Case Cx40B Hydraulic Excavator Shop Manual-21113C200177.pdf -Bookmark created by https://wimanual.com SAFETY PRECAUTIONS GENERAL SAFETY INFORMATION SAFETY PRECAUTIONS 1. OUTLINE 1.1 GENERAL PRECAUTIONS FOR REPAIRS 1.2 INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS� STANDARD HANDBOOK FOR MECHANICAL ENGINEERS) 2. SPECIFICATIONS 2.1 COMPONENTS NAME 2.2 MACHINE DIMENSIONS 2.3 SPECIFICATIONS AND PERFORMANCE 2.4 MACHINE & COMPONENTS WEIGHT (DRY) 2.5 TRANSPORTATION 2.6 TYPE OF CRAWLER SHOES 2.7 TYPE OF BUCKET 2.8 ENGINE SPECIFICATIONS 3. ATTACHMENT DIMENSIONS 3.1 BOOM 3.2 ARM 3.3 BUCKET 3.4 DOZER 3.5 SWING 11. TOOLS 11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS 11.2 SCREW AND TOOL SIZES 11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES 11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS 11.5 SPECIAL SPANNERS FOR TUBES 11.6 SPECIAL TOOLS 11.7 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS 11.8 COUNTERWEIGHT LIFTING JIG 11.9 UPPER FRAME LIFTING JIG 12. STANDARD MAINTENANCE TIME TABLE 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR 13. MAINTENANCE STANDARDS AND TEST PROCEDURES 13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS 13.2 PERFORMANCE INSPECTION STANDARD TABLE 13.3 MEASURING ENGINE SPEED 13.4 MEASURING HYDRAULIC OIL PRESSURE 13.5 MEASURING TRAVEL PERFORMANCES 13.6 MEASURING SLEW PERFORMANCES 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES 13.8 MEASURING SLEW BEARING PERFORMANCES 13.9 MEASURING CRAWLER TENSION 22. HYDRAULIC SYSTEM 22.1 SUMMARY 22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS 22.3 HYDRAULIC CIRCUIT OPERATION 23. ELECTRICAL SYSTEM 23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION 23.2 ELECTRICAL EQUIPMENT & HARNESS 24. COMPONENTS SYSTEM 24.1 HYDRAULIC COMPONENTS 24.1.1 HYDRAULIC PUMP 24.1.2 PILOT VALVE (ATT) 24.1.3 2PILOT VALVE (TRAVEL) 24.1.4 CONTROL VALVE 24.1.5 SLEWING MOTOR 24.1.6 TRAVEL MOTOR 24.1.7 SWIVEL JOINT 24.1.8 CYLINDER 24.2 ELECTRICAL EQUIPMENT 24.2.1 ELECTRICAL EQUIPMENT LIST 24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT 31. GENERAL DISASSEMBLY AND ASSEMBLY 31.1 GENERAL DISASSEMBLY AND ASSEMBLY 32. ATTACHMENTS 32.1 REMOVING AND INSTALLING 32.2 DISASSEMBLING AND ASSEMBLING 33. UPPER SLEWING STRUCTURE 33.1 REMOVING AND INSTALLING 33.2 DISASSEMBLING AND ASSEMBLING CX40-50_2.pdf 34.1 REMOVING AND INSTALLING 34-3 34.1.1 NAME OF TRAVEL SYSTEM PARTS 34-3 34.1.2 CRAWLER 34-3 34.1.3 UPPER ROLLER 34-12 34.1.4 MAINTENANCE STANDARDS 34-17 34.1.5 TOOLS AND JIGS 34-18 34.1.6 LOWER ROLLER 34-19 34.1.7 FRONT IDLER 34-27 34.1.8 IDLER ADJUSTER 34-33 34.1.9 SPROCKET 34-37 34.1.10 TRAVEL MOTOR 34-38 34.1.11 SLEWING BEARING 34-40 34.2 DISASSEMBLING AND ASSEMBLING 34-43 34.2.1 TRAVEL MOTOR 34-43 34. TRAVEL SYSTEM PREFACE 34.1 REMOVING AND INSTALLING 34.1.1 NAME OF TRAVEL SYSTEM PARTS Fig. 34-1 Name and location of parts 2. Craweler 3. Upper roller 4. Lower roller 5. Front idler 