CASE CONSTRUCTION CX210D User manual

1/3
CX210D
Crawler Excavator
SERVICE MANUAL
CX210D
Crawler Excavator
Part number 47996199
English
March 2016
© 2016 CNH Industrial Italia S.p.A. All Rights Reserved.
Part number 47996199
SERVICE MANUAL

SERVICEMANUAL
CX210DCrawlerexcavatorsLCversion(TIER4FINAL)-EUMarket
4799619914/03/2016
EN

Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.102]Panandcovers....................................................................10.2
[10.106]Valvedriveandgears..............................................................10.3
[10.101]Cylinderheads.....................................................................10.4
[10.105]Connectingrodsandpistons.......................................................10.5
[10.103]Crankshaftandywheel............................................................10.6
[10.216]Fueltanks..........................................................................10.7
[10.206]Fuellters..........................................................................10.8
[10.218]Fuelinjectionsystem...............................................................10.9
[10.202]Aircleanersandlines............................................................10.10
[10.250]Turbochargerandlines...........................................................10.11
[10.254]Intakeandexhaustmanifoldsandmufer.......................................10.12
[10.500]SelectiveCatalyticReduction(SCR)exhausttreatment.........................10.13
[10.501]ExhaustGasRecirculation(EGR)exhausttreatment............................10.14
[10.400]Enginecoolingsystem...........................................................10.15
[10.414]Fananddrive....................................................................10.16
[10.310]Aftercooler........................................................................10.17
[10.304]Enginelubricationsystem........................................................10.18
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.300]Reservoir,cooler,andlters........................................................35.2
[35.106]Variabledisplacementpump.......................................................35.3
[35.102]Pumpcontrolvalves................................................................35.4
[35.359]Maincontrolvalve..................................................................35.5
[35.357]Pilotsystem........................................................................35.6
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[35.355]Hydraulichandcontrol.............................................................35.7
[35.356]Hydraulicfootcontrol...............................................................35.8
[35.352]Hydraulicswingsystem............................................................35.9
[35.353]Hydraulictravelsystem..........................................................35.10
[35.354]Hydrauliccentraljoint............................................................35.11
[35.736]Boomhydraulicsystem..........................................................35.12
[35.737]Dipperhydraulicsystem..........................................................35.13
[35.738]Excavatorandbackhoebuckethydraulicsystem................................35.14
[35.360]Hammerandrotatingbuckethydraulicsystem..................................35.15
Framesandballasting.................................................................39
[39.140]Ballastsandsupports..............................................................39.1
Tracksandtracksuspension........................................................48
[48.130]Trackframeanddrivingwheels....................................................48.1
[48.100]Tracks..............................................................................48.2
[48.134]Tracktensionunits.................................................................48.3
[48.138]Trackrollers........................................................................48.4
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.200]Airconditioning.....................................................................50.2
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.100]Harnessesandconnectors.........................................................55.2
[55.525]Cabenginecontrols................................................................55.3
[55.015]Enginecontrolsystem..............................................................55.4
[55.201]Enginestartingsystem.............................................................55.5
[55.301]Alternator...........................................................................55.6
[55.302]Battery..............................................................................55.7
[55.202]Coldstartaid.......................................................................55.8
4799619914/03/2016

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[55.011]Fueltanksystem...................................................................55.9
[55.010]Fuelinjectionsystem.............................................................55.10
[55.014]Engineintakeandexhaustsystem...............................................55.11
[55.988]SelectiveCatalyticReduction(SCR)electricalsystem..........................55.12
[55.989]ExhaustGasRecirculation(EGR)electricalsystem.............................55.13
[55.012]Enginecoolingsystem...........................................................55.14
[55.013]Engineoilsystem................................................................55.15
[55.640]Electronicmodules...............................................................55.16
[55.512]Cabcontrols......................................................................55.17
[55.036]Hydraulicsystemcontrol.........................................................55.18
[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.19
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem...............55.20
[55.524]Cabcontrols(Liftarm,Boom,Dipper,Bucket)...................................55.21
[55.416]Swingcontrolsystem............................................................55.22
[55.417]Travelcontrolsystem............................................................55.23
