Case cx290 crawler excavator service repair manual

CX290 Crawler Excavators Table of contents DIVISION/SECTION

SECTION No.

REFERENCE No.

1

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

7-27690GB 9-36330GB

2

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

3

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

4

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

9-40330GB 9-43460GB 9-43450GB

5

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

7-27750GB 9-42920GB 9-36890GB 9-43000GB

6

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 assembly and disassembly ...........................................6005

9-43140GB 9-44010GB 9-43220GB 9-43150GB

7

UNDERCARRIAGE HYDRAULICS

8

UPPERSTRUCTURE HYDRAULICS Depressurising and decontaminating the hydraulic system, use of the vacuum pump and bleeding the components ..............................................8000 Specifications, troubleshooting, checks and hydraulic pressure settings ........8001 Hydraulic reservoir removal and installation ....................................................8002 Main and pilot pumps, removal and installation ...............................................8003 Main hydraulic control valve, removal and installation.....................................8004 Attachment cylinders, removal and installation................................................8005 Hydraulic swivel, removal and installation .......................................................8006 Pilot blocs, removal and installation.................................................................8007 Swing motor, removal and installation .............................................................8008 Main hydraulic pump, disassembly and assembly...........................................8010 Main hydraulic control valve, disassembly and assembly................................8011 Attachment cylinders, disassembly and assembly...........................................8012 Hand control levers, disassembly and assembly .............................................8013 Foot control levers, disassembly and assembly ..............................................8014 Six-solenoid valves, disassembly and assembly .............................................8015 Caution valve, disassembly and assembly ......................................................8016 Safety valve .....................................................................................................8017 Hydraulic swivel, disassembly and assembly ..................................................8018 Swing motor, disassembly and assembly ........................................................8019 Hydraulic functions...........................................................................................8020 Travel hydraulic motor, disassembly and assembly.........................................8021

9-43820GB 9-44490GB

7-27970GB

9-44030GB 9-36870GB 7-27990GB 9-44050GB 9-44410GB 7-27791GB 7-27811GB 7-28130GB 9-44020GB 9-35491GB 9-43550GB 9-44420GB 7-28110GB 7-28210GB 9-43360GB 7-27942GB 7-29631GB 7-28080GB 9-43440GB 9-43030GB 9-43160GB

DIVISION/SECTION 9

SECTION No.

REFERENCE No.

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

9-43760GB 9-27961GB 9-40960GB 9-43750GB 7-xxxxxFR 7-29910GB 7-xxxxxFR 7-xxxxxFR 7-27622GB

* 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 descript ion of t he models shown in t his manual has been m ade in accordance with the technical specifications known as of the date of design of this document.

Cre 9-44510GB

Issued 04-02

1001 SAFETY, GENERAL INFORMATION AND STANDARD TORQUE DATA

Case

Cre 7-27690GB

1001

Section

1001-2

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

Cre 7-21930GB

Issued 01-99

Printed in U.K.

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.

Cre 7-27690GB

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 Operator’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.

Issued 09-00

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.

Cre 7-27690GB

Issued 09-00

1001-5

!

!

!

!

WARNING: When servicing or repairing the machine, keep the shop floor and operator’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.

Cre 7-27690GB

Issued 09-00

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.

JS00481A

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.

Cre 7-27690GB

Issued 09-00

1001-7

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

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

Socket Head Cap Screw

Cre 7-27690GB

Spanner Tightening torque

M6 [mm]

M8

M10

M12

M14

M16

M18

M20

10

13

17

19

22

24

27

30

[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

157.2

196.0

274.0

[lb-ft]

5.1

14.5

29.0

43.4

72.5

116.0

144.6

202.4

[mm]

5

6

8

10

12

14

14

17

[in.]

0.20

0.24

0.32

0.39

0.47

0.55

0.55

0.67

[Nm]

8.8

21.6

42.1

78.4

117.6

176.4

245.0

343.0

[lb-ft]

6.5

15.9

31.1

57.8

86.8

130.1

180.8

253.1

Issued 09-00

1001-8

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

Cre 7-27690GB

Issued 09-00

1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

Case

Cre 9-36330GB

1002

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 ....................................................................................................................................................... 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 ............................................................................................................................................................ 9 Weight of components ........................................................................................................................................10 DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY ...........................................................................11 Sprocket ..............................................................................................................................................................11 Idler wheel...........................................................................................................................................................12 Upper roller .........................................................................................................................................................13 Lower roller .........................................................................................................................................................14 Track ...................................................................................................................................................................15 DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES ......................................................................16 Boom foot/Frame ................................................................................................................................................16 Boom cylinder foot/Frame ...................................................................................................................................17 Boom cylinder head/Boom ..................................................................................................................................17 Dipper cylinder foot/Boom...................................................................................................................................18 Boom/Dipper .......................................................................................................................................................18 Dipper cylinder head/Dipper................................................................................................................................18 Bucket cylinder foot/Dipper .................................................................................................................................19 Connecting rod/Dipper ........................................................................................................................................19 Compensator/Bucket...........................................................................................................................................19 Connecting rod/Compensator/Bucket cylinder head...........................................................................................20 Dipper/Bucket......................................................................................................................................................20 SPECIAL TORQUE SETTINGS ..............................................................................................................................21 MACHINE OVERALL DIMENSIONS.......................................................................................................................24

!

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

Cre 9-36330GB

Issued 12-01

1002-3

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

3

2 CP98N006

CS01J532

(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......................................................................................................................................................

Cre 9-36330GB

Issued 12-01

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

Greases

The CASE hydraulic fluid is specially adapted for high pressure and CASE’s hydraulic circuit. The type of fluid to be used depends on the ambient temperature.

The type of grease to be used depends on the ambient temperature.

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

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

Hot and temperate climates -20°C to +60°C Extreme pressure EP NLGI grade 2 grease with molybdenum disulfide.

