Case 850L Operating instructions

CRAWLER DOZER
REPAIR MANUAL
Issued 01Mar 08
87728445 NA
750L
850L
TIER 3

REPAIRMANUAL
750L
850L
8772844512/28/2008

Contents
INTRODUCTION
DISTRIBUTIONSYSTEMSA
PRIMARYHYDRAULICPOWERSYSTEMA.10.A
SECONDARYHYDRAULICPOWERSYSTEMA.12.A
ELECTRICALPOWERSYSTEMA.30.A
LIGHTINGSYSTEMA.40.A
FAULTCODESA.50.A
POWERPRODUCTIONB
ENGINEB.10.A
FUELANDINJECTIONSYSTEMB.20.A
AIRINTAKESYSTEMB.30.A
ENGINECOOLANTSYSTEMB.50.A
LUBRICATIONSYSTEMB.60.A
STARTINGSYSTEMB.80.A
POWERTRAINC
POWERCOUPLINGFixedcouplingC.10.B
TRANSMISSIONHydrostaticC.20.F
TRAVELLINGD
FinaldriveD.15.A
SERVICEBRAKEHydraulicD.30.C
PARKINGBRAKEHydraulicD.32.C
WHEELSANDTRACKSTracksD.50.B
BODYANDSTRUCTUREE
USERCONTROLSANDSEATE.32.A
USERCONTROLSANDSEATOperatorseatE.32.C
USERPLATFORME.34.A
ENVIRONMENTCONTROLHeatingsystemE.40.B
ENVIRONMENTCONTROLAirconditioningsystemE.40.C
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ENVIRONMENTCONTROLHeating,ventilationandairconditioningE.40.D
SAFETYSECURITYACCESSORIESSafetyE.50.B
TOOLPOSITIONINGG
LIFTINGG.10.A
TILTINGG.20.A
SWINGINGG.40.A
WORKINGARMH
SINGLEARMTOOLATTACHMENTLiftH.50.B
TOOLSANDCOUPLERSJ
DIGGINGNonarticulateddiggingtoolsJ.20.B
LANDSCAPINGDozerbladeJ.40.F
8772844512/28/2008

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8772844512/28/2008

INTRODUCTION
8772844512/28/2008
1

Contents
INTRODUCTION
Basicinstructions3
Generalspecification7
Conversionfactors11
Hydrauliccontamination13
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2

INTRODUCTION
Basicinstructions
TechnicalInformation
Thismanualhasbeenproducedbyanewtechnicalinformationsystem.Thisnewsystemisdesignedtodeliver
technicalinformationelectronicallythroughCDROMandinpapermanuals.AcodingsystemcalledICEhasbeen
developedtolinkthetechnicalinformationtootherProductSupportfunctionse.g.Warranty.
Technicalinformationiswrittentosupportthemaintenanceandserviceofthefunctionsorsystemsonacustomers
machine.Whenacustomerhasaconcernonhismachineitisusuallybecauseafunctionorsystemonhismachine
isnotworkingatall,isnotworkingefficiently,orisnotrespondingcorrectlytohiscommands.Whenyourefertothe
technicalinformationinthismanualtoresolvethatcustomersconcern,youwillfindalltheinformationclassifiedusing
thenewICEcoding,accordingtothefunctionsorsystemsonthatmachine.Onceyouhavelocatedthetechnical
informationforthatfunctionorsystemthenyouwillfindallthemechanical,electricalorhydraulicdevices,compo
nents,assembliesandsubassembliesforthatfunctionorsystem.Youwillalsofindallthetypesofinformationthat
havebeenwrittenforthatfunctionorsystem,thetechnicaldata(specifications),thefunctionaldata(howitworks),
thediagnosticdata(faultcodesandtroubleshooting)andtheservicedata(remove,installadjust,etc.).
ByintegratingthisnewICEcodingintotechnicalinformation,youwillbeabletosearchandretrievejusttheright
pieceoftechnicalinformationyouneedtoresolvethatcustomersconcernonhismachine.Thisismadepossibleby
attaching3categoriestoeachpieceoftechnicalinformationduringtheauthoringprocess.
ThefirstcategoryistheLocation,thesecondcategoryistheInformationTypeandthethirdcategoryistheProduct:
•LOCATIONisthecomponentorfunctiononthemachine,thatthepieceoftechnicalinformationisgoingto
describee.g.Fueltank.
