Case 9040B Operating instructions

9040B Excavator
Troubleshooting and Schematic Set No .. 7-63132
Table of Contents
Description
~;~~~;~"OrqL!e.~
Specifications
~~_~1ItIIs
Electrical Specifications and Troubleshooting
'iE~~~.~)
' ... ' ' ";~ ;<",)V"t;":.i~.. '.' .; ;. _" ('
Tracks, Rollers, and !dlers
:"~::. .1,_"Ihtmi.and'~.~;:j;;;~;
Hydraulic Schematic Foldout (In Process)
Section No.
1:1001 .
1002
5u~,~.~,
4001
m,:~~ ..
5002
, 'ilal
In Rear Pocket
NOTE: Cue Co~ ~ the right to make improvements in design or
changes in ~iIorIs at any til"l'Ull witho!Jt il'lClJrring any to inatal!
them on UI'IIts pmviolJs!y sold.
CASE CORPORATION
100 State Street
Racine, M A404 U.s.A.
Form No,
1~10
7~11250
~
7-62401
1~15a
7·11290
1~11:
7~15360
CASE CANADA CORl'ORAl1ON
450 smmmm Avem.Ie
C'l999Cue~
Printed in U.S.A.
Hamilton, ON I.8N 4C4 CANADA
April,1999

CASE CORPORATION
Section
1001
SAFETY, GENERAL INFORMATION
AND TORQUE SPECIFICATIONS
Rac 7-62010 © 1994 Case Corporation
Printed in U.S.A.
December 1994

1001-2
TABLE OF CONTENTS
SAFETY ..................................................................................................................................................................... 3
GENERAL INFORMATION ............................................................................................................................................ 5
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS ........................................................................................... 6
Rae 7·62010
Issued 12-94 Printed in U.S.A.

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1001-3
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOL VED. The message that follows the
~ symbolcontains importantinformation aboutsafety. Carefully
read the message. Make sure you fully understand the
causes
of possible injury or death. SB001
To prevent injury always follow the Warning, Caution and
Danger notes in this section and throughout the manual.
Put the warning tag shown below on the key for the keyswitch
when servicing or repairing the machine. One warning tag is
supplied with each machine. Additional tags Part Number
331-4614 are available from your service parts supplier.
See Other Side
Reason ___ _
JICase
c- .......
us.
1001-01
WARNING: Read the operator's manual to
~ familiarize yourself with the correct control
functions.
46-27
WARNING: Operate the machine and
.. equipment controls from the seat position
~ only. Any other method could result in
serious injury.
48-55
.. WARNING: This is a one man machine, no
~ riders allowed. 35-8
Rae 7-62010
WARNING: Before starting engine, study
Operator's Manual safety messages. Read
allsafetysigns on machine. Clearthe area
of
other persons. Learn and practice safe use
of controls before operating.
~ It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service and to observe
pertinent laws
and regulations. Operator's
and Service Manuals
may be obtained from
your Case dealer.
SAO 55
WARNING: If you wear clothing that is too
loose or do not use the correct safety
equipment for yourjob, you can be injured.
.. Always wear clothing that will not catch on
LU objects. Extra safety equipment that can be
required includes hardhat, safetyshoes, ear
protection, eye
or face protection, heavy
gloves and reflector clothing. 45-3A
WARNING: When working in the area of the
.. fan belt with the engine running, avoid loose
LU clothing if possible, and use extreme
caution. 35-4
WARNING: When doing checks and tests
.. on the equipment hydraulics, follow the
LU procedures as they are written. DO NOT
change the procedure. 47-44
WARNING: When putting the hydrauliC
cylinders on this machine through the
~ necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way. 47-45
Issued 12-94 Printed in U.S.A.

