CASE CX55B Mini Excavator Service Repair Manual

control valve

Hydraulic hand control Hydraulic foot control

Hydraulic swing system Hydraulic travel system Hydraulic central joint

Excavator and backhoe bucket hydraulic system

Hammer and rotating bucket hydraulic system

Swing arm hydraulic system

Dozer blade cylinders

Frames and ballasting

Upper frame

Swing ring assembly

Ballasts and supports

T racks and track suspension

T rack frame and driving wheels

T racks

T rack tension units

T rack rollers

Foreword - Important notice regarding equipment servicing

All repair and maintenance work listed this manual must carried out only qualified dealership strictly complying with the instructions and whenever the special

Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall responsible for any subsequent

The manufacturer and all the organizations its distribution chain, including - without limitationnational, regional, local reject any responsibility for damages caused parts and / components not approved the facturer , including those used for the servicing repair the product manufactured marketed the manufacturer any case, warranty given attributed the product manufactured marketed the manufacturer case damages caused parts and / components not approved the manufacturer

The information this manual - - date the date the the policy the manufacturer for continuous Some information could not updated due modifications a technical commercial type, changes the laws and regulations dif ferent countries.

case refer your CASE CONSTRUCTION Sales and Service

INTRODUCTION

Safety rules

Personal safety

This the safety alert used alert you potential personal injury Obey all safety messages that follow this symbol avoid possible death injury

Throughout this manual you will find the signal words W and CAUTION followed special These precautions are intended for the personal safety you and those working with

Read and understand all the safety messages this manual before you operate service the

DANGER indicates a hazardous situation not will result death serious injury

W

ARNING indicates a hazardous situation not could result death serious injury

CAUTION indicates a hazardous situation not could result minor moderate injury

F AILURE T O FOLLOW DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .

Machine safety

NOTICE: Notice indicates a situation that, not avoided, could result machine property damage.

Throughout this manual you will find the signal word Notice followed special instructions prevent machine property damage. The word Notice used address practices not related personal safety .

Information

NOTE: Note indicates additional information that clarifies other information this

Throughout this manual you will find the word Note followed additional information about a step, other information the The word Note not intended address personal safety property

Personal safety

NOTICE: The proper and safe lubrication and maintenance for this recommended Manufacturer , are outlined the OPERA T OR’S MANUAL for the Improper performance lubrication maintenance procedures are dangerous and could result injury Read and understand the MANUAL before performing any lubrication

The serviceman mechanic may unfamiliar with many the systems this machine. This makes a careful use the systems very important when performing maintenance Sound knowledge the system and components important before the removal disassembly any

Because the size some the machine the serviceman mechanic should check the weights noted this Use proper lifting procedures when removing any W eight components table shown this

The following a list basic precautions that must always

Read and understand all W arning plates and decals the machine before Maintaining Repairing this

Always wear protective glasses and protective shoes when working around particular , wear tive glasses when using punches drifts any part the machine Use welders gloves, hood / goggles, apron and the protective clothing appropriate the welding job being performed. not wear loose fitting torn Remove all rings from loose jewellery , confine long hair and loose ing before working this machinery

Disconnect the battery and hang a tag the operator ’ s Remove starter key make all repairs with the machine parked a level and firm Block the machine does not roll while working under the machine. Hang a tag the operator ’ s seat. not work any machine that supported only jacks a Always use blocks stops for the jack before carrying out any disassembly operation.

NOTICE: not operate this machine unless you have read and understood all instructions contained this manual. Improper machine operation dangerous and could result injury

Relieve all pressure air , oil water systems before any lines, fittings related items are disconnected Always make sure all raised components are blocked correctly and alert for possible pressure when disconnecting any device from a system under

Lower the dozer other attachments the ground before performing any work the this cannot make sure the blade other attachment blocked correctly prevent from dropping unexpectedly .

