Case cx460 crawler excavator service repair manual by 1639701yu

CX460 Crawler Excavators Table of Contents SECTION NÂ°

REFERENCE NÂ°

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

7-27690GB 9-36460GB

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

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

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

9-40950GB 9-43460GB 9-43450GB

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

9-42910GB 9-44830GB 9-36890GB 9-44820GB

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 9-44810GB 9-44590GB 9-53710GB

UNDERCARRIAGE HYDRAULICS

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

DIVISION/SECTION

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9-43470GB

9-44560GB 9-36910GB 9-43230GB 9-53950GB 9-53990GB 9-43250GB 9-43390GB 9-53980GB 9-53970GB 9-43330GB 9-54310GB 9-53690GB 9-54000GB 7-28210GB 9-54050GB 7-27942GB 9-54100GB 9-43190GB 9-54140GB 9-42740GB 9-43160GB

DIVISION/SECTION 9

SECTION N°

REFERENCE N°

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

9-43410GB 9-53280GB 9-40960GB 9-53410GB 7-xxxxxFR 7-29910GB 7-xxxxxFR 7-xxxxxFR 9-36070GB

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

Cre 9-53350GB

Edition 10-02

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

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.

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1001-5

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

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

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

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

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

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

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

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

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

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1001-6

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of Cap Screws 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.

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1001-7

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

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

Socket Head Cap Screw

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Spanner Tightening torque

M6 [mm]

M10

M12

M14

M16

M18

M20

[in.]

0.39

0.51

0.67

0.75

0.87

0.95

1.06

1.18

[Nm]

6.9

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]

[in.]

0.20

0.24

0.32

0.39

0.47

0.55

0.67

[Nm]

8.8

21.6

42.1

78.4

117.6

176.4

245.0

343.0

[lb-ft]

6.5

15.9

31.1

57.8

86.8

130.1

180.8

253.1

Issued 09-00

1001-8

NOTES ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... ..................................................................................................................................................................................... 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1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

Case

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1002

Section

1002-2

TABLE OF CONTENTS TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE ....................................................3 Machine.................................................................................................................................................................3 Engine ................................................................................................................................................................... 3 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 Low 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.

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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

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......................................................................................................................................................

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1002-4

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

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

Hydraulic fluid

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

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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.

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1002-6

Low 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 -36Â°C, use a 50% mixture of antifreeze in an ethylene glycol base. In environments with a temperature less than -36Â°C, it is recommended that you use a 40% water and 60% antifreeze mixture.

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1002-7

SPECIFICATIONS CX460

Engine Make ................................................................................................................................................................... Isuzu Model.......................................................................................................................................................... 6SD1XQB Type: Four stroke, water cooled with overhead valves, direct injection in-line cylinder (electronic control) with turbocharger. Number of cylinders...................................................................................................................................................6 Bore and stroke .................................................................................................................................... 120 x 145 mm Displacement............................................................................................................................................... 9839 cm3 Operating conditions Idle..................................................................................................................................................................900 rpm Max speed ....................................................................................................................................................1950 rpm Power ECC 1289 ....................................................................................................................... 250.1 kW (335.4 HP) Max torque................................................................................................................................ 1344 Nm at 1600 rpm

Capacities Engine oil capacity.......................................................................................................................................... 33 litres Engine cooling circuit................................................................................................................................... 45.5 litres Capacity of only the radiator .......................................................................................................................... 21 litres Fuel reservoir................................................................................................................................................ 611 litres Hydraulic fluid reservoir capacity .................................................................................................................. 220 litres Total hydraulic circuit capacity ...................................................................................................................... 450 litres Capacity of only the oil-cooler ..................................................................................................................... 16.5 litres Travel reduction gear housing capacity .......................................................................................................... 15 litres Swing drive housing capacity ...................................................................................................................... 10.5 litres Idler pulley capacity ....................................................................................................................................... 260 cm3 Upper roller capacity........................................................................................................................... 245 to 250 cm3 Lower roller capacity...................................................................................................................................... 280 cm3 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 ...................................................................................................................................................... 140 Ah Reserve ...................................................................................................................................................... 160 min Cold startability at -17Â° .................................................................................................................................. 800 A Load for load control...................................................................................................................................... 400 A Starter Voltage ........................................................................................................................................................24 volts Power ...........................................................................................................................................................5.5 kW Voltage regulator .............................................................................................................. built-in, without adjustment

