PDF Service Manual Case CX300C Crawler Excavator - 10 MB
This is the official service repair manual for the Case CX300C Tier 4 Crawler Excavator.
It provides technicians with the detailed information needed to perform diagnostics, repairs, and maintenance.
The manual includes step-by-step procedures, specifications, and schematics.
Ensure your CX300C excavator is serviced to the highest standards with this comprehensive guide.
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SERVICE MANUAL
Lep 84420825B EN
CX300C Tier 4
Crawler Excavator
Issue date June 2011
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84420825B - June 2011 Copyright © 2011 CNH FRANCE S.A.
1002A-2 PRINTED IN FRANCE
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Main Equipment Table (CX300C)
Control-related
Control Valve
(STD) (with 2nd option add-on valve)
Manufacturer KYB Corporation
Maximum flow 243 L/min (at 1800 min-1)
Overload set pressure 29.4 MPa boom down
39.2 MPa boom up, arm, bucket
Main relief set pressure 34.3 MPa
(at boost-
37.3 MPa
ing)
Foot relief set pressure 2.55 MPa
Function Straight travel circuit
Boom-up/arm 2 pumps internal flow
Boom and arm load holding circuit
Boom-down regenerative circuit
Bucket-close regenerative circuit
Arm-in forced regenerative circuit
Swing priority variable orifice
2 pumps flow (external flow merging)
Weight 200 kg 208 kg
Solenoid Valve (5 stack)
Manufacturer Yuken Kogyo Co., Ltd.
Valve specifications
Maximum flow P → B 25 L/min Other 5 L/min
Rated pressure 4.5 MPa
Port size G3/8 P.T.B. port
G1/4 C1, C2, C3, C4, C5 ports
Solenoid specifications
Operating voltage DC 20 - 32 V
Power consumption 17 W max.
Weight 6.7 kg
84420825B - June 2011
1002B-8
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Maintenance Standards
Lower Roller
* See the gauge list for measurement gauges.
Cod- Measurement di- Standard Usage limit
Part name Judgment Solution
e mension (mm) value (mm) (mm)
a Acceptable/
D D180 D168
Unacceptable
Cladding by weld-
Acceptable/
Track roller b 20 16 ing or replace-
Unacceptable
ment
Acceptable/
d 203 211
Unacceptable
e Acceptable/
Shaft D D75 D74 Replacement
Unacceptable
e Acceptable/
D D75 D76
Unacceptable
Bushing Replacement
Acceptable/
f D82 D81
Unacceptable
g Acceptable/
Collar 17.7 17.2 Replacement
Unacceptable
84420825B - June 2011
1002D-6
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84420825B - June 2011 Copyright © 2011 CNH FRANCE S.A.
1003-2 PRINTED IN FRANCE
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List of special tools
Lower Roller Special Tool
CX300C
84420825B - June 2011
1003-22
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84420825B - June 2011 Copyright © 2011 CNH FRANCE S.A.
1004-2 PRINTED IN FRANCE
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84420825B - June 2011 Copyright © 2011 CNH FRANCE S.A.
2000-2 PRINTED IN FRANCE
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Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
15. Use a wrench (13 mm) to remove the 3 bolts (1), 18. Install the 2 shackles (1) to the top of the radiator,
and then remove the brackets (2). and then use the wire rope (2) and liftcrane to lift the
radiator.
16. Use a box wrench (12 mm) to remove the 5 bolts
(2) from the fan shroud (1), and then move the fan
shroud (1) towards the engine.
19. Lift until the fixtures (1) at the bottom of the radiator
17. Remove the 2 butterfly bolts (1), and then remove become disconnected.
the front anti-insect net (2).
84420825B - June 2011
2001-10
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Removal and Installation of EGR Cooler and EGR Valve
9) Remove the EGR pipe A from the exhaust EGR valve Installation
manifold.
1. EGR valve Installation
1) Install the EGR valve to the inlet pipe.
Tightening torque： 46 N・m ｛4.7 kgf・m /
33.9 lb・ft｝
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
4. EGR valve Removal 1 EGR valve
1) Disengage the harness connector from the
2) Connect the harness connector to the EGR
EGR valve.
valve.
2) Remove the EGR valve from the inlet pipe.