[55.530]Camera...........................................................................55.24
[55.518]Wiperandwashersystem........................................................55.25
[55.404]Externallighting..................................................................55.26
[55.514]Cablighting......................................................................55.27
[55.408]Warningindicators,alarms,andinstruments....................................55.28
[55.992]Anti-theftsystem.................................................................55.29
[55.DTC]FAULTCODES..................................................................55.30
Booms,dippers,andbuckets.......................................................84
[84.910]Boom...............................................................................84.1
[84.912]Dipperarm.........................................................................84.2
[84.100]Bucket..............................................................................84.3
Platform,cab,bodywork,anddecals.............................................90
[90.150]Cab.................................................................................90.1
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[90.156]Cabglazing........................................................................90.2
[90.118]Protectionsandfootboards.........................................................90.3
[90.114]Operatorprotections...............................................................90.4
[90.120]Mechanically-adjustedoperatorseat...............................................90.5
[90.100]Enginehoodandpanels...........................................................90.6
[90.116]Fendersandguards................................................................90.7
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4799619914/03/2016

INTRODUCTION
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1

Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing....................................3
Safetyrules.....................................................................................4
Safetyrules–Generalinformation.............................................................5
Safetyrules–Personalsafety..................................................................6
Safetyrules–ROPSjudgment.................................................................8
Safetyrules-Ecologyandtheenvironment..................................................11
Torque–Boltandnut.........................................................................12
Torque-Specialtorquesetting...............................................................13
Basicinstructions-Shopandassembly......................................................17
Hydrauliccontamination......................................................................19
Generalspecication.........................................................................20
Generalspecication-Mainequipment......................................................25
Weight........................................................................................35
Dimension....................................................................................38
Capacitiesanduids..........................................................................41
Conversionfactors............................................................................45
Abbreviation..................................................................................57
Productidentication..........................................................................60
Productidentication-Machineorientation..................................................63
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INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecicationsatanytimewithout
noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specications,descriptions,and
illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
Incaseofquestions,refertoyourCASECONSTRUCTIONSalesandServiceNetworks.
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY.
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Safetyrules–Generalinformation
Cleaning
Cleanthemetalpartswithcleaningsolutionthatmeetsthestandardandsteamcleaning.(exceptforbearings)
Aftercleaning,drywell,andinjectoilinallparts.
Alsoinjectoilintothebearingsafterdrying.
Inspection
Whendisassemblingparts,checkalltheparts.
Ifthereareanywornordamagedparts,replacethem.
Inspectcarefullytopreventinitialbreakdowns.
Bearing
Replaceanyloosebearings.
Airdrybearingsbeforeinstallingthem.
Needlebearing
Wheninsertingneedlebearings,beverycarefulnottodamagethem.
Applygreasetothesectionwheretheneedlebearingwillbeinserted.
Gear
Checkthatthereisnowearandnodamage.
Oilseal,O-ring,gasket
Alwaysinstallnewoilseals,O-rings,andgaskets.
ApplygreasetosectionswhereoilsealsandO-ringswillbeinserted.
Shaft
Checkthatthereisnowearandnodamage.
Checkthebearingsandcheckfordamagedoilsealsontheshaft.
Serviceparts
InstallCASECONSTRUCTIONgenuineserviceparts.
Whenplacinganorder,checkthepartscatalog.ItcontainstheCASECONSTRUCTIONgenuinepartnumbers.
Anybreakdownsarisingfromtheinstallationofnon-genuinepartsarenotcoveredbythewarranty.
Lubricants(fuel,hydraulicoil)
Usetheoilfromthespeciedcompanyorspeciedintheoperator'smanualorserviceManual.
Anybreakdownsarisingfromanyfuelorhydraulicoilotherthanthosespeciedarenotcoveredbythewarranty.
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INTRODUCTION
Safetyrules–Personalsafety
WARNING:
Thissymbolindicatesaprecaution.
Itgivesinformationconcerningthesafetyoftheoperatorandthoseinthesurroundings.
Readandunderstandtheseprecautionsthoroughlybeforeperformingthework.
Alwayscomplywithwarningsandprecautionssoastoavoidanyaccidents.
Thissectioncoversinformationrelatedtooverallsafety.
Checkwhetherallwarninglabelsareinplace.
AdditionallabelscanbeorderedfromServiceParts.
WARNING:
Readtheoperator'smanualtogainathoroughunderstandingofmachinecontroloperations.
WARNING:
Performanymachineoperationsfromtheseatingposition.
Anyothermethodmaycausesevereinjuries.
WARNING:
Onlytheoneoperatoristorideonthemachine.Nooneelseistorideonit.
WARNING:
Checkthesafetymessagesintheoperator'smanualbeforestartingtheengine.
Checkallthewarninglabelsonthemachine.
Checkthatnooneiswithinthemachine’soperatingrange.
