Case cx800 crawler excavator service repair manual by 163757

CX800 Crawler Excavators Table of Contents SECTION NÂ°

REFERENCE NÂ°

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

9-44840 9-44850

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

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

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

9-44860 9-36830GB 9-36840GB

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

9-36860GB 9-36880GB 9-36890GB 9-36900GB

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

9-36980GB 9-40350GB 9-36990GB 9-42630GB

UNDERCARRIAGE HYDRAULICS

UPPERSTRUCTURE HYDRAULICS Depressurising and decontaminating the hydraulic system, use of the vacuum pump and bleeding the components ..............................................8000 Specifications, troubleshooting, checks and hydraulic pressure settings ........8001 Hydraulic reservoir removal and installation ....................................................8002 Main and pilot pumps, removal and installation ...............................................8003 Main hydraulic control valve, removal and installation.....................................8004 Attachment cylinders, removal and installation................................................8005 Hydraulic swivel, removal and installation .......................................................8006 Pilot blocs, removal and installation.................................................................8007 Swing motor, removal and installation .............................................................8008 Free swing disassembly and assembly ...........................................................8009 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 Anti-hose burst valves......................................................................................8017 Hydraulic swivel, disassembly and assembly ..................................................8018 Swing motor, disassembly and assembly ........................................................8019 Hydraulic functions...........................................................................................8020

DIVISION/SECTION

9-36800GB 9-42540GB

9-36820GB

9-40270GB 9-44870 9-40280GB 9-40770GB 9-40910GB 9-27791GB 9-40920GB 9-44940 9-40260GB 9-44920 9-42560GB 9-42760GB 9-40940GB 9-40980GB 9-40990GB 9-42520GB 7-27941GB 9-42770GB 9-42510GB 9-42530GB 9-44880

DIVISION/SECTION 9

SECTION NÂ°

REFERENCE NÂ°

UPPERSTRUCTURE Upperstructure, turntable bearing and counterweight......................................9002 Boom, dipper and bucket .................................................................................9003 Seat and seat belt ............................................................................................9004 Cab and cab equipment...................................................................................9005 Air conditioning troubleshooting.......................................................................9006 Air conditioning unit disassembly and assembly..............................................9007 Air conditioning servicing .................................................................................9008 Air conditioning components............................................................................9009 Removal and installation attachment, counterweight and side fram ................9010 Attachment reinforcement procedures.............................................................9012 Large format hydraulic and electrical schematics .........................................Pocket

9-42550GB 9-42620GB 9-40960GB 9-40970GB 7-xxxxxFR 7-29910GB 7-xxxxxFR 7-xxxxxFR 9-44890 9-43940 9-42650

* Consult the Engine Service Manual Sections to be distributed at a later date NOTE: Case Company reserves the right to make changes in the specification and design of the machine without prior notice and without incurring any obligation to modify units previously sold. The description of the models shown in t his manual has been made in accordance wit h t he t echnical specif ications known a s of t he da te of design of this document.

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Edition 05-02

1001 SAFETY, GENERAL INFORMATION AND STANDARD TORQUE DATA

Case

Cre 9-44840

1001

Section

1001-2

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

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1001-3

GENERAL INFORMATION Cleaning

Gears

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

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

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

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

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

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

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

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

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

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1001-4

SAFETY

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

To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual.

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

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

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

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

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

Place a “Do not operate“ tag on the starter switch key before carrying out any service or repair work on the machine. .

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

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

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

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

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

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

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

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

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

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

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

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

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1001-6

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of Cap Screws and Nuts Tighten alternately so that tightening torque can be ap plied evenly. The numbers in the figure below indicate the order of tightening.

JS00481B

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

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

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

Socket Head Cap Screw

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Spanner Tightening torque

0.39

0.51

0.67

0.75

0.87

0.95

1.06

1.18

[mm]

[lb-ft]

5.1

11.6

23.9

43.4

72.5

116.0

144.6

202.4

[Nm]

6.9

15.7

32.5

58.8

98.1

157.2

196.0

274.0

[in.]

0.20

0.24

0.32

0.39

0.47

0.55

0.67

[mm]

[lb-ft]

6.5

15.9

31.1

57.8

86.8

130.1

180.8

253.1

[Nm]

8.8

21.6

42.1

78.4

117.6

176.4

245.0

343.0

[in.]

