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.
Therstpartofthe(A.B)codeisreectedinthepagenumbering.
THERESTOFTHECODINGISNOTLISTEDINALPHA-NUMERICORDERINTHISMANUAL.
•Youwillndatableofcontentsatthebeginningandendofeachsectionandchapter.
Youwillndanalphabeticalindexattheendofeachchapter.
•Thereforeitistherstpartofthe(A.B)coding,thenthetablesofcontentsandindex(pagenumbers)whichwillallowyouto
quicklyndtheinformationyouarelookingfor.
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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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INTRODUCTION
CRIL04B072H011
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INTRODUCTION
CRIL04B073H012
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INTRODUCTION
Dimension(-A.92.A.30)
CX225SR
Machinettedwithmonoblocboom5.70m
CRPH04B001F001
Dippers1.90m2.40m3.00m
(A)3.08m3.14m2.90m
(B)2.97m
(C)8.97m8.93m8.85m
(D)6.74m6.70m6.62m
(E)2.80m
(F)1.40m
(G)1.68m
(H)4.46m
(I)3.66m
(J)2.39m
(K)0.60m
(L)withtrackpads600mm2.99m
(L)withtrackpads700mm3.09m
(L)withtrackpads800mm3.19m
(M)0.46m
(N)1.40m
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INTRODUCTION
Weight(-A.92.A.40)
CX225SR
Weightofmachine
CongurationWeightGround
pressure
Withtrackpads600mm,monoblocboom5.70m,dipper2.40m,760kg
backhoe,driverandfullfueltank
22700kg0.47bar
Weightofcomponents
Engine487kg
Hydraulicpump125kg
Attachmentcontrolvalve187kg
Swingmoto-reductiongear223kg
Travelmoto-reductiongear250kg
Boomcylinder200kg
Dippercylinder257kg
Bucketcylinder151kg
Counterweight5880kg
Cabkg
Turntable244kg
Upperstructurewithequipment(counterweightandturntable)11770kg
Hydraulicswivel27kg
UndercarriagewithequipmentEUROPE
7020kg
NA
7730kg
MachinewithoutequipmentEUROPE
18840kg
NA
19550kg
Attachment3870kg
Boomwithequipment2200kg
Dipperwithequipment3.00m910kg
Dipperwithoutequipment3.00m599kg
Radiatorandoil-coolerassembly55kg
Fueltank160kg
Hydraulicreservoir145kg
Idlerwheel82kg
Upperroller17kg
Lowerroller35kg
Tensionshockabsorber142kg
Track600mm1350kg
Track700mm1570kg
Track800mm1710kg
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INTRODUCTION
Consumables(-A.92.A.55)
CX225SR
FLUIDSANDLUBRICANTS
Lubricantsmusthavethecorrectpropertiesforeachapplication.
ATTENTION:Youmustrespecttheoperatingconditionsforthedifferentingredients.
Hydraulicuid
CASEAKCELAhydraulicuidisspeciallydesignedforhighpressureapplicationsandfortheCASEhydraulic
system.
Thetypeofuidtobeuseddependsontheambienttemperature.
•TEMPERATECOUNTRIES-20°Cto+40°C
CASEAKCELAHYDRAULICEXCAVATORFLUID
(MS1230.ISOVG46.DIN51524PART2HV)
•HOTCOUNTRIES0°Cto+60°C
CASEAKCELAHYDRAULICEXCAVATORFLUID"HOTCLIMATE"
(MS1230.ISOVG100.DIN51524PART2HV)
•COLDCOUNTRIES-40°Cto+20°C
CASEAKCELAHYDRAULICEXCAVATORFLUID"COLDCLIMATE"
(MS1230.ISOVG22.DIN51524PART2HV)
•BIODEGRADABLEFLUID-30-+40°C
Thisyellowuidcanbemixedwithstandarduid.
Ifthisliquidisused,itisadvisabletocompletelydrainthehydrauliccircuit.
