Case CX800B, Service Manual

Page 1: ...1 2 CX800B Crawler Excavator SERVICE MANUAL Crawler Excavator CX800B Part number 48020292 English June 2016 2016 CNH Industrial Italia S p A All Rights Reserved SERVICE MANUAL Part number 48020292...

Page 2: ...SERVICE MANUAL CX800B CX800B RTC MASS EXC 48020292 15 06 2016 EN Find manuals at https best manuals com...

Page 3: ...0 216 Fuel tanks 10 8 10 206 Fuel filters 10 9 10 218 Fuel injection system 10 10 10 202 Air cleaners and lines 10 11 10 250 Turbocharger and lines 10 12 10 254 Intake and exhaust manifolds and muffle...

Page 4: ...r hydraulic system 35 15 35 738 Excavator and backhoe bucket hydraulic system 35 16 35 360 Hammer and rotating bucket hydraulic system 35 17 Frames and ballasting 39 39 140 Ballasts and supports 39 1...

Page 5: ...ote control valve electric control 55 17 55 036 Hydraulic system control 55 18 55 051 Cab Heating Ventilation and Air Conditioning HVAC controls 55 19 55 050 Heating Ventilation and Air Conditioning H...

Page 6: ...ywork and decals 90 90 150 Cab 90 1 90 156 Cab windshield and windows 90 2 90 120 Mechanically adjusted operator seat 90 3 90 100 Engine hood and panels 90 4 48020292 15 06 2016 Find manuals at https...

Page 7: ...48020292 15 06 2016 Find manuals at https best manuals com...

Page 8: ...INTRODUCTION 48020292 15 06 2016 1 Find manuals at https best manuals com...

Page 9: ...y and the environment 9 Torque Bolt and nut 10 Torque Special torque setting 11 Basic instructions Shop and assembly 14 Hydraulic contamination 16 General specification 17 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: ...head 367 496 N m 270 69 365 83 lb ft 16 Hydraulic tank M20 24 mm 225 6 264 8 N m 166 195 lb ft 17 Fuel tank M20 24 mm 232 4 276 N m 171 204 lb ft 18 Control valve M20 30 mm 333 392 N m 245 61 289 12...

Page 19: ...INTRODUCTION 66B91CE4 1 48020292 15 06 2016 12...

Page 20: ...INTRODUCTION 79A11AE7 2 48020292 15 06 2016 13...

Page 21: ...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 22: ...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 23: ...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 24: ...oolant Coolant 55 Water 45 Oil cooler capacity 174 4 kW fin type Plate fin fin space 3 mm 0 12 in Intercooler capacity 63 3 kW fin type Straight fin fin space 2 0 mm 0 08 in Fuel cooler capacity 3 58...

Page 25: ...system ISO control pattern Travel Pilot pressure control system SP mode H mode Work mode select Auto mode Travel mode select 2 speed travel Attachment cushion control Hydraulic lock gate lock left sid...

Page 26: ...mirror Cab side Right side Undercarriage Hydraulic service brake Brake valve Final drive Planetary gear reduction High 4 3 km h 2 7 mph Automatic travel speed shifting Travel speeds Low 3 0 km h 1 9...

Page 27: ...inimum ground clearance 890 mm 35 039 in Wheel base Center to center of wheels 5070 mm 199 606 in Crawler overall length 6360 mm 250 394 in Track gauge Extended 3450 mm 135 827 in Track gauge Retracte...

Page 28: ...1 974 Dry weight 1052 kg 2319 263 lb Take up roller Weight 537 kg 1183 8823 lb Upper roller Weight 74 5 kg 164 2444 lb Lower roller Weight 187 kg 412 2644 lb Recoil spring Item Weight Quantity Special...

Page 29: ...vertical in line direct injection type electronic control Number of cylinders bore stroke 6 147 mm 5 79 in 154 mm 6 06 in Total displacement 15 681 L 4 142 US gal Compression ratio 16 Rated output 37...

