Case WX148 User manual

SERVICE MANUAL
1/1
WX148
Wheeled Excavator
SERVICE MANUAL
WX148
Wheeled Excavator
1/1
Part number 47500167
English
January 2013
Copyright © 2013 CNH Europe Holding S.A. All Rights Reserved.
Part number 47500167

SERVICEMANUAL
WX148
47500167A31/01/2013
EN
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.202]Aircleanersandlines..............................................................10.2
[10.206]Fuellters..........................................................................10.3
[10.216]Fueltanks..........................................................................10.4
[10.254]Intakeandexhaustmanifoldsandmufer.........................................10.5
[10.400]Enginecoolingsystem.............................................................10.6
Transmission..............................................................................21
[21.105]Powershifttransmissionlubricationsystem........................................21.1
[21.113]Powershifttransmission............................................................21.2
[21.135]Powershifttransmissionexternalcontrols..........................................21.3
[21.155]Powershifttransmissioninternalcomponents......................................21.4
Four-WheelDrive(4WD)system..................................................23
[23.314]Driveshaft..........................................................................23.1
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.108]Finaldrivehub,steeringknuckles,andshafts.....................................25.3
[25.122]Axlesuspensioncontrol............................................................25.4
Rearaxlesystem........................................................................27
[27.100]Poweredrearaxle..................................................................27.1
[27.106]Rearbevelgearsetanddifferential................................................27.2
[27.120]Planetaryandnaldrives..........................................................27.3
Brakesandcontrols....................................................................33
[33.110]Parkingbrakeorparkinglock......................................................33.1
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[33.202]Hydraulicservicebrakes...........................................................33.2
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.102]Pumpcontrolvalves................................................................35.2
[35.106]Variabledisplacementpump.......................................................35.3
[35.300]Reservoir,cooler,andlters........................................................35.4
[35.304]Combinationpumpunits...........................................................35.5
[35.352]Hydraulicswingsystem............................................................35.6
[35.353]Hydraulictravelsystem............................................................35.7
[35.354]Hydrauliccentraljoint..............................................................35.8
[35.357]Pilotsystem........................................................................35.9
[35.359]Maincontrolvalve................................................................35.10
[35.360]Hammerandrotatingbuckethydraulicsystem..................................35.11
[35.703]Stabilizerhydraulicsystem.......................................................35.12
[35.730]Positioningarmhydraulicsystem................................................35.13
[35.736]Boomhydraulicsystem..........................................................35.14
[35.737]Dipperhydraulicsystem..........................................................35.15
[35.738]Excavatorandbackhoebuckethydraulicsystem................................35.16
[35.741]Dozerbladecylinders............................................................35.17
Framesandballasting.................................................................39
[39.103]Swingringassembly...............................................................39.1
[39.129]Stabilizers..........................................................................39.2
[39.140]Ballastsandsupports..............................................................39.3
Steering.....................................................................................41
[41.101]Steeringcontrol....................................................................41.1
[41.106]Tierods.............................................................................41.2
[41.200]Hydrauliccontrolcomponents......................................................41.3
[41.216]Cylinders...........................................................................41.4
Wheels......................................................................................44
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[44.511]Frontwheels........................................................................44.1
Cabclimatecontrol.....................................................................50
[50.200]Airconditioning.....................................................................50.1
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.010]Fuelinjectionsystem...............................................................55.2
[55.012]Enginecoolingsystem.............................................................55.3
[55.014]Engineintakeandexhaustsystem.................................................55.4
[55.015]Enginecontrolsystem..............................................................55.5
