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Part number 48149001 English May 2017 SERVICE MANUAL CX245D SR Crawler Excavator

SERVICEMANUAL CX245DSRCrawlerexcavatorsLCW/Bladeversion(TIER4FINAL)-NA Market CX245DSRCrawlerexcavatorsLCversion(TIER4FINAL)-NAMarket 4814900125/05/2017

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 [35.300]Reservoir,cooler,andfilters........................................................35.2 4814900125/05/2017

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 4814900125/05/2017

[35.737]Dipperhydraulicsystem..........................................................35.13 [35.738]Excavatorandbackhoebuckethydraulicsystem................................35.14 [35.360]Hammerandrotatingbuckethydraulicsystem..................................35.15 [35.741]Dozerbladecylinders............................................................35.16

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[55.989]ExhaustGasRecirculation(EGR)electricalsystem.............................55.13 [55.012]Enginecoolingsystem...........................................................55.14 [55.013]Engineoilsystem................................................................55.15 [55.640]Electronicmodules...............................................................55.16 [55.512]Cabcontrols......................................................................55.17 [55.036]Hydraulicsystemcontrol.........................................................55.18 [55.DTC]FAULTCODES..................................................................55.30 Booms,dippers,andbuckets.......................................................84 [84.910]Boom...............................................................................84.1 [84.912]Dipperarm.........................................................................84.2 [84.100]Bucket..............................................................................84.3 Dozerbladeandarm...................................................................86 4814900125/05/2017

Platform,cab,bodywork,anddecals.............................................90

[90.156]Cabwindshieldandwindows......................................................90.2

[90.118]Protectionsandfootboards.........................................................90.3

[90.119]Guardsandshields.................................................................90.4

[90.120]Mechanically-adjustedoperatorseat...............................................90.5

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INTRODUCTION

Contents INTRODUCTION Safetyrules.....................................................................................4 Hydrauliccontamination......................................................................19 Generalspecification(*)......................................................................20 Generalspecification(*)......................................................................25 Generalspecification-Mainequipment(*)...................................................30 Generalspecification-Mainequipment(*)...................................................39 Weight(*).....................................................................................48 Weight(*).....................................................................................50 Dimension-Grousershoe(*).................................................................52 Dimension-Linkchain(*)....................................................................56 Dimension-Grousershoe(*).................................................................61 Dimension-Linkchain(*)....................................................................65 Fluidsandlubricants..........................................................................67 Conversionfactors............................................................................70 Productidentification..........................................................................85 Productidentification-Machineorientation..................................................88 4814900125/05/2017 2

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: 4814900125/05/2017 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. 4814900125/05/2017 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: 4814900125/05/2017 6

INTRODUCTION 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: 4814900125/05/2017 7

INTRODUCTION Safetyrules-ROPSjudgment Purpose CompliancewithROPSishighlydependentonitsdeadweightandboom. However,thejudgmentisrequiredbecauseitsdeadweightorboompositionmaygobeyondtheassumptiondeROPScriteria Weight Itisnotapplicablebeyondthecriterion. TheROPS-compliantmodelshallnotexceedtheweightshowninthetable. (ThefollowingweightisshownonthedecalintheROPScab.) Grossbodyweight: 28500kg ( 62831.74lb 4814900125/05/2017 8

INTRODUCTION Boomposition WARNING Avoidinjury! FollowALLoftheprecautionslistedbelow. W1091A • • • SMIL14CEX2001EA 1 (a)Groundpoint Moreover,itcannotbesaidthatthe24-tonmodel,closetothelimitweight,withacabthatcanbearupto31-tonsand Prohibitions • ficationasreducesthefunctionoftheretaininganchorintheleftrearofthecab) • SuchmodificationasaffectstheROPSstrengthoftheROPScab. Modificationprohibited(Redcomponents) Allchanges(grinding,welding,drilling,removal,etc.) Conditionalmodificationpermitted(Graycomponents) Weldinganddrillingofbars(limitedto 20mm ( 0.79in ) orlessindiameter)areallowed. 4814900125/05/2017 9

INTRODUCTION 6533FAE6 2 4814900125/05/2017

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 4814900125/05/2017 11

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 ) 4814900125/05/2017

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 Boltnominal diameter Wrench Tighteningtorque Travelmotor M1624mm ( ) Drivesprocket M1624mm ( ) M1624mm ( ) Upperroller M2030mm ( ) Lowerroller M1827mm ( ) Trackguard M1827mm ( ) 7 Shoe M2030mm ( ) 8 Counterweight M3350mm ( ) M20 (outside) 30mm ( ) Turntablebearing M20 (inside) 30mm ( ) 10* Swingunit M2030mm ( ) 11* Mount M1624mm 264.9–313.9N·m ( ) 12* Frontbracket M1017mm 63.8–73.6N·m ( ) 13* Engine Rearbracket M1624mm 205.9–247.1N·m ( ) 14* Radiator M1624mm ( ) M20 17mm hexagon socket head ( ) 15* Hydraulic pump Pump M1017mm 63.7–72.6N·m ( ) 16* Hydraulictank M1624mm 232.4–276N·m ( ) 17* Fueltank M1624mm ( ) 18*Controlvalve M1624mm ( ) 19* Lockbar M1219mm 88.3–107N·m ( ) 20* Centerjoint Joint M1219mm ( ) Cab M1624mm ( ) Battery M1017mm 19.6–29.4N·m ( ) NOTE: Makesuretoapply L OCTITE ®262™ orequivalenttothelocationswiththe*mark,andtightenthemwiththe specifiedtorque. 4814900125/05/2017

INTRODUCTION SMIL17CEX0918HB 1 4814900125/05/2017