CASE CX75SR TIER 3 CRAWLER EXCAVATOR Service Repair Manual Instant Download

1
CRAWLER EXCAVATOR
SERVICE MANUAL
CX75SR CX80 TIER 3
87676026A NA
Issued 01Aug 08
2
CRAWLER EXCAVATOR CX75SR/CX80 TIER 3 SERVICE
MANUAL
TABLE OF CONTENTS SECTION N
DIVISION/SECTION
REFERENCE N

• GENERAL INFORMATION
• Safety, general information and standard torque
  data..................................... 1001
• General specifications and special torque setting
  ........................................... 1002
• ENGINE
• Removal and installation of the
  engine............................................
  ................ 2000 Engine specifications......
  ..................................................
  ......................................
• Disassembly and assembly of the engine
  ..................................................
  ............
• FUEL SYSTEM
• Removal and installation of the fuel tank
  ..................................................
  ....... 3001 Fuel engine system
  ..................................................
  ..............................................
• ELECTRICAL SYSTEM
• Electrical and engine functions and service
  support .......................................
  4001
• Electrical equipment and electrical circuit
  diagrams........................................
  4020
• UNDERCARRIAGE
• Removal and installation of tracks
  ..................................................
  ................. 5001 Rollers
  ..................................................
  ..................................................
  ......... 5003
• Take-up roller....................................
  ..................................................
  ............. 5005
• DRIVE TRAIN
• Removal and installation of the drive motor and
• final drive transmission..........................
  ..................................................
  .... 6001
• Disassembly and assembly of the drive motor and
• final drive transmission..........................
  ..................................................
  .... 6002

7-27691NA SC75SRCX80-1002-0NA
SM75SR2000-0EN
SM75SR3001-0EN
SC75SRCX80-4001-0NA SC75SRCX80-4020-0NA
SM75SR5001-0EN SM75SR5003-0EN SM75SR5005-0EN
SM75SR6001-0EN
SM75SR6002-0EN
SM75SR6003-0EN See 8019
Consult the Engine Service Manual
Copyright 2008 CNH France S.A. Printed in
France August 2008
CNH
Lep SM75SRTOC-0NA
3
DIVISION/SECTION SECTION N
REFERENCE N

• UPPERSTRUCTURE HYDRAULICS
• Specifications, troubleshooting, checks and
• hydraulic pressure settings ......................
  ..................................................
  .. 8001
• Removal and installation of the hydraulic
  reservoir ........................................
  . 8002
• Removal and installation of the main hydraulic
  pump...................................... 8003
  Removal and installation of the main hydraulic
  control valve - CX75SR ......... 8004 Removal
  and installation of the main hydraulic control
  valve - CX80 ..............8004 Removal and
  installation of the attachment cylinders..........
  ............................ 8005
• Removal and installation of the hydraulic swivel
  ..............................................8006
  
• Removal and installation of the pilot blocs
  ..................................................
  ..... 8007 Disassembly and assembly of the main
  hydraulic pump .................................80
  10 Disassembly and assembly of the main
  hydraulic control valve - CX75SR ..... 8011
  Disassembly and assembly of the main hydraulic
  control valve - CX80 ..........8011 Disassembly
  and assembly of the attachment cylinders
  .................................8012
• Disassembly and assembly of the hand control
  levers ....................................8013
• Disassembly and assembly of the foot control
  levers ......................................
  8014
• Disassembly and assembly of the solenoid valve
  block .................................. 8015
• Disassembly and assembly of the cushion
  valve.............................................
  8016
• Disassembly and assembly of the hydraulic swivel
  ......................................... 8018
• Disassembly and assembly of the swing motor
  ...............................................
  8019 Hydraulic functions ........................
  ..................................................
  ................ 8020
• Hydraulic component functions.....................
  ..................................................
  .8030
• UPPERSTRUCTURE
• Air conditioning unit ............................
  ..................................................
  ........... 9007
• Large size hydraulic schematics - CX75SR
  ..................................................
  Pocket
• Large size electrical schematics - CX75SR
  ..................................................
  Pocket
• Large size hydraulic schematics -
  CX80..............................................
  ......... Pocket