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

Cold climates -40°C to +20°C Fluid type: ISO VG 22 CASE reference: POHYPF Temperate climate biodegradable fluid: This yellow-coloured fluid is miscible with standard fluid.

When introducing this fluid, it is recommended to drain the hydraulic system completely.

Fluid type: ISO VG 46 CASE reference: CASYNTH 46 These different grades of fluids must comply with the CASE specification.

Transmission assembly oil Extreme pressure oil used for transmission assemblies in housing.

Extreme pressure oil TYPE API GL5 GRADE 80W90 and ISO VG 150

Cre 9-36330GB

Issued 12-01

1002-5

Engine oil The CASE No. 1 engine oil is recommended for your engine. This oil ensures proper lubrication of your engine for all operating conditions.

If you are unable to procure the 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

CS98M561

(A) FAHRENHEIT TEMPERATURE (2) WINTER (B) CELSIUS TEMPERATURE (3) TROPICAL (1) ALL SEASONS (4) ARCTIC (*) SHOWS THAT IT IS NECESSARY TO USE AN ENGINE OIL HEATER OR THERMAL COOLER.

Cre 9-36330GB

Issued 12-01

1002-6

Fuel

Environment

The fuel to be used must comply with the D975 norm of the American Society for Testing and Materials (ASTM).

Before carrying out any maintenance operation on this machine and before throwing away the liquids or lubricants used, always think of the environment.

Never throw oil or liquids on the ground and never put them in leaking containers.

Use type No. 2 fuel, use of other fuels can cause a loss of engine power and excessive fuel consumption.

In cold weather, it is provisionally accepted that a mixture of No. 1 and No. 2 fuels be used. Contact your fuel supplier.

If the temperature drops below the freezing point of the fuel (point where paraffin appears), paraffin crystals in the fuel will cause loss of engine power or starting trouble.

IMPORTANT: In cold weather, fill up the reservoir with fuel after each workday, in order to avoid the formation of condensation.

Consult your local centre for ecological recycling for information on the appropriate method for disposing off these substances.

Plastic and resin parts When cleaning plastic parts, on the console, the instrument panel, the indicator and gauges etc., do not use petrol, paraffin, paint solvents, etc. Use only water, soap and a soft cloth.

The use of petrol, paraffin, paint solvents etc... causes discoloration, cracks or deformation of these parts.

Storing fuel Prolonged storage of fuel promotes the accumulation of foreign bodies or condensed moisture in the storage tank. Many engine failures are caused by the presence of water in fuel.

The storage tank must be placed outside and the fuel should be maintained at as low a temperature as possible. Drain the condensed moisture at regular intervals.

Antifreeze/anticorrosive Use the antifreeze in all seasons to protect the coolant system from corrosion and to avoid any risk of freezing.

In environments with a temperature greater than -36°C, use a 50% mixture of antifreeze in an ethylene glycol base.

In environments with a temperature less than -36°C, it is recommended that you use a 40% water and 60% antifreeze mixture.

Cre 9-36330GB

Issued 12-01

1002-7

SPECIFICATIONS CX290

Engine Make ................................................................................................................................................................... Isuzu Model......................................................................................................................................................... CC-6BG1T Type: Four stroke, water cooled with overhead valves, direct injection in-line cylinder (electronic control) with turbocharger.

Number of cylinders...................................................................................................................................................6 Bore and stroke .................................................................................................................................... 105 x 125 mm Displacement.................................................................................................................................................. 6494 cc Operating conditions Idle................................................................................................................................................................1000 rpm Max speed ....................................................................................................................................................2200 rpm Power ECC 1289 .......................................................................................................................... 140.5 kW (191 HP) Max torque............................................................................................................................... 676.2 Nm at 1800 rpm

Capacities Engine oil capacity.......................................................................................................................................... 24 litres Engine cooling circuit...................................................................................................................................... 29 litres Capacity of only the radiator .......................................................................................................................... 20 litres Fuel reservoir................................................................................................................................................ 340 litres Hydraulic fluid reservoir capacity .................................................................................................................. 120 litres Total hydraulic circuit capacity ...................................................................................................................... 240 litres Capacity of only the oil-cooler ..................................................................................................................... 15.7 litres Travel reduction gear housing capacity ......................................................................................................... 4.7 litres Swing drive housing capacity ........................................................................................................................... 6 litres Idler pulley capacity .......................................................................................................................................... 250 cc Upper roller capacity.............................................................................................................................. 245 to 250 cc Lower roller capacity......................................................................................................................................... 280 cc 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.................................................................................................................................50 amperes Battery Number of batteries required ................................................................................................................................2 Voltage of each battery ...............................................................................................................................12 volts Capacity ...................................................................................................................................................... 112 Ah Reserve ...................................................................................................................................................... 160 min Cold startability at -17° .................................................................................................................................. 800 A Load for load control...................................................................................................................................... 400 A Starter Voltage ........................................................................................................................................................24 volts Power ...........................................................................................................................................................4.5 kW Voltage regulator .............................................................................................................. built-in, without adjustment

Cre 9-36330GB

Issued 12-01

1002-8 CX290

Hydraulic system Main hydraulic pump Variable flow double pump, with axial pistons.