Use steps and grab handles when mounting dismounting a Remove any debris mud from walkways work platforms before using Always face the machine when using ladders and When not possible use the designed access provide scaf platforms perform safe repair

T o avoid back injury , use a hoist when lifting components which weigh lb) Make sure all are good condition and are the correct capacity sure hooks are positioned correctly Lifting eyes are not side loaded during a lifting

T o avoid alert for hot parts and surfaces immediately after stopping the machine such hot fluids tubes and compartment

1 careful when removing cover Gradually back f the last two capscrews nuts located opposite ends the cover device and carefully pry the cover loose relieve any spring other before removing the last two capscrews nuts completely .

Be careful when removing filler breathers and plugs the Hold a rag over the cap plug prevent being sprayed splashed liquids under Danger even greater the machine has just been liquids might boiling

Always use the proper tools that are good condition and that are suited for the job sure you understand how use them before performing any service

Reinstall all clamps with the same spare part number not use clamps inferior quality replacement necessary . 47574282B

Repairs which require welding should performed only with the benefit the appropriate reference tion and personnel adequately trained and skilled welding

Determine the type metal being welded and select the correct welding procedure and rods wires provide a metal weld strength least equivalent that the parent Make sure disconnect the battery before any welding operation performed.

not damage wiring during removal Reinstall the wiring not damaged nor will damaged operation the machine contacting sharp rubbing against some object hot not connect wiring a line containing sure all protective including guards and are properly installed and functioning correctly before starting a repair . a guard shield must removed perform the repair work, use extra caution and replace the guard shield after repair

18. Performing maintenance and repair operations while the bucket lifted dangerous, because there the sibility a device not fail lower such device and place the bucket the ground before starting the

Loose dirty lubrication and hydraulic pipes and hoses may cause not bend strike high - pressure not install bent damaged Inspect tubes and hoses carefully not check for leaks with your hands. V ery small (pinhole) leaks can result a high velocity oil jet that will invisible close the This oil can penetrate the skin and cause personal injury Use card - board paper locate pinhole

T ighten connections the correct Make sure that all protections against the clamps and the ator ’ s protective devices are correctly installed order prevent excessive vibrations rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components event a tube seal failure must installed correctly

not operate a machine any rotating part damaged contacts any other part during Any high speed rotating component that has been damaged altered should checked for balance before careful when servicing separating the Chips can fly when removing installing a track W ear safety glasses and long sleeve protective T racks can unroll very quickly when Keep away from front and rear The machine can move unexpectedly when both tracks (crawlers) are disengaged from the Block the machine prevent from

Part identification

1

Engine - External view

Filler port (engine oil)

T urbocharger

Engine - Engine and crankcase

Air intake port (from air cleaner , optional)

Lifting eye

Coolant pump

Fan

V - belt

Crankshaft V - pulley

Filler port (engine oil)

Drain plug (engine oil)

Engine oil cooler (4TNV98T , 4TNV106 and 4TNV106T)

Engine oil filter

Dipstick (engine oil)

Fuel injection pump

Governor lever

Fuel filter

Fuel cock

17.

Fuel filter mounting

19. Lifting eye

Engine name plate

21. Rocker arm cover

Flywheel

23. Starter motor

Exhaust manifold

Generator

NOTE: This illustration shows the 4TNV98T engine (with

The drain plug (engine oil) location depends the engine installed the machine unit the fuel injection pump side (above illustration) starter motor

TULI12EXN4782CA 1

Engine - Engine and crankcase

Engine - Static description

Emission reduction

New fuel injection pressure

• Mono plunger

• Higher injection pressure

• Injection speed timer , load timer , cold start timer control

Noise reduction

Higher stif fness cylinder block

Higher stif fness gear - case

Emission reduction

Injection nozzle

• Low suck volume

• Multi injection holes

Emission reduction

Cylinder head

• Optimal nozzle angle

• Optimal swirl ratio

• Optional valve timing

Emission reduction

Piston

• New combustion chamber

Noise reduction

New lube oil pan

• Change rotor shape for low pulsation

• Driven crankshaft directly

Emission reduction

Cylinder head

• 4 valve / cylinder (intake - exhaust -

• Optimal installation the injection nozzle vertical installation and location the centre cylinder