SC75SRCX80-8001-0NA SM75SR8002-0EN
SM75SR8003-0EN SM75SR8004-0EN SM80-8004-0EN
SM75SR8005-0EN SM75SR8006-0EN SM75SR8007-0EN
SM75SR8010-0EN SM75SR8011-0EN SM80-8011-0EN
SM75SR8012-0EN SM75SR8013-0EN SM75SR8014-0EN
SM75SR8015-0EN SM75SR8016-0EN SM75SR8018-0EN
SM75SR8019-0EN SC75SRCX80-8020-0NA
SC75SRCX80-8030-0NA
SM75SR9007-0EN 87725725A 87742052A KAJ11600-E00
KAR11060-E00
NOTE CNH Company reserves the right to make
changes in the specification and design of the
machine without prior notice and without
incurring any obliga- tion to modify units
previously sold. The description of the models
shown in this manual has been made in accord-
ance with the technical specifications known as
of the date of design of this document.
Lep SM75SRTOC-0NA
Issued 08-08
4
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Section 1001
1001
SAFETY, GENERAL INFORMATION AND TORQUE
SPECIFICATIONS
Copyright ? 2006 CNH America LLC. All rights
reverved. Printed in U.S.A. Issued February,
2006
CNH
Lep 7-27691NA
6
1001-3
GENERAL INFORMATION Gears
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 Chec
k 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
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 Operators
or Service Manuals. Failures due to the use of
non-specified oils and lubricants are not
covered by warranty.
DRY BEARINGS WITH
to air dry. DO NOT 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.
Lep 7-27691NA
Issued 02-06
7
1001-4
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 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 operating.
! It is your responsibility to understand and
follow manufacturers instructions on machine
operation, service and to observe pertinent laws
and regulations. Operators and Service Manuals
may be obtained from your Case dealer.
WARNING Read the operators manual to
! familiarize yourself with the correct control
functions.
WARNING If you wear clothing that is too loose
or do not use the correct safety equipment for
your job, you can be injured.
WARNING Operate the machine and
! equipment controls from the seat position
! Always wear clothing that will not catch on
only. Any other method could result in serious
injury.
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 This is a one man machine, no riders
allowed.
!
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.
Lep 7-27691NA
Issued 02-06
8
1001-5
WARNING When servicing or repairing the
machine, keep the shop floor and operators
WARNING Use insulated gloves or mittens when
working with hot parts.
!
! 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 Lower all attachments to the
! ground or use stands to safely support the
attachments before you do any maintenance or
service.
WARNING Some components of this
! machine are very heavy. Use suitable lifting
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
equipment or additional help as instructed in
this Service Manual.
! immediately. Maintain all hoses and tubes in
WARNING Engine exhaust fumes can cause death.
If it is necessary to start the
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.
! 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
WARNING When removing hardened pins such as a
pivot pin, or a hardened shaft, use
! start and run the engine. To prevent the
! a soft head (brass or bronze) hammer or use
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.
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.
Lep 7-27691NA
Issued 02-06
9
Section 2000
REMOVAL AND INSTALLATION OF THE ENGINE
2000
Copyright ? 2008 CNH France S.A. Printed in
France August 2008
CNH
Lep SM75SR2000-0EN
10
2000-3
ENGINE
10
4.9 to 5.9 Nm
6 7
8 74 9
8.8 to 9.8 Nm 8.8 to 9.8 Nm
4
20 2 22
13 2
B
X3 X3 68.7 to 98.1 Nm 16 7 19 20
15
5
X2 4 3
8 X2 5 66
8.8 to 9.8 Nm 2
C
0 2
4
X4 28 32 63.8 to 73.6 Nm
39
3 24 25 26
29 24 25 26 27
X4 28
264.9 to 313.9 Nm
63.8 to 73.6 Nm 264.9 to 313.9 Nm
23
A
4.9 to 5.9 Nm
4.9 to 5.9 Nm
4.9 to 5.9 Nm
52
4.9 to 5.9 Nm
X2 5
X2 53 55
50 5
6 59 4.9 to 5.9 Nm 62 30 63 64 65 66
24 25 26 27 28
23
X4 73 63.8 to 73.6 Nm
X4 28 30 67
X4 69 70 23 24 25 26 27 28 28 32 264.9 to
313.9 Nm
72 7
68
63.8 to 73.6 Nm
63.8 to 73.6 Nm
KAH11280-E02

1. Coat the thread of sym (24) (30) (32) (45) with
   loc- tite 262 or equivalent after removing any
   oil film and fasten by tightening torque.
2. apply packing liquid (50) to the connection of
   radia- tor hose after removing any oil film and
   fasten by tightening torque.

