CASE CK25 Crawler Excavator Service Repair Manual.pdf
- 1. CK25-CK28 Crawler Excavators Table of contents DIVISION/SECTION SECTIONW FORMW 1. GENERAL Safety, General Information and Torque Specifications ..............................1001 .................................7-55741 GB General specifications .................................................................................1002 .................................7-37930GB 2. ENGINE Engine Removal and Installation ................................................................2002 .................................7-37940GB Engine Disassembly/Assembly, Lubrication System, Cooling System and Fuel System ...........................................................2010 .................................7-37950GB 4. ELECTRICAL Electrical Troubleshooting and Schematics.................................................4001 .................................7-37960GB Alternator .....................................................................................................4002 .................................7-37980GB Starter Motor................................................................................................4003 .................................7-37970GB 5. UNDERCARRIAGE Tracks, Rollers and Idlers ............................................................................5002 .................................7-37990GB 6. POWER TRAIN Travel Motor and Reduction .......................................................................6002 .................................7-38000GB Swing Reduction Gear.................................................................................6003 .................................7-38150GB 7. UNDERCARRIAGE HYDRAULICS Hydraulic Swivel ..........................................................................................7004 .................................7-3801 OGB 8. UPPERSTRUCTURE HYDRAULICS Pressure setting, Troubleshooting, Hydraulic Schematics ..........................8001 .................................7-38020GB Hydraulic Reservoir .....................................................................................801 0 .................................7-38030GB Main hydraulic Pump ...................................................................................8020 .................................7-38040GB Hydraulic Pilot Pump ...................................................................................8021 .................................7-38130GB Attachment valve .........................................................................................8032 .................................7-38050GB Swing and offset cylinder flow selector valve ..............................................8035 .................................7-38060GB Pressure Limiter and Flow Cut-Off Valve ....................................................8036 .................................7-38140GB Swing Motor (CK25) ....................................................................................8037 .................................7-56660GB Swing Motor (CK28) ....................................................................................8037 .................................7-37920GB Hand Control Valve......................................................................................8050 .................................7-38120GB Attachment cylinders ...................................................................................8081 .................................7-38070GB 9. UPPERSTRUCTURE/AITACHMENTS Upperstructure and Turntable Bearing ........................................................9001 .................................7-38080GB Boom, Dipper, Bucket and Dozer Blade ......................................................9002 .................................7-38090GB Pedals and Levers .......................................................................................9003 .................................7-381 OOGB Operator's Cab and Canopy........................................................................9004 .................................7-3811 OGB Case Lep 7·37912GB Copyright © 1995 Case Corporation Printed in England February 1995
- 2. Section 1001 SAFETY INSTRUCTIONS, GENERAL INFORMATION . AND TORQUE SPECIFICATIONS J I Case Lap 7-55741 Copyright © 1991 JI Case Company Printed in England November 1991
