CASE Construction CX160 Crawler Excavator Service Manual 7-29061 English

Name: CASE Construction CX160 Crawler Excavator Service Manual 7-29061 English
SKU: 7-29061.pdf
Price: 18.99 USD
Availability: InStock

$ 18.99 USD

Official Manual Overview

Dominate the 13-to-18-ton earthmoving class with this definitive OEM Service Manual, engineered explicitly for the CASE CX160 Crawler Excavators. Designed for advanced diagnostic technicians, this volume bypasses routine upkeep to deliver surgical chassis and fluid system rebuild protocols. It provides elite-level calibration data for dual hydraulic architectures, detailing specific flow and pressure metrology for both the Uchida (CX130/CX160) and Kawasaki (CX130/CX160/CX180) main hydraulic pumps. Furthermore, it transforms the cabin into a digital command center, detailing the exact keystrokes required to navigate the onboard monitor's hidden CHK1, DIAG, and HR screens for deep CAN-bus electronic troubleshooting. Structural integrity is guaranteed through uncompromising tolerances, from verifying strict 171.45 to 190 mm track pitch limits to applying massive torque specifications—such as the 3150 to 4130 Nm required for the boom cylinder piston nuts. Please note: In strict adherence to the manufacturer's publication strategy, while the chassis, complex hydraulics, and complete electrical networks are exhaustively covered, deep internal Isuzu diesel engine block teardowns (BB/DD-4BG1TRA) are explicitly redirected to a dedicated Engine Service Manual.

Brands: CASE Construction
Equipment Type: Crawler Excavator
Manuals Type: Service Manual
Machine Model: CX160
Serial Number: N/R
Region: N/R
Book Code: 7-29061
Issued: Printed in France, December 2001
Language: English
Pages: 634
File Format: PDF (Searchable)

Core Selling Points

Deep-Level Monitor & CAN-Bus Hacking: Turn the cabin display into an advanced diagnostic terminal. The manual details the exact button sequences (e.g., holding the travel speed and work mode selectors) to unlock hidden "CHK1" and "DIAG" engineering screens. It allows mechanics to instantly decode critical CAN communication faults (Code M0090), engine controller errors (Code M00B0), and linear motor circuit failures (Code E0031) without blind guessing.
Extreme-Torque Cylinder Reconstruction: Prevent catastrophic seal blowout during high-pressure operations. The literature provides uncompromising torque architectures for all major cylinders, dictating massive fastening values up to 4130 Nm for the CX160 boom cylinder piston nut, and an immense 13,600 Nm parameter for the CX240 dipper cylinder, ensuring absolute structural integrity.
Dual-Architecture Hydraulic Calibration: Master fluid delivery for both Uchida and Kawasaki main pumps. Technicians are guided through step-by-step pressure metrology using the CAS 30038 test kit. It mandates strict multi-stage adjustments, such as calibrating the standard main relief valve to 343±3 bar (34.3±0.3 MPa) and precisely tuning the 2-stage higher pressure relief to exactly 363±5 bar (36.3±0.5 MPa).

Features & Highlights

Surgical Undercarriage Metrology: Stop replacing tracks and rollers based on visual estimates. The documentation provides exhaustive micrometer thresholds, demanding technicians verify the standard 171.45 mm track pitch and mandating a hard replacement limit when the toothed sprocket wheel wears down to exactly 53 mm. It also dictates precise shimming to maintain a strict 0.5 to 3 mm clearance at the boom-to-chassis articulation.
Pin-by-Pin Electrical Mapping: Eradicate parasitic draws and intermittent harness shorts. Utilizing the specialized CAS-30039 service connector kit, the manual maps out complex voltage paths, instructing users to verify absolute targets like the 24V output at CN6 terminal 28 for the travel speed solenoid or the exact 10 to 80-ohm resistance parameters for the fuel sender circuit.
Dynamic Fluid Logic Charts: Navigating heavy earthmover hydraulics is made straightforward. The manual extensively charts the internal spool logic and flow paths for specialized networks, completely breaking down how the "Variable Priority Valve Circuit" pilots the cancellation valve to maintain maximum swing torque even while the dipper is fully engaged.

