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Case CRAWLER DOZER 650L TIER3 Service Manual
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Case CRAWLER DOZER 650L TIER3 Service Manual

Case CRAWLER DOZER 650L TIER3 Service Manual

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SERVICE MANUAL
CRAWLER DOZER 650L TIER3
84276960
Replaces 84260831
Issued October 2009

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Summary of Contents for Case CRAWLER DOZER 650L TIER3

  • Page 1 SERVICE MANUAL CRAWLER DOZER 650L TIER3 84276960 Replaces 84260831 Issued October 2009...
  • Page 2 Contents INTRODUCTION DISTRIBUTION SYSTEMS............. A PRIMARY HYDRAULIC POWER SYSTEM ..........A.10.A SECONDARY HYDRAULIC POWER SYSTEM.
  • Page 3 TILTING ................. . G.20.A SWINGING .
  • Page 4 84260831 21/08/2009 Find manuals at https://best-manuals.com...
  • Page 5 INTRODUCTION 84260831 21/08/2009 Find manuals at https://best-manuals.com...

  • Page 6: Table Of Contents

    Contents INTRODUCTION Basic instructions ................3 Torque .

  • Page 7: Basic Instructions

    INTRODUCTION Basic instructions Technical Information This manual has been produced by a new technical information system. This new system is designed to deliver technical information electronically through CDROM and in paper manuals. A coding system called ICE has been developed to link the technical information to other Product Support functions e.g. Warranty. Technical information is written to support the maintenance and service of the functions or systems on a customers machine.
  • Page 8 INTRODUCTION Sections Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by a letter A, B, C etc. The amount of Sections included in the manual will depend on the type and function of the machine that the manual is written for.
  • Page 9 INTRODUCTION INDEX The Chapter Index lists in alphabetical order all the types of information (called Information Units) that have been written in that Chapter for that function or system on the machine. Index POWER PRODUCTION - B ENGINE ENGINE - Dynamic description (B.10.A - C.30.A.10) ENGINE - General specification (B.10.A - D.40.A.10) ENGINE - Remove (B.10.A - F.10.A.10) ENGINE - Troubleshooting (B.10.A - G.40.A.10)
  • Page 10 INTRODUCTION Page Header and Footer The page header will contain the following references: Section and Chapter description • The page footer will contain the following references: Publication number for that Manual, Section or Chapter. • Version reference for that publication. •...

  • Page 11: Torque

    INTRODUCTION Torque Ripper Torque Component Ripper mounting bolts 700 - 1260 Nm (515 - 925 lb ft) Ripper pin retaining and tube cover bolts 145 - 260 Nm (110 - 190 lb ft) Hydraulic Pump Torque Component Non PTO pump Cover bolts 66 - 80 Nm (50 - 60 lb ft) PTO type pump...
  • Page 12 INTRODUCTION Component Torque Motor mount bolts to final drives 122 - 135.6 Nm ( 90 - 100 lb ft) Pump to motor hoses spit flange clamps 90 - 100 Nm ( 66 - 74 lb ft). Inlet hose clamps 6.5 - 7.6 Nm ( 58 - 68 lb in). Rear Frame Cover Component Torque...
  • Page 13 INTRODUCTION Air Conditioning Compressor Component Torque Compressor rotor shaft nut 15 - 20 Nm ( 11 - 15 lb ft) Oil filler plug 15 - 24 Nm ( 11 - 18 lb ft) Dust cover screws 7 - 11 Nm ( 5 - 8 lb ft) Lift Cylinder Component Torque...

  • Page 14: General Specification

    INTRODUCTION General specification BOLT TORQUE INFORMATION DECIMAL HARDWARE 1. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. 2. Make sure the fasteners threads are clean and that thread engagement is started. This will prevent them from failing when being tightened.
  • Page 15 INTRODUCTION GRADE 2 * GRADE 5, 5.1 or 5.2 GRADE 8 or 8.2 GRADE L9 (Alloy) Dry ** Lubricated Dry** Lubricated Dry** Lubricated Head SIZE Nm lb/ft lb/ft lb/ft lb/ft lb/ft lb/ft lb/ft lb/ft 1234 910 1051 775 1383 1020 1031 760 1220 900 1-1/8 1071 790...
  • Page 16 INTRODUCTION GRADE 8.8 Bolts, Nuts and Studs GRADE 10.9 Bolts, Nuts and Studs SIZE lb/in lb/ft lb/in lb/ft 1375 to 1545 1010 to 1140 1900 to 2140 1400 to 1580 2400 to 2700 1770 to 1990 3315 to 3730 2445 to 2750 Use the above torques when specifications are not given.
  • Page 17 INTRODUCTION O-Ring Face Seal End Nom. SAE Tube OD Thread Size Newton lb/in lb/ft metres Dash Size 6.4 mm 1/4 inch 9/16 - 18 23 to 26 204 to 228 9.5 mm 3/8 inch 11/16 - 16 34 to 40 300 to 348 12.7 mm 1/2 inch...