- 3. 1001-3 SAFETY This symbol means ATTENTION ! BECOME ALERT! YOUR SAFETY IS A INVOLVED. The message that follows the symbol contains important Lll information aboutsafety. Carefully read the message, Make sure you fully understand the causes of possible injury or death. To prevent injury always follow the Waming, Caution and Danger notes in this section and throughout the manual. Put the waming tag shown below on the key for the keyswitch when servicing or repairing the machine. One warning tag is supplied with each machine. Additional tags Part Number 331-4614 are available from your service parts supplier. See Other Side Reason _ _ __ JICase ~ .1.-.co~ ~ c.._... _.. USA 8004 A Read the operator's manual to familiarize ~ yourself with the correct control functions. Operate the machine and equipment &. controls from the seat position only. Any other method could result in serious injury. A This is a one man machine, no riders ~ allowed. Lap 7-55741 I A When working in the area ofthe fan beltwith Lll the engine running, avoid loose clothing if poSSible, and use extreme caution. When doing checks and tests on the A equipment hydraulics, follow the Lll procedures as they are written. DO NOT change the procedure. 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. Issued 11-91 Printed in England
- 4. 1001-4 I:. Use insulated gloves or mittens when ~ working with hot parts. I:. Lower all attachments to the ground or use ~ stands to safety support the attachments before you do any maintenance or service. Use suitable floor (service) jacks or chain I:. hoist to raise wheels or tracks off the floor. ~ Always block machine in place with suitable safety stands. Lep 7-55741 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 materialandorshop cloths asrequired. Use safe practices at all times. Some components ofthis machine are very I:. heavy. Use suitable lifting equipment or Lll additional help as instructed in this Service Manual. Batteries contain acid and explosive gas. Explosions can result from sparks, flames or I:. wrong cable connections. To connect the ill jumper cables correctlyto the batteryofthis machine see the Operator's Manual. Failure to follow these instructions can cause serious injury or death. Issued 11-91 Printed in England
- 5. 1001-5 GENERAL INFORMATION CLEANING Clean all metal components, except bearings, with steam or white spirit. Do not use caustic soda when steam-cleaning. After cleaning, dry and oil the components. Clean oil lines with compressed air. Clean bearings in kerosene, dry them completely and oil them. INSPECTIONS Carefully examine all disassembled components. Replace all parts showing signs of wear or damage. Light scores and scratches can be removed by honing or with a buffing compound. Fast, abnormal wear of components can be avoided by careful examination and early detection of wear and pitting. BEARINGS Check that bearings run freely. Replace bearings that show signs of too much play or seizing. Clean bearings in a good solvent or kerosene and allow them to dry naturally. DO NOT DRY BEARINGS WITH COMPRESSED AIR. NEEDLE BEARINGS Before installing needle bearings in their housing, remove any metal edges inside or around the housing. When installing bearings with a hydraulic press, grease the inside and the outside'of the bearing with petroleum jelly. GEARS Check all gears for signs of damage or wear. Replace damaged or worn gears. Lep 7-55741 SEAL RINGS, 0 RINGS AND FLAT SEALS Always install new seal rings, O-rings and flat seals, if removed. Lubricate seal rings and O-rings with petroleum jelly. SHAFTS Check all shafts showing signs of damage or wear. Check particularly to make sure that any surface of the shaft in contact with bearings or seal rings is not damaged. SERVICE PARTS Always use genuine CASE service parts. To order service parts, see the Spare Parts Catalog and remember to give the correct reference of the necessary CASE part. No warranty claims will be considered for failures involving parts which are not of CASE origin. LUBRICATION Never use oil or grease which is different from that specified in the Operator's Manual or the Service Manual. No warranty claims will be considered for failures due to the use of wrong oil or grease. Issued 11·91 Printed in England
- 6. J I Case Section 2002 ENGINE REMOVAL AND INSTALLATION Don 7-37940 Copyright © 1992 J I Case Company Printed in England May 1992
