Case CX220C 2 Series User manual

Service Manual
Service Manual
1/1
Part Number
48024959
1st Edition
English 11/2016
Printed in Brazil
Copyright © 2016 – CNH Industrial Latin America LTDA.
All Rights Reserved..
Part Number
48024959
1st Edition
English 11/2016
CX220C Series 2
CX240C
Hydraulic
Excavator
CX220C Series 2
CX240C
Hydraulic Excavator

SERVICEMANUAL
CX220CSERIES2Standardmodel,TIER3levelengine
CX240CCrawlerexcavator-Massexcavator-TIER3
4802495917/11/2016
EN

Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.216]Fueltanks..........................................................................10.2
[10.254]Intakeandexhaustmanifoldsandmufer.........................................10.3
[10.310]Aftercooler..........................................................................10.4
[10.400]Enginecoolingsystem.............................................................10.5
Hydraulicsystems.......................................................................35
[35.106]Variabledisplacementpump.......................................................35.1
[35.102]Pumpcontrolvalves................................................................35.2
[35.353]Hydraulictravelsystem............................................................35.3
[35.359]Maincontrolvalve..................................................................35.4
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.5
[35.300]Reservoir,cooler,andlters........................................................35.6
[35.304]Combinationpumpunits...........................................................35.7
[35.357]Pilotsystem........................................................................35.8
[35.355]Hydraulichandcontrol.............................................................35.9
[35.356]Hydraulicfootcontrol.............................................................35.10
[35.352]Hydraulicswingsystem..........................................................35.11
[35.354]Hydrauliccentraljoint............................................................35.12
[35.736]Boomhydraulicsystem..........................................................35.13
[35.737]Dipperhydraulicsystem..........................................................35.14
[35.738]Excavatorandbackhoebuckethydraulicsystem................................35.15
[35.360]Hammerandrotatingbuckethydraulicsystem..................................35.16
Framesandballasting.................................................................39
4802495917/11/2016

[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
[55.010]Fuelinjectionsystem...............................................................55.2
[55.013]Engineoilsystem..................................................................55.3
[55.015]Enginecontrolsystem..............................................................55.4
[55.201]Enginestartingsystem.............................................................55.5
[55.640]Electronicmodules.................................................................55.6
[55.036]Hydraulicsystemcontrol...........................................................55.7
[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls...................55.8
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.9
[55.100]Harnessesandconnectors.......................................................55.10
[55.301]Alternator.........................................................................55.11
[55.302]Battery............................................................................55.12
[55.404]Externallighting..................................................................55.13
[55.416]Swingcontrolsystem............................................................55.14
[55.417]Travelcontrolsystem............................................................55.15
[55.530]Camera...........................................................................55.16
[55.518]Wiperandwashersystem........................................................55.17
[55.514]Cablighting......................................................................55.18
4802495917/11/2016

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[55.408]Warningindicators,alarms,andinstruments....................................55.19
[55.512]Cabcontrols......................................................................55.20
[55.950]Hammerelectricsystem.........................................................55.21
[55.992]Anti-theftsystem.................................................................55.22
[55.DTC]FAULTCODES..................................................................55.23
Booms,dippers,andbuckets.......................................................84
[84.910]Boom...............................................................................84.1
[84.912]Dipperarm.........................................................................84.2
[84.100]Bucket..............................................................................84.3
Platform,cab,bodywork,anddecals.............................................90
[90.100]Enginehoodandpanels...........................................................90.1
[90.120]Mechanically-adjustedoperatorseat...............................................90.2
[90.150]Cab.................................................................................90.3
[90.156]Cabwindshieldandwindows......................................................90.4
4802495917/11/2016