Maximum flow......................................................................................................................................... 2 x 221 l/min Displacement............................................................................................................................................. 2 x 97.2 cc

Hydraulic pilot pump Fixed flow pump Max flow ...................................................................................................................................................... 22.3 l/min Displacement...................................................................................................................................................... 10 cc

Pressure setting Pilot circuit relief ..........................................................................................................................................39 ± 1 bar Main circuit relief (standard) ......................................................................................................................343 ± 3 bar Main circuit relief (power-up) .....................................................................................................................373 ± 5 bar Secondary relief (boom, dipper and bucket)..............................................................................................392 ± 5 bar Secondary relief (swing) ............................................................................................................................294 ± 4 bar Secondary relief (travel) ............................................................................................................................380 ± 5 bar Safety valve (boom and dipper) .................................................................................................................392 ± 5 bar

Cylinder Boom cylinder Cylinder bore ..................................................................................................................................................135 mm Rod diameter .................................................................................................................................................... 95 mm Stroke ........................................................................................................................................................... 1369 mm

Dipper cylinder Cylinder bore ..................................................................................................................................................150 mm Rod diameter ..................................................................................................................................................105 mm Stroke ........................................................................................................................................................... 1438 mm

Bucket cylinder Cylinder bore ..................................................................................................................................................130 mm Rod diameter .................................................................................................................................................... 90 mm Stroke ........................................................................................................................................................... 1073 mm

Cylinder leakage - attachment lowering (without load) Boom cylinders (rods retracted) ............................................................................................................... 3 mm/5 min Dipper cylinder (rod extended) ................................................................................................................. 5 mm/5 min Dipper cylinder (rod extended) ................................................................................................................. 7 mm/5 min Total (at the end of the attachment)...................................................................................................... 200 mm/5 min

Cylinder speed (in S mode) Boom raised (bucket open and on the ground) ..................................................................................... 4.6 ± 0,6 sec.

Boom lowered (bucket open) ................................................................................................................. 3.7 ± 0.6 sec.

Dipper extended .................................................................................................................................... 2.9 ± 0.5 sec.

Dipper retracted..................................................................................................................................... 4.0 ± 0.5 sec.

Bucket open........................................................................................................................................... 2.5 ± 0.5 sec.

Bucket closed ........................................................................................................................................ 4.9 ± 0.5 sec.

Cre 9-36330GB

Issued 12-01

1002-9 CX290

Control valve Five-element control valve for dipper, boom acceleration, swing, option and right travel.

Four-element control valve for dipper, bucket, boom acceleration 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................................................................................................................10.4 rpm Displacement................................................................................................................................................. 164.8 cc Work flow ...................................................................................................................................................... 217 l/min Reduction ratio .................................................................................................................................................27.143 Brake torque .................................................................................................................................................................≥ 927 Nm Minimum brake release pressure ......................................................................................................................29 bar Permissible motor leak ................................................................................................................................... 16 l/min

Travel Two-speed motor with axial pistons.

Automatic disk brakes.

Low speed ....................................................................................................................................................... 3.0 kph High speed ...................................................................................................................................................... 5.1 kph Gradeability .................................................................................................................................................70% (35°) Tractive effort ............................................................................................................................................ 24 100 daN Displacement....................................................................................................................................... 244.3/141.1 cc Work flow ...................................................................................................................................................... 217 l/min Reduction ratio .................................................................................................................................................39.875 Braking torque (reduction gear excluded) ...............................................................................................................≥ 902 Nm Number of sprocket turns (10 turns) Mode "S", high speed.................................................................... ................................................. 17.7 ± 0.6 sec.

Mode "S", low speed ..................................................................... ................................................. 30.0 ± 0.7 sec.

Permissible deviation in travel over a distance of 20 m Mode "H", full speed..........................................................................................................................................1 m Permissible motor leak ................................................................................................................................... 13 l/min

Undercarriage Monobloc frame with fabricated elements.

Lubricated rollers and idler wheels.

Grease track tension.

Weight load on track with 600 mm track pads .............................................................................................................................0.54 bar with 700 mm track pads .............................................................................................................................0.48 bar with 800 mm track pads .............................................................................................................................0.42 bar Track tension........................................................................................................................................340 to 360 mm

Attachment Digging force............................................................................................................................................. 17 300 daN Break-out force 2.65 m dipper ....................................................................................................................................... 13 700 daN 3.20 m dipper ....................................................................................................................................... 12 500 daN 3.65 m dipper ....................................................................................................................................... 10 900 daN

Cre 9-36330GB

Issued 12-01

1002-10 CX290

Weight of components Engine .............................................................................................................................................................. 512 kg Hydraulic pump................................................................................................................................................. 139 kg Attachment control valve .................................................................................................................................. 187 kg Swing motor and reduction gear assembly ...................................................................................................... 402 kg Travel motor and reduction gear assembly ....................................................................................................... 365 kg Boom cylinder................................................................................................................................................... 235 kg Dipper cylinder.................................................................................................................................................. 335 kg Bucket cylinder ................................................................................................................................................. 194 kg Counterweight ................................................................................................................................................ 5400 kg Cab ................................................................................................................................................................... 254 kg Turntable........................................................................................................................................................... 543 kg Upperstructure assembly............................................................................................................................. 10 910 kg Hydraulic swivel .................................................................................................................................................. 31 kg Frame assembly .......................................................................................................................................... 11 610 kg Machine without attachment........................................................................................................................ 23 070 kg Attachment ..................................................................................................................................................... 5270 kg Boom assembly .............................................................................................................................................. 2590 kg Dipper assembly............................................................................................................................................. 1570 kg Radiator and oil-cooler assembly ..................................................................................................................... 165 kg Fuel reservoir...................................................................................................................................................... 87 kg Hydraulic reservoir............................................................................................................................................ 127 kg Idler wheel ........................................................................................................................................................ 154 kg Upper roller......................................................................................................................................................... 44 kg Lower roller ......................................................................................................................................................... 60 kg Tension damper ................................................................................................................................................ 497 kg 600 mm track .................................................................................................................................................. 2190 kg 700 mm track .................................................................................................................................................. 2386 kg 800 mm track .................................................................................................................................................. 2580 kg

Cre 9-36330GB

Issued 12-01

1002-11

DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY Sprocket Dimensions a

P

Ød

Øb Øc

CS01B512

Mark a Øb Øc Ød P

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

83 73 660.7 649.2 748 738 732.5 --215.9 ---

Gauge 300 215.9 43.3 5.1

117.8

100

37.2

6 3∼

R 93 .7 °

R

12

35 .

