Case CX800 Tier 3 User manual

CRAWLER EXCAVATOR
SERVICE MANUAL
Issued 07-2006
87571787 NA
CX800
TIER III

CX800
TIER III
CRAWLER EXCAVATOR
SERVICE MANUAL
Bur • Issued 07-2006
Printed in U.S.A. • Book/Form Number 87571787 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Find manuals at https://best-manuals.com

87571787 NACX800 TIER III Crawler Excavator07-2006First Edition
REVISION HISTORY
RemarksIssue Issue Date Applicable Machines
CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not
necessarily show products in standard condition.For exact information about any particular product, please consult your Dealer.
Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America LLC. Carol Stream, IL U.S.A.60188
Find manuals at https://best-manuals.com

Copyright ©2006 CNH America LLC.
All rights reserved.
Printed in USA.
CNH Lep 9-42691NA September 2006.
CX800 Tier 3 Crawler Excavators
Table of Contents
DIVISION/SECTION SECTION N°REFERENCE N°
1 GENERAL INFORMATION
Safety, general information and standard torque data .....................................1001 7-27691NA
General specifications and special torque setting............................................1002 9-94710NA
Numerical value conversion table ....................................................................1003 9-35540
2ENGINE
Radiator and engine, removal and installation .................................................2001 9-94910NA
Engine specifications- Refer to Engine Service Manual ........................................ 9-36410NA
Disassembly and assembly of the engine-Refer to Engine Service Manual ......... 9-36410NA
3 FUEL SYSTEM
Fuel tank ..........................................................................................................3001 9-36821NA
Fuel engine system................................................................................................ *
4 ELECTRICAL SYSTEM
Electrical system, electrical and electronic troubleshooting.............................4001 9-94700NA
Inspection and maintenance of batteries and connecting a booster battery....4002 9-36830NA
Main and engine electronic control boxes........................................................4003 9-94510NA
5 UNDERCARRIAGE
Removal and installation of tracks ...................................................................5001 9-36860NA
Rollers..............................................................................................................5003 9-36881NA
Sprocket ...........................................................................................................5004 9-36890NA
Idler wheel and tension shock absorber ..........................................................5005 9-94350NA
6 DRIVE TRAIN
Drive motor and final drive transmission removal and installation ...................6001 9-36980NA
Drive motor and final drive transmission disassembly and assembly ..............6002 9-40351NA
Swing reduction gear, removal and installation................................................6003 9-36991NA
Swing reduction gear, disassembly and assembly...........................................6004 9-42631NA
7 UNDERCARRIAGE HYDRAULICS
8 UPPERSTRUCTURE HYDRAULICS
Depressurising and decontaminating the hydraulic system, use of the
vacuum pump and bleeding the components ..............................................8000 9-94430NA
Specifications, troubleshooting, checks and hydraulic pressure settings.........8001 9-94740NA
Hydraulic reservoir removal and installation ....................................................8002 9-94490NA
Main and pilot pumps, removal and installation ...............................................8003 9-40771NA
Main hydraulic control valve, removal and installation .....................................8004 9-94501NA
Attachment cylinders, removal and installation ................................................8005 7-27792NA
Hydraulic swivel, removal and installation........................................................8006 9-94600NA
Pilot blocs, removal and installation .................................................................8007 9-94520NA
Swing motor, removal and installation..............................................................8008 9-94420NA
Main hydraulic pump, disassembly and assembly ...........................................8010 9-94590NA
Main hydraulic control valve, disassembly and assembly ................................8011 9-94781NA
Attachment cylinders, disassembly and assembly...........................................8012 9-40941NA
Hand control levers, disassembly and assembly .............................................8013 9-94630NA
Foot control levers, disassembly and assembly ...............................................8014 9-40992NA
Six-solenoid valves, disassembly and assembly..............................................8015 9-42521NA
Caution valve, disassembly and assembly.......................................................8016 9-94531NA
Safety valve......................................................................................................8017 9-42770NA
Hydraulic swivel, disassembly and assembly...................................................8018 9-42511NA
Swing motor, disassembly and assembly ........................................................8019 9-42530NA
Hydraulic functions...........................................................................................8020 9-94720NA
Find manuals at https://best-manuals.com

