Case cx330 crawler excavator service repair manual
- 4. Case Copyright 2002 Case France Printed in U.S.A. June 2002Cre 9-53360 1001 SAFETY, GENERAL INFORMATION Section 1001
- 5. 1001-3 Cre 9-53360 Issued 06-02 GENERAL INFORMATION Cleaning Clean all metal parts except bearings, in a suitable cleaning solvent or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning, dry and put oil on all parts. Clean oil passages with compressed air. Clean bearings in a suitable cleaning solvent. Dry the bearings completely and put oil on the bearings. Inspection Check all parts when the parts are disassembled. Replace all parts that have wear or damage. Small scoring or grooves can be removed with a hone or crocus cloth. Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early failures. Bearings Check bearings for easy action. If bearings have a loose fit or rough action, replace the bearing. Wash bearings with a suitable cleaning solvent and permit to air dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR. Needle Bearings Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position, put petroleum jelly on the inside and outside diameter of the bearings. Gears Check all gears for wear and damage. Replace gears that have wear or damage. Oil Seals, O-rings and Gaskets Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings. Shafts Check all shafts that have wear or damage. Check the bearing and oil seal surfaces of the shafts for damage. Service Parts Always install genuine Case service parts. When ordering refer to the Parts Catalog for the correct part number of the genuine Case replacement items. Failures due to the use of other than genuine Case replacement parts are not covered by warranty. Lubrication Only use the oils and lubricants specified in the Operator’s or Service Manuals. Failures due to the use of non-specified oils and lubricants are not covered by warranty.
- 6. 1001-4 Cre 9-53360 Issued 06-02 SAFETY This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death. ! To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Place a “Do not operate“ tag on the starter switch key before carrying out any service or repair work on the machine. . WARNING: Read the operator’s manual to familiarize yourself with the correct control functions. ! WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury. ! WARNING: This is a one man machine, no riders allowed.! WARNING: Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturers instructions on machine operation, service and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from your Case dealer. ! WARNING: If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing. ! WARNING: When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution. ! WARNING: When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure. ! WARNING: When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way. !
- 7. 1001-5 Cre 9-53360 Issued 06-02 WARNING: Use insulated gloves or mittens when working with hot parts.! WARNING: Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. ! WARNING: Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood. ! WARNING: When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. ! WARNING: When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors). ! WARNING: Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands. ! WARNING: When servicing or repairing the machine, keep the shop floor and operator’s compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use safe practices at all times. ! WARNING: Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual. ! WARNING: Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area. ! WARNING: When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured. !
- 8. Case Copyright 2002 Case France Printed in U.S.A. June 2002Cre 9-43540GB 2000 REMOVAL AND INSTALLATION OF THE ENGINE Section 2000
- 9. 2000-3 Cre 9-43540GB Issued 06-02 ENGINE Removal and installation STEP 1 JS00163A Park the machine on hard, flat ground. Lower the attachment to the ground. STEP 2 Release pressure in the hydraulic system and in the hydraulic reservoir (see Section 8000). STEP 3 CD01C162 Disconnect the battery ground (-) cable (1) from the battery. STEP 4 Refer to Section 8003 and remove the hydraulic pump. STEP 5 Refer to Section 2001 and remove the radiator and oil-cooler assembly. STEP 6 CD02C151 Remove the engine shutdown control (arrow). Disconnect the fuel supply pipe (1) and the fuel return pipe (2) and plug them. STEP 7 CD01D131 Remove the screws (1) from the compressor and put it away from the engine. 1 1 2 1 1
- 10. 2000-4 Cre 9-43540GB Issued 06-02 STEP 8 CD02C152 Label and disconnect the electrical connections from the water temperature sensor (1). STEP 9 CD02C153 Label and disconnect the electrical connections from the oil pressure sensor (1). STEP 10 CD00J030 Label and disconnect the electrical supply (1) to the pre-heating plugs. STEP 11 CD02C154 Label and disconnect the electrical connections to the starter motor (1). Remove the earth cable (2) at the engine end. STEP 12 CD02C152 Label and disconnect the electrical connections of the electronic regulation (1) from the engine. STEP 13 CD02C155 Remove the hose connecting the turbo-charger to the air filter (1). 1 1 1 1 2 1 1
- 11. 2000-5 Cre 9-43540GB Issued 06-02 STEP 14 CD01M004 Label and disconnect the electrical connections to the alternator (arrows). STEP 15 Remove all the clips, etc, which fasten the electrical harnesses to the engine and move the harnesses out of the way. STEP 16 Install a suitable lifting device on the engine lifting rings (for the weight of the engine, see Section 1002). STEP 17 Remove the engine retaining hardware. NOTE: When installing, make a visual inspection of the condition of the rubber flexible mountings and change them if necessary. Respect the colours, light blue on the fan side, light green on the hand-wheel side. Tighten the engine retaining screws to a torque of 231 ± 18 lb-ft. STEP 18 When there is nothing interfering with the removal of the engine, raise the engine carefully and install it on a suitable repair bench. NOTE: When installing the engine in the machine, proceed in the reverse order from removal. Before operating the machine, carry out the following operations: - Bleed and prime the fuel system (see Operator’s Manual). - Fill and bleed the engine cooling system (see Oper- ator’s Manual). - Check the hydraulic, fuel and cooling systems for leaks. - Check the oil level in the hydraulic reservoir. Top up if necessary.