9

R

49 .6

90°

R

26.1

° 40.7

84.5

66.

D3 PC 74 R3 2 CI01N501

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Issued 12-01

1002-12

Idler wheel Dimensions Mark

Dimension (mm)

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

b c

Øa

e

560 550 22.5 --102 92 85 84 85 86 82 81 24 23.6

f

Ød

CS01B514

Gauge 250 204

22.5 15

R3

R5

R50

R3

° 10

75

37.5

102

0.2

CI01N502

Cre 9-36330GB

Issued 12-01

1002-13

Upper roller Dimensions Mark g

e

Øa

Ød

b f

Dimension (mm)

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

c

150 140 15 --104 --65 64 65 66 69 68 9 8.5 30 ---

CS01B516

Gauge 5

210 104 97

R3

R3

R3

15

65

35

° .1 13

R3

15

R3

125

120 245 CI01N503

Cre 9-36330GB

Issued 12-01

1002-14

Lower roller Dimensions d

f

g

Øe

Øa

b CS01B518

Mark Øa b d Ø e (shaft)

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

Mark

180 170 25 20 216 224 75 74

Dimension (mm) Standard Limit Standard Limit Standard Limit

Ø e (ring) f g

75 76 82 81 17.5 17

Gauge 268 262.7 225.5 212

37.5

10 33.1

25

10

R1 0

R

5°

R5

° 10

23.5

55

R5

° 1.5

R5

25

16°

5 R1

R5

80

100

300 CI01N504

Cre 9-36330GB

Issued 12-01

1002-15

Track

c d Øe

Øe’

Øf’

Øf

Øg’

Øg h

h

b

a CS01B520

Mark a b c d

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

49 34 129 124 43 41 28.4 27

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

Cre 9-36330GB

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

71.35 67 47.9 50.4 47.25 45 215.9 --71.35 67

Standard Limit

48.4 50.9

Standard Limit

49.57 45

Issued 12-01

1002-16

DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES 4

3

1

5

6

9

2

11 10

7

8

CS01B521

1. Boom foot/Frame a

c

b

Ød

CS01B522

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

Cre 9-36330GB

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

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

Issued 12-01

1002-17

2. Boom cylinder foot/Frame a

c

b

Ød

CS01B523

Mark

Dimension (mm)

Standard a Limit Standard b Limit Standard c (play) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

109 115 108 106 1 to 2.5 Shims 95 94 95 96.5

3. Boom cylinder head/Boom a

b

a

c

Ød

CS01B524

Mark Standard a Limit Standard b Limit Standard c (play) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

Cre 9-36330GB

Dimension (mm) 108 106 528 522 1 to 2.5 Shims 95 94 95 96.5

Issued 12-01

1002-18

4. Dipper cylinder foot/Boom a

c

Mark

Dimension (mm)

Standard a Limit Standard b Limit Standard c (a - b) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

b

Ød

124 130 123 121 0.5 to 3 Shims 95 94 95 96.5

CS01B525

5. Boom/Dipper a

b

c

Mark a b (boom) b (dipper)

Ød c (play) CS01B526

Ø d (shaft) Ø d (dipper) Ø d (boom)

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

82 80 330 333.5 329.5 327.5 0.5 to 1.1 Shims 100 99 100 101.5 100 101.5

6. Dipper cylinder head/Dipper Mark

Ød b a

c CS01B527

Cre 9-36330GB

Standard a Limit Standard b Limit Standard c (a - b) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

Dimension (mm) 139 144 138 136 0.5 to 3 Shims 95 94 95 96.5

Issued 12-01

1002-19

7. Bucket cylinder foot/Dipper a b

Mark

c

Ød

CS01B528

Standard a Limit Standard b Limit Standard c (a - b) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

Dimension (mm) 116 122 115 113 0.5 to 3 Shims 80 79 80 81.5

8. Connecting rod/Dipper Mark Standard Limit Standard b Limit Standard c (play) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

a

c

b

a Ød

Dimension (mm) 40 38 316 314 1 to 1.5 Shims 80 79 80 81.5

CS01B529

9. Compensator/Bucket Mark

Ød

Standard Limit Standard b Limit Standard c (play) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

a

c

b

a

Dimension (mm) 326 331 325 322 1 to 3.5 Shims 90 89 90 91.5

CS01B530

Cre 9-36330GB

Issued 12-01

1002-20

10. Connecting rod/Compensator/Bucket cylinder head Mark a f b

e

d

c Øg CS01B531

Dimension (mm)

Standard a 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 Øg (compensator) Limit

Ø g (cylinder)

Standard Limit

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

11. Dipper/Bucket Mark

Øe

a b

d

c (a - b) a

b

d Ø e (shaft)

c Ø e (dipper) CS01B532

Cre 9-36330GB

Ø e (bucket)

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

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

Issued 12-01

1002-21

SPECIAL TORQUE SETTINGS No.