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1002-8 CX460

Hydraulic system Main hydraulic pump Variable flow dual pump, with axial pistons. Maximum flow......................................................................................................................................... 2 x 360 l/min Displacement............................................................................................................................................2 x 182 cm3

Hydraulic pilot pump Fixed flow pump Max flow ......................................................................................................................................................... 30 l/min Displacement................................................................................................................................................... 15 cm3

Pressure setting Pilot circuit relief ..........................................................................................................................................39 ± 1 bar Main circuit relief (standard) ......................................................................................................................314 ± 3 bar Main circuit relief (power-up) .....................................................................................................................343 ± 5 bar Secondary relief (boom raising, dipper and bucket) ..................................................................................363 ± 5 bar Secondary reliefs (boom lowering) ............................................................................................................245 ± 5 bar Secondary reliefs (swing) ..........................................................................................................................294 ± 5 bar Secondary relief (travel) ............................................................................................................................380 ± 5 bar Safety valve (boom and dipper) .................................................................................................................363 ± 5 bar

Cylinder Boom cylinder Cylinder bore ..................................................................................................................................................170 mm Rod diameter ..................................................................................................................................................115 mm Stroke ........................................................................................................................................................... 1550 mm

Dipper cylinder Cylinder bore ..................................................................................................................................................200 mm Rod diameter ..................................................................................................................................................140 mm Stroke ........................................................................................................................................................... 1820 mm

Bucket cylinder Cylinder bore ..................................................................................................................................................165 mm Rod diameter ..................................................................................................................................................115 mm Stroke ........................................................................................................................................................... 1285 mm

Cylinder leakage - attachment lowering (without load) Boom cylinders (rods retracted) ............................................................................................................... 3 mm/5 min Dipper cylinder (rod extended) ................................................................................................................. 3 mm/5 min Dipper cylinder (rod extended) ................................................................................................................. 7 mm/5 min Total (at the end of the attachment).................................................................................................... 200 mm/10 min

Cylinder speed (in S mode) Boom raised (bucket open and on the ground) ................................................................................................... 4.9 s Boom lowering (bucket open) .............................................................................................................................. 3.6 s Dipper extend ...................................................................................................................................................... 3.8 s Dipper retract....................................................................................................................................................... 4.7 s Bucket open......................................................................................................................................................... 3.4 s Bucket close ........................................................................................................................................................ 5.6 s

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1002-9

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. CX460

Swing Fixed flow engine with axial pistons. Automatic disk brakes. Upperstructure frame swing speed..................................................................................................................9.0 rpm Displacement................................................................................................................................................. 250 cm3 Work flow ...................................................................................................................................................... 360 l/min Reduction ratio .................................................................................................................................................27.143 Brake torque ..............................................................................................................................................Š 1287 Nm Minimum brake release pressure ......................................................................................................................29 bar Permissible motor leak ................................................................................................................................... 18 l/min

Travel Two-speed motor with axial pistons. Automatic disk brakes. Low speed ....................................................................................................................................................... 3.1 kph High speed ...................................................................................................................................................... 5.3 kph Gradeability .................................................................................................................................................70% (35°) Tractive effort ............................................................................................................................................ 35 600 daN Displacement.................................................................................................................................... 290.7/170.1 cm3 Work flow ................................................................................................................................................... 360.4 l/min Reduction ratio .................................................................................................................................................60.652 Braking torque (reduction gear excluded)....................................................................................................Š 902 Nm Number of sprocket turns (10 turns) Mode "S", high speed.................................................................................................................................... 18.2 s Mode "S", low speed ..................................................................................................................................... 30.5 s Permissible deviation in travel over a distance of 20 m Mode "H", full speed..........................................................................................................................................1 m Permissible motor leak ................................................................................................................................... 14 l/min

