Case cx145 csr tier 4 crawler excavator service repair manual

Printed in U.S.A.
Copyright © 2012 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.
Part number 47395870A
1st edition English
July 2012
SERVICE MANUAL
CX145CSR
Tier 4
Crawler Excavator

Section
1001
Safety, general information and standard torque data
47395870A NA - June 2012

GENERAL INFORMATION
CLEANING
Clean all metal parts except bearings, in a suitable cleaning solvent or by steam cleaning.
Do not use caustic soda for steam cleaning.
After cleaning, dry and put oil on all parts.
Clean oil passages with compressed air.
Clean bearings in a suitable cleaning solvent,
dry the bearings completely and put oil on the bearings.
INSPECTION
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage.
Small scoring or grooves can be removed with a hone or crocus cloth.
Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early
failures.
BEARINGS
Check bearings for easy action.
If bearings have a loose fit or rough action replace the bearing.
Wash bearings with a suitable cleaning solvent and permit to air dry.
DO NOT DRY BEARINGS WITH COMPRESSED AIR.
NEEDLE BEARINGS
Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore.
Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.
GEARS
Check all gears for wear and damage.
Replace gears that have wear or damage.
Oil seals, O-rings and gaskets.
Always install new oil seals, O-rings and gaskets.
Put petroleum jelly on seals and O-rings.
SHAFTS
Check all shafts that have wear or damage.
Check the bearing and oil seal surfaces of the shafts for damage.
SERVICE PARTS
Always install genuine Case service parts.
When ordering refer to the
Parts Catalogue for the correct part number of the genuine Case replacement items.
Failures due to the use of other than genuine Case replacement parts are not covered by warranty.
LUBRICATION
Only use the oils and lubricants specified in the Operator’s or Service Manuals.
Failures due to the use of non-specified oils and lubricants are not covered by warranty.
47395870A NA - June 2012
1001-3

Safety
This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.
The message that follows the symbol contains important information about safety.
Carefully read the message.
Make sure you fully understand the causes of possible injury or death.
To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual.
Put the warning tag shown below on the key for the key switch when servicing or repairing the machine.
One warning tag is supplied with each machine.
Additional tags are available from your service parts supplier.
WARNING
Read the operator's manual to familiarize yourself with the correct control functions.
WARNING
Operate the machine and equipment controls from the seat position only.
Any other method could result in serious injury.
WARNING
This is a one man machine, no riders allowed.
WARNING
Before starting engine, study Operator’s Manual safety messages.
Read all safety signs on machine.
Clear the area of other persons.
Learn and practice safe use of controls before operating.
It is your responsibility to understand and follow manufacturers instructions on machine operation, ser-
vice and to observe pertinent laws and regulations.
Operator's and Service Manuals may be obtained from your CASE dealer.
WARNING
If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can
be injured.
Always wear clothing that will not catch on objects.
Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face
protection, heavy gloves and reflector clothing.
WARNING
When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and
use extreme caution.
WARNING
When doing checks and tests on the equipment hydraulics, follow the procedures as they are written.
DO NOT change the procedure.
WARNING
When putting the hydraulic cylinders on this machine through the necessary cycles to check operation
or to remove air from a circuit, make sure all people are out of the way.
WARNING
Use insulated gloves or mittens when working with hot parts.
47395870A NA - June 2012
1001-4

WARNING
Lower all attachments to the ground or use stands to safely support the attachments before you do any
maintenance or service.
WARNING
Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious
infection.
If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately.
Maintain all hoses and tubes in good condition.
Make sure all connections are tight.
Make a replacement of any tube or hose that is damaged or thought to be damaged.
DO NOT use your hand to check for leaks, use a piece of cardboard or wood.
WARNING
When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze)
hammer or use a driver made from brass or bronze and a steel head hammer.
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.
WARNING
When servicing or repairing the machine, keep the shop floor and operator's compartment and steps
free of oil, water, grease, tools, etc.
Use an oil absorbing material and/or shop cloths as required.
Use safe practices at all times.
WARNING
Some components of this machine are very heavy.
Use suitable lifting equipment or additional help as instructed in this Service Manual.
WARNING
Engine exhaust fumes can cause death.
If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an
exhaust pipe extension.
Open the doors and get outside air into the area.
WARNING
When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2),
you try to jump start and run the engine.
To prevent the battery electrolyte from freezing, try to keep the battery at full charge.
If you do not follow these instructions, you or others in the area can be injured.
47395870A NA - June 2012
1001-5