1. Tighten up the clip jubilee from the direction
   shown on the drawing.
2. Arrow mark ( ) in the labels (69) represent the
   top.

Lep ASM-17-11-002EN
Issued 08-2008
11
2000-4

• Air inlet pipe (1)
• Hose clamp (2)
• Radiator stay (1)
• Bolt (6)
• Air hose (1)
• Vacuum indicateur (1)
• Cushion seal (1)
• Radiator (standard) assy (1)
• Label (1)
• Rubber hose (L 800) (1)
• Corrugated tube 13 x 8 00 (1)
• Hose band (3)
• Jubilee clip 50 - 65 (1)
• Hose clamp (1)
• Air hose (1)
• High strength nut M8 (3)
• Spring washer 8 (3)
• Exhaust pipe (1)
• Clamp (1)

36
X2 4 33 8.8 to 9.8 Nm
35
B
40 4 X8 42 43 44 28 45 46 63.8 to 73.6 Nm
47
C
36
34
72
D
KAH11280-E02b
Lep ASM-17-11-002EN
Issued 08-2008
12
3001-3
FUEL TANK
See detail A
2
1
x 2 7 x 2 7
2 12
8 11
x 2 x 2 4 5 6
x 2 8 9
3
x 2 10
7
13
See detail B
21
22
x 2 7
25 14 22
23
See detail C
3
20
14 x 2 x 2 15 16 17
6
24
19
18
KAH10760-D00

• NOTE
• The specifications of fuel tank refer to the
  bollows. Tank capacity 100L
• Limited inclined angle 35
• Do not cover the drill hole.

Lep AST-15-11-003
Issued 08-2008
13
3001-4

1. Fuel tank
2. Bracket
3. Tank belt
4. Hige strength washer
5. High strength nut
6. Bracket
7. Sems bolt M10x25
8. Hose band
9. Rubber hose
10. Sems bolt M10x16
11. Drain cock
12. Plate
13. Filter
14. Bracket
15. High strength bolt M10x40
16. Hige strength washer
17. Bond 262
18. Sponge cushion
19. Sponge cushion

12
33 34 35 36
A
21
36 35 34 37
B
5.9 to 6.9 Nm
x 8 26 27 28
29 30 31
x 5 32
C
KAH10760-D00
Lep AST-15-11-003
Issued 08-2008
14
5001-3
TRACK SHOE
1
2
10
8
5
11 9 11 6
13
3
7
12
13 4
16
14 15
AQ10002-001

1. Grouser shoe
2. Track link assembly
3. Track link (right)
4. Track link (left)
5. Master link (right)
6. Master link (left)
7. Track bushing
8. Track pin

1. Master bushing
2. Master pin
3. Collar

1. Locking pin
2. Seal
3. Shoe plate
4. Shoe bolt
5. Shoe nut

Lep ASM-17-10-002EN
Issued 08-2008
15

• 5001-4
• 1 Removal
• Position the master pin (1) of the track shoe as
  shown in the drawing on the left.
• Place track shoe support blocks as shown in the
  draw-
• ing.

1
AQ10002-002
2 Loosen the track shoe.
AQ10002-003
WARNING Discharge the grease from the grease
cylinder gradually by loosening the cylinder
check valve. Loosen the check valve slowly and
carefully. Stop loosening when the grease starts
to comes out. (If the valve is loosened too much,
the extremely high pressure inside may cause
grease to erupt or the plug to pop out).
3 Separate the track shoe.
2 AQ10002-004

1. Remove the locking pin (2).
2. Pull out the master pin using a jig.
3. Remove the track shoe supporting blocks.

4 Lift one side of the lower frame about 20 cm
and hold it there. WARNING Place protection
blocks under the lower frame and secure
them. Move the travel unit as shown in the
drawing to the left to remove the track shoe.
AQ10002-006
Lep ASM-17-10-002EN
Issued 08-2008
16
5001-5

• 2 Installation
• Lift the track shoe and align it to the drive
  sprocket.

