Case 40 Crawler D Series User manual

40 Crawler
Series D
Service Manual
S-406294
IReprinted I

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY
MESSAGES IN THIS MANUAL. WHEN YOU
SEE THIS SYMBOL,
CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE
ALERT TO THE POSSIBILITY OF PERSONAL INJURYOR DEA TH .
M171B
It Safety Decals on this machine use the words Danger, Warning or Caution,
which are defined as follows:
• DANGER: Indicates an immediate hazardous situation which if not avoided,
will result
in death or serious injury. The color associated with Danger is RED .
• WARNING: Indicates an potentially hazardous situation which if not avoided,
will result
in serious injury. The color associated with Warning is ORANGE.
• CAUTION: Indicates an potentially hazardous situation which if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices. The color associated with Caution
is YELLOW.
If Safety Decals
on this machine are ISO two panel Pictorial, decals are defined
as follows:
• The first panel indicates the nature of the hazard.
• The second panel indicates the appropriate avoidance of the hazard.
• Background color
is YELLOW. I(:\
• Prohibition symbols such as \:::I X and eif used, are RED.
Lh WARNING
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR
DEATH. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY
OPERATOR:
•
Is instructed in safe and proper use of the machine.
• Reads and understands the Manual(s) pertaining to the machine.
• Reads and understands ALL Safety Decals
on the machine.
• Clears the area of other persons.
• Learns and practices safe use of machine controls
in a safe, clear area
before operating this machine
on a job site.
It is your responsibility to observe pertinent laws and regulations and
follow Case Corporation instructions on machine operation and
maintenance.
© 2001 Case Corporation Bur 0-00000
issued November, 1994
CASE and
IH are registered trademarks of Case Corporation
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CONTENTS
GENERAL
Index
................................................................................
2
Safety Precautions
.....................................................................
3
Introduction
..........................................................................
5
Nomenclature, Description and Specifications
...........................................
6-8
SECTION 1 - SCHEDULED PREVENTIVE MAINTENANCE
Introduction
..........................................................................
9
Hydraulic System Pressures
............................................................
10
Component
Capacities, Lubricants, and Fluids
............................................
11
1
Maintenance Chart
.................................................................
12,
13
Illustrated Listing
of
Grease
Fittings
..................................................
14,
15
Itemized Maintenance Instructions
...................................................
16-21
SECTION 2 - MECHANICAL SYSTEM
Undercarriage Components
..........................................................
22-30
Engine and Related Parts
............................................................
31-34
2
Turntable Swing
...................................................................
34-39
Boom and Attachments
.............................................................
39, 40
Control Linkages
..................................................................
41, 42
SECTION 3 - ELECTRICAL SYSTEM
~~~;~d~~~~~~;t~~
(M~·c·h·i~~~·th·r~~g·h·
PiN
.6.270·8·5~;)
·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·.·4·4·-:;
3
24
Volt System (Machines
with
PIN
6270855
and After)
...................................
55-65
SECTION 4 - HYDRAULIC SYSTEM
(For pressures, see page 10)
Introduction
.........................................................................
66
System Maintenance
.............................................................
;
.67,
68
Main HydraulicSystem
.............................................................
69-81
Track Drive
Circuit
.................................................................
82-89
4
Swing
Circuit
.....................................................................
90,
91
Hoist
CylinderCircuit
..............................................................
92,
93
Crowd CylinderCircuit
....................
·
............................................
94
Tool Cylinder
Circuit
..................................................................
95
Leveler Cylinders Circuit
...............................................................
96
SECTION 5 - TROUBLESHOOTING
Introduction
....
·
..................................................................
97,
98
Mechanical Components
..........................................................
99,
100
5
12/24 Volt Electrical System
.......................................................
101-103
24 Volt Electrical System
..........................................................
103-106
Hydraulic System and Components
.................................................
106-113
SECTION 6 - DISASSEMBLY AND REPAIR
General Cleaning Instructions
.........................................................
114
Mechanical Components
..........................................................
115-160
6
Electrical Components
...............................................................
160
Hydraulic Components
..................
,
........................................
160-209
TORQUE CHARTS AND SCHEMATICS
Torque Charts
...................................................................
210,211
Electrical Schematics
............................................................
212,
213
Hydraulic Schematic
.................................................................