6. Idler adjuster 7. Sprocket 8. Travel motor 9. Slewing bearing 34.1.2 CRAWLER 34.1.2.1 REMOVAL AND INSTALLATION PROCEDURES 34.1.2.1.1 Removing Rubber Crawler Fig. 34-2 Crawler removing posture Fig. 34-3 Loosing crawler tension Fig. 34-4 Removing rubber crawler 34.1.2.1.2 Installing rubber crawler Fig. 34-5 Installing rubber crawler Fig. 34-6 Feeding grease Fig. 34-7 Crawler tension 34.1.2.2 REMOVAL AND INSTALLATION PROCEDURES (STEEL: OPT) Fig. 34-8 Position of master pin Fig. 34-9 Removing of master pin Fig. 34-10 Loosening grease nipple for adjustment Fig. 34-11 Removing lock pin Fig. 34-12 Removing master pin Fig. 34-13 Removing crawler Fig. 34-14 Direction of crawler Fig. 34-15 Installing crawler Fig. 34-16 Alignment of pin holes Fig. 34-17 Press fitting master pin Fig. 34-18 Extension of track link (Example for rubber crawler) 34.1.2.3 CONSTRUCTION Fig. 34-19 Rubber crawler assy Fig. 34-20 Construction of steel crawler 34.1.2.4 MAINTENANCE STANDARDS Fig. 34-21 Rubber crawler shoe 34.1.3 UPPER ROLLER 34.1.3.1 REMOVAL AND INSTALLATION PROCEDURES 34.1.3.1.1 Removal Fig. 34-22 Releasing crawler tension Fig. 34-23 Supporting with wooden blocks 34.1.3.1.2 Installation Fig. 34-24 Removing 34.1.3.2 CONSTRUCTION Fig. 34-25 Construction of upper roller 34.1.3.3 DISASSEMBLY AND ASSEMBLY 34.1.3.3.1 Disassembling Fig. 34-26 Preparation for disassembly Fig. 34-27 Extruding shaft Fig. 34-28 Removing out floating seal Fig. 34-29 Extruding bushing 34.1.3.3.2 Installing Fig. 34-30 Fixing floating seal Fig. 34-31 Pressing shaft Fig. 34-32 Installing cover Fig. 34-33 Filling oil 34.1.4 MAINTENANCE STANDARDS Fig. 34-34 Sectional view of upper roller 34.1.5 TOOLS AND JIGS 34.1.5.1 Tightening tools 34.1.5.2 Jig 34.1.6 LOWER ROLLER 34.1.6.1 REMOVAL AND INSTALLATION PROCEDURES 34.1.6.1.1 Removing Fig. 34-35 Lower roller assembly Fig. 34-36 Crawler removing posture 34.1.6.1.2 Installing Fig. 34-37 Installing lower roller 34.1.6.2 CONSTRUCTION Fig. 34-38 Lower roller construction 34.1.6.3 DISASSEMBLY AND ASSEMBLY 34.1.6.3.1 Disassembling Fig. 34-39 Removing shaft (4), collar (2) and O-ring (8) Fig. 34-40 Removing collar (13) Fig. 34-41 Removing the seal (7) Fig. 34-42 Removing the seal (7) Fig. 34-43 Removing bush (5) 34.1.6.3.2 Assembly Fig. 34-44 Attach O-ring (8) to one side Fig. 34-45 Press fitting bushing (5) Fig. 34-47 Installing roller (1) Fig. 34-48 Installing the collar (12) Fig. 34-48 Installing oil supply plug (9) 34.1.6.4 MAINTENANCE STANDARDS Fig. 34-50 Lower roller 34.1.7 FRONT IDLER 34.1.7.1 REMOVAL AND INSTALLATION PROCEDURES 34.1.7.1.1 Removing Fig. 34-51 Removing idler assembly Fig. 34-52 Disassembling idler assembly 34.1.7.1.2 Installing Fig. 34-53 Installing idler assembly 34.1.7.2 CONSTRUCTION Fig. 34-54 Idler assembly construction 34.1.7.3 DISASSEMBLY AND ASSEMBLY 34.1.7.3.1 Disassembly Fig. 34-55 Extruding pin Fig. 34-56 Extruding shaft Fig. 34-57 Removing bushing 