Case CX800B Service Manual
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Case CX800B Service Manual

Crawler excavator
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CX800B
Crawler Excavator
SERVICE MANUAL
Part number 48020292
English
June 2016
© 2016 CNH Industrial Italia S.p.A. All Rights Reserved.

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  • Page 1 CX800B Crawler Excavator SERVICE MANUAL Part number 48020292 English June 2016 © 2016 CNH Industrial Italia S.p.A. All Rights Reserved.
  • Page 2 SERVICE MANUAL CX800B CX800B RTC MASS EXC 48020292 15/06/2016 Find manuals at https://best-manuals.com...
  • Page 3 Contents INTRODUCTION Machine completion and equipment ..........05 [05.200] Product shipment ..............05.1 Engine..................
  • Page 4 [35.106] Variable displacement pump ............35.4 [35.102] Pump control valves.
  • Page 5 [55.015] Engine control system............. . 55.4 [55.201] Engine starting system .
  • Page 6 Platform, cab, bodywork, and decals ..........90 [90.150] Cab ................. 90.1 [90.156] Cab windshield and windows .
  • Page 7 48020292 15/06/2016 Find manuals at https://best-manuals.com...
  • Page 8 INTRODUCTION 48020292 15/06/2016 Find manuals at https://best-manuals.com...

  • Page 9: Table Of Contents

    Contents INTRODUCTION Foreword - Important notice regarding equipment servicing ........3 Safety rules .

  • Page 10: Foreword - Important Notice Regarding Equipment Servicing

    In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

  • Page 11: Safety Rules

    INTRODUCTION Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in- structions.

  • Page 12: Safety Rules - General Information

    Service parts Install CASE CONSTRUCTION genuine service parts. When placing an order, check the parts catalog. It contains the CASE CONSTRUCTION genuine part numbers. Any breakdowns arising from the installation of non-genuine parts are not covered by the warranty. Lubricants (fuel, hydraulic oil) Use the oil from the specified company or specified in the operator's manual or service Manual.

  • Page 13: Safety Rules - Personal Safety

    Check the operating methods in a safe location before starting the actual work. Understand the machine operations well, then operate in compliance with all service-related laws and regulations. The operator's manual can be purchased at your CASE CONSTRUCTION dealer. WARNING: Working with sloppy clothes or clothes with which safety cannot be ensured leads to damage to the machine and injury to the operator.
  • Page 14 INTRODUCTION WARNING: Check that there is no one in the surroundings before draining the pressure from hydraulic circuits during machine hydraulic cylinder inspection. WARNING: Use gloves when handling high-temperature parts. WARNING: Bring the lower parts or attachments in contact with the ground before inspecting or repairing them. WARNING: Check that hoses and tubes are securely connected.

  • Page 15: Safety Rules - Cab Protective Structure

    INTRODUCTION Safety rules - Cab protective structure Cab protective structure Modifying the cab main components is prohibited in order to protect the operator. Prohibited items • Modifications that reduce the strength of a platform that has a cab with a protective structure mounted on it. (Actions or modifications that reduce the functionality of the anchoring part at the left-rear of the cab) •...

  • Page 16: Safety Rules - Ecology And The Environment

    Improper disposal of batteries can contaminate the soil, groundwater, and waterways. CASE CONSTRUCTION strongly recommends that you return all used batteries to a CASE CONSTRUCTION dealer, who will dispose of the used batteries or recycle the used batteries properly.

  • Page 17: Torque - Bolt And Nut

    INTRODUCTION Torque - Bolt and nut • Tighten alternating between left and right and top and bottom so that uniform tightening force is applied. LPIL12CX00005EA • If L ® was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the OCTITE old L ®...

  • Page 18: Torque - Special Torque Setting

    INTRODUCTION Torque - Special torque setting Nominal bolt Retightening location Tightening torque Code Wrench diameter 1350 - 1580 N·m (996 - 1165 lb ft) Travel motor 41 mm Drive sprocket 1307 - 1526 N·m (964 - 1126 lb ft) 41 mm Take-up roller 24 mm 1307 - 1526 N·m (964 - 1126 lb ft)
  • Page 19 INTRODUCTION 66B91CE4 48020292 15/06/2016...
  • Page 20 INTRODUCTION 79A11AE7 48020292 15/06/2016...

  • Page 21: Basic Instructions - Shop And Assembly

    Only use CNH Original Parts or CASE CONSTRUCTION Original Parts. Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same parts that are assembled during standard production. Only CNH Original Parts or CASE CONSTRUCTION Original Parts can offer this guarantee.
  • Page 22 W0111A Special tools The special tools that CASE CONSTRUCTION suggests and illustrate in this manual have been specifically re- searched and designed for use with CASE CONSTRUCTION machines. The special tools are essential for reliable repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting oper- ation.