  • Page 18: Conversion Factors

    INTRODUCTION Conversion factors Metric to U.S. MULTIPLY TO OBTAIN AREA: square meter 10.763 91 square foot hectare 2.471 05 acre FORCE: newton 3.596 942 ounce force newton 2.224 809 pound force LENGTH: millimeter 0.039 370 inch meter 3.280 840 foot kilometer 0.621 371 mile...
  • Page 19 INTRODUCTION U.S. to Metric MULTIPLY TO OBTAIN VOLUME: cubic inch 16.387 06 cubic centimeter cubic foot 0.028 317 cubic meter cubic yard 0.764.555 cubic meter ounce (US fluid) 29.573 53 milliliter quart (US liquid) 0.946 353 litre quart (Imperial) 1.136 523 litre gallon (US) 3.785 412...

  • Page 20: 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. (A) When you drain the oil or disconnect any line. (B) When you disassemble a component.

  • Page 21: Consumables Loctite® Product Chart

    INTRODUCTION Consumables Loctite® Product Chart Bonding Adhesives Prod- Color Strength Fixture/Full Recom- Description Cure (Steel/ mended Steel) Time Primer or Activator Clear 9.8 - 17.2 MPa 2 min/24 hrs Typical applications include bonding dissimilar (1421 - 2495 materials such as metals, glass or ceramics and psi) where fast fixturing is required between close fitting parts.
  • Page 22 INTRODUCTION Surface Preparation Product Color Active (Steel/Steel) Description Time 7380 Yellow 6 hours Is designed to initiate the cure of Loctite toughened acrylic to light adhesives. amber 7471 Yellow 30 to 70 seconds Is used where increased cure speed of LOCTITE® anaerobic to light products is required.
  • Page 23 INTRODUCTION Retain, Cylindrical Assemblies Prod- Color Strength Fixture/Full Recom- Description Cure (Steel/ mended Steel) Time Primer or Activator 13.5 - 25.0 MPa 7471 or Green 4 min/6 hrs Is designed for the bonding of cylindrical fitting (1958 - 3626 7469 parts, particularly where bond gaps can approach psi) 0.25 mm (0.01 in.) and where maximum strength...
  • Page 24 INTRODUCTION RTV Sealants Product Color Strength Fixture/Full Description Cure (Steel/ Steel) Time Clear 1.5 MPa (218 psi) 5 min/24 hrs Is designed for superior bonding and sealing properties to most surfaces (not recommended for concrete). This product resists aging, weathering and thermal cycling without hardening, shrinking or cracking.
  • Page 25 INTRODUCTION Gasket Sealants Prod- Color Strength Fixture/Full Recom- Description Cure (Steel/ mended Steel) Time Primer or Activator none White 0.113 - 0.330 72 hrs Is a medium strength anaerobic sealant with Nm (1 - 3 lb in) Teflon® for tapered pipe threads. The high lubricating properties of this compound prevent galling on pipe threads and fittings.
  • Page 26 INTRODUCTION Thread Locker and Sealing Prod- Color Strength Fixture/Full Recom- Description Cure (Steel/ mended Steel) Time Primer or Activator 7471 or Green 10 - 40 Nm (90 20 min/4 hrs Is designed for the locking and sealing of threaded - 355 lb in) 7469 fasteners.

