.

Idling control

Engine sp eed ca n be

switched to/form Pushing knob of switch on the right allows the engine to run idle and pushing it again to return it as it was.

idling by control of onetouch switch.

It makes engine to r un idle while machine Selection of auto-idle allows the engine to is not being operated. run at idling speed automatically in 5 minutes after he lever is sh ifted to its neutral. Shifting lever ma kes t he engine to r eturn to its normal speed automatically. 5

Breaker mode

Pressing t he b reaker ped al allo ws th e Turning ON the pressure switch in breaker engine t o run at t he set spee d a utomati- pilot line allows the engine to run at prevically and boosting pressure will be cut. ously set speed. Als o, pump c urrent will be set as th at in S- mode a nd b oosting pressure is to be cut.

Auto preheat

It helps the engine to start easily at a low temperature. Als o, it stabiliz es engine speed immediately af ter st art of the engine to reduce exhausting smoke.

Auto warm-up

When coolant temperature is low, it allows In ca se wh ere no op eration of th e the e ngine to st art warming up au tomati- machine after the engine has been started cally after it has been started. is carried out when coolant temperature is low, it automat ically i ncreases engine speed gradually to warm it up.

Overheat protection

When engine coola nt t emperature has When coola nt te mperature g oes o ver been incre ased, r educe inject ion quantity 100Â°C, r educe f uel injection qu antity. to protect engine. Coolant temperature sensor to ECM.

Lep SC4604001-0EN

Depending on co oling w ater t emperature at the time when the key switch is t urned ON, t he g low plug is energized f or a period o f tim e be ing se t. It is to be energized for a ce rtain period of set time after the e ngine h as bee n sta rted t o r educe exhausting smoke.

Issued 03-07

4001-5 ITEM 9

FUNCTION

METHOD

Correction o f a tmos- It prevents black smoke and engine dam- Fuel is to be restricted by an atmospheric pheric pressure age when intake air quantity is decreased sensor when altitude is over 2500 meters. such as operating in highland.

10 Control on engine start

It incr eases f uel injection a ccording t o It monitors coolant temperature when it is coolant t emperature t o imp rove st arting under 0Â°C. It watches a lapse of time after performance.It improves starting perform- cranking has been started. ance whe n suf ficient fu el f ails to be injected due t o wear in t he mach ine a s it has been operated for a long time.

11 Engine stop control

Engine co ntroller (EC M) re cognizes It s tops fuel injec tion from injector .It engine key O FF b y tu rning k ey s witch insructs pressure control valve to opened OFF fully. It makes EGR valve to be fully open.

12 Emergency eng ine Emergency stop s witch is set u p wit h no Signal of emergency stop switch is transstop engine stop by key switch in mind. ferred t o engine c ontroller (ECM) t o perform engine stop control. 13 Engine pr function

otection When the en gine is op erated wit h w ater Water t emperature, b oost t emperature, temperature, boost t emperature, a nd and e ngine oil pr essure ar e supe rvised, engine oil p ressure e xceeded t he le vel and engine is protected respectively specified, it is t o protect b y limitation of the engine output or by stopping the engine

14 Lever lock

It allo ws t he ma chine no t t o be operated by control of levers while cab is being moved Up/Down or when the machine will not be needed for operation.

15 Auto boost control

Boost control

When the lever is raised by control of the gate le ver on th e le ft co nsole, the le ver lock solenoid turns OFF which in turn pilot pressure is cut off.

Whether boo st of pr essure is ne eded o r not is judged by the input data on load facIt i ncreases main r elief pressure b y tor o f the engine a nd on p ump d ischarge approx. 10%. pressure. (Boosting for 8 seconds.) Boost -cut control It d oes not allow b oosting accor ding t o a certain co ndition t o protect ma chine a nd equipment.

Boosting w ill not f unction when reserve pressure switches are turned OFF.

16 Swing lock

It disab les s wing e ven wh en th e s wing Turning ON the s wing loc k s witch allo ws lever is mistakenly controlled. the swing brake solenoid to be energized to actuate mechanical brake.

17 Swing brake control

When swing lo ck is OF F, in o rder to pr otect s wing de vice, it controls s wing mechanical br ake ON/ OFF automatically according to operating conditions.

It controls swing br ake s olenoid v alve b y the data obtained from switches of swing, attachments, and t ravel p ressure, an d also from pump discharge pressure.

18 Travel sp eed s witch- It allo ws t ravel spee d t o s witch t o eit her It controls solenoid valve by th e tr avel ing-over one of 2 levels. mode s witch to s witch o ver tilt angle of swash plate in the traction motor. 19 Travel alarm

Alarm buzzer functions when traveling.