2. EGR cooler Installation
1) Temporarily tighten the EGR pipe A to the ex-
haust manifold.
2) Temporarily tighten the EGR cooler A to the
EGR pipe A.
1 EGR valve
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
3) Temporarily tighten the EGR cooler bracket A
to the EGR cooler A.
4) Temporarily tighten the EGR cooler B to the
EGR cooler A.
5) Temporarily tighten the EGR bracket C to the
EGR cooler B.
84420825B - June 2011
2005-4
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Primary specifications
Electrical system main specifications
Generator
Item Specifications
Manufacturer name Mitsubishi Electric Corporation
Isuzu parts number 1-81200-633-0 1-81200-603-2
Manufacturer type A009TU3782 A004TU6285
Nominal voltage 24V
Output current 90 A 50 A
Rated rotation count -1
500 min {5000 rpm}
Output current/voltage 114 A/27 V/5000 min-1 {5000 rpm} 50 A/27 V/5000 min-1 {5000 rpm}
No-load voltage 24 V/900 min-1 {900 rpm}
Rotational direction Clockwise direction
Polarity (－)
Pulley diameter (P.C.D) ： 90.0 mm {3.54 in} ： 80.0 mm {3.15 in}
Starter
Item Specifications
Manufacturer Mitsubishi Electric Corporation
Isuzu parts number 181100-4140
Manufacturer code number M008T60971
Output 24 V/5.0 kW
Rating 30 sec
York outer diameter : 85.0 mm {3.35 in}
Rotational direction Right
Protection type Dust proof, drip proof
Low speed mechanism Inner contact gear
Weight ： 7.2 kg {15.9 lb}
Module 3
Pressure angle 14.5
Pinion Number of teeth 11
Gear ratio
12.8 {129/11}
{ring gear/pinion gear}
Voltage 23 V
No load Current 85 A or less
Rotational speed 3,300 min-1 {3,300 rpm} or more
Voltage 9V
Restraint Current 1,400 or less
Torque 88 N・m {9kgf・m} or more
Pinion/engaged voltage 16.0 V or less
Glow plug
Item Type
Preheat device model Glow plug
Glow plug rated voltage/current 23 V/3.5 A
84420825B - June 2011
2401-4
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Removal and Installation of Cylinder Head
2) Remove the idle gear C cover from the cylin- Special tool: remover, valve spring (refer
der head assembly using the pliers. to section 1003)
3) Remove the idle gear C from the cylinder head Special tool: pivot ASM (refer to section
assembly. 1003)
2) Remove the split collar from the spring seat.
1 Idle gear C 3) Remove the special tool from the cylinder
2 Idle gear shaft head assembly.
4) Remove the valve spring seat from the valve
10. Valve spring Removal spring.
5) Remove the valve spring from the cylinder
1) Press the valve spring using the special tool.
head assembly.
ANNOTATION:
• Store the removed valve springs according
to the cylinders.
11. Inlet valve Removal
1) Remove the inlet valve from the cylinder head
assembly.
ANNOTATION:
• Organize the removed valve according to
the cylinders.
12. Exhaust valve Removal
84420825B - June 2011
2415-18
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Removal and Installation of Cylinder Head
1) Install the injector harness to the cylinder head 3) Install the connector to the lower cover.
assembly. Tightening torque： 2 N・m {0.2 kgf・m / 18
lb・in}
ANNOTATION:
14. Cylinder head cover Installation
• Tighten the bolts on the bracket and in-
stall the injector harness together with the 1) Align the head cover gasket to the cylinder
bracket. head cover.
2) Install the cylinder head cover to the lower
Tightening torque： 22 N・m {2.2 kgf・m / 16
cover.
lb・ft} Tightening torque： 13 N・m {1.3 kgf・m /
115 lb・in}
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.
1 Injector harness terminal
2 Injector harness bracket
2) Connect the injector harness to the injector.
CAUTION
• Be careful not to damage the injec-
tor side stud bolts.
1 Cylinder head cover
2 Head cover gasket
3 Lower cover
1 Injector 3) Connect the ventilation hose to the air
2 Injector harness breather.
3 Terminal nut 15. Inlet pipe Installation
84420825B - June 2011
2415-38
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Removal and Installation of Cylinder Block
1) Remove the crankshaft front oil seal from the
timing gear case.