INTRODUCTION
4802495917/11/2016
1

Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing(*)................................3
Safetyrules(*)..................................................................................4
Safetyrules-Generalinformation(*)...........................................................5
Safetyrules-Personalsafety(*)...............................................................6
Safetyrules-Cabprotectivestructure(*)......................................................8
Torque-Boltandnut(*)........................................................................9
Torque-Specialtorquesettings(*)...........................................................10
Basicinstructions-Shopandassembly(*)...................................................14
Generalspecication(*)......................................................................16
Generalspecication-Mainequipment(*)...................................................20
Weight(*).....................................................................................27
Dimension(*).................................................................................29
Dimension(*).................................................................................31
Conversionfactors(*).........................................................................34
Consumables(*)..............................................................................46
Capacities(*).................................................................................49
Abbreviation(*)...............................................................................50
Productidentication(*)......................................................................53
Productidentication-Machineorientation(*)...............................................55
(*)Seecontentforspecicmodels
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2

INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
CX220CSERIES2Standardmodel,TIER3levelengineLA
CX240CCrawlerexcavator-Massexcavator-TIER3LA
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecicationsatanytimewithout
noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specications,descriptions,and
illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
Incaseofquestions,refertoyourCASECONSTRUCTIONSalesandServiceNetworks.
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INTRODUCTION
Safetyrules
CX220CSERIES2Standardmodel,TIER3levelengineLA
CX240CCrawlerexcavator-Massexcavator-TIER3LA
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY.
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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4

INTRODUCTION
Safetyrules-Generalinformation
CX220CSERIES2Standardmodel,TIER3levelengine
CX240CCrawlerexcavator-Massexcavator-TIER3LA
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)
Usetheoilfromthespeciedcompanyorspeciedintheoperator'smanualorserviceManual.
Anybreakdownsarisingfromanyfuelorhydraulicoilotherthanthosespeciedarenotcoveredbythewarranty.
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INTRODUCTION
Safetyrules-Personalsafety
CX220CSERIES2Standardmodel,TIER3levelengine
CX240CCrawlerexcavator-Massexcavator-TIER3LA
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-Cabprotectivestructure
CX220CSERIES2Standardmodel,TIER3levelengine
CX240CCrawlerexcavator-Massexcavator-TIER3LA
Cabprotectivestructure
Modifyingthecabmaincomponentsisprohibitedinordertoprotecttheoperator.
Prohibiteditems
•Modicationsthatreducethestrengthofaplatformthathasacabwithaprotectivestructuremountedonit.(Actions
ormodicationsthatreducethefunctionalityoftheanchoringpartattheleft-rearofthecab)
•Modicationsthateffectthestrengthofthecabwithaprotectivestructure.
Modicationsprohibited(redpart)Allmodications(grinding,welding,drillingholes,removing,etc.)
areprohibited.
Modicationspermittedunderconditions(gray
part)
Removalofpartsisprohibited.Barweldingandmakingholes(up
todiameter20mm(0.787in))bydrillingarepossible.
SMPH15CEX6544FA1
4802495917/11/2016
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INTRODUCTION
Torque-Boltandnut
CX220CSERIES2Standardmodel,TIER3levelengine
CX240CCrawlerexcavator-Massexcavator-TIER3LA
•Tightenalternatingbetweenleftandrightandtopandbottomsothatuniformtighteningforceisapplied.
LPIL12CX00005EA1
•IfLOCTITE®wasusedonaremovedbolt(thereissomethingwhitestickingtotheboltwhenitisremoved),cleanthe
oldLOCTITE®offwithcleaninguid,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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INTRODUCTION
Torque-Specialtorquesettings
CX220CSERIES2Standardmodel,TIER3levelengine
CX240CCrawlerexcavator-Massexcavator-TIER3LA
CodeRetighteninglocationBoltnominal
diameterWrenchTighteningtorque
1*TravelmotorM1624mm267-312N·m(196.93-230.12lbft)
2*DrivesprocketM1624mm267-312N·m(196.93-230.12lbft)
3*Take-uprollerM1624mm267-312N·m(196.93-230.12lbft)
4*UpperrollerM2030mm521-608N·m(384.27-448.44lbft)
5*LowerrollerM1827mm371-432N·m(273.64-318.63lbft)
6*TrackguardM1827mm400-462N·m(295.02-340.75lbft)
7ShoeM2030mm755-853N·m(556.86-629.14lbft)
8CounterweightM3350mm1862-2058N·m(1373.34-1517.90lbft)
9TurntablebearingM2030mm468-545N·m(345.18-401.97lbft)
10*SwingunitM2030mm539.4-629.6N·m(397.84-464.37lbft)
11*MountM1624mm264.9-313.9N·m(195.38-231.52lbft)
12*FrontbracketM1017mm63.8-73.6N·m(47.06-54.28lbft)
13*
Engine
RearbracketM1624mm205.9-247.1N·m(151.86-182.25lbft)
14RadiatorM1624mm147.2-176.6N·m(108.57-130.25lbft)
15*Hydraulic
pumpPumpM20
17mm
hexagon
socket
head
367-496N·m(270.69-365.83lbft)
16*HydraulicoiltankM1624mm232.4-276N·m(171.41-203.57lbft)
17*FueltankM1624mm232.4-276N·m(171.41-203.57lbft)
18*ControlvalveM1624mm267-312N·m(196.93-230.12lbft)
19*CenterLockbarM1219mm88.3-107N·m(65.13-78.92lbft)
20*JointJointM1219mm109-127N·m(80.39-93.67lbft)
21M1624mm149-173N·m(109.90-127.60lbft)
22CabM1017mm19.6-29.4N·m(14.46-21.68lbft)
CAUTION:
•Foritemsmarkedwith*,alwaysapplyLOCTITE®262™ortheequivalentandtightentothespeciedtorque.
Thetighteningtorqueinkgf•misdeterminedwithN・m÷9.8(lbf・ft÷7.2).
4802495917/11/2016
10

