Case WX168, WX188 Wheeled Excavator Service Repair Manualublication by Repair manual download

SERVICEMANUAL WX168 WX188 4800537027/04/2016

Contents INTRODUCTION Engine.......................................................................................10 [10.202]Aircleanersandlines..............................................................10.1 [10.206]Fuelfilters..........................................................................10.2 [10.216]Fueltanks..........................................................................10.3 [10.254]Intakeandexhaustmanifoldsandmuffler.........................................10.5 [10.310]Aftercooler..........................................................................10.6 Transmission..............................................................................21 Four-WheelDrive(4WD)system..................................................23 [23.314]Driveshaft..........................................................................23.1 Frontaxlesystem.......................................................................25 Rearaxlesystem........................................................................27 [27.100]Poweredrearaxle..................................................................27.1 [27.106]Rearbevelgearsetanddifferential................................................27.2 [27.120]Planetaryandfinaldrives..........................................................27.3 Brakesandcontrols....................................................................33 4800537027/04/2016

Hydraulicsystems.......................................................................35

[35.000]Hydraulicsystems..................................................................35.1

[35.106]Variabledisplacementpump.......................................................35.2

[35.300]Reservoir,cooler,andfilters........................................................35.3

[35.304]Combinationpumpunits...........................................................35.4

[35.352]Hydraulicswingsystem............................................................35.5

[35.353]Hydraulictravelsystem............................................................35.6

[35.354]Hydrauliccentraljoint..............................................................35.7 [35.357]Pilotsystem........................................................................35.8

[35.359]Maincontrolvalve..................................................................35.9 [35.360]Hammerandrotatingbuckethydraulicsystem..................................35.10

[35.703]Stabilizerhydraulicsystem.......................................................35.11 [35.730]Positioningarmhydraulicsystem................................................35.12 [35.736]Boomhydraulicsystem..........................................................35.13

[35.737]Dipperhydraulicsystem..........................................................35.14

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[35.738]Excavatorandbackhoebuckethydraulicsystem................................35.15 [35.741]Dozerbladecylinders............................................................35.16 Framesandballasting.................................................................39 Steering.....................................................................................41 [41.101]Steeringcontrol....................................................................41.1 [41.106]Tierods.............................................................................41.2 [41.200]Hydrauliccontrolcomponents......................................................41.3 [41.216]Cylinders...........................................................................41.4

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Wheels......................................................................................44 [44.511]Frontwheels........................................................................44.1 [44.520]Rearwheels........................................................................44.2 Cabclimatecontrol.....................................................................50 Electricalsystems.......................................................................55 [55.000]Electricalsystem...................................................................55.1 [55.010]Fuelinjectionsystem...............................................................55.2 [55.011]Fueltanksystem...................................................................55.3 [55.012]Enginecoolingsystem.............................................................55.4 [55.014]Engineintakeandexhaustsystem.................................................55.5 [55.015]Enginecontrolsystem..............................................................55.6 [55.020]Transmissionspeedsensors.......................................................55.7 [55.036]Hydraulicsystemcontrol...........................................................55.8 [55.100]Harnessesandconnectors.......................................................55.10 [55.110]Electricalrotaryjoint..............................................................55.11 [55.302]Battery............................................................................55.12 [55.404]Externallighting..................................................................55.13 [55.416]Swingcontrolsystem............................................................55.14 [55.425]Boom,dipper,andbucketcontrolsystem........................................55.15 4800537027/04/2016

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Dozerbladeandarm...................................................................86 [86.110]Dozerblade........................................................................86.1 Platform,cab,bodywork,anddecals.............................................90 [90.124]Pneumatically-adjustedoperatorseat..............................................90.2

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INTRODUCTION

Contents

Safetyrules.....................................................................................4 Personalsafety.................................................................................5 Torque........................................................................................14 Basicinstructions-Howtousethemaintenancestandardandprecautions.................25 Basicinstructions-Precautionfordisassemblyandassembly...............................27 Basicinstructions-Electricalequipmentprecautions........................................29 Productidentification-Machineorientation..................................................43 4800537027/04/2016 2

INTRODUCTION

INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing

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Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.

