Case CX800 Tier 3 Service Manual

Case CX800 Tier 3 Service Manual

Crawler excavator

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

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  • Page 1 SERVICE MANUAL CRAWLER EXCAVATOR CX800 TIER III 87571787 NA Issued 07-2006...
  • Page 2 SERVICE MANUAL CRAWLER EXCAVATOR CX800 TIER III 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...
  • Page 3 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.
  • Page 4 CX800 Tier 3 Crawler Excavators Table of Contents DIVISION/SECTION SECTION N° REFERENCE N° 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 ENGINE Radiator and engine, removal and installation ..........2001 9-94910NA Engine specifications- Refer to Engine Service Manual ........
  • Page 5 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 UPPERSTRUCTURE Upperstructure, turntable and counterweight...........9002 9-42551NA Boom, dipper and bucket .................9003 9-42621NA Seat and seat belt ....................9004 9-40960NA...
  • Page 6 Section 1001 SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS Copyright © 2006 CNH America LLC. All rights reverved. Printed in U.S.A. Issued February, 2006 Lep 7-27691NA Find manuals at https://best-manuals.com...
  • Page 7 1001-2 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. Lep 7-27691NA Issued 02-06 Find manuals at https://best-manuals.com...
  • Page 8 Parts Catalog for the correct part Bearings number of the genuine Case replacement items. Failures due to the use of other than genuine Case Check bearings for easy action. If bearings have a replacement parts are not covered by warranty.
  • Page 9 Operator’s and Service Manuals may be obtained from WARNING: Read the operator’s manual to your Case dealer. familiarize yourself with the correct control functions. WARNING: If you wear clothing that is too...
  • Page 10 1001-5 WARNING: When servicing or repairing the WARNING: Use insulated gloves or mittens machine, keep the shop floor and operator’s when working with hot parts. compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use WARNING: Lower all attachments to the safe practices at all times.
  • Page 11 1001-6 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the order of tightening. JS00481A Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or suitable cleaning solvent and dried.
  • Page 12 Section 1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS Copyright © 2006 CNH America LLC. All rights reserved. Lep 9-94710NA Printed in USA. June 2006...
  • Page 13: Table Of Contents

    1002-2 TABLE OF CONTENTS WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it. TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE....................3 FLUIDS AND LUBRICANTS .............................
  • Page 14: Type, Serial Number And Year Of Manufacture Of The Machine

    For all part orders, request for information or assistance, always specify the type and the serial number of the machine to your Case dealer. Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the serial numbers of the hydraulic and mechanical components.
  • Page 15: Fluids And Lubricants

    CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) Hot climates: 0×C to +50×C (32° to 122° F) CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP) Cold climates: -25°C to +20°C (-13° to 68° F) CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216.
  • Page 16 This oil ensures proper lubrication of your engine for all operating conditions. If you are unable to procure the CASE No. 1 Multiper- formance or Performance engine oil, use the corre- sponding oil from the API/CG/CF category.
  • Page 17 Using fuels other than those recommended can damage the fuel injection pump, the injector and other parts of the fuel supply system and the engine. CASE disowns any responsibility concerning this kind of damage, which is not covered by the guarantee. To avoid any damage to the engine fuel supply system, you are recommended to take the following safety messages into account: Some fuel suppliers mix used engine oil with diesel fuel.
  • Page 18 Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710) For areas where the temperature goes down to -38°C (-36°4F), mix 50/50 with water. IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the system.
  • Page 19: Specifications