Page 30: ...y 15 cm rev 0 92 in rev Operating pressure 4 4 MPa 638 220 psi Maximum discharge flow 27 8 L min 7 344 US gpm at 1850 RPM Hydraulic simultaneous constant output control Maximum flow adjustment control...

Page 31: ...valve performance Reseat pressure 14 7 MPa 2132 24 psi at 5 0 l min 5 000 US gpm Rated pressure 17 8 MPa 2581 89 psi Rated flow 64 0 l min 64 000 US gpm Maximum operating speed 1600 RPM Minimum operat...

Page 32: ...32 V Power consumption 17 W max Weight 6 7 kg 14 7710 lb Remote control valve for left right operations Manufacturer Kawasaki Heavy Industries Ltd Operating pressure 3 92 MPa 569 psi Secondary pressu...

Page 33: ...kg 27 5578 lb Center joint High pressure passage ABCD 34 3 MPa 4975 psi Drain port T 1 0 MPa 145 psi Operating pressure Pilot port P 3 9 MPa 566 psi High pressure passage ABCD 500 L min 132 086 US gp...

Page 34: ...0 157 in 2175 mm 85 630 in large soil amount Weight 1055 kg 2325 877 lb Bucket cylinder Cylinder bore 190 mm 7 480 in 215 mm 8 465 in large soil amount Rod diameter 130 mm 5 118 in 150 mm 5 906 in lar...

Page 35: ...00 kg 55776 952 lb C Counterweight 12500 kg 27557 783 lb D Lower component with grouser shoe 12400 kg 27337 321 lb E Main unit weight 64300 kg 141757 235 lb F Attachment 18700 kg 41226 443 lb G Boom i...

Page 36: ...547 lb 7 Engine including engine oil 1165 kg 2568 385 lb 8 Radiator 700 kg 1543 236 lb 9 Hydraulic pump 300 kg 661 387 lb 10 Fuel tank 510 kg 1124 358 lb 11 Hydraulic oil tank 445 kg 981 057 lb 12 Co...

Page 37: ...hout notice due to a design change or other rea sons NOTE The values indicated in the diagram include the shoe lug height a 50 mm 1 969 in NOTE The dimension within the brackets indicates the maximum...

Page 38: ...tice due to a design change or other rea sons NOTE The values indicated in the diagram include the shoe lug height a 50 mm 1 969 in NOTE The dimension within the brackets indicates the maximum retract...

Page 39: ...tice due to a design change or other rea sons NOTE The values indicated in the diagram include the shoe lug height a 50 mm 1 969 in NOTE The dimension within the brackets indicates the maximum retract...

Page 40: ...notice due to a design change or other rea sons NOTE The values indicated in the diagram include the shoe lug height a 50 mm 1 969 in NOTE The dimension within the brackets indicates the maximum retr...

Page 41: ...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 42: ...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 43: ...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 44: ...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 45: ...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 46: ...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 47: ...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 48: ...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 49: ...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 50: ...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 51: ...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 52: ...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 53: ...E CONSTRUC TION hydraulic systems The type of hydraulic oil to be used depends on the ambient temperature Temperate Climates 20 40 C 4 0 104 0 F CASE AKCELA HYDRAULIC EXCAVATOR FLUID MS1230 ISO VG 46...

Page 54: ...ngine fuel and filter maintenance The use of oils other than light oils stipulated in National Standard III exhaust gas regulations or oils containing a maximum of 350 ppm of sulfur content will have...

Page 55: ...e fuel line Please obtain an analysis of the fuel from the supplier to ensure that the fuel actually conforms to the above standards Precautions If the fuel for the diesel engine cannot satisfy the sp...

Page 56: ...in the machine NOTICE do not leave a biodiesel fuel blend stored in the fuel system for longer than 3 months When it is necessary to store the machine for a long time it is necessary to run the engin...

Page 57: ...INTRODUCTION Local environmental agency will in many cases be able to help you as well 48020292 15 06 2016 50...

Page 58: ...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 59: ...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 60: ...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...

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