Personalsafety

INTRODUCTION

Safetyrules

ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage. ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety. Information NOTE: 4800537027/04/2016 4

INTRODUCTION

mediately. DANGER Unexpectedmovement! Makesureparkingbrakeisapplied.Secure machinewithwheelchocks. Failuretocomplywillresultindeathorserious injury. D0013A

4800537027/04/2016 5

Personalsafety structedstaff;specificprecautionshavetobetakenwhen grinding,weldingorwhenusingmalletsorheavyhammers. Notauthorizedpersonsarenotallowedtorepairorcarry outmaintenanceonthismachine.Donotcarryoutany Askyouremployeraboutthesafetyinstructionsinforce Nobodyshouldbeallowedinthecabduringmachine maintenanceunlessheisaqualifiedoperatorhelping fromanyotherpositionthantheoperator’sseat. TULI12WEX2004AA 1 Nevercarryoutanyoperationonthemachinewhenthe engineisrunning,exceptwhenspecificallyindicated. Stoptheengineandensurethatallpressureisrelieved fromhydrauliccircuitsbeforeremovingcaps,covers, Allrepairandmaintenanceoperationsshouldbecarried Servicestairsandplatformsusedinaworkshoporinthe fieldshouldbebuiltincompliancewiththesafetyrulesin

TULI12WEX2005AA 2

INTRODUCTION Emergency ufacturer’sinstructions. SMIL12WEX0174AA 3 Equipment Wearclosefittingclothingandsafetyequipmentappropriateforthejob: • Safetyhelmet • Safetyshoes • Heavygloves • Reflectiveclothing • Wetweatherclothing equipmentshouldbeonhand: • Respirators(ordustproofmasks) • Earplugsoracousticearsprotections • Goggleswithlateralshieldormasksforeyesprotection jacketsorshirtswithopenzipswhichcouldgetcaughtinto TULI12WEX2008AA 4 Engine-Radiator NeverleavetheenginerunninginenclosedspaceswithTULI12WEX2009AA 5 4800537027/04/2016 6

INTRODUCTION Payattentiontorotatingcomponentsanddonotallow toanyonetoapproachtheseareastoavoidbecoming Hands,clothingortoolsgettingcaughtinthefanblades Forthisreasonavoidtouchingorapproachingallrotating Asurgingsprayofthecoolantfromtheradiatorcancause TULI12WEX2010AA 6 andlampsexplicitlydesignatedasexplosionproof.If TULI12WEX2011AA 7 Hydraulicsystems Relievetheresidualpressurebymovingthehydraulic Protectyourhandsandbodyfrompossiblejetsoffluids Swallowinghydraulicoilisaseverehealthhazard. TULI12WEX2012AA 8 4800537027/04/2016 7

INTRODUCTION ofinjuryimmediately. Anyfluidpenetratingtheskinmustberemovedwithinfew hourstoavoidseriousinfections. Flammablesplashesmayoriginatebecauseofheating nearlineswithfluidsunderpressure,resultinginserious Linesunderpressurecanaccidentallybepiercedwhen Arrangefortemporaryfireresistantshieldstoprotect upbindingagentanddisposeofitseparatelyfromother hydraulichosesimmediatelyondetectinganydamaged TULI12WEX2013AA 9 4800537027/04/2016 8

Hosesandtubes

Alwaysreplacehosesandtubesiftheconeendorthe foretighteningtheconnections.Clampsshouldbetightenedsufficientlytoholdthehosewithoutcrushingandto

Afterhosereplacementtoamovingcomponent,check thatthehosedoesnotfoulbymovingthecomponent

TULI12WEX2014AA

movementfromtheoriginalpositionhavefailedandwill subsequentlyoccuralongthehoselengthwithresultant hosefailure.

Ballooningofthehoseindicatesaninternalleakagedueto structuralfailure.Thisconditionrapidlydeterioratesand

sufferinternalstructuraldamagewhichcanresultinoil restriction,areductioninthespeedofoperationandultimatehosefailure.

condition.AlwayslubricatenewsealringsandO-rings withhydraulicoilbeforeinstallationtorelevantseats.

