Case CX210C, Service Manual

Page 1: ...1 2 CX210C Crawler Excavator SERVICE MANUAL Crawler Excavator CX210C Part number 48063128 English October 2016 2016 CNH Industrial Italia S p A All Rights Reserved SERVICE MANUAL Part number 48063128...

Page 2: ...SERVICE MANUAL CX210C Crawler excavator LC version ISUZU engine GI 4HK1X TIER 3 48063128 27 10 2016 EN Find manuals at https best manuals com...

Page 3: ...nes 10 11 10 254 Intake and exhaust manifolds and muffler 10 12 10 501 Exhaust Gas Recirculation EGR exhaust treatment 10 13 10 400 Engine cooling system 10 14 10 414 Fan and drive 10 15 10 310 Afterc...

Page 4: ...tem 35 16 Frames and ballasting 39 39 140 Ballasts and supports 39 1 Tracks and track suspension 48 48 130 Track frame and driving wheels 48 1 48 100 Tracks 48 2 48 134 Track tension units 48 3 48 138...

Page 5: ...n and Air Conditioning HVAC control system 55 18 55 416 Swing control system 55 19 55 417 Travel control system 55 20 55 530 Camera 55 21 55 518 Wiper and washer system 55 22 55 404 External lighting...

Page 6: ...90 100 Engine hood and panels 90 4 48063128 27 10 2016 Find manuals at https best manuals com...

Page 7: ...48063128 27 10 2016 Find manuals at https best manuals com...

Page 8: ...INTRODUCTION 48063128 27 10 2016 1 Find manuals at https best manuals com...

Page 9: ...and the environment 9 Torque Bolt and nut 10 Torque Special torque settings 11 Basic instructions Shop and assembly 15 Hydraulic contamination 17 General specification 18 General specification Main e...

Page 10: ...nts not approved by the manu facturer including those used for the servicing or repair of the product manufactured or marketed by the manufacturer In any case no warranty is given or attributed on the...

Page 11: ...h or serious injury CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AND CAUTION MESSAGES COULD RESULT IN DEATH OR...

Page 12: ...e inserted Gear Check that there is no wear and no damage Oil seal O ring gasket Always install new oil seals O rings and gaskets Apply grease to sections where oil seals and O rings will be inserted...

Page 13: ...it WARNING Check the safety messages in the operator s manual before starting the engine Check all the warning labels on the machine Check that no one is within the machine s operating range Check the...

Page 14: ...a soft head WARNING Wear eye protection when using a hammer to install a pin or when working with a grinder At this time use goggles or eye protectors that meet standards WARNING Park the machine in a...

Page 15: ...or modifications that reduce the functionality of the anchoring part at the left rear of the cab Modifications that effect the strength of the cab with a protective structure Modifications prohibited...

Page 16: ...w coolant mixtures to get into the soil Collect and dispose of coolant mixtures properly The air conditioning system contains gases that should not be released into the atmosphere Consult an air condi...

Page 17: ...meter size M6 M8 M10 M12 M14 M16 M18 M20 Wrench 10 mm 13 mm 17 mm 19 mm 22 mm 24 mm 27 mm 30 mm Hexagon bolt Tighten ing torque 6 9 N m 5 089 lb ft 19 6 N m 14 456 lb ft 39 2 N m 28 912 lb ft 58 8 N m...

Page 18: ...4 629 6 N m 397 84 464 37 lb ft 11 Mount M16 24 mm 264 9 313 9 N m 195 38 231 52 lb ft 12 Front bracket M10 17 mm 63 8 73 6 N m 47 06 54 28 lb ft 13 Engine Rear bracket M16 24 mm 205 9 247 1 N m 151 8...

Page 19: ...INTRODUCTION LPIL12CX00034HB 1 48063128 27 10 2016 12...

Page 20: ...INTRODUCTION SMIL13CEX1312GB 2 48063128 27 10 2016 13...

Page 21: ...INTRODUCTION SMIL13CEX1313GB 3 48063128 27 10 2016 14...

Page 22: ...n tool Do not tap the seal with a hammer or mallet 6 While you insert the seal check that the seal is perpendicular to the seat When the seal settles make sure that the seal makes contact with the thr...

Page 23: ...ground cable from the machine battery The electronic monitoring system and charging system will be damaged if this is not done 5 Remove the battery ground cable Reconnect the cable when you complete w...

Page 24: ...lief valves or check valves held open by dirt Quick failure of components that have been repaired Slow cycle times are slow The machine does not have enough power If your machine has any of these prob...

Page 25: ...4 755 US gpm Working circuit pressure 3 9 MPa 565 7 psi Control valves With Boom Arm holding valve One 4 spool valve for Right track travel Bucket Boom and Arm acceleration One 5 spool valve for Left...