Undercarriage One-piece frame with fabricated elements. Lubricated rollers and idler wheels. Grease track tension. Weight load on track with 600 mm track pads .............................................................................................................................0.81 bar with 750 mm track pads .............................................................................................................................0.66 bar with 900 mm track pads .............................................................................................................................0.56 bar Track tension........................................................................................................................................360 to 380 mm

Attachment Break-out force ......................................................................................................................................... 27 000 daN Break-out force 2.50 m dipper ....................................................................................................................................... 28 100 daN 3.40 m dipper ....................................................................................................................................... 22 900 daN

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1002-10 CX460

Weight of components Engine .............................................................................................................................................................. 700 kg Hydraulic pump................................................................................................................................................. 210 kg Attachment control valve .................................................................................................................................. 426 kg Swing motor and reduction gear assembly ...................................................................................................... 534 kg Travel motor and reduction gear assembly ....................................................................................................... 600 kg Boom cylinder....................................................................................................................................................xxx kg Dipper cylinder...................................................................................................................................................xxx kg Bucket cylinder ..................................................................................................................................................xxx kg Counterweight ................................................................................................................................................ 9180 kg Cab ................................................................................................................................................................... 254 kg Turntable........................................................................................................................................................... 710 kg Upperstructure assembly............................................................................................................................. 18 260 kg Hydraulic swivel .................................................................................................................................................. 54 kg Frame assembly .......................................................................................................................................... 17 750 kg Machine without attachment........................................................................................................................ 36 710 kg Attachment .................................................................................................................................................. 10 230 kg Boom assembly .............................................................................................................................................. 4810 kg Dipper assembly............................................................................................................................................. 3040 kg Radiator and oil-cooler assembly ..................................................................................................................... 170 kg Fuel reservoir.................................................................................................................................................... 242 kg Hydraulic reservoir............................................................................................................................................ 220 kg Idler wheel ........................................................................................................................................................ 235 kg Upper roller......................................................................................................................................................... 45 kg Lower roller ......................................................................................................................................................... 80 kg Tension damper ................................................................................................................................................ 359 kg 600 mm track .................................................................................................................................................. 2590 kg 750 mm track .................................................................................................................................................. 2935 kg 800 mm track .................................................................................................................................................. 3050 kg 900 mm track .................................................................................................................................................. 3285 kg

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1002-11

DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY Sprocket Dimensions a

Ød

Øb Øc

CS01B512

Mark a Øb Øc Ød P

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

90 78 773.6 761.6 867.5 854.5 847.3 --229 ---

Gauge 300 228.6 44.8 5.4

3. 1°

117.8

99.6

37.9

6 R 3∼

R 36 .9

95 .

.7 R 50

24.5

90°

° 40.2

87.6

7 2 3. R4 .8 33 R4 CI01N501

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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

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

Ød

CS01B514

Gauge 250 204

R50

° 10

15 22.5

42.5

102

0.2

CI01N502

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1002-13

Upper roller Dimensions Mark g

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

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

CS01B516

Gauge 210

104 97

° .1 13

125

120 245 CI01N503

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1002-14

Lower roller Dimensions d

Øe

Øa

b CS01B518

Mark Øa b d Ø e (shaft)

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

Mark

200 188 25 20 223 233 85 84

Dimension (mm) Standard Limit Standard Limit Standard Limit

Ø e (ring) f g

85 86 93 92 24.5 23.9

Gauge 280 260 230.6 218

38.1

42.5

5°

R1 0

° 20

23.5

5 R

° 1.5

15°

5 R1

100

CI01N504

Cre 9-36460GB

Issued 12-01

1002-15

Track

c d Øe

Øe'

Øf'

Øf

Øg'

Øg h

a CS01B520

Mark a b c d

Cre 9-36460GB

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

52 32 129 121 47 45.5 28 26.5

Mark Standard Ø e (ring) Limit Standard Ø f (ring) Limit Standard Ø g (shaft) Limit Standard h Limit Standard Ø e' (bushing) Limit Standard Ø f' (bushing) Limit Standard Ø g' (shaft) Limit

