Case CX210, CX230, CX240 excavator pdf service manual
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Case CX210, CX230, CX240 excavator pdf service manual

CASE-9-93610-SM
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Format: PDF

Pages: 648

File size: 70.59 MB

Language: English

Models: CX210, CX230, CX240

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Table of Contents for CASE-9-93610-SM-EN manual

  • CX210 CX230 CX240 Crawler Excavators Table of Contents
  • SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS
    • TABLE OF CONTENTS
    • GENERAL INFORMATION Cleanning
    • Gears
    • Oil seals, O-rings and gaskets
    • Shafts
    • Inspection
    • Service parts
    • Bearings
    • Lubrication
    • Needle bearings
    • SAFETY
    • STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts
    • Torque table
  • GENERAL SPECIFICATIONS AND SPECIAL TORQUE SETTINGS
    • TABLE OF CONTENTS
    • TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE
    • Machine
    • Engine
    • Component serial numbers
    • FLUIDS AND LUBRICANTS
    • Grease
    • Hydraulic fluid
    • Transmission component oil
    • Engine oil
    • Oil viscosity/Oil range
    • Environment
    • Fuel
    • Components made from plastic or resin
    • Anti-freeze/Anti-corrosion
    • SPECIFICATIONS Engine
    • Capacities
    • Electrical system
    • Hydraulic system
    • Cylinder
    • Control valve
    • Swing
    • Travel
    • Undercarriage
    • Attachment
    • Weight of components
    • DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE TRACKS SET Toothed wheel
    • Idler wheel
    • Upper roller
    • Lower roller
    • Track
    • DIMENSIONS AND LIMIT OF WEAR AND TEAR OF THE MOBILE JOINTS OF THE ATTACHMENT
    • 1. Boom foot/Undercarriage
    • 2. Boom cylinder foot/Undercarriage
    • 3. Boom cylinder head/Boom
    • 4. Dipper cylinder foot/Boom
    • 5. Boom/Dipper
    • 6. Dipper cylinder head/Dipper
    • 7. Bucket cylinder foot/Dipper
    • 8. Connecting rod/Dipper
    • 9. Compensator/Bucket
    • 10. Connecting rod/Compensator/Bucket cylinder head
    • 11. Dipper/Bucket
    • SPECIAL TORQUE SETTINGS
    • MACHINE OVERALL DIMENSIONS
  • REMOVAL AND INSTALLATION OF THE ENGINE
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • ENGINE Removal and installation
  • RADIATOR AND OIL-COOLER
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • RADIATOR AND OIL-COOLER
    • Removing the oil-cooler
    • Installing the oil-cooler
    • Removing the radiator
    • Installing the radiator
    • CHANGING THE RADIATOR OR THE OIL-COOLER Disassembly and assembly
  • REMOVAL AND INSTALLATION OF THE FUEL RESERVOIR
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • FUEL RESERVOIR Removal
    • Installation
    • Description
  • ELECTRICAL AND ELECTRONIC CIRCUIT AND TROUBLESHOOTING
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TOOLS
    • LOCATION OF COMPONENTS General location of the components (outside the cab)
    • General location of the components (outside the cab)
    • Relay and main fuses (battery compartment)
    • General location of the components (inside the cab)
    • Fuse box
    • Instrument panel
    • OPERATING PRINCIPLES Engine checks
    • Work mode selection
    • H/S/L mode checking
    • Auto mode checking
    • Acceleration checking
    • Engine idle checking (automatic/manual)
    • Breaker mode checking
    • Automatic engine preheat
    • Auto engine warm-up
    • Idle checking using the battery voltage and the coolant temperature
    • Engine emergency stop
    • Back-up mode
    • Function locking
    • Power boost
    • Swing brake
    • Travel mode
    • Supply cut-off delayed
    • Protection by power transistor
    • Coolant temperature indicator
    • Hydraulic oil temperature indicator
    • Fuel level
    • Engine fuel injection pump electronic regulator
    • ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode) Access to monitor displays
    • Machine condition
    • Diagnostic code
    • Machine history
    • Re-initialisation
    • WARNING MESSAGES Message display
    • EXCAVATOR MODEL SELECTION PROCEDURE
    • Changing the language code
    • CHANGING THE ACCESS CODE FOR THE ANTI-THEFT SYSTEM