214
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GENERAL
ALPHABETICAL INDEX
A L
Air
cleaner
....................................
17,
33
Leveler,
turntable
..............................
23,
96
Alternator
.....................................
48,57
Lights
........................................
54,
65
Alternator
Belt
Adjustment
.........................
54
Lubricants
.....................................
9,
11
Attachments
....................................
148
M
B
Battery
..........................................
17
Bearing,
turntable
..............................
18,
35
Belts, fan
........................................
32
Boom
.........
,
.............................
39,
148
Brakes
Swing (house)
..............................
36,
132
Track (digging)
.............................
29,
122
Buckets
....................................
152-158
C
Cab
Insulation
....................................
9
Capacities,
Lubricants
and
Fluids
...................
11
Cold Start System
................................
63
Control
Linkages
.................................
41
Maintenance Chart
.............................
12,
13
Main Relief
Adjustment
............................
79
Motors, hydraulic
Swing
.................................
90, 186,192
Track Drive
.............................
84,
175, 178
0
Oil Cooler
.......................................
70
Oil Recommendations
.............................
10
p
Pillow
Blocks
................................
27,
129
PowerSensingValve
..........................
77,174
Pressure
Settings,
hydraulic
........................
10
Pump Drive Plate
................................
130
Pump
............
•
...........................
70,
160
R
Cooler, oil
.......................................
70
Radiator
.........................................
31
Cooling
System, engine
............................
31
Cylinders, hydraulic
..............................
203 Relief Valves
..............................
74, 79,
172
s
D
Specifications
....................................
8
Digging
Brake
................................
29,
122 Summated Hydraulics, explanation
....
.'
.............
77
Drive Locks
................................
53,
64,
86
Swing
Brake (House)
..........................
36,
132
Drive Range
................................
53,
64,
83
Swing Gearbox
............................
18,
35,
134
Drive Transmission, Final
...................
21,
27,
124
Swivel, ?-Port
................................
88,
200
E
Electrical System,
24
volt
..........................
55
Electrical System, 12/24 volt
........................
44
Engine
.......................................
16,31
F
Fast
Hoist
.................................
53,
63,
92
Filters
Air
Cleaner
..................................
17,33
Fuel
.......................................
16,
32
Hydraulic
...................................
19,
70
T
Tank, hydraulic
oil
..........................
21,
70,208
Teeth, bucket
................................
40,
156
Track
Adjustment
....................................
25
Chain
.....................................
25,
116
Final Drive
Transmission
..................
21, 28,
124
Frame
........................................
23
ldlerWheel
................................
26,
120
Roilers
....................................
23,
118
Troubleshooting
Charts
........................
97-113
G Turntable Bearing
Gauges
......................................
54,65
Alignment
of
Swing Gearbox
....................
145
Grease
Fittings
...................................
14
Capscrews,
torquing
procedure
...................
36
H
Lubrication
....................................
18
Heater, Cab
......................................
64
Hydraulic
Circuits
Crowd
........................................
94
Replacement
..................................
142
V
Valves
Hoist
.........................................
92
Drive Range
....................................
84
Leveler
........................................
96 Leveler Lock
...............................
96,
198
Main
..........................................
69 Main Control
...............................
72,
169
Swing
.........................................
90
Tool
..........................................
95 Main Relief
................................
79,173
Port Relief
.................................
74,172
Track Drive
....................................
82
PowerSensing
.............................
77,174
Hydraulic Oil Tank
.........................
21,
70,
208
Hydraulic
Swivel, ?-Port
........................
88,
200
Hydraulic System, maintenance
.....................
67
I
InnerSwivel
.....................................
83
Instruments
.....................................
65
Solenoid
Control
(Monoblock)
.................
87,
209
Swing
Cushion
.............................
90,
197
Voltage Regulator
..............................
48,
57
Voltmeter
.......................................
65
w
Wiring
Harness, replacement
......................
160
Wrist-o-Twist
...
~
................................
159
2
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GENERAL
SAFETY
A THIS SAFETY ALERT SYMBOL INDICATES
IMPORTANT SAFETY MESSAGES IN THIS
MANUAL, WHEN YOU SEE THIS SYMBOL,
CAREFULLY READ THE MESSAGE THAT
FOLLOWS
AND
BE
ALERT TO THE
POSSIBILITY OF PERSONAL INJURY
OR
DEATH.