M10

M12

M14

M16

M18

M20

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1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

Case

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Section

1002-2

TABLE OF CONTENTS TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE ....................................................3 Machine.................................................................................................................................................................3 Engine ................................................................................................................................................................... 3 Serial numbers of the components ....................................................................................................................... 3 INGREDIENTS ..........................................................................................................................................................4 Hydraulic fluid chart .............................................................................................................................................. 4 Transmission assembly oil ................................................................................................................................... 4 Greases ................................................................................................................................................................ 4 Engine oil .............................................................................................................................................................. 5 Viscosity of oils/Operating range of oils ................................................................................................................ 5 Fuel ..... ................................................................................................................................................................. 6 Antifreeze/anticorrosive ........................................................................................................................................ 6 Environment ..... .................................................................................................................................................... 6 Plastic and resin parts .......................................................................................................................................... 6 SPECIFICATIONS..................................................................................................................................................... 7 Engine ................................................................................................................................................................... 7 Capacities ............................................................................................................................................................. 7 Electrical system ................................................................................................................................................... 7 Hydraulic system ................................................................................................................................................... 8 Cylinder .................................................................................................................................................................8 Control valve ......................................................................................................................................................... 9 Swing .................................................................................................................................................................... 9 Travel .................................................................................................................................................................... 9 Undercarriage ....................................................................................................................................................... 9 Attachment ..........................................................................................................................................................10 Weight of components ........................................................................................................................................10 DIMENSIONS AND WEAR LIMIT OF THE TRACK-LAYER ASSEMBLY ..............................................................11 Sprocket ..............................................................................................................................................................11 Idler wheel...........................................................................................................................................................12 Upper roller .........................................................................................................................................................13 Lower roller .........................................................................................................................................................14 Track ...................................................................................................................................................................15 DIMENSIONS AND WEAR LIMITS OF ATTACHMENT MOBILE JOINTS.............................................................16 1. Boom foot/Frame ............................................................................................................................................16 2. Boom cylinder foot/Frame ...............................................................................................................................17 3. Boom cylinder head/Boom ..............................................................................................................................17 4. Dipper cylinder foot/Boom ...............................................................................................................................18 5. Boom/Dipper ...................................................................................................................................................18 6. Dipper cylinder head/Dipper............................................................................................................................18 7. Bucket cylinder foot/Dipper .............................................................................................................................19 8. Connecting rod/Dipper ....................................................................................................................................19 9. Compensator/Bucket.......................................................................................................................................19 10. Connecting rod/Compensator/Bucket cylinder head.....................................................................................20 11. Dipper/Bucket................................................................................................................................................20 SPECIAL TORQUE SETTINGS ..............................................................................................................................21 MACHINE OVERALL DIMENSIONS.......................................................................................................................24

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.

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TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE For a ll p art o rders, r equest for i nformation or assistance, always s pecify the t ype a nd the s erial number of th e 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 3

2 CP98N006

CS00M518

(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 ................................................................................................................................................. Travel control valve...................................................................................................................................................... Attachment control valve ............................................................................................................................................. Swing control valve......................................................................................................................................................

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1002-4

INGREDIENTS The ingredients must correspond to specific characteristics for every usage.

WARNING: You must respect the operating conditions for the different ingredients.

Hydraulic fluid chart NOTE: Use only hydraulic oils meeting Case specifications or equivalent AW (anti-wear) hydraulic oils.

TEMPERATURE FAHRENHEIT

TEMPERATURE CELSIUS

CS02K507

NOTE: Case specification MS1209 Fluid is used in place of ISO VG 32 (-5° to + 65° F) and ISO VG 46 (+10° to + 90° F). NOTE: Case specifications MS1230 Grade NT or Grade LT is used in place of ISO VG 32 (-5° to + 65°F), ISO VG 46 (+10° to + 90°F), ISO VG 100 (+30° to +115°F) and MS1210 TCH

Transmission assembly oil Extreme pressure oi l us ed for transmission assemblies in housing. Extreme pre ssure oil TYPE API GL5 GR ADE 80W9 0 and ISO VG 150

Greases The ty pe of gr ease to be use d dep ends on th e ambient temperature.

Hot and temperate climates -4°F to + 140°F (-20°C to +60°C) Extreme pr essure EP N LGI gr ade 2 g rease wit h molybdenum disulfide.