CASEAKCELAHYDRAULICEXCAVATORSFLUIDBIO
(MS1230.ISOVG46.DIN51524PART2HV)
Transmissioncomponentoil
Extremepressureoilusedintransmissioncomponentsinsidesealedhousings.
CASEAKCELA135HEPGEARLUBESAE80W-90
(SAE80W-90.APIGL5.MIL-L-2105D.MS1316.ZFTE-ML05A)
Grease
"ExtremePressure"multi-purposegrease
•CASEAKCELAMOLYGREASE241HEP-M(251HEP-MNLGI2)
withlithiumandmolybdenumbisulphidesoap.
•CASEAKCELA251HEPMULTI-PURPOSEGREASE(251HEP .NLGI2)
withlithiumandcalciumsoap.
•CASEAKCELAPREMIUMGREASEEP-2(NLGI2)
withlithiumsoap.
HYDRAULICHAMMERS
UseonlyCASEAKCELAPREMIUMGREASEEP-2(NLGI2)greasewithlithiumsoap.
Engineoil
CASEAKCELANO.1ENGINEOILisrecommendedfortheengine.
Thisoilprovidescorrectlubricationforyourengineinallworkingconditions.
IfCASEAKCELANO.1ENGINEOILMultigradecannotbeobtained,useoilcorrespondingtooneofthefollowing
categories:ACEAE5.MS1121.APICH-4.
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INTRODUCTION
CRIL03H015F011
OILUSERANGE
1.Mineral-based
2.Semi-syntheticbased
3.Syntheticbased
Fuel
UsefuelthatiscompliantwithASTM(AmericanSocietyforTestingandMaterials)standardD975.
•UseGradeNo2fuel.Theuseofothertypesoffuelcanresultinalossofpowerandmaycausehighfuel
consumption.
•Whenthetemperatureisverycold,theuseofamixtureofNo1andNo2fuelispermitted.Seeyourfuel
vendorforwinterfuelrequirementsinyourarea.
•Ifthetemperaturefallsbelowthefuelcloudpoint(pointatwhichwaxbeginstoform)thewaxcrystalswill
causepowerlossorwillpreventtheenginefromstarting.
IMPORTANT:Incoldweather,llthefueltankattheendoftheday’sworktopreventcondensationfromforming.
FUELSTORAGE
Longstoragecanleadtotheaccumulationofimpuritiesandcondensationinthefueltank.Enginetroublecan
oftenbetracedtothepresenceofwaterinthefuel.
Thestoragetankmustbeplacedoutsideandthetemperatureofthefuelshouldbekeptaslowaspossible.
Drainoffwaterandimpuritiesregularly.
Anti-freeze/Anti-corrosion
Useanti-freezeinallseasonstoprotectthecoolingsystemfromcorrosionandallriskoffreezing.
CASEAKCELAPREMIUMANTI-FREEZELRD-25°C
Forenvironmentswithtemperaturesfallingto-25°C,donotmixwithwater.
CASEAKCELAPREMIUMANTI-FREEZE(MS1710)
Forenvironmentswithtemperaturesfallingto-38°C,usewithwaterinaproportionof50/50.
IMPORTANT:Donotmixproductsofadifferentoriginoradifferentmake.
Thesystemmustbetoppedupwiththesameproduct.
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INTRODUCTION
Environment
Beforecarryingoutanyservicingoperationonthismachineandbeforedisposingofuseduidsorlubricants,always
thinkoftheenvironment.Neverthrowuidoroilonthegroundandneverkeeptheminleakingreceptacles.
Contactyourlocalecologicalrecyclingcentreforinformationonappropriatewaystodisposeofthesesubstances.
Componentsmadefromplasticorresin
Whencleaningplasticparts,(theconsole,theinstrumentpanel,theindicatorsetc...)avoidusingpetrol,parafn,
paintsolventsetc.
Useonlywater,soapandasoftcloth.Theuseofpetrol,parafn,paintsolvents,etc,willcausediscoloration,
crackingordeformationofthesecomponents.
