Repair Manual For Case 40XT Skid Steer Loader. Illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-up.

Format: PDF
Language: English
Pages: 627
Bookmarks: Yes
Searchable: Yes
Number: 6-45070
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes

Model

Case 40XT

Contents

General
Engines
Electrical
Power Train
Brakes
Hydraulics
Mounted Equipment
Schematic Set

Fill contents

– General
–FLUIDS AND LUBRICANTS
CAPACITIES AND LUBRICANTS
ENVIRONMENT
ENGINE LUBRICATION
Engine Oil Selection
Oil Viscosity/Temperature Ranges
DIESEL FUEL SYSTEM
Fuel Storage
Specifications For Acceptable No 2 Diesel Fuel
–STANDARD TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS-DECIMAL HARDWARE
Grade 5 Bolts, Nuts, And Studs
Grade 8 Bolts, Nuts, And Studs
TORQUE SPECIFICATIONS – METRIC HARDWARE
Grade 88 Bolts, Nuts, And Studs
Grade 129 Bolts, Nuts, And Studs
Grade 109 Bolts, Nuts, And Studs
TORQUE SPECIFICATIONS-STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting
Straight Threads With O-Ring
Split Flange Mounting Bolts
O-Ring Face Seal End
O-Ring Boss End
Fitting Or Lock Nut
Pipe Fittings
–METRIC CONVERSION CHART
CONVERSION FACTORS
Metric To US
US To Metric
–LOCTITE PRODUCT CHART
-Engines
–RADIATOR
Removal
Installation
–ENGINE
Removal
Installation

-Fuel Systems
Section Index – Fuel Systems
For Fuel System Repair – See the Engine Service Manual

-Electrical
–ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING
Interlock System
–ELECTRICAL SYSTEM SPECIFICATIONS AND TROUBLESHOOTING
GENERAL INFORMATION
Circuit Diagram Legends
Fuses
LEFT HAND INSTRUMENT PANEL
Standard RIGHT HAND INSTRUMENT PANEL
Optional Engine Shutdown System
Right Hand INSTRUMENT PANEL
CONTROL LEVERS
Left Hand Control Lever
Right Hand Control Lever
HOW TO TEST A WIRING HARNESS
Visual Inspection
Testing For Open Circuits
Finding An Open Circuit
Testing For Short Circuits
Finding A Short Circuit
Testing For A High Resistance Circuit
Finding A High Resistance Circuit
TROUBLESHOOTING EXAMPLE
TROUBLESHOOTING
–Battery
SAFETY RULES
MAINTENANCE
Electrolyte Level
Inspecting and Cleaning a Battery
NONSPILL CAPS
BATTERY TEST
Visual Checks
Specific Gravity Check
Capacity (Load) Test
CHARGING A BATTERY
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES
PREPARING A DRY CHARGED BATTERY FOR USE
CHARGING GUIDE FOR BATTERIES OTHER THAN
MAINTENANCE FREE BATTIERES
–STARTER AND STARTER SOLENOID
SPECIFICATIONS
LUBRICATION
NO-LOAD TEST
General Information
Test Equipment
Test Procedure
DISASSEMBLY
INSPECTION
Brushes and Brush Springs
Brush Holder
Armature
Field Coil Test
ASSEMBLY
STARTER SOLENOID TEST
Starter Solenoid Test Procedure
–ALternator
ALTERNATOR
Disassembly
Inspection of Brushes
Inspection and Testing of Rotor
Inspection and Testing of Stator
Testing the Capacitor
Testing the Rectifier Bridge
Inspection and Replacement of Bearings
Assembly

