Part of the Case Repair Manuals.
The Case 9020 service manual PDF, OEM part 7-45980, tears this excavator down on paper: 542 pages of factory removal, rebuild, and pressure test procedures running from cylinder head to turntable bearing. Foldout hydraulic and electric schematics trace each circuit from the main pump through the pilot control valves to the swing motor and reduction gearbox. A dedicated troubleshooting section walks the track system, power train, and hydraulics through symptom, cause, and correction, with pressure check points called out. Set track deflection between 2.0 and 2.8 inches (51 to 70 mm), then measure your cylinder block bores against the 102.116 mm service limit before you commit to a reman. Guess at a travel motor and you buy it twice. Pay for this bookmarked, text searchable file once and it stays yours for the working life of the machine.
What's Inside This Case 9020 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 3-16 | Section Index - General (Standard Torque Specifications for 9000 Series Excavators, Fluids and Lubricants) |
| Engines | 17-228 | Section Index - Engines (Engine Removal and Installation, Radiator Removal and Installation, Detailed Engine Specifications, Aftercooler, Cylinder Head and Valve Train, Cylinder Block, Lubrication, Cooling System, Turbocharger, Turbocharger Failure Analysis) |
| Fuel System | 229-272 | Section Index - Fuel System (System and Filters, Injectors, Injection Pump) |
| Electrical | 273-358 | Section Index - Electrical (Electrical Specifications and Troubleshooting, Electric Schematic Foldout, Batteries, Systems Display Panel, Starter and Starter Solenoid, Alternator) |
| Tracks | 359-388 | Troubleshooting the Track System, Rollers, And Idlers |
| Power Train | 389-396 | Section Index - Power Train (Troubleshooting - See Section 8001, Drive Motor and Final Drive Transmission) |
| Hydraulics | 397-514 | Section Index - Hydraulics (Cleaning the Hydraulic System, Hydraulic Specifications, Troubleshooting, And Pressure Checks, Hydraulic Schematic Foldout, Main Hydraulic Pump, Pilot Control Circuit Pump, Hydraulic Swivel, Main Control Valve, Remote Control Valves, Solenoid Valves, Swing Motor and Swing Reduction Gear Box, Cylinders, Cushion Control Valve, Boom Holding Valve, Auxiliary Control Valve) |
| Mounted Equipment | 515-542 | Section Index - Mounted Equipment (Pedals and Levers, Turntable Bearing, Boom and Arm, Seat and Seat Belts, Electric and Hydraulic Schematic Foldout) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Grade 5 Bolts, Nuts, and Studs 1/4 in | 9-11 Pound-Feet (12-15 Newton metres) | p. 6 |
| Grade 5 Bolts, Nuts, and Studs 5/16 in | 