- 12. 2001-3 Cre 9-43480GB Issued 06-02 CHANGING THE RADIATOR OR THE OIL-COOLER Description CI02A513 1 SCREW 2 PIPE 3 OIL COOLER 4 OIL-COOLER 5 HOSE 6 HOSE 7 RADIATOR 8 HOSE 9 HOSE 10 HOSE 11 HOSE 6 4 8 7 2 1 10 9 2 1 5 9 11 5 3
- 13. 2001-4 Cre 9-43480GB Issued 06-02 RADIATOR AND OIL-COOLER Before carrying out any operation on the machine, perform the following operations in the order shown: - Park the machine on hard, flat ground. - Lower the attachment to the ground. - Shut down the engine. - Remove the starter switch key. - Make sure that pressure in the hydraulic system has been completely released (see Operator’s Manual). Removal of the radiator and oil- cooler assembly STEP 1 CD01K055 Remove the hood (1) from the engine. STEP 2 Remove the inner cover plate from the engine. STEP 3 Remove the cap from the expansion reservoir. IMPORTANT: Do not remove the cap when the engine is hot, since the system would still be under pressure and you could be scalded. STEP 4 Drain the cooling system (see Operator’s Manual). STEP 5 Release pressure in the hydraulic reservoir to allow the vacuum pump to be mounted (see Section 8000). NOTE: The numbers within brackets refer to the fig- ure on page 3. STEP 6 Remove the screws (1), then the pipe (2) from the oil cooler (3), finally drain the latter into a clean con- tainer. STEP 7 Disconnect the radiator hoses (5) and (6) from the oil- cooler, finally drain the latter into a clean container. STEP 8 Remove the expansion reservoir hose (8) from the radiator (7). Disconnect the return hose (9) and the water pump suction hose (10) from the engine. STEP 9 Disconnect the radiator hose (11) from the oil drain plug. STEP 10 CS02C554 Remove the screws (A) and remove the guardrails (B). Remove the screws (C). WARNING: When the machine is working, the engine components and the hydraulic pump reach a high temperature. To avoid being burnt by hot metal or scalded by high temperature water or oil, allow the machine to cool down before starting any servicing operation.! 1 A B C
- 14. 2001-5 Cre 9-43480GB Issued 06-02 STEP 11 CS00G513 Pass a suitable sling right around the radiator and oil- cooler assembly and, using a suitable lifting device, remove the radiator and oil-cooler assembly. NOTE: During the lifting operation, unlock the radia- tor and oil-cooler assembly in order to free the engine cooling fan. Installation When installing, proceed in the reverse order from that of removal. Before operating the machine: - Check the oil level in the hydraulic reservoir. Top up if necessary. - Check the hydraulic fluid cooling circuit for leaks. - Fill and bleed the engine cooling system (see Oper- ator’s Manual). - Check the engine cooling system for leaks.
- 15. 4001-6 Cre 9-53640 Issued 06-02 General location of the components (outside the cab) CS02M515 Y18 B27 B81 B2 M13 B22 K15 G2B8 K7 F30 F29 G1 Y8 H2 R6 A2 B43 Y7 B44 B42 R5 X1 M4 E1 E2 Y16 X3 Y17 B7 S52 F22 F23 F24 F32 Y2 B41B6 B21B1 B46 B47 M1 B26 Y4 Y6 Y1 Y3 Y5 K13 M9 B48 M12 B25Y9 B23
- 16. 4001-7 Cre 9-53640 Issued 06-02 A2 Engine controller B1 Coolant temperature sensor B2 Hydraulic oil temperature sensor B6 Air temperature sensor B7 Water in fuel sensor B8 Coolant level sensor B21 Engine oil pressure switch B22 Swing pilot pressure switch B23 Breaker / crusher pilot pressure switch B25 Breaker pilot pressure switch B26 Upper pilot pressure switch B27 Travel pilot pressure switch B41 Engine rpm sensor B42 Pump pressure sensor (P1) B43 Pressure sensor (nega-cont) B44 P2 Pump pressure sensor (yellow band) B46 Engine position sensor B47 Boost pressure sensor B48 Ambient air pressure sensor B81 Horn E1 Working light (upperstructure) E2 Working light (attachment) F22 Fuse 20 A; main fuse for circuits F1, F11 and F12 circuits F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20 circuits F24 Fuse 20 A; main fuse for circuit F2 F29 Fuse 120 A; gread heater F30 Box fuse F32 Engine controller fuse box G1 Batteries G2 Alternator H2 Travel alarm K7 Relay-battery K13 Relay-starter K15 Relay-gread heater M1 Starter motor M4 Washer motor M9 Air conditioner condensor fan motor M12 Fuel pump M13 Prime pump motor R5 Fuel sensor R6 Gread heater S52 Air