-Power Train
–HYDROSTATIC SYSTEM – “HOW IT WORKS”
System Overview
Hydrostatic Pump
Hydrostatic Drive Motor
Mechanical Parking Brake Overview
Hydraulic Brake Option
Hydrostatic Control Levers
Hydrostatic System Cleanup
Hydrostatic Start-Up Procedure
–HYDROSTATIC SYSTEM TROUBLESHOOTING
SPECIFICATIONS
SPECIAL TOOLS
SAFETY RULES
CHECKS TO DO BEFORE TROUBLESHOOTING
HYDROSTATIC SYSTEM TROUBLESHOOTING
One Transmission (Right Or Left) Works Correctly And The Other Does Not
Machine Does Not Have Enough Power
HYDROSTATIC SYSTEM TROUBLESHOOTING CHECKS
Check 1- Checking Charge Pressure/Flow
Check 2 – Checking Circuit Relief Valve Pressure
–REMOVAL AND INSTALLATION OF HYDROSTATIC COMPONENTS
TORQUE SPECIFICATIONS
TANDEM (HYDROSTATIC) PUMP
Removal
Installation
HYDRAULIC (DRIVE) MOTOR
Removal
Installation
HYDRAULIC (DRIVE) MOTOR
(EUROPEAN MACHINES AND OPTIONAL NORTH AMERICAN MACHINES)
Removal
Installation
–DRIVE COUPLER
TORQUE SPECIFICATIONS
DRIVE COUPLER
Disassembly
Inspection
AssemblY
–PISTON PUMP
SPECIFICATIONS
SPECIAL TORQUES
GENERAL INFORMATION
SEPaRATING THE PUMPS
ASSEMBLING THE PUMPS
REAR PUMP
Disassembly
Inspection
Assembly
FRONT PUMP
Disassembly, Inspection, and Assembly
–DRIVE MOTORS
Disassembly
Inspection
Assembly
–SPROCKET. CHAINS, AND AXLE ASSEMBLIES
TORQUE SPECIFICATIONS
ADJUSTING THE DEFLECTION OF THE CHAINS
REMOVAL AND INSTALLATION OF AXLES
Removal
Installation
AXLE DISASSEMBLY
AXLE INSPECTION
AXLE ASSEMBLY
–WHEELS AND TIRES
WHEELS AND TIRES
Tire Pressure
Inflating The Tire
Wheel Nut Torque

-Brakes
–BRAKE SYSTEM – “HOW IT WORKS”
(Spring Applied-Cable Release Park Brakes)
EXPLODED VIEW OF SPRING APPLIED – CABLE RELEASE PARK BRAKES
Brake System Overview (Spring Applied – Hydraulic Release Park Brakes)
EXPLODED VIEW OF SPRING APPLIED – HYDRAULIC RELEASE BRAKES AND HYDROSTATIC DRIVE
MOTOR
BRAKE SYSTEM HYDRAULIC DIAGRAM
–BRAKE SYSTEM TROUBLESHOOTING
SPECIFICATIONS
SPECIAL TOOL
Safety Rules
Brake System Troubleshooting (Pin Lock – Cable Release Park Brakes)
Checks To Do Before Troubleshooting
Brake System Troubleshooting
Spring Applied – Hydraulic Release (European Machines And Optional For North American Machines)
–REMOVAL AND INSTALLATION OF PARK BRAKE COMPONENTS
SPECIFICATIONS
Safety Rules
Removal of Pin Lock Park Brakes
Installation of Pin Lock Park Brakes
Removal of Spring Applied, Hydraulic Release Park Brakes
Installation of Spring Applied, Hydraulic Release Park Brakes
–BRAKE SOLENOID VALVE
SOLENOID VALVE
Disassembly
Assembly
–BRAKES – SPRING APPLIED – HYDRAULIC RELEASE(EUROPEAN AND OPTIONAL NORTH AMERICAN MACHINES)
Disassembly
Assembly
–BRAKES – PIN LOCK – CABLE RELEASE
Disassembly
Inspection
Assembly
–BRAKE PUMP
Disassembly
Assembly