ROPS Judgment Method
1. Purpose
Check against the ROPS judgment criteria to judge whether the machine satisfies the ROPS criteria or not.
The weight and boom of the machine greatly effects whether the ROPS judgment criteria is satisfied or not.
The ROPS test assumes that the weight being used is the weight of the machine when the maximum number of
selectable options are mounted (as of 2009).
However, depending on the derivative machinery or the order details, the weight and boom position may differ
from the assumed weight or position.
2. Criteria for judging whether a machine satisfies the ROPS criteria
1) Weight
The weight must not be over the weight shown below for each class.
If the weight is exceeded, there is a danger that the cab could be damaged and the operator could die or
sustain a serious injury when the machine falls over.
If the weight exceeds the stipulated weight, the machine will not satisfy the ROPS criteria.
• Weight (X3 model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)
Machine body total weight Class
16000 kg (35274.146 lb) or less
CX75C
CX145C
20500 kg (45195.000 lb) or less
CX130C
CX160C
CX180C
28000 kg (61729.756 lb) or less CX235C
31000 kg (68343.658 lb) or less
CX210C
CX250C
CX250C LR
CX300C
40000 kg (88185.365 lb) or less CX370C
50000 kg (110231.707 lb) or less CX470C
* The ROPS test assumes that the CX470C has a cage guard (alone).
16000 kg (35274.146 lb) or less
CX75C
CX145C
20500 kg (45195.000 lb) or less
CX130C
CX160C
CX180C
28000 kg (61729.756 lb) or less CX235C
31000 kg (68343.658 lb) or less
CX210C
CX250C
CX250C LR
CX300C
50000 kg (110231.707 lb) or less CX470C
* The ROPS test assumes that the CX470C has a cage guard (alone).
• Weight (X2 model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)
26600 kg (58643.268 lb) or less
CX130B
CX160B
CX180B
CX210B
CX240B
47395870A NA - June 2012
1001-6

2) Boom position
WARNING
• If the machine has been modified so that the boom position has been lowered, the machine
will not satisfy the ROPS criteria.
• It is necessary to consult with our company if it is possible that the boom's position has been
lowered by modification.
• The extent to which a boom position has moved cannot be determined in the same way for
all machines.
a Ground point
With the tip of the bucket in contact with the ground surface at maximum work radius, if the position (* in the
diagram) that overlaps with the cab when viewed from the side is markedly lower than that of a standard
machine (standard arm), the machine will not satisfy the ROPS criteria.
Also, with a machine body with a cab mounted that can withstand up to 31 tons, the effect of mounting a
24 ton machine, which is near the restriction weight, and a 21 ton machine to the same cab will not be the
same.
3. Prohibited items
• Modifications that reduce the strength of a platform that has a cab with a ROPS mounted to it. (Actions or
modifications that reduce the functionality of the anchoring part at the left-rear of the cab)
• Modifications that effect the strength of the ROPS of a cab.
A forbidden all
modifications
(red part)
All modifications (grinding, welding, drilling holes, removing, etc.) are prohib-
ited.
Allow under spec-
ified conditions
(gray part)
Removal of parts is prohibited.
Bar welding and making holes [up to diameter 20 mm (0.787 in)] by drilling
are possible.
47395870A NA - June 2012
1001-7

Section
2000
Removal and Installation of Engine Assembly
47395870A NA - June 2012