Cold climates -40°F to +68°F (-40°C to +20°C) Extreme pressure EP NLGI grade 0 grease.

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Engine Oil THE CASE No. 1 engine oil is recommended for your engine. T his oil ensures proper lub rication of yo ur engine for all operating conditions. If you a re un able to p rocure th e CASE No. 1 Multiperformance or Performance engine oil, use the corresponding oil from the API/CG/CF category. NOTE: Do not put any Performance Additives or any other additives in the engine housing .The oil changing intervals are indicated in this manual based on tests carried out on CASE lubricants.

RD97F136

RD97F100

Viscosity of oils/Operating range of oils A 3 1

2 4 B

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

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1002-6

Fuel

Environment

The fuel to be used must comply with the D975 norm of the American Soc iety for T esting and Ma terials (ASTM).

Before c arrying o ut an y m aintenance op eration o n this machine and before throwing away the liquids or lubricants us ed, al ways thi nk of the env ironment. Never throw oil or liquids on the ground and never put them in leaking containers.

Use type N°2 fuel, use of other fuels can cause a loss of engine power and excessive fuel consumption. In cold weather, i t i s pr ovisionally accepted th at a mixture of N°1 et N°2 fuels be used. Contact your fuel supplier. If the te mperature dr ops bel ow the freezing point of the fuel (point where paraffin appears), paraffin crystals i n th e fue l wi ll cause los s of en gine po wer or starting trouble. IMPORTANT: In cold weather, fill up the reservoir with fuel after each workday, in order to avoid the formation of condensation.

Storing fuel

Consult yo ur local ce ntre for ecological r ecycling for information on th e ap propriate m ethod for di sposing off these substances.

Plastic and resin parts When c leaning pl astic par ts, the console, th e ins trument pa nel, the ind icators etc ... a void u sing petrol, kerosene, pai nt s olvents etc ... Us e o nly wa ter, s oap and a soft cloth. The u se o f petr ol, k erosene, pai nt s olvents etc... causes discoloration, cracks or deformation of these parts.

Prolonged storage of fuel promotes the accumulation of foreign bodies or condensed moisture in the storage tank. Man y en gine fai lures ar e c aused by th e presence of water in fuel. The storage tank must be placed outside and the fuel should be ma intained at as lo w a temperature as possible. Dr ain the co ndensed moi sture at r egular intervals.

Antifreeze/anticorrosive Use the antifreeze in all seasons to pr otect the c oolant system fr om c orrosion and to avoid an y r isk of freezing. In en vironments wi th a te mperature g reater th an 33°F (-36°C), us e a 50 % mi xture of an tifreeze in a n ethylene glycol base. In environments with a temper ature less t han - 33°F ( 36°C), it is r ecommended that you us e a 40% water and 60% antifreeze mixture.

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SPECIFICATIONS Engine Make................................................................................................................................................................... Isuzu Model................................................................................................................................................... BB-6WG1XQB Type: Four stroke, water cooled with overhead valves, direct injection in-line cylinder (electrical control) with turbocharger. Number of cylinders...................................................................................................................................................6 Bore and stroke .............................................................................................................................................. 5.7x6 in Displacement................................................................................................................................................ 957 cu in Operating conditions Idle..................................................................................................................................................................900 rpm Max speed ....................................................................................................................................................1870 rpm SAE net horse power.......................................................................................................................................450 HP Max torque................................................................................................................................1410 lb ft to 1500 rpm

Capacities

Engine oil capacity.......................................................................................................................................... 12.4 gal Engine cooling circuit...................................................................................................................................... 26.4 gal Capacity of only the radiator ............................................................................................................................ 9.5 gal Fuel reservoir................................................................................................................................................ 237.7 gal Hydraulic fluid reservoir capacity.................................................................................................................... 81.8 gal Total hydraulic circuit capacity ...................................................................................................................... 190.2 gal Capacity of only the oil-cooler ........................................................................................................................ 15.8 gal Travel reduction gear housing capacity ............................................................................................................ 3.5 gal Swing drive housing capacity ........................................................................................................................... 3.5 gal NOTE: These capacities are given only for information purposes. To check the fluid levels, always use the oil gauge, visual gauges or the filler cap.