[55.020]Transmissionspeedsensors.......................................................55.6
[55.031]Parkingbrakeelectricalsystem....................................................55.7
[55.036]Hydraulicsystemcontrol...........................................................55.8
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.9
[55.100]Harnessesandconnectors.......................................................55.10
[55.110]Electricalrotaryjoint..............................................................55.11
[55.302]Battery............................................................................55.12
[55.404]Externallighting..................................................................55.13
[55.425]Boom,dipper,andbucketcontrolsystem........................................55.14
[55.512]Cabcontrols......................................................................55.15
[55.514]Cablighting......................................................................55.16
[55.525]Cabenginecontrols..............................................................55.17
[55.530]Camera...........................................................................55.18
[55.640]Electronicmodules...............................................................55.19
Booms,dippers,andbuckets.......................................................84
[84.100]Bucket..............................................................................84.1
[84.910]Boom...............................................................................84.2
Dozerbladeandarm...................................................................86
[86.110]Dozerblade........................................................................86.1
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Platform,cab,bodywork,anddecals.............................................90
[90.118]Protectionsandfootboards.........................................................90.1
[90.120]Mechanically-adjustedoperatorseat...............................................90.2
[90.150]Cab.................................................................................90.3
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INTRODUCTION
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Contents
INTRODUCTION
Safetyrules.....................................................................................3
NotetotheOwner..............................................................................4
Personalsafety.................................................................................6
Productoverview.............................................................................15
Basicinstructions.............................................................................19
Dimension....................................................................................20
Weight........................................................................................26
Generalspecication.........................................................................27
Capacities.....................................................................................33
Generalspecication.........................................................................35
Consumables.................................................................................40
Productidentication..........................................................................41
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INTRODUCTION
Safetyrules
Carefullyreadthesafetyrulescontainedhereinandfol-
lowadvisedprecautionstoavoidpotentialhazardsandto
safeguardyoursafetyandpersonalintegrity.
Inthismanualyouwillndthefollowingindications:
NOTICE:Withspecicwarningsaboutpotentialdangers
fortheoperator’sorotherpersonsintegritydirectlyorin-
directlyinvolved.
ATTENTION:Thissymbolwarnsaboutthepossibilityof
potentialdamagestothemachinethatcaninvolvethe
operator’ssafety.
Thenoncompliancewiththewarningprecededbythe
abovementionedkey-words(DANGERandWARNING)
cancauseseriousaccidentsorthedeathofthepersons
involved.
Moreover,thismanualcontainssomeinstructions,pre-
cededbythewordsNOTEandCAUTION,withfollowing
meaningsformachineprotection:
NOTE:Itemphasizesandunderlinestotheoperatorthe
correcttechniqueorcorrectproceduretofollow.
ATTENTION:Itwarnstheoperatorofapossiblehazardof
machinedamageincasehedoesnotfollowadetermined
procedure.
Yoursafetyandthatofpeoplearoundyoudependson
you.Itisessentialthatyouunderstandthismanualto
performtheoperationcorrectlyandsafely.
TULI12WEX2001AA1
47500167A31/01/2013
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INTRODUCTION
NotetotheOwner
Thewheeledexcavatorsareoperationhydraulicma-
chines.
Theyessentiallyconsistinawheeledundercarriageon
whichaslewingbearingismounted,whichiscoupledto
theupperframe.
Theupperframesupportsthefrontattachment,theen-
gine,thehydrauliccomponents,thecab,thefueltankand
thecounterweight.
Whentheoperatoractivatesthecontrols(hydrauliccon-
trolleversandpedals),thehydraulicpumpsrotatedbythe
enginesuckoilfromthetankandconveyittothecontrol
valve,thecontrolvalve,inturn,sendsittotherelevant
users.
SMIL12WEX0181AA1
Acoolingsystemkeepsthehydraulicuidatanormal
operatingtemperature.
SMIL12WEX0182AA2
Designateduse
Themachinehasbeenbuiltinaccordancewithstate-of-the-artstandardsandtherecognizedsafetyrules.Thema-
chinemustbeusedinaccordancewithitsdesignateduse,byobservingthesafetyandprecautionaryrulesandby
strictlyfollowingtheoperatinginstructions.Anyfunctionaldisorders,especiallythoseaffectingthesafetyofthema-
chine,shouldthereforeberectiedimmediately.