• Optimal valve timing

TULI12EXN4783CB 1

Emission reduction

New fuel injection nozzle

• Low suck volume

• Multi injection holes

Emission reduction

New fuel injection pump

• Mono plunger

• Higher injection pressure

• Mechanical control injection timing, speed timer , load timer , cold start timer

Emission reduction

Piston

• New combustion chamber

Noise reduction (only applied for 4TNV84T)

New lube oil pan

• Change rotor shape for low pulsation

• Driven crankshaft directly

Engine - Engine and crankcase

Engine - Service instruction

Periodic maintenance schedule

The engine periodic inspection timing hard determine varies with the load qualities the fuel and lubricating oils used and handling General rules are described here. : User - maintenance

Air intake system

cleaner cleaning and element replacement

Diaphragm assy inspection

T urbocharger blower

W arning lamp and instruments function check Electrical system Battery electrolyte

level check and battery recharging

Intake / exhaust valve

Cylinder

head

head clearance adjustment

Intake / exhaust valve

seat lapping

Fuel injection nozzle pressure inspection

Fuel injection pump and nozzle

Fuel injection timing adjustment

Fuel injection pump

inspection and adjustment

*EP A allows servicing the emission related parts every 1500 - 3000 h

Engine - Engine and crankcase

Engine - Inspect - Daily Inspection

sure check the following points before starting engine every day:

No. Inspection item

V isual check around the machine

Fuel tank level check and fuel supply

Lube oil level check and replenishment

Coolant level check and replenishment

Fuel pipe and coolant pipe inspection and maintenance

Inspection and adjustment governor lever and accelerator

W arning lamp and instruments function check

W ater separator draining

V isual check around the machine any problem not use before the engine pairs have been

• Oil leak from the lubrication system

• Fuel leak from the fuel system

• Coolant leak from the water cooling system

• Damaged parts

• Loosened lost screws

• radiator rubber cracked V - loosened clamp

Fuel tank level check and fuel supply

Check the remaining fuel oil level the fuel tank and refuel the recommended fuel necessary

Lube oil level check and replenishment

(a) Checking oil level

Check the lubricating oil level with the dipstick (A) , after adjusting the position the machine that the engine

Insert the dipstick fully and check the oil The oil shall not contaminated heavily and have priate viscosity

coolant water diesel fuel shall

When lube oil supplied after the engine has been check the lube oil level after about min after the engine shutdown that the lube oil has filled the oil

The level shall between the upper (AU) and lower (AL) limit lines the dipstick (A)

Lube oil capacity may dif fer from the above volume pending engine installed a machine

(b) Replenishing oil pan with lube oil

the remaining engine oil level low , remove the filler port cap (B) and fill the oil pan with the specified engine oil the specified level through the filler port (C)

NOTE: The oil should not overfilled exceed the per limit Otherwise a naturally - aspirated engine may intake lube oil the combustion chamber during the operthen white oil hummer urgent rotation may occur , because the blow - gas reduced the suction air flow case turbocharged engine oil may jet out from the breather the engine may become faulty

Coolant check

Daily inspection coolant water should done only coolant recovery

NOTICE: Never open the radiator filler cap (R) while the engine and radiator are still Steam and hot water will spurt out and seriously burn W ait until the radiator cooled down after the engine has stopped, wrap the filler cap with a rag piece and turn the cap slowly gently lease the pressure inside the radiator

Securely tighten the filler port plug (R) after checking the diator Steam can spurt out during engine tightening loose.