WARNING
• Keep away from fire.
• Be sure to release hydraulic pressure before
beginning work.
• The air conditioner circuit is filled with high-
pressure gas, so beware of the gas released
when loosening lines.
• Do not use open flames and do not allow
sparks near the battery.
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches [7 mm (0.276 in), 10 mm (0.394 in), 13 mm
(0.512 in), 14 mm (0.551 in), 17 mm (0.669 in), 19 mm
(0.748 in), 36 mm (1.417 in)]
• Box wrench [24 mm (0.945 in)]
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Crane (with the required lifting capacity)
• Pliers
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Wood planks, etc.
Removal of Engine Assembly
1. Use a wrench [17 mm (0.699 in)] to remove the bolt
(1), and then remove the battery cable (2) on the
negative side.
• After removing the terminal and harness, secure
them so that they do not interfere with the frame
and other parts.
Also, cover with a rubber cap to protect against
sparks.
• Tightening torque for bolt installation: [10.6 - 13.0
N·m (7.82 - 9.59 lbf·ft)]
2. Remove the counterweight.
For details, see "Removal and Installation of Coun-
terweight".
3. Remove the muffler.
For details, see "Removal and Installation of Muf-
fler".
4. Remove the pump.
For details, see "Removal and Installation of Hy-
draulic Pump".
(1), use a wrench [7 mm (0.276 in)] to loosen the
hose bands (2) (3), and then remove the intercooler
hose (high-temperature side) (4) and hose (5) from
the air cleaner.
• Tightening torque for band (2) installation: [8.8 -
9.8 N·m (6.49 - 7.23 lbf·ft)]
7.3 N·m (4.65 - 5.39 lbf·ft)]
47395870A NA - June 2012
2000-3

6. Loosen the hose bands (1), and then remove the
intercooler hose (low-pressure side) (2).
• Tightening torque for hose band (2) installation:
[8.8 - 9.8 N·m (6.49 - 7.23 lbf·ft)]
7. Use a wrench [14 mm (0.551 in)] to remove the bolts
(1) (2), and then remove the fan shroud (3).
8. Use a wrench to remove the bolts (1), and then re-
move the fan guard (2).
9. Use a wrench [7 mm (0.276 in)] to loosen the radia-
tor hose bands (1) in 2 locations, and then remove
the upper hose (2) and lower hose (3).
• Use caps to cover the radiator and hoses to pre-
vent any entry of water, dust or dirt.
• Before removing the radiator hose, completely
drain the coolant.
5.9 N·m (3.615 - 4.352 lbf·ft)]
47395870A NA - June 2012
2000-4

10. Use a wrench [13 mm (0.512 in)] to remove the 2
bolts (1), and then remove the connector brackets
(2).
11. Use a wrench [13 mm (0.512 in)] to remove the hose
bands (1) in 2 locations from the bracket, and then
remove the 5 connectors (2).
• Wrap the removed connectors in plastic after tying
them together.
• Tightening torque for bolt installation: [21.6 - 37.2
N·m (15.93 - 27.44 lbf·ft)]
12. Remove the connector (1) from the air conditioner
compressor.
(1), and then remove the terminal cap (2).
Use a wrench to remove the wiring (3) (4) from the
starter.
Use a wrench [17 mm (0.669 in)] to remove the bolt
(5), and then remove the wiring (6) from the frame.
14. Use a wrench [10 mm (0.394 in)] to remove the bolts
(1).
Remove the connector (2) from the alternator.
Use a wrench to remove the wiring (3) from the al-
ternator.
15. Use a wrench [13 mm (0.512 in)] to loosen the line
bolts (1) in 2 locations, and then remove the lines
(2) (3) from the compressor.
• Always remove the low-pressure (suction side)
line (2) first.
• Install caps or plugs to the compressor and lines
to prevent any entry of water, dust or dirt.
• Tightening torque for bolt (1) installation: [20 - 25
N·m (14.75 - 18.44 lbf·ft)]
47395870A NA - June 2012
2000-5