WARNING:
Always
use a
non-flammable
A,
solvent
for
cleaning
parts.
DO
NOT use
~
gasoline
or
other
flammable
substances.
A
A
WARNING:
Clean
Rubber
parts
by
washing
in clean brake fluid. DO NOT
use
mineral
base
cleaning
solvents
such
as
acetone
or
paint
thinner
on any
rubber
parts.
If
a
mineral
base
solvent
is
used,
the
rubber
wi
11
start
to
deteriorate
and
continue
to
deteriorate
after
the
part
is
put
back
into
service.
The
continued
deterioration
of
the
rubber
could
cause
the part
to
fail.
WARNING:
DO NOT service
the
machine
with
the
engine
running. If
necessary
to
make
checks
with
engine
operating,
have one man stay at
the
controls
while
the
other
makes
the
check.
Whenever
servicing
the
machine,
·
A,
always
tag mark
the
ignition
switch
to
~
alert
other
operators
and
prevent
accidental
start-ups.
A WARNING:
To
help
prevent eye
injury,
wear
eye
protection
when
servicing
this
machine.
A CAUTION:
When
checking
coolant
level,
remove cap on
radiator
slowly
to
relieve
pressure
within
the system.
CAUTION:
Disconnect
both
~eads
from
A,
the
batteries
when
working
on
the
~
engine
or
electrical
system.
Always
disconnect
the
Ground
lead first.
WARNING:
Use
extreme
care
when
A
handling
the track. Never
insert
fingers
between
track
shoes
when
removing
track.
A DANGER:
Exhaust
fumes
can
kill.
If
necessary
to
start
engine
in an
enclosed
area, be
sure
to
provide
'
adequate
ventilation.
A CAUTION:
ENGINE FAN
AND
BELTS·
To prevent
possible
serious
injury
avoid
contact
with
rotating
fan and
belts.
,
A,
DO NOT wear
loose
clothing
which
may
I~
catch
in
moving
parts.
3
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GENERAL
CAUTION:
Hydraulic systems are high
pressurized.
Escaping
hydraulic
oil,
even
an
invisible
pinhole
leak, can
penetrate body tissues causing serious
injury. Use a piece
of
wood
or
cardboard
when looking for leaks -never use the
hands or other parts
of
the body.
A Relieve
hydraulic
pressure
before
disconnecting
circuits.
When
reassembling, make absolutely certain
that all connections are tight.
If
injured
by
hydraulic
oil
escaping
under
pressure, see a
doctor
immediately.
Serious
complications
may arise
if
medical
attention
is not
given at once.
A
WARNING:
This machine is
equipped
with a 24-volt starting system. Sparking
will
occur
across greater distances than
with
a
conventional
12
volt
system.
NEVER WEAR RINGS
OR
OTHER
METAL OBJECTS that may ground a live
circuit.
CAUTION:
Warn all
personnel
who
may
Abe
servicing
or
in
path
of
machine
before
starting
engine.
Be
sure
all
operating
controls
are in neutral and
Parking Brake is set.
CAUTION:
The
idler
wheel
spring
is
A
under
tension. If
for
any reason
this
~
spring must
be
removed, use EXTREME
caution.
A
Inspect
the
machine
daily
for
loose,
worn
or
damaged parts. Have unsafe
conditions
corrected immediately.
CAUTION:
Before
removing
or
J").,.
disassembling
the
swing
brake, SET
~
BOOM ON
GROUND
to
prevent
turntable from rotating.
4
A
WARNING:
To
avoid personal
injury,
keep hands clear
of
turntable
ring
gear
while
turntable
is
being rotated.
Keep a fire
extinguisher
on hand and
A
KNOW
HOW
TO USE IT.
Check
it
regularly to ensure
it
is in good working
order.
A
WARNING:
Any changes to the
controls
must
be
clearly noted and posted in the
Operator's Cab. If any
control
changes
are made, a new
Operator's
Control
Pattern decal
must
be installed in the
cab
to
warn
other
operators
of
the
changes.
A
Wipe
oil spills, immediately and keep
work
area as
clean
as
possible.
A
cluttered work area invites accidents.