- 7. Removal and Installation STEP 1 Park the machine on hard level ground. Lower the attachment to the ground. Release pressure in the hydraulic circuits and stop the engine. STEP 2 Disconnect the battery, positive (+) terminal first. NOTE: For Installation, install and tighten the negative (-) terminal first. STEP 3 Remove the Cab or Canopy, refer to Section 9004. STEP 4 / / Remove the bolts (1) and the protector (2). NOTE: For Installation, apply Loctite 271 to the bolts and tighten to a torque of: M12 - 77 to 90 Nm M16 - 166 to 197 Nm Don 7-37940 2002-3 STEPS Remove the Hydraulic Oil Reservoir, refer to Section 8010. STEP 6 ~ . "~£lL9 ; L~-@-·~ Put a container with a capacity of at least 5 Litres under the radiator drain valve and drain the coolant. NOTE: For Installation, install coolant to the correct level. STEP 7 Remove the hood mounting bolts (1) from the inside of the engine compartment. NOTE: For Installation, apply Loctite 271 to the bolts (1) and tighten to a torque of: M10 - 48 to 56 Nm M12 - 77 to 90 Nm Issued 5-92 Printed in England
- 8. 2002-4 STEP 8 Remove the bolts (2) and slide the control box (1) forwards. STEP 9 ~..h.. i Disconnect and remove the gas strut (1) on the hood. Support the hood on suitable lifting equipment. Remove the hood. NOTE: When the hood (1) is closed make sure the catch (2) comes in close contact with the bracket (4). When opening the hood (1) make sure the catch (2) easily comes offthe bracket (4), ifnecessaryadjustwith shims (5). Don 7-37940 STEP 10 Remove the battery and the fluid level sensor. , Disconnect and cap the radiator hoses (1) and (2). --- . --=--. _,'---A • Disconnect and cap the oil cooler hoses (1) and radiator retum hose (2). STEP 13 @ @ ----=----l~© ® Remove the radiator/oil cooler assembly. NOTE: For Installation, make sure the radiator (1) and fan (2) have the following clearances: A = 30 mm or more B = 15 mm or more C = 20 mm or more Issued 5-92 Printed in England
- 9. Disconnect the throttle cable (1), tachometer cable (2), fuel hose (3) and clamp (4). NOTE: For Installation, refer to Section 9003 for throttle cable adjustment. STEP 15 Remove the cover next to the right control lever stand. Disconnectthe main electrical harness from the engine. , ----,' -....... ---- - I Disconnect and cap the heater hoses, (if equipped). Don 7-37940 2002-5 STEP 17 , . --- Disconnect and cap the hoses (1) and (2) from the hydraulic pump. '" Support the engine on suitable lifting equipment. Remove the engine mounting bolts (1). NOTE: For Instal/ation, apply Loctite 271 to the engine mounting bolts and tighten to a torque of: M10 - 48 to 56 Nm M12 - 77 to 90 Nm M14 - 124 to 147 Nm. Issued 5-92 Printed in England
- 10. 2002-6 STEP 19 Carefully remove the engine from the machine. NOTE: For Installation, follow the same procedure in reverse order. Open the heater valve, situated on top of the engine, to allow the coolant to circulate. Start and run the engine for appro>dmately 5 minutes. Stop the engine and check the coolantlevel, engine oil level and hydraulic oil level. Add coolant or oil if necessary. WARNING: Never run an engine in an A closed building. Proper ventilation is required under all circumstances. Don 7-37940 Issued 5-92 Printed in England
- 11. 2010-8 SHOP EQUIPMENT TOOLS 1. TORQUE WRENCH, OEM 6474 AND OEM 6477 10. MICROMETER (25 to 50 mm), OEM 10058M 2. VALVE SPRING COMPRESSOR, OEM 6414 11. SMAU HOLE GAUGE SET, OEM 1023 3. PISTON RING EXPANDER, OEM 6266 12. DIAL GAUGE, CAS l0066-1A 4. SPRING TESTER, OEM 1282 AND MAGNETIC BASE, CAS 10149 5. PISTON RING COMPRESSOR, OEM 6269 13. TELESCOPING GAUGE, OEM 1015 6. PULLER, OEM 4212 14. TELESCOPING GAUGE, OEM 1017 7. COOUNG SYSTEM PRESSURE TESTER, OEM 1347 15. TELESCOPING GAUGE, OEM 1018 8. DEPTH MICROMETER, CASl 0064-1 M 16. TELESCOPING GAUGE, OEM 1019 9. MICROMETER (0 to 25 mm), OEM l0057M 17. CYUNDER BORE GAUGE, OEM 10340 TOOLS TO BE MADE 9(0.354) l-l' 5(0.2) J ,. -i==+ I , ! + i ., 120(472) ~~I ~~i c5S 55,! 3. SMALL END BUSHING DRIVER 1. VALVE GUIDE DRIVER ~ .. .. - 2 .. .. C'; ..4 C'; 0 .. :; ~-----~r---------. 0 -.-~--.-.- ..~ £ ... .~ 0 24(0.945) '50(5.~) '94(7.638) 4. CRANKSHAFT BEARING 1 DRIVER '" 2. IDLER GEAR BUSHING DRIVER ..~ .... <00 ~; ~~ ~N ~ C'; c5§. 0; - --,... f-.- _.- ~r----. is ~ ~ 'r ~; 150(5.9) 188(74) 5. GOVERNOR GEAR HOLDER BUSHING DRIVER Don 7-37950 Issued 6-92 Printed in England