TheExcavatorisintendedtobeusedindiggingandloadingoperation(withbucketorgraborclamshellbucket),
groundlevelling(withbladewheninstalled)anduseofhydraulichammertobreakconcreteorothersolidmaterial.
Notice
Adifferentuseoftheexcavatororofitsworkingequipment:
•Forliftingortransportingpersons.
•Asaworkingplatform.
•Forliftingloadswithouttheattachmentbeingapprovedforthispurpose.
•Forpullingslungloads.
•Fordrivinginposts,supports,sheet-piles,withouttheattachmentbeingapprovedforthispurpose.
Isconsideredcontrarytothedesignateduse.
Improperusemaycauseinjuryorlife-threateningrisksfortheoperatorandforotherpersons.
Themanufacturer/suppliercannotbeheldresponsibleforanydamageresultingfromotherthanthedesignateduse.
Theriskinvolvedinsuchmisuseliesentirelywiththeuser.
NOTICE:Forclaritypurposes,someguresinthisManualshowthemachinewithprotectionpanelsorcoversre-
moved.Neveroperatethemachinewithanyprotectionpanelsorcoversremoved.
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INTRODUCTION
NOTICE:Itisabsolutelyforbiddentotamperand/orchangethesettingofanyofthehydraulicsystemvalvestoavoid
damagingmachinecomponentswithconsequentriskstopersonalsafety.
Instructionsconcerningsafety,operationandmaintenancehavebeendevelopedtopermitsafeserviceandoperation
ofthismachine.
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INTRODUCTION
Personalsafety
CarefullyreadthisManualbeforeproceedingwithmain-
tenance,repairs,refuellingorothermachineoperations.
Repairshavetobecarriedoutonlybyauthorizedandin-
structedstaff;specicprecautionshavetobetakenwhen
grinding,weldingorwhenusingmalletsorheavyham-
mers.
Notauthorizedpersonsarenotallowedtorepairorcarry
outmaintenanceonthismachine.Donotcarryoutany
workontheequipmentwithoutpriorauthorization.
Askyouremployeraboutthesafetyinstructionsinforce
andsafetyequipment.
Nobodyisallowedtoseatontheoperator’splaceduring
machinemaintenanceunlessheisaqualiedoperator
helpingwiththemaintenancework.
Ifitisnecessarytomovetheequipmenttocarryoutre-
pairsormaintenance,donotliftorlowertheequipment
fromanyotherpositionthantheoperator’sseat.
TULI12WEX2004AA1
Nevercarryoutanyoperationonthemachinewhenthe
engineisrunning,exceptwhenspecicallyindicated.
Stoptheengineandensurethatallpressureisrelieved
fromhydrauliccircuitsbeforeremovingcaps,covers,
valves,etc.
Allrepairandmaintenanceoperationsshouldbecarried
outwiththegreatestcareandattention.
Servicestairsandplatformsusedinaworkshoporinthe
eldshouldbebuiltincompliancewiththesafetyrulesin
force.
Anyfunctionaldisorders,especiallythoseaffectingthe
safetyofthemachine,shouldthereforeberectiedim-
mediately.
DANGER
Unexpectedmovement!
Makesureparkingbrakeisapplied.Secure
machinewithwheelchocks.
Failuretocomplywillresultindeathorserious
injury.D0013A
TULI12WEX2005AA2
Beforeperforminganyworkonthemachine,attacha
maintenanceinprogresstag.Thistagcanbeappliedon
theleft-handcontrollever,safetyleverorcabdoor.
TULI12WEX2006AA3
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INTRODUCTION
Emergency
Bepreparedforemergencies.Alwayskeepatdisposalon
themachinearstaidkitandareextinguisher.Make
surethatthereextinguisherisservicedinaccordance
withthemanufacturer’sinstructions.
