CASE 650L Tier3 Crawler Dozer Service Repair Manual

84276960

Replaces 84260831

SERVICE MANUAL

CRAWLER DOZER 650L TIER3

Final drive

SER VICE BRAKE Hydraulic

WHEELS AND TRACKS T racks

BODY AND STRUCTURE

USER CONTROLS AND SEA T

USER CONTROLS AND SEA T Operator seat

USER PLA TFORM

ENVIRONMENT CONTROL

Heating system

ENVIRONMENT CONTROL Air - conditioning system

ENVIRONMENT CONTROL ventilation and air - conditioning

SAFETY SECURITY

DIGGING Non - articulated digging tools

LANDSCAPING Dozer blade 84260831 21/08/2009

Basic instructions

T echnical Information

This manual has been produced a new technical information This new system designed deliver technical information electronically through CDROM and paper manuals. A coding system called ICE has been developed link the technical information other Product Support functions W arranty

T echnical information written support the maintenance and service the functions systems a customers When a customer has a concern his machine usually because a function system his machine not working not working ficiently , not responding correctly his When you refer the technical information this manual resolve that customers you will find all the information classified using the new ICE according the functions systems that Once you have located the technical information for that function system then you will find all the mechanical, electrical hydraulic devices, assemblies and sub - assemblies for that function Y will also find all the types information that have been written for that function the technical data the functional data (how the diagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.).

integrating this new ICE coding into technical information , you will able search and retrieve just the right piece technical information you need resolve that customers concern his machine. This made possible attaching 3 categories each piece technical information during the authoring

The first category the Location, the second category the Information T ype and the third category the Product:

• LOCA TION - the component function the that the piece technical information going describe Fuel

• INFORMA TION TYPE - the piece technical information that has been written for a particular component function the machine Capacity would a type T echnical Data that would describe the amount fuel held the Fuel tank.

• PRODUCT - the model that the piece technical information written for

Every piece technical information will have those 3 categories attached Y will able use any combination those categories find the right piece technical information you need resolve that customers concern his

That information could be:

• the description how remove the cylinder head

• a table specifications for a hydraulic pump

• a fault code

• a troubleshooting table

• a special tool

How Use this Manual

This manual divided into Each Section then divided into Contents pages are included the beginning the then inside every Section and inside every Chapter alphabetical Index included the end a Chapter Page number references are included for every piece technical information listed the Chapter Contents Chapter Index.

Each Chapter divided into four Information types:

• (D) T echnical Data (specifications) for all the mechanical, electrical hydraulic devices, components and,

• (C) Functional Data (how works) for all the electrical hydraulic components and

• (G) Diagnostic Data (fault electrical and hydraulic troubleshooting) for all the electrical draulic components and

• (F) Service data (remove disassembly , install) for all the electrical hydraulic components and assemblies.

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INTRODUCTION

Sections

Sections are grouped according the main functions a systems the machine. Each Section identified a letter C The amount Sections included the manual will depend the type and function the machine that the manual written for Each Section has a Contents page listed alphabetic / numeric order This table illustrates which Sections could included a manual for a particular

SECTION

A - Distribution Systems

B - Power Production

C - Power T rain

D - T ravelling

E - Body and Structure

F - Frame Positioning

G - T ool Positioning

H - W orking Arm

J - T ools and Couplers

Chapters

Each Chapter identified a letter and number combination Engine The first letter identical the Section letter Chapter inside Section Power CONTENTS

The Chapter Contents lists all the (D) technical data (specifications), (C) functional data (how works), (F) service data install and (G) diagnostic data (fault codes and troubleshooting) that have been written that Chapter for that function system the

INDEX

The Chapter Index lists alphabetical order all the types information (called Information Units) that have been written that Chapter for that function system the

Information Units and Information Search

Each chapter composed information Each information unit has the ICE code shown parentheses which indicates the function and the type information written that information unit. Each information unit has a page erence within that Chapter The information units provide a quick and easy way find just the right piece technical information you are looking for

information unit

valve - Sectional V iew -

CRIL03J033E01 1

Navigate the correct information unit you are searching for identifying the function and information type from the ICE

• (1) Function and (2) Information

•

(A) corresponds the sections the repair

(B) corresponds the chapters the repair manual.

(C) corresponds the type information listed the chapter (D) , T echnical (C) , Functional (G) , and (F) ,

(A) and (B) are also shown the page numbering the page footer THE REST THE CODING NOT LISTED ALPHA - NUMERIC ORDER THIS

• Y will find a table contents the beginning and end each section and chapter Y will find alphabetical index the end each chapter

• referring (A) , (B) and (C) the you can follow the contents index (page numbers) and quickly find the information you are looking for 84260831 21/08/2009

Page Header and Footer

The page header will contain the following references:

• Section and Chapter description

The page footer will contain the following references:

• Publication number for that Section Chapter

• V ersion reference for that publication.