•INFORMATIONTYPEisthepieceoftechnicalinformationthathasbeenwrittenforaparticularcomponentor
functiononthemachinee.g.CapacitywouldbeatypeofTechnicalDatathatwoulddescribetheamountoffuel
heldbytheFueltank.
•PRODUCTisthemodelthatthepieceoftechnicalinformationiswrittenfor.
Everypieceoftechnicalinformationwillhavethose3categoriesattachedtoit.Youwillbeabletouseanycombination
ofthosecategoriestofindtherightpieceoftechnicalinformationyouneedtoresolvethatcustomersconcernonhis
machine.
Thatinformationcouldbe:
•thedescriptionofhowtoremovethecylinderhead
•atableofspecificationsforahydraulicpump
•afaultcode
•atroubleshootingtable
•aspecialtool
HowtoUsethisManual
ThismanualisdividedintoSections.EachSectionisthendividedintoChapters.Contentspagesareincludedatthe
beginningofthemanual,theninsideeverySectionandinsideeveryChapter.AnalphabeticalIndexisincludedatthe
endofaChapter.PagenumberreferencesareincludedforeverypieceoftechnicalinformationlistedintheChapter
ContentsorChapterIndex.
EachChapterisdividedintofourInformationtypes:
•(D)T echnicalData(specifications)forallthemechanical,electricalorhydraulicdevices,componentsand,as
semblies.
•(C)FunctionalData(howitworks)forallthemechanical,electricalorhydraulicdevices,componentsandas
semblies.
•(G)DiagnosticData(faultcodes,electricalandhydraulictroubleshooting)forallthemechanical,electricalor
hydraulicdevices,componentsandassemblies.
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3

INTRODUCTION
•(F)Servicedata(removedisassembly,assemble,install)forallthemechanical,electricalorhydraulicdevices,
componentsandassemblies.
Sections
Sectionsaregroupedaccordingtothemainfunctionsorasystemsonthemachine.EachSectionisidentifiedby
aletterA,B,Cetc.TheamountofSectionsincludedinthemanualwilldependonthetypeandfunctionofthe
machinethatthemanualiswrittenfor.EachSectionhasaContentspagelistedinalphabetic/numericorder.This
tableillustrateswhichSectionscouldbeincludedinamanualforaparticularproduct.
SECTION
ADistributionSystems
BPowerProduction
CPowerTrain
DTravelling
EBodyandStructure
FFramePositioning
GT oolPositioning
HWorkingArm
JToolsandCouplers
KCropProcessing
LFieldProcessing
PRODUCT
TractorsXXXXXXXX
Vehicleswithworkingarms:backhoes,
excavators,skidsteers,.....
XXXXXXXXX
Combines,forageharvesters,balers,....XXXXXXXXXX
Seeding,planting,floating,spraying
equipment,....
XXXXXXXXX
Mountedequipmentandtools,.....XXXX
Chapters
EachChapterisidentifiedbyaletterandnumbercombinatione.g.EngineB.10.AThefirstletterisidenticaltothe
Sectionletteri.e.ChapterB.10isinsideSectionB,PowerProduction.
CONTENTS
TheChapterContentslistsallthe(D)technicaldata(specifications),(C)functionaldata(howitworks),(F)service
data(remove,installadjust,etc.)and(G)diagnosticdata(faultcodesandtroubleshooting)thathavebeenwrittenin
thatChapterforthatfunctionorsystemonthemachine.
Contents
POWERPRODUCTION
ENGINE_10.A
TECHNICALDATA
ENGINEGeneralspecification(B.10.AD.40.A.10)3
FUNCTIONALDATA
ENGINEDynamicdescription(B.10.AC.30.A.10)4
SERVICE
ENGINERemove(B.10.AF.10.A.10)5
DIAGNOSTIC
ENGINETroubleshooting(B.10.AG.40.A.10)6
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4

INTRODUCTION
INDEX
TheChapterIndexlistsinalphabeticalorderallthetypesofinformation(calledInformationUnits)thathavebeen
writteninthatChapterforthatfunctionorsystemonthemachine.