-Hydraulics
–HYDRAULIC SYSTEM – “HOW IT WORKS”
HYDRAULIC SYSTEM OVERVIEW
HYDRAULIC COMPONENTS
Components Defined
Reservoir
Hydraulic Pump
LOADER CONTROL VALVE
Functional Overview Of The Loader Control Valve
Component Overview Of The Loader Control Valve
MAIN RELIEF VALVE
Operation: Closed Position
Operation: Open Position
CIRCUIT RELIEF VALVE / ANTI-CAVITATION CHECK VALVE
Direct Acting Circuit Relief Valve
LOADER CONTROL VALVE FUNCTION
Loader Spool Actuated To Raise Loader
Loader Spool Actuated To Lower Loader
Loader Spool Actuated To Raise, Bucket Spool To Rollback
Loader Spool Actuated To Lower, Bucket Spool To Rollback
Loader Spool Actuated To Float
SPOOL LOCK SOLENOIDS
AUXILIARY CIRCUIT
AUXILIARY CONTROL VALVE
HIGH FLOW HYDRAULICS
FILTER RESTRICTION INDICATOR
BI-DIRECTIONAL SELF-LEVELING (BDSL) SYSTEM
Bucket Self-Leveling
Functional Overview Of The Bi-Direction Self-Level Loader Control Valve
Loader Raise & Bucket Self-Leveling
Loader Raise-Bucket At Full Dump
Loader Lower & Bucket Self-Leveling
Loader In Float
Loader Raise & Bucket Dump Self-Leveling Off
BI-DIRECTIONAL SELF-LEVELING SYSTEM TROUBLESHOOTING
–HYDRAULIC SYSTEM TROUBLESHOOTING
SPECIFICATIONS
SPECIAL TOOLS
PRESSURE CHECKS
Loader Main Relief
TESTING CIRCUIT RELIEF VALVES WITH A HAND PUMP
FLOWMETER TESTS
General Information
Test No 1 – Gear Pump
Test No 2 – Loader Circuits and Main Relief Valve
METRIC MEASURE CHECK SHEET
US MEASURE CHECK SHEET
–CLEANING THE HYDRAULIC SYSTEM AND HYDROSTATIC SYSTEM
General Information
Types Of Contamination
Cleaning The Hydraulic System
Lushing Water From The Hydraulic System
Cleaning The Hydrostatic System
Cleaning Hoses, Tubes, And Fittings
–REMOVAL AND INSTALLATION OF HYDRAULIC COMPONENTS
GEAR (EQUIPMENT) PUMP
Removal
Installation
LOADER CONTROL VALVE
Removal
Installation
HYDRAULIC FILTER BASE ASSEMBLY
Removal
Inspection
Installation
HIGH FLOW PUMP (IF EQUIPPED)
Removal
Installation
HIGH FLOW VALVE (IF EQUIPPED)
Removal
Installation
AUXILIARY VALVE (IF EQUIPPED)
Removal
Installation
RIDE CONTROL ACCUMULATOR (IF EQUIPPED)
Removal
Installation
RIDE CONTROL SOLENOID VALVE (IF EQUIPPED)
Removal
Installation
SOLENOID VALVE FOR HYDRAULIC COUPLER
(IF EQUIPPED)
Removal
Installation
HYDRAULIC OIL COOLER
Removal
Installation
–GEAR (EQUIPMENT) PUMP
GEAR (EQUIPMENT) PUMP
Disassembly
Inspection
Assembly
–LOADER CONTROL VALVE
CONTROL VALVE
Disassembly
Inspection
Assembly
DUAL SELF-LEVELING CONTROL VALVE
Disassembly
Inspection
Assembly
–Cylinders
SPECIFICATIONS
SPECIAL TOOLS
GENERAL
Retaining Screw – Tube To Gland Procedure
LOADER LIFT CYLINDER
Disassembly
Inspection
Assembly
LOADER BUCKET CYLINDER
Disassembly
Inspection
Assembly
BACKHOE SWING CYLINDER
Disassembly
Inspection
Assembly
BACKHOE BOOM AND DIPPER CYLINDER
Disassembly
Inspection
Assembly
BACKHOE BUCKET CYLINDER
Disassembly
Inspection
Assembly
BACKHOE FOLD DOWN STABILIZER CYLINDER
Disassembly
Inspection
Assembly
BACKHOE VERTICAL STABILIZER CYLINDER
Disassembly
Inspection
Assembly
–FLAT FACED COUPLERS
FEMALE COUPLER
Disassembly
Assembly
MALE COUPLER
Disassembly
Assembly
–High Flow Valve
HIGH FLOW VALVE
Disassembly
Inspection
Assembly
–D-125 BACKHOE CONTROL VALVE – NA ONLY
SEPARATING THE PARTS OF THE BACKHOE CONTROL VALVE
Inspection
Assembly
CHECK VALVE ASSEMBLY
Disassembly
Assembly
MAIN RELIEF VALVE
CIRCUIT RELIEF VALVE
ASSEMBLING THE PARTS OF THE BACKHOE CONTROL VALVE
–ACCUMULATOR FOR RIDE CONTROL
SPECIFICATIONS
SPECIAL TOOLS
DISCHARGING AN ACCUMULATOR
Disassembly
Inspection
Assembly
CHECKING THE NITROGEN CHARGE IN THE ACCUMULATOR
CHARGING THE ACCUMULATOR WITH DRY NITROGEN