conditioning compressor clutch switch X1 Fuel filler pump connector X3 Optional power connector (breaker and crusher) Y1 Swing pilot shut-off solenoid valve (green band) Y2 Pilot pressure solenoid valve (blue band) Y3 Swing brake solenoid valve (pink band) Y4 2 stage travel solenoid valve (red band) Y5 Power-up solenoid valve (yellow band) Y6 Cushion control solenoid valve (light green band) Y7 Main pump proportional solenoid Y8 Air conditioner magnet clutch Y9 Crusher / breaker option two flow solenoid valve Y16 Multi-purpose solenoid valve (R) (optional) Y17 Multi-purpose solenoid valve (L) (optional) Y18 Free swing solenoid valve
- 17. 4001-8 Cre 9-53640 Issued 06-02 Relay and main fuses (battery compartment) CS02M505 1 Battery cables 2 Bloc ; terminal F22 Fuse 20 A; main fuse for circuits F1, F11 and F12 F23 Fuse 65 A; main fuse for F3 to F10 and F13 to F20 circuits F24 Fuse 20 A; main fuse for circuit F2 F29 Fuse 120 A; gread heater F30 Box fuse F32 Engine controller fuse box K7 Relay-battery K13 Relay-starter K15 Relay-gread heater F23F24F22 K13F32 F30 K15F29 K71 2
- 18. 4001-10 Cre 9-53640 Issued 06-02 General location of the components (inside the cab) CS02M517 U1A1 F21 E53 S13 S53 S24 S51 S15 X8 R3 S1 P8 E4 E51 B61 A4M3 S54 S16 P1 S25 S21 S14 X5 X4 P6 E52 R4 M7 M8 M5 M6 K3K4K1X10K6
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- 20. 4001-11 Cre 9-53640 Issued 06-02 A1 Computer A4 Wiper controller B61 Sunload sensor E4 Cab light E51 Cigarette lighter E52 Air conditioner E53 Heater F21 Fuse box K1 Relay-engine emergency stop K3 Relay-horn K4 Relay -working lights K6 Relay-air conditioner condensor fan M3 Wiper motor M5 Motor (air changing) M6 Air vent direction control motor M7 Motor act (air-mix) M8 Blower motor P1 Instrument panel P6 Air conditioner control panel P8 Heater control panel R3 Throttle volume R4 Thermistor S1 Key switch S13 Overload switch S14 Breaker/crusher switch S15 Horn switch S16 One touch idle S21 One touch multipurpose switch (R) S24 Option line switch S25 One touch multipurpose switch (L) S51 Hydraulic function cancellation lever switch S53 Door limit switch S54 Front window limit switch U1 DC-DC converter 24 V - 12 V X8 Radio connector X4 Engine test point connector X5 Controller test point connector X10 Condensor fan relay connector
- 21. 4001-12 Cre 9-53640 Issued 06-02 Fuse box CM00E005 F1 Fuse 10 A: Engine controller test point connector F2 Fuse 20 A: Computer, instrument panel and diagnostic test socket F3 Fuse 20 A: Computer power F4 Fuse 10 A: Hydraulic function cancellation lever switch F5 Fuse 10 A: Optional power connector F6 Fuse 20 A: Option line connector F7 Fuse 20 A: Fuel filler pump F8 Fuse 10 A: Cab seat air sus (not used) F9 Fuse 10 A: Condensor fan relay F10 Fuse 10 A: Breaker and crusher option / second option F11 Fuse 10 A: Back-up F12 Fuse 10 A: Key switch F13 Fuse 20 A: Heater / air conditioner F14 Fuse 5 A: Air conditioner compressor F15 Fuse 15 A: Working lights F16 Fuse 15 A: Optional power connector F17 Fuse 10 A: DC-DC converter (24 V - 12 V) F18 Fuse 15 A: Wiper and washer F19 Fuse 10 A: Horn F20 Fuse 15 A: Cigarette lighter
- 22. 4001-13 Cre 9-53640 Issued 06-02 Instrument panel CM00K003 H1 Audible warning device P4 Monitor display P5 Hourmeter S2 Travel mode switch S3 Work mode switch S4 Auto mode switch S5 Cushion control switch S7 Audible alarm cut out switch S8 Swing brake switch S9 Engine emergency stop switch S10 Working light switch S11 Wiper switch S12 Washer switch S22 Free swing CS00F521 1 Travel speed indicator 2 Work mode indicator 3 Idle mode indicator 4 Coolant temperature indicator 5 Hydraulic oil temperature indicator 6 Fuel level indicator S5 P5S9S8S7S4S3S2P4 S22 S10 S11 S12H1 1 2 3 P4 4 5 6
- 23. 4001-14 Cre 9-53640 Issued 06-02 Working Mode Selection 1) Circuit configuration CS00F505 2) Timing diagram 1. Engine 2. Serial communication A1.Computer A2.Engine controller A3.Electronic acceleration P1.Instrument panel P4.Monitor display S3.Work mode switch S4.Auto mode switch Y7.Main pump proportional solenoid S4 S3 P4 P1 A1 2 Y7 A2 1 A3 AUTO H L 24V 0V a Contact switch Working mode b S AUTO H L S AUTO H L AUTO H c 5V 0V 5V 0V S3 S4