SMIL12WEX0174AA4
Equipment
Wearclosettingclothingandsafetyequipmentappropri-
ateforthejob:
•Safetyhelmet
•Safetyshoes
•Heavygloves
•Reectiveclothing
•Wetweatherclothing
Ifenvironmentconditionrequireitfollowingpersonal
safetyequipmentshouldbeathand:
•Respirators(ordustproofmasks)
•Earplugsoracousticearsprotections
•Goggleswithlateralshieldormasksforeyesprotection
Donotwearrings,wristwatches,jewels,unbuttonedor
appingclothingsuchasties,tornclothes,scarves,open
jacketsorshirtswithopenzipswhichcouldgetcaughtinto
movingparts.
TULI12WEX2008AA5
Engine-Radiator
Neverleavetheengineruninclosedspaceswithoutventi-
lationandnotabletoevacuatetoxicexhaustgases.Keep
theexhaustmanifoldandtubefreefromcombustionma-
terials.
Donotrefuelwiththeenginerunning,especiallyifhot,as
thisincreasesrehazardincaseoffuelspillage.
Neverattempttocheckoradjustthebeltswhentheen-
gineisrunning.
Neverlubricatethemachinewiththeenginerunning.
TULI12WEX2009AA6
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INTRODUCTION
Payattentiontorotarypiecesanddonotallowtoanyone
toapproachtoavoidbecomingentangled.
Ifhands,clothesortoolsgetcaughtinthefanbladesorin
thetransmissionbelt,thiscancauseamputations,violent
tearsandgenerateconditionofseriousdanger;forthis
reasonavoidtouchingortocomeclosetoallrotaryor
movingparts.
Aviolentjetofthecoolantfromtheradiatorcancause
damagesandscalds.
Ifyouaretocheckthecoolantlevel,youhavetoshut-off
theenginepreviouslyandtoletcooldowntheradiatorand
itspipes.Slowlyunscrewthecaptoreleasetheinside
pressure.
TULI12WEX2010AA7
Ifnecessary,removethecapwithhotengine,wearsafety
clothesandequipment,thenloosenthecapslowlytore-
lievethepressuregradually.
Whencheckingthefuel,oilandcoolantlevels,useex-
clusivelyexplosionproofclassiedlamps.Ifthiskindof
lampsarenotusedresorexplosionsmayoccur.
TULI12WEX2011AA8
Hydraulicsystems
Splashesofuidsunderpressurecanpenetratetheskin
causingseriousinjuries.
Avoidthishazardbyrelievingpressurebeforedisconnect-
inghydraulicorotherlines.
Relievetheresidualpressurebymovingthehydraulic
controlleversseveraltimes.
Tightenallconnectionsbeforeapplyingpressure.
Toprotecttheeyeswearafacialshieldorsafetygoggles.
Protectyourhandsandbodyfrompossiblesplashesof
uidsunderpressure.
Swallowinghydraulicoilisaseverehealthhazard.
TULI12WEX2012AA9
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INTRODUCTION
Whenhydraulicoilhasbeenswallowed,avoidvomiting,
butconsultadoctororgotoahospital.
Ifanaccidentoccurs,seeadoctorfamiliarwiththistype
ofinjuryimmediately.
Anyuidpenetratingtheskinmustberemovedwithinfew
hourstoavoidseriousinfections.
Flammablesplashesmayoriginatebecauseoftheheat
nearpipeswithuidsunderpressure,withtheresultof
seriousscaldsforthepersonshit.Donotweldoruse
torchesnearpipescontaininguidsorotherammable
materials.
Pipesunderpressurecanaccidentallybepiercedwhen
theheatexpandsbeyondtheareaimmediatelyheated.
Arrangeforreresistanttemporaryshieldstoprotect
hosesorothercomponentsduringwelding.
Haveanyvisibleleakagerepairedimmediately.
Escapingoilpollutestheenvironment.Soakupanyoil
thathasescapedwithaproperbindingagent.Sweep
upbindingagentanddisposeofitseparatelyfromother
waste.
Neversearchforleakageswiththengers,butuseapiece
ofcardboardandalwaysweargoggles.