Lep 9-42691NA Edition 09-06
DIVISION/SECTION SECTION N° REFERENCE N°
Fan motor, removal and installation .................................................................8022 9-94660NA
Fan motor, disassembly and assembly ............................................................8023 9-94670NA
Fan pump, removal, disassembly, assembly and installation ...........................8024 9-94680NA
Hydraulic component functions........................................................................8030 9-94130NA
9 UPPERSTRUCTURE
Upperstructure, turntable and counterweight...................................................9002 9-42551NA
Boom, dipper and bucket .................................................................................9003 9-42621NA
Seat and seat belt ............................................................................................9004 9-40960NA
Cab and cab equipment...................................................................................9005 9-94650NA
Air conditioning troubleshooting.......................................................................9006 7-xxxxxFR
Air conditioning unit disassembly and assembly..............................................9007 9-94640NA
Air conditioning servicing .................................................................................9008 7-xxxxxFR
Air conditioning components............................................................................9009 7-xxxxxFR
Removal and installation attachment, counterweight and side fram ................9010 9-94730NA
Large format hydraulic schematic .................................................................Pocket 87528728
Large format electrical schematic .................................................................Pocket 87519792
* Consult the Engine Service Manual 9-36410NA
Sections to be distributed at a later date
NOTE: CNH Company reserves the right to make changes in the specifi-
cation and design of the machine without prior notice and without incur-
ring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in
accordance with the technical specifications known as of the date of
design of this document.
Find manuals at https://best-manuals.com

CNH
Copyright ©2006 CNH America LLC.
All rights reverved.
Printed in U.S.A.
Issued February, 2006
Lep 7-27691NA
1001
SAFETY, GENERAL INFORMATION
AND TORQUE SPECIFICATIONS
Section
1001
Find manuals at https://best-manuals.com

1001-2
Lep 7-27691NA Issued 02-06
TABLE OF CONTENTS
GENERAL INFORMATION .......................................................................................................................................3
SAFETY.....................................................................................................................................................................4
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6
WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see
this symbol, carefully read the message that follows, as there is a risk of serious injury.
!
Find manuals at https://best-manuals.com

1001-3
Lep 7-27691NA Issued 02-06
GENERAL INFORMATION
Cleanning
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.
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.
Find manuals at https://best-manuals.com

1001-4
Lep 7-27691NA Issued 02-06
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
!
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
.
WARNING: Read the operator’s manual to
familiarize yourself with the correct control
functions.
!
WARNING: Operate the machine and
equipment controls from the seat position
only. Any other method could result in
serious injury.
!
WARNING: This is a one man machine, no
riders allowed.
!
WARNING: Before starting engine, study
Operator’s Manual safety messages. Read
all safety signs on machine. Clear the 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.
!
WARNING: If you wear clothing that is too
loose or do not use the correct safety
equipment for your job, you can be injured.
Always wear clothing that will not catch on
objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
gloves and reflector clothing.
!
WARNING: When working in the area of the
fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
!
WARNING: When doing checks and tests
on the equipment hydraulics, follow the
procedures as they are written. DO NOT
change the procedure.
!
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.
!
Find manuals at https://best-manuals.com

1001-5
Lep 7-27691NA Issued 02-06
WARNING: Use insulated gloves or mittens
when working with hot parts.
!
WARNING: Lower all attachments to the
ground or use stands to safely support the
attachments before you do any maintenance
or service.
!
WARNING: Pin sized and smaller streams
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
immediately. Maintain all hoses and tubes in
good condition. Make sure all connections
are tight. Make a replacement of any tube 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.
!
WARNING: When removing hardened pins
such as a pivot pin, or a hardened shaft, use
a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
steel head hammer.
!
WARNING: 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
other approved eye protectors).
!
WARNING: Use suitable floor (service)
jacks or chain hoist to raise wheels or tracks
off the floor. Always block machine in place
with suitable safety stands.
!
WARNING: When servicing or repairing the
machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
grease, tools, etc. Use an oil absorbing
material and/or shop cloths as required. Use
safe practices at all times.
!
WARNING: Some components of this
machine are very heavy. Use suitable lifting
equipment or additional help as instructed in
this Service Manual.
!
WARNING: Engine exhaust fumes can
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
fumes from the area with an exhaust pipe
extension. Open the doors and get outside
air into the area.
!
WARNING: When the battery electrolyte is
frozen, the battery can 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 not follow
these instructions, you or others in the area
can be injured.
!
Find manuals at https://best-manuals.com