AQ10002-007
2 Feed the track shoe toward the take-up roller
by moving the travel unit slowly as shown in the
drawing to the left.
AQ10002-008
NOTE Be careful. Sudden and quick movements may
cause the track shoe to jump and run
off. (During work, lift the roller shoe using the
steel bar when crossing over the upper
roller). 3 Remove protection blocks and lower
the lower frame.

1. Wind the end of the track shoe onto the take-up
   roller of the track shoe.
2. Connect the track shoe.

AQ10002-009

1. Place the track shoe supporting blocks.
2. Insert the master pin using a jig.
3. Insert a locking pin.

• Adjust the track shoe to the specified tension.
• Fasten the check valve to the original position.
• Fill the grease cylinder with grease, while
  observ- ing the track shoe tension.
• NOTE For the track shoe tension adjustment,
  refer to Inspec- tion and Maintenance in the
  Instruction Manual.

AQ10002-010
Lep ASM-17-10-002EN
Issued 08-2008
17
5001-6 1 Track link changing procedure

1. Remove the track shoe.
2. Remove bolts, nuts and shoe plates for three sec-
   tions, including the sections on both sides of
   the damaged link section.
3. Pull the track pin using a jig.
4. Remove the damaged link.
5. Align a new track link.
6. Press fit the track pin using a jig.
7. Align the shoe plate and tighten the bolts to the
   specified torque.
8. Install the track shoe.

AQ10002-011
Lep ASM-17-10-002EN
Issued 08-2008
18
5003-3
TRACK SHOE 1 Upper roller
AQ10002-023

1. Upper roller
2. Bolt
3. Loctite 262
4. Shim

Lep ASM-17-10-002EN
Issued 08-2008
19

• 5003-4
• 1 Removal
• Loosen track shoe. See Track shoe, removal.
• Place the hydraulic jack (A) as shown in the
  drawing to the left.

A
AQ10002-024

• Using the hydraulic jack (A), lift the track shoe
  high enough that the upper roller can be
  removed.
• Place blocks between the track shoe and side
  frame and secure them.
• Loosen the upper roller mounting bolt (2)
  slightly (so that the bolt head comes off 2 to 4
  mm).
• Hit the upper roller gently with a copper hammer
  and detach it from the side frame.
• Attach lifting tools on the upper roller.
• Remove the upper roller by removing mounting
  bolts (2) completely while lifting the upper
  roller using the lifting tools.
• NOTE Be careful to keep fingers and hands clear.
• 2 Installation
• Apply Loctite No. 262 to the upper roller
  mounting bolts (2).
• Finger tighten all upper roller mounting bolts
  (2) while lifting the upper roller.

A AQ10002-025

• NOTE Adjust the position of the upper roller if
  necessary, using shims (4) so that the track
  links are evenly supported.
• Tighten the upper roller mounting bolts (2) to
  the speci- fied torque.
• Remove the blocks and jack.
• Fill grease into the grease cylinder and give the
  track shoe the specified tension.
• (See Track shoe, installation).

Lep ASM-17-10-002EN
Issued 08-2008
20
3 Component diagram 5003-5
1. Cover
2. O-ring
3. Plug
4. Snap ring
5. Ball bearing
6. Roller
7. Shaft
8. Oil seal
9. Cover
10. Bracket
AQ14002-001
4 Tools and jigs 1. Tools Hammer
AQ13002-002
Hexagon bar wrench
AQ13002-003
Lep ASM-17-14-002EN
Issued 08-2008
21
5003-6 2. Jigs Install jig.
AQ13002-004
Pulling jig
AQ13002-005
Lep ASM-17-14-002EN
Issued 08-2008
22