Electrical system Type of system ........................................................................................................................24 volts earth negative Alternator amperage.................................................................................................................................90 amperes Battery Number of batteries required ................................................................................................................................2 Voltage of each battery .............................................................................................................................. 12 volts Capacity ...................................................................................................................................................... 200 Ah Backup ......................................................................................................................................................... xx min Starter Voltage ....................................................................................................................................................... 24 volts Power ..............................................................................................................................................................7 kW Voltage regulator .............................................................................................................. built-in, without adjustment

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1002-8

Hydraulic system Main hydraulic pump Variable flow double pump, with axial pistons. Max flow ................................................................................................................................................. 2x135.7 gpm Displacement........................................................................................................................................... 2x16.9 cu in

Hydraulic pilot pump Fixed flow pump Max flow .........................................................................................................................................................7.1 gpm Displacement................................................................................................................................................. 0.9 cu in

Pressure setting Pilot circuit main relief...................................................................................................................................... 638 psi Main relief (standard)..................................................................................................................................... 4554 psi Main relief (boost).......................................................................................................................................... 4974 psi Secondary relief (boom, dipper and bucket).................................................................................................. 5264 psi Secondary relief (swing) ................................................................................................................................ 4046 psi Secondary relief (travel) ................................................................................................................................ 4975 psi Safety valve (boom and dipper)..................................................................................................................... 5265 psi

Cylinder Boom cylinder Cylinder bore .................................................................................................................................................... 7.87 in Rod diameter ...................................................................................................................................................... 5.5 in Stroke ............................................................................................................................................................... 74.5 in

Dipper cylinder Cylinder bore .................................................................................................................................................... 8.46 in Rod diameter ...................................................................................................................................................... 5.9 in Stroke ............................................................................................................................................................... 90.1 in

Bucket cylinder Cylinder bore ...................................................................................................................................................... 7.4 in Rod diameter ...................................................................................................................................................... 5.1 in Stroke .................................................................................................................................................................. 61 in

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Control valve Five-element control valve for dipper, boom acceleration, swing, option and right travel. Four-element control valve for dipper acceleration, bucket, boom and left travel. Load holding relief valve for boom and dipper.

Swing Fixed flow engine with axial pistons. Automatic disk brakes. Upperstructure frame swing speed..................................................................................................................7.6 rpm Swing torque................................................................................................................................................. 55845 lbf Tail swing ....................................................................................................................................................... 13 ft 4 in Displacement............................................................................................................................................... 12.8 cu in Work load ........................................................................................................................................................66 gpm Braking torque ................................................................................................................................... 856 to 1109 lb ft Minimum brake release pressure .................................................................................................................... 333 psi Permissible motor leakage ...........................................................................................................................1.32 gpm

Travel Two-speed motor with axial pistons. Automatic disk brakes. Low speed ......................................................................................................................................................1.8 mph High speed .....................................................................................................................................................2.7 mph Surmountable ramp .....................................................................................................................................70% (35Â°) Tractive effort.............................................................................................................................................. 122390 lbf Displacement....................................................................................................................................... 20.5/13.9 cu in Work load ......................................................................................................................................................132 gpm Reduction ratio .................................................................................................................................................91.974 Braking torque (reduction gear excluded) ...................................................................................................... 680 lb ft Permissible motor leakage ...........................................................................................................................3.43 gpm

Undercarriage Monobloc frame with fabricated elements. Lubricated rollers and idler wheels. Grease track tension. Ground pressure with 29.5 in track pads .................................................................................................................................. 14 psi

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Attachment

Digging force ................................................................................................................................................ 84218 lbf Thrust force 9 ft 9 in dipper............................................................................................................................................... 74760 lbf 12 ft 0 in dipper............................................................................................................................................. 64852 lbf 14 ft 7 in dipper............................................................................................................................................. 55620 lbf 18 ft 5 in dipper............................................................................................................................................. 47062 lbf