Component

Screw (Ă˜)

Wrench (mm)

Torque setting (Nm)

1*

Travel motor and reduction gear assembly

M24

36

900-1050

2*

Sprocket

M20

30

521-608

3*

Idler wheel

M16

24

267-312

4*

Upper roller

M20

30

521-608

5*

Lower roller

M24

36

900-1050

6

Chain guide

M24

36

900-1050

7

Track pad

M24

32

1236-1510

8

Counterweight

M30

46

1060-1235

9

Turntable (frame)

M24

36

783-913

10

Turntable (upperstructure)

M24

36

783-913

11 *

Swing motor and reduction gear assembly

M24

36

783-913

12 *

Engine

M16

24

265-313

13 *

Engine bracket

M10

17

64-74

14

Radiator

M16

24

147-176

15 *

Hydraulic pump

M10

17

64-74

M20

Hexagonal

367-496

16 *

Hydraulic reservoir

M16

24

232-276

17 *

Fuel reservoir

M16

24

232-276

18 *

Control valve

M16

24

267-312

19 *

Hydraulic swivel

M12

19

109-127

20

Cab

M16

24

78-80

21

Battery

M10

17

20-29

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

Cre 9-36330GB

Issued 12-01

1002-22

17

15

16 18

11

12 13 14

8

21 7 19

1 9 10

2

5

6 20 3

4 CS00E507

6 1

2 CS01N968

CS01N969

7 4 5 8

3 CS01N970

Cre 9-36330GB

CS01N971

Issued 12-01

1002-23

11

13 12

9

10

9

CS00E512

CS00E514

15

15 CS00E517

14 CS01N974

16

17

CS01N520

CS00E519

18

CS00E521

19 20

CS00E522

Cre 9-36330GB

CS00E523

21

CS01N981

Issued 12-01

1002-24

MACHINE OVERALL DIMENSIONS E

G

A

B

F

M K

I H D

J L C

CS01B533

A B C D E F G H I J K (standard track pads) L (with 600 mm track pads) L (with 700 mm track pads) L (with 800 mm track pads) M

Cre 9-36330GB

2.65 m 3.27m 3.05 m 10.42 m 5.62 m 2.79 m 1.20 m 3.18 m 4.88 m 3.93 m 2.60 m 0.60 m 3.20 m 3.30 m 3.40 m 0.49 m

CX290 Dippers 3.20 m 3.27 m 3.05 m 10.41 m 5.62 m 2.79 m 1.20 m 3.18 m 4.88 m 3.93 m 2.60 m 0.60 m 3.20 m 3.30 m 3.40 m 0.49 m

3.65 m 3.48 m 3.05 m 10.43 m 5.62 m 2.79 m 1.20 m 3.18 m 4.88 m 3.93 m 2.60 m 0.60 m 3.20 m 3.30 m 3.40 m 0.49 m

Issued 12-01

Section 2000

Case

Cre 9-43820GB

2000

REMOVAL AND INSTALLATION OF 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 Retaining screw of the engine ................................................................................................................ 290 ± 25 Nm Motor bracket retaining screws................................................................................................................... 69 ± 5 Nm

Cre 9-43820GB

Issued 04-02

2000-3

ENGINE Removal and installation

STEP 6

STEP 1 1

2 3 CD02C168

JS00163A

Park the machine on hard, flat ground. Lower the attachment to the ground.

STEP 2

Remove the engine shutdown control (1).

Disconnect the fuel supply pipe (2) and the fuel return pipe (3) and plug them.

STEP 7

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

1

STEP 3 2 1

CD00J039

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

STEP 8 CD00F091

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

STEP 4 Refer to Section 8003 and remove the hydraulic pump.

STEP 5 Refer to Section 2001 and remove the radiator and oil-cooler assembly.

1 CD00J044

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

Cre 9-43820GB

Issued 04-02

2000-4

STEP 9

STEP 12

1

2

CD00J046

Label and disconnect the electrical connection for the oil pressure sender (1) and the engine speed sender (2).

STEP 10

CD02C168

Identify and disconnect the connectors for the electronic regulator and disconnect the fuel flow regulator resistor.

STEP 13 2

1

1

3 CD00J047

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

STEP 11 2

CD02C171

Remove the hose (1) which connects the turbocharger to the air filter, disassemble the hose (2) which connects the turbo-charger to the heat exchanger and also the hose (3) which connects the heat exchanger to the inlet pipe.

1

CD02C170

Label and disconnect the electrical connections to the starter motor (1). Remove the earth cable (2) at the engine end.

Cre 9-43820GB

Issued 04-02

2000-5

STEP 14

STEP 18 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, proceed in the reverse order to disassembly, taking care to use the correct flexible mountings, yellow at the fan end and blue at the flywheel end.

2 1

Before operating the machine, carry out the following operations:

CD02C172

Label and disconnect the electrical connections to the alternator (1).

NOTE: If the machine is equipped with air conditioning (2), remove the compressor retaining hardware and move the compressor away from the engine.

- Bleed and prime the fuel system (see Operator’s Manual).

- Fill and bleed the engine cooling system (see Operator’s Manual).

- Check the hydraulic, fuel and cooling systems for leaks.

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

STEP 15 Remove all the clips, etc, which fasten the electrical harnesses to the engine and move the harnesses out of the way.

STEP 16

CD02C173

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

STEP 17 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 a torque of 290 ± 25 Nm.

Cre 9-43820GB

Issued 04-02

2000-6

Cre 9-43820GB

Issued 04-02

2001 Section 2001 RADIATOR AND OIL-COOLER

Case

Cre 9-44490GB

2001-2

TABLE OF CONTENTS SPECIFICATIONS .................................................................................................................................................. 2 CHANGING THE RADIATOR OR THE OIL-COOLER ........................................................................................... 3 Description .......................................................................................................................................................... 3 AIR CONDITIONING CONDENSER ...................................................................................................................... 4 RADIATOR AND OIL-COOLER ............................................................................................................................. 5 Removal of the radiator and oil-cooler assembly ................................................................................................ 5 Installation ........................................................................................................................................................... 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 Coolant solution.............................................................................................................................. See Section 1002 Total cooling system capacity ......................................................................................................... See Section 1002 Thermostat opening range Starts opening .................................................................................................................................................82°C Completely open .............................................................................................................................................97°C Hydraulic fluid ................................................................................................................................. See Section 1002

Cre 9-44490GB

Issued 04-02

2001-3

CHANGING THE RADIATOR OR THE OIL-COOLER Description

4

3 6 5 8

9 9

3 5 2

4

1 7 1 2

10

11 CI02A513

1 2 3 4 5

SCREW PIPE OIL COOLER AIR COOLER HOSE

Cre 9-44490GB

6 7 8 9 10 11

HOSE RADIATOR HOSE HOSE HOSE HOSE Issued 04-02

2001-4

AIR CONDITIONING CONDENSER 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.

