PDF Schematic Manual Case CX800 Crawler Excavator - 1 MB
This is the complete schematic set for the Case CX800 Tier 3 Crawler Excavator.
The manual provides detailed electrical and hydraulic diagrams essential for advanced troubleshooting and repair.
Technicians can use these schematics to trace circuits and understand the complex interactions between systems.
This resource is invaluable for diagnosing and resolving intricate issues efficiently.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
SCHEMATIC SET
CRAWLER EXCAVATOR
CX800 TIER 3
87539044 NA
Issued 06-2006
--- Page 3 ---
1001-5
WARNING: Use insulated gloves or mittens WARNING: When servicing or repairing the
! when working with hot parts. machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
! grease, tools, etc. Use an oil absorbing
WARNING: Lower all attachments to the material and/or shop cloths as required. Use
ground or use stands to safely support the safe practices at all times.
! attachments before you do any maintenance
or service.
WARNING: Some components of this
machine are very heavy. Use suitable lifting
WARNING: Pin sized and smaller streams ! equipment or additional help as instructed in
of hydraulic oil under pressure can penetrate this Service Manual.
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
WARNING: Engine exhaust fumes can
immediately. Maintain all hoses and tubes in
! good condition. Make sure all connections
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
! fumes from the area with an exhaust pipe
extension. Open the doors and get outside
damaged. DO NOT use your hand to check
air into the area.
for leaks, use a piece of cardboard or wood.
WARNING: When the battery electrolyte is
WARNING: When removing hardened pins frozen, the battery can explode if (1), you try
such as a pivot pin, or a hardened shaft, use to charge the battery, or (2), you try to jump
start and run the engine. To prevent the
! a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
! battery electrolyte from freezing, try to keep
steel head hammer. the battery at full charge. If you do not follow
these instructions, you or others in the area
can be injured.
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
! grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
WARNING: Use suitable floor (service)
jacks or chain hoist to raise wheels or tracks
! off the floor. Always block machine in place
with suitable safety stands.
Lep 7-27691NA Issued 02-06
--- Page 4 ---
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 ...................................................................................................................... 345 ± 7.0 kW / 1850 min-1
Maximum torque.............................................................................................. 2250 N•m (1659.51 lb-ft) / 1500 min-1
Engine dimensions (LxWxH) ............................................................. 1462x1017x1422 mm (57.55 x40.03x55.98 in)
Oil pan ............................................................................................................................... All direction 35°, inclinable
Oil pan capacity ........................................ Maximum: 52 L (13.73 gal) Minimum: 37 L (9.77 gal) (excluding oil filter)
Direction of rotation ............................................................................... Right (viewed from fan side); compliant with
Starter, reduction type ................................................................................................................................24 V, 7 kW
Alternator, AC type ..................................................................................................................................... 24 V, 50 A
Battery .................................................................................................................................. 2x 12V/24V,140 Ah/5 Hr
Cooling system
Fan drive system ..................................................................................................................................hydraulic drive
Fan type..................................................................... diameter 1016 mm (40 in), suction type-6blades, resin & steel
Radiator capacity...........................................................................................................................................205.7kW
Fin type ...........................................................................................................................................................wavy
Fin space.......................................................................................................................................2.0 mm (0.07 in)
Oil cooler capacity ........................................................................................................................................174.4 kW
Fin type ........................................................................................................................................................... plate