Dimension (mm) 73.33 68.23 49.2 51.7 48.5 45.1 228.6 --73.33 68.23 49.5 52.4 48.8 44.9

Issued 12-01

1002-16

DIMENSIONS AND WEAR LIMITS OF ATTACHMENT LINKAGES 4

11 10

CS01B521

1. Boom foot/Frame a

Ød

CS01B522

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

Cre 9-36460GB

Dimension (mm) 874 882 873 870 1.5 to 3.5 Shims 120 119 120 121.5

Issued 12-01

1002-17

2. Boom cylinder foot/Frame a

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

126 132 125 122 1.5 to 3.5 Shims 120 119 120 121.5

3. Boom cylinder head/Boom a

Ød

CS01B524

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

Cre 9-36460GB

Dimension (mm) 140 137 679 675 1.5 to 3 Shims 120 119 120 121.5

Issued 12-01

1002-18

4. Dipper cylinder foot/Boom a

Mark

Dimension (mm)

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

Ød

156 162 155 153 1 to 3.5 Shims 120 119 120 121.5

CS01B525

5. Boom/Dipper a

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

98 96 437 440 436.6 433.5 1 to 2 Shims 120 119 120 121.5 120 121.5

6. Dipper cylinder head/Dipper Mark Standard Limit Standard b Limit Standard c (a - b) Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit

Ød b a

c CS01B527

Cre 9-36460GB

Dimension (mm) 156 161 155 153 1 to 3 Shims 120 119 120 121.5

Issued 12-01

1002-19

7. Bucket cylinder foot/Dipper a b

Mark

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) 141 146 140 138 1 to 3 Shims 110 109 110 111.5

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 Ød

Dimension (mm) 50 47 442 438 1.5 to 2 Shims 95 94 95 96.5

CS01B529

9. Compensator/Bucket Mark

Ød

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

Dimension (mm) 480 485 479 476 1.5 to 4 Shims 100 99 100 101.5

CS01B530

Cre 9-36460GB

Issued 12-01

1002-20

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

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

50 48 441 436 1.5 to 2.5 Shims 141 143 140 138 1.5 to 4 Shims 110 109 111 111.5 110 111.5

11. Dipper/Bucket Mark

Øe

a b

c (a - b) a

d Ø e (shaft)

c Ø e (dipper) CS01B532

Cre 9-36460GB

Ø e (bucket)

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

480 --479 476 1.5 to 4 Shims 16 10 100 99 100 101.5 100 101.5

Issued 12-01

1002-21

SPECIAL TORQUE SETTINGS No. 1*

Component Travel motor and reduction gear assembly

Screw (Ă&#x2DC;)

Wrench (mm)

Torque setting (Nm)

M24

900-1050

Sprocket

M24

900-1050

Idler wheel

M16

267-312

Upper roller

M20

521-608

Lower roller

M24

900-1050

Chain guide

M24

900-1050

6â&#x20AC;&#x2122;

Chain guide

M24

353-431

Track pad

M24

1236-1510

Counterweight

M30

1765-2010

Turntable (frame)

M24

950-1050

Turntable (upperstructure)

M24

950-1050

11 *

Swing motor and reduction gear assembly

M24

900-1050

12 *

Engine

M20

289-337

13 *

Engine bracket

M10

64-74

Radiator

M16

147-176

15 *

Hydraulic pump

M10

64-74

M20

Hexagonal

367-496

16 *

Hydraulic reservoir

M16

226-265

17 *

Fuel reservoir

M16

226-265

18 *

Control valve

M20

333-392

19 *

Hydraulic swivel

M16

267-312

Cab

M16

78-80

Battery

M10

20-29

Undercarriage (transport/working position)

M30

1470-1920

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

16 18

12 13 14

21 7 19

22 9 10 6

20 3

4 CS00E507

Cre 9-36460GB

Issued 12-01

1002-22

6â&#x20AC;&#x2122;