1001-4
.. WARNING: Use insulatedgloves or mittens
~ when working with hotparts. 47-41 A
CAUTION: Lower all attachments to the
.. ground or use stands to safely support the
~ attachments before you do any maintenance
or service. 49-11
CAUTION: Pin sizedandsmallerstreams of
hydraulic oil under pressure can penetrate
the skin
and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
.. immediate/~ .. Maintain allhoses and tubes in
~ good condItIon. Make sure all connections
are tight. Make a replacement
of anytube or
hose that is damaged or thought to be
damaged. DO NOT use your hand to check
for leaks, use a piece
of cardboard or wood.
40-6A
CAUTION: When removing hardened pins
such as a pivotpin,
or a hardenedshaft, use
~ a softhead (brass or bronze) hammer or use
a driver made from brass or bronze and a
steelheadhammer. 46-17
CAUTION: When using a hammer to
remove and install pivot pins or separate
.. parts using compressed air or using a
~ grinder, wear eye protection that completely
encloses the eyes (approved goggles or
otherapproved eye protectors). 46-13
CAUTION: Use suitable floor (service) jacks
.. or chain hoistto raise wheels or tracks off the
~ floor. Always block machine in place with
suitable safetystands.
40-7A
Rae 7-62010
CAUTION: When servicing or repairing the
machine, keep the shop floor andoperator's
.. compartment and steps free of oil, water,
~ grease, tools, etc. Use an oil absorbing
materialand/orshop cloths as required. Use
safe practices
at all times. 40-8
CAUTION: Some components of this
.. ma~hine are very heavy. Use suitable lifting
~ eqUIpment or additional help as instructed in
this Service Manual.
40-10
DANGER: Engine exhaust fumes can
cause death. If it is necessary to start the
.. engine in a closedplace, remove the exhaust
~ fumes from the area with an exhaust pipe
extension. Open the doors
and get outside
airinto the area.
48-56
WARNING: When the battery electrolyte is
frozen, the batterycan explode
if (1), you try
to charge the battery,
or (2), you try to jump
.. start and run the engine. To prevent the
~ battery electrolyte from freezing, try to keep
the battery
at full charge. If you do notfollow
these instructions, you
or others in the area
can be injured.
SA033
Issued 12-94
Printed in U.S.A.

1001-5
GENERAL INFORMATION
CLEANING
Clean all metal parts except bearings, in a suitable cleaning
solvent or by steam cleaning. Do not use caustic soda for
steam cleaning. After cleaning, dry and put oil on all parts.
Clean oil passages with compressed air. Clean bearings in a
suitable cleaning solvent, dry the bearings completely and
put oil on the bearings.
INSPECTION
Check all parts when the parts are disassembled. Replace all
parts that have wear or damage. Small scoring or grooves
can be removed with a hone or crocus cloth. Complete a
visual inspection for indications of wear, pitting and the
replacement of parts necessary to prevent early failures.
BEARINGS
Check bearings for easy action. If bearings have a loose fit or
rough action replace the bearing. Wash bearings with a
suitable cleaning solvent and permit to air dry. DO NOT DRY
BEARINGS WITH COMPRESSED AIR.
NEEDLE BEARINGS
Before you press needle bearings in a bore always remove
any metal protrusions in the bore or edge of the bore. Before
you press bearings into position put petroleum jelly on the
inside and outside diameter of the bearings.
Rae 7-62010
GEARS
Check all gears for wear and damage. Replace gears that
have wear or damage.
OIL SEALS, O-RINGS AND GASKETS
Always install new oil seals, O-rings and gaskets. Put
petroleum jelly on seals and O-rings.
SHAFTS
Check all shafts that have wear or damage. Check the
bearing and oil seal surfaces of the shafts for damage.
SERVICE PARTS
Always install genuine Case service parts. When ordering
refer to the Parts Catalog for the correct part number of the
genuine Case replacement items. Failures due to the use of
other than genuine Case replacement parts are not covered
by warranty.
LUBRICATION
Only use the oils and lubricants specified in the Operator's or
Service Manuals. Failures due to the use of non-specified oils
and lubricants are not covered by warranty.
Issued 12-94
Printed in U.S.A.