Weight of components Engine ........................................................................................................................................................... 2756 lbs Hydraulic pump................................................................................................................................................ 661 lbs Attachment control valve ................................................................................................................................. 948 lbs Swing motor and reduction gear assembly ................................................................................................... 1810 lbs Travel motor and reduction gear assembly ................................................................................................... 2866 lbs Boom cylinder................................................................................................................................................ 1576 lbs Dipper cylinder............................................................................................................................................... 2260 lbs Bucket cylinder .............................................................................................................................................. 1323 lbs Counterweight ............................................................................................................................................. 27558 lbs Cab .................................................................................................................................................................. 560 lbs Turntable ....................................................................................................................................................... 2954 lbs Upperstructure assembly..............................................................................................................................52911 lbs Hydraulic swivel............................................................................................................................................... 225 lbs Frame assembly .......................................................................................................................................... 28880 lbs Machine without attachment...................................................................................................................... 140667 lbs Attachment .................................................................................................................................................. 33201 lbs Boom assembly ........................................................................................................................................... 17196 lbs Dipper assembly............................................................................................................................................ 9480 lbs Radiator and oil-cooler assembly ...................................................................................................................1146 lbs Fuel reservoir................................................................................................................................................. 1029 lbs Hydraulic reservoir........................................................................................................................................... 932 lbs Idler wheel ..................................................................................................................................................... 1471 lbs Upper roller...................................................................................................................................................... 166 lbs Lower roller...................................................................................................................................................... 397 lbs Tension damper ............................................................................................................................................. 1517 lbs 29.5 in track (25)............................................................................................................................................ 5015 lbs 35.4 in track (25)............................................................................................................................................ 5697 lbs 43.3 in track (25)............................................................................................................................................ 6554 lbs

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1002-11

DIMENSIONS AND WEAR LIMIT OF THE TRACK-LAYER ASSEMBLY Sprocket Dimensions a

Ød

Øb Øc

CS01B512

Mark a Øb Øc Ød P

Dimension (in)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

38.5 38 10.24

Gauge 10.24 in .8" 64°

0.19 in

R0.23 in

Ø3

R1 .6

8 in

R1 .68

R0.23 in

0.19 in

Ø3 8.5 i

15° 39’ 7

CI01M506

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1002-12

Idler wheel Dimensions Dimension (in)

Mark Øa b

Ø d (shaft) Ød (ring)

Øa

e f

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

32.6

0.88 4.9

Ød

CS01B514

R0.15 in 4.9 in

R0.15 in

0.88 in

Gauge

15°

10.4 in

CI01M507

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1002-13

Upper roller Dimensions g

Øa b c Øa

Ø d (shaft)

Ød

Ød (ring) e

f f

Dimension (in)

Mark

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

8.58 0.62 4.9

CS01B516

Gauge

0.62 in

R0.11 R0.11

4.9 in

10°

10.6 in

CI01M508

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1002-14

Lower roller Dimensions d

Øe

Øa

b CS01B518

Mark Øa b d Ø e (shaft)

Standard Limit Standard Limit Standard Limit Standard

Dimension (in) 10.6 0.98 10.7

Dimension (in)

Mark Ø e (ring) f g

Standard Limit Standard Limit Standard Limit

Limit

Gauge

R0 .11 R 0.1 1

10.7 in

0.98 in

4.9 in

17°

13.5 in

CI01M509

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1002-15

Track c d

Øe

Øe Øf

Øf

Øg

Øg h

a CS01B520

Mark a b c d

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Standard Limit Standard Limit Standard Limit Standard Limit

Dimension (in)

Mark Ø e (ring) Ø f (ring) Ø g (shaft) h

Standard Limit Standard Limit Standard Limit Standard Limit

Dimension (in)

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1002-16

DIMENSIONS AND WEAR LIMITS OF ATTACHMENT MOBILE JOINTS 4

CS01B521

1. Boom foot/Frame a

Ød

CS01B522

Dimension (in)

Mark a b c (a - b) Ø d (shaft) Ød (ring)

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Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

43.7 43.6 0.04 5.9

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1002-17

2. Boom cylinder foot/Frame a

b Ød

CS01B523

Dimension (in)

Mark a b c (play) Ø d (shaft) Ød (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

6.6 6.5 0.04 5.1

3. Boom cylinder head/Boom a

Ød

CS01B524

Dimension (in)

Mark a b c (play) Ø d (shaft) Ød (ring)

Cre 9-44850

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

6.1

5.11

Issued 05-02

1002-18

4. Dipper cylinder foot/Boom a

Dimension (in)

Mark

a b c (a - b)

Ød

Ø d (shaft) Ød (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

6.6 6.5 0.04 5.1

CS01B525

5. Boom/Dipper a

Dimension (in)

Mark a b c (play)

Ød

Ø d (shaft) CS01B526

Ø d (dipper) Ø d (boom)