- 12. 2010-9 Removal and Installation STEP 1 CYLINDER HEAD STEPS Remove the drain plug and drain the engine oil. Drain the coolant from the cylinder block. STEP 2 Remove the air filter assembly and muffler. NOTE: For Installation, install the mufflergasket with the steel side facing the muffler. STEP 3 Remove the alternator (1), fan belt (2) and fan. NOTE: For Installation, tighten the fan belt to 7 to 9 mm deflection at 98 N. STEP 4 Remove and cap the fuel injection pipes. Remove the fuel overflow pipes. Remove the nozzle holder assemblies (1). NOTE: For Installation, tighten the nozzle holder assemblies to a torque of49 to 68.6Nm (36to 50.61b tt) andthe fuelinjectionpipenuts to a torque of24.5to 34.3 Nm (18 to 251b ft) Don 7-37950 Remove the rocker cover retaining nuts. Remove the rocker cover (1) and discard the gasket. NOTE: ForInstallation, install a newrocker covergasket and tighten the retaining nuts to a torque of 6.9 to 8.8 Nm (5 to 6.5 Ib tt) STEP 6 Remove the rocker shaft retaining nuts and remove the rocker shaft assembly. Remove the push rods. NOTE: ForInstallation, tighten the rockershattretaining nuts to a torque of 21.6 to 26.5 Nm (16 to 19.51b tt) Issued 6-92 Printed in England
- 13. 2010-10 STEP 7 10 2 7 14 0 6 0 3 0 11 °0°0°0° o 0 0 0 13 0 S 0 4 0 12 9 1 8 ""'-~ ) 14 6 3 11 18 0 10 0 2 0 7 0 1S 0, ... .... ··.0· ... ·0 .... .0 0 0···. ··0· ....... o· .. o· 0 17 0 9 0 1 0 8 0 16 13 S 4 12 ./ Loosen the clamp and remove the coolant return pipe. Remove the cylinder head retaining bolts (14 to 1 for 3 cylinder engines) or (18 to 1 for 4 cylinder engines) and remove the cylinder head. Remove and discard the gasket. NOTE: For Installation, install a new cylinder head gasket. Install and tighten the cylinder head bolts (1 to 14 for 3 cylinder engines)or (1 to 18 for 4 cylinder engines) to a torque of 63.7 to 68.6 Nm (47 to 511b ft). NOTE: Check the torque ofthe cylinderhead bolts after approximately 30 minutes running. STEPS Remove the tappets (1) from the crankcase. Put identification marks on the tappets (1) for installation. NOTE: Coat the tappets (1) with clean engine oil before installation. NOTE: For Installation, follow the same procedure in reverse order. Don 7-37950 Disassembly and Assembly STEP 9 Remove the valve cap (1). Use a valve spring compressor to compress the valve spring, remove the collet (2), retainer (3), valve spring (4) and valve (5). Remove and discard the seal (A). NOTE: For Assembly, install a new seal (A). Issued 6-92 Printed in England
- 14. 2010-11 Disassembly and Assembly STEP 1 CRANKCASE STEP 4 Remove the fuel feed pump (1) and tachometer drive housing plate. STEP 2 Remove the water pump assembly. Remove and discard the gasket. NOTE: ForAssembly, install a new waterpump gasket. STEP 3 Remove the front gear cover. Remove and discard the gasket. NOTE: For Assembly, install a new front cover gasket. Don 7-37950 Remove the engine stop solenoid (1). Remove and discard the gasket. NOTE: For Assembly, install a new engine stop solenoid gasket. STEP 5 Remove the speed control plate (1) and governor springs. NOTE: Take care not to drop the govemorsprings into the crankcase. NOTE: ForAssembly, install a new speed control plate gasket. Issued 6-92 Printed in England
- 15. 2010-12 STEPS Align the control rack pin (3) with the notch (1) in the crankcase and remove the injection pump (2). Remove the injection pump shims, make a note ofthe number of shims removed. NOTE: ForAssembly, make sure the controlrackpin (3) is located in the groove of the fork and thrust lever. IMPORTANT: Install the same amount of shims between the crankcase and injection pump, as removedin Step 6. Checkthe injection timing, adding or removing one shim retards or advances the injection timing by 1.5 degrees. STEP 7 Remove the fuel camshaft retaining bracket (1). Remove the fuel camshaft (3) and timing gear (2): Don 7-37950 STEP 8 Remove the oil pressure pump. Remove the snap ring (1) from the governor shaft. Remove the governor shaft assembly (2). 1. SNAP RING 2. GOVERNOR SHAFT 3. GOVERNOR SHAFT BUSHING Before installing the governor shaft (2) into the crankcase, install a new bushing (3) using the Bushing Installation Driver, refer to Tools to be Made, Page 8. Install the shaft (2) and snap ring (1), checkthe shaft (2) rotates freely. Issued 6-92 Printed in England
- 16. STEP 9 5 Remove the cover (1), spring (4) and shaft (5). Remove the spacer (2) and bearing (3). Remove the levers (6) and (7). NOTE: For Assembly, install a new gasket onto the cover (1). STEP 10 Install the lever (6) to the RH side of the fuel limit bolt (8), as shown. Don 7-37950 2010-13 STEP 11 Remove the snap ring (A) and idler gear (1). Remove the camshaft retaining bolts (8) and carefully remove the camshaft gear (3) and camshaft (2). NOTE: For Assembly, make sure the ilming marks are aligned, as shown. Issued 6-92 Printed in England