34.1.7.3.2 Assembly Fig. 34-58 Pressing in bushing (2) Fig. 34-59 Pressing in shaft (6) Fig. 34-60 Inserting floating seal (4) Fig. 34-61 Pressing in collar (3) Fig. 34-62 Driving pin (5) 34.1.7.4 MAINTENANCE STANDARDS Fig. 34-52 Idler assembly 34.1.7.5 TOOLS AND JIGS 34.1.8 IDLER ADJUSTER 34.1.8.1 REMOVAL AND INSTALLATION PROCEDURES 34.1.8.1.1 Removing Fig. 34-53 Disassembling idler assembly 34.1.8.1.2 Installing 34.1.8.2 CONSTRUCTION 34.1.8.3 DISASSEMBLY AND ASSEMBLY Fig. 34-66 Spring set special jig (V) Fig. 34-67 Slinging work of idler adjuster Fig. 34-68 Fixing Holding-down nut (H) Fig. 34-69 Compression of spring Fig. 34-70 Removing retainer plate Fig. 34-71 Removing and installing of idler adjuster assembly Fig. 34-72 Attach idler adjuster assembly to the jig 34.1.8.4 MAINTENANCE STANDARDS Fig. 34-73 Idler adjuster assembly 34.1.9 SPROCKET 34.1.9.1 REMOVAL AND INSTALLATION PROCEDURES 34.1.9.1.1 Removing Fig. 34-74 Making sprocket free 34.1.9.1.2 Installing Fig. 34-75 Removing sprocket Fig. 34-76 Tightening capscrew 34.1.9.2 MAINTENANCE STANDARDS Fig. 34-77 Sprocket 34.1.10 TRAVEL MOTOR 34.1.10.1 REMOVAL AND INSTALLATION PROCEDURES 34.1.10.1.1 Removing Fig. 34-78 Making sprocket free Fig. 34-79 Removing cover and travel motor Fig. 34-80 Removing and installing travel motor 34.1.10.1.2 Installing Fig. 34-81 Installing travel motor Tightening torque N.m (lbf.ft) Port Thread size (PF) Spanner used (mm) O-ring type fitting 30 flare type fitting A,B P DR 1 1 3 27 17 22 108 (80) 36.3 (27) 73.5 (54) 78.5 (58) 29.4 (22) 49.0 (36) Fig. 34-82 Installing hydraulic pipings (LH-travel motor) Fig. 34-83 Checking oil level 34.1.10.2 MAINTENANCE STANDARDS 34.1.11 SLEWING BEARING 34.1.11.1 REMOVAL AND INSTALLATION PROCEDURES 34.1.11.1.1 Removing Fig. 34-84 Slewing bearing Fig. 34-85 Lifting slewing bearing 34.1.11.1.2 Installing Fig. 34-86 Location of "S" mark to install slewing bearing 34.1.11.2 CONSTRUCTION 34.1.11.3 DISASSEMBLY AND ASSEMBLY 34.1.11.3.1 Disassembling Fig. 34-88 Disassembling slewing bearing 34.1.11.3.2 Assembling Fig. 34-89 Removing balls Fig. 34-90 Installing balls Fig. 34-91 Installing spacer 34.1.11.4 MAINTENANCE STANDARDS 34.2 DISASSEMBLING AND ASSEMBLING 34.2.1 TRAVEL MOTOR 34.2.1.1 SUMMARY OF. Oil filling port OL. Oil level check port DP. Drain port Rotating direction Oil inlet port Oil outlet port Clockwise A B Counterclockwise B A HS. High speed LS. Low speed 34.2.1.2 TOOLS AND JIGS Application �A� Hub M12 Spindle M12 Travel motor M12 34.2.1.3 DISASSEMBLY 34.2.1.3.1 PREPARATIONS FOR DISASSEMBLY 34.2.1.3.2 GENERAL PRECAUTIONS FOR WORKING 34.2.1.3.3 DISASSEMBLING Fig. 34-92 Mounting lifting eye Fig. 34-93 Cleaning travel motor Fig. 34-94 Placing travel motor on workbench Fig. 34-95 Fixing travel motor on workbench Fig. 34-96 Removing plug (33) Fig. 34-97 Draining oil Fig. 34-98 Removing ring (45) Fig. 34-99 Removing cover (13) Fig. 34-100 Removing sun gear 1 (4) Fig. 34-101 Removing carrier assembly Fig. 34-102 Disassembling carrier assembly Fig. 34-103 Removing thrust washer (9) Fig. 34-104 Unscrewing hexagonal head screw (40) Fig. 34-105 Removing planetary gear 2 (7) Fig. 34-106 Unscrewing plug (224) Fig. 34-107 Unscrewing plug (226) Fig. 34-108 Removing socket bolt (243) Fig. 34-109 Removing rear flange (201) Fig. 34-110 Removing parallel pin (42) Fig. 34-111 Removing O-rings (43) and (44) Fig. 34-112 Removing timing plate (109) Fig. 34-113 Removing parallel pin (241) Fig. 34-114 Removing bearing (150) Fig. 34-115 Removing plug (224) Fig. 34-116 Removing stopper (225), spring (228) and spool (223) Fig. 34-117 Remove the plug (226) Fig. 34-118 Removing spring (230) and valve (227) Fig. 34-119 Removing O-ring (236) Fig. 34-120 Removing O-ring (237) Fig. 34-121 Removing plug (221) Fig. 34-122 Removing spool (263) Fig. 34-123 Removing piston (112) Fig. 34-124 Removing piston (112) Fig. 34-125 Lifting cylinder block (104) Fig. 34-126 Removing cylinder block (104) Fig. 34-127 Removing retainer plate (107) Fig. 34-128 Removing piston assembly (105) and (106) Fig. 34-129 Removing thrust ball (105) Fig. 34-130 Removing roller (104) Fig. 34-131 Removing spring (114) Fig. 34-132 Removing spring (114) Fig. 34-133 Removing internals of cylinder block (104) Fig. 34-134 Removing swash plate (103) Fig. 34-135 Removing drive shaft (102) Fig. 34-136 Removing 2-speed switching piston kit Fig. 34-137 Removing ball bearing (149) Fig. 34-138 Fixing spindle (2) Fig. 34-139 Removing hexagon set screw (47) Fig. 34-140 Loosen ring nut (22) Fig. 34-141 Installing jig Fig. 34-142 Removing ring nut (22) Fig. 34-143 Removing spindle (2) Fig. 34-144 Removing floating seal (31) Fig. 34-145 Removing ball bearing (24) Fig. 34-146 Removing floating seal (31) Fig. 34-147 Removing oil seal (132) Fig. 34-148 Cleaning each part Fig. 34-149 Cleaning each section Fig. 34-150 Finish cleaning Fig. 34-151 Finish cleaning 34.2.1.4 ASSEMBLY 34.2.1.4.1 PREPARATION 34.2.1.4.2 GENERAL PRECAUTIONS FOR ASSEMBLY 34.2.1.4.3 ASSEMBLING PROCEDURE NOTE: After replacing any of the following parts with new ones, adjust the preload of the ball bearing and thickness of the snap ring without fail: NOTE: When replacing any of the above parts, use the parts previously adjusted. Otherwise, the travel motor may malfunction resulting in premature breakage. Fig. 34-152 Inserting bearing (24) Fig. 34-153 Installing floating seal (31) Fig. 34-154 Lifting hub (1) Fig. 34-155 Installing hub (1) to the workbench Fig. 34-156 Installing floating seal (31) Fig. 34-157 Inserting spindle (2) Fig. 34-158 Installing ring nut (22) Fig. 34-159 Attaching hexagon set screw (47) Fig. 34-160 Removing fixing plate Fig. 34-161 Installing Oil seal (132) Fig. 34-162 Installing piston kit Fig. 34-163 Inserting bearing (149) Fig. 34-164 Inserting shaft Fig. 34-165 Installing swash plate (103) Fig. 34-166 Assembling