INTRODUCTION
LPIL12CX00034HB1
4802495917/11/2016
11

INTRODUCTION
SMIL13CEX1312GB2
4802495917/11/2016
12

INTRODUCTION
SMIL13CEX1313GB3
4802495917/11/2016
13

INTRODUCTION
Basicinstructions-Shopandassembly
CX220CSERIES2Standardmodel,TIER3levelengine
CX240CCrawlerexcavator-Massexcavator-TIER3LA
Shimming
Foreachadjustmentoperation,selectadjustingshimsandmeasuretheadjustingshimsindividuallyusingamicrom-
eter,thenadduptherecordedvalues.Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,or
theratedvalueshownoneachshim.
Rotatingshaftseals
Forcorrectrotatingshaftsealinstallation,proceedasfollows:
1.Beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes.
2.Thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged.
3.Positionthesealinglipfacingtheuid.
NOTE:Withhydrodynamiclips,takeintoconsiderationtheshaftrotationdirectionandpositionthegroovessothat
theywillmovetheuidtowardstheinnersideoftheseal.
4.Coatthesealinglipwithathinlayeroflubricant(useoilratherthangrease).Fillthegapbetweenthesealinglip
andthedustlipondoublelipsealswithgrease.
5.Insertthesealinitsseatandpressdownusingaatpunchorsealinstallationtool.Donottapthesealwitha
hammerormallet.
6.Whileyouinserttheseal,checkthatthesealisperpendiculartotheseat.Whenthesealsettles,makesurethat
thesealmakescontactwiththethrustelement,ifrequired.
7.Topreventdamagetotheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.
O-ringseals
LubricatetheO-ringsealsbeforeyouinsertthemintheseats.ThiswillpreventtheO-ringsealsfromoverturningand
twisting,whichwouldjeopardizesealingefciency.
Sealingcompounds
Applyasealingcompoundonthematingsurfaceswhenspeciedbytheprocedure.Beforeyouapplythesealing
compound,preparethesurfacesasdirectedbytheproductcontainer.
Spareparts
OnlyuseCNHOriginalPartsorCASECONSTRUCTIONOriginalParts.
Onlygenuinesparepartsguaranteethesamequality,duration,andsafetyasoriginalparts,astheyarethesame
partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorCASECONSTRUCTIONOriginal
Partscanofferthisguarantee.
Whenorderingspareparts,alwaysprovidethefollowinginformation:
•Machinemodel(commercialname)andProductIdenticationNumber(PIN)
•Partnumberoftheorderedpart,whichcanbefoundinthepartscatalog
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14
This manual suits for next models
1
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