  • Page 23: Hydraulic Contamination

    INTRODUCTION Hydraulic contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways: • When you drain the oil or disconnect any line •...

  • Page 24: General Specification

    INTRODUCTION General specification Bucket capacity Bucket capacity 4.5 m3/ISO heaped. Engine Water-cooled, 4-cycle diesel, 6-cylinder in line, high pressure common rail system (electric control), Type turbocharger with air cooled intercooler, without cooling fan Model ISUZU GH-6WG1KYSS-01 (without fan-pump) 377.0 kW (512.58 Hp) at 1800 RPM Rated flywheel horse power (ISO 14396) (with fan-pump)
  • Page 25 INTRODUCTION Planetary gear reduction Final drive Turn table bearing Ball bearing type with internal gear Maximum swing speed 6.4 RPM Swing torque 266500 N·m (196560 lb ft) Cylinders NO. of cylinders – bore X Rod diameter X Stroke Boom 2 x Ø 200 mm (7.874 in) - Ø 140 mm (5.512 in) - 1893 mm (74.528 in) 1 x Ø...
  • Page 26 INTRODUCTION Operator environment Operator's cab Smooth and round shape design cab, fabricated by press work Safety glass for all windows Shock-less cab suspension by 4-point fluid mounting Sliding front window with auto lock Built-in type full-color LCD monitor display Membrane switch on monitor display Windshield wiper &...
  • Page 27 INTRODUCTION With auto power up 340 kN (76435 lb) Bucket digging force 414 kN (93071 lb) With auto power up 452 kN (101614 lb) Dimensions 2.98 m (9.7769 ft) Arm Overall length (without attachment) 7460 mm (293.701 in) Overall length (with attachment) 13230 mm (520.866 in) Overall height (with attachment) 5030 mm (198.031 in)

  • Page 28: General Specification - Main Equipment

    INTRODUCTION General specification - Main equipment Lower component Travel unit Manufacturer KYB Corporation Motor type Variable displacement piston motor Automatic 2-speed switchover with parking brake Intake amount 337.2 - 228.6 cm³/rev (20.58 - 13.95 in³/rev) Operating pressure 34.3 MPa (4975 psi) Operating flow 500 l/min (500.0000 US gpm) Brake torque...
  • Page 29 INTRODUCTION Upper component Swing unit Swing motor assembly Swing motor Manufacturer Kawasaki Precision Machinery Ltd. Motor type Fixed displacement piston motor With parking brake Intake amount 210.1 cm³/rev (12.82 in³/rev) Operating pressure 26.5 MPa (3844 psi) Operating flow 257 l/min (257.0000 US gpm) Mechanical brake torque 1161 - 1504 N·m (856.310 - 1109.293 lb ft) min.
  • Page 30 INTRODUCTION Radiator Manufacturer T.RAD CO.,LTD. Weight 215 kg (473.994 lb) Oil cooler Oil volume 48 L (12.680 US gal) Weight 29.5 kg (65.036 lb) Radiator Coolant capacity 9.9 L (2.615 US gal) Weight 35.5 kg (78.264 lb) Air cooler Capacity 32.5 L (8.586 US gal) Weight 6 kg (13.228 lb)
  • Page 31 INTRODUCTION Maximum operating speed 1870 RPM Minimum operating speed 900 RPM Shaft input horsepower 27.5 kW (37.4 Hp) Shaft input torque 140.7 N·m (103.775 lb ft) Use temperature range –30 - 100 °C (–86.0 - 212.0 °F) Hydraulic oil used ISO viscosity grade VG46-equivalent hydraulic oil Dry weight 6.1 kg (13.4482 lb)
  • Page 32 INTRODUCTION Straight travel circuit Boom-up/arm 2 pumps internal flow Boom and arm load holding circuit Boom-down regenerative circuit Arm-in forced regenerative circuit Function Boom-up priority (bucket speed regulations) Boom-up priority (swing speed regulations) Swing priority (arm speed regulations) Bucket 2 pumps internal flow Option 2 pumps internal flow Weight 430 kg (947.988 lb)
  • Page 33 INTRODUCTION A. Secondary pressure [MPa (psi)] B. Push rod stroke [mm (in)] C. Operating angle [deg.] Secondary pressure Independent operating torque SMIL15CEXY884AB Travel remote control valve control diagram A. Secondary pressure [MPa (psi)] B. Push rod stroke [mm (in)] C. Pedal operating angle [deg.] Secondary pressure Operating torque SMIL15CEXY885AB...
  • Page 34 INTRODUCTION Boom cylinder Weight 715 kg (1576.305 lb) Arm cylinder Cylinder bore ∅ 215 mm (8.465 in) Rod diameter ∅ 150 mm (5.906 in) Maximum retracted 3195 mm (125.787 in) 3080 mm (121.260 in) (large soil amount) length Stroke 2290 mm (90.157 in) 2175 mm (85.630 in) (large soil amount) Weight 1055 kg (2325.877 lb)