• Publication date

• chapter and page reference / 9

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PRIMAR Y HYDRAULIC POWER SYSTEM - Special tools

RCPH09CWL005AAD 1

CAS1804 Hydraulic pressure fitting kit

RCPH09CWL006AAD 2

CAS1808 Flowmeter fitting kit

RCPH09CWL004AAD 3

CAS10090 Hand pump

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DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

PRIMAR Y HYDRAULIC POWER SYSTEM - General specification

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

Stack valve - T orque

Stack valve - Special tools RCPH09CWL075AAD

Stack valve - Calibration

Stack valve - General specification

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

Hydraulic pump - General specification

Rotation

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

Relief valve - Exploded view

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

Relief valve - Sectional view

Stack valve - Exploded view

PRIMAR Y HYDRAULIC POWER SYSTEM - Cleaning

Contamination the hydraulic system a major cause the malfunction hydraulic Contamination any foreign material the hydraulic Contamination can enter the hydraulic system several ways.

(A) When you drain the oil disconnect any

(B) When you disassemble a

(C) From normal wear the hydraulic

(D) From damaged worn

(E) From a damaged component the hydraulic

All hydraulic systems operate with some The design the components this draulic system permits ficient operation with a small amount increase this amount contamination can cause problems the hydraulic The following list includes some these

(A) Cylinder rod seals

(B) Control valve spools not return neutral.

(C) Movement control valve spools dif

(D) Hydraulic oil becomes too

(E) Pump and other parts wear rapidly

(F) Relief valves check valves held open dirt.

(G) Quick failure components that have been

(H) Cycle times are slow; machine does not have enough power

your machine has any these check the hydraulic oil for contamination. See types tamination below you find use the Portable Filter clean the hydraulic

NOTE: There are two types microscopic and

Microscopic contamination occurs when very fine particles foreign material are suspension the hydraulic

These particles are too small see scopic contamination can found identification the following problems testing a laboratory

Examples the problems:

(A) Cylinder rod seal

(B) Control valve spools not return

(C) The hydraulic system has a high operating

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

V isible contamination foreign material that can found odor V isible contamination can cause a sudden failure ples visible contamination:

(A) Particles metal dirt the

(B) Air the oil.

(C) The oil dark and

(D) The oil has odor burned

(E) W ater the

NOTE: The hydrostatic system uses a third port bypass filter the filter becomes plugged bypasses back the reservoir stop contamination from entering the hydrostatic Upon completion cleaning the hydraulic system replace the hydrostatic system filter

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

PRIMAR Y HYDRAULIC POWER SYSTEM - Decontaminating

CAS10162A CAS10508 CAS10192

Prepare the portable filter CAS10162A doing the following steps:

(A) Remove all the hydraulic oil from the inlet and outlet hoses for the portable filter

(B) Remove the filter element from the portable filter

(C) Remove all hydraulic oil from the portable filter

(D) Clean the inside the housing for the filter

Y must know whether the contamination scopic Refer PRIMAR Y HYDRAULIC POWER SYSTEM - Cleaning

the contamination microscopic:

(A) Check the maintenance schedule for the chine learn the hydraulic oil must change the hydraulic Change the draulic filter

(B) steps 6 through 35.

the contamination visible:

(A) Change the hydraulic oil and hydraulic filter

(B) steps 5 through

Check the amount contamination the hydraulic system doing the following steps:

(A) Disassemble one cylinder two dif ferent Check for damage seals, scoring the cylinder Repair the cylinders necessary

(B) your the damage the cylinders was caused sever contamination and not the sult normal wear , necessary clean and repair valves, pump, lines, cylinders, hydraulic reservoir , the hydraulic

Remove the breather from the reservoir and connect the vacuum pump the Start the vacuum pump.

Loosen and remove the drain plug from the reservoir

Using the fitting kit CAS10508 , install the valve the hole for the drain Make sure that the valve closed.

Stop the vacuum

Connect the inlet hose for the portable filter the valve that installed the hole for the drain plug.