(a) Checking coolant water volume

Check the coolant level the expansion tank (C) the water level close the LOW mark, open the coolant expansion tank plug (H) and replenish the tank with soft clean water the FULL

The level shall between the upper and lower limit lines the

(b) Replenishing radiator with water

the coolant recovery tank water level lower than the LOW open the radiator cap (R) and check the coolant water level the radiator

Replenish the radiator with the level low

• Check the coolant level while the engine Checking when the engine hot And the water volume expanded due the

• Daily coolant level check and replenishing shall done only from the expansion

Usually not open the radiator cap check

T T ighten Loosen

NOTICE: the coolant water runs short quickly when the radiator runs short water with the coolant expansion tank level water may leaking the air tightness may lost. Increase the coolant expansion tank ter level during operation not The increased water the coolant expansion tank returns the radiator when the engine cooled the water level normal the coolant expansion tank but low the radiator , check loosened clamping the rubber hose between the radiator and coolant recovery tank tear the

Engine: The radiator shall filled

Engine coolant water capacity may dif fer from the above volume depending engine installed a machine

Fuel pipe and coolant pipe inspection and maintenance

Check the rubber hoses for fuel and coolant water pipes

the cracked hose replace with new Check the loosened tighten

Inspection and adjustment governor lever and accelerator

Make sure the accelerator the machine unit can ated smoothly before starting the feels heavy lubricate the accelerator cable joints and ots. Adjust the accelerator cable there a dislocation excessive play between the accelerator and the governor lever Refer Engine - Inspect – Every 250 hours 3 months

W arning lamp and instruments function check

Before and after starting the check see that the alarm function normally Failure alarm cannot warn the lack the engine oil the coolant water Make a rule check the alarm operation before and after starting gine every day . Refer each manual for machine units

W ater separator draining

Drain f the water separator (W) whenever there a lot drain collected the water separator the bottom the cup (C) even the time for periodic inspection has not elapsed The cup the water separator (C) made semi - transparent material and, the cup itself, the red colored floating ring (FR) which rises the surface the drain installed visualize the amount A level sensor connected a warning device the gauge cluster provided optional

Drain f the water separator the following manner: Prepare a waste oil container collecting waste oil.

Close the fuel cock (FC)

Loosen the drain cock (DC) the bottom the water separator , and drain f any water collected

T ighten the drain cock (DC) manually

Air bleeding from fuel

NOTE: drain drips when the drain cock loosen the air bleeding bolt (A) the top the water arator turning counterclockwise 2 - 3 times using driver . (This may occur case the water separator sition higher than the fuel oil level the fuel

After sure tighten the air bleeding bolt (A)

Engine - Engine and crankcase

Inspection after initial h operation

sure check the following points after initial h thereafter every 250 h 3 months

Lube oil and filter replacement

V - belt tension check

Lubricating oil change and filter replacement s t time)

NOTICE: When engine still careful with a splash engine oil which may cause Replace gine oil after the engine oil becomes warm. most effective drain the engine oil while the engine still

early period the engine oil gets dirty rapidly cause the initial wear internal Replace the gine oil earlier Lube oil filter should also replaced when the engine oil The procedure lube oil and lube oil filter replacement follows:

Drain engine oil

• Prepare a waste oil container collecting waste oil.

Inspection item

• Remove the oil filler cap drain easily while draining the lube oil.

• Loosen the drain plug (DP) using a wrench tomer procured) drain the lube

• Securely tighten the drain plug after draining the lube

• Drain The location depends the engine installed the machine

NOTE: Use a socket wrench a closed wrench when moving tightening a drain plug. not use a spanner because there the possibility that the spanner slips and you get

Replacing oil filter

• T urn the lube oil filter (E) counterclockwise using a filter wrench (customer procured) remove

• Clean the mounting face the oil filter .

• Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manually turning clockwise until comes into contact with the ing and tighten further 3 / 4 a turn with the filter wrench.