    • TROUBLESHOOTING Prior inspections
    • Reading the organisation charts
    • Procedures
    • Low fuel
    • Add coolant solution
    • Low engine oil pressure
    • Overheating
    • Defective battery charge circuit
    • Electrical system troubleshooting
    • Travel
    • ELECTRICAL INSPECTION OF COMPONENTS Inspection equipment
    • Proportional solenoid
    • 6 solenoid valve block
    • Engine emergency stop motor
    • Engine rpm sensor
    • Engine coolant and hydraulic oil temperature sensor
    • Pressure sensor
  • INSPECTION AND MAINTENANCE OF BATTERIES AND CONNECTING A BOOSTER BATTERY
    • TABLE OF CONTENTS
    • SAFETY INSTRUCTIONS SPECIFICATIONS
    • MAINTENANCE Electrolyte level
    • Inspecting and cleaning the battery
    • INSPECTING THE BATTERY
    • Visual checks
    • Checking the specific gravity
    • Charge test
    • CHARGING THE BATTERY
    • BATTERY CHARGING GUIDE
    • PREPARING A DRY CHARGED BATTERY FOR USE
    • CONNECTING A BOOSTER BATTERY
  • MAIN ELECTRONIC CONTROL BOX ENGINE ELECTRONIC CONTROL BOX
    • TABLE OF CONTENTS
    • MAIN ELECTRONIC CONTROL BOX AND ENGINE ELECTRONIC CONTROL BOX Removal
    • Main electronic control box
    • Engine electronic control box
    • Installation
  • REMOVAL AND INSTALLATION OF THE TRACKS SET
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • SPECIAL TOOLS
    • TRACKS SET Description
    • Removal
    • Installation
    • Track tension adjustment
    • Checking pin and bushing wear
  • UPPER AND LOWER ROLLERS
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • SPECIAL TOOLS
    • LOWER ROLLER Description
    • Removal
    • Reconditioning
    • Disassembly
    • Assembly
    • Inspection
    • Installation
    • UPPER ROLLER Description
    • Removal
    • Reconditioning
    • Disassembly
    • Inspection
    • Assembly
    • Installation
    • CHECKING FOR LEAKS
  • SPROCKET
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • SPROCKET Removal
    • Installation
  • IDLER WHEEL AND TENSION SHOCK ABSORBER
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • SPECIAL TOOLS
    • REMOVAL AND INSTALLATION OF THE IDLER WHEEL AND THE TENSION SHOCK ABSORBER Removal
    • Installation
    • DISASSEMBLY AND ASSEMBLY OF THE IDLER WHEEL Description
    • Reconditioning
    • Disassembly
    • Inspection
    • Assembly
    • Leakage test
    • DISASSEMBLY AND ASSEMBLY OF THE TENSION SHOCK ABSORBER Description
    • Assembly
    • Disassembly
    • TRACK TENSION CYLINDER (CX130, CX160, CX230 AND CX240) Description
    • Removal
    • Disassembly
    • Assembly
    • Inspection
    • Installation
    • TRACK TENSION CYLINDER (CX180/CX210) Description
    • Removal
    • Disassembly
    • Inspection
    • Assembly
    • Installation
  • DRIVE MOTOR AND FINAL DRIVE TRANSMISSION REMOVAL AND INSTALLATION
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUES
    • DRIVE MOTOR AND FINAL DRIVE TRANSMISSION Removal and installation
    • NOTES
  • DISASSEMBLY AND ASSEMBLY OF THE TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • INTERCHANGEABLE PRODUCTS
    • TRAVEL MOTOR/REDUCTION GEAR ASSEMBLY
    • HYDRAULIC MOTOR
  • REMOVAL AND INSTALLATION OF THE SWING REDUCTION GEAR
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • TOOLS REQUIRED
    • SWING REDUCTION GEAR Removal
    • Installation
  • SWING REDUCTION GEAR CX210 CX230
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • SWING REDUCTION GEAR Description
    • Disassembly
    • Assembly
  • SWING REDUCTION GEAR CX240
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • SWING REDUCTION GEAR Description
    • Disassembly
    • Assembly
  • DEPRESSURISING AND DECONTAMINATING THE HYDRAULIC SYSTEM, USE OF THE VACUUM PUMP AND BLEEDING THE COMPONENTS
    • TABLE OF CONTENTS
    • SPECIAL TOOLS
    • RELEASING PRESSURE IN THE HYDRAULIC SYSTEM
    • BLEEDING AIR FROM THE MAIN HYDRAULIC SYSTEM COMPONENTS
    • Attachment cylinders
    • Hydraulic pump
    • Hydraulic swing motor
    • VACUUM PUMP Installation
    • Removal
    • CLEANING THE HYDRAULIC SYSTEM General
    • Types of contamination
    • Decontamination of the hydraulic system
  • SPECIFICATIONS, TROUBLESHOOTING, CHECKS AND HYDRAULIC PRESSURE SETTINGS
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TOOLS Tester