CAUTION
• Be careful not to damage the oil
seal press-fitting surface of the tim-
ing gear case.
10. Water pump assembly Removal
1) Remove the fan pulley from the water pump
assembly.
1 Felt
2 Slinger
3 Crankshaft front oil seal
2) Remove the slinger from the crankshaft using
the special tool.
2) Remove the water bypass hose from the wa-
ter pump assembly and the water duct.
Special tool: rear oil seal remover (refer
to section 1003)
CAUTION
• When replacing the oil seal, replace
the slinger. 1 Water bypass hose
3) Remove the water hose from the EGR cooler
water pipe and the water pump assembly.
4) Remove the water pump assembly from the
gear case cover cover.
11. Cover of gear case cover Removal
1) Remove the adjust plate from the gear case
cover cover.
2) Remove the gear case cover cover from the
cylinder block.
12. Turbocharger assembly Removal
84420825B - June 2011
2425-4
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Removal and Installation of Cylinder Block
Bead hight： 3 - 4 mm {0.118 - 0.157 in}
15) Tighten the bolt using the torque wrench.
Tightening torque： 98 N・m {10.0 kgf・m /
CAUTION 72 lb・ft} M14 bolt
16) Tighten the bolt using the torque wrench.
• After applying the liquid gasket, in- Tightening torque： 132 N・m {13.5 kgf・m
stall the crankcase within 5 min- / 97 lb・ft} M14 bolt
utes. 17) Tighten the bolt using the special tool.
13) Put the crankcase on the cylinder block.
CAUTION
• Be careful not to let the thrust bear-
ing fall.
Special tool: angle gauge (refer to section
1003)
Tightening angle： 30 ° M14 Bolt
18) Tighten the bolt using the torque wrench.
Tightening torque： 37 N・m {3.8 kgf・m / 27
lb・ft} M10 bolt
19) Tighten the bolt using the torque wrench.
14) Apply the disulfide molybdenum grease to the Tightening torque：142 N・m {14.5 kgf・m /
bolt. 105 lb・ft} Check the tightening M14 bolt
ANNOTATION:
CAUTION
• Apply to the threaded portion and seat sur-
face on the M14 bolt for crankcase installa- • Confirm that the crankshaft turns
tion. smoothly after tightening the bolts.
CAUTION 6. Piston Installation
• Do not apply grease to the M10 bolt. 1) Install the connecting rod bearing to the con-
necting rod.
ANNOTATION: 2) Apply the engine oil to the connecting rod
bearing.
• Tightening order
CAUTION
• Apply engine oil only to the inter-
nal diameter of the connecting rod
bearing.
3) Apply the engine oil to the piston ring.
84420825B - June 2011
2425-24
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Removal and Installation of Cylinder Block
6) Install the injector leak-off pipe to the injector. 1) Install the glow plug to the cylinder head as-
sembly.
CAUTION Tightening torque： 20 N・m {2.0 kgf・m /
14.8 lb・ft}
• Use new gaskets.
CAUTION
Tightening torque： 14 N・m {1.4 kgf・m /
126 lb・in} • Be careful not to exceed the speci-
fied torque when tightening.
32. Injection pipe Installation
1) Securely tighten the injection pipe to the injec-
tor.
Tightening torque： 44 N・m {4.5 kgf・m /
32.5 lb・ft}
2) Securely tighten the injection pipe to the com-
mon rail assembly.
Tightening torque： 44 N・m {4.5 kgf・m /
32.5 lb・ft}
3) Install the clip to the inlet cover.
Tightening torque： 6 N・m {0.6 kgf・m / 53.1
lb・in}
2) Install the glow plug connector to the glow
plug.
Tightening torque： 1 N・m {0.1 kgf・m / 8.9
lb・in}
CAUTION
• Confirm that the glow plug connec-
tor does not interfere with the sur-
rounding parts.
1 No.1 injection pipe
2 No.2 injection pipe
3 No.3 injection pipe
4 No.4 injection pipe
5 No.5 injection pipe
6 No.6 injection pipe
7 Fuel pipe
33. Glow plug Installation
34. Injector harness Installation
84420825B - June 2011
2425-44
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Lubrication System
11) Remove the water feed pipe from the cylinder 2) Remove the EGR pipe B from the EGR valve
block. and the EGR cooler C.
