Case CX225SR Crawler Excavator OEM Service & Repair Manual

REPAIR MANUAL CX225SR 9-40691 1 02/12/2004

Contents INTRODUCTION DISTRIBUTION SYSTEMS A POWER PRODUCTION B TRAVELLING D BODY AND STRUCTURE E FRAME POSITIONING F WORKING ARM H TOOLS AND COUPLERS J 9-40691 1 02/12/2004

INTRODUCTION 9-40691 1 02/12/2004 1

Contents INTRODUCTION Foreword ( - A.10.A.40) CX225SR 3 Safety rules ( - A.50.A.10) CX225SR 4 Basic instructions ( - A.90.A.05) CX225SR 6 Torque ( - A.90.A.10) CX225SR 7 Torque ( - A.90.A.10) CX225SR 8 Dimension ( - A.92.A.30) CX225SR 11 Weight ( - A.92.A.40) CX225SR 12 Consumables ( - A.92.A.55) CX225SR 13 Hydraulic contamination ( - A.92.A.60) CX225SR 16 Product identication ( - A.80.A.10) CX225SR WE 18 Product identication ( - A.80.A.10) CX225SR NA 19 9-40691 1 02/12/2004 2

INTRODUCTION Foreword ( - A.10.A.40) CX225SR INTRODUCTION TO THE REPAIR MANUAL This manual has been designed so that in the near future it can be made available on CD and in a database via a computer network. This will allow fast and targeted search and navigation between the various information modules. Information search CRIL03J033E01 1 This manual is organised according to types of function and information. • The function and information types are codied and appear in parentheses after the title and separated by a dash: (1) Function (2) Information type. • Only the rst letter (A) and the rst number (B) of the function need to be used for the information search. The rst letter (A) corresponds to the sections of the repair manual. The rst number (B) corresponds to the chapters of the repair manual. The rst part of the (A.B) code is reected in the page numbering. THE REST OF THE CODING IS NOT LISTED IN ALPHA-NUMERIC ORDER IN THIS MANUAL. • You will nd a table of contents at the beginning and end of each section and chapter. You will nd an alphabetical index at the end of each chapter. • Therefore it is the rst part of the (A.B) coding, then the tables of contents and index (page numbers) which will allow you to quickly nd the information you are looking for. 9-40691 1 02/12/2004 3

INTRODUCTION Safety rules ( - A.50.A.10) CX225SR CAUTION M171C - THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY. ATTENTION: To avoid injury, always observe the Safety Notices, CAUTION and ATTENTION, contained in this section and throughout the manual. Place a “Do not start the machine” warning notice on the starter switch key before all maintenance or repair operations. CAUTION M489 - Read the operators manual to familiarize yourself with the correct control functions. CAUTION M490 - Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury. CAUTION M265A - A frequent cause of personal injury or death is persons falling off and being run over. Do not permit anyone to ride on the machine. CAUTION SB055 - Before starting engine, study operators manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operation. It is your responsibility to understand and follow manufacturers instructions on machine operation, service, and to observe pertinent laws and regulation. Operators and service manuals can be obtained from your dealer. ATTENTION: You risk injury if you wear loose clothing or if you do not use safety equipment for your work. Always wear clothes which are unlikely to become caught in the machinery. Other safety equipment may be required, in particular: hard hat, safety boots, ear protectors, safety goggles or mask, thick gloves and reective clothing. CAUTION M124A - Rotating machine parts, stay clear, keep shields installed to help protect from clothing entanglement and injury. Wear close-tted clothing. CAUTION SB071 - Rotating fan and belts: Contact will cause injury. Keep clear. ATTENTION: Follow the procedures exactly when carrying out checks or inspections on the vehicle’s hydraulic systems. DO NOT CHANGE the procedures. ATTENTION: Before running the hydraulic cylinders in this vehicle through the cycles necessary for checking their functioning or for draining a circuit, warn people nearby to move away. 9-40691 1 02/12/2004 4

INTRODUCTION CAUTION SM121A - Always wear heat protective gloves to prevent burning your hands when handling heated parts. CAUTION M132B - Lower or block elevated implements and other attachments before servicing or when leaving the equipment. CAUTION R149C - Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting uid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking uid, see your doctor immediately. ATTENTION: To remove a hardened pin, such as a pivot pin, or a hardened shaft, use a soft-headed hammer (brass or bronze) or a brass or bronze peg and a steel-headed hammer. CAUTION M428 - Always wear safety glasses when using a drill, hammer, saw, or other tools that may cause chips to y. ATTENTION: Use suitable servicing jacks or a chain hoist for raising the wheels or tracks. Always chock the vehicle in place with suitable safety supports. ATTENTION: When carrying out maintenance or repair operations on the vehicle, keep the workshop oor, the driving position and the steps free from oil, water, grease, tools, etc... Use an oil absorbent material and/or workshop cloths as necessary. Always use sound methods. ATTENTION: Some parts of this vehicle are very heavy. Use lifting devices or additional assistance recommended in the Operator’s Manual. CAUTION M532 - Do not operate the engine in a closed building. Proper ventilation is required under all circumstances. CAUTION M503 - 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. CAUTION M244A - BATTERIES CONTAIN ACID AND EXPLOSIVE GAS. EXPLOSION CAN RESULT FROM SPARKS, FLAMES, OR WRONG CABLE CONNECTIONS. TO CONNECT JUMPER CABLES OR CHARGER, SEE MANUAL(S) FOR THE CORRECT PROCEDURE. FAILURE TO FOLLOW THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS PERSONAL INJURY OR DEATH. 9-40691 1 02/12/2004 5