- 17. 2010-14 PISTON AND CONNECTING RODS Removal and Installation STEP 1 Remove the oil pan retaining screws. Remove the oil pan, remove and discard the gasket. Remove the oil strainer (1), remove and discard the o-ring. NOTE: For Installation, install a new o-ring onto the oil strainer, install the oil strainer. Install a new oil pan gasket and install the oil pan. When tightening the oil pan retaining bolts, tighten diagonally from the center. Don 7-37950 STEP 2 Remove the connecting rod cap retaining screws. Remove the connecting rod cap. NOTE: For Installation, coat the retaining screws lightly with clean engine oil. Tighten to a torque of41.2 to 46. 1 Nm (30.4 to 341b tt). NOTE: For Installation, align the identification marks on the connecting rod and cap. STEP 3 Tum the flywheel until the No.1 piston is at top dead center. Remove the piston and connecting rod. Issued 6-92 Printed in England
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- 19. STEP 4 1.57rad a (90.)~(d) (b) O.31rad l (18·) (a) Position the piston rings on the piston, as shown. STEP 5 Use a ring compressor (1) and install the piston and connecting rod using a hammer shaft, as shown. NOTE: Make sure the identification marks on the connecting rod and cap are facing the injection pump. IMPORTANT: DO NOT interchange the pistons and liners. Disassembly and Assembly STEP 6 ~~ ~~7 @-- ~ ~.,.:..... ~~ ':: ®- ';!C) Remove the piston rings (4, 5 and 6). Remove the snap ring (3) and piston pin (1). Remove the connecting rod (7) from the piston (2). Don 7-37950 2010-15 STEP 7 Install the connecting rod (7) into the piston (2) with the casting mark (9) and identification numbers (10) in the same direction. STEP 8 -++--+-® a PISTON PIN HOLE c. SECOND RING GAP b. TOP RING GAP d. OIL RING GAP Install the oil ring onto the piston with the expander joint (11) on the opposite side to the gap (12). Install the remaining piston rings with the manufacturers marks (13) facing the top of the piston. Issued 6-92 Printed in England
- 20. 2010-16 Removal and Installation STEP 1 CRANKSHAFT STEP 3 Lock the flywheel and remove the retaining bolts. Use a suitable extractor to remove the flywheel. NOTE: For Installation, tighten the retaining bolts to a torque of 53.9 to 58.8 Nm (39.8 to 43.4 Ib tt). STEP 2 Check the side clearance of the crankshaft, refer to Specifications, Page 4. Remove the bearing case retaining screws and remove the bearing case (3). Remove and discard the oil seal. NOTE: ForAssembly, install a new oilseal. Installa new gasket onto the bearing case. Install the bearing case (3) with the mark "upn (4), in the position shown. Tighten the retaining screws diagonally to a torque of 29.4 to 34.3 Nm (21.7 to 25.31b tt). Don 7-37950 Remove the crankshaft bearing retaining screws (5) and carefully remove the crankshaft. NOTE: For Installation, install the crankshatt with the holes in the bearing case (2) aligned with the cylinder block (1}.Installandtighten the retaining screws (5) to a torque of 49 to 53.9 Nm (36.2 to 39.8 Ib tt). Issued 6-92 Printed in England
- 21. Disassembly and Assembly STEP 4 Remove the two screws from the bearing case (1). Remove the bearing case (1) from the crankshaft. Remove the thrust bearing (3) and bearing from the bearing case. Repeat procedure for the remaining bearing cases. Don 7-37950 2010-17 STEPS Clean the oil passage in the bearing case. Apply clean engine on the thrust bearings and bearings. Make sure the bearing cases are installed on the crankshaft in the same position as removed. NOTE: ForAssembly, make sure the face ofthe bearing case marked "FLYWHEELn is facing towards the flywheel and the oil grooves in the thrust bearings face outwards from the bearing cases. Issued 6-92 Printed in England
- 22. 2010-18 Inspection STEP 1 CYLINDER HEAD STEP 2 Thoroughly clean the surface of the cylinder head. Check the cylinder surface for warpage, using a straight edge and feeler gauge in the positions shown. NOTE: If the measurement is more than 0.05 mm the cylinder head must be machined or replaced. IMPORTANT: Ifthe cylinder head has been machined, refer to Step 2 to check the valve recess. Don 7-37950 Install thevalve intothe cylinder head and using a depth micrometer measure the distance between surface of the valve and cylinder head. If the measurement is not within specification, replace the valve. If the measurement is still greater than specification check the valve seat face and correct if necessary. Valve recess - 0.05 to 0.15 mm (0.4 mm maximum) STEP 3 Valve and Valve Guide I -?- Measure the outside diameterofthe valve stem and the inside diameter of the valve guide. If the clearance is greater than 0.10 mm, replace the valve guide or valve. Referto Specifications, Page 4, for the 0.0. of the valve stem and 1.0. of the valve guide. Issued 6-92 Printed in England