1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS
TIGHTENING OF CAP SCREWS, NUTS
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the order of tightening.
9 4 1 6 7
00000
00000
8 5 2 3 10
1001·02
Apply engine oil to the thread portion of the cap screw so that uniform tightening torque is obtained.
The cap screws and nuts that cannot be inspected externally or those as indicated in the assembly/installation sections should be
saftied with lockwire, cotter pin or bent washer.
Right Right Wrong
Right Wrong
Right Wrong
1001·03
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with light oil or suitable cleaning
solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then tighten.
Rae 7·62010
Issued 12-94 Printed in U.S.A.

1001-7
TORQUE TABLE
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20
[mm] 10 13 17 19
22 24
27
30
Spanner [in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18
Cap Screw Tightening [Nm]
6.9 15.7 32.3 58.8 98.0 137.2 196.0 274.0
torque [Ib-ft]
5.1 11.6 23.9 43.4 72.3 101.2 144.6 202.4
[mm] 5 6 8 10 12 14 14
17
Spanner
Socket [in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67
Head Cap
Screw Tightening [Nm]
8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
torque [Ib-ft] 6.5 15.9 31.1 57.8 86.8 130.1 180.8 253.1
Rae 7-62010 Issued 12-94 Printed in U.S.A.

CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION
3350 SOUTH SERVICE ROAD
BURLINGTON, ON L7N 3M6 CANADA
Section
1002
SPECIFICATIONS
Bur 7-11250
© 1998 Case Corporation
Printed in U.S.A.
June, 1998

1002-2
TABLE OF CONTENTS
MODEL AND PIN NUMBERS ................................................................................................................................. 3
GENERAL SPECIFICATIONS ................................................................................................................................ 4
Capacities ............................................................................................................................................................ 4
Drawbar Pull ........................................................................................................................................................ 4
Drive Speed ......................................................................................................................................................... 4
Electrical System ................................................................................................................................................. 4
Fluids and Lubricants ........................................................................................................................................... 4
Fuel .................................................................................................................................................................... 5
Hydraulic System ................................................................................................................................................. 5
Tracks, Rollers and Idlers .................................................................................................................................... 6
Weights ..............................................................................................................................................................
12
Buckets .............................................................................................................................................................. 12
GAUGE TABLE ..................................................................................................................................................... 13
RUN-IN INSTRUCTIONS ...................................................................................................................................... 15
Engine Lubrication ........................................................................................................................................... 15
Run-In Procedure For Rebuilt Engine .............................................................................................................. 15
Run-In Procedure For Rebuilt Engine (With A Dynamometer) ........................................................................ 15
Run-In Procedure For Rebuilt Engines (Without A Dynamometer) .................................................................. 15
Run-In Procedure ............................................................................................................................................... 15
Engine Cooling System ...................................................................................................................................... 16
Engine Lubrication ............................................................................................................................................. 16
Engine Oil Type ................................................................................................................................................ 16
Engine Oil Viscosity Chart ................................................................................................................................. 16
GENERAL ENGINE SPECIFICATIONS ................................................................................................................ 17
General .............................................................................................................................................................. 17
Pistons and Connecting Rods ............................................................................................................................ 17
Main Bearings .................................................................................................................................................... 17
Engine Lubricating System ................................................................................................................................ 17
Fuel System ....................................................................................................................................................... 18
DETAILED ENGINE SPECIFICATIONS ............................................................................................................... 19
Cylinder Block .................................................................................................................................................... 19
Pistons ............................................................................................................................................................... 19
Piston Pins .........................................................................................................................................................
19
Piston Rings ....................................................................................................................................................... 19
Cylinder Head .................................................................................................................................................... 19
Lifters ................................................................................................................................................................. 19
Connecting Rods ............................................................................................................................................... 20
Crankshaft .......................................................................................................................................................... 20
Camshaft ............................................................................................................................................................
21
Turbocharger ..................................................................................................................................................... 21
GearTrain .......................................................................................................................................................... 21
Rocker Arm Assembly ....................................................................................................................................... 21
Intake Valves ..................................................................................................................................................... 22
Exhaust Valves .................................................................................................................................................. 22
Valve Springs ..................................................................................................................................................... 22
TRANSPORTING DIMENSIONS .......................................................................................................................... 23
Bur 7-11250 Issued 6-98 Printed in U.S.A

