Part Number 71114551 1st Edition English 03/2015 CX220C Hydraulic Excavator
Service Manual
SERVICEMANUAL CX220CStandardmodel 7111455119/03/2015
LinkProduct/Engine Product MarketProduct Engine CX220CModelopadrão LatinAmerica F4GE9684E*J615 7111455119/03/2015
Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.202]Aircleanersandlines..............................................................10.2 [10.216]Fueltanks..........................................................................10.3 [10.254]Intakeandexhaustmanifoldsandmuffler.........................................10.4 Hydraulicsystems.......................................................................35 [35.000]Hydraulicsystems..................................................................35.1 [35.102]Pumpcontrolvalves................................................................35.2 [35.106]Variabledisplacementpump.......................................................35.3 [35.300]Reservoir,cooler,andfilters........................................................35.4 [35.304]Combinationpumpunits...........................................................35.5 [35.352]Hydraulicswingsystem............................................................35.6 [35.353]Hydraulictravelsystem............................................................35.7 [35.354]Hydrauliccentraljoint..............................................................35.8 [35.355]Hydraulichandcontrol.............................................................35.9 [35.356]Hydraulicfootcontrol.............................................................35.10 [35.359]Maincontrolvalve................................................................35.11 [35.736]Boomhydraulicsystem..........................................................35.12 [35.737]Dipperhydraulicsystem..........................................................35.13 [35.738]Excavatorandbackhoebuckethydraulicsystem................................35.14 Framesandballasting.................................................................39 7111455119/03/2015
Contents INTRODUCTION
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[50.100]Heating.............................................................................50.1 [50.200]Airconditioning.....................................................................50.2 Electricalsystems.......................................................................55 [55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls...................55.4 Booms,dippers,andbuckets.......................................................84 Platform,cab,bodywork,anddecals.............................................90 [90.116]Fendersandguards................................................................90.1 [90.150]Cab.................................................................................90.3 7111455119/03/2015
INTRODUCTION 7111455119/03/2015 1
Contents INTRODUCTION Foreword-Ecologyandtheenvironment......................................................4 Safetyrules.....................................................................................5 Safetyrules.....................................................................................6 Personalsafety.................................................................................8 Personalsafety—Donotoperatetag..........................................................9 Torque–Bolttypes...........................................................................13 Basicinstructions-ShopandAssembly......................................................14 Torque—Minimumtighteningtorquesfornormalassembly.................................16 Torque-Standardtorquedataforhydraulics.................................................19 Conversionfactors–Unitsused..............................................................23 7111455119/03/2015 2
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein type,orchangestothelawsandregulationsofdifferentcountries. 7111455119/03/2015
INTRODUCTION Advice-Importantnoticeregardingequipmentservicing
3
•
Foreword-Ecologyandtheenvironment productsofachemicalandpetrochemicalnature.
NOTE: Thefollowingarerecommendationsthatmaybeofassistance:
• Wherenolegislationexists,obtaininformationfromsuppliersofoils,filters,batteries,fuels,antifreeze,cleaning
• Helpfulhints
• Avoidfillingtanksusingcansorinappropriatepressurizedfueldeliverysystemsthatmaycauseconsiderable
•
• Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
• Donotmixdrainedbrakefluidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofinaproper
•
• Donotopentheair-conditioningsystemyourself.Itcontainsgasesthatshouldnotbereleasedintotheatmosphere.
YourCASECONSTRUCTIONdealerorairconditioningspecialisthasaspecialextractorforthispurposeandwill
• Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately.
•
•
INTRODUCTION
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Safetyrules
Plasticandresinparts • Avoidusinggasoline,paintthinner,etc.whencleaningplasticparts,console,instrumentcluster,etc. •
Usinggasoline,thinners,etc.cancausediscoloration,cracking,ordeformationofthepartbeingcleaned.
INTRODUCTION
Improperoperationorserviceofthismachinecanresultinanaccident. Donotoperatethismachineorperformanylubrication,maintenance,orrepaironituntilyouhave readandunderstoodtheoperation,lubrication,maintenance,andrepairinformation. D0010A WARNING Maintenancehazard! optimumperformancelevelsandmaximumsafetyduringmachineoperation. Failuretocomplycouldresultindeathorseriousinjury. W0132A WARNING Pressurizedsystem! Beforeattemptinganyserviceprocedure,itisyourresponsibilitytoknowthenumberofaccumulators Failuretocomplycouldresultindeathorseriousinjury. W0136A NOTICE: UseCasefluids,lubricants,andfiltersforthebestprotectionandperformanceofyourmachine.Allfluids,lubricants, Readthesafetydecalsandinformationdecalsonthemachine.ReadtheOperator’sManualandsafetymanual. Beforeyouservicethemachine,puta'DoNotOperate'tagonthesteeringwheeloroverthekeyswitch.Ensurethe withyournewmachine.Additionaltagsareavailablefromyourdealer.
