Case CX225SR Operating instructions

REPAIRMANUAL
CX225SR
9-40691102/12/2004

Contents
INTRODUCTION
DISTRIBUTIONSYSTEMSA
POWERPRODUCTIONB
TRAVELLINGD
BODYANDSTRUCTUREE
FRAMEPOSITIONINGF
WORKINGARMH
TOOLSANDCOUPLERSJ
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INTRODUCTION
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Contents
INTRODUCTION
Foreword(-A.10.A.40)
CX225SR3
Safetyrules(-A.50.A.10)
CX225SR4
Basicinstructions(-A.90.A.05)
CX225SR6
Torque(-A.90.A.10)
CX225SR7
Torque(-A.90.A.10)
CX225SR8
Dimension(-A.92.A.30)
CX225SR11
Weight(-A.92.A.40)
CX225SR12
Consumables(-A.92.A.55)
CX225SR13
Hydrauliccontamination(-A.92.A.60)
CX225SR16
Productidentication(-A.80.A.10)
CX225SRWE18
Productidentication(-A.80.A.10)
CX225SRNA19
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INTRODUCTION
Foreword(-A.10.A.40)
CX225SR
INTRODUCTIONTOTHEREPAIRMANUAL
ThismanualhasbeendesignedsothatinthenearfutureitcanbemadeavailableonCDandinadatabase
viaacomputernetwork.
Thiswillallowfastandtargetedsearchandnavigationbetweenthevariousinformationmodules.
Informationsearch
CRIL03J033E011
Thismanualisorganisedaccordingtotypesoffunctionandinformation.
•Thefunctionandinformationtypesarecodiedandappearinparenthesesafterthetitleandseparatedbyadash:
(1)Function
(2)Informationtype.
•Onlytherstletter(A)andtherstnumber(B)ofthefunctionneedtobeusedfortheinformationsearch.
Therstletter(A)correspondstothesectionsoftherepairmanual.
Therstnumber(B)correspondstothechaptersoftherepairmanual.
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THERESTOFTHECODINGISNOTLISTEDINALPHA-NUMERICORDERINTHISMANUAL.
•Youwillndatableofcontentsatthebeginningandendofeachsectionandchapter.
Youwillndanalphabeticalindexattheendofeachchapter.
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INTRODUCTION
Safetyrules(-A.50.A.10)
CX225SR
CAUTION
M171C-THISSAFETYALERTSYMBOLINDICATESIMPORTANTSAFETYMESSAGESINTHISMANUAL.
WHENYOUSEETHISSYMBOL,CAREFULLYREADTHEMESSAGETHATFOLLOWSANDBEALERTTO
THEPOSSIBILITYOFDEATHORSERIOUSINJURY .
ATTENTION:Toavoidinjury,alwaysobservetheSafetyNotices,CAUTIONandATTENTION,containedinthis
sectionandthroughoutthemanual.
Placea“Donotstartthemachine”warningnoticeonthestarterswitchkeybeforeallmaintenanceorrepair
operations.
CAUTION
M489-Readtheoperatorsmanualtofamiliarizeyourselfwiththecorrectcontrolfunctions.
CAUTION
M490-Operatethemachineandequipmentcontrolsfromtheseatpositiononly.Anyothermethodcould
resultinseriousinjury.
CAUTION
M265A-Afrequentcauseofpersonalinjuryordeathispersonsfallingoffandbeingrunover.Donot
permitanyonetorideonthemachine.
CAUTION
SB055-Beforestartingengine,studyoperatorsmanualsafetymessages.Readallsafetysignsonmachine.
Cleartheareaofotherpersons.Learnandpracticesafeuseofcontrolsbeforeoperation.Itisyour
responsibilitytounderstandandfollowmanufacturersinstructionsonmachineoperation,service,andto
observepertinentlawsandregulation.Operatorsandservicemanualscanbeobtainedfromyourdealer.
ATTENTION:Youriskinjuryifyouwearlooseclothingorifyoudonotusesafetyequipmentforyourwork.Always
wearclotheswhichareunlikelytobecomecaughtinthemachinery.Othersafetyequipmentmayberequired,in
particular:hardhat,safetyboots,earprotectors,safetygogglesormask,thickglovesandreectiveclothing.
