PDF Service Manual Case CX800 Tier 3 Crawler Excavator - 10 MB
This is the complete factory service manual for the Case CX800 Tier 3 Crawler Excavator.
It provides technicians with detailed information for diagnostics, repairs, and maintenance.
The manual covers the hydraulic system, engine, electrical components, and more, with clear diagrams and step-by-step procedures.
Ensure your CX800 excavator is serviced correctly and efficiently with this indispensable resource.
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--- Page 11 ---
4001-15
WORK MODE SELECTION
1) Circuit configuration
Y7
S3 1
S4
3
P4 2 A1 A2
P1
700-1-04-01-23AP
1 Engine P1 Instrument panel
2 SERIAL communication P4 Monitor display
3 CAN communication S3 Work mode switch
A1 Computer S4 Auto mode switch
A2 Engine controller Y7 Main pump proportional solenoid
2) Timing diagram
S3
S4
700-1-04-01-23 AQ
S3 Work mode switch
S4 Auto mode switch
Lep 9-94970NA Issued 02-06
--- Page 12 ---
4001-25
IDLING CONTROL (AUTO/ONE-TOUCH)
1) Circuit configuration
P1 B26
H1
B27
S16
B25
P4 A1 B22 A2 1
700.1.04.01.1.23AX
1 Engine B27 Travel pilot pressure switch
A1 Computer/Controller H1 Audible warning device
A2 Engine controller P1 Instrument panel
B22 Swing pilot pressure switch P4 Monitor display
B25 Breaker pilot pressure switch S16 One touch idle
B26 Upper pilot pressure switch (yellow band)
2) Switching between auto idle and one- the machine was manoeuvred though the lever.
touch idle 8. LCD displays “IDLING” on the monitor during idling
control.
1. Pushing the knob switch (IN1) down and holding it
for 3 seconds will trigger the modes to toggle 3) Switching between auto idle and one-
between auto and one-touch. When the mode touch idle
switches, the ON/OFF display on the auto idle
1. When setting idling revolutions based on condi-
section of the LCD also switches, and the buzzer
tions described in 2). Switching between auto idle
buzzes for 3 seconds.
and one-touch idle, the controller transmits an
2. At the time of auto idle/one-touch idle selection, the
idling signal to the engine controller via CAN com-
previous setting will still prevail even after the key
munication. Also, a signal is sent to the monitor
switch was turned ON. (Previous data is retained.)
display via serial communication to display
3. The LCD will display ON/OFF status of auto idle. ON
“IDLING” on the screen.
on the display indicates the auto idle, OFF indicates
2. The engine controller, upon receiving the signal,
one-touch idle.
selects idling mode and adjusts engine speed to
4. If there occurs no handling through the lever for 5 that of the idling state.
seconds with auto idle turned ON (both attachment 3. The monitor displays “IDLING” on the LCD accord-
pressure switch and travel pressure switches are ing to the signal sent.
OFF), the engine speed automatically goes back to 4. When recovering from idle control based on the con-
the idling state. (For 5 seconds, the initial setting ditions described in 2). Circuit configuration, the
prevails. Programming is possible through adjusting controller transmits a signal to the engine controller
settings on the back panel for the duration between via CAN communication conveying the previous
1 and 30 seconds.) engine mode selection. Also, the serial transmission
5. During auto idle, if operated via lever while engine is that has been sent to the monitor for displaying
idling (either attachment pressure switch or travel “IDLING” on the screen will be terminated.
pressure switch is on), the engine speed automati- 5. The engine controller, depending on the mode sig-
cally goes back to the previous rate. nal received, switches the idling mode back to the
6. Even during auto idle, idling/recovery operation is previous mode and adjusts the engine speed.
attained by pressing the knob switch (one-touch 6. The monitor recognizes the termination of the idling
switch). signal transmission and stops the “IDLING” display
7. When auto idle is OFF (i.e. during one-touch idle), on LCD.
idling/recovery is attained by simply operating the
knob switch (one-touch idle switch), whether or not
Lep 9-94970NA Issued 02-06
--- Page 13 ---
4001-35
CONTROL WHEN STOPPING ENGINE
1. Operation
1) Turn OFF the key switch. 5) EGR valve is instructed so that it is fully closed
2) When the engine controller recognizes that the and its initial point is corrected.
key is turned OFF, steps 3) through 5) below 6) After steps 3) through 5) have been completed,
are carried out simultaneously. information such as history failure is written in
3) Fuel injection quantity stops to be calculated. EPROM in the ECM.
4) Pressure control valve (PCV) is instructed so 7) Turn OFF the main relay and turn OFF the
that it is fully closed. power supplied to ECM.
EMERGENCY STOP OF THE ENGINE
1. Alteration
In current type 3 (engine meeting emission control regulation of 2nd-stage), depression of the emergency stop
switch allows the engine stop motor to rotate to the stop position by way of the relay and allows the engine gov-
ernor to control for stopping engine by the engine stop signal from the engine controller (ECU).
In the next type (engine meeting emission control regulation of 3rd-stage), depression of the emergency stop
switch allows the controller to transfer engine stop signal to ECM controlling the engine to be stopped.