STEP 1 2

3 4

1 2

CD02D032

If the machine is air conditioned, the condenser (1) must be removed by removing the screws (2). Put the condenser (1) and the receiver/dryer (3) assembly aside, without disconnecting the hoses (4).

Cre 9-44490GB

Issued 04-02

2001-5

RADIATOR AND OIL-COOLER Removal of the radiator and oilcooler assembly STEP 1

NOTE: The numbers within brackets refer to the figure on page 3.

STEP 6 Remove the screws (1), then the pipe (2) from the oil cooler (3), finally drain the latter into a clean container.

STEP 7

1

Disconnect hoses (5) and (6) from the air cooler.

STEP 8 Remove the expansion reservoir hose (8) from the radiator (7). Disconnect the return hose (9) and the water pump inlet hose (10) from the engine, drain the coolant solution into a clean container.

STEP 9 CD01K055

Open the hood (1) of the engine.

Remove the crosspiece (2).

STEP 2

Disconnect the radiator hose (11) from the oil drain plug.

STEP 10

Remove the inner cover plate from the engine.

STEP 3 Remove the cap from the expansion reservoir.

B

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

A

STEP 4 Drain the cooling system (see Operator’s Manual).

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

C CS02C554

Remove the screws (A) and remove the threaded rods (B). Remove the screws (C).

Cre 9-44490GB

Issued 04-02

2001-6

STEP 11

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 Operator’s Manual).

- Check the engine cooling system for leaks.

Cre 9-44490GB

Issued 04-02

3001 Section 3001 REMOVAL AND INSTALLATION OF THE FUEL RESERVOIR

Case

Cre 7-27970GB

3001-2

TABLE OF CONTENTS SPECIFICATIONS .................................................................................................................................................. 2 FUEL RESERVOIR ................................................................................................................................................

Removal ..... .........................................................................................................................................................

Installation .. .........................................................................................................................................................

Description . .........................................................................................................................................................

3 3 4 5

SPECIFICATIONS See Section 1002

Cre 7-27970GB

Issued 04-01

3001-3

FUEL RESERVOIR Removal STEP 1

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

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

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

Remove the two screws (13) that hold the fuel oil filter (14). Attach ta gs to the two ho ses (15) a nd (16).

Remove th e fu el oi l f ilter ( 14) b y removing th e tw o hoses (15) and (16) and the circlips (17) and (18).

STEP 2

STEP 12

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

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

JS00163A

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

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

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

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

STEP 5

STEP 15

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

See the operator’s manual for removing the fuel filter.

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

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

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

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

Cre 7-27970GB

Issued 04-01

3001-4

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

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

STEP 2 Install the shims (24) as well as the four screws (23), tighten th e s crews t o a torque, s ee s pecifications.

Install the v alve ( 3) and tighten the va lve ( 3) to a torque of 14.7 Nm.

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

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

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

STEP 9 Fill the fuel reservoir (see the operator’s manual) and make sure that there are no leaks.

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

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

Tighten using circlips (18) and (17).

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

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

Cre 7-27970GB

of the fuel

Issued 04-01

3001-5

Description Location 5

4 7

11 6

12

4

10

CS00F539

9

6

4

8 4 5 6 7 8 9

SCREW ACCESS RAMP SCREW PROTECTIVE HOUSING SCREW FUEL RESERVOIR PROTECTIVE PLATE

Cre 7-27970GB

4 10 SCREW 11 SCREW 12 RESERVOIR PROTECTIVE PLATE

CS00F540

Issued 04-01

3001-6

Fuel reservoir 2

1

13

17

18

15

20 22 21

14

19

17 18

16

3

24 23

1 2 3 13 14 15 16

FUEL RESERVOIR PLUG VALVE SCREW FUEL OIL FILTER HOSE HOSE

Cre 7-27970GB

17 18 20 21 22 23 24

CIRCLIP CIRCLIP FUEL PROBE SCREW SEAL SCREW SCREW

CI00F506

Issued 04-01

4001 Section 4001 ELECTRICAL AND ELECTRONIC CIRCUIT AND TROUBLESHOOTING

Case

Cre 9-40330GB

4001-2

TABLE OF CONTENTS SPECIFICATIONS.................................................................................................................................................... 4 SPECIAL TOOLS ..................................................................................................................................................... 4 General location of the components (outside the cab).......................................................................................... 6 General location of the components (inside the cab)..........................................................................................10 Fuse box .............................................................................................................................................................12 Instrument panel .................................................................................................................................................13 OPERATING PRINCIPLES .................................................................................................................................... 14 Engine checks ....................................................................................................................................................14 Work mode selection ..........................................................................................................................................16 H/S/L mode checking ..........................................................................................................................................18 Auto mode checking............................................................................................................................................19 Acceleration checking .........................................................................................................................................20 Engine idle checking (automatic/manual) ...........................................................................................................21 Breaker mode checking ......................................................................................................................................22 Automatic engine preheat ...................................................................................................................................23 Auto engine warm-up ..........................................................................................................................................26 Idle checking using the battery voltage and the coolant temperature ................................................................28 Engine emergency stop ......................................................................................................................................30 Back-up mode .....................................................................................................................................................32 Function locking ..................................................................................................................................................34 Power boost ........................................................................................................................................................35 Swing brake ........................................................................................................................................................36 Travel mode ........................................................................................................................................................38 Supply cut-off delayed.........................................................................................................................................41 Protection by power transistor.............................................................................................................................42 Coolant temperature indicator .............................................................................................................................42 Hydraulic oil temperature indicator......................................................................................................................44 Fuel level.............................................................................................................................................................45 Engine fuel injection pump electronic regulator ..................................................................................................46 ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode)........................................................... 48 Access to monitor displays..................................................................................................................................48 Machine condition ...............................................................................................................................................49 Diagnostic code...................................................................................................................................................52 Machine history ...................................................................................................................................................55 Re-initialisation....................................................................................................................................................58 WARNING MESSAGES ......................................................................................................................................... 61 Message display .................................................................................................................................................61 EXCAVATOR MODEL SELECTION PROCEDURE .............................................................................................. 62 Changing the language code .............................................................................................................................63 CHANGING THE ACCESS CODE FOR THE ANTI-THEFT SYSTEM .................................................................. 64 Cre 9-40330GB