INTRODUCTION

O-rings

Free-moving,unsupportedhosesmustneverbeallowed totoucheachotherorrelatedworkingsurfaces.This duringmountingwhichwilljeopardizesealing. 4800537027/04/2016 9

INTRODUCTION Battery Batteriesgiveoffexplosivegases. Neverhandlenakedflamesandunshieldedlightsources nearbatteries.(Nosmokingisaddressedinnextinstrucinstructions: • Whendisconnectingthebatterycables,alwaysdiscon• • Nevershort-circuitthebatteryterminalswithmetalob• TULI12WEX2015AA 11 Antidote: • • mouth.Consultadoctor. • EYES:Rinseabundantlywithwaterfor 15min andconsultadoctor. • plodeifyouattempttochargethebatteryorifyoutryto Providegoodventilationwhenchangingabatteryorusing whenworkingnearabattery. TULI12WEX2016AA Disposeofusedbatteriesseparatelyfromotherwastein TULI12WEX2017AA 4800537027/04/2016

INTRODUCTION Flammableliquids Whenhandlingflammableliquids: • • Keepawayfromunshieldedlightsourcesandnaked Fuelsoftenhavealowflashpointandarereadilyignited. Use: • Drypowder • Carbondioxide • Foam stantaneouslyoncontactwithburningsubstancesand generatesshortcircuitsintheelectricalsystem,possibly TULI12WEX2016AA Stayawayfromopenflamesduringrefillingofhydraulic Fueloroilspillscancauseslippinghazards;thoroughly Alwaystightenthesafetyplugsoffueltankandhydraulic Neverusefueltocleanmachinepartsthatwillbeexposed Useanon-inflammableproductforcleaningparts. TULI12WEX2018AA Duringrefuellingholdthepistolfirmlyandalwayskeepit TULI12WEX2019AA 4800537027/04/2016 11

INTRODUCTION Tires Beforeinflatingthetires,alwayschecktheconditionof Wheninflatingtires,ensuretirepressuredoesnotexceed pressureoftherighttirecorrespondstothepressureof NOTE: heattreatmentsorbrazingsnotperformedcorrectlycan ures.Deflatethetiresbeforetheirdisassembly. itisnecessarytodeflatethetires.Inflatetiresbymeans ofaninflationpistolcompletewithextensionandpressure TULI12WEX2020AA Cleaning Cleantheexteriorofallcomponentsbeforecarryingout Solventsshouldbecheckedthattheyaresuitableforthe cleaningofcomponentsandalsothattheydonotriskthe Formachinecleaning,useajetofwarmwaterorsteam Avoiddirectsprayofsealsandseamstopreventwater TULI12WEX2021AA 4800537027/04/2016

•

INTRODUCTION

isthereforeadvisabletopreparesuitablecontainersto

quiringdisposal:

Wastedisposal

collectandstoremomentarilyallsolidandfluidmaterials thatmustnotbescatteredintheenvironmenttoavoid

Lubricatingoil

Brakesystemoil

tifreeze

Fuel

• Filterelements,airfilters

Battery Alsopollutingrags,paper,sawdustandglovesmustbe Donotusefoodorbeveragecontainersthatmaymislead

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•

conditioningrefrigerantsescapingintotheaircandamage theEarth’satmosphere.Governmentregulationsmayrequireacertifiedairconditioningservicecentretorecover formationontheproperwaytorecycleordisposeofwaste TULI12WEX2022AA

Torque

13mm 6mm 29.5N·m ( 22lbft ) M10 17mm 8mm ( 47lbft ) M12 19mm 10mm 108N·m ( 80lbft ) M14 22mm 12mm 175N·m ( 129lbft ) M16 24mm 14mm ( 195lbft ) M18 27mm 14mm ( 288lbft ) M20 30mm 17mm 540N·m ( 398lbft ) M22 32mm 17mm 740N·m ( 546lbft ) M24 36mm 19mm ( 686lbft ) M27 41mm 19mm 1370N·m ( 1010lbft ) M30 46mm 22mm 1910N·m ( 1409lbft ) M33 50mm 24mm 2550N·m ( 1881lbft ) M36 55mm 27mm ( 2316lbft )

INTRODUCTION

Bolttypes NOTICE:

twokindsofbolts;hexagonTbolts (1) andsocketbolts (2) .Thetwotypesofboltsaremadefromdifferentmate-

Specifiedtighteningtorquechart Boltdia.

10% 5.Makesurethatthenutandboltthreadsarecleanbeforeinstalling.Removedirtorcorrosion,ifany. 4800537027/04/2016

TULI12ECX0475AA 1

RAPH12CEX1320AA 2