2. Circuit configuration
MONITOR DISPLAY
24V-OUTPUT ENGINE STOP
P4 CN6-21(PNP)
WR501
1
BrR530
CN3-43
S9 A1 A2 ENGINE
SWITCH CONTROLLER ENGINE CONTROLLER
(EMERGENCY STOP)
700.1.04.01.23BO
1 Engine P4 Monitor display
A1 Computer/Controller S9 Engine emergency stop switch
A2 Engine controller
3. Operation
1) Depression of emergency stop switch on the
monitor display allows the output signal from
transistor in the controller to be turned ON and
at the same time, the engine stop signal is
transferred from the controller to the engine
controller (ECM)
2) ECM performs stopping control for the engine.
Lep 9-94970NA Issued 02-06
--- Page 14 ---
4001-45
CONTROL OF HYDRAULIC DRIVEN FAN
1) Outline of control
Main control of hydraulic driven fan is illustrated below.
Detailed description for each section is shown after next section.
1) Fan speed control according to water temperature
2) Spool stick prevention control
3) Engine start/stop control
4) Reversing fan control (cleaning mode)
5) Actual fan speed checking mode
2) Basic circuit configuration
A1 CONTROLLER ENGINE CONTROLLER
ENGINE
THROTTLE TARGET SPEED
VOLUME 5V b
SIG CAN-H
R3 A2 1
GND CAN-L
a
FAN REVERSING
ENGINE SPEED
SWITCH
5V ENGINE COOLANT TEMP.
S64 FAILURE CODE FAN MOTOR
M
MONITOR
UART M9
KEY SWITCH P1
24V
S1
Y31 FAN REVERSING
SOLENOIDE VALVE
PNP out
24V
GATE LIMIT LEVER LOCK
S51 SWITCH SOLENOID Y1
RELAY
ELECTROMAGNETIC
Y32 PROPORTIONAL VALVE
FOR CONTROLLING
PWM out FAN SPEED
PWM return
P
700.1.04.01.23CA
a) Target speed information, A2 Engine controller
b) Engine speed, engine coolant temperature and R3 Throttle volume
failure mode information S1 Key switch
1 Engine
A1 Computer/ controller
Lep 9-94970NA Issued 02-06
--- Page 54 ---
8016-7
.
1
2
T C D
R
3
S
A B
4 5 6
12 12
7
C D
8
7
9 f
10
E
A E B
CRPH06D017F1
1 TO RETURN FILTER 7 PILOT PRESSURE
2 TO BOOM OR ARM SPOOL 8 FROM CONTROL VALVE RETURN
3 SPOOL F 9 CUSHION SHUT-OFF SOLENOID VALVE
4 SPOOLS E 10 S PORT
5 ORIFICES 11 TO RETURN FILTER
6 SPOOLS E 12 FROM HAND CONTROL
Lep 9-94530NA Issued 05-06
--- Page 59 ---
8020-9
Low Speed Travel Circuit
TRACTION MOTOR
BOOM CYLINDER
21 21
P1 P2 26 25
P2 P1
Pi Pi
4B1
4A1 4pa1 TRAVEL
(RIGHT)
5A1 4pb1
5B1
TRAVEL 5pb1
SWITCH PANEL (LEFT)
5pa1
S2 TRAVEL Y2
T 15
C1
P1 R1 P2 CONTROL VALVE
R2
P1
A1 Y4
CONTROLLER
A1 A2 A3
HYDRAULIC PUMP
61 8-WAY SOLENOID VALVE
10
700-1-03-03-18B
Lep 9-49090NA Issued 02-06
--- Page 60 ---
8020-19
Free Swing switch
OV
10A Fuse
RPM Signal
Hertz CONTROLLER
24V
24V OFF
550/600PSI
Free Swing
Solenoid
Free Swing Swing Brake Pilot Solenoid
orifice Solenoid
Control Valve
Swing
Motor
Free Swing
Solenoid
Free Swing
orifice
Swing
Motor
CS02e657
Lep 9-49090NA Issued 02-06
--- Page 61 ---
8020-29
Boom-Up Circuit (Combined)
BOOM CYLINDER
27 ARM 26 25
CYLINDER
4B3
5B4
4A3
BOOM2
5pb4 BOOM1
4pa3
5pa4
4pb3
57 CUSHION VALVE
G H 4B2
4A2 BUCKET 28
4pa2
4pb2
4pc4 BUCKET CYLINDER
4B1
4A1
4pa1
4pb1
T F 5A1
5B1
5pb1
5pa1
15
P1 R1 R2 P2 CONTROL VALVE
REMOTE CONTROL VALVE
53
A1 A2 A3
HYDRAULIC PUMP
4
10
700-1-03-07-18B
Lep 9-49090NA Issued 02-06
--- Page 62 ---
8020-39
High Dump
BOOM CYLINDER
25 26
22 SWING MOTOR
4B3
61 8-WAY SOLENOID VALVE 5B4
4A3
BOOM2 5pb4
C1 BOOM1
Y2 4pa3
P1 5pa4
4pb3
5A2
5B2
5pb2
C7 4B1
5pa2 4A1
4pa1
5pc5
Y10 4pb1
5A1
5B1
5pb1
REMOTE CONTROL VALVE
53 5pa1
ON
15
P1 R1 R2 P2 CONTROL VALVE
S17
4 OFF
HIGH DUMP
B29 SWITCH
BOOM-UP
PRESSURE A1 A2 A3
SWITCH HYDRAULIC PUMP
57 CUSHION VALVE
CONTROLLER A1
10
700-1-03-13-03A
Lep 9-49090NA Issued 02-06