cylinder block Fig. 34-167 Installing snap ring (145) Fig. 34-168 Installing rollers (151) Fig. 34-169 Assembling piston assembly into retainer plate Fig. 34-170 Inserting cylinder block (104) Fig. 34-171 Installing friction plates (115) and separator plates (116) Fig. 34-172 Installing piston (112) Fig. 34-173 Inserting plug (226) Fig. 34-174 Temporarily tightening plug (226) Fig. 34-175 Inserting spool (223) Fig. 34-176 Installing O-ring (236) Fig. 34-177 Temporarily tightening plug (224) Fig. 34-178 Inserting spool (263) Fig. 34-179 Installing bearing (150) Fig. 34-180 Installing timing plate (109) Fig. 34-181 Installing O-rings (43) and (44) Fig. 34-182 Installing parallel pin (42) Fig. 34-183 Installing rear flange (201) Fig. 34-184 Tightening socket bolts (243) Fig. 34-185 Tightening plug (226) Fig. 34-186 Tightening plug (224) NOTE: If the tapped hole of carrier (3) is smeared oil or grease, degrease it by using the tap (M8 1.25). After that clean it wi... Fig. 34-187 Installing planetary gear 1 (5) Fig. 34-188 Tightening hexagon head screw (40) Fig. 34-189 Installing planetary gear 2 Fig. 34-190 Tightening hexagon head screw (40) Fig. 34-191 Installing sun gear (102) Fig. 34-192 Installing carrier assembly Fig. 34-193 Installing sun gear 1 (4) Fig. 34-194 Supplying lubricating oil Fig. 34-195 Installing cover (13) Fig. 34-196 Removing travel motor 34.2.1.5 34.2.1.5 MAINTENANCE STANDARDS 34.2.1.6 Performance verification test 42.1 GENERAL PRECAUTIONS 42-3 42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE 42-3 42.2 TROUBLE DIAGNOSIS: HYDRAULIC 42-4 42.3 TROUBLESHOOTING 42-5 42.3.1 ATTACHMENT 42-5 42.3.2 TRAVEL OPERATION 42-7 42.3.3 SLEWING OPERATION 42-10 42.3.4 PUMP 42-11 42. TROUBLESHOOTING (HYDRAULIC SYSTEM) 42.1 GENERAL PRECAUTIONS 42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE Fig. 42-1 Make field investigation Fig. 42-2 Verifying background of trouble occurred. Fig. 42-3 Diagnosing trouble by means troubleshooting. 42.2 TROUBLE DIAGNOSIS: HYDRAULIC 42.3 TROUBLESHOOTING 42.3.1 Attachment 42.3.1.1 Attachment operational failure (Excluding swing operations) 42.3.1.2 Attachment speed is slow 42.3.1.3 Attachment operating power is low 42.3.1.4 Malfunction of attachment 42.3.2 Travel operation 42.3.2.1 Travel operational failure 42.3.2.2 Travel speed is slow 42.3.2.3 Travel power is low 42.3.2.4 It deviates in travel independent operation 42.3.3 Slewing operation 42.3.3.1 Slewing operational failure 42.3.3.2 Slewing speed is slow 42.3.3.3 Slewing power is low 42.3.3.4 Malfunction of slewing operation 42.3.4 Pump 42.3.4.1 Engine speed is reduced due to pump load 42.3.4.2 Malfunction of pump 43.1 TROUBLE DIAGNOSIS: ELECTRIC SYSTEM 43-3 43.2 TROUBLESHOOTING 43-4 43.2.1 GENERAL 43-4 43.2.2 ATTACHMENT OPERATION 43-8 43.2.3 TRAVEL OPERATION 43-9 43.2.4 DECELERATION 43-10 43. TROUBLESHOOTING (ELECTRICAL SYSTEM) 43.1 TROUBLE DIAGNOSIS: ELECTRIC SYSTEM 43.2 TROUBLESHOOTING 43.2.1 GENERAL 43.2.1.1 Engine does not start. 