Index
POWERPRODUCTIONB
ENGINE
ENGINEDynamicdescription(B.10.AC.30.A.10)4
ENGINEGeneralspecification(B.10.AD.40.A.10)3
ENGINERemove(B.10.AF.10.A.10)5
ENGINETroubleshooting(B.10.AG.40.A.10)6
InformationUnitsandInformationSearch
Eachchapteriscomposedofinformationunits.EachinformationunithastheICEcodeshowninparentheseswhich
indicatesthefunctionandthetypeofinformationwritteninthatinformationunit.Eachinformationunithasapageref
erencewithinthatChapter.Theinformationunitsprovideaquickandeasywaytofindjusttherightpieceoftechnical
informationyouarelookingfor.
exampleinformationunitStackvalveSectionalView(A.10.A.18C.10.A.30)
InformationUnitICEcodeA10.A18C10.A.30
ICEcodeclassificationDistribution
systems
Primary
hydraulic
power
StackvalveFunctional
data
Sectionalview
CRIL03J033E011
Navigatetothecorrectinformationunityouaresearchingforbyidentifyingthefunctionandinformationtype
fromtheICEcode.
•(1)Functionand(2)Informationtype.
•(A)correspondstothesectionsoftherepairmanual.
(B)correspondstothechaptersoftherepairmanual.
(C)correspondstothetypeofinformationlistedinthechaptercontents,(D),T echnicaldata,(C),Functional
Data,(G),Diagnostic,and(F),Service.
(A)and(B)arealsoshowninthepagenumberingonthepagefooter.
THERESTOFTHECODINGISNOTLISTEDINALPHANUMERICORDERINTHISMANUAL.
•Youwillfindatableofcontentsatthebeginningandendofeachsectionandchapter.
Youwillfindanalphabeticalindexattheendofeachchapter.
•Byreferringto(A),(B)and(C)ofthecoding,youcanfollowthecontentsorindex(pagenumbers)andquickly
findtheinformationyouarelookingfor.
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INTRODUCTION
PageHeaderandFooter
Thepageheaderwillcontainthefollowingreferences:
•SectionandChapterdescription
Thepagefooterwillcontainthefollowingreferences:
•PublicationnumberforthatManual,SectionorChapter.
•Versionreferenceforthatpublication.
•Publicationdate
•Section,chapterandpagereferencee.g.A.10.A/9
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6

INTRODUCTION
Generalspecification
BOLTTORQUEINFORMATION
DECIMALHARDWARE
1.Fastenersshouldbereplacedwiththesameorhighergrade.Ifhighergradefastenersareused,theseshould
onlybetightenedtothestrengthoftheoriginal.
2.Makesurethefastenersthreadsarecleanandthatthreadengagementisstarted.Thiswillpreventthemfrom
failingwhenbeingtightened.
3.Tightenplasticinsertorcrimpedsteeltypelocknutstoapproximately50%ofthedrytorque,appliedtothenut,
nottothebolthead.Tightentoothedorserratedtypelocknutstothefulltorquevalue.
4.TheL9(Alloy)fastenerstorquevaluesareforabolt,nut,andtwowashers.
WhenusingL9(Alloy)fasteners,donotusethevaluesinthistablefortappedholes.