Problem Solver

Eradicates "Parts Cannon" Diagnostics: Stop blindly replacing expensive ECMs and valve banks. By testing the exact proportional solenoid amperages—such as verifying a strict 600 mA draw in "H-Mode" for the Uchida pump—technicians can definitively prove whether sluggish machine response is caused by a burned-out solenoid, a corrupted computer, or a physical line restriction.
Cures Intermittent Overheating: Resolves hidden bypassing issues that cook hydraulic fluid. The troubleshooting matrices map out specific diagnostic trees for high temperature warnings, guiding mechanics to isolate failing components like the 39-bar pilot supply block or a sticking non-return check valve within the main control manifold.
Prevents Reassembly Catastrophes: Improperly sequenced control valves will destroy hydraulic efficiency. This guide safeguards your rebuilds with rigid teardown and fastening sequences, ensuring components like the dipper semi-parallel valve block (requiring exactly 60 Nm on the M27 plugs) and the swing priority plate are reconstructed to absolute factory tolerances.

Important Pre-Purchase Advisories

Dedicated Engine Repair Not Included: In strict adherence to CASE Corporation's publication strategy, this manual extensively covers chassis wiring, CAN-bus networks, and complete engine removal/installation procedures. However, deep internal Isuzu diesel engine block teardowns are explicitly marked to "Consult the Engine Service Manual."
Bonus - Complete "Pocket" Schematics Included: Unlike many digital copies that omit the physical pocket inserts, this specific manual fully incorporates the original large-format electrical wiring diagrams and complete hydraulic circuit charts (OEM Reference 7-27612). Technicians receive 100% unbroken end-to-end component routing and fluid logic without the need to purchase supplemental publications.