-Mounted Equipment
–PEDALS AND LEVERS
SPECIFICATIONS
SPECIAL TORQUES
THROTTLE CONTROL LINKAGE ADJUSTMENT
Throttle Lever Tension Adjustment
Hand Throttle Adjustment (Without Foot Throttle Option)
Hand Throttle Adjustment (With Foot Throttle Option)
Foot Throttle Adjustment
LOADER CONTROL LINKAGE ADJUSTMENT
Fore/Aft Adjustment
Loader And Bucket Adjustment
LAP BAR HEIGHT ADJUSTMENT
AUXILIARY HYDRAULIC PEDAL
DRIVE CHAINS
Checking The Drive Chain Tension
Drive Chain Tension Adjustment
–LOADER
REPLACING THE CUTTING EDGE ON 40XT BUCKETS
Replacing Welded Cutting Edges
Replacing Bolt-On Cutting Edges
WELD SPECIFICATIONS FOR 40XT BUCKETS
REMOVAL OF THE 40XT LOADER FRAME
INSPECTION OF THE 40XT LOADER FRAME
INSTALLATION OF THE 40XT LOADER FRAME
–ATTACHMENT COUPLER
ATTACHMENT COUPLER (MECHANICAL)
Disassembly
Inspection
Assembly
ATTACHMENT COUPLER (HYDRAULIC)
Disassembly
Inspection
Assembly
–ROPS Canopy, Seat, Seat Belts, and Operators Compartment
Possible Damage To The Rops Canopy
Maintenance And Inspection Of The Rops Canopy
Removal Of The Rops Canopy
Installation Of The Rops Canopy
Removal Of The Rear Window
Installation Of The Rear Window
Removal Of The Side Windows
Installation Of The Side Windows
Removal Of Top Window
Installation Of Top Window
Removal Of The Door Frame Window
Installation Of The Door Frame Window
Removal Of The Front Door
Installation Of The Front Door
Removal Of The Xt Non-Suspension Seat
Installation Of The Seat Belts
Installation Of The Xt Non-Suspension Seat
Removal Of The Xt Suspension Seat
Installation Of The Seat Belts
Installation Of The Xt Suspension Seat
–HEATER
BASIC HEATER
Removal
Inspection
Installation
DELUXE HEATER
Removal
Inspection
Installation
–Backhoe (D125 Backhoe)
BACKHOE
Removal
Installation
PIVOT PIN INSTALLATION
BUCKET TEETH
Tooth Shank Replacement
Tooth Point Replacement
CUTTING EDGES
Bottom Cutting Edge Replacement
Side Cutting Edge Replacement