Fin space.......................................................................................................................................3.0 mm (0.11 in)
Inter-cooler capacity .......................................................................................................................................63.3 kW
Fin type ....................................................................................................................................... triangular straight
Fin space.......................................................................................................................................2.0 mm (0.07 in)
Fuel cooler capacity........................................................................................................................................3.58 kW
Fin type ...........................................................................................................................................................wavy
Fin space.......................................................................................................................................2.0 mm (0.07 in)
Coolant capacity .............................................................................................................36 L (9.51 gal) (engine only)
Capacity of coolant and lubricants
Coolant .............................................................................................................................................108 L (28.53 gal)
Fuel.................................................................................................................................................900 L (237.75 gal)
Lubricant for engine ............................................................................................................................52 L (13.73 gal)
Lubricant for travel reduction gear (per side) .....................................................................................13.8 L (3.64 gal)
Lubricant for swing reduction gear (per side) ......................................................................................4.7 L (1.24 gal)
Hydraulic oil ....................................................................................................................................720 L (190.20 gal)
Capacity of hydraulic oil tank ............................................................................................................310 L (81.89 gal)
Hydraulic oil filter
Suction filter (inside tank) ............................................................................................................................ 150 mesh
Return filter (inside tank) ..................................................................................................................................10 µ m
Nephron filter (inside housing)............................................................................................................................1 µ m
Pilot line filter (inside housing)..........................................................................................................................10 µ m
Lep 9-94710NA Issued 06-06
--- Page 5 ---
1002-19
Idler wheel
Dimensions
Dimension
Mark
b mm in
Standard 830 32.67
c Øa
Limit 824 32.44
Standard 22.5 0.88
b
Limit 25.5 1.00
Standard 127 4.99
c
Limit 125 4.92
Standard 125 4.92
Ø d (shaft)
Limit 124 4.88
Standard 125 4.92
a Ø d (bushing)
e f Limit 126 4.96
Standard 110 4.33
d e (bushing)
Limit 109.5 4.31
Standard 21.6 0.85
f
Limit - -
700-6-10-00-10B
Gauge
Unit in mm
[Unit: mm]
800-6-10-03-14B
Lep 9-94710NA Issued 06-06
--- Page 6 ---
1002-29
SPECIAL TORQUE SETTINGS
No. Component Screw Wrench (mm) Torque setting
1* Travel motor and reduction gear assembly M27 41 1307-1526 Nm (964 - 1125 lb-ft)
2* Sprocket M27 41 1307-1526 Nm (964 - 1125 lb-ft)
3* Idler wheel
4* Upper roller M20 30 521-608 Nm (384-448 lb-ft)
5* Lower roller M27 41 1307-1526 Nm (964-1125 lb-ft)
6* Chain guide M30 46 1307-1526 Nm (964-1125 lb-ft)
7 Track pad M27 30 1588-1869 Nm (1171-1378 lf-ft)
8 Counterweight M42 65 2256-2550 Nm (1664-1880 lb-ft)
9* Turntable (frame) M30 46 1800-2100 Nm (1328-1549 lb-ft)
10* Turntable (upperstructure) M30 46 1800-2100 Nm (1328-1549 lb-ft)
11 * Swing motor and reduction gear assembly M24 36 900-1050 Nm (664-775 lb-ft)
12 * Engine M24 36 902-1049 Nm (665-774 lb-ft)
13 * Engine bracket M14 22 173-202 Nm (128-149 lb-ft)
14 Radiator M20 30 520-608 Nm (384-448 lb-ft)
15 * Hydraulic pump M12 19 109-127 Nm (80-94 lb-ft)
16 * Hydraulic reservoir M20 30 471-258 Nm (347-419 lb-ft)
17 * Fuel reservoir M20 30 471-258 Nm (347-419 lb-ft)
18 * Control valve M20 30 343-392 Nm (253-289 lb-ft)
M12 19 109-127 Nm (80-94 lb-ft)
19 * Hydraulic swivel
M16 24 267-312 Nm (197-230 lb-ft)
20 Cab M16 24 78-80 Nm (58-59 lb-ft)
21 Battery M10 17 20-29 Nm (15-21 lb-ft)
22 Frame M36 55 2550-2942 Nm (1880-2170 lb-ft)
23 Frame M30 46 1781-2078 Nm (1314-1533 lb-ft)
24 Air cleaner
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).
