CASE CX160 Crawler Excavators Service Repair Manual

Copyright  2001 Case France Printed in France Case Cre 7-29871GB December 2001 CX160 Crawler Excavators Table of Contents DIVISION/SECTION SECTION N° REFERENCE N° 1 GENERAL INFORMATION Safety, general information and standard torque data .....................................1001 7-27690GB General specifications and special torque setting............................................1002 7-27712GB 2 ENGINE Removal and installation of the engine ............................................................2000 7-28220GB Radiator and oil-cooler .....................................................................................2001 7-28040GB Engine specifications ............................................................................................. * Disassembly and assembly of the engine.............................................................. * 3 FUEL SYSTEM Fuel tank ..........................................................................................................3001 7-27970GB Fuel engine system................................................................................................ * 4 ELECTRICAL SYSTEM Electrical system, electrical and electronic troubleshooting .............................4001 7-27721GB Inspection and maintenance of batteries and connecting a booster battery ....4002 7-27921GB Main and engine electronic control boxes........................................................4003 7-27931GB 5 UNDERCARRIAGE Removal and installation of tracks ...................................................................5001 7-27750GB Rollers ..............................................................................................................5003 7-27770GB Sprocket ...........................................................................................................5004 7-27781GB Idler wheel and tension shock absorber ..........................................................5005 7-27801GB 6 DRIVE TRAIN Drive motor and final drive transmission removal and installation ...................6001 7-27841GB Drive motor and final drive transmission disassembly and assembly ..............6002 7-29860GB Swing reduction gear, removal and installation................................................6003 7-29900GB Swing reduction gear, disassembly and assembly ..........................................6004 7-28370GB 7 UNDERCARRIAGE HYDRAULICS 8 UPPERSTRUCTURE HYDRAULICS Depressurising and decontaminating the hydraulic system, use of the vacuum pump and bleeding the components ..............................................8000 7-27951GB Specifications, troubleshooting, checks and hydraulic pressure settings ........8001 7-27701GB Hydraulic reservoir removal and installation ....................................................8002 7-27990GB Main and pilot pumps, removal and installation ...............................................8003 7-27870GB Main hydraulic control valve, removal and installation .....................................8004 7-27880GB Attachment cylinders, removal and installation ................................................8005 7-27791GB Hydraulic swivel, removal and installation .......................................................8006 7-27811GB Pilot blocs, removal and installation .................................................................8007 7-28100GB Swing motor, removal and installation .............................................................8008 7-29890GB Main hydraulic pump, disassembly and assembly ...........................................8010 7-29770FR Main hydraulic control valve, disassembly and assembly................................ 8011 7-28200FR Attachment cylinders, disassembly and assembly...........................................8012 7-27900GB Hand control levers, disassembly and assembly .............................................8013 7-28110GB Foot control levers, disassembly and assembly ..............................................8014 7-28300FR Six-solenoid valves, disassembly and assembly .............................................8015 7-27910GB Caution valve, disassembly and assembly ......................................................8016 7-27940GB Safety vave ......................................................................................................8017 7-29630GB Hydraulic swivel, disassembly and assembly ..................................................8018 7-28080GB Swing motor, disassembly and assembly ........................................................8019 7-28010GB Hydraulic functions...........................................................................................8020 7-28480GB

Cre 7-29871GB Edition 12-01 DIVISION/SECTION SECTION N° REFERENCE N° 9 UPPERSTRUCTURE Upperstructure, turntable and counterweight ...................................................9002 7-27981GB Boom, dipper and bucket .................................................................................9003 7-27961GB Seat and seat belt ............................................................................................9004 7-28120GB Cab and cab equipment ...................................................................................9005 7-28021GB Air conditioning troubleshooting .......................................................................9006 Air conditioning unit disassembly and assembly..............................................9007 Air conditioning servicing .................................................................................9008 Air conditioning components ............................................................................9009 Large format hydraulic and electrical schematics .........................................Pocket 7-27612 * Consult the Engine Service Manual Sections to be distributed at a later date NOTE: CASE Company reserves the right to make changes in the spec- ification and design of the machine without prior notice and without incurring any obligation to modify units previously sold. The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document.

Case Copyright  2000 Case France Printed in France September 2000 Cre 7-27690GB 1001 SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS Section 1001

1001-2 Cre 7-27690GB Issued 09-00 TABLE OF CONTENTS GENERAL INFORMATION ....................................................................................................................................... 3 SAFETY..................................................................................................................................................................... 4 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6 WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury. !

1001-3 Cre 7-27690GB Issued 09-00 GENERAL INFORMATION Cleanning 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.

1001-4 Cre 7-27690GB Issued 09-00 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. Put the warning 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 . 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 al l people are out of the way. !

1001-5 Cre 7-27690GB Issued 09-00 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. I f hydraulic oil under pressure does penetrate the skin, seek medical treatmen t 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. !

1001-6 Cre 7-27690GB Issued 09-00 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the order of tightening. JS00481A Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then tighten.

1001-7 Cre 7-27690GB Issued 09-00 Torque table Tighten cap screws and nuts according to the table below if there are no other special instructions. Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20 Cap Screw Spanner [mm] 10 13 17 19 22 24 27 30 [in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18 Tightening torque [Nm] 6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.0 [lb-ft] 5.1 11.6 23.9 43.4 72.3 101.2 144.6 202.4 Socket Head Cap Screw Spanner [mm] 5 6 8 10 12 14 14 17 [in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67 Tightening torque [Nm] 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0 [lb-ft] 6.5 15.9 31.1 57.8 86.8 130.1 180.8 253.1

1001-8 Cre 7-27690GB Issued 09-00

CASE CX160 Crawler Excavators Service Repair Manual

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