Case CX300C Crawler Excavator Service Repair Manual (APAC Region – ANZ Market) by Repair manual download

SERVICEMANUAL CX300CCrawlerexcavatorsLCversion(TIER4)-APACRegion-ANZMarket 4779540514/10/2015

Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.102]Panandcovers....................................................................10.2 [10.106]Valvedriveandgears..............................................................10.3 [10.101]Cylinderheads.....................................................................10.4 [10.105]Connectingrodsandpistons.......................................................10.5 [10.218]Fuelinjectionsystem...............................................................10.9 [10.250]Turbochargerandlines...........................................................10.10 Hydraulicsystems.......................................................................35 [35.000]Hydraulicsystems..................................................................35.1 [35.300]Reservoir,cooler,andfilters........................................................35.2 [35.106]Variabledisplacementpump.......................................................35.3 4779540514/10/2015

[35.736]Boomhydraulicsystem..........................................................35.13 [35.737]Dipperhydraulicsystem..........................................................35.14 [35.738]Excavatorandbackhoebuckethydraulicsystem................................35.15 [35.734]Toolquickcouplerhydraulicsystem.............................................35.16 Framesandballasting.................................................................39 Tracksandtracksuspension........................................................48 Cabclimatecontrol.....................................................................50 Electricalsystems.......................................................................55 [55.000]Electricalsystem...................................................................55.1 [55.100]Harnessesandconnectors.........................................................55.2 [55.525]Cabenginecontrols................................................................55.3 [55.015]Enginecontrolsystem..............................................................55.4 [55.201]Enginestartingsystem.............................................................55.5 [55.301]Alternator...........................................................................55.6 [55.302]Battery..............................................................................55.7 4779540514/10/2015

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[55.640]Electronicmodules...............................................................55.14 [55.512]Cabcontrols......................................................................55.15 [55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.17 [55.524]Cabcontrols(Liftarm,Boom,Dipper,Bucket)...................................55.19 [55.992]Anti-theftsystem.................................................................55.28 [55.DTC]FAULTCODES..................................................................55.29 Booms,dippers,andbuckets.......................................................84 [84.910]Boom...............................................................................84.1 [84.912]Dipperarm.........................................................................84.2 Platform,cab,bodywork,anddecals.............................................90 [90.150]Cab.................................................................................90.1 4779540514/10/2015

[90.120]Mechanically-adjustedoperatorseat...............................................90.3 4779540514/10/2015

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INTRODUCTION

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INTRODUCTION

Contents

Safetyrules.....................................................................................4 Safetyrules–Generalinformation.............................................................5 Torque–Boltandnut.........................................................................16 Productidentification-Machineorientation..................................................47 4779540514/10/2015 2

Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein

Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.

INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing

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Personalsafety

Machinesafety

Information

NOTE:

INTRODUCTION Safetyrules

ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY.

NOTICE: Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage. ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.

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Bearing

INTRODUCTION Safetyrules–Generalinformation Cleaning Aftercleaning,drywell,andinjectoilinallparts. Inspection

Needlebearing Gear Alwaysinstallnewoilseals,O-rings,andgaskets. Shaft Checkthebearingsandcheckfordamagedoilsealsontheshaft. Serviceparts InstallCASECONSTRUCTIONgenuineserviceparts. Lubricants(fuel,hydraulicoil) Usetheoilfromthespecifiedcompanyorspecifiedintheoperator'smanualorserviceManual. 4779540514/10/2015 5

WARNING:

WARNING: WARNING:

WARNING:

Checkthatnooneiswithinthemachine’soperatingrange.

WARNING:

INTRODUCTION Safetyrules–Personalsafety

Itgivesinformationconcerningthesafetyoftheoperatorandthoseinthesurroundings. Alwayscomplywithwarningsandprecautionssoastoavoidanyaccidents. Checkwhetherallwarninglabelsareinplace.

Readtheoperator'smanualtogainathoroughunderstandingofmachinecontroloperations.

Checkthesafetymessagesintheoperator'smanualbeforestartingtheengine.

Theoperator'smanualcanbepurchasedatyourCASECONSTRUCTIONdealer.

Workingwithsloppyclothesorclotheswithwhichsafetycannotbeensuredleadstodamagetothemachine andinjurytotheoperator. Inordertoworkmoresafely,itisrecommendedtowearadditionalsafetyequipment.

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WARNING:

WARNING: WARNING:

WARNING:

INTRODUCTION

Checkthatthereisnooneinthesurroundingsbeforedrainingthepressurefromhydrauliccircuitsduring

Usegloveswhenhandlinghigh-temperatureparts.

Weareyeprotectionwhenusingahammertoinstallapinorwhenworkingwithagrinder.

Checktheoil,coolant,grease,andtools. Payenoughattentiontosafety.

Someofthemachine'spartsareextremelyheavy. Forweightsandprocedures,seetheServiceManual.

Exhaustgasesaretoxic.

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INTRODUCTION Safetyrules–ROPSjudgment 1.Purpose TheweightandboomofthemachinegreatlyeffectswhethertheROPSjudgmentcriteriaissatisfiedornot. TheROPStestassumesthattheweightbeingusedistheweightofthemachinewhenthemaximumnumberof Weight seriousinjurywhenthemachinefallsover. ○ Weight(X3model) Machinebodytotalweight Class CX75C CX80C16000kg ( CX145C CX130C 20500kg ( 45194.76lb)max. CX160C 28000kg ( 61729.43lb CX235C CX210C CX250C CX250CLR31000kg ( 68343.30lb)max. CX300C 50000kg ( CX470C *TheROPStestassumesthattheCX470Chasacageguard(alone). ○ Weight(X2model) indicatedontheplatewithintheROPScab.) Machinebodytotalweight Class CX130B CX160B CX180B CX210B 26600kg ( CX240B 4779540514/10/2015 8

INTRODUCTION Boomposition WARNING: • • Itisnecessarytoconsultwithusifitispossiblethattheboom'spositionhasbeenloweredbymodification. • Theextenttowhichaboompositionhasmovedcannotbedeterminedinthesamewayforallmachines. SMIL14CEX2001EA 1 (a)Groundpoint Withthetipofthebucketincontactwiththegroundsurfaceatmaximumworkradius,iftheposition(*inthediagram) thatoverlapswiththecabwhenviewedfromthesideismarkedlylowerthanthatofastandardmachine(standard Also,withamachinebodywithacabmountedthatcanwithstandupto 31ton ,theeffectofmountinga 24ton 21ton 3.Prohibiteditems • • Modificationprohibited(Redpart) Modificationpermittedunderconditions(Graypart) Barweldingandmakingholes(uptodiameter 20mm ( 4779540514/10/2015 9

INTRODUCTION [X3cab(CX75C/CX80C/CX145C)] SMIL15CEX3363FA 2 4779540514/10/2015

[X3cab(CX235C)]

SMIL15CEX3364FA 3

ThecabfortheMSRmodel(CX235C)isthecaboftheMSRmodelonthediagram(CX75C/CX80C/CX145C)with

INTRODUCTION

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SMIL15CEX3365FA

INTRODUCTION [X3cab(CX130C/CX160C)]

4 4779540514/10/2015

INTRODUCTION [X3cab(CX210C/CX240C/CX290C)] SMIL15CEX3366FA 5 4779540514/10/2015

INTRODUCTION [X3cab(CX350C)] SMIL15CEX3367FA 6 4779540514/10/2015