Lep 9-94710NA Issued 06-06
--- Page 7 ---
1003-5
Feet to meters
IW IW
P P P P P P P P P P
Meters to feet
P P
IW IW IW IW IW IW IW IW IW IW
Miles to kilometers
PLOHV PLOHV
NP NP NP NP NP NP NP NP NP NP
Cre 9-35540 Issued 07-01
--- Page 8 ---
4001
Section
4001
ELECTRICAL AND ELECTRONIC
CIRCUIT AND TROUBLESHOOTING
Copyright © 2006 CNH America LLC.
All rights reserved.
CNH Lep 9-94700NA Printed in USA.
June 2006
--- Page 9 ---
4001-11
B47. Boost pressure sensor B50. Camshaft position sensor (or G sen-
sor)
700.1.04.01.23AM
B51. Boost temperature sensor
700.1.04.01.23AK
B48. Atmospheric pressure sensor
700.1.04.01.23AH
R5. Fuel level sensor
700.1.04.01.23AJ
1 Power, positive (+)
2 Power, negative (-)
3 Output
B49. Crankshaft position sensor 700.1.04.01.23AO
S62. Vacuum sensor
Operating negative pressure: 6.27 ± 0.29kPa.
700.1.04.01.23AN
700.1.04.01.23AL
Lep 9-94700NA Issued 06-06
--- Page 10 ---
4001-21
B) Load pre-fetch control
1) Purpose
Pump current is controlled as measures against black smoke.
2) Circuit configuration
Y7
B26
1
A2
B27
A1
700.1.04.01.23AU
1 Engine B26 Upper pilot pressure switch (yellow band)
A1 Computer/Controller B27 Travel pilot pressure switch
A2 Engine controller Y7 Main pump proportional solenoid
3) Operation
1. When no operation is carried out (attachment and
travel pressure switches OFF), the pump current
is always 0 mA regardless of operation mode and
engine speed.
2. When attachment or travel pressure switch is
turned ON, the controller provides pump current
so that it can get to the set current for the work
mode being selected after 0.8 second.
* No control for decreasing transient load has been
employed for machines above current model of
CX330.
Control for decreasing transient load is illustrated
below:
Since engine response (or returning property) has
been improved (or no difference between target
speed and actual speed), if an abrupt engagement
of the lever from inching operation is carried out, and
when difference between target speed and actual
speed reaches within 150 min-1, pump current of 0
mA is to be applied to ease the engine load.
This is for the purpose of taking measures against
black smoke and of prevention from engine stop.
Lep 9-94700NA Issued 06-06
--- Page 11 ---
4001-31
AUTO WARM UP
1) Circuit configuration
S16 B26 R3
H1
A2 1
P4 A1
700.1.04.01.23BB
1 Engine H1 Audible warning device
A1 Computer/Controller P4 Monitor display
A2 Engine controller R3 Throttle volume
B26 Upper pilot pressure switch (yellow band) S16 One touch idle
2) Operation
1. A coolant temperature sensor is installed inside 5. Once auto warm-up control is cancelled, the control-
the engine. The signal from this sensor goes out ler does not initiate auto warm-up control again
to the engine controller and is converted into a unless key switch is turned from OFF to ON.
temperature value. The engine controller then 6. While controller is executing the auto warm-up con-
transmits the coolant temperature data to the con- trol, an “AUTO WARM UP” message is displayed on
troller via CAN communication. the monitor's LCD.
2. If the coolant temperature is below 50°C (122°F)
after engine starts, the controller transmits the auto
warm-up signal to the engine controller via CAN
communication.
3. The engine controller executes the auto warm-up
control upon receiving the signal transmission from
the controller.
4. The controller terminates the auto warm-up con-
trol on the following conditions. The engine con-
troller terminates the auto warm-up control once
the command is cancelled.
*When one of the following switches turns on: attach-
ment pressure switch, travel pressure switch, and
knob switch (one-touch idle switch).