GRADE
1or255.15.288.2L9(Alloy)
SAEMarkings
forBoltsand
CapScrews
258L9(Alloy)
SAEMarkings
forHexNuts
GRADE2*GRADE5,5.1or5.2GRADE8or8.2GRADEL9(Alloy)
Dry**Lubricated
**
Dry**Lubricated
**
Dry**Lubricated
**
HeadNut
SIZENmlb/ftNmlb/ftNmlb/ftNmlb/ftNmlb/ftNmlb/ftNmlb/ftNmlb/ft
1/4
UNF
7.55.55.74.210.888.56.316.31212.2913.61014.911
1/4
UNC
8.56.36.44.713.6109.87.2191413.61016.31217.613
5/16
UNF
1511118231718133324241826192821
5/16
UNC
1612129261919143727272027203123
3/8
UNF
27202015413031236145473541304533
3/8
UNC
31232317473534256850473547355238
7/16
UNF
43323324685047359570685075558160
7/16
UNC
493637277555544010880816081608865
1/2
UNF
68504735102757555149110108801158512995
1/2
UNC
755554401158588651631201229012995142105
9/16
UNF
9570755514911010880203150149110163120190140
9/16
UNC
10880816016312012290231170176130183135203150
5/8
UNF
13610010275203150149110285210217160231170251185
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INTRODUCTION
GRADE2*GRADE5,5.1or5.2GRADE8or8.2GRADEL9(Alloy)
Dry**Lubricated
**
Dry**Lubricated
**
Dry**Lubricated
**
HeadNut
SIZENmlb/ftNmlb/ftNmlb/ftNmlb/ftNmlb/ftNmlb/ftNmlb/ftNmlb/ft
5/8
UNC
14911011585231170176130325240244180258190278205
3/4
UNF
237175176130353260271200515380380280359265393290
3/4
UNC
271200190140407300298220570420420310447330481355
7/8
UNF
231170170125583430434320814600610450644475685505
7/8
UNC
244180190140637470475350909670678500705520793585
1
UNF
33925025819086864065148012349109226807465501051775
1
UNC
3802802852109767207325401383102010317609497001220900
11/8
UNF
47535036627010717908005901749129013159701390102515591150
11/8
UNC
542400407300120789090967019531440146410801559115017971325
11/4
UNF
67850051538015191120113984024681820184413601898140021701600
11/4
UNC
74655057042016811240126193027262010204815102170160023731750
11/2
UNF
1180870881650264419501980146042853160321423703932290044073250
11/2
UNC
1329980990730298322002224164048273560362126704475330049493650
IMPORTANT:DONOTusethesevaluesifadifferenttorquevalueortighteningprocedureisgivenforaspecific
application.Torquevalueslistedareforgeneraluseonly.Checktightnessoffastenersperiodically.Shearboltsare
designedtofailunderpredeterminedloads.Alwaysreplaceshearboltswithidenticalgrade.
NOTES
•*Grade2appliesforhexcaps(nothexbolts)upto152mm(6in)long.Grade1appliesforhexcapscrews
over152mm(6in)long,andforallothertypesofboltsandscrewsofanylength.
•**"Lubricated"meanscoatedwithalubricantsuchasengineoil,orfasterswithphosphateandoilcoatings.
"Dry"meansplaindorzincplatedwithoutanylubriation.
TORQUESPECIFICATIONSMETRICHARDWARE
GRADE8.8Bolts,NutsandStudsGRADE10.9Bolts,NutsandStuds
DryDry
SIZENmlb/inlb/ftNmlb/inlb/ft
M43to431to355to644to49
M55to649to558to971to79
M610to1184to9414to15120to136
M823to26229to27733to37293to329
M1046to51408to46065to7448to54
M1280to9059to66114to12885to94
M14128to14594to106183to205136to153
M16200to220149to161285to320208to235
M20400to450293to330555to620406to460
M24690to780510to575955to1075705to790
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INTRODUCTION
GRADE8.8Bolts,NutsandStudsGRADE10.9Bolts,NutsandStuds
DryDry
SIZENmlb/inlb/ftNmlb/inlb/ft
M301375to15451010to11401900to21401400to1580
M362400to27001770to19903315to37302445to2750
Usetheabovetorqueswhenspecificationsarenotgiven.
Thesevaluesapplytofastenerswithbothcoarseandfinethreadsasreceivedfromsupplier,platedorunplated,
orwhenlubricatedwithengineoil.ThesevaluesdonotapplyifgraphiteorMolydisulfidegreaseoroilisused.
Useofaclicktypetorquewrench,orbetterisrequired.
Grade12.9Bolts,Nuts,andStuds
Usuallytorquevaluesspecifiedtograde10.9fastenerscanbeusedsatisfactorilyongrade12.9fasteners.