Table of Contents

General Information
- Safety, general information and standard torque data
  - General information
  - Safety
  - Standard torque data for cap screws and nuts
- General specifications and special torque setting
  - Type, serial number and year of manufacture of the machine
    - Machine
    - Engine
    - Component serial numbers
  - Fluids and lubricants
    - Hydraulic fluid
    - Transmission component oil
    - Grease
    - Engine oil
    - Oil viscosity/Oil range
    - Fuel
    - Anti-freeze/Anti-corrosion
    - Environment
    - Components made from plastic or resin
  - Specifications
    - Engine
    - Capacities
    - Electrical system
    - Hydraulic system
    - Cylinder
    - Control valve
    - Swing
    - Travel
    - Undercarriage
    - Attachment
    - Weight of components
  - Dimensions and limit of wear and tear of the mobile joints of the attachment
    - Boom foot/Undercarriage
    - Boom cylinder foot/Undercarriage
    - Boom cylinder head/Boom
    - Dipper cylinder foot/Boom
    - Boom/Dipper
    - Dipper cylinder head/Dipper
    - Bucket cylinder foot/Dipper
    - Connecting rod/Dipper
    - Compensator/Bucket
    - Connecting rod/Compensator/Bucket cylinder head
    - Dipper/Bucket
  - Special torque settings
  - Machine overall dimensions CX130 CX160
  - Machine overall dimensions CX180
Engine
- Removal and installation of the engine
  - Specifications
  - Special torque settings
  - Engine
    - Removal and installation
- Radiator and oil-cooler
  - Specifications
  - Radiator and oil-cooler
    - Removing the radiator and oil-cooler assembly
    - Installation
  - Changing the radiator or oil-cooler
    - Disassembly and assembly
Fuel System
- Fuel tank
  - Specifications
  - Fuel reservoir
    - Removal
    - Installation
    - Description
Electrical System
- Electrical system, electrical and electronic troubleshooting
  - Specifications
  - Special tools
  - Location of components
    - General location of the components (outside the cab)
    - Relay and main fuses (battery compartment)
    - General location of the components (inside the cab)
    - Fuse box
    - Instrument panel
  - Operating principles
    - Engine checks
    - Work mode selection
    - H/S/L mode checking
    - Auto mode checking
    - Acceleration checking
    - Engine idle checking (automatic/manual)
    - Breaker mode checking
    - Automatic engine preheat
    - Auto engine warm-up
    - Idle checking using the battery voltage and the coolant temperature
    - Engine emergency stop
    - Back-up mode
    - Function locking
    - Power boost
    - Swing brake
    - Travel mode
    - Fuel level
    - Engine fuel injection pump electronic regulator
  - Access and contents of monitor displays (Diagnostic mode)
    - Access to monitor displays
    - Machine condition
    - Diagnostic code
    - Machine history
    - Re-initialisation
  - Warning messages
    - Message display
  - Excavator model selection procedure
    - Changing the language code
  - Changing the access code for the anti-theft system
  - Troubleshooting
    - Prior inspections
    - Reading the organisation charts
    - Procedures
    - Low fuel
    - Add coolant solution
    - Low engine oil pressure
    - Overheating
    - Defective battery charge circuit
    - Electrical system troubleshooting
    - Travel
  - Electrical inspection of components
    - Inspection equipment
    - Proportional solenoid
    - Engine emergency stop motor
    - 6 solenoid valve block
    - Engine rpm sensor
    - Engine coolant and hydraulic oil temperature sensor
    - Pressure sensor
- Inspection and maintenance of batteries and connecting a booster battery
  - Safety instructions
  - Specifications
- Main and engine electronic control boxes
  - Main electronic control box and engine electronic control box
    - Removal
    - Main electronic control box
    - Engine electronic control box
    - Installation
Undercarriage
- Removal and installation of tracks
  - Specifications
  - Special torque settings
  - Special tools
  - Tracks set
    - Description
    - Removal
- Rollers
  - Specifications
  - Special torque settings
  - Special tools
  - Lower roller
    - Description
    - Removal
    - Reconditioning
    - Disassembly
    - Inspection
    - Assembly
    - Installation
  - Upper roller
    - Description
    - Removal
    - Reconditioning
    - Disassembly
    - Inspection
    - Assembly
    - Installation
- Sprocket
- Idler wheel and tension shock absorber
  - Disassembly and assembly of the idler wheel
    - Description
    - Reconditioning
    - Disassembly
    - Inspection
    - Assembly
    - Leakage test
  - Disassembly and assembly of the tension shock absorber
    - Description
    - Disassembly
    - Assembly
  - Track tension cylinder (CX130, CX160 AND CX210)
    - Description
    - Removal
    - Disassembly
    - Inspection
    - Assembly
    - Installation
  - Track tension cylinder (CX210)
    - Description
    - Removal
    - Disassembly
    - Inspection
    - Assembly
Drive Train
- Drive motor and final drive transmission removal and installation
  - Specifications
  - Special torques
  - Drive motor and final drive transmission
    - Removal and installation
- Drive motor and final drive transmission disassembly and assembly
  - Specifications
  - Special torque settings
  - Travel motor and reduction gear assembly
    - Description
    - Disassembly
- Swing reduction gear, removal and installation
- Swing reduction gear, disassembly and assembly
  - Disassembly
Upperstructure Hydraulics