    1002-8 SPECIFICATIONS Main data Model name........................CX800 Hydraulic Excavator Operating weight ........................80800 kg (178133.3 lbs) Engine output ..........................397 kW / 1800 rpm Performance Standard weight..........................43.2 kN (9711 lbf) Swing speed ...............................6.4 Tr/min. Travel speed......................Low Speed 2.9 km/h (1.80 mph) ..........................
  • Page 20 1002-9 Engine Name ..............................ISUZU, 6WG1X Type: 4-cycle, water-cooled, overhead camshaft, common rail injection (electric control), with air-cooling type inter-cooler turbo with air-cooling. No. of cylinders - bore x stroke ..............6-dia. 147 mm x 154 mm (5.78 x 6.06 in) Displacement.............................15.7 L (4.15 gal) Compression ratio ..............................16 Rated output ........................
  • Page 21 1002-10 Operating devices Operator's seat Location; left side Structure; low frequency air suspension with helical springs and double acting hydraulic damper. Smooth and round shape design cab, fabricated by press work Safety glass for all windows, high impact plastic for all other windows. Levers and pedals For travel use;...
  • Page 22 1002-11 Hydraulic system Hydraulic pump drive system, directly coupled to the engine (no transmission) Main pump Manufacturer ............................Kawasaki Pump type ..................double variable displacement piston pump Displacement ...................... 278 cm (16.96 cu in) X 2 /rev Rated operating pressure ....................31.4 MPa (4555 psi) Maximum operating pressure .....................34.3 MPa (4975 psi) Input revolution speed........................1850 min-1 Maximum flow ................
  • Page 23 1002-12 Rotating Joint Operating pressure High pressure passage (ABCD)..................34.4 MPa (4989 psi) Drain port (E) ..........................1.0 MPa (145 psi) Pilot port (F) ..........................3.9 MPa (566 psi) Hydrostatic test pressure High pressure passage (ABCD)..................51.5 MPa (7470 psi) Drain port (E) ........................2.0 MPa (290 psi) Pilot port (F) ..........................
  • Page 24 1002-13 Digging force (New JIS) Bucket digging force (Standard power boost) Standard ........................... 430 kN (96667 lbf) Power boost ..........................470 kN (105660 lbf) Arm (dipper) digging force (Standard boom specifications) Standard 2.98 m arm ........................... 317 kN (71264 lbf) Power boost 2.98 m arm ...........................
  • Page 25 1002-14 Work Unit Model; backhoe attachment Capacity / dimensions / working dimensions Boom length (Standard boom spec.) ....................... 7700 mm Boom length (Mass boom spec.) ......................6580 mm Standard boom Mass boom Standard arm Long arm Super long (3.66 m) (4.44 m) arm (5.62 m) (12 ft 0.09 in)
  • Page 26 1002-15 Reference Values Numerical values for performance may change without notice due to product improvement. Reference Items Conditions values Idling 900 ± 10 Engine speed (RPM) Mode: H Maximum without load 1870 ± 10 31.4 ± 1.0 MPa Standard 4554 ± 145 PSI Main Relief 34.3 ±...
  • Page 27: Component Weight

    1002-16 COMPONENT WEIGHT Major component weight 700-3-01-00-45A Weight information is approximate 1) Overhall machine ......................80300 kg (177031 lbs) 2) Machine without attachment .................... 63300 kg (139552lbs) 3) Upperstructure assembly ....................25200 kg (55556 lbs) 4)Counterweight ........................12500 kg (27560 lbs) 5) Side Frame 900 mm (35.43 in) (47 shoe) ..............
  • Page 28 1002-17 Other component weight Engine ........................Approximately 1214 kg (2676 lbs) Air cleaner ............................40.3 kg (89 lbs) Hydraulic pump........................... 300 kg (661lbs) Attachment control valve ........................430 kg (948 lbs) Swing motor and reduction gear assembly (2) ................487 kg (1074 lbs) Travel motor and reduction gear assembly ..................
  • Page 29: Dimensions And Wear Limit Of The Track Assembly

    1002-18 DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY Sprocket Dimensions 800-6-10-00-11A1 Dimension Mark Standard 4.17 Limit 3.62 Standard 34.48 Ø b Limit Standard 38.58 Ø c Limit Standard 3.89 Ø d Limit Standard 46.7 1.83 Limit 51.7 2.035 Standard 260.35 10.24 Limit...
  • Page 30 1002-19 Idler wheel Dimensions Dimension Mark Standard 32.67 Ø a Limit 32.44 Standard 22.5 0.88 Limit 25.5 1.00 Standard 4.99 Limit 4.92 Standard 4.92 Ø d (shaft) Limit 4.88 Standard 4.92 Ø d (bushing) Limit 4.96 Standard 4.33 e (bushing) Limit 109.5 4.31...
  • Page 31 1002-20 Upper roller Dimensions Dimension Mark Standard 8.58 Ø a Limit 8.11 Standard 0.62 Limit 0.86 Standard 4.96 Limit 4.64 800.6.10.00.11C Gauge Unit in mm [Unit: mm] 800-6-10-03-14C Lep 9-94710NA Issued 06-06...
  • Page 32 1002-21 Lower roller Dimensions 700-6-10-00-10D Dimension Dimension Mark Mark Standard 10.62 Standard 115.4 4.54 Ø a Ø e (bushing) Limit 9.92 Limit 116.4 4.58 Standard 0.98 Standard 4.44 Limit 1.33 Limit 112.5 4.42 Standard 10.7 Standard 1.25 Limit 11.18 Limit 31.5 1.24 Standard...
  • Page 33 1002-22 Track c’ d’ e’ f’ (4 pieces) 800-6-10-00-11E-1 Dimension Dimension Mark Mark Standard 70.5 2.77 Standard 3.46 Ø c’ (bushing) Limit 42.5 1.67 Limit 85.5 3.36 Standard 6.14 Standard 55.65 2.19 Ø d’ (bushing) Limit 5.86 Limit Standard 3.46 Standard 55.65 2.19...
  • Page 34: Dimensions And Wear Limits Of Attachement Mobile Joints