  • Page 35: Weight

    INTRODUCTION Weight Divided weight ( LC Standard undercarriage) 603243F6 Weight Code Part name Operating weight 83200 kg (183424.602 lb) Upper component (including counterweight and 25300 kg (55776.952 lb) turntable bearing) Counterweight 12500 kg (27557.783 lb) Lower component (with grouser shoe) 12400 kg (27337.321 lb) Main unit weight 64300 kg (141757.235 lb)
  • Page 36 INTRODUCTION Stand alone part weight Weight Part name Travel unit (travel motor + drive sprocket) 1160 kg (2557.362 lb) Take-up roller 690 kg (1521.190 lb) Upper roller 74.5 kg (164.244 lb) 190 kg (418.878 lb) Lower roller Swing unit (including pinion) 490 kg (1080.265 lb) Turntable bearing 1200 kg (2645.547 lb)

  • Page 37: Dimension

    INTRODUCTION Dimension Standard arm [ 3.66 m (12.01 ft) ] NOTE: The values used in this document are subject to change without notice due to a design change or other rea- sons. NOTE: The values indicated in the diagram include the shoe lug height (a) [ 50 mm (1.969 in) ]. NOTE: The dimension within the brackets indicates the maximum retracted length during transport.
  • Page 38 INTRODUCTION Short arm [ 2.98 m (9.78 ft) ] NOTE: The values used in this document are subject to change without notice due to a design change or other rea- sons. NOTE: The values indicated in the diagram include the shoe lug height (a) [ 50 mm (1.969 in) ]. NOTE: The dimension within the brackets indicates the maximum retracted length during transport.
  • Page 39 INTRODUCTION Long arm [ 4.44 m (14.57 ft) ] NOTE: The values used in this document are subject to change without notice due to a design change or other rea- sons. NOTE: The values indicated in the diagram include the shoe lug height (a) [ 50 mm (1.969 in) ]. NOTE: The dimension within the brackets indicates the maximum retracted length during transport.
  • Page 40 INTRODUCTION Ultra-long Arm [ 5.62 m (18.44 ft) ] NOTE: The values used in this document are subject to change without notice due to a design change or other rea- sons. NOTE: The values indicated in the diagram include the shoe lug height (a) [ 50 mm (1.969 in) ]. NOTE: The dimension within the brackets indicates the maximum retracted length during transport.