    • IDENTIFICATION OF HYDRAULIC COMPONENTS Pump CX130/CX160 (Uchida)
    • Pump CX130/CX160/CX180/CX210/CX230/CX240 (Kawasaki)
    • Control valve CX130/CX160/CX180
    • Control valve CX210/CX230/CX240
    • 6 solenoid valve manifold
    • PREPARATION BEFORE INSPECTION Releasing pressure in the hydraulic system
    • Installing the flowmeter
    • Installing the pilot pressure test point
    • Display on diagnostic screen "CHK1"
    • Warming up the engine
    • Warming up the hydraulic fluid
    • CHECKING AND PRESSURE SETTING PROCEDURE
    • Checking the pilot accumulator
    • Pilot system secondary relief valve (H)
    • Main relief valve (A)
    • Secondary control valve attachment relief valves (B, C, D, E, F and G)
    • Secondary relief valves of the boom safety valves (B1 and B2)
    • Dipper secondary relief valve (D1)
    • Swing secondary relief valves (I, J)
    • Checking the swing braking pressure
    • Travel secondary relief valve (K, L)
    • Checking the pressure delivered by the proportional valve
    • Checking for leaks on the travel motor
    • By-pass travel checking
    • Checking the swing motor for leaks
    • TROUBLESHOOTING Travel drift
    • Not possible to select 2nd travel speed
    • No swing or slow swing
    • With the excavator on a slope, the swing brake does not hold
    • No movement on any function
    • Lack of power or speed on one of the attachment movements
    • Not possible to select hard/soft shock absorbing system The boom or the dipper does not lower
  • REMOVAL AND INSTALLATION OF THE HYDRAULIC RESERVOIR
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • HYDRAULIC RESERVOIR Removal
    • Installation
    • Description
  • REMOVAL AND INSTALLATION OF THE MAIN HYDRAULIC PUMP AND THE PILOT PUMP
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • MAIN HYDRAULIC PUMP Removal and installation
    • PILOT PUMP Removal and installation
    • HYDRAULIC PUMP COUPLING Description
    • Removal and installation
  • REMOVAL AND INSTALLATION OF THE MAIN HYDRAULIC CONTROL VALVE
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • MAIN HYDRAULIC CONTROL VALVE Removal and installation
  • REMOVAL AND INSTALLATION OF THE ATTACHMENT CYLINDERS
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • PREPARATION BEFORE REMOVAL/INSTALLATION
    • BOOM CYLINDER Description
    • Removal
    • Installation
    • DIPPER CYLINDER Description
    • Removal
    • Installation
    • BUCKET CYLINDER Description
    • Removal
    • Installation
  • REMOVAL AND INSTALLATION OF THE HYDRAULIC SWIVEL
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • HYDRAULIC SWIVEL Removal and installation
  • REMOVAL AND INSTALLATION OF THE PILOT FUNCTION BLOCKS
    • TABLE OF CONTENTS
    • SPECIAL TORQUE SETTINGS
    • PILOT FUNCTION BLOCKS Travel pedal block
    • LH control lever
    • RH control lever
    • Swing shuttle block
    • Cushion control valve
    • Servo control and return manifold block
    • 6 solenoid valve block
  • REMOVAL AND INSTALLATION OF THE SWING MOTOR CX210 CX230
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • SWING MOTOR Removal and installation
  • MAIN HYDRAULIC PUMP
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • WEAR INSPECTION
    • IDENTIFYING THE COMPONENTS
    • Description
    • DISASSEMBLY
    • ASSEMBLY
  • REMOVAL AND INSTALLATION OF THE CONTROL VALVE
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • TOOLS REQUIRED
    • SPECIAL TORQUE SETTINGS
    • CONTROL VALVE Description
    • Identifying the ports
    • Disassembly
    • General instructions
    • Separating the sections
    • Load holding block
    • Precautions before assembly
    • Assembly
    • Cleaning
    • Inspection
  • DISASSEMBLY AND ASSEMBLY OF THE ATTACHMENT CYLINDERS
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • SPECIAL TOOLS
    • CYLINDERS Boom cylinder description
    • Dipper cylinder description
    • Bucket cylinder description
    • Disassembly
    • Inspection
    • Assembly
  • DISASSEMBLY AND ASSEMBLY OF THE CONTROL LEVERS
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • CONTROL LEVER Description
    • Disassembly
    • Inspection
    • Assembly
  • DISASSEMBLY AND ASSEMBLY OF THE CONTROL PEDALS