    1002-23 DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS CRIL06C002 1. Boom foot/Frame 700-1-06-02-05JA Dimension Mark Standard 1110 43.70 a (frame) Limit 1118 44.01 Standard 1106 43.54 b (boom) Limit 1103 43.42 Standard 4 to 6.5 0.15 to 0.25 c (clearance) Limit Shim adjustment Standard...
  • Page 35 1002-24 2. Boom cylinder foot/Frame 700-1-06-02-05A Dimension Mark Standard 6.57 a (boom) Limit 6.81 Standard 6.53 b (cylinder) Limit 6.41 Standard 1 to 3.5 0.03 to 0.13 c (clearance) Limit Shim adjustment Standard 5.11 Ø d (shaft) Limit 5.07 Standard 5.11 Ø...
  • Page 36 1002-25 4. Arm cylinder foot/Boom Dimension Mark Standard 6.57 a (boom) Limit 6.81 Standard 6.53 b (cylinder) Limit 6.45 Standard 0.5 to 3 0.019 to 0.11 c (clearance) Limit Shim adjustment Standard 5.11 Ø d (shaft) Limit 5.07 Standard 5.11 Ø...
  • Page 37 1002-26 7. Bucket cylinder foot/Arm Dimension Mark Standard 6.57 a (arm) Limit 6.77 Standard 6.53 b (cylinder) Limit 6.45 Standard 0.5 to 3 0.019 to 0.11 c (clearance) Limit Shim adjustment Standard 5.11 Ø d (shaft) Limit 5.07 Standard 5.11 Ø...
  • Page 38 1002-27 10. Connecting rod/Compensator/Bucket cylinder head Dimension Mark Standard 3.22 Limit 3.14 Standard 19.68 Limit 19.48 Standard 1 to 1.5 0.039 to 0.059 c (clearance) Limit Shim adjustment Standard 6.57 d (link) Limit 6.65 Standard 6.53 e (cylinder) Limit 6.45 Standard 1 to 2 0.039 to 0.078...
  • Page 39: Shims For Adjusting Attachment Gaps

    1002-28 SHIMS FOR ADJUSTING ATTACHMENT GAPS For boom foot O.D I.D 000-6-10-02-02A Part No. I.D. O.D. Shim Material Thickness KNV1132 SPHC KRV2390 SPHC KBV1441 SPHC KBV1748 SPHC KSV1805 SPHC 000-6-10-02-02B Part No. I.D. O.D. Shim Material Thickness KSV1930 Urethone KSV11380 Urethone KSV1931 Urethone...
  • Page 40: Special Torque Settings

    1002-29 SPECIAL TORQUE SETTINGS Component Screw Wrench (mm) Torque setting Travel motor and reduction gear assembly 1307-1526 Nm (964 - 1125 lb-ft) Sprocket 1307-1526 Nm (964 - 1125 lb-ft) Idler wheel Upper roller 521-608 Nm (384-448 lb-ft) Lower roller 1307-1526 Nm (964-1125 lb-ft) Chain guide 1307-1526 Nm (964-1125 lb-ft) Track pad...
  • Page 41 1002-30 12 13 700-2-01-00-15A 700-2-01-01-44AA Lep 9-94710NA Issued 06-06...
  • Page 42 1002-31 12 13 14 3-29-1- Lep 9-94710NA Issued 06-06...
  • Page 43: Machine Overall Dimensions

    1002-32 MACHINE OVERALL DIMENSIONS NOTE: Numeral values may be changed without notice due to desing alterations or other reasons. The values in the diagram include the lug height of shoe (50 mm) () Show the smallest dimension in the transport. (1) Counterweight dimension Standard arm (3.66 m) 800-1-01-01-58A...
  • Page 44 1002-33 Long arm (4.44 m) 800-1-01-01-58B Super long arm (5.62 m) 800-1-01-01-58C Lep 9-94060NA Issued 02-06...
  • Page 45 1002-34 Mass digging arm (298 m) 800-1-01-01-58D Lep 9-94060NA Issued 02-06...
  • Page 46 Section 1003 NUMERICAL VALUE CONVERSION TABLE Copyright  2001 Case France Printed in U.S.A. Case Cre 9-35540 July 2001...
  • Page 47 1003-2 TABLE OF CONTENTS NUMERICAL VALUE CONVERSION TABLE ......................3 Unit conversion rate .............................3 Length .................................. 4 Area ..................................6 Volume .................................7 Mass ..................................9 Pressure ................................10 Torque ................................11 Temperature ...............................13 Cre 9-35540 Issued 07-01...
  • Page 48 1003-3 NUMERICAL VALUE CONVERSION TABLE Unit conversion rate Gravitational SI Unit ÷ 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 0.981 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 0.746 kgf•m 9.807...
  • Page 49 1003-4 Length Millimeters to inches Inches to millimeters 1/64 0.3969 33/64 13.0969 0.0394 1.3780 2.7165 1/32 0.7938 17/32 13.4938 0.0787 1.4173 2.7559 3/64 1.1906 35/64 13.8906 0.1181 1.4567 2.7953 1/16 1.5875 9/16 14.2875 0.1575 1.4961 2.8346 5/64 1.9844 37/64 14.6844 0.1969 1.5354 2.8740...
  • Page 50 1003-5 Feet to meters                                       ...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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