CS01N968

CS01N502

4 5 8

3 CS01N501

CS01N503

11 13 12 10 9

9 CS01N504

CS01N972

14 CS01N505

Cre 9-36460GB

CS01N506

Issued 12-01

1002-23

18 16

17 CS01N507

CS01N508

CS01N509

19 21

CS01N979

CS01N980

CS01N981

CS01N510

Cre 9-36460GB

Issued 12-01

1002-24

MACHINE OVERALL DIMENSIONS G

N E

B F I H D C

M K J L O CS01M503

A B C D E F G H I J (working position) J (transport position) K L (with 600 mm track pads, working position) L (with 600 mm track pads, transport position) L (with 750 mm track pads, working position) L (with 750 mm track pads, transport position) L (with 800 mm track pads, working position) L (with 800 mm track pads, transport position) L (with 900 mm track pads, working position) L (with 900 mm track pads, transport position) M N O (working position) O (transport position)

Cre 9-36460GB

CX460 Dippers 2.50 m 3.40 m 3.73 m 3.66 m 3.42 m 3.42 m 11.97 m 11.91 m 6.33 m 6.33 m 3.04 m 3.04 m 1.48 m 1.48 m 3.60 m 3.60 m 5.45 m 5.45 m 4.40 m 4.40 m 2.89 m 2.89 m 2.39 m 2.39 m 0.60 m 0.60 m 3.49 m 3.49 m 2.99 m 2.99 m 3.64 m 3.64 m 3.14 m 3.14 m 3.69 m 3.69 m 3.19 m 3.19 m 3.79 m 3.79 m 3.29 m 3.29 m 0.74 m 0.74 m 3.25 m 3.25 m 3.70 m 3.70 m 3.20 m 3.20 m

Issued 12-01

Section 2000

CNH

Cre 9-54180GB

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 for the engine ............................................................................................................... 313 Â± 24 Nm

Cre 9-54180GB

Issued 10-02

2000-3

ENGINE Removal and installation

STEP 5

STEP 1

Refer to Sec tion 20 01 an d r emove the r adiator an d oil-cooler assembly.

STEP 6

JS00163A

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

CD02K003

STEP 2

Remove the engine shutdown control (arrow).

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

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

STEP 3

STEP 7 1 1

CD02H003

Disconnect the b attery g round (-) cable (1) f rom the battery.

CD02K004

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

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

Cre 9-54180GB

Issued 10-02

2000-4

STEP 8

STEP 11

1 1

CD02K005

CD02K007

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

Disconnect th e s peed control s ensor e lectrical connections (1).

STEP 9

STEP 12

2 3

1 CD02K006

Label and disconnect the oi l pr essure sensor electrical connection (1), disconnect the starter motor electrical cables (2) and the earthing braid (3).

STEP 10

CD02K008

Label an d disconnect th e e lectrical connections o f the electronic regulation (1) from the engine.

STEP 13

1 1

CD02K009

CD00J030

Label a nd d isconnect th e el ectrical supply ( 1) to th e pre-heating plugs.

Cre 9-54180GB

Remove the hose connecting the turbo-charger to the air filter (1).

Issued 10-02

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 in the machine, proceed in the reverse order from removal. Before operating the machine, carry out the following operations:

1 CD02K010

Label an d d isconnect th e e lectrical c onnections t o the alternator (1).

STEP 15

- Bleed an d pr ime th e fu el system ( see Operatorâ&#x20AC;&#x2122;s Manual). - Fill and bleed the eng ine cooling sy stem ( see Operatorâ&#x20AC;&#x2122;s Manual). - Check the hy draulic, fu el a nd c ooling s ystems for leaks. - Check the oil level in the hydraulic reservoir. Top up if necessary.

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

STEP 16 Install a s uitable l ifting dev ice on th e e ngine l ifting rings (for the weight of the engine, see Section 1002).

STEP 17

CD02K011

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. Respect the colours, light blue on the fan side, light green on the hand-wheel side. Tighten the engine retaining screws to torque (see special torque settings on page 2).