1002-3
MODEL AND PIN NUMBERS
When ordering parts or when requesting information or assistance, always give the identification numbers of your machine. Write the
model and PIN numbers of your machine on the lines below.
Machine Model Number ___________ _
Machine PIN Number
Engine Serial Number ___ . _______ _
Bur 7-11250
Issued 6-98 Printed in U.S.A.

1002-4
GENERAL SPECIFICATIONS
Capacities
Engine Crank Case Capacity .................................................................................................. 23.2 liters
Engine Cooling System ........................................................................................................... 25.8 liters
Fuel Tank ................................................................................................................................. 310 liters
Hydraulic Oil Tank Capacity ..................................................................................................... 120 liters
Total Hydraulic System Capacity .............................................................................................. 224 liters
Final Drive Case Capacity ......................................................................................................... 4.7 liters
Swing Drive Case Capacity ....................................................................................................... 6.0 liters
Swing Ring Gear ............................................................................................................................ 20 kg
Track Front Idlers ............................................................................................................... 360 to 370 cc
Track Lower Rollers ........................................................................................................... 190 to 200 cc
6.1 US gallons
6.8 US gallons
82 US gallons
31.7 US gallons
59 US gallons
1.2 gallons
1.6 gallons
44 pounds
11.8 to 12.21 oz
6.27 to 6.60 oz
NOTE: These capacities are only a guide to the quantities. Always use the dipstick, sight gauges or level plug to make
sure that fluid levels are correct.
Drawbar Pull
Drawbar Pull ............................................................................................................................ 18400 kg
Drive Speed
Drive Speed: High ..................................................................................................................... 5.0 km/h
Drive Speed: Middle .................................................................................................................. 3.5 km/h
Drive Speed: Low ...................................................................................................................... 2.5 km/h
Electrical System
405651b
3.1 mph
2.2 mph
1.5 mph
Type of System ............................................................................................................................................ 24 volts negative ground
Alternator
Manufacturer ............................................................................................................................................................. Robert Bosch
Output .......................................................................................................................................................................... 65 amperes
Batteries
Number of batteries required ........................................................................................................................................................2
Voltage of each battery ....................................................................................................................................................... 12 volts
Reserve capacity ......................................................................................................................................................... 160 minutes
Cold cranking capacity at -17'C (O'F) ......................................................................................................................... 800 amperes
Load for capacity (load) test ....................................................................................................................................... 400 amperes
Starter Motor
Manufacturer ................................................................................................................................................................ DelcoRemy
Voltage ............................................................................................................................................................................... 24 volts
Fluids and Lubricants
Batteries ............................................................................................................................................... add drinking or distilled water
Engine Coolant Solution ............................................................................................................................................. refer to page 16
Engine Lubrication ..................................................................................................................................................... refer to page 16
Fuel ............................................................................................................................................................... refer to entry on page 5
Hydraulic System .................................................................................................................................... CASE MS-1210 TCH FLUID
Final Drive Lubricant .............................................................................................................................................. API GL -4, SAE 90
Swing Drive Case Lubricant ................................................................................................................................... API GL-4, SAE 90
Track Roller and Front Idler Lubricant ......................................................................... Case IH No.1 Single Grade engine oil SAE 30
Turntable Ring Gear Lubricant .......................................................................................................................No.2 EP lithium grease
Grease Fitting Lubricant. ................................................................................................................................ No. 2 EP lithium grease
Bur 7·11250
Issued 6·9B
Printed in U.S.A.

