SERVICE MANUAL Crawler Excavator CX800B Part number 48020292 English June 2016 © 2016 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICEMANUAL CX800BCX800BRTCMASSEXC 4802029215/06/2016
Contents INTRODUCTION Machinecompletionandequipment..............................................05 Engine.......................................................................................10 [10.501]ExhaustGasRecirculation(EGR)exhausttreatment..............................10.1 [10.001]Engineandcrankcase.............................................................10.2 [10.102]Panandcovers....................................................................10.3 [10.106]Valvedriveandgears..............................................................10.4 [10.101]Cylinderheads.....................................................................10.5 Hydraulicsystems.......................................................................35 [35.300]Reservoir,cooler,andfilters........................................................35.2 4802029215/06/2016
Framesandballasting.................................................................39 [39.140]Ballastsandsupports..............................................................39.1 Tracksandtracksuspension........................................................48 [48.130]Trackframeanddrivingwheels....................................................48.1 [48.100]Tracks..............................................................................48.2 [48.134]Tracktensionunits.................................................................48.3 [48.138]Trackrollers........................................................................48.4 Cabclimatecontrol.....................................................................50 4802029215/06/2016
[35.359]Maincontrolvalve..................................................................35.6 [35.357]Pilotsystem........................................................................35.7 [35.752]Hydraulicfandrivecoolingsystem.................................................35.8 [35.355]Hydraulichandcontrol.............................................................35.9
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[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.19 [55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem...............55.20 [55.514]Cablighting......................................................................55.25 [55.408]Warningindicators,alarms,andinstruments....................................55.26 Booms,dippers,andbuckets.......................................................84 [84.912]Dipperarm.........................................................................84.2 [84.100]Bucket..............................................................................84.3 4802029215/06/2016
Platform,cab,bodywork,anddecals.............................................90
[90.150]Cab.................................................................................90.1
[90.156]Cabwindshieldandwindows......................................................90.2
[90.100]Enginehoodandpanels...........................................................90.4
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INTRODUCTION
Contents
Safetyrules.....................................................................................4 Hydrauliccontamination......................................................................16 Generalspecification.........................................................................17 Productidentification-Machineorientation..................................................56 4802029215/06/2016 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: 4802029215/06/2016 4
INTRODUCTION Safetyrules-Generalinformation Cleaning Aftercleaning,drywell,andinjectoilinallparts. Inspection Bearing Needlebearing Gear Alwaysinstallnewoilseals,O-rings,andgaskets. Shaft Checkthebearingsandcheckfordamagedoilsealsontheshaft. Serviceparts InstallCASECONSTRUCTIONgenuineserviceparts. Lubricants(fuel,hydraulicoil) Usetheoilfromthespecifiedcompanyorspecifiedintheoperator'smanualorserviceManual. 4802029215/06/2016 5
INTRODUCTION Safetyrules-Personalsafety WARNING: Itgivesinformationconcerningthesafetyoftheoperatorandthoseinthesurroundings. Alwayscomplywithwarningsandprecautionssoastoavoidanyaccidents. Checkwhetherallwarninglabelsareinplace. WARNING: Readtheoperator'smanualtogainathoroughunderstandingofmachinecontroloperations. WARNING: WARNING: WARNING: Checkthesafetymessagesintheoperator'smanualbeforestartingtheengine. Checkthatnooneiswithinthemachine’soperatingrange. Theoperator'smanualcanbepurchasedatyourCASECONSTRUCTIONdealer. WARNING: Workingwithsloppyclothesorclotheswithwhichsafetycannotbeensuredleadstodamagetothemachine andinjurytotheoperator. Inordertoworkmoresafely,itisrecommendedtowearadditionalsafetyequipment. WARNING: WARNING: 4802029215/06/2016 6