  • Page 41: Conversion Factors

    INTRODUCTION Conversion factors Unit conversion rate - x → Gravitational unit SI unit ← ÷ - 9.807 4.448 kgf•cm 0.0981 N•m lbf•ft 1.356 N•m lbf•in 0.113 N•m kgf/cm 0.0981 0.1013 lbf/in 0.0069 mm Hg 133.3 in Hg 3386 kgf・m/s 0.00981 lbf•ft/s 0.00136 0.7355...
  • Page 42 INTRODUCTION Inches to millimeters 1/64 0.3969 17/64 6.7469 33/64 13.0969 49/64 19.4469 1/32 0.7938 9/32 7.1438 17/32 13.4938 25/32 19.8438 3/64 1.1906 19/64 7.5406 35/64 13.8906 51/64 20.2406 1/16 1.5875 5/16 7.9375 9/16 14.2875 13/16 20.6375 5/64 1.9844 21/64 8.3344 37/64 14.6844 53/64...
  • Page 43 INTRODUCTION Miles to kilometers miles miles 　 　 　 　 　 　 ---- 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 ---- 16.093 17.703 19.312 20.921 22.531 24.140 25.750 27.359 28.968 30.578 32.187 33.796 35.406 37.015 38.624 40.234 41.843 43.452 45.062 46.671...
  • Page 44 INTRODUCTION Square centimeters to square inches 　 　 　 　 　 　 ---- 　 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 ---- 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340...
  • Page 45 INTRODUCTION Gallons (U.S) to liters U.S- U.S- .gal. .gal. 　 　 　 　 　 　 liters liters liters liters liters liters liters liters liters liters ---- 3.7853 7.5707 11.3560 15.1413 18.9266 22.7120 26.4973 30.2826 34.0680 ---- 37.8533 41.6386 45.4239 49.2093 52.9946 56.7799 60.5653 64.3506 68.1359 71.9213 10 102.203 105.989 109.774...
  • Page 46 INTRODUCTION Gallons (Imp.) to liters Imp- p.g- .gal. 　 　 　 　 　 　 liters liters liters liters liters liters liters liters liters liters ---- 　 4.5455 9.0909 13.6364 18.1818 22.7273 27.2727 31.8182 36.3636 40.9091 ---- 45.4545 50.0000 54.5455 59.0909 63.6364 68.1818 72.7273 77.2727 81.8182 86.3636 10 100.000 104.545 109.090...
  • Page 47 INTRODUCTION Kilograms to pounds 　 　 　 　 　 　 lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. ---- 2.205 4.409 6.614 8.819 11.023 13.228 15.432 17.637 19.842 ---- 22.046 24.251 26.456 28.660 30.865 33.069 35.274 37.479 39.683 41.888 44.093 46.297...
  • Page 48 INTRODUCTION Pressure Weight pounds/square inch to weight kilograms/square centimeter lbf/in lbf/in (psi) kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm (psi) ---- 　 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5624 0.6327 ---- 0.7030 0.7733 0.8436 0.9139 0.9842 1.0545 1.1248 1.1951...
  • Page 49 INTRODUCTION Kilopascals to weight kilograms/square centimeter 　 　 　 　 　 　 kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm ---- 　 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 ---- 1000 10.197 11.217 12.237 13.256 14.276 15.296 16.315 17.335...
  • Page 50 INTRODUCTION Weight kilogram meters to Newton meters kgf·m kgf·m 　 　 　 　 　 　 N·m N·m N·m N·m N·m N·m N·m N·m N·m N·m ---- 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 ---- 98.07 107.87 117.68 127.49 137.29 147.10 156.91...
  • Page 51 INTRODUCTION Temperature Fahrenheit to centigrade °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C -51.1 -18.9 13.3 45.6 77.8 142.2 174.4 -17.8 14.4 46.7 78.9 111.1 143.3 175.6 -48.9 -16.7 15.6 47.8 80.0 112.2 144.4 176.7...
  • Page 52 INTRODUCTION Centigrade to fahrenheit °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F -58.0 -0.4 57.2 114.8 172.4 230.0 287.6 345.2 -56.2 59.0 116.6 174.2 231.8 289.4 347.0 -54.4 60.8 118.4 176.0 233.6 291.2 348.8 -52.6...

  • Page 53: Consumables

    ( MS 1230. ISO VG-46. DIN 51524 PART 2 2 HV) Transmission component oil Extreme pressure oil used for enclosed transmission components CASE AKCELA GEAR 135 H EP 80W-90 ( SAE 80W - 90. API GL-5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
  • Page 54 CASE AKCELA NO. 1™ ENGINE OIL (recommended) This oil can be supplied to the engine appropriately for all operating conditions. If you cannot obtain CASE AKCELA NO. 1™ ENGINE OIL, use the oil in the following category: API CJ-4 Fuel WARNING Fuel vapors are explosive and flammable.
  • Page 55 Note that if biodiesel fuel is used that does not meet the above standards, it may cause serious damage to the engine of this machine and to its fuel system. If fuel that is not permitted is used, the CASE CONSTRUCTION warranty may be invalidated.
  • Page 56 If biodiesel fuel is spilled, it must be cleaned up immediately before it causes damages to the environment and finish coating of the machine. Before using a biodiesel fuel blend, ask your local CASE CONSTRUCTION dealer for infor- mation about blends approved for this machine and about detailed usage conditions.
  • Page 57 INTRODUCTION • Local environmental agency will, in many cases, be able to help you as well. 48020292 15/06/2016...

  • Page 58: Abbreviation

    INTRODUCTION Abbreviation Abbreviation Explanation Air-conditioner Analog/digital ABDC After bottom dead center Alternating current Accessories Alternating current generator Actuator American Petroleum Institute Assembly ATDC After top dead center Automatic transmission fluid Drilled hole B Notch hole bolt Eye B Eyebolt Full threaded B Full threaded bolt Hexagon socket head B Hexagon socket head bolt...
  • Page 59 INTRODUCTION Abbreviation Explanation Fuel temperature Forward Generator Ground HBCV Hose burst check valve Hydrocarbons HO2S Heated O2 sensor Time High reach demolition machine Idle air control Suction air temperature Integrated circuit Nameplate, ID plate ID Plate Intake manifold temperature Suction air Injection International Organization for Standardization Intake shutter position...
  • Page 60 INTRODUCTION Abbreviation Explanation Right hand Read-only memory Rail pressure Rear Rearward + Flush head S + Flush head Screw + Phillips pan head S + Phillips pan head Screw + Screw tapping S + Screw tapping Screw Subassembly Society of Automotive Engineers Slow blow fuse Suction control valve Signal...

  • Page 61: Product Identification

    This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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