ANNOTATION:
• Remove the clip.
12) Disengage the harness connector from the
turbocharger assembly.
13) Remove the turbocharger assembly from the
exhaust manifold.
1 EGR valve
2 EGR pipe B
3 EGR cooler C
3) Remove the EGR cooler C from the EGR
bracket C.
1 Oil feed pipe 4) Remove the EGR bracket C from the EGR
2 Clip cooler B.
3 Oil return pipe 5) Remove the EGR cooler B from the EGR
cooler bracket A.
4 Water feed pipe
6) Remove the EGR cooler bracket A from the
5 Water return pipe EGR cooler A.
6. EGR cooler Removal
1) Disengage the water rubber hose from the
EGR cooler.
1 EGR cooler C
2 EGR bracket C
3 EGR cooler B
1 Water rubber hose 4 EGR cooler bracket A
84420825B - June 2011
2445-6
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Lubrication System
3) Align the fuel supply pump to the cylinder 10. Cylinder head assembly Installation
block.
CAUTION
ANNOTATION:
• Clean the aligning surface of the cylinder
• Confirm that the white paint can be seen head and cylinder block before installing
through the timing confirmation hole on the the cylinder head assembly.
top surface of the flywheel housing.
• Be careful not to damage the cylinder
head and cylinder block while cleaning.
1) Apply the liquid gasket to the cylinder block.
ANNOTATION:
• Use ThreeBond 1207B.
Bead width: 3.0 mm {0.1181 in}
Bead height: 2.0 mm {0.0787 in}
1 Confirmation hole
2 Supply pump gear
4) Install the fuel supply pump to the cylinder
block.
Tightening torque: 75 N・m {7.6 kgf・m / 55
lb・ft} No.5 in the diagram
Tightening torque: 75 N・m {7.6 kgf・m / 55
lb・ft} No.8 in the diagram CAUTION
Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft} No.10 in the diagram • After applying liquid gasket, install
the cylinder head within 5 minutes.
2) Install the cylinder head gasket to the cylinder
block.
CAUTION
• Use a new cylinder head gasket.
3) Install the cylinder head assembly to the cylin-
der block.
CAUTION
• Be careful not to damage the cylin-
der head gasket.
1 Fuel supply pump
2 Bracket
3 Gear
4 Nut
5 Bolt
6 O-ring
7 O-ring
8 Nut
9 Bolt
10 Nut
5) Connect the harness connector to the fuel
supply pump.
84420825B - June 2011
2445-26
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Lubrication System
84420825B - June 2011
2445-46
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84420825B - June 2011 Copyright © 2011 CNH FRANCE S.A.
2465-2 PRINTED IN FRANCE
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84420825B - June 2011 Copyright © 2011 CNH FRANCE S.A.
3001-2 PRINTED IN FRANCE
--- Page 24 ---
Removal and Installation of Common Rail Assembly
4) Remove the fuel leak-off pipe from the inlet
pipe.
ANNOTATION:
• Remove the clip.
1 No.1 injection pipe
2 No.2 injection pipe
3 No.3 injection pipe
4 No.4 injection pipe
5 No.5 injection pipe
6 No.6 injection pipe
1 Fuel leak-off pipe
7 Fuel pipe
10. Fuel pipe Removal 12. Common rail assembly Removal
1) Remove the fuel pipe from the fuel supply 1) Disengage the harness connector from the
pump and the common rail assembly. fuel pressure sensor.
ANNOTATION: 2) Remove the common rail assembly from the
inlet cover.
• Remove the clip.
CAUTION
• Do not reuse the removed fuel pipe.
11. Fuel leak off pipe assembly Removal
1) Disengage the fuel leak-off pipe from the cylin-
der head.
2) Remove the fuel leak-off pipe from the fuel
supply pump.
ANNOTATION:
• Remove the eyebolt tightened together with
the fuel feed pipe.
3) Disengage the fuel leak-off pipe from the com-
mon rail assembly. 1 Common rail assembly
84420825B - June 2011
3004B-6
--- Page 25 ---
Anti-theft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Enabling the anti-theft function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Immobilizer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Feed Pump Automatic Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Coolant Level Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Hydraulic Oil Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Air Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fuel Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
DPD Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Automatic Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Manual Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Forced Manual Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hydraulic Assist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61