Travel pressure buzzer.

switch

controls

the

20 Power shut-off delay This ensures power supply for engine stop It allows a time-lag until main relay shuts function. off after key switch has been turned OFF. 21 Hydraulic dr iven f an It p erforms pr oper coolin g co ntrol while control monitoring coolant temperature by driving cooling f an h ydraulically. With c leaning mode. L ow noise and lo w f uel consumption.

It controls fan motor speed by current output obtained by entering coolant temperature. At tached reversing f unction allows radiator fan to be cleaned.

22 Fuel supp ly p ump It makes an automatic stop when fuel tank Enter sig nal of f uel sensor t o t urn O FF control becomes full on refueling. switch. Lep SC4604001-0EN

Issued 03-07

4001-6 ITEM

FUNCTION

METHOD

23 Power transistor pro- It pr otects con troller in case whe re a cir - Over-current detection shuts off transistor tection cuit connected to transistor output is short- output. circuited. 24 Travel sp eed switch- a) Normal display ing-over It displays current status of the machine. b) Message display Warning. Functioning operation. When to service the machine

Lep SC4604001-0EN

Temperature of hydraulic oil and of coolant temperature, an d f uel le vel ar e disp layed in b ar g raphs on LCD mo nitor and w ork/ travel mode is also displayed. Each information is to be dis played by letters on LCD monitor.

Issued 03-07

4001-7

ENGINE CONTROL Fuel Injection Control (Common rail type) 1. Process to determine quantity of fuel injection 1) System diagram Engine control module (ECM)

CAN communication Basic fuel injection amount

Shovel Controller

Boost pressure sensor input CKP sensor input CMP or G sensor input

Correction Engine coolant temperature correction Barometric Pressure Fuel temperature boost pressure correction Correction between cylinders Q-key correction QR correction

ECT Sensor input

Correction

SCV or PCV opening time determination

Injector coil energizing time Timing determination

Common rail pressure sensor Common rail Injector coil SCV or PCV Injector Supply pump

Fuel tank

Lep SC4604001-0EN

Issued 03-07

4001-8 2) Operation Engine controller (ECM) gets information (signal from mounted sensors) such as engine speed and engine load. Based on the information, ECM sends electric signals to supply pump and to injector to make a proper control of fuel injection quantity and injection timing for each cylinder. 1) Injection quantity control Based mainly on engine speed and load given to actual machine, Injection rate control is carried out for optimum injection by controlling fuel injector. 2) Injection pressure control Injection pressure is controlled by control of fuel pressure in the common-rail. The right pressure in the common-rail is calculated by using engine speed and fuel injection quantity. The supply pump and the pressure control valve are controlled according to the calculated pressure so that it can discharge proper quantity of fuel to pressure-feed into the common-rail for control. 3) Injection timing control The control substitutes timer function and an appropriate fuel injection timing is calculat ed by mainly using engine speed and fuel injection quantity to control the injector. 4) Injection rate control In order to improve fuel consumption in the cylinder, a sm all amount of fuel is inject ed (pre injection) for ignition at first, then 2nd time injection (main injection) into the ignited cylinder is carried out. In this control, the injection quantity control in section 1) and the injection timing control in section 3) are carried out by controlling injector.

Lep SC4604001-0EN

Issued 03-07

4001-9

2. Mounting position of accessories related to engine B3 B50

B49

B51 B47

B48 Engine harness connector

S62

EST connector Tech 2 connector ECM memory clear

A2 B1 B3 B6 B47 B48 B49

Engine controller Coolant temperature sensor Fuel temperature sensor Air intake temperature sensor Boost pressure sensor Atmospheric pressure sensor Crankshaft position sensor (or engine speed sensor (flywheel mounted))

Lep SC4604001-0EN

700.1.04.01.28F

B50 Camshaft po sition sensor (o r G sen sor: cylin der recognition sensor (detects rotation of cam shaft)) B51 Boost temperature sensor M9 Air conditioner condenser fan motor R5 Fuel sensor S62 Air cleaner sensor

Issued 03-07

4001-10

3. Appearances of accessories related to the Tier 3 emission control regulation A2. Engine controller (ECM)

700-1-04-01-23AF

Controller for the engine meeting Tier 3 emission control regulation (hardware is common to the vehicle). Quantity of pin is 121 as against 104 for the engine meeting Tier 2 emission control regulation.

Reliability is equivalent to the unit for current engine meeting Tier 2 emission control regulation (evaluation of single unit has been completed). In area indicated by an arrow, ISUZU part number and TRANSTRON part number, and serial number are recorded.

B1. Coolant temperature sensor

B3. Fuel temperature sensor

700.1.04.01.23AG

1 Power, positive (+) 2 Power, negative (-) 3 For water temperature indicator (not in use)

700.1.04.01.23AI

B6. Intake air temperature sensor

700.1.04.01.23AH

Lep SC4604001-0EN

Issued 03-07

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