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

5.2 21.8

5.5

6. Dipper cylinder head/Dipper Dimension (in)

Mark a b

Ød b a

c (a - b) c

Ø d (shaft) CS01B527

Cre 9-44850

Ød (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

6.6 6.5 0.04 5.1

Issued 05-02

1002-19

7. Bucket cylinder foot/Dipper a b

Dimension (in)

Mark a Ød

b c (a - b) Ø d (shaft) CS01B528

Ød (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

6.6 6.5 0.04 5.1

8. Connecting rod/Dipper Dimension (in)

Mark c

a b

c (play) Ø d (shaft)

a Ød

Ød (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

4.09 22.6 0.47 5.11

CS01B529

9. Compensator/Bucket Ød

Dimension (in)

Mark a

b b

c (play) Ø d (shaft) Ød (ring)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

19.7 19.6 0.04 5.5

CS01B530

Cre 9-44850

Issued 05-02

1002-20

10. Connecting rod/Compensator/Bucket cylinder head Dimension (in)

Mark a f b

Standard Limit Standard b Limit Standard c (play) Limit Standard d Limit Standard e Limit Standard f (d - e) Limit Standard Ø g (shaft) Limit Standard Ø g (compensator) Limit Standard Ø g (cylinder) Limit

c Øg CS01B531

3.2 19.6 0.7 6.5 6.5 0.04 4.7

11. Dipper/Bucket Øe

a d a

b c (a - b)

d Ø e (shaft)

c CS01B532

Ø e (dipper) Ø e (bucket)

Cre 9-44850

Dimension (in)

Mark Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

22.6 21.8

0.78 5.11

Issued 05-02

1002-21

SPECIAL TORQUE SETTINGS No.

Component

Screw (Ă&#x2DC;)

Wrench (mm)

Torque setting (lb-ft)

Travel motor and reduction gear assembly

M27

964 - 1125

Sprocket

M27

964 - 1125

Idler wheel

Upper roller

M20

384 - 448

Lower roller

M27

964 - 1125

Chain guide

M27

964 - 1125

Track pad

M26

1171 - 1378

Counterweight

M42

1664

Turntable (frame)

M30

1328 - 1549

10*

Turntable (upperstructure)

M30

1328 - 1549

11 *

Swing motor and reduction gear assembly

M24

664 -774

12 *

Engine

M24

665 - 774

13 *

Engine bracket

M14

127- 149

Radiator

M20

383 - 448

15 *

Hydraulic pump

M12

80 - 94

16 *

Hydraulic reservoir

M20

347 - 419

17 *

Fuel reservoir

M20

347 - 419

18 *

Control valve

M20

253

19 *

Hydraulic swivel

M16

197 - 230

Cab

M16

57 - 59

Battery

M10

15 - 21

Frame

M36

1881 - 2170

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

Cre 9-44850

Issued 05-02

1002-22

16 18 15

12 13 14

15 7 19

1 9 10

6 20

4 CS01M511

2 6 CS00E508

CS01M510

7 4 6 3

8 CS00E510

Cre 9-44850

CI01M504

Issued 05-02

1002-23

13 10

CI01M500

CI01M501

CS00E517

CS00E515

CS01M508

CS01M509

17 CI01M503

CI01M502

22 CS00E523

CI01M505 CS00E525

Cre 9-44850

Issued 05-02

1002-24

MACHINE OVERALL DIMENSIONS

CS01M512

Boom

23 ft 9 in

Dippers

9 ft 9 in

12 ft 0 in

14 ft 7 in

18 ft 5 in

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

16 ft 7 in

15 ft 9 in

16 ft 5 in

16 ft 4 in

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

12 ft 5 in

12 ft 4 in

27 ft 6 in

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

42 ft 8 in

46 ft 5 in

46 ft 3 in

46 ft 2 in

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

23 ft 10 in

23 ft 8 in

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

13 ft 7 in

13 ft 5 in

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

5 ft 3 in

5 ft 2 in

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

13 ft 4 in

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

20 ft 10 in

20 ft 8 in

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

16 ft 8 in

16 ft 6

J*...................................................

11 ft 4 in

11 ft 3 in

J** .................................................

9 ft 3 in

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

2 ft 5 in

L* (with 25.5 in track pads).........

13 ft 9 in

L** (with 29.5 in track pads) .......

11 ft 9 in

L* (with 35.4 in track pads).........

14 ft 3 in

L** (with 35.4 in track pads) .......