• 5003-7
• 5 Disassembly instructions
• Preparation
• Prior to disassembly, take full preparatory
  measures.
• Workbench with vises
• Prepare a suitable workbench large enough to
  arrange and keep parts and perform the work.
• Tools and Jigs
• For tools and jigs, refer to the previous
  section.
• 2 General cautions
• Handle precision parts carefully during the
  operation do not drop or hit them on other parts
  during the operation.
• Do not attempt to finish the operation quickly
  do not forcedly pry or hit the parts.
• Perform the operation carefully and patiently in
  order to prevent parts deformation, oil leakage
  and lower effi- ciency.
• As disassembled parts tend to get rusted or
  collect dust and dirt, dust proof and rust
  prevention treatment should be applied
  immediately after disassembling the parts.
• 3 Disassembling procedure

1)
AQ14002-006

1. Clean the upper roller with kerosene.
2. Remove the plug (3) from the cover to drain the
   oil.

2)
AQ14002-003

1. Remove the cover (1) from the upper roller (6)
   using a press and a pulling jig.
2. Remove O-ring (2) from the cover (1).

Lep ASM-17-14-002EN
Issued 08-2008
23
5003-8 3) Remove snapring (4) from shaft (7).
AQ14002-004
4) Pull out the roller (6) from the shaft (7).
AQ14002-005
5) Remove the cover (9) and oil seal (8) from
roller using a press and a pulling jig.
AQ14002-006
Lep ASM-17-14-002EN
Issued 08-2008
24
5003-9
6) Remove ball bearings (5) from roller (6) using
a press and a pulling jig. Do not disassemble
ball bearings (5) unless they are unusable due
to wear.
AQ14002-007

• Cleaning parts
• Place parts in the preparatory cleaning container
  containing cleaning oil.
• NOTE Wash off deposited substances which may
  cause scratches.
• NOTE Leave the parts submerged in the kerosene
  until the dirt and grease come off and float up
• Put the parts in the finish cleaning container
  containing cleaning oil and wash them by slowly
  moving them.
• Wipe off remaining cleaning oil with clean cloth.
• NOTE Place the parts somewhere free of dust and
  moisture, and dry them using compressed air.
  After drying, apply engine oil to the parts.
• 6 Assembly instructions
• Prior to assembly
• Clean all the parts.
• Polish scratches, flashes or burrs using oil
  stons.
• Change sealing parts such as O-rings with new
  ones.
• Assembling procedure

1) Press fit the shaft (7) into the bracket (10).
Press fitting should be securely conducted
through the side of the plug hole.
AQ14002-008
NOTE In an ordinary case, do not disassembly the
bracket from the shaft. Reassembly will be a
very difficult task.
Lep ASM-17-14-002EN
Issued 08-2008
25
5003-10 2) Install the ball bearings (5) on
roller (6) using a jig and a hammer. NOTE Use
new ball bearings (5).
AQ14002-009
3)
AQ14002-010

1. Install the oil seal (8) and cover (9) to the
   roller (6).
2. Apply oil to the surface (lip section) of the
   floating seal.

NOTE Do not reuse oil seal (8).
4)
AQ14002-011

1. Apply grease to the shaft (7) surface.
2. Install roller (6) into shaft (7).

Lep ASM-17-14-002EN
Issued 08-2008
26
5003-11
5) Install snap ring (4) on shaft (7). NOTE Do
not reuse O-ring (4).
AQ14002-012
6)
AQ14002-013

1. Apply grease to O-ring (2) and install on cover
   (1).
2. Press fit the cover (1) with the O-ring attached
   on roller (6), using a press and a jig.

NOTE Use a new O-ring.
7) Check for leakage in the assembly using
compressed air. Compressed air pressure 0.2 MPa.
AQ14002-014
Lep ASM-17-14-002EN
Issued 08-2008
27
5003-12 8) Fill oil through the plug hole.
AQ14002-015
9) Install the plug (3). NOTE Clean the assembly
and dry it using compressed air.
AQ14002-016
Now the assembly has been completed.
Lep ASM-17-14-002EN
Issued 08-2008
28
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5003-13
7 Assembly drawings
K1182lt00

• 1. Cover (1)
• 2. O-ring 1B-G65 (1)
• 3. Plug 1/8 (1)
• Snap ring (1)
• Ball bearing (2)

1. Roller (1)
2. Shaft (1)
3. Oil seal (1)
4. Cover (1)

10. Bracket (1)
Lep ASM-17-14-002EN
Issued 08-2008
30
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com