Neverrepairdamagedpiping;alwaysreplaceit.Replace
hydraulichosesimmediatelyondetectinganydamageor
moistareas.
Alwaysstorehydraulicoilintheoriginalcontainers.
TULI12WEX2013AA10
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INTRODUCTION
Hosesandtubes
Alwaysreplacehosesandtubesiftheconeendorthe
endconnectionsonthehosearedamaged.
Wheninstallinganewhose,looselyconnecteachend
andmakesurethehosetakesupthecorrectpositionbe-
foretighteningtheconnections.Clampsshouldbetight-
enedsufcientlytoholdthehosewithoutcrushingandto
preventchang.
Afterhosereplacementtoamovingcomponent,check
thatthehosedoesnotfoulbymovingthecomponent
throughthecompleterangeoftravel.Besureanyhose
whichhasbeeninstalledisnotkinkedortwisted.
Hoseconnectionswhicharedamaged,dented,crushed
orleaking,restrictoilowandtheproductivityofthecom-
ponentsbeingserved.Connectorswhichshowsignsof
movementfromtheoriginalpositionhavefailedandwill
ultimatelyseparatecompletely.
Ahosewithafrayedoutersheathwillallowthewaterpen-
etration.Concealedcorrosionofthewirereinforcement
willsubsequentlyoccuralongthehoselengthwithresul-
tanthosefailure.
Ballooningofthehoseindicatesaninternalleakagedueto
structuralfailure.Thisconditionrapidlydeterioratesand
totalhosefailuresoonoccurs.
Kinked,crushed,stretchedordeformedhosesgenerally
sufferinternalstructuraldamagewhichcanresultinoil
restriction,areductioninthespeedofoperationandulti-
matehosefailure.
Free-moving,unsupportedhosesmustneverbeallowed
totoucheachotherorrelatedworkingsurfaces.This
causeschangwhichreduceshoselife.
TULI12WEX2014AA11
O-rings
ReplaceO-rings,sealringsandgasketswheneverthey
aredisassembled.
NevermixnewandoldsealsorO-rings,regardlessof
condition.AlwayslubricatenewsealringsandO-rings
withhydraulicoilbeforeinstallationtorelevantseats.
ThiswillpreventtheO-ringsfromrollingoverandtwisting
duringmountingwhichwilljeopardizesealing.
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INTRODUCTION
Battery
Batteriesgiveoffexplosivegases.
Neverhandlenakedamesandunshieldedlightsources
nearbatteries,neversmoke.
Topreventanyriskofexplosion,observethefollowing
instructions:
•Whendisconnectingthebatterycables,alwaysdiscon-
nectthenegative(-)cablerst.
•T oreconnectthebatterycables,alwaysconnectthe
negative(-)cablelast.
•Nevershort-circuitthebatteryterminalswithmetalob-
jects.
•Donotweld,grindorsmokenearabattery.
Batteryelectrolytecausessevereburns.Thebatterycon-
tainssulphuricacid.Avoidanycontactwiththeskin,eyes
orclothing.
TULI12WEX2015AA12
Antidote:
•EXTERNAL:Rinsewellwithwater,removinganysoiled
clothing.
•INTERNAL:Avoidvomiting.Drinkwatertorinseyour
mouth.Consultadoctor.
•EYES:Rinseabundantlywithwaterfor15minandcon-
sultadoctor.
•Whentheelectrolyteofabatteryisfrozen,itcanex-
plodeifyouattempttochargethebatteryorifyoutryto
starttheengineusingaboosterbattery.Alwayskeep
thebatterychargedtopreventtheelectrolytefreezing.
Providegoodventilationwhenchangingabatteryorusing
abatteryinanenclosedspace.Alwaysprotectyoureyes
whenworkingnearabattery.
TULI12WEX2016AA13
Neversettoolsdownonthebattery.Theymayinduce
ashortcircuit,causingirreparabledamagetothebattery
andinjuringpersons.