DANGER
•
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INTRODUCTION
Safetyrules
Standardsafetyprecautions
•
•
• onaregularbasisandpersonnelmustbetrainedonproperinterventionsandpriorities.
•
• Smokinginworkingareassubjecttofiredangermustbestrictlyprohibited.
Preventionofinjury
• Wearsuitableworkattireandsafetyglasseswithnojewelrysuchasringsandchainswhenworkingclosetoengines
• Wearsafetyglovesandgoggleswhenperformingthefollowingoperations:
•
• Usingcompressedairorliquidsatapressuregreaterthan 2bar ( 29psi
• • • •
• Inthepresenceofvoltagesexceeding 48-60V electricity.
•
• Placesoiledragswithoil,dieselfuelorsolventsinspeciallyprovidedanti-firecontainers.
•
•
Duringmaintenance
• 50°C ( 122°F
•
• awareofalltherisksinvolvedwithsuchanoperation.
•
• Keepenginecleanofanyspilledfluidssuchasoil,dieselfuel,andorchemicalsolvents.
• Disconnectthebatteriespriortoperforminganyworkontheequipment.
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• • • •
6
INTRODUCTION
• • • Beforedisconnectinganypipelines(pneumatic,hydraulic,fuelpipes,etc.),verifythatallpressurehasbeenre-
• Donotalterthelengthsofanywires.
• DonotconnectanyelectronicservicetooltotheengineelectricalequipmentunlessspecificallyapprovedbyCASE
• Forengineequippedwithanelectroniccontrolunit
•
• Removetheincaseofworkrequiringheatingover 80°C ( 176°F
• • componentswillvoidenginewarrantyassistanceandmayaffectthecorrectworkingorderandlifespanofthe engine.
RespectoftheEnvironment
• Respectoftheenvironmentshouldbeofprimaryimportance.Takeallnecessaryprecautionstoensurepersonnel's
•
•
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Personalsafety Safetyprecautions
INTRODUCTION
• • • • resultingincreaseinpressuremaycausethepackageorsystemtoexplode. • • • • Whenchargingordischargingthesystem,alwayswearsafetygogglesandtakeadequateprecautionstoprotect • Therefrigerantandoilmixtureinsidetheairconditioningsystemispressurised.Becauseofthis,neverloosenthe • • Ifrefrigerantgetsintotheeyes,washimmediatelywithcopiousamountsofdistilledortapwater,andtakethevictim • Ifrefrigerantcomesintocontactwiththeskin,washwithcoldwaterandseekmedicalassistanceimmediatelyata
8
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INTRODUCTION Personalsafety—Donotoperatetag WARNING Maintenancehazard! Beforeyoustartservicingthemachine,attachaDONOTOPERATEwarningtagtothemachineina visiblearea. W0004A AttachaDONOTOPERATE(TAG)tothemachineinanareathatisclearlyvisiblewheneverthemachineisnot Completethetaginformationforthe"REASON"thetagisattachedbydescribingthemalfunctionorservicerequired. havebeencompleted. (A) (D) (E) (B) (F) (C) 87358697 1 TagComponents C.CNHPartNumber-(RequestthispartnumberfromyouServicePartsDealertoobtainthisDONOTOPERATE D.DONOTOPERATE-(Warning!) F.Signedby-(Signaturearea-tobesignedbythepersonvalidatingthereasonforinstallationofthetag.) 7111455119/03/2015 9
Basicinstructions
Maintenancestandards
Inspectionofcomponents
Partname Inspectionitem
• Theslidingpartsoftheholeinthe
Casing
Spool
Needle
Springandrelatedparts
• Areaofthesealingpartthatisin
• Sealingandseatingpartsofthe mainreliefvalveortheoverload
•
• Defectsinotherpartsthatmay andcorrosion.
Ifanydefectcanbedetectedby runningafingernailoverthesliding
Installthespoolbyturningthespool doesnotmovesmoothly,repairor
Checktheneedleandthespringfor Iftheseatoftheneedleorthespring aredamaged,replacetheseatofthe
Iftheneedlemovessmoothlywithout
Checkforrust,corrosion, Replaceifheavilydamaged.
Checkforrustanddamageonthe outersurface.
Inspectthecontactfaceofthevalve seat. theseal)
INTRODUCTION
Criterionandremedy
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NOTICE:
Servicerecommendationsforsplitflange
LAIL11CX0070A0A 1 thattheslotiscentrallylocatedandperpendicularto theorifice.Tightentheboltsbyhandtosecurethe wrenchesoftenfullytightenoneboltbeforetightening LAIL11CX0071A0A 2
LAIL11CX0072A0A 3
INTRODUCTION
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Lockingthenutsandbolts
• Lockplate
NOTICE:
• Cotterpin
NOTICE:
• LockWire
NOTICE: Applythewiretotheboltsinthedirectionof
INTRODUCTION
(2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
(1)
BRAG12CXCNH0011 4
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BRAG12CXCNH0012 5
Torque–Bolttypes
Correctlytightenthenutsandboltsaccordingtothe hexagonTboltandsocketbolt(Allen),eachmadeof
Ensurethatyoutightenthemtothespecifications.