Page 26: ...on condition etc Work mode display SP H Auto Machine condition Power boost etc Alarm display and buzzer Water temperature Hydraulic oil temperature Fuel level Diagnosis system Rear Right side view cam...

Page 27: ...ach side 49 Type of shoe Triple grouser shoe Link pitch 190 mm 7 480 in Width of shoe 600 mm 23 622 in S T D Grade ability 70 35 Mass Operating mass 21400 kg 47178 924 lb with 2 94 m 9 6457 ft Arm 0 9...

Page 28: ...094 in Crawler overall length 4470 mm 175 984 in 4470 mm 175 984 in Track gauge 2390 mm 94 094 in 2390 mm 94 094 in Undercarriage overall width with 600 mm 23 622 in shoes 2990 mm 117 717 in 2990 mm 1...

Page 29: ...ratio 43 246 Dry weight 263 kg 579 816 lb Take up roller Weight 96 4 kg 212 5256 lb Upper roller Weight 17 8 kg 39 2423 lb Lower roller Weight 35 5 kg 78 2641 lb Recoil spring Item Weight Quantity Yo...

Page 30: ...l engine Engine type 4 cycle water cooled overhead camshaft type straight cylinder direct fuel injection type electronic control Number of cylinders bore stroke 4 115 mm 4 53 in 125 mm 4 92 in Total d...

Page 31: ...draulic device Hydraulic pump Manufacturer Kawasaki Heavy Industries Ltd Main pump Pump type Double variable displacement piston pump Displacement capacity 118 5 cm rev 7 231 in rev x 2 Rated 34 3 MPa...

Page 32: ...21 US gpm Rated pressure 4 5 MPa 652 psi Port size P T B port G3 8 C1 C2 C3 C4 C5 ports G1 4 Solenoid specifications Operating voltage DC 20 32 V Power consumption 17 W max Weight 6 7 kg 14 7710 lb Va...

Page 33: ...Operating angle deg 1 Secondary pressure SMIL14CEX0416AB 1 Ports 2 4 A Secondary pressure MPa psi B Push rod stroke mm in C Operating angle deg 1 Secondary pressure SMIL14CEX0418AB 2 Travel remote con...

Page 34: ...MPa 4975 psi Drain port E 0 5 MPa 73 psi Pilot port F 3 9 MPa 566 psi Flow High pressure passage ABCD 234 l min 61 816 US gpm Drain port E 10 l min 2 642 US gpm Pilot port F 21 l min 5 548 US gpm Port...

Page 35: ...in Rod diameter 100 mm 3 937 in Maximum retracted length 2020 mm 79 528 in Stroke 1460 mm 57 480 in Weight 251 kg 553 3603 lb Bucket cylinder Manufacturer KYB Corporation Cylinder bore 120 mm 4 724 i...

Page 36: ...le bearing 9800 kg 21605 302 lb C Counterweight 4120 kg 9083 045 lb D Lower component with grouser shoe 7180 kg 15829 190 lb E Main unit weight 17000 kg 37478 585 lb F Attachments 4300 kg 9479 877 lb...

Page 37: ...7 lb 10 Fuel tank 169 kg 372 581 lb 11 Hydraulic tank 137 kg 302 033 lb 12 Control valve 200 kg 440 925 lb 13 Center joint 30 kg 66 139 lb 14 Boom 1553 kg 3423 779 lb Shoe weight per side Component na...

Page 38: ...ange without notice due to design change or other reason The diagrams give values that include the shoe lug height a 26 mm 1 024 in 9CF74B31 1 b 1040 mm 40 945 in e 440 mm 17 323 in c 2390 mm 94 094 i...

Page 39: ...thout notice due to design change or other reason The diagrams give values that include the shoe lug height a 26 mm 1 024 in B8AEDAD5 2 b 1040 mm 40 945 in e 440 mm 17 323 in c 2390 mm 94 094 in f 143...

Page 40: ...5 2 1654 80 3 1496 6 0 2362 31 1 2205 56 2 2047 81 3 1890 7 0 2756 32 1 2598 57 2 2441 82 3 2283 8 0 3150 33 1 2992 58 2 2835 83 3 2677 9 0 3543 34 1 3386 59 2 3228 84 3 3071 10 0 3937 35 1 3780 60 2...

Page 41: ...3 50 60 18 288 18 593 18 898 19 202 19 507 19 812 20 117 20 422 20 726 21 031 60 70 21 336 21 641 21 946 22 250 22 555 22 860 23 165 23 470 23 774 24 079 70 80 24 384 24 689 24 994 25 298 25 603 25 90...