CAUTION
M124A-Rotatingmachineparts,stayclear,keepshieldsinstalledtohelpprotectfromclothing
entanglementandinjury.Wearclose-ttedclothing.
CAUTION
SB071-Rotatingfanandbelts:Contactwillcauseinjury.Keepclear.
ATTENTION:Followtheproceduresexactlywhencarryingoutchecksorinspectionsonthevehicle’shydraulic
systems.DONOTCHANGEtheprocedures.
ATTENTION:Beforerunningthehydrauliccylindersinthisvehiclethroughthecyclesnecessaryforcheckingtheir
functioningorfordrainingacircuit,warnpeoplenearbytomoveaway.
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INTRODUCTION
CAUTION
SM121A-Alwayswearheatprotectiveglovestopreventburningyourhandswhenhandlingheatedparts.
CAUTION
M132B-Lowerorblockelevatedimplementsandotherattachmentsbeforeservicingorwhenleavingthe
equipment.
CAUTION
R149C-Hydraulicoilordieselfuelleakingunderpressurecanpenetratetheskinandcauseinfection
orotherinjury.ToPreventPersonalInjury:Relieveallpressure,beforedisconnectinguidlinesor
performingworkonthehydraulicsystem.Beforeapplyingpressure,makesureallconnectionsaretight
andcomponentsareingoodcondition.Neveruseyourhandtocheckforsuspectedleaksunderpressure.
Useapieceofcardboardorwoodforthispurpose.Ifinjuredbyleakinguid,seeyourdoctorimmediately.
ATTENTION:Toremoveahardenedpin,suchasapivotpin,orahardenedshaft,useasoft-headedhammer
(brassorbronze)orabrassorbronzepegandasteel-headedhammer.
CAUTION
M428-Alwayswearsafetyglasseswhenusingadrill,hammer,saw,orothertoolsthatmaycausechips
toy.
ATTENTION:Usesuitableservicingjacksorachainhoistforraisingthewheelsortracks.Alwayschockthe
vehicleinplacewithsuitablesafetysupports.
ATTENTION:Whencarryingoutmaintenanceorrepairoperationsonthevehicle,keeptheworkshopoor,the
drivingpositionandthestepsfreefromoil,water,grease,tools,etc...Useanoilabsorbentmaterialand/orworkshop
clothsasnecessary.Alwaysusesoundmethods.
ATTENTION:Somepartsofthisvehicleareveryheavy.Useliftingdevicesoradditionalassistancerecommended
intheOperator’sManual.
CAUTION
M532-Donotoperatetheengineinaclosedbuilding.Properventilationisrequiredunderallcircumstances.
CAUTION
M503-Whenthebatteryelectrolyteisfrozen,thebatterycanexplodeif(1),youtrytochargethebattery,or
(2),youtrytojumpstartandruntheengine.Topreventthebatteryelectrolytefromfreezing,trytokeepthe
batteryatfullcharge.Ifyoudonotfollowtheseinstructions,youorothersintheareacanbeinjured.
CAUTION
M244A-BATTERIESCONTAINACIDANDEXPLOSIVEGAS.EXPLOSIONCANRESULTFROMSPARKS,
FLAMES,ORWRONGCABLECONNECTIONS.TOCONNECTJUMPERCABLESORCHARGER,SEE
MANUAL(S)FORTHECORRECTPROCEDURE.FAILURETOFOLLOWTHEABOVEINSTRUCTIONSCAN
CAUSESERIOUSPERSONALINJURYORDEATH.
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INTRODUCTION
Basicinstructions(-A.90.A.05)
CX225SR
GENERAL
Cleaning
Cleanallmetalpartsexceptthebearingswithwhitespiritorsteam.Donotusecausticsodaforsteamcleaning.
Aftereachcleaning,dryandoilallparts.Cleantheoilductswithcompressedair.Cleanthebearingswithparafn,
thendrythemcompletelyandlubricatethem.