43.2.1.2 Horn does not sound. 43.2.1.3 Working light does not light up. 43.2.1.4 Hourmeter does not actuate. 43.2.1.5 Fuel gauge does not actuate. 43.2.1.6 Water temperature meter does not actuate. 43.2.2 Attachment operation 43.2.2.1 All controls do not function (Excluding swing operations) 43.2.3 Travel operation 43.2.3.1 Travel 1 & 2 speed change can not be carried out. 43.2.4 Deceleration 43.2.4.1 Decel change operation in option can not be carried out. 44.1 TROUBLE DIAGNOSIS: ENGINE 44-3 44.2 TROUBLESHOOTING 44-6 44.2.1 STARTING TROUBLE 44-6 44.2.2 E 44.2.3 OUTPUT DROPS DOWN 44-9 44.2.4 OTHER TROUBLE 44-10 44.3 ELECTRICAL EQUIPMENT 44-13 44.3.1 ELECTRICAL EQUIPMENT LIST 44-13 44. TROUBLESHOOTING (ENGINE) 44.1 TROUBLE DIAGNOSIS: ENGINE 44.2 TROUBLESHOOTING 44.2.1 STARTING TROUBLE 44.2.1.1 Starter does not rotate 44.2.1.2 Starter rotates but hard to start NOTE: Check with the engine start key being in ON position. 44.2.2 E NOTE: Check the above items in the condition of coolant temperature at more than 50C. (122F) 44.2.3 OUTPUT DROPS DOWN 44.2.3.1 Engine output not enough NOTE: Check in the condition of operating at high speed. 44.2.3.2 Knocking at high temperature NOTE: Check in the condition at engine coolant temperature of more than 50C. (122F) 44.2.4 OTHER TROUBLE 44.2.4.1 Exhaust trouble NOTE: Note: Check in the condition at engine coolant temperature of more than 50C. (122F) NOTE: A breather mechanism of blow-by gas reduction system is applied to the engine as shown in the right drawing. Remove and plug the suction manifold to check blow-by gas. Costruction of breather mechanism 44.2.4.2 Excessive oil consumption NOTE: Check in the condition of no engine oil leakage. 44.2.4.3 Excessive fuel consumption NOTE: Check in the condition the proper fuel is used. 44.2.4.4 Engine not stop when key turned OFF NOTE: Check with the engine start key being in OFF position. 44.3 ELECTRICAL EQUIPMENT 44.3.1 ELECTRICAL EQUIPMENT LIST 71.1 HYDRAULIC CIRCUIT DIAGRAM 71-1 71.1.1 STANDARD SPECIFICATION 71-1 71.1.2 HYDRAULIC CIRCUIT OPERATION 71-3 71.1.3 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM 71-13 71.2 ELECTRIC CIRCUIT DIAGRAM 71-15 MIR CX40B -50B_A3_gb.pdf This page is blank because of editing convenience. 71.2 ELECTRIC CIRCUIT DIAGRAM Fig. 71- 13 (3 MIR CX40B -50B_A3_gb.pdf This page is blank because of editing convenience. 71.2 ELECTRIC CIRCUIT DIAGRAM Fig. 71- 13 (3 0051_MOTORE.pdf 51.1 General 51.2 Inspection and Adjustment 51.3 Troubleshooting 51.4 Disassembly, Inspection and Reassembly of Engines 51.5 LUBRICATION SYSTEM 51.6 COOLING SYSTEM 51.7 FUEL INJECTION PUMP 51.8 TURBOCHAGER: Disassembly, inspection and reassembly 51.9 STARTING MOTOR 51.10 ALTERNATOR 51.11 ELECTRIC WIRING 51.12 SERVICE STANDARDS 51.13 TIGHTENING TORQUE for BOLTS and NUTS . 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