1002-5
Use only hydraulic oils meeting Case specifications or equivalent AW (anti-wear) hydraulic oils.
Temperature Fahrenheit
_30°_20°_10° 0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100°110°120°
Temperature Celsius
JS01435A
NOTE: Case specification MS-1210 TCH Fluid is used in place of ISO VG 32 (-5 to +65 F) and
ISO VG 46 (+10 to +90 F).
Case specifications MS-1230 Grade NT or Grade LT is used in place of SO VG 32 (-5 to +65 F).
ISO VG 46 (+10 to +90 F). ISO VG 100 (+30 to +115 F). and MS-1210 TCH.
Hydraulic Fluid Chart
Fuel
Use Number Two Diesel fuel having a grade of ASTM D 975 - Grade 2-D.
Hydraulic System
Hydraulic Pump
Kawasaki K3V112DT-1 M4R (KB2316)
Displacement ............................................................................................................. 96.5 cm
3
/rev x2
Working Pressure: Set ............................................................................................................ 314 Bar
Working Pressure: Maximum ...................................................................................... 343 (travel) Bar
Speed .................................................................................................................................................
Maximum Flow .................................................................................................................... 211 IImin-
1
Minimum Flow ....................................................................................................................... 50 l/min-
1
Regulator
Proportional Pressure Reducing Valve
Maximum Primary Pressure ................................................................................................... 39.2 Bar
Maximum Back Pressure (Allowable Pressure) ........................................................................ 9.8 Bar
Secondary Pressure Range Setting .................................................................................0 - 39.2 Bar
Maximum Flow Rate .................................................................................................................6 I/min
Flow in Drain Line: ...................... Maximum 0.2 I (0.4 pints)/min at secondary pressure =0- 39.2 Bar
Maximum 1.2 I (2.5 pints)/min at secondary pressure = 19.6 Bar
Hydraulic Oil Test Temperature ............................................................................................... 45 - 55°C
Circuit Relief Valves:
Main Relief: standard ....................................................................................................... 318 ±20 Bar
Main Relief: pressure raising ............................................................................................ 343 ±20 Bar
Boom Port Relief: raising ................................................................................................. 382 ±15 Bar
Boom Port Relief: lowering ............................................................................................... 245 ±15 Bar
Bucket Port Relief: open, close ........................................................................................ 382 ±15 Bar
Arm Port Relief: open, close ............................................................................................ 382 ±15 Bar
Swing Port Relief; left, right.. ............................................................................................ 304 ±15 Bar
Left Travel Port Relief: rear, front.. ................................................................................... 402 ±20 Bar
Right Travel Port Relief: rear, front.. ................................................................................. 402 ±20 Bar
Pilot Relief ........................................................................................................................... 40 ±3 Bar
Bur 7-11250 Issued 6-98
5.89 in
3
/rev x2
4553 psi
4980 (travel) psi
2200 min-
1
55.75 gpm-
1
13.21 gpm-
1
569 psi
142 psi
0- 569 psi
1.6 gpm
0- 569 psi
285 psi
113-131°F
4612 ±290 psi
4975 ±290 psi
5540 ±217 psi
3553 ±217 psi
5540 ±217 psi
5540 ±217 psi
4409 ±217 psi
5830 ±290 psi
5830 ±290 psi
580 ±43 psi
Printed in U.S.A.