•TORQUESPECIFICATIONSSTEELHYDRAULICFITTINGS
37DegreeFlareFitting
Nom.SAE
DashSize
TubeOD/HoseIDThreadSizeNewton
metres
lb/inlb/ft
25/16248to972to84
33/82411to1296to108
46.4mm1/4inch7/162014to16120to144
57.9mm5/16inch1/22018to21156to192
69.5mm3/8inch9/161827to33240to300
812.7mm1/2inch3/4164656408to504
1015.9mm5/8inch7/81477to85684to756
1219.0mm3/4inch11/1612107to11979to88
1422.2mm7/8inch13/1612127to14094to103
1625.4mm1.0inch15/1612131to15697to117
2031.8mm11/4inch15/812197to223145to165
2438.1mm11/2inch17/812312to338230to250
StraightThreadwithOring
Nom.SAE
DashSize
TubeOD/HoseIDThreadSizeNewton
metres
lb/inlb/ft
25/16248to972to84
33/82411to1296to108
46.4mm1/4inch7/162020to25180to228
57.9mm5/16inch1/22027to33240to300
69.5mm3/8inch9/161843to54384to480
812.7mm1/2inch3/41673to90648to804
1015.9mm5/8inch7/814100to12474to92
1219.0mm3/4inch11/1612138to173102to128
1422.2mm7/8inch13/1612173to216128to160
1625.4mm1.0inch15/1612203to253150to187
2031.8mm11/4inch15/812308to357227to264
2438.1mm11/2inch17/812492to542363to400
SplitFlangeMountingBolts
SizeNewtonmetreslb/inlb/ft
5/161820to27180to240
3/81627to34240to300
7/161447to61420to540
1/21374to8855to65
5/811190to203140to150
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INTRODUCTION
ORingFaceSealEnd
Nom.SAE
DashSize
TubeODThreadSizeNewton
metres
lb/inlb/ft
46.4mm1/4inch9/161823to26204to228
69.5mm3/8inch11/161634to40300to348
812.7mm1/2inch13/161652to57456to504
1015.9mm5/8inch11481to90720to792
1219.0mm3/4inch13/1612117to12886to94
1625.4mm1.0inch17/1612152to174112to128
2031.8mm11/4inch111/1612179to201132to148
2438.1mm11/2inch212213to235157to173
ORingBossEndFittingorLockNut
Nom.SAEDash
Size
ThreadSizeNewtonmetreslb/inlb/ft
69/161848to54432to480
83/41670to78612to684
107/814102to11475to84
1211/1612142to160105to117
1615/1612237to254175to187
PipeFitting
Nom.SAEDashSizeThreadSizeTFFT(TurnsForFingerTight)
21/8272.03.0
31/8272.03.0
41/8272.03.0
51/8272.03.0
61/4181.53.0
83/8182.03.0
101/2142.03.0
123/4142.03.0
143/4142.03.0
161111/21.52.5
2011/4111/21.52.5
2411/2111/21.52.5
322111/21.52.5
NOTE:Applysealant/lubricanttomalepipethreads.Thefirsttwothreadsshouldbeleftuncoveredtoavoidsystem
contamination.Screwpipefittingintofemalepipeporttothefingertightposition.Wrenchtightenfittingtotheap
propriateturnsfromfingertight(TFFT)shownintableabove,makingsurethetubeendofanelboworteefittingis
alignedtoreceiveincomingtubeorhosefitting.
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INTRODUCTION
Conversionfactors
MetrictoU.S.
MULTIPLYBYTOOBTAIN
AREA:squaremeter
hectare
10.76391
2.47105
squarefoot
acre
FORCE:newton
newton
3.596942
2.224809
ounceforce
poundforce
LENGTH:millimeter
meter
kilometer
0.039370
3.280840
0.621371
inch
foot
mile
MASS:kilogram2.204622pound
MASS/AREA:kilogram/hectare0.000466ton/acre
MASS/ENERGY:gr/kW/hr.0.001644lbs/hp/hr.
MASS/VOLUME:kg/cubicmeter1.685555lb/cubicyd.
POWER:kilowatt1.34102horsepower
PRESSURE:kilopascal
bar
0.145038
14.50385
lb/sq.inch
lb/sq.inch
TEMPERATURE:degreeC1.8xC+32degreeF
TORQUE:newtonmeter
newtonmeter
8.850748
0.737562
lb/inch
lb/foot
VELOCITY:kilometer/hr.0.621371miles/hr.
VOLUME:cubiccentimeter
cubicmeter
cubicmeter
milliliter
litre
litre
litre
litre
0.061024
35.31466
1.307950
0.033814
1.056814
0.879877
0.264172
0.219969
cubicinch
cubicfoot
cubicyd.
ounce(USfluid)
quart(USliquid)
quart(Imperial)
gallon(USliquid)
gallon(Imperial)
VOLUME/TIME:litre/min.
litre/min.