Cre 9-54180GB

Issued 10-02

2000-6

Issued 10-02

2001 Section 2001 RADIATOR AND OIL-COOLER

Case

Cre 9-43480GB

2001-2

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

SPECIFICATIONS Coolant solution.............................................................................................................................. See Section 1002 Total cooling system capacity ........................................................................................................................ 42 litres Thermostat opening range Starts to open ..................................................................................................................................................82°C Completely open .............................................................................................................................................97°C Hydraulic fluid ................................................................................................................................. See Section 1002

Cre 9-43480GB

Issued 03-02

2001-3

CHANGING THE RADIATOR OR THE OIL-COOLER Description

6 5 8

9 9

3 5 2

1 7 1 2

11 CI02A513

1 2 3 4 5 6

SCREW PIPE OIL COOLER OIL-COOLER HOSE HOSE

Cre 9-43480GB

7 8 9 10 11

RADIATOR HOSE HOSE HOSE HOSE Issued 03-02

2001-4

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

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

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

Removal of the radiator and oilcooler assembly STEP 1

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

Disconnect the radiator hoses (5) and (6) from the oilcooler, finally drain the latter into a clean container.

STEP 8 Remove the expansion reservoir hose (8) from the radiator (7). Disconnect the return hose (9) and the water pump suction hose (10) from the engine.

STEP 9 CD01K055

Remove the hood (1) from the engine.

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

B A

STEP 4 Drain the cooling system (see Operatorâ&#x20AC;&#x2122;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 guardrails (B). Remove the screws (C).

Cre 9-43480GB

Issued 03-02

2001-5

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 Operatorâ&#x20AC;&#x2122;s Manual). - Check the engine cooling system for leaks.

Cre 9-43480GB

Issued 03-02

2001-6

Cre 9-43480GB

Issued 03-02

3001 Section 3001 REMOVAL AND INSTALLATION OF THE FUEL TANK

Case

Cre 9-43470GB

3001-2

3 3 4 5

SPECIFICATIONS See Section 1002.

Cre 9-43470GB

Issued 03-02

3001-3

FUEL TANK Removal STEP 1

STEP 9 Remove the screws (8) and the protective plate (9) from on top of the fuel reservoir (1).

STEP 10 Loosen the two screws (10) located under the machine. Open the side portion of the machine and 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 machine on hard, flat ground. Lower the attachment to the ground.

Remove the two screws that hold the fuel oil filter. Attach labels on the two hoses. Remove the fuel oil filter by removing the two hoses and the retaining clips.

STEP 2

STEP 12

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

Shift the plastic protection (13) from the fuel sensor (14). Remove the retaining screws (15) then the fuel sensor (14) as well as the seal (16).

JS00163A

STEP 3 Turn the ignition key to "ON" without starting the engine.

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

STEP 13 Remove the six screws (17) from the fuel tank (1), and the shims (18).

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

STEP 5

STEP 15

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

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

Remove the access panel under the fuel reservoir (1).

STEP 6 Open the filling plug (2) of the tank (1). Bleed the remaining fuel using the valve (3) then remove the latter. Remove the filter (19) and the fuel gauge (20).

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 screws (6) on top and then inside the front boot, then remove the protective housing (7).

Cre 9-43470GB

Issued 03-02

3001-4

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

STEP 1 Using a hoist, position the fuel reservoir (1) on the machine.

STEP 2 Install the shims (18) as well as the six screws (17), tighten the screws to a torque of 232.4 to 276 Nm. Install the valve (3) and tighten the valve (3) to a torque of 14.7 Nm.

STEP 3 Install a new seal (16), then the fuel probe (14) using the five screws (15), reposition the plastic protection correctly (13).

STEP 7 Install the protective housing (7) on top of the front boot using the screws (6) then put back the screw mask.

STEP 8 Install the access ramp (5) using screws (4). Close 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 oil filter on the reservoir using screws. Install the two hoses by taking help of the labels attached during removal. Tighten using retaining clips.

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

STEP 6 Install the protective plate (9) on top of the fuel reservoir (1). Tighten the screws (8).