Checktheoperatingmethodsinasafelocationbeforestartingtheactualwork.
Understandthemachineoperationswell,thenoperateincompliancewithallservice-relatedlawsandregulations.
Theoperator'smanualcanbepurchasedatyourCASECONSTRUCTIONdealer.
WARNING:
Workingwithsloppyclothesorclotheswithwhichsafetycannotbeensuredleadstodamagetothemachine
andinjurytotheoperator.
Alwayswearclothesthatensuressafety.
Inordertoworkmoresafely,itisrecommendedtowearadditionalsafetyequipment.
Helmet,safetyshoes,earprotection,goggles,workclothes,andgloves
WARNING:
Paycarefulattentionwhenworkingwiththeenginerunning.
WARNING:
Checkhydraulicequipment.
Workaccordingtotheprocedure.
Donotchangetheprocedure.
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INTRODUCTION
WARNING:
Checkthatthereisnooneinthesurroundingsbeforedrainingthepressurefromhydrauliccircuitsduring
machinehydrauliccylinderinspection.
WARNING:
Usegloveswhenhandlinghigh-temperatureparts.
WARNING:
Bringthelowerpartsorattachmentsincontactwiththegroundbeforeinspectingorrepairingthem.
WARNING:
Checkthathosesandtubesaresecurelyconnected.
Ifthereisanydamagetoahoseortube,replaceit.
Donotcheckforoilleaksbyhand.Usecardboardorwood.
WARNING:
Whenremovinganattachmentpinorotherhardenedpin,useahammerthathasasofthead.
WARNING:
Weareyeprotectionwhenusingahammertoinstallapinorwhenworkingwithagrinder.
Atthistime,usegogglesoreyeprotectorsthatmeetstandards.
WARNING:
Parkthemachineinasafelocationwhenrepairingorinspectingit.
WARNING:
Useworksiteprotectionwhenrepairingthemachine.
Checktheoil,coolant,grease,andtools.
Recovermaterialsandpartsasnecessary.
Payenoughattentiontosafety.
WARNING:
Someofthemachine'spartsareextremelyheavy.
Useanappropriateliftingequipmentforsuchparts.
Forweightsandprocedures,seetheServiceManual.
WARNING:
Exhaustgasesaretoxic.
Alwaysprovidegoodventilationwhenworkingindoorsorinanyotherenclosedspace.
WARNING:
Iftheelectrolyticbatterysolutionfreezes,itmayexplode.
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INTRODUCTION
Safetyrules–ROPSjudgment
1.Purpose
JudgewhetherornotthemodeliscompliantwithROPSbytheROPScriteria.
CompliancewithROPSishighlydependentonitsdeadweightandboom.
ThemodelhaspassedtheROPStestforitsdeadweightwithallselectableoptionsinstalled(asof2014).
However,thejudgmentisrequiredbecauseitsdeadweightorboompositionmaygobeyondtheassumptionde-
pendingonderivativeororderconditions.
2.ROPScriteria
Weight
Foreachclass,thefollowingweightshallnotbeexceeded.
Iftheweightisexceeded,acabmaybecomedamagedincaseofarollover,causingtheoperatortodieorbecome
severelydisabled.
Itisnotapplicablebeyondthecriterion.
TheROPS-compliantmodelshallnotexceedtheweightshowninthetable.
(ThefollowingweightisshownonthedecalintheROPScab.)
GrossbodyweightClass
CX130D
CX160D20500kg(45194.76lb)orless
CX180D
CX210D
CX230D
CX250D32000kg(70547.92lb)orless
CX300D
Boomposition
Warning
•Ifyoumakesuchmodicationaslowerstheboomposition,ROPSisnotapplicable.
•Consultationwithusisrequiredwheneveritisassumedthattheboompositionisloweredbymodication.
•Therangeofchangeintheboompositioncannotbedetermineduniformly.
SMIL14CEX2001EA1
(a)Groundpoint
Itisnotapplicableifthepositionoverlappingwithacabonthesideview(mark*inthegure)isloweredsignicantly
ascomparedwiththestandardmodel(standardarm),withinthemaximumdiggingradiuswiththebuckettiponthe
surfaceoftheground.
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INTRODUCTION
Moreover,itcannotbesaidthatthe24-tonmodel,closetothelimitweight,withacabthatcanbearupto31-tonsand
the21-tonmodelwiththesamecabarethesameinthedegreeofinuence.