BRAG12CXCNH0009 1
Tableofspecifiedtighteningtorque
1.Applylubricant(i.e.,whitezincBdissolvedinbearingoil)totheboltsandnutstostabilizetheircoefficientoffriction. foraspecificapplication.
Boltstighteningsequence
BRAG12CXCNH0010 2 diagonally.
INTRODUCTION
(1) (2) Socketbolt(Allen)
Bolt diameter Wrench size Hexagon WrenchSize Tbolt, socketbolt M813 6 29.5N·m M1017 8 64N·m M121910 108N·m M142212 175N·m M162414 265N·m M182714 M203017 540N·m M223217 M243619 930N·m M274119 1370N·m M304622 1910N·m M335024 2550N·m M36 3140N·m
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INTRODUCTION Basicinstructions-ShopandAssembly SHIMS ROTATINGSHAFTSEALS • • • andpositionthegroovessothattheywilldeviatethefluidtowardstheinnersideoftheseal. • thedustlipondoublelipsealswithgrease • • • O-RINGSEALS SEALINGCOMPOUNDS L OCTITE ®RTV598™ L OCTITE ®I NST ANT G ASKET 587B LUE .Beforeyouapplythesealingcompound,preparethe surfacesasdirectedonproductcontainerorasfollows: • removeanydepositswithawirebrush •
Onlyuse"CNHOriginalParts"or"CASECONSTRUCTIONParts". partsthatareassembledduringstandardproduction.Only"CNHOriginalParts"or"CASECONSTRUCTION Parts"canofferthisguarantee. • machinemodel(commercialname)andserialnumber • partnumberoftheorderedpart,whichcanbefoundinthe"Microfiches"orthe"SparePartsCatalogue",usedto processorders 7111455119/03/2015
SPAREPARTS
PROCEDURETOPROTECTTHEELECTRONICSYSTEMSANDELECTRICALSYSTEMS
DURINGCHARGINGOPERATIONSORWELDINGOPERATIONS
DANGER
NOTICE:
TOOLS
ThetoolsthatCASECONSTRUCTIONsuggestsandillustratedinthismanualhavebeen:
• specificallyresearchedanddesignedforusewithCASECONSTRUCTIONmachines
• essentialforreliablerepairoperations
• IfRepairPersonnelusethesetools,theywillbeableto:
• operateinoptimaltechnicalconditions
• obtainthebestresults
• savetimeandeffort
• workinsafeconditions
NOTE: Youshouldinterprettheterms"front","rear","right-hand"and"left-hand"(whenyourefertodifferentparts)
INTRODUCTION
Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):flush withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge quantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately. Failuretocomplywillresultindeathorseriousinjury. D0117A 2.Nevershortanyofthechargingcomponentstoearth. • positiontheweldergroundclampasclosetotheweldingareaaspossible
module • performweldingoperations
•
thebatterygroundcablefromthebattery.Theelectronicmonitoringsystemandchargingsystemwillincurdamage Removethebatterygroundcable.Reconnectthecablewhenweldingoperationsarecomplete.
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Torque—Minimumtighteningtorquesfornormalassembly Decimalhardware Size lbin/lbft 1/4in 5/16in 23-28Nm 204-252lbin 3/8in 48-57Nm 420-504lbin 7/16in 73-87Nm 1/2in 109-130Nm 80-96lbft 9/16in 5/8in 203-244Nm 150-180lbft 3/4in 7/8in 542-651Nm 400-480lbft 1in 580-696lbft 1-1/8in 1085-1193Nm 800-880lbft 1-1/4in 1519-1681Nm 1120-1240lbft 1980-2278Nm 1-1/2in 2631-2983Nm 1940-2200lbft Grade8bolts,nutsandstuds Size lbin/lbft 1/4in 16-20Nm 144-180lbin 5/16in 33-39Nm 288-348lbin 3/8in 7/16in 95-114Nm 70-84lbft 1/2in 110-132lbft 9/16in 217-260Nm 160-192lbft 5/8in 298-358Nm 220-264lbft 3/4in 515-618Nm 380-456lbft 7/8in 814-976Nm 600-720lbft 1in 1220-1465Nm 1-1/8in 1736-1953Nm 1280-1440lbft 1-3/8in 3227-3688Nm 2380-2720lbft 1-1/2in 3160-3560lbft NOTE: UsethicknutswithGrade8bolts. Metrichardware Grade8.8bolts,nutsandstuds Size lbin/lbft 4mm 3-4Nm 24-36lbin 5mm 6mm 11-12Nm 96-108lbin 8mm 26-31Nm 228-276lbin 10mm 52-61Nm 456-540lbin 12mm 90-107Nm 66-79lbft 14mm 144-172Nm 106-127lbft 16mm 217-271Nm 20mm 434-515Nm 320-380lbft 24mm 30mm 1250-1500Nm 920-1100lbft 36mm 1600-1950lbft 7111455119/03/2015
INTRODUCTION