*When throttle volume is changed.
*When engine speed stays above 1800 min-1 for 3
minutes.
Lep 9-94700NA Issued 06-06
--- Page 12 ---
4001-41
2) Timing diagram
KEY SWITCH
POWER
SWING LOCK
SWITCH
OUT
(IN1)
SWING
PRESSURE
SWITCH (IN3)
SWING LOCK
LED
700-1-04-01-23 BT2
3) Swing brake auto control
1) Overview
The auto control of the swing brake takes place when the swing lock is OFF.
The auto control also releases the mechanical brake automatically during a digging operation as well as during
swing operation. If the operation is halted, the auto control turns on the mechanical brake automatically.
The detailed conditioning for ON/OFF of the swing mechanical brake is shown below.
• The swing brake will be turned OFF based on the following conditions.
1. Pressure switch (swing) is ON
2. P1>15 MPa (2175 psi) or P2>15 MPa (2175 psi)
• The swing brake will be turned ON based on the following conditions.
1. Pressure switch (attachment) stays OFF for 5 seconds
2. Key switch is OFF
• The swing mechanical brake will be deactivated once when the pump delivery pressure (P1 or P2) grows over
15 MPa (2175 psi) during travel. However, it will take effect in 5 seconds.
Lep 9-94700NA Issued 06-06
--- Page 13 ---
4001-51
4. Reversing fan control
Flowing direction of air is reversed by reversing fan revolution so that trifling dust clogged in the radiator core is
possible to be removed.
Since heat radiation capacity declines while the fan rotation is being reversed by which overheat of the engine
becomes possible, do not operate any control lever.
Change over of mode
1) Outline
1) Turning ON fan reversing switch (momentary) after the key switch has been turned ON allows the fan to
change rotation from normal mode to reverse mode.
During this period, the buzzer gives warning sound of 2Hz from the monitor to inform that the fan is rotated
in reverse mode. When the reversing switch is turned ON again, it changes rotation from reverse to normal
and the buzzer stops sounding.
2) For reverse mode, previous data are to be reset.
This means that turning OFF the key switch in either of mode, reverse or normal, allows it to be operated in
normal mode when the key switch is turned ON next time.
3) When warning message «OVER HEAT» is displayed on the monitor, it will not be operated in reverse mode.
The fan reversing switch functions and the mode can be switched over after overheated condition is released
and warning message «OVER HEAT» is disappeared from the monitor.
4) When the message «ELEC PROBLEM» is displayed on the monitor due to functioning of «power transistor
protection», it will not be operated in reverse mode as stated above.
2) Time chart
ON
KEY SWITCH
OFF
FAN REVERSING ON ON ON ON ON
SWITCH OFF
MODE Normal Reverse Normal Reverse Normal Normal Reverse
700-1-04-01-23CG
Lep 9-94700NA Issued 06-06
--- Page 14 ---
4001-61
ACCESS AND CONTENTS OF MONITOR DISPLAYS (Diagnostic mode)
Access to monitor displays
Normal A Service support (a)
display display (b) B
H
Status B Diagnostic B Usage B
Machine Reset
I display trouble history
information D E
B
C
B
CHK7 CHK1 DIAG1 HR 12 HR 1 RST1
C C C C
F
CHK5 CHK2 DIAG2 D HR 11 HR 2 RST2
G C C C C J
CHK6 CHK3 DIAG3 D HR 10 HR 3 RST11
C C C C C
CHK4 DIAG4 HR 9 HR 4 RST12
C C C C C
CHK5 DIAG5 D HR 8 HR 5 RST13
C C C C C
DIAG6 D HR 7 HR 6 RST14
C C C
RST15
C
RST16
C
800.1.04.04.08A
a) Bar graph (Hydraulique oil temperature, coolant temperature, fuel level)
b) Mode (Travel, work, auto, idle)
Operating Switches