Neverwearmetalnecklaces,braceletsorwatchstraps
whenworkingonthebattery.Themetalpartsmayinduce
ashortcircuitresultinginburns.
Disposeofusedbatteriesseparatelyfromotherwastein
theinterestsofenvironmentalprotection.
TULI12WEX2017AA14
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INTRODUCTION
Flammableliquids
Whenhandlingammableliquids:
•Donotsmoke.
•Keepawayfromunshieldedlightsourcesandnaked
ames.
Fuelsoftenhavealowashpointandarereadilyignited.
Neverattempttoextinguishburningliquidswithwater.
Use:
•Drypowder
•Withcarbondioxide
•Withfoam
Waterusedforextinguishingpurposeswouldvaporizein-
stantaneouslyoncontactwithburningsubstancesand
spreadburningoil,forexample,overawidearea.Water
generatesshortcircuitsintheelectricalsystem,possibly
producingnewhazards.
TULI12WEX2016AA15
Stayawayfromopenamesduringrellingofhydraulic
oilorfuel.
Fueloroilsplashescancauseslippingandthereforeacci-
dents;cleanimmediatelyandaccuratelytheareaseven-
tuallysmeared.
Alwaystightenthesafetyplugsoffueltankandhydraulic
oiltankrmly.
Neverusefueltocleanthemachinepartseventually
smearedwithoilordust.
Useanon-inammableproductforcleaningparts.
Alwaysperformfueloroilrellinginwellairedandventi-
latedareas.
TULI12WEX2018AA16
Duringrefuellingholdthepistolrmlyandkeepitalways
incontactwiththellerneckuntiltheendoftherefuelling,
toavoidsparklesduetostaticelectricity.
Donotoverllthetankbutleaveaspaceforfuelexpan-
sion.
Neverrefuelwhentheengineisrunning.
Takeallthenecessarysafetymeasureswhenwelding,
grindingorwhenworkingnearanakedame.
TULI12WEX2019AA17
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INTRODUCTION
Tyres
Beforeinatingthetyres,alwayschecktheconditionof
rimsandtheouterconditionoftyrestondoutthepres-
enceofdents,cuts,tearsofreinforcementpliesorother
faults.Beforeinatingatyre,makesurethatthereareno
nearbypersons,thenpositionyourselfattreadside.
Makesurethattheinatingpressureoftyresisthesame
prescribedbymanufacturerandthatthepressureofthe
righttyrecorrespondstothepressureofthelefttyre.
Neverusereconditionedrimsbecausepossiblewelds,
heattreatmentsorbrazingsnotperformedcorrectlycan
weakenthewheelsandcausefollowingdamagesorfail-
ures.Deatethetyresbeforetheirdisassembly.
Beforetakingoutpossiblejammedobjectsfromtherims,
itisnecessarytodeatethetyres.Inatetyresbymeans
ofapistolcompletewithextensionandpressureswitchof
control.
TULI12WEX2020AA18
Cleaning
Cleantheexteriorofallcomponentsbeforecarryingout
anyformofrepair.Dirtanddustcanreducetheefcient
workinglifeofacomponentandleadtocostlyreplace-
ment.
Solventsshouldbecheckedthattheyaresuitableforthe
cleaningofcomponentsandalsothattheydonotriskthe
personalsafetyoftheuser.
Dirtfromoilorgreaseandscatteredtoolsorfaultypieces
aredangerousforpersons,becausetheycangenerate
slippingorfalls.
Forthemachinecleaning,useajetofwarmwateror
steamunderpressureandcommercialdetergents.Never
usefuel,petroleumorsolvents,becausetherstones
leaveanoilylayerthatfavoursthestickingofdust,while
solvents(evenifweak)damagethepaintandfavourthe
formationofrust.
Neverusewaterjetsorsteamonsensors,connectorsor
otherelectriccomponents.
Preventthatthewaterjetpenetratesinsidethecab.
TULI12WEX2021AA19
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