Cre 9-43470GB

Issued 03-02

3001-5

Description Location 6

9 11

5 12 11

CS02B557

4 5 6 7 8 9 10 11 12

CS02B556

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

Cre 9-43470GB

Issued 03-02

3001-6

Fuel tank 2 20

14 13

16 15

18 17 3 CS02C553

1 2 3 13 14

FUEL RESERVOIR PLUG VALVE PLASTIC PROTECTION FUEL PROBE

Cre 9-43470GB

15 16 17 18 19

SCREW SEAL SCREW SHIM FILTER

Issued 03-02

4001 Section 4001 ELECTRICAL AND ELECTRONIC CIRCUIT AND TROUBLESHOOTING

Case

Cre 9-40950GB

4001-2

TABLE OF CONTENTS SPECIFICATIONS.................................................................................................................................................... 4 SPECIAL TOOLS ..................................................................................................................................................... 4 OPERATING PRINCIPLES .................................................................................................................................... 16 Engine checks ....................................................................................................................................................16 Work mode selection ..........................................................................................................................................18 H/S/L mode checking .........................................................................................................................................20 Auto mode checking ...........................................................................................................................................21 Limitation of black smoke ...................................................................................................................................22 Engine idle checking (automatic/manual) ..........................................................................................................24 Breaker mode checking .....................................................................................................................................25 Acceleration checking ........................................................................................................................................26 Automatic engine preheat ..................................................................................................................................27 Auto engine warm-up .........................................................................................................................................30 Idle checking using the battery voltage and the coolant temperature ...............................................................32 Engine emergency stop .....................................................................................................................................34 Back-up mode ....................................................................................................................................................36 Function locking .................................................................................................................................................38 Power boost .......................................................................................................................................................39 Swing brake .......................................................................................................................................................40 Travel mode .......................................................................................................................................................42 Supply cut-off delayed ........................................................................................................................................45 Protection by power transistor ............................................................................................................................46 Coolant temperature indicator ............................................................................................................................46 Hydraulic oil temperature indicator .....................................................................................................................48 Fuel level ............................................................................................................................................................49 Engine fuel injection pump electronic regulator .................................................................................................50 ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode)........................................................... 52 Access to monitor displays .................................................................................................................................52 Machine condition ..............................................................................................................................................53 Diagnostic code ..................................................................................................................................................56 Machine history ..................................................................................................................................................59 Re-initialisation ...................................................................................................................................................62 WARNING MESSAGES ......................................................................................................................................... 65 Message display ................................................................................................................................................65 EXCAVATOR MODEL SELECTION PROCEDURE .............................................................................................. 66 Changing the language code .............................................................................................................................67 CHANGING THE ACCESS CODE FOR THE ANTI-THEFT SYSTEM .................................................................. 68

Cre 9-40950GB

Issued 01-02

4001-3 TROUBLESHOOTING ........................................................................................................................................... 69 Prior inspections .................................................................................................................................................69 Reading the organisation charts ........................................................................................................................70 Procedures .........................................................................................................................................................71 Fuel ....................................................................................................................................................................72 Add coolant solution ...........................................................................................................................................73 Low engine oil pressure .....................................................................................................................................74 Overheating ........................................................................................................................................................75 Defective battery charge circuit ..........................................................................................................................78 Electrical system troubleshooting .......................................................................................................................80 Travel .................................................................................................................................................................84 ELECTRICAL INSPECTION OF COMPONENTS.................................................................................................. 85 Inspection equipment .........................................................................................................................................85 Proportional solenoid .........................................................................................................................................87 Engine emergency stop motor ...........................................................................................................................88 6 solenoid valve bank .........................................................................................................................................89 Engine rpm sensor .............................................................................................................................................89 Coolant solution and hydraulic oil temperature sensor ......................................................................................90 Pressure sensor .................................................................................................................................................91

Cre 9-40950GB

Issued 01-02

4001-4

SPECIFICATIONS See section 1002.

SPECIAL TOOLS

BS98G045

1 2

Service connector kit CAS-30039 Multimeter CAS-1559

Cre 9-40950GB

Issued 01-02

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