Page 42: ...98 26 719 27 340 27 962 28 583 29 204 29 826 30 447 40 50 31 069 31 690 32 311 32 933 33 554 34 175 34 797 35 418 36 040 36 661 50 60 37 282 37 904 38 525 39 146 39 768 40 389 41 010 41 632 42 253 42...

Page 43: ...7 770 194 786 581 802 968 40 50 819 355 835 742 852 129 868 516 884 904 901 291 917 678 934 065 950 452 966 839 50 60 983 226 999 613 1016 00 0 1032 38 7 1048 77 5 1065 16 2 1081 54 9 1097 93 6 1114 3...

Page 44: ...348 250 3 352 035 6 355 820 9 359 606 3 363 391 6 367 176 9 370 962 2 374 747 6 90 100 378 532 9 382 318 2 386 103 6 389 888 9 393 674 2 397 459 5 401 244 9 405 030 2 408 815 5 412 600 9 100 Liters t...

Page 45: ...000 3 5200 3 7400 3 9600 4 1800 10 20 4 4000 4 6200 4 8400 5 0600 5 2800 5 5000 5 7200 5 9400 6 1600 6 3800 20 30 6 6000 6 8200 7 0400 7 2600 7 4800 7 7000 7 9200 8 1400 8 3600 8 5800 30 40 8 8000 9 0...

Page 46: ...62 85 372 65 382 46 30 40 392 27 402 07 411 88 421 69 431 49 441 30 451 11 460 91 470 72 480 53 40 50 490 33 500 14 509 95 519 75 529 56 539 37 549 17 558 98 568 79 578 59 50 60 588 40 598 21 608 01 6...

Page 47: ...84 07 398 30 412 52 20 30 426 75 440 97 455 20 469 42 483 65 497 87 512 10 526 32 540 55 554 77 30 40 569 00 583 22 597 45 611 67 625 90 640 12 654 35 668 57 682 80 697 02 40 50 711 25 725 47 739 70 7...

Page 48: ...843 4 981 5 119 5 258 5 396 30 40 5 534 5 673 5 811 5 949 6 088 6 226 6 365 6 503 6 641 6 780 40 50 6 918 7 056 7 195 7 333 7 471 7 610 7 748 7 887 8 025 8 163 50 60 8 302 8 440 8 578 8 717 8 855 8 9...

Page 49: ...990 47 1000 28 1010 08 1019 89 1029 70 1039 5 1049 31 1059 12 1068 92 100 Newton meters to weight kilogram meters N m 0 10 20 30 40 50 60 70 80 90 N m kgf m kgf m kgf m kgf m kgf m kgf m kgf m kgf m...

Page 50: ...6 370 187 8 34 36 7 24 4 4 82 27 8 140 60 198 92 2 256 124 4 314 156 7 372 188 9 32 35 6 26 3 3 84 28 9 142 61 1 200 93 3 258 125 6 316 157 8 374 190 0 30 34 4 28 2 2 86 30 0 144 62 2 202 94 4 260 12...

Page 51: ...4 60 140 0 92 197 6 124 255 2 156 312 8 188 370 4 35 31 0 3 26 6 29 84 2 61 141 8 93 199 4 125 257 0 157 314 6 189 372 2 34 29 2 2 28 4 30 86 0 62 143 6 94 201 2 126 258 8 158 316 4 190 374 0 33 27 4...

Page 52: ...ENGINE OIL MS 1121 SAE 15W40 API CI 4 Swing reduction unit 5 L 1 3 US gal CASE AKCELA GEAR 135 H EP 80W 90 MS 1316 SAE 80W 90 API GL 5 Travel reduction unit 5 L 1 3 US gal CASE AKCELA GEAR 135 H EP 8...

Page 53: ...s proper performance of the engine cooling system in the above mentioned operating temper ature range of the machine CASE AKCELA ACTIFULL OT EXTENDED LIFE COOLANT is available as 50 50 PREMIXED coolan...

Page 54: ...NOTICE consult the fuel supplier or the CASE CONSTRUCTION Dealer regarding appropriate use of fuel additives NOTICE in order to prevent condensation during cold weather fill the fuel tank to full aft...

Page 55: ...B Circuit breaker C U Control unit CAL Calibration CAN A type of control unit communication technique controller area network CFG Config CHK Check CKP Crankshaft position CMP Camshaft position CO Car...

Page 56: ...ord LED Light emitting diode LH Left LLC Long life coolant LM Lifting magnet M V Magnet valve MAF Mass air flow MAP Manifold air pressure Max Maximum MIL Malfunction indicator lamp diagnostic milli am...

Page 57: ...neers SBF Slow blow fuse SCV Suction control valve SIG Signal SLD Shield SP pin Special pin ST Starter start STD Standard SW Switch TDC Top dead center TEMP Temperature TP Throttle position UART Unive...