16. Loosen the hose bands (1) in 2 locations, and then
remove the heater hoses (2) (3).
• Install caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
17. Prepare the waste oil can (1).
• Drain the engine oil before removing the engine
oil hose.
Use a wrench [36 mm (1.417 in)] to remove the 2
engine oil remote hoses (1).
• Mark the engine and hoses so that the connectors
match at the time of assembly.
• Clean the engine and hoses by spraying them
with a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.
• Tightening torque for installation: [54.1 - 63.9 N·m
(39.91 - 47.14 lbf·ft)]
18. Remove the hose bands (1), and then remove the
fuel hoses (2).
19. Install the 2 shackles (1), then use the wire rope (2)
and liftcrane to secure the engine main unit.
47395870A NA - June 2012
2000-6

20. Use a box wrench [24 mm (0.945 in)] to remove the
4 bolts (1) from the mount.
• Tightening torque for bolt installation: [264.9 -
313.9 N·m (195.41 - 231.56 lbf·ft)]
21. Use the wire rope (1) and liftcrane to lift the engine
main unit.
• Be sure to check all hoses and connectors for any
disconnections before lifting.
Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.
• Thoroughly secure the engine so that it does not
fall over.
Installation of Engine Assembly
1. To install the engine, perform the reverse of the re-
moval procedure.
After installing the engine, resupply coolant and en-
gine oil, perform fuel line air bleeding, and perform
filling for the air conditioner gas.
For details, see the individual explanations for each
procedure.
2. Run the engine at no-load idling and check for any
water or oil leaks.
3. Attach the hydraulic pump, covers, and counter-
weight.
For details, see the individual explanations for each
procedure.
47395870A NA - June 2012
2000-7

Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Fuel
Cooler
CAUTION
work.
• As the fuel hose will be removed, strictly pro-
hibit open flames.
Items to prepare
• Wrenches [13 mm (0.512 in)]
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan
Removal of Fuel Cooler
1. Mark the fuel cooler (5) and hoses (1) (2) so that the
connectors match at the time of assembly.
• Use pliers to loosen the hose bands (3) (4), and
then remove the hoses.
• Fuel will spill out, so place a drip pan directly be-
low the area.
• Install caps or plugs to the fuel cooler and hoses
to prevent any entry of water, dust or dirt.
bolts (1), and then remove the fuel cooler (2).
47395870A NA - June 2012
2001-3

Installation of Fuel Cooler
Perform the reverse of the removal procedure.
After connecting the hoses, carefully check for any fuel
leaks.
When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for a bolt or other part, see
the Bolt Size and Torque Table.
Removal and Installation of Engine
Intercooler
CAUTION
• Be sure to release the pressure within the cir-
cuit before beginning work.
work.
load.
Items to prepare
(0.512 in), 14 mm (0.551 in), 19 mm (0.748 in)]
• Pliers
• Shackles (with the required lifting capacity) x 2
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Rag
• Cleaning fluid
47395870A NA - June 2012
2001-4

Removal of Intercooler
• Remove the counterweight.(For details, see "Removal
and Installation of Counterweight".)
bolts (1), and then remove the cover (2) (3).
7 bolts (1) from the radiator cover.
3. Use a wrench [7 mm (0.276 in)] to loosen the hose
band (1) in the 2 locations, and then remove the
upper hose (2) and lower hose (3) from the inter
cooler.
• Use caps to cover the intercooler and hoses to
prevent the entry of water, dust or dirt.
Tightening torque for band (1) installation: 8.8 -
9.8 N·m (6.492 - 7.229 lbf·ft)
bolts (1), and then remove the brackets (2).
47395870A NA - June 2012
2001-5

bolts (1), and then remove the fan guard (2).
Remove the bracket on the opposite side using the
same procedure.
7. Remove the 4 one-touch clips (1), and then remove
the front anti-insect net (2).
(1), and washer (2).
9. Install the shackle (1) to the top of the radiator, and
then use the wire rope (2) and liftcrane to lift the inter
cooler.
10. Lift until the fixtures (1) at the bottom of the inter
cooler become disconnected.
47395870A NA - June 2012
2001-6

11. Thoroughly check that the location is safe before
lowering the inter cooler on square wooden piece.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (1).
Installation of Intercooler
To install, perform the reverse of the removal procedure.
Check for any air leaks.
When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for a bolt or other part, see
the Bolt Size and Torque Table.
47395870A NA - June 2012
2001-7