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INTRODUCTION
Hydrauliccontamination(-A.92.A.60)
CX225SR
CLEANINGTHEHYDRAULICSYSTEM
General
Contaminationofthehydraulicsystemisamajorcauseofincorrectoperationofhydrauliccomponents.
Contaminationisindicatedbythepresenceofforeignparticlesinthehydraulicuid.
Contaminationofthehydraulicsystemcanoccurinanyofthefollowingsituations:
1.Whendrainingtheuidordisconnectingahydraulicline.
2.Whendisassemblingacomponent.
3.Duetonormalcomponentwear.
4.Duetodamagedorwornseals.
5.Duetoadamagedcomponentinthehydraulicsystem.
Allhydraulicsystemscanfunctioneveniftheyareslightlycontaminated.Thecomponentsofthehydraulicsystem
aredesignedtosupportslightcontamination.Anyincreaseinthedegreeofcontaminationcancauseserious
problemsinthehydraulicsystem.
Thefollowingisanincompletelistoftheseproblems:
1.Thecylinderrodsealsleak.
2.Controlvalvespoolsdonotreturntotheneutralposition.
3.Controlvalvespoolsdonotmoveeasily.
4.Hydraulicuidistoohot.
5.Hydrauliccomponentswearquickly.
6.Safetyvalvesorcheckvalvesdonotcloseduetocontamination.
7.Repairedcomponentsbreakdownsoon.
8.Cyclesareslow;themachinedoesnothaveenoughpower.
Ifanyoftheabovesituationsoccurs,itisanindicationofexcessivecontaminationofthehydraulicsystem.
Toeliminatecontamination,effectively,refertoPRIMARYHYDRAULICPOWERSYSTEM-Decontaminating
(A.10.A-F .30.A.60).
Typesofcontamination
Contaminationexistsbasicallyintwoforms:microscopicorvisible.
Wespeakofmicroscopiccontaminationwhenverysmallparticlesofforeignbodiesareinsuspensioninthe
hydraulicuid.Theseparticlesaretoosmalltobeseenorfelt.Microscopiccontaminationcanbedetectedby
identifyingtheproblemsrelatingtomicroscopiccontaminationorbylaboratorytests.
Thefollowingareafewexamplesofproblemscausedbymicroscopiccontamination:
•Thecylinderrodsealsleak.
•Controlvalvespoolsdonotreturntotheneutralposition.
•Theoperatingtemperatureofthehydraulicsystemistoohigh.
•Componentswearquickly.
Wespeakofvisiblecontaminationwhenthepresenceofforeignbodiescanbedetectedvisually,bytouchorby
smell.Visiblecontaminationcancausethesuddenfailureofacomponent.
Thefollowingareafewexamplesofproblemscausedbyvisiblecontamination:
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INTRODUCTION
•Theuidcontainsmetalorotherfragments.
•Theuidcontainsair.Theuidisdarkandthick.
•Thereisasmellofburningintheuid.Theuidcontainswater.
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INTRODUCTION
Productidentication(-A.80.A.10)
CX225SRWE
NOTE:Forallpartsorders,requestsforinformationorassistance,alwaysspecifythetypeandtheserialnumberof
themachinetoyourCASEdealer.
Filloutthefollowinglineswiththerequiredinformation:type,yearofmanufacture,serialnumberofthemachine
(manufacturer’splate),mark,typeandserialnumberoftheengine,andserialnumbersofhydrauliccomponents.
Manufacturer’splate
CRIL03H001E011
(1)TYPE(2)YEAROFMANUFACTURE(3)SERIALNUMBER
Engine
MAKETYPESERIALNUMBER
Serialnumbersofhydrauliccomponents
COMPONENTSSERIALNUMBER
Hydraulicpump
Swingreductiongear
Travelreductiongear
Travelcontrolvalve
Attachmentcontrolvalve
Swingcontrolvalve
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