T

ightening torque: - N·m ( - )

Oil filling and inspection

• Fill with new engine oil until reaches the specified

NOTICE: not overfill the oil pan (O) with engine sure keep the specified level between upper and lower limit the dipstick (D)

T T ighten

Loosen

• W arm the engine running for 5 min while checking any oil

• Stop the engine after warming and leave ping for about min recheck the engine oil level with dipstick and replenish the engine oil. any oil wipe away with a clean

V - belt tension check

When there not enough tension the V - belt (V) , the V - belt will slip making impossible for the alternator (A) generate power and cooling water pump and cooling fan (R) will not work causing the engine

Check and adjust the V - belt tension (deflection) the lowing manner:

NOTE: especially careful not splash engine oil the V - because will cause stretching and aging the

Press the V - belt with your thumb [approximately N ( ) ] the middle the V - belt span check the tension

A vailable positions check and adjust the V - belt tension (deflection) are the B C direction shown the 6

Y may choose a position whichever you can ily carry out the check and adjustment the chine

• V - refers a V - belt which has been used less than 5 min a running engine.

• V - refers a V - belt which has been used a running engine for 5 min The specified deflection measured each position should follows:

Engine - Engine and crankcase

necessary , adjust the V - belt tension

T o adjust the V - belt loosen the setscrew (S) and move the alternator (A) tighten the Vbelt.

(Adjust the V - belt tension inserting a bar

After replacing with a new V - belt and adjusting run the engine for 5 min and readjust the deflection the value the table

After replacing with a new V - belt and adjusting it, run the engine for 5 min and readjust the deflection the value the table

V isually check the V - belt for oiliness wear any , replace the V - belt with new

Engine - Inspect – Every hours

sure check the following points before starting engine every day .

No.

Fuel tank drain

Fuel system bleeding

Inspection item

Battery electrolyte level check and battery recharging

Fuel tank drain

Prepare a waste oil container collecting waste

Remove the drain plug (D) the fuel tank (F) drain (water , from the fuel tank

Drain until fuel with water and dust flow

Then tighten the drain plug firmly

Fuel system bleeding

Bleed the fuel system according the following

When there air the fuel the fuel jection pump (FI) will not able

Check the fuel oil level the fuel Refuel insuf

Open the cock (FC) the water separator (W)

Loosen the air bleeding bolt (A) the water rator turning counterclockwise 2 - 3 times using a screwdriver a spanner .

When the fuel coming out clear and not mixed with any tighten the air bleeding bolt (A)

Feed fuel with the fuel priming pump (FP) tro - magnetic fuel feed

• case the engine uses the electro - magnetic fuel feed

T urn the starter switch the “ON” position and hold the position for - s operate the fuel feed

• case the engine uses the electro - magnetic fuel feed pump (FP)

The priming pump the top the fuel filter

Move the priming pump and down feed fuel until feel your hand slightly heavy .

• W ater separator (W)

(Installed the pipe line)

• Fuel filter (FF)

(Mounting with fuel priming pump) (option)

Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL.NOWAITING

NOTE:

If there is no response to click on the link above, please download the PDF document first and then clickonit.

Battery electrolyte level check and battery recharging

W ARNING

Hazardous chemicals!

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result severe irritation and Always wear splash - proof goggles and protective clothing (gloves and W ash hands after handling.

Failure comply could result death serious injury

W ARNING

Battery acid causes burns. Batteries contain sulfuric acid.

A void contact with eyes Antidote (external): Flush with water Antidote (eyes): flush with water for minutes and seek medical attention immediately . Antidote (internal): Drink large quantities water milk. not induce vomiting. Seek medical attention immediately .