Issued 12-01

4001-3 TROUBLESHOOTING ........................................................................................................................................... 65 Prior inspections..................................................................................................................................................65 Reading the organisation charts .........................................................................................................................66 Procedures ..........................................................................................................................................................67 Fuel .....................................................................................................................................................................68 Add coolant solution ............................................................................................................................................69 Low engine oil pressure ......................................................................................................................................70 Overheating.........................................................................................................................................................71 Defective battery charge circuit ...........................................................................................................................74 Electrical system troubleshooting........................................................................................................................76 Travel ..................................................................................................................................................................80 ELECTRICAL INSPECTION OF COMPONENTS.................................................................................................. 81 Inspection equipment .........................................................................................................................................81 Proportional solenoid .........................................................................................................................................83 Engine emergency stop motor ...........................................................................................................................84 6 solenoid valve bank .........................................................................................................................................84 Engine rpm sensor .............................................................................................................................................85 Coolant solution and hydraulic oil temperature sensor ......................................................................................86 Pressure sensor .................................................................................................................................................87

Cre 9-40330GB

Issued 12-01

4001-4

SPECIFICATIONS See section 1002.

SPECIAL TOOLS

BS98G045

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

Cre 9-40330GB

Issued 12-01

4001-6

General location of the components (outside the cab) E2

B45

B81 E1

E3 M4

X1 X2 R5 B27 B26

B22

B41 G1

B21 K7

F22 F23

M2

F24 F25 52

B44

B42

S55

S52

B1

G2

Y8

R1

R2 A3

M1

B43

B2

Y7 CM01N001

Cre 9-40330GB

Issued 12-01

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

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

Cre 9-40330GB

Issued 12-01

4001-8

Relay and main fuses (battery compartment)

F23

F22

F24

F25

1

K7 CI00E502

1 F22 F23 F24 F25 K7

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

Cre 9-40330GB

Issued 12-01

4001-10

General location of the components (inside the cab)

M3 A4

S54

S16

S15

P1 S51

R3 S1

S14 S53

P6 S13

E4

E52 E51 F21 X8 A1 B61 A2 K5

K1

K4

K3

K2

U1 CM00E002

Cre 9-40330GB

Issued 12-01

4001-11 A1 A2 A4 B61 E4 E51 E52 F21 K1 K2 K3 K4 K5 M3 P1 P6 R3 S1 S13 S14 S15 S16 S51 S53 S54 U1 X8

Computer Engine controller Wiper controller Sunload sensor Cab light Cigarette lighter Air conditioner Fuse box Relay-engine emergency stop Relay-glow plug Relay-horn Relay -working lights Relay-rotary light Wiper motor Instrument panel Air conditioner control panel Throttle volume Key switch Overload switch Breaker/crusher switch Horn switch One touch idle Hydraulic function cancellation lever switch Door limit switch Front window limit switch DC-DC converter 24 V - 12 V Radio connector

Cre 9-40330GB

Issued 12-01

4001-12

Fuse box

CM00E005

F1

Fuse 20 A:

Engine controller

F2

Fuse 20 A:

Computer, instrument panel and diagnostic test socket

F3

Fuse 20 A:

Computer power

F4

Fuse 10 A:

Hydraulic control cancellation

F5

Fuse 15 A:

Lubrication device (not used)

F6

Fuse 10 A:

Rotary light

F7

Fuse 20 A:

Fuel filler pump

F8

Fuse 15 A:

Engine emergency stop motor

F9

Fuse 30 A:

Glow plugs

F10 Fuse 10 A:

Option line and lubricator connector

F11 Fuse 10 A:

Back-up

F12 Fuse 10 A:

Key switch

F13 Fuse 20 A:

Heater / air conditioner

F14 Fuse 5 A:

Air conditioner compressor

F15 Fuse 15 A:

Working lights

F16 Fuse 15 A:

Working light (not used)

F17 Fuse 10 A:

DC-DC converter (24 V - 12 V)

F18 Fuse 15 A:

Wiper and washer

F19 Fuse 10 A:

Horn

F20 Fuse 15 A:

Cigarette lighter, cab seat adjustment compressor

Cre 9-40330GB

Issued 12-01

4001-13

Instrument panel

P4

S2

S3

S5

S4

S7

S6

S10

S8

S9

S11

P5

S12

CM00E001

P4 P5 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12

Monitor display Hourmeter Travel mode switch Work mode switch Auto mode switch Cushion control switch Rotary light switch Audible alarm cut out switch Swing brake switch Engine emergency stop switch Working light switch Wiper switch Washer switch

1

4

2

5

3

P4

6 CS00F521

1 2 3 4 5 6

Cre 9-40330GB

Travel speed indicator Work mode indicator Idle mode indicator Coolant temperature indicator Hydraulic oil temperature indicator Fuel level indicator