12 ft 3 in

L* (with 43.3 in track pads).........

14 ft 11 in

L** (with 43.3 in track pads) .......

12 ft 11 in

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

2 ft 11 in

NOTE: * (working position); ** (transport position).

Cre 9-44850

Issued 05-02

Section 2000

Case

Cre 9-36800GB

2000

REMOVING AND INSTALLING THE ENGINE

2000-2

TABLE OF CONTENTS SPECIFICATION ...................................................................................................................................................... 2 TORQUE SETTING.................................................................................................................................................. 2 ENGINE.................................................................................................................................................................... 3 Removal and installation ...................................................................................................................................... 3

SPECIFICATION Weight of engine............................................................................................................................. See Section 1002

TORQUE SETTING Engine retaining screws ................................................................................................................. See Section 1002

Cre 9-36800GB

Issued 05-02

2000-3

ENGINE Removal and installation

STEP 6

STEP 1

Remove the engine throttle control. JS00163A

Park the m achine o n hard, f lat ground. Lo wer t he attachment to the ground.

CD01M001

STEP 7

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

STEP 3

CD01D047

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

STEP 8

CD01C162

Remove the bat tery c over and di sconnect the eart h cable (-) (1) from the battery.

STEP 4 Refer t o Section 8003 an d rem ove the hy draulic pump.

STEP 5 Refer to S ection 2001 and rem ove the radi ator an d oil-cooler assembly.

CD01D131

Remove the screws (1) from the compressor and put it away from the engine.

Cre 9-36800GB

Issued 05-02

2000-4

STEP 9

STEP 12

1 1 CD01D523

CD00J030

Label and disconnect the electrical connections from the water temperature sensor (1).

Label and disconnect the el ectrical supply (1) to the pre-heating plugs.

STEP 10

STEP 13

CD01D047

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

STEP 11

CD00J031

Label and di sconnect the el ectrical c onnections t o the starter m otor. Re move the earth cable (1) at the engine end.

STEP 14

1 CD01M002

Label and disconnect the electrical connections from the oil pressure sensor (1).

Cre 9-36800GB

CD01M003

Label and di sconnect the el ectrical c onnections of the electronic regulation (1) from the engine.

Issued 05-02

2000-5

STEP 15

STEP 18 Install a s uitable l ifting dev ice on t he engine l ifting rings (for the weight of the engine, see Section 1002).

STEP 19 Remove the engine retaining hardware. 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 20 CI01B050

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

STEP 16

When there is nothing interfering with the removal of the engine, raise the engine carefully and install it on a suitable repair bench. NOTE: When installing the engine in the machine, proceed in the reverse order from removal. Before operating the machine, carry out the following operations: - Bleed and pri me t he f uel s ystem (see Operat orâ&#x20AC;&#x2122;s Manual). - Fill and bleed the engine cooling system (see Operatorâ&#x20AC;&#x2122;s Manual). - Check t he hy draulic, f uel and c ooling s ystems f or leaks. - Check the oil level in the hydraulic reservoir. Top up if necessary.

CD00J035

Label and di sconnect the el ectrical c onnections t o the alternator.

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

Cre 9-36800GB

Issued 05-02

2000-6

NOTES ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... Cre 9-36800GB

Issued 05-02

2001 Section 2001 RADIATOR AND OIL-COOLER

Case

Cre 9-42540GB

2001-2

TABLE OF CONTENTS SPECIFICATIONS .................................................................................................................................................. 2 CHANGING THE RADIATOR OR THE OIL-COOLER ........................................................................................... 3 Description .......................................................................................................................................................... 3 RADIATOR AND OIL-COOLER ............................................................................................................................. 4 Removal of the radiator and oil-cooler assembly ................................................................................................ 4 Installation ........................................................................................................................................................... 5

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

SPECIFICATIONS Coolant solution.............................................................................................................................. See Section 1002 Total cooling system capacity ........................................................................................................................ 26.4 gal Thermostat opening range Starts to open ................................................................................................................................................ 180°F Completely open ........................................................................................................................................... 207°F Hydraulic fluid ................................................................................................................................. See Section 1002

Cre 9-42540GB

Issued 05-02

2001-3

CHANGING THE RADIATOR OR THE OIL-COOLER Description

5 6

9 CS02A513

1 2 3 4 5

SCREW PIPE HOSE HOSE HOSE

Cre 9-42540GB

6 7 8 9 10

HOSE HOSE RADIATOR RETAINING SCREW HOSE Issued 05-02

2001-4

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

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

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

Removal of the radiator and oilcooler assembly STEP 1

STEP 6 Remove the screws (1), then the pipe (2) and the hose (3) from the oil-cooler, finally drain the oil-cooler into a clean container (see page 3).