Failure comply could result death serious injury

NOTICE: Make sure turn off the battery switch disconnect the negative cable ( before inspecting the electrical Failure could cause short - circuiting and Always disconnect the ( Negative battery cable first before disconnecting the battery cables from battery dental - may cause fire and personal injury

And remember connect the ( Negative battery cable (back onto the battery) LAST

NOTICE: Keep the area around the battery well paying attention keep away any fire During operation hydrogen gas generated from the battery and can easily

Electrolyte level

• Check the electrolyte level (EL) the battery When the amount fluid nears the lower limit (LL) , fill with battery fluid (available the market) the upper limit (UL) operation continues with insuf ficient battery the battery life and the battery may overheat and

• Battery fluid tends evaporate more quickly the summer , and the fluid level should checked lier than the specified

• the engine cranking speed slow that the gine does not start recharge the battery

• the engine still will not start after replace the battery

• Remove the battery from the battery mounting the machine unit after daily use letting the machine unit leave the place that the ambient temperature could drop ( ) And store the battery a warm place until the next use the unit start the engine easily low ambient

Battery charge

Use a battery tester hydrometer and check the battery the battery recharge

Measurement with a battery tester (BT)

When checking the battery with the batter tester , connect the red clip the tester the battery positive (+) terminal and black clip the battery negative ( terminal ing them securely , and judge the battery charge level from the indicator position.

Green zone: Normal

Y ellow zone: Slightly discharged

Red zone: Defective much discharged

Measurement with hydrometer

When using a hydrometer , the measured specific gravity must corrected according the temperature the time

Engine - Engine and crankcase

The specific gravity battery electrolyte defined with ( ) the

Since the specific gravity increases decreases when the temperature varies 1 ( ) correct the value according the equation below

S20 = St + 0.007(t - 20)

t = Electrolyte temperature measurement

= Specific gravity measurement S20 = Converted specific gravity ( )

T erminals

Clean corroded

Mounting bracket

Repair replace

Retighten

Battery appearance

Replace the battery cracked

Clean with fresh water

Engine - Inspect – Every 250 hours 3 months

sure check the following points every 250 h 3 months operation, whichever comes first.

No. Inspection item

Lube oil and filter replacement

Radiator fin cleaning

V - belt tension check

Inspection and adjustment governor lever and accelerator

Air cleaner cleaning and element replacement

W ater separator cleaning

Lube oil and filter replacement (The second replacement and after)

Replace the engine oil every 250 h operation from 2 n d time and Replace the engine oil filter the same

Radiator fin cleaning

NOTICE: Beware dirt from air

W ear protective equipment such goggles protect your eyes when blowing compressed air Dust flying debris can hurt eyes.

Dirt and dust “DD” adhering the radiator fins (RF) reduce the cooling causing Make a rule check the radiator fins daily and clean

• Blow f dirt and dust from fins and periphery with compressed air ( 0.19 MPa ( psi ) less order not damage the fins).

• contaminated heavily , apply thoroughly clean and rinse with tap water shower

NOTICE: Never use high pressure water air from close fins never attempt clean using a wire Radiator fins (RF) can

V - belt tension check (The second time and after)

Check and adjust the V - belt tension.

Inspection and adjustment governor lever and accelerator

The governor lever (GL) and accelerating devices erating lever , the machine unit are nected accelerating wire rod. the wire becomes stretched the connections the deviation the position may result and make operation Check the wire periodically and adjust necessary not strongly move the accelerating wire accelerating pedal. may deform the governor lever stretch the wire cause irregular engine speed

Checking and adjusting procedure are follows:

• Check that the governor lever (GL) the engine makes uniform contact with the high idling (H) and low idling (LI) limiting screws when the ing devices are the high idling speed low idling speed

• either the high the low idling speed side does not make contact with the limiting screw , adjust the accelerating Loosen the accelerating wire fastening screw (AF) and just the wire contact with the limiting screw

NOTICE: Never loosen the limiting will impair the safety and performance the product and functions and result shorter engine

Air cleaner cleaning and element replacement

NOTICE: Beware dirt from air W ear protective equipment such goggles protect your eyes when blowing compressed air Dust flying debris can hurt

The engine performance adversely fected when the air cleaner element (E) clogged periodical cleaning after disassembly

• Undo the clamps (L) the dust pan (DP) and move the dust

• Loosen the wing nut the element and pull out the element (E)