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • TORQUE SETTING
    • SPECIAL TOOLS
    • CONTROL PEDAL
  • DISASSEMBLY AND ASSEMBLY OF THE SIX SOLENOID VALVES BLOCK
    • TABLE OF CONTENTS
    • SIX SOLENOID VALVES BLOCK Identifying the ports and the solenoid valves
    • Section
    • Disassembly and assembly
    • Inspection
  • DISASSEMBLY AND ASSEMBLY OF THE CUSHION CONTROL VALVE
    • TABLE OF CONTENTS
    • CUSHION CONTROL VALVE Description
    • Disassembly
    • Assembly
    • Inspection
  • HOSE BURST CHECK VALVE
    • TABLE OF CONTENTS
    • TORQUE SETTINGS
    • BOOM RELIEF VALVE Marking the ports
    • Installation
    • Removal
    • Disassembly
    • Assembly
    • ARM RELIEF VALVE Marking the ports
    • Installation
    • Removal
    • Disassembly
    • Assembly
  • DISASSEMBLY AND ASSEMBLY OF THE HYDRAULIC SWIVEL
    • TABLE OF CONTENTS
    • SPECIAL TORQUE SETTINGS
    • HYDRAULIC SWIVEL
  • DISASSEMBLY AND ASSEMBLY OF THE HYDRAULIC SWING MOTOR
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • TORQUE SETTINGS
    • HYDRAULIC SWING MOTOR Description
    • Disassembly
    • Inspection
    • Assembly
    • RELIEF VALVE Disassembly
    • Inspection
    • Assembly
  • DISASSEMBLY AND ASSEMBLY OF THE SWING HYDRAULIC MOTOR
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • TOOL TO BE MANUFACTURED
    • HYDRAULIC SWING MOTOR Description
    • Disassembly
    • Inspection
    • Wear limit
    • Assembly
  • HYDRAULIC FUNCTIONS
    • TABLE OF CONTENTS
    • HYDRAULIC FUNCTIONS Function List
    • Controls in Neutral
    • High Speed Travel Circuit
    • Low Speed Travel Circuit
    • Straight Line Travel Circuit
    • Swing Circuit
    • Variable Priority Valve Circuit
    • Boom Raising Circuit
    • Boom Lowering Circuit, Load Holding Valve
    • Boom Lowering Reinjection Circuit
    • Boom Lowering Anti-vibration Circuit
    • Dipper Extending Circuit
    • Dipper Retracting Circuit
    • Dipper Retracting Reinjection Circuit
    • Bucket Opening Circuit
    • Bucket Closing Circuit
    • Crusher Circuit
    • Breaker Circuit
    • NOTES
  • QUICK COUPLER
    • TABLE OF CONTENTS
    • IDENTIFICATION OF COMPONENTS Description
    • QUICK COUPLER Removal
    • Inspection
    • Hook and cylinder removal
  • UPPERSTRUCTURE, TURNTABLE AND COUNTERWEIGHT
    • TABLE OF CONTENTS
    • SPECIAL TORQUE SETTINGS
    • SPECIFICATIONS
    • UPPERSTRUCTURE Inspection
    • Removal
    • Installation
    • COUNTERWEIGHT Description
    • Removal
    • Installation
  • BOOM, DIPPER AND BUCKET
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • BUCKET Description
    • Removal
    • Installation
    • Shimming the bucket
    • DIPPER Description
    • Removal
    • Installation
    • BOOM Description
    • Removal
    • Installation
  • SEAT AND SAFETY BELT
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • OPERATOR'S SEAT Description
    • Removal
    • Installation
    • SAFETY BELT Removal
    • Installation
  • CAB AND CAB EQUIPMENT
    • TABLE OF CONTENTS
    • SPECIFICATIONS
    • SPECIAL TORQUE SETTINGS
    • CAB Removal
    • Installation
    • HEATING BLOCK/AIR-CONDITIONING BLOCK Description
    • Removal
    • Installation
    • WINDSHIELD WIPER MOTOR Description
    • Removal
    • Installation
  • AIR CONDITIONER TROUBLESHOOTING AND SYSTEM CHECKS
    • TABLE OF CONTENTS
    • SAFETY PROCEDURES
    • SPECIAL TOOLS
    • OPERATION
    • REFRIGERANT SCHEMATIC
    • ELECTRICAL SCHEMATIC
    • PRE-STUDIES The Blow is not cool
    • The speed of blower motor is not changeable
    • Magnetic Clutch does not work
    • Blow air is not changeable in fresh or recycle
    • A/C Mode is not changeable
    • TROUBLESHOOTING
    • The Blow is not COOL
    • TROUBLESHOOTING The Blow is not HOT
    • TROUBLESHOOTING Blower Motor does not work
    • TROUBLESHOOTING The speed of blower motor is not changeable
    • Magnet Clutch does not work
    • TROUBLESHOOTING
    • Blow air is not changeable in fresh or recycle
    • A/C mode is not changeable
    • Troubleshooting for coolant circuit
Language
English
Document type
Service manual
Machinery type
excavator
CASE-9-93610-SM-EN-preview.pdf - 4.43MB

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