STEP 7 2

Remove the expansion reservoir hose (7) from the radiator (8). Disconnect the return hose (5) and the water pump suction hose (6) from the engine (see page 3).

STEP 8 Disconnect the hose (10) (see page 3).

STEP 9

CS02A512

Lift the hood (1), then remove all the screws (2), to finally remove the hood (3)

STEP 2 Remove the inner cover plate from the engine.

STEP 3 Remove the cap from the expansion reservoir. IMPORTANT: Do not remove the cap when the engine is hot, since the system would still be under pressure and you could be scalded.

3 CS02A575

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

Remove the screws (1) and remove the guardrails (2). Remove the screws (3).

STEP 5 Release pressure in the hydraulic reservoir to allow the vacuum pump to be mounted (see Section 8000).

Cre 9-42540GB

Issued 05-02

2001-5

STEP 10

CS00G513

Pass a suitable sling right around the radiator and oilcooler assembly and, using a suitable lifting device, remove the radiator and oil-cooler assembly. NOTE: During the lifting operation, unlock the radiator and oil-cooler assembly in order to free the engine cooling fan.

Installation When installing, proceed in the reverse order from that of removal. 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 Operatorâ&#x20AC;&#x2122;s Manual). - Check the engine cooling system for leaks.

Cre 9-42540GB

Issued 05-02

3001 Section 3001 REMOVING AND INSTALLING THE FUEL TANK

Case

Cre 9-36820GB

3001-2

TABLE OF CONTENTS SPECIFICATIONS .................................................................................................................................................. 2 FUEL TANK ............................................................................................................................................................ 3 Removal ..... ......................................................................................................................................................... 3 Description . ......................................................................................................................................................... 4

SPECIFICATIONS See Section 1002.

Cre 9-36820GB

Issued 05-02

3001-3

FUEL TANK Removal STEP 1

STEP 7 Remove the two screws (11) that hold the fuel oil filter (12). Attach ta gs to the two ho ses (13) a nd (14). Remove th e fu el oi l f ilter ( 12) b y removing th e tw o hoses (13) and (14) and the circlips (15) and (16).

STEP 8 Shift the pla stic protection ( 17) from the fu el s ensor (18). Remove the retaining screws (19) then the fuel sensor (18) as well as the seal (20).

STEP 9 JS00163A

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

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

STEP 3 Attach a "DO NOT OPERATE" tag to th e ignition key in the cab.

STEP 4

Remove the fou r s crews ( 21) fr om the fu el tan k ( 2), and the shims (22).

STEP 10 Remove the fuel tank (2) using a hoist.

STEP 11 See the operatorâ&#x20AC;&#x2122;s manual for removing the fuel filter.

Installation To in stall, p roceed i n th e r everse or der from t hat o f removal. NOTE: For torque settings, see Section 1002.

NOTE: The numbers within brackets refer to the figures on pages 5 and 6. Remove the ac cess c over plate ( 1) fr om under th e fuel tank (2).

STEP 5 Open the fil ling pl ug of the tank ( 3). Empty the tank using the valve (4) then remove the latter.

STEP 6 Remove the r etaining s crews ( 5) fr om the ac cess ramps (6) and (7), as well as the plate (8), the screws (9) and the nuts (10). Remove the access ramps (6) and (7).

Cre 9-36820GB

Issued 05-02

3001-4

Description Location

10 6

CI01M511

5. 6. 7. 8. 9. 10.

Screw Access ramp Access ramp Plate Screw Nut

Cre 9-36820GB

11. 12. 13. 14. 15. 16.

Screw Fuel oil filter Hose Hose Circlip Circlip

Issued 05-02

3001-5

Fuel tank 3

1 18

21 20

19 1. 2. 3. 4. 17.

Access cover plate Fuel tank Plug Valve Plastic protection

Cre 9-36820GB

18. 19. 20. 21. 22.

Fuel probe Screw Seal Screw Shims

CI01M510

Issued 05-02

3001-6

Issued 05-02

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