INTRODUCTION Basic instructions ( - A.90.A.05) CX225SR GENERAL Cleaning Clean all metal parts except the bearings with white spirit or steam. Do not use caustic soda for steam cleaning. After each cleaning, dry and oil all parts. Clean the oil ducts with compressed air. Clean the bearings with parafn, then dry them completely and lubricate them. Inspection Check all the parts when they are disassembled. Replace all parts that show signs of wear or damage. Supercial scratches and grooves can be removed with an oil stone or with a cloth dipped in red oxide. A complete visual inspection is necessary to detect wear and pitting, and replacing parts as soon as it becomes necessary will help to avoid premature breakdowns. Bearings Check that the bearings turn freely. Replace them if their adjustment is too free or if their functioning is irregular. Wash the bearings with a good solvent or parafn and allow them to air dry. DO NOT DRY THE BEARINGS WITH COMPRESSED AIR. Needle bearings Before pushing needle bearings into a cylinder bore, always remove all metallic projections from the bore and its edges. Before pushing in bearings with a press, coat the inside and edges of the bearings with Vaseline. Gears Check all the gears and ensure that they do not show any signs of wear or damage. Replace the worn out or damaged gears. Gaskets, O-rings and at seals Always install new gaskets, O-rings, and at seals. Coat the gaskets and O-rings with Vaseline. Shaft Check all shafts showing wear or damage. Enusre that the surface of a shaft carrying a bearing or gasket is not damaged. Spare parts Always use CASE spare parts. To order these, refer to the Spare Parts Catalogue and indicate the correct reference number of the CASE spare parts. Breakdowns caused by the use of parts other than CASE spare parts are not covered by the warranty. Lubrication Use only the oils and lubricants specied in the Operator’s Manual or the Service Manual. Breakdowns caused by the use of oils and lubricants not specically listed are not covered by the warranty. 9-40691 1 02/12/2004 6

INTRODUCTION Torque ( - A.90.A.10) CX225SR STANDARD TIGHTENING TORQUE Order of tightening nuts and cap screws. Tighten alternately so that torque remains uniform. Cap screws which are tted with Loctite (look for traces of a white residue on the thread after removal), must be cleaned with a thin oil or a suitable solvent, then dried. Add two or three drops of Loctite to the cap screw thread, then t the screw. CRIL03H012E01 1 The numbers in the diagrams represent the order of tightening. Tightening torque Where there are no special instructions, tighten cap nuts screws to the torques given in the table below. Standard torque setting table. Designation of cap screws (dimensions) M6 M8 M10 M12 M14 M16 M18 M20 Spanner in mm 10 13 17 19 22 24 27 30 Cap screw Torque setting in Nm 6.9 19.6 39.2 58.8 98.1 157.2 196 274 Wrench in mm 5 6 8 10 12 14 14 17 Socket head screw Torque setting in Nm 8.8 21.6 42.1 78.4 117.6 176.4 245 343 9-40691 1 02/12/2004 7

INTRODUCTION Torque ( - A.90.A.10) CX225SR SPECIAL TORQUE SETTINGS No. Component Screw diameter Wrench in mm Tightening torque (1)* Travel motor and reduction gear assembly M16 24 267 - 312 Nm (2)* Sprocket M16 24 267 - 312 Nm (3)* Idler wheel M16 24 267 - 312 Nm (4)* Upper roller M20 30 521 - 608 Nm (5)* Lower roller M18 27 371 - 432 Nm (6) Chain guide M18 27 380 - 443 Nm (7) Track pad M20 30 300 Nm+120 ° (8) Counterweight M36 55 2750 - 2940 Nm (9) Turntable (chassis) M20 30 468 - 545 Nm (10) Turntable (upperstructure) M20 30 468 - 545 Nm (11)* Swing motor and reduction gear assembly M20 30 521 - 608 Nm (12)* Engine M16 24 265 - 313 Nm (13)* Engine mounts M10 17 64 - 74 Nm (14) Radiator M16 24 147 - 176 Nm M10 17 64 - 74 Nm (15)* Hydraulic pump M20 30 367 - 496 Nm (16)* Hydraulic reservoir M20 30 412 - 471 Nm (17)* Fuel tank M20 30 412 - 471 Nm (18)* Control valve M16 24 267 - 312 Nm (19)* Hydraulic swivel M12 19 109 - 127 Nm (20) Cab M16 24 78 - 80 Nm (21) Batteries M10 17 20 - 29 Nm Use Loctite 262 or an equivalent on mounting screws marked with an asterisk (*). 9-40691 1 02/12/2004 8

Case CX225SR Crawler Excavator OEM Service & Repair Manual

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