Issued 12-01

4001-14

OPERATING PRINCIPLES Engine checks 1) Circuit configuration A2

S1

1

A3

R3 S9 P1 B41 R2 B1 A1

A2

A3 Current position signal

Current value

2

Target value Target position signal

3

4

5

Back-up mode Stop signal

CS01M536

1 Engine 2 Rack sensor 3 Test circuit 4 Linear motor control circuit 5 Electronic acceleration circuit A1 Computer A2 Engine controller A3 Electronic acceleration B1 Coolant temperature sensor B41Engine rpm sensor P1 Instrument panel Cre 9-40330GB

R2 Fuel flow adjustment resistor R3 Throttle volume S1 Key switch S9 Engine emergency stop switch

Issued 12-01

4001-15

2) Fuel consumption checking

4) Engine checking when stopped

1. The engine controller (A2) calculates the target speed on the basis: - of data on the work mode sent through CAN communications from the computer (A1), - on the voltage signals of the throttle volume (R3), - on the voltage signals of the water temperature sensor (B1) - of the voltage signals (key switch S1) that power the engine controller.

When the engine controller receives the engine stop signal (when the ignition is turned off or the emergency stop (S9) is activated), it (A2) transmits the rack "no injection" position signal to the electronic acceleration (A3) and activates the engine stop signal.

2. The engine controller (A2) calculates the fuel flow by analysing the difference between the target speed (electronic acceleration tachometric sensor) and the actual speed (engine rpm sensor (B41).

3. The engine controller (A2) converts the fuel flow in the target position of the electronic acceleration rack (A3) and corrects this target position according to the adjustment regulator (R2).

3) Engine checking while starting 1. By putting the switch (S1) in the start position, the start signal is sent simultaneously to the starter motor and the engine controller (A2).

5) Electronic acceleration power-assist error and back-up mode 1. The rack sensor signal comes to the engine controller (A2).

2. The engine controller (A2) compares the target position and the actual position of the rack.

3. If the engine controller (A2) determines that the rack is not in its correct target position, it considers it as a power-assist error and stops the engine.

4. If the back-up mode is activated during an electronic acceleration power-assist error (A3), the engine runs in back-up mode (see chapter on back-up mode).

2. The engine controller (A2) determines the fuel flow injection. This flow is determined by the data on the water temperature and the actual engine rpm.

3. Once the start signal is switched off, the engine controller (A2) goes from start fuel control to normal flow injection control.

Cre 9-40330GB

Issued 12-01

4001-16

Work mode selection 1) Circuit configuration 1

Y7 S3

A3 S4

2

P4 A1

P1

A2 CS01N579

2) Timing diagram e

Battery master key

1

2 Work mode

24V 0V

d

b

5V 0V

c

c

5V 0V

AUTO

S

H

S

H

L

S

AUTO

AUTO S

H

AUTO S

S

H

a

1 Engine 2 SERIAL communication A1 Computer A2 Engine controller A3 Electronic acceleration

Cre 9-40330GB

P1 P4 S3 S4 Y7

Instrument panel Monitor display Work mode switch Auto mode switch Main pump proportional solenoid

Issued 12-01

4001-17

3) Mode selection switch

4) Operation

a)

When the ignition switch is turned on, the "S" mode is selected by default (except if auto mode was selected at the time of turning off the ignition switch).

1. The work mode (S3) and auto mode (S4) switches signal is managed by the computer (A1) that changes the mode according to the input signal.

b)

Each time the work mode switch (S3) is pressed, the mode changes: S→H→L→S→H

c)

If the auto mode switch (S4) is activated, the mode changes to auto mode. If the auto mode switch (S4) is pressed once again, the mode changes to "S" mode.

d)

When auto mode is activated, if the work mode switch (S3) is pressed, the work mode does not change.

e)

After turning off the ignition switch in auto mode, when the ignition switch is turned on again, the mode remains automatic.

Cre 9-40330GB

2. The computer (A1) transmits the selected mode to the monitor display (P4) via series communication (2). The monitor display (P4) displays the selected mode.

3. The computer (A1) transmits the selected mode to the engine controller (A2) via CAN communications that control the electronic acceleration (A3).

The engine controller (A2) transmits the mode and the data concerning the rpm to the computer (A1) via CAN communications.

4. The computer (A1) calculates the proportional solenoid (Y7) current based on the selected mode and the data on the actual rpm and the target rpm of the engine.

5. The computer (A1) transmits the new data to the monitor display (P4) via series communications.

Issued 12-01

4001-18

H/S/L mode checking 1) Circuit configuration Y7

A1

A2

1 A3

Y5

CS00F509

1 Engine A1 Computer A2 Engine controller

A3 Electronic acceleration Y5 Power-up solenoid valve (yellow band) Y7 Main pump proportional solenoid

2) Fixed values for each model Hydraulic power boost Engine rpm (Max) (Max) Current (variable current) (Min) Engine rpm (Max -200) S mode Fixed current intensity (90% torque) Engine rpm (Max -300) L mode Fixed current intensity (70% torque) Idle Engine rpm Engine rpm at maximum torque H mode

rpm mA mA rpm

2250±10 415 305 2050±10

mA

305

rpm

1950±10

mA

< 50

rpm rpm

1000±10 1800

Automatic checking Automatic checking Constant ---------

NOTE: The values listed above are those in normal conditions, the following are exceptions: 1. If the target engine rpm is less than the maximum torque rpm, the pump is controlled by the "L" mode current value (same in H/S modes).

3. In "L" mode, if the hydraulic breaker or the grab is used, the pump is controlled by the "S" mode current value.

2. In "L" mode, if only travel is selected, the pump is controlled by the "S" mode current value.

4. If the engine coolant temperature is too low, or if the voltage coming in to the engine controller (A2) is too low, the idle rpm increases to avoid over-cooling of the engine or discharging of the battery.

Cre 9-40330GB

Issued 12-01

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