0.264172
0.219969
gallon/min.(USliquid)
gallon/min.(Imperial)
U.S.toMetric
MULTIPLYBYTOOBTAIN
AREA:squarefoot
acre
0.092903
0.404686
squaremeter
hectare
FORCE:ounceforce
poundforce
0.278014
4.448222
newton
newton
LENGTH:inch
foot
mile
25.4*
0.3048*
1.609344*
millimeter
meter
kilometer
MASS:pound
ounce
0.453592
28.35
kilogram
gram
MASS/AREA:ton/acre2241702kilogram/hectare
MASS/ENERGY:lb/hp/hr608.2774gr/kW/hr
MASS/VOLUME:lb/cubicyd.0.593276kg/cubicmeter
POWER:horsepower0.745700kilowatt
PRESSURE:lbs/sq.in
lbs/sq.in
lbs/sq.in
6.894757
0.069
0.070303
kilopascal
bar
kg/sq.cm
TEMPERATURE:degreeF1.8F32degreeC
TORQUE:pound/inch
pound/foot
0.112985
1.355818
newtonmeter
newtonmeter
VELOCITY:miles/hr.1.609344*kilometer/hr.
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INTRODUCTION
U.S.toMetric
MULTIPLYBYTOOBTAIN
VOLUME:cubicinch
cubicfoot
cubicyard
ounce(USfluid)
quart(USliquid)
quart(Imperial)
gallon(US)
gallon(Imperial)
16.38706
0.028317
0.764.555
29.57353
0.946353
1.136523
3.785412
4.546092
cubiccentimeter
cubicmeter
cubicmeter
milliliter
litre
litre
litre
litre
VOLUME/TIME:gallon/min.3.785412litre/min.
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INTRODUCTION
Hydrauliccontamination
Contaminationinthehydraulicsystemisamajorcauseofthemalfunctionofhydrauliccomponents.Contamination
isanyforeignmaterialinthehydraulicoil.Contaminationcanenterthehydraulicsysteminseveralways.
(A)Whenyoudraintheoilordisconnectanyline.
(B)Whenyoudisassembleacomponent.
(C)Fromnormalwearofthehydrauliccomponents.
(D)Fromdamagedorwornseals.
(E)Fromadamagedcomponentinthehydraulicsystem.
Allhydraulicsystemsoperatewithsomecontamination.Thedesignofthecomponentsinthishydraulicsystemper
mitsefficientoperationwithasmallamountofcontamination.Anincreaseinthisamountofcontaminationcancause
problemsinthehydraulicsystem.Thefollowinglistincludessomeoftheseproblems.
(A)Cylinderrodsealsleak.
(B)Controlvalvespoolsdonotreturntoneutral.
(C)Movementofcontrolvalvespoolsisdifficult.
(D)Hydraulicoilbecomestoohot.
(E)Pumpgears,housing,andotherpartswearrapidly.
(F)Reliefvalvesorcheckvalvesheldopenbydirt.
(G)Quickfailureofcomponentsthathavebeenrepaired.
(H)Cycletimesareslow;machinedoesnothaveenoughpower.
Ifyourmachinehasanyoftheseproblems,checkthehydraulicoilforcontamination.Therearetwotypesofcontam
ination,microscopicandvisible.
Microscopiccontaminationoccurswhenveryfineparticlesofforeignmaterialareinsuspensioninthehydraulicoil.
Theseparticlesaretoosmalltoseeorfeel.Microscopiccontaminationcanbefoundbyidentificationofthefollowing
problemsorbytestinginalaboratory.Examplesoftheproblems:
(A)Cylinderrodsealleak.
(B)ControlvalvespoolsdonotreturntoNEUTRAL.
(C)Thehydraulicsystemhasahighoperatingtemperature.
Visiblecontaminationisforeignmaterialthatcanbefoundbysight,touch,orodor.Visiblecontaminationcancause
asuddenfailureofcomponents.Examplesofvisiblecontamination:
(A)Particlesofmetalordirtintheoil.
(B)Airintheoil.
(C)Theoilisdarkandthick.
(D)Theoilhasanodorofburnedoil.
(E)Waterintheoil.
Ifyoufindcontamination,useaPortableFiltertocleanthehydraulicsystem.
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INTRODUCTION
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