A Never smoke
while
refueling, servicing
the
fuel
system
or
working
with
batteries.
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GENERAL
GENERAL
INFORMATION
INTRODUCTION
This manual is designed to serve as a guide
in
maintaining and servicing the
DROTT
40
Crawler,
series
"D".
All components and systems are
included, with the exception of the engine which is
covered in the engine manufacturer's manual
supplied with each machine.
The manual is divided into six sections, preceded by
ageneral section on safety, machine description and
specifications.
A separate section entitled "Scheduled Preventive
Maintenance" is provided
to
cover all components
which require periodic maintenance. Refer
to
this
section whenever performing normal maintenance.
It includes a Maintenance Schedule, Component
Capacities, Hydraulic System Operating Pressures,
Maintenance Chart and Maintenance Details.
The Service section is divided into three general
areas -
Mechanical,
Electrical
and
Hydraulic.
Included in the Service section is general descriptive
and operational
information
to
provide a basic
understanding
of
each system and its components.
All disassembly and repair information is contained
in the last section
of
the manual and arranged in the
general sequence established in the service section,
i.e. Mechanical, Electrical and Hydraulic.
Troubleshooting
charts
for
all the
systems
are
contained in aseparate section
(See
Section
5).
Torque Charts and
Schematic
Drawings
of
the
Electrical and Hydraulic systems are located in back
of
this
manual
for
easy reference when
troubleshooting the machine.
If further service information is required, contact
your
nearest DROTT
dealer
or
Service
Representative forassistance.
EXPLANATION
OF
INTERNATIONAL SYMBOLS
Symbols speak a universal language. International
symbols are used in this manual
to
help identify
components requiring service.
PARTS AND SERVICE
When writing to the dealer or manufacturer about
you
DROTT
machine, always give reference
to
the
model and
PIN
(Product Identification Number) in
addition to the part name and location. The
PIN
plate
is
on
the lower right corner of the cab (Figure 1
).
All main components
of
the machine have
an
identification plate or number
on
the component
housing. The location of the engine plate is shown in
Figure
2.
PRODUCT IDENTIFICATION
Al
NUMBER PLATE
~=====---~-
-~
-
-~
91!11
,i
.J
Figure
1.
Machine Identification
~·~--
)
[))
~
II
CASE
1/~ENGINE·
Figure 2. Engine Identification
EQ]
r!J
♦
(J)
G(AR
BOX
HVQH~ull(
HYDRAULIC
HES(
RVOU~
FILTER
FILTER. AHi
..--..,
9 ©
Ii)
0,.
LUBRICATE with
COOLANT
ENGINE
Oil
DIESEL FUEL
Mul11purpl,)SI'
Grr•H•
5
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GENERAL
NOMENCLATURE
(Unit Shown in Digging Position)
1.
Boom Crowd Cylinder
8.
Track Drive Motor and Track Brake Location
2.
"E"
Main Boom
9.
Final Urive Transmission
3.
Operator's Compartment with Controls
10.
Tool -(Backhoe Buckets Shown)
4.
Engine Location
11.
Tool Link and Levers
5.
Counterweights
12.
Boom Tool Cylinder
6.
Hydraulic Oil Reservoir Location
13.
"E"
Boom Dipperstick
7.
Turntable Bearing, Ring Gear and Leveler
14.
Boom Hoist Cylinder
Figure
3.
Nomenclature
6
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GENERAL
DIRECTIONAL
REFERENCE
The turntable.on
this
machine rotates through a full
360
degrees. The normal driving position is with the
Boom over the front
of
the undercarriage (track drive
transmission
to
the rear), as shown in figure
4.
In
this
position, directional callouts for both the turntable
and the undercarriage are the same. All references
to
Front, Rear, Right and Left will be made with respect
to
this
position. RIGHT is the Operator's right; LEFT
is the Operator's left.
V
E
L
(UNDERCARRIAGE)
OPERATOR
SITS
HERE
LEFT
RIGHT
(TURNTABLE)
Figure
4.
Directional Reference
GENERAL DESCRIPTION
FRONT
REAR
The Drott
40
Crawler is a fully hydraulic excavator.
Engine power is converted to hydraulic energy, then
reconverted
to
mechanical force by means
of
cylinders and motors.
single
spool
valve
(optional)
to
the
machine's
functions. To get maximum use
of
the engine's
power, a
"Power
Sensing"
valve
is
connected
between the two main pumping circuits.