WARNING: Checkthatthereisnooneinthesurroundingsbeforedrainingthepressurefromhydrauliccircuitsduring WARNING: Usegloveswhenhandlinghigh-temperatureparts. WARNING: WARNING: WARNING: WARNING: Weareyeprotectionwhenusingahammertoinstallapinorwhenworkingwithagrinder. WARNING: WARNING: Checktheoil,coolant,grease,andtools. Payenoughattentiontosafety. WARNING: Someofthemachine'spartsareextremelyheavy. Forweightsandprocedures,seetheServiceManual. WARNING: Exhaustgasesaretoxic. WARNING: 4802029215/06/2016 7
INTRODUCTION
INTRODUCTION Safetyrules-Cabprotectivestructure Cabprotectivestructure Prohibiteditems • • Modificationsprohibited(redpart) Modificationspermittedunderconditions(gray part) todiameter 20mm ( 0.787in ))bydrillingarepossible. SMPH15CEX6544FA 1 4802029215/06/2016 8
INTRODUCTION Safetyrules-Ecologyandtheenvironment Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,filters,batteries,fuels,anti-freeze, cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use, Helpfulhints • • • • etc.Donotmixdrainedbrakefluidsorfuelswithlubricants.Storealldrainedfluidssafelyuntilyoucandisposeof • Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly. • • • • Batteryrecycling Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful CONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoaCASE batteriesproperly.Insomecountries,thisisalegalrequirement. Mandatorybatteryrecycling NOTE: Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead, CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany Pointsofsaleareobligedto: • Acceptthereturnofyourusedbatteries • Storethereturnedbatteriesinasuitablelocation • Sendthereturnedbatteriestothebatterymanufacturerforrecycling 4802029215/06/2016 9
6.9N·m ( )
19.6N·m ( )
39.2N·m ( )
58.8N·m ( )
98.1N·m ( )
156.9N· m ( 3lbft )
196.1N· m ( 6lbft )
294.2N· m ( 1lbft ) Wrench 5mm 6mm8mm10mm12mm14mm14mm17mm Hexagon socket headbolt ingtorque
8.8N·m ( 6.491lb )
21.6N·m ( 15.931lb )
42.1N·m ( 31.051lb )
78.5N·m ( 57.899lb )
117.7N·m ( 86.811lb ) 4802029215/06/2016
176.5N· m ( 130.18 0lbft )
245.2N· m ( 180.85 0lbft )
343.2N· m ( 253.13 1lbft )
INTRODUCTION Torque-Boltandnut •
diameter(size)
LPIL12CX00005EA 1 • L OCTITE ® old L OCTITE ® L OCTITE ® Torquetable Boltnominal
M6M8M10M12M14M16M18M20
Wrench 10mm13mm17mm19mm22mm24mm27mm30mm Hexagon bolt ingtorque
INTRODUCTION Torque-Specialtorquesetting Code Retighteninglocation Nominalbolt diameter Wrench Tighteningtorque Travelmotor M2741mm ( 996-1165lbft ) Drivesprocket M2741mm ( ) M20 24mm ( 964-1126lbft ) Upperroller M2030mm ( ) Lowerroller M2741mm ( 964-1126lbft ) Trackguard M2741mm ( ) 7 Shoe M2741mm ( 1171-1379lbft ) 8 Counterweight M42 50mm ( ) Turntablebearing M30 36mm ( ) 10* Swingunit M2436mm ( ) 11* Mount M2441mm ( 622-723lbft ) 12* Engine Frontsupport M14 17mm 63.8-73.6N·m ( 47-54lbft ) 13* Radiator M20 24mm 147.2-176.6N·m ( ) 14* Plate M1219mm ( ) 15* Hydraulic pump Pump M24 17mm hexagon socket head ( ) 16* Hydraulictank M2024mm 225.6-264.8N·m ( 166-195lbft ) 17* Fueltank M2024mm 232.4-276N·m ( ) M2030mm ( ) 19* Lockbar M1624mm ( ) 20* Centerjoint Joint M1219mm ( ) Cab M1624mm ( ) Battery M1017mm ( ) Lowerframejoint M36 55mm ( ) NOTE: Makesuretoapply L OCTITE ®262™ orequivalenttothelocationswiththe*mark,andtightenaccordingto Nominalboltdiameter(Size) M6M8M10M12M14M16M18M20 Wrench 10mm13mm17mm19mm22mm24mm27mm30mm Hexagonbolt Tightening torque 19.6N· m 39.2N· m 58.8N· m 98.1N· m 156.9N· m N·m 294.2N· m Wrench 5mm 6mm8mm10mm12mm14mm14mm17mm Hexagonsocket headbolt Tightening torque 8.8N·m 21.6N· m 42.1N· m 78.5N· m 117.7N· m 176.5N· m 245.2 N·m 343.2N· m 4802029215/06/2016 11
INTRODUCTION 66B91CE4 1 4802029215/06/2016
INTRODUCTION 79A11AE7 2 4802029215/06/2016
INTRODUCTION Basicinstructions-Shopandassembly Shimming Rotatingshaftseals NOTE: andthedustlipondoublelipsealswithgrease. O-ringseals Sealingcompounds compound,preparethesurfacesasdirectedbytheproductcontainer. Spareparts OnlyuseCNHOriginalPartsorCASECONSTRUCTIONOriginalParts. partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorCASECONSTRUCTIONOriginal Whenorderingspareparts,alwaysprovidethefollowinginformation: • Machinemodel(commercialname)andProductIdentificationNumber(PIN) • 4802029215/06/2016