1002-6
Tracks, Rollers and Idlers
Lower Mechanism (with standard 800 grouser shoe)
Total Length ......................................................................................................................... 4840 mm
Total Width ........................................................................................................................... 3400 mm
Total Weight (approximate) .................................................................................................... 11728 kg
Drive Sprocket
Sprocket:
a
a standard value .............................................................. 80 mm
service limit. .................................................................. 70 mm
b standard value ............................................................ 686 mm
service limit ................................................................. 678 mm
c standard value ............................................................ 770 mm
service limit.. ............................................................... 760 mm
d standard value ............................................................ 753 mm
service limit
P standard value ......................................................... 203.2 mm
service limit
p
Drive Sprocket
NOTE: Refer to Gauge Table for measurement gauges to be used.
Bur 7-11250 Issued 6-98
15 It. 10.5 in.
111t.1.9in.
25801 Ib
3.15 in.
2.76 in.
27 in.
26.69 in.
30.31 in.
29.92 in.
29.65 in.
8 in.
1002-3
Printed in U.S.A.

Take-Up Roller
Take-Up Roller:
Shaft:
Bushing:
Hub:
.0
a standard value ............................................................. 600 mm
service limit ................................................................. 590 mm
b standard value ............................................................... 20 mm
service limit
c standard value .............................................................1 02 mm
service limit ................................................................... 92 mm
d standard value ............................................................... 80 mm
service limit ................................................................... 79 mm
d standard value ............................................................... 80 mm
service limit ................................................................ 81.5 mm
e standard value ............................................................ 81.5 mm
service limit ................................................................... 80 mm
standard value ............................................................... 17 mm
service limit ................................................................ 16.5 mm
Take-Up Roller
NOTE: Refer to Gauge Table for measurement gauges to be used.
Bur 7-11250
Issued 6-98
1002-7
23.62 in.
23.23 in.
0.79 in.
4.02 in.
3.62 in.
3.15 in.
3.11 in.
3.15 in.
3.21 in.
3.21 in.
3.15 in.
0.67 in.
0.65 in.
1002-4
Printed in U.S.A.

1002-8
Upper Roller
Carrier Roller:
Shaft:
Bushing:
Bushing:
Thrust Plate:
Cover:
t
a standard value ............................................................ 145 mm
service limit ................................................................. 137 mm
b standard value .............................................................. 10 mm
service limit
c standard value ............................................................ 100 mm
service limit ................................................................... 92 mm
d standard value .............................................................. 60 mm
service limit ................................................................... 59 mm
d standard value .............................................................. 60 mm
service limit ................................................................... 61 mm
e standard value ............................................................. 4.5 mm
service limit .................................................................. 3.5 mm
standard value ................................................................6 mm
service limit .................................................................. 5.5 mm
g standard valve ........................................................... 28.5 mm
service limit ................................................................ 22.5 mm
----- c---- ..
~~~~~~~-J--------------
I
'0
j
Upper Roller
5.71 in.
5.39 in.
0.39 in.
3.94 in.
3.62 in.
2.36 in.
2.32 in.
2.36 in.
2.40 in.
0.18 in.
0.14 in.
0.24 in.
0.22 in.
1.12 in.
0.89 in.
NOTE: Refer to Gauge Table for measurement gauges to be used.
JS01444A
Bur 7-11250
Issued 6-98
Printed in U.S.A.

Lower Roller (Inside)
Track Roller (Inside):
Shaft:
Bushing:
Collar:
..0
a standard value ............................................................. 180 mm
service limit ................................................................. 192 mm
b standard value ............................................................... 20 mm
service limit
c standard value ............................................................. 100 mm
service limit ................................................................... 92 mm
e standard value ............................................................... 70 mm
service limit ................................................................... 69 mm
e standard value ............................................................... 70 mm
service limit ................................................................ 71.5 mm
standard value ............................................................ 82.5 mm
service limit ................................................................ 81.5 mm
g standard value ............................................................ 20.5 mm
service limit ................................................................... 20 mm
c
Lower Roller (Inside)
NOTE: Refer to Gauge Table for measurement gauges to be used.
Bur 7·11250
Issued 6-98
1002-9
7.09 in.
7.56 in.
0.79 in.
3.94 in.
3.62 in.
2.76 in.
2.72 in.
2.76 in.
2.81 in.
3.25 in.
3.21 in.
0.81 in.
0.79 in .
1002·6
Printed in U.S.A.