3.Prohibitions
•SuchmodicationasreducesthestrengthoftheplatformwheretheROPScabisinstalled.(Suchactionormodi-
cationasreducesthefunctionoftheretaininganchorintheleftrearofthecab)
•SuchmodicationasaffectstheROPSstrengthoftheROPScab.
Modicationprohibited(Redcomponents)Allchanges(grinding,welding,drilling,removal,etc.)
areprohibited.
Conditionalmodicationpermitted(Graycomponents)
Removalofcomponentsisprohibited.
Weldinganddrillingofbars(limitedto20mm(0.79in)
orlessindiameter)areallowed.
Cab(CX130D/CX160D/CX180D)
SMPH15CEX5805FA2
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INTRODUCTION
Cab(CX210D/CX230D/CX250D/CX300D)
SMIL14CEX2002FA3
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INTRODUCTION
Safetyrules-Ecologyandtheenvironment
Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe
treatmentofsomeofthesubstancesthatadvancedtechnologyrequires,soundjudgmentshouldgoverntheuseand
disposalofproductsofachemicalandpetrochemicalnature.
Familiarizeyourselfwiththerelativelegislationapplicabletoyourcountry,andmakesurethatyouunderstandthis
legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,anti-freeze,
cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use,
anddisposeofthesesubstances.
Helpfulhints
•Avoidtheuseofcansorotherinappropriatepressurizedfueldeliverysystemstolltanks.Suchdeliverysystems
maycauseconsiderablespillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostoftheseproductscontainsubstances
thatmaybeharmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhenyoudrainuidssuchasusedenginecoolantmixtures,engineoil,hydraulicuid,brakeuid,
etc.Donotmixdrainedbrakeuidsorfuelswithlubricants.Storealldraineduidssafelyuntilyoucandisposeof
theuidsinaproperwaythatcomplieswithalllocallegislationandavailableresources.
•Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly.
•Theair-conditioningsystemcontainsgasesthatshouldnotbereleasedintotheatmosphere.Consultanair-condi-
tioningspecialistoruseaspecialextractortorechargethesystemproperly.
•Repairanyleaksordefectsintheenginecoolingsystemorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringwelding.Penetratingweldsplattermayburnaholeorweakenhoses,allowingthelossofoils,
coolant,etc.
Batteryrecycling
Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful
effectontheenvironmentifthebatteriesarenotproperlyrecycledafteruse.Improper
disposalofbatteriescancontaminatethesoil,groundwater,andwaterways.CASE
CONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoaCASE
CONSTRUCTIONdealer,whowilldisposeoftheusedbatteriesorrecycletheused
batteriesproperly.Insomecountries,thisisalegalrequirement.
Mandatorybatteryrecycling
NOTE:ThefollowingrequirementsaremandatoryinBrazil.
Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead,
CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany
batteries.Donotdisposeofbatteriesinyourhouseholdgarbage.
Pointsofsaleareobligedto:
•Acceptthereturnofyourusedbatteries
•Storethereturnedbatteriesinasuitablelocation
•Sendthereturnedbatteriestothebatterymanufacturerforrecycling
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INTRODUCTION
Torque–Boltandnut
•Tightenalternatingbetweenleftandrightandtopandbottomsothatuniformtighteningforceisapplied.
LPIL12CX00005EA1
•IfLOCTITE®wasusedonaremovedbolt(thereissomethingwhitestickingtotheboltwhenitisremoved),cleanthe
oldLOCTITE®offwithcleaninguid,drythebolt,thenapply2-3dropsofLOCTITE®tothethreadsectionofthebolt.
Torquetable
Boltnominal
diameter(size)M6M8M10M12M14M16M18M20
Wrench10mm13mm17mm19mm22mm24mm27mm30mm
Hexagon
boltTighten-
ingtorque
6.9N·m
(5.089lb
ft)
19.6N·m
(14.456lb
ft)
39.2N·m
(28.912lb
ft)
58.8N·m
(43.369lb
ft)
98.1N·m
(72.355lb
ft)
156.9N·
m(115.72
3lbft)
196.1N·
m(144.63
6lbft)
294.2N·
m(216.99
1lbft)
Wrench5mm6mm8mm10mm12mm14mm14mm17mm
Hexagon
socket
headbolt
Tighten-
ingtorque
8.8N·m
(6.491lb
ft)
21.6N·m
(15.931lb
ft)
42.1N·m
(31.051lb
ft)
78.5N·m
(57.899lb
ft)
117.7N·m
(86.811lb
ft)
176.5N·
m(130.18
0lbft)
245.2N·
m(180.85
0lbft)
343.2N·
m(253.13
1lbft)
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