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SERVICEMANUAL CX250CCrawlerexcavatorLCversion(TIER3)-Turkishmarket 4809034402/01/2017

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 [10.202]Aircleanersandlines............................................................10.10 [10.250]Turbochargerandlines...........................................................10.11 [10.304]Enginelubricationsystem........................................................10.17 Hydraulicsystems.......................................................................35 4809034402/01/2017

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 4809034402/01/2017

[35.736]Boomhydraulicsystem..........................................................35.13 [35.737]Dipperhydraulicsystem..........................................................35.14 [35.738]Excavatorandbackhoebuckethydraulicsystem................................35.15 [35.360]Hammerandrotatingbuckethydraulicsystem..................................35.16

[55.640]Electronicmodules...............................................................55.14 [55.512]Cabcontrols......................................................................55.15 [55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.17 [55.416]Swingcontrolsystem............................................................55.19 [55.417]Travelcontrolsystem............................................................55.20 [55.518]Wiperandwashersystem........................................................55.22 [55.404]Externallighting..................................................................55.23 [55.992]Anti-theftsystem.................................................................55.26 Booms,dippers,andbuckets.......................................................84 [90.150]Cab.................................................................................90.1 [90.156]Cabwindshieldandwindows......................................................90.2 [90.120]Mechanically-adjustedoperatorseat...............................................90.3 4809034402/01/2017

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INTRODUCTION

Contents

Safetyrules.....................................................................................4 Hydrauliccontamination......................................................................17 Generalspecification.........................................................................18 Productidentification-Machineorientation..................................................54 4809034402/01/2017 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: 4809034402/01/2017 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. 4809034402/01/2017 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: 4809034402/01/2017 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: 4809034402/01/2017 7

INTRODUCTION

INTRODUCTION Safetyrules-Cabprotectivestructure Cabprotectivestructure Prohibiteditems • • Modificationsprohibited(redpart) Modificationspermittedunderconditions(gray part) todiameter 20mm ( 0.787in ))bydrillingarepossible. SMPH15CEX6544FA 1 4809034402/01/2017 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 4809034402/01/2017 9

Wrench 10mm13mm17mm19mm22mm24mm27mm30mm Hexagon bolt ingtorque

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 )

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

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INTRODUCTION Torque-Specialtorquesettings Code Retighteninglocation Boltnominal diameter Wrench Tighteningtorque Travelmotor M16 24mm ( ) Drivesprocket M16 24mm ( ) M16 24mm ( ) Upperroller M20 30mm ( ) Lowerroller M18 27mm ( ) Trackguard M18 27mm ( ) 7 Shoe M20 30mm ( ) Tighteningangle: 8 Counterweight M33 50mm ( ) 9 Turntablebearing M24 36mm ( ) 10* Swingunit M24 36mm ( ) 11* Mount M16 24mm 264.9–313.9N·m ( ) 12* FrontbracketM10 17mm 63.8–73.6N·m ( ) 13* Engine Rearbracket M16 24mm ( ) 14Radiator M16 24mm 147.2–176.6N·m ( ) 15* Hydraulic pump Pump M20 17mm hexagon socket head ( ) 16* Hydraulictank M16 24mm ( ) 17* Fueltank M16 24mm ( ) M16 24mm ( ) Lockbar M12 19mm 88.3–107N·m ( ) 20* JointJoint M12 19mm ( ) Cab M16 24mm ( ) Battery M10 17mm 19.6–29.4N·m ( ) NOTICE: Foritemsmarkedwith*,alwaysapply L OCTITE ®262™ Thetighteningtorqueinkgf•misdeterminedwithN ・・ 4809034402/01/2017 11

INTRODUCTION 1 4809034402/01/2017

INTRODUCTION

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INTRODUCTION 0CF469FD 3 4809034402/01/2017