Page 58: ...8EA 1 When ordering parts obtaining information or assistance always supply your CASE CONSTRUCTION Dealer with the type and serial number of your machine or accessories Write the following in the spac...

Page 59: ...s with ISO 12117 2 Identification number 15UUEH 001 5 Cab protection FOPS Falling Objects Pro tective Structure Complies with ISO 10262 level 2 Product identification number E4E41FA0 6 Component seria...

Page 60: ...llustration shows the machine in normal travel position In normal travel position the cab is over the idler wheels The travel reduction gears are at the rear of the upperstructure This manual uses the...

Page 61: ...INTRODUCTION 48063128 27 10 2016 54...

Page 62: ...SERVICE MANUAL Engine CX210C Crawler excavator LC version ISUZU engine GI 4HK1X TIER 3 48063128 27 10 2016 10...

Page 63: ...10 7 10 206 Fuel filters 10 8 10 218 Fuel injection system 10 9 10 202 Air cleaners and lines 10 10 10 250 Turbocharger and lines 10 11 10 254 Intake and exhaust manifolds and muffler 10 12 10 501 Exh...

Page 64: ...Engine 10 Engine and crankcase 001 CX210C Crawler excavator LC version ISUZU engine GI 4HK1X TIER 3 48063128 27 10 2016 10 1 10 001 1...

Page 65: ...ecification 3 FUNCTIONAL DATA Engine Identification 5 External view 6 Static description 8 SERVICE Engine Prepare 10 Remove 12 Install 20 Check Engine oil 21 Compression test 22 Service instruction 24...

Page 66: ...Lubrication oil amount 13 0 20 5 L 3 434 5 416 US gal Oil filter type Full flow filter with integral bypass valve cartridge type Oil cooled type Built in water cooled Cooling system Cooling type Water...

Page 67: ...M Regulator type IC type Regulated voltage 28 5 V Weight 9 5 kg 20 9 lb Starter Type Manufacturer Nikko Voltage 24 V Output 5 kW 6 8 Hp Rated Time 30 s No of pinion gears 13 Direction of rotation towa...

Page 68: ...Engine Engine and crankcase Engine Identification Engine number 023AF579 1 1 Engine number stamping 48063128 27 10 2016 10 1 10 001 5...

Page 69: ...Engine Engine and crankcase Engine External view Engine structural diagram 03F011FB 1 05210A95 2 48063128 27 10 2016 10 1 10 001 6...

Page 70: ...Engine Engine and crankcase 1507C342 3 48063128 27 10 2016 10 1 10 001 7...

Page 71: ...n the coolant temperature engine speed or engine load and other data It purifies the exhaust gas by recirculating it The main components are the EGR valve EGR cooler and sensors Connecting rod cap bol...

Page 72: ...ug and glow indicator lamp The preheat system operates when the engine coolant temperature is low and assists engine starting Lubricating system A full flow bypass integrated oil filter is used and th...

Page 73: ...A WARNING Crushing hazard The lifting systems must be operated by qualified personnel who are aware of the correct procedures to follow Make sure all lifting equipment is in good condition and all hoo...

Page 74: ...m 17 mm 36 mm Box wrench 24 mm Shackle with the required lifting capacity x 2 Wire rope with the required breaking load Lifting equipment with the required lifting capacity Marking pen Caps Plugs Wast...

Page 75: ...ere with the frame Also cover with a rubber cap to protect against sparks 2 Remove the counterweight For details See Coun terweight Remove 39 140 3 Remove the pump For details See Pump Remove 35 106 4...

Page 76: ...tely drain the coolant SMIL13CEX1231AB 4 8 Use a wrench 13 mm to loosen the 2 line bolts 1 and then disconnect the 2 lines 2 and 3 from the compressor Always remove the low pressure suction side line...

Page 77: ...gine and hoses so that the connectors match at the time of assembly Install caps or plugs to the engine and hoses to pre vent any entry of water dust or dirt Clean the engine and hoses by spraying the...

Page 78: ...plugs to the engine and hose to pre vent any entry of water dust or dirt SMIL13CEX1240AB 12 16 Remove the hose band 1 and then disconnect the fuel hose 2 Install caps or plugs to the engine and hoses...

Page 79: ...or plugs to the engine and hose to pre vent any entry of water dust or dirt SMIL13CEX1244AB 16 20 Loosen the hose band 1 and then disconnect the heater hose 2 Install caps or plugs to the engine and...

Page 80: ...EX1247AB 19 23 Use a wrench 7 mm to loosen the hose band 1 and then disconnect the air hose 2 Use caps to cover the line and hose to prevent any entry of water dust or dirt SMIL13CEX1248AB 20 24 Disco...

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