Disconnect the vacuum pump from the hydraulic reservoir air breather Remove the filler

Install the outlet hose for the portable filter the hydraulic reservoir filler

Open the valve that installed the hole for the drain

Move the switch for the portable filter the Start and run the engine 1500 rpm /

15. Run the portable filter for minutes.

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

16. Continue run the portable filter . Increase the gine speed full Heat the oil operating temperature doing the following steps:

(A) Hold the blade control lever the TIL T position for five

(B) Return the blade control lever the NEUTRAL position for five

(C) Repeat steps A and B until the oil the hydraulic system operating

Continue run the engine full Continue run the portable filter

Operate each hydraulic circuit completely extend and retract the cylinders. Continue operate each hydraulic circuit two one after the other for

Decrease the engine speed low

Continue run the portable filter for

Stop the portable filter

Stop the

Remove the hose from the hydraulic reservoir

Close the valve that installed the hole for the drain

Disconnect the inlet hose for the portable filter from the Remove the outlet hose from the reservoir filter neck and replace filler

Connect a vacuum pump the breather hose the hydraulic reservoir .

27. Start the vacuum pump.

Remove the valve from the hole for the drain

Install the drain

Stop the vacuum Disconnect the vacuum pump from the opening the reservoir and install the breather .

Remove the hydraulic and hydrostatic filter elements from the

Install new hydraulic and hydrostatic filter elements the

Start the Check for oil leakage around the new hydraulic and hydrostatic

Stop the

Check the oil level the hydraulic reservoir Add oil required.

NOTE: THE FOLLOWING PROCEDURES ARE FOR FLUSHING W A TER FROM THE HYDRAULIC SYSTEM

36. Start and run the engine 1500 rpm / min).

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DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

37. Completely retract the cylinders all attachments the Angle the blade the the right cylinder will fully retracted and the left will fully Stop the

W ARNING

retracting the cylinder rods causes the attachment raised, block the attachment place before ceeding the next

Move each control lever both directions release pressure the hydraulic circuits.

39. Loosen and remove the filler cap from the reservoir .

Drain the hydraulic oil from the reservoir

(A) The reservoir holds approximately 75.5 l ( gal ) hydraulic

(B) Have available acceptable equipment drain the hydraulic

(C) Remove the drain plug from the bottom the reservoir

41. Remove the hydraulic and hydrostatic filter elements from the

Install new hydraulic and hydrostatic filter elements the

Install the drain plug the bottom the reservoir

Fill the hydraulic reservoir with refer Capacities for proper quantities and

Disconnect the line from the OPEN end and CLOSED end each cylinder

Be sure all control levers are the NEUTRAL tion.

Start and run the engine low

IMPOR T ANT : Check the oil level the hydraulic reservoir frequently while doing step 48. Have another person hold a container under the hydraulic lines while you step

Slowly move each control lever both directions til oil begins flow from the open Hold the trol lever place until clean oil flows from the open

49. Stop the engine.

50. Connect the system line the CLOSED end each cylinder

Connect a suitable drain line the OPEN end each cylinder and place the other end able container for contaminated

Start the engine and run the engine low

Slowly and completely extend all the piston rod comes / out the cylinder , oil will pushed out the OPEN end the

IMPOR T ANT : Any attachment part attachment that raised must supported with acceptable equipment prevent the attachment from

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54. Support any attachments that will the RAISED

Stop the

Disconnect the drain lines and connect the system lines the

Check the oil level the hydraulic reservoir Add oil

Install the filler cap the reservoir

Remove the hydraulic and hydrostatic filter elements from the

Install new hydraulic and hydrostatic filter elements the machine.

Start and run the engine 1500 rpm / ate each hydraulic circuit completely extend and retract the

Stop the engine and check for Check the oil level the hydraulic reservoir Add oil

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DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

Relief valve - Pressure setting

Remove the cover from the main relief valve and loosen the lock nut the adjusting screw

T urn the adjusting screw into the main relief valve increase the pressure out the main relief valve decrease the

Refer Relief valve - Pressure test (A.10.A) and check the pressure setting. Adjust the main relief valve again necessary

When the pressure setting prevent the adjusting screw from turning while the lock nut Install the cover the main relief

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

Relief valve - Disassemble

Prior operation:

Stack valve Inlet section - Disassemble (A.10.A)

Fasten the main relief valve a vise with soft Remove the

Hold the adjusting screw position while you loosen the lock

Remove the adjusting screw . Make sure that you count the number turns required remove the adjusting screw that you can install the adjusting screw correctly during Assembly

Remove the spring.

Remove the plunger

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

Remove the body from the housing.

Remove the

Replace the O - ring and the backup ring the

T the main relief valve lightly against a solid face that the poppet can removed from the

DISTRIBUTION SYSTEMS - PRIMAR Y HYDRAULIC POWER SYSTEM

10. Replace the O - ring the body .

1 Replace the O - ring the adjusting screw .

Replace the O - ring and the backup ring the

Next operation: Relief valve - V isual inspection