- Depressurising and decontaminating the hydraulic system, use of the vacuum pump and bleeding the components
  - Special tools
  - Releasing pressure in the hydraulic system
  - Bleeding air from the main hydraulic system components
    - Hydraulic pump
    - Attachment cylinders
    - Hydraulic swing motor
  - Vacuum pump
    - Installation
- Specifications, troubleshooting, checks and hydraulic pressure settings
  - Specifications
  - Special tools
    - Tester
  - Identification of hydraulic components
    - Pump CX130/CX160 (Uchida)
    - Pump CX130/CX160/CX180/CX210/CX240 (Kawasaki)
    - Control valve CX130/CX160/CX180
    - Control valve CX210/CX240
    - 6 solenoid valve manifold
  - Display on diagnostic screen "CHK1"
  - Warming up the engine
  - Warming up the hydraulic fluid
  - Checking and pressure setting procedure
    - Pilot system secondary relief valve (H)
    - Checking the pilot accumulator
    - Main relief valve (A)
    - Secondary control valve attachment relief valves
    - Secondary relief valves of the boom safety valves (B1 and B2)
    - Dipper secondary relief valve (D1)
    - Swing secondary relief valves
    - Checking the swing braking pressure
  - Troubleshooting
    - Not possible to select hard/soft shock absorbing system
    - The boom or the dipper does not lower
- Hydraulic reservoir removal and installation
  - Specifications
  - Fuel reservoir
    - Removal
    - Installation
    - Description
- Main and pilot pumps, removal and installation
  - Specifications
  - Special torque settings
  - Main hydraulic pump
    - Removal and installation
  - Pilot pump
    - Removal and installation
- Main hydraulic control valve, removal and installation
- Attachment cylinders, removal and installation
  - Specifications
  - Preparation before removal/installation
  - Boom cylinder
    - Description
    - Removal
    - Installation
  - Dipper cylinder
    - Description
    - Removal
    - Installation
  - Bucket cylinder
    - Description
- Hydraulic swivel, removal and installation
- Pilot blocs, removal and installation
  - Pilot function blocks
    - Travel pedal block
    - LH control lever
    - RH control lever
    - Swing shuttle block
    - Cushion control valve
    - Servo control and return manifold block
    - 6 solenoid valve block
- Swing motor, removal and installation
  - Specifications
  - Special torque settings
  - Swing motor
    - Removal
    - Installation
- Main hydraulic pump, disassembly and assembly
  - Specifications
  - Special torque settings
  - Regulating control
  - Disassembly
  - Assembly
- Main hydraulic control valve, disassembly and assembly
  - Torque setting
  - Description
  - Non return check valve
    - Disassembling the non-return check valve for dipper, bucket and boom 1
    - Inspection
    - Assembly
    - Disassembling the non-return check valves for option, boom 2 and swing
    - Inspection
    - Assembly
    - Disassembling the non-return check valve for RH travel and dipper
    - Inspection
    - Assembly
    - Disassembling the LH travel non-return check valve
    - Inspection
    - Assembly
    - Boom non-return check valve
    - Disassembly
    - Inspection
    - Assembly
  - 39 bar supply block
    - Disassembly
    - Inspection
    - Assembly
  - Swing priority block
    - Disassembly
    - Inspection
    - Assembly
  - Semi-parallel valve block
    - Disassembly
    - Inspection
    - Assembly
  - Cancellation valve
    - Disassembly
    - Inspection
    - Assembly
  - Free passage locking
    - Disassembly
    - Inspection
    - Assembly
- Attachment cylinders, disassembly and assembly
  - Specifications
  - Special torque settings
  - Special tools
  - Cylinders
    - Boom cylinder description
    - Dipper cylinder description
- Hand control levers, disassembly and assembly
  - Specifications
- Foot control levers, disassembly and assembly
  - Torque settings
- Six-solenoid valves, disassembly and assembly
  - Six solenoid valves block
    - Identifying the ports and the solenoid valves
    - Section
    - Disassembly and assembly
    - Inspection
- Caution valve, disassembly and assembly
- Safety vave
- Hydraulic swivel, disassembly and assembly
- Swing motor, disassembly and assembly
  - Hydraulic swing motor
    - Description
    - Disassembly
- Hydraulic functions
  - Hydraulic functions
    - Function list
    - Controls in neutral (Pump Uchida) (CX130/CX160)
    - Controls in neutral (Pump Kawasaki) (CX130/CX160/CX180)
    - High speed travel circuit
    - Low speed travel circuit
    - Straight line travel circuit
    - Swing circuit
    - Variable priority valve circuit
    - Boom raising circuit
    - Boom lowering circuit with load holding valve
    - Boom lowering reinjection circuit
    - Boom lowering anti-vibration circuit
    - Dipper extending circuit
    - Dipper retracting circuit
    - Dipper retracting reinjection circuit
    - Bucket opening circuit
    - Bucket closing circuit
    - Crusher circuit
    - Breaker circuit
Upperstructure
- Upperstructure, turntable and counterweight
  - Special torque settings
  - Specifications
  - Upperstructure
    - Inspection
    - Removal
    - Installation
- Boom, dipper and bucket
  - Boom
    - Description
    - Removal
    - Installation
- Seat and seat belt
  - Specifications
  - Operator’s seat
    - Description
    - Removal
    - Installation
- Cab and cab equipment
  - Specifications
  - Special torque settings
  - Cab
    - Removal
    - Installation
  - Heating block/Air-conditioning block
    - Description
    - Removal
    - Installation
- Air conditioning unit disassembly and assembly