In the hydraulic system, oil from a 2-section gear
pump is routed through
two
4-spool valves and a Figure 5 shows the distribution of the engine power
to
the hydraulic and electrical systems.
SWING
MOTOR
GE_ARBOX
1-----HPOWER
SENSING
VALVE
t+-----1
SWING·
CROWD
RIGHT TRACK·FAST
HOIST
CO'ITROL VALVE
HOIST-TOOL
LEFT TRACK • AUXILIARY
CONTROL VALVE
AUX.
VALVE
(OPT.)
LEVELER
- - -
-:
CYLINDERS :
CROWD
CYLINDER
CIRCUIT
HOIST
CYLINDER,
CIRCUIT CYLINDER
CIRCUIT
-.------T--------
1
I
I
CIRCUIT
I
2SECTION
HYD.PUMP
AUXILIARY
CIRCUIT
I
r-
1
I
3OLENOID
CONTROL
VALVE
GEARBOX
1 GEARBOX I
I
....._
__
~
I
I I
L - - - - - - - - - - - - - -
_.J
Figure 5. Block Diagram -
~O
Crawler, Series
"D"
ENGINE
ELECTRICAL
SYSTEM
7
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GENERAL
SPECIFICATIONS
Engine:
MODEL DETROIT DIESEL 4-71 N CASE 504BDT
No.
of
Cylinders 4 4
Bore and Stroke
4.25
in. x 5 in.
(108
mm x 127 mm) 4.625 in. x 5 in.
(118
mm x 127 mm)
Displac·ement 284 cu. in.
(4
654 cm3) 504 cu. in.
(8
259 cm3)
Horsepower @ Goy.
RPM
157
(117
kw) 163
(122
kw)
SAE Net Horsepower 142.9
(107
kw) 148
(110
kw)
Maximum Torque
400
lb-ft
(542
Nm) @ 1600 rpm
445
lb-ft
(603
Nm) @ 1500 rpm
Compression Ratio
18.7:1
15.8:1
Governed
RPM
2300 2100
High (No Load)
RPM
2470 2280-2320
Low Idle
600
700-750
Undercarriage:
Track Frame
..............................................................
Rigid, welded construction
Track Idlers
...............................................
Sealed hub, spring cushion, hydraulic adjust
Crawler Drive
........................
two-speed optional, hydraulic gear motor, spurgearfinal drive
Track Brake
....................................
hydraulically re.leased
disc,_
on input to final drive
Track Rollers
.............................
cast and machined construction, sealed hub, 8 per side
Carrier Rollers
................................
cast and machined construction, sealed, 2 per side
Turntable Swing:
Single race ball bearing with integral ring gear; powered by hydraulic gear motorthrough
DROTT gearbox. Mechanicallyactuated disc brake on input
to
gearbox (forholding brake only).
Electrical System:
Machines through PIN 6270854:
Type
....................................
12
volt, with
24
volt start,
direct
current, negative ground
Batteries
...................................
Two
12
volt "maintenance-free", connected in series,
625 amps @ 0° F for
30
seconds
Alternator
.........................................................................
72
amp
Charge Control Unit
............................................
Duvac®
, solid state, automatic
Machines
with
PIN
6270855 and After:
Type
...................................................
24-volt,
direct
current, negative ground
Batteries
.....................................
Two
12
volt, 625 amp batteries connected in series
Alternator
.........................................................................
42
amp
Lights
.................................................................•............
24
volt .
Hydraulic System:
Type
................................•......................
Two pumping circuits, summated
Pump (Main)
.........................................
Two section gear, driven
off
rear
of
engine
Main Control Valves
.......
Two 4-spool valves, single spool auxiliary valve optional;
Series
and
parallel
spools
for
simultaneous operation
of
two
or
more
functions
·
Filters
..........
Two 100 mesh screensand
two
10 micron full
flow
filters in return lines;
four
140 mesh
screens in summatorsystem;
two
screen
diffusers
and
filler
screen in tank
Cylinders
..........
Double-acting type
for
hoist, crowd, tool and auxiliary functions, single-acting type
for
optional leveler
Motors
.................................................
Geartype
for
swing and track drive
functions
8
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