Removal and Installation of
Radiator
WARNING
• Do not remove the radiator cap when the ra-
diator coolant temperature is high.
Hot liquid could spray out.
CAUTION
• Be sure to release the pressure within the cir-
cuit before beginning work.
work.
load.
Items to prepare
(0.551 in), 17 mm (0.669 in)]
• Pliers
• Cap
• Plug
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
Removal of Radiator
• Remove the counterweight.(For details, see "Removal
and Installation of Counterweight".)
bolts (1), and then remove the under cover (2).
2. Install the drain hose (1), and then prepare the drain
tank (2).
3. To make it easier to drain the coolant, remove the
radiator cap (1).
47395870A NA - June 2012
2001-8

4. Loosen the drain plug (1), and then drain the
coolant.
bolts (1), and then remove the covers (2) (3).
7 bolts (1) from the radiator cover.
bands (1) in the 2 locations, use a wrench [13 mm
(0.512 in)] to remove the bolt (2), and then remove
the upper hose (3) and lower hose (4) from the ra-
diator.
• Use caps to cover the radiator and hoses to pre-
vent the entry of water, dust or dirt.
• Tightening torque for band (1) installation: 4.9 -
5.9 N·m (3.615 - 4.352 lbf·ft)
8. Remove the drain plug (1), loosen the hose band
(2), and then remove the hose (3).
47395870A NA - June 2012
2001-9

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9. Loosen the hose band (2), and then remove the
hose (1) from the radiator cap.
• Install caps or plugs to the hoses to prevent any
entry of water, dust or dirt.
bolts (1), and then remove the fan guard (2).
Remove the bracket on the opposite side using the
same procedure.
the front anti-insect net (2).
bolts (1), the 2 washers (2).
47395870A NA - June 2012
2001-10

15. Install the 2 shackles (1) to the top of the radiator,
and then use the wire rope (2) and liftcrane to lift the
radiator.
16. Lift until the fixtures (1) at the bottom of the radiator
become disconnected.
lowering the radiator on square wooden piece.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (1).
Installation of Radiator
Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Bolt Size and
Torque Table".
Coolant capacity is 16.2 L (4.280 gal).
Finally, check that the level of coolant is correct.
47395870A NA - June 2012
2001-11

Removal and Installation of Oil
Cooler
WARNING
• Keep away from fire.
CAUTION
work.
load.
Items to prepare
(0.669 in)]
• Hexagon wrench [6 mm (0.236 in)]
• Pliers
• Screwdriver
• Eyebolts x 2
• Cap
• Waste oil can
• Rag
• Cleaning fluid
Removal of Oil Cooler
• Drain the hydraulic oil from the hydraulic oil tank.
See Draining Oil from Hydraulic Oil Tank for details of
the procedure.
bolts (1), and then remove the under cover (2).
2. Prepare the waste oil can (1).
bolts (1), and then remove the cover (2) (3).
47395870A NA - June 2012
2001-12

the anti-insect net (2).
band (1), and then remove the hose (2).
• Use caps to cover the oil cooler and lines to pre-
6. Use a hexagon wrench [6 mm (0.236 in)] to remove
the 4 bolts (1), and then remove the lines (2).
• Use caps to cover the oil cooler and lines to pre-
bolts (1).
8. Install the 2 eyebolts (1) on the top of the oil cooler.
• Fully tighten the eyebolts, and then loosen them
by a half turn.
47395870A NA - June 2012
2001-13

9. Install the 2 shackles (1) to the eyebolts, and then
use the wire rope (2) and liftcrane to lift the oil cooler
main unit.
• When lifting the oil cooler unit, be careful not to
let the line on the bottom of the oil cooler catch on
the fan shroud.
lowering the oil cooler on wood planks, etc.
Installation of oil cooler
Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Bolt Size and
Torque Table".
The O-rings cannot be reused.
Replace them with new parts.
47395870A NA - June 2012
2001-14

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