Inspection
Checkallthepartswhentheyaredisassembled.Replaceallpartsthatshowsignsofwearordamage.Supercial
scratchesandgroovescanberemovedwithanoilstoneorwithaclothdippedinredoxide.Acompletevisual
inspectionisnecessarytodetectwearandpitting,andreplacingpartsassoonasitbecomesnecessarywillhelpto
avoidprematurebreakdowns.
Bearings
Checkthatthebearingsturnfreely.Replacethemiftheiradjustmentistoofreeoriftheirfunctioningisirregular.
Washthebearingswithagoodsolventorparafnandallowthemtoairdry.
DONOTDRYTHEBEARINGSWITHCOMPRESSEDAIR.
Needlebearings
Beforepushingneedlebearingsintoacylinderbore,alwaysremoveallmetallicprojectionsfromtheboreandits
edges.Beforepushinginbearingswithapress,coattheinsideandedgesofthebearingswithVaseline.
Gears
Checkallthegearsandensurethattheydonotshowanysignsofwearordamage.Replacethewornout
ordamagedgears.
Gaskets,O-ringsandatseals
Alwaysinstallnewgaskets,O-rings,andatseals.CoatthegasketsandO-ringswithVaseline.
Shaft
Checkallshaftsshowingwearordamage.Enusrethatthesurfaceofashaftcarryingabearingorgasketis
notdamaged.
Spareparts
AlwaysuseCASEspareparts.Toorderthese,refertotheSparePartsCatalogueandindicatethecorrectreference
numberoftheCASEspareparts.
BreakdownscausedbytheuseofpartsotherthanCASEsparepartsarenotcoveredbythewarranty.
Lubrication
UseonlytheoilsandlubricantsspeciedintheOperator’sManualortheServiceManual.
Breakdownscausedbytheuseofoilsandlubricantsnotspecicallylistedarenotcoveredbythewarranty.
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INTRODUCTION
Torque(-A.90.A.10)
CX225SR
STANDARDTIGHTENINGTORQUE
Orderoftighteningnutsandcapscrews.
Tightenalternatelysothattorqueremainsuniform.CapscrewswhicharettedwithLoctite(lookfortracesofa
whiteresidueonthethreadafterremoval),mustbecleanedwithathinoilorasuitablesolvent,thendried.
AddtwoorthreedropsofLoctitetothecapscrewthread,thentthescrew.
CRIL03H012E011
Thenumbersinthediagramsrepresenttheorderoftightening.
Tighteningtorque
Wheretherearenospecialinstructions,tightencapnutsscrewstothetorquesgiveninthetablebelow.
Standardtorquesettingtable.
Designationofcapscrews
(dimensions)
M6M8M10M12M14M16M18M20
Spannerinmm1013171922242730 Capscrew
Torquesettingin
Nm
6.919.639.258.898.1157.2196274
Wrenchinmm5681012141417
Sockethead
screwTorquesettingin
Nm
8.821.642.178.4117.6176.4245343
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INTRODUCTION
Torque(-A.90.A.10)
CX225SR
SPECIALTORQUESETTINGS
No.ComponentScrew
diameter
Wrench
inmm
Tighteningtorque
(1)*TravelmotorandreductiongearassemblyM1624267-312Nm
(2)*SprocketM1624267-312Nm
(3)*IdlerwheelM1624267-312Nm
(4)*UpperrollerM2030521-608Nm
(5)*LowerrollerM1827371-432Nm
(6)ChainguideM1827380-443Nm
(7)TrackpadM2030300Nm+120°
(8)CounterweightM36552750-2940Nm
(9)Turntable(chassis)M2030468-545Nm
(10)Turntable(upperstructure)M2030468-545Nm
(11)*SwingmotorandreductiongearassemblyM2030521-608Nm
(12)*EngineM1624265-313Nm
(13)*EnginemountsM101764-74Nm
(14)RadiatorM1624147-176Nm
M101764-74Nm
(15)*Hydraulicpump
M2030367-496Nm
(16)*HydraulicreservoirM2030412-471Nm
(17)*FueltankM2030412-471Nm
(18)*ControlvalveM1624267-312Nm
(19)*HydraulicswivelM1219109-127Nm
(20)CabM162478-80Nm
(21)BatteriesM101720-29Nm
UseLoctite262oranequivalentonmountingscrewsmarkedwithanasterisk(*).
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