  • Page 27: Capacities

    INTRODUCTION Capacities 650L Component Capacity Type of lubricant Fuel tank refill 154.4 l (40.8 US gal) Diesel fuel Cooling system 21.4 l (22.6 US qt) 50/50 mixture antifreeze and water Transmission and hydraulic 72.7 l (19.2 US gal) MAT3508 system refill Engine with filter 12.3 l (13 US qt) MAT3520...
  • Page 28 INTRODUCTION 84260831 21/08/2009...
  • Page 29 SERVICE MANUAL DISTRIBUTION SYSTEMS 650L 84260831 21/08/2009...
  • Page 30 Contents DISTRIBUTION SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM ..........A.10.A 650L SECONDARY HYDRAULIC POWER SYSTEM.
  • Page 31 DISTRIBUTION SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A 650L 84260831 21/08/2009 A.10.A / 1...
  • Page 32 Contents DISTRIBUTION SYSTEMS - A PRIMARY HYDRAULIC POWER SYSTEM - 10.A TECHNICAL DATA PRIMARY HYDRAULIC POWER SYSTEM Special tools ................4 General specification .
  • Page 33 Install ..................36 Hydraulic pump Disassemble without PTO .
  • Page 34 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM PRIMARY HYDRAULIC POWER SYSTEM - Special tools RCPH09CWL005AAD CAS1804 Hydraulic pressure fitting kit RCPH09CWL006AAD CAS1808 Flowmeter fitting kit RCPH09CWL004AAD CAS10090 Hand pump 84260831 21/08/2009 A.10.A / 4...
  • Page 35 RCPH09CWL339AAD CAS10280 Flowmeter PRIMARY HYDRAULIC POWER SYSTEM - General specification Type of oil CASE AKCELA AW68 HYD FLUID MAT 3508 Temperature of hydraulic oil when testing 52 - 79 °C (125 - 175 °F) Neutral system pressure 12 - 15 bar (180 - 220 psi) at 2000 RPM...
  • Page 36 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Stack valve - Torque Special torques Bolts and nuts that fasten the sections 39 - 47 Nm 28.7 - 34.6 lb ft together Relief valves and load check valves 24 - 30 Nm 17.7 - 22 lb ft Allen head screws 12 - 15 Nm...
  • Page 37 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Hydraulic pump - General specification Rotation Clockwise as seen from end of shaft Hydraulic pump output 72 l at 207 bar at 2000 RPM 19 US gpm at 3000 psi at 2000 RPM 84260831 21/08/2009 A.10.A / 7...
  • Page 38 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Relief valve - Exploded view BS99M034 (1) Cap (5) O-ring (9) Backup ring (2) Lock nut (6) Spring (10) Poppet (3) Spacer (7) Plunger (11) Housing (4) Adjusting screw (8) Body 84260831 21/08/2009 A.10.A / 8...
  • Page 39 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Relief valve - Sectional view BS00A057 (1) Inlet port passage (4) Pilot passage poppet (2) Return port passage (5) Jam nut (3) Main relief poppet (6) Pressure adjusting screw 84260831 21/08/2009 A.10.A / 9...
  • Page 40 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Stack valve - Exploded view BC02J007 (1) Main relief valve (5) Dozer angle section (2) Inlet secton (6) Ripper/auxiliary section (3) Dozer lift section (7) Outlet section (4) Dozer tilt section 84260831 21/08/2009 A.10.A / 10...
  • Page 41 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM PRIMARY HYDRAULIC POWER SYSTEM - Cleaning 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.
  • Page 42 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components. Exam- ples of visible contamination: (A) Particles of metal or dirt in the oil. (B) Air in the oil.
  • Page 43 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM PRIMARY HYDRAULIC POWER SYSTEM - Decontaminating CAS10162A CAS10508 CAS10192 Prepare the portable filter CAS10162A by doing the following steps: (A) Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter. (B) Remove the filter element from the portable filter.
  • Page 44 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Continue to run the portable filter. Increase the en- gine speed to full throttle. Heat the oil to operating temperature by doing the following steps: (A) Hold the blade control lever in the TILT position for five seconds.
  • Page 45 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Completely retract the cylinders of all attachments on the machine. Angle the blade to the right, the right cylinder will be fully retracted and the left will be fully extended. Stop the engine. WARNING If retracting the cylinder rods causes the attachment to be raised, block the attachment in place before pro-...
  • Page 46 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Support any attachments that will be in the RAISED position. Stop the engine. Disconnect the drain lines and connect the system lines to the cylinders. Check the oil level in the hydraulic reservoir. Add oil as required.
  • Page 47 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Relief valve - Pressure setting Remove the cover from the main relief valve and loosen the lock nut on the adjusting screw. Turn the adjusting screw into the main relief valve to increase the pressure or out of the main relief valve to decrease the pressure.
  • Page 48 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Relief valve - Disassemble Prior operation: Stack valve Inlet section - Disassemble (A.10.A) Fasten the main relief valve in a vise with soft jaws. Remove the cap. RCPH09CWL193AAD Hold the adjusting screw in position while you loosen the lock nut.
  • Page 49 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Remove the plunger. RCPH09CWL190AAD Remove the body from the housing. Remove the spring. RCPH09CWL189AAD Replace the O-ring and the backup ring in the hous- ing. RCPH09CWL188AAD Tap the main relief valve lightly against a solid sur- face so that the poppet can be removed from the housing.
  • Page 50 DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM Replace the O-ring on the body. RCPH09CWL117AAD Replace the O-ring on the adjusting screw. RCPH09CWL116AAD Replace the O-ring and the backup ring on the pop- pet. RCPH09CWL083AAD Next operation: Relief valve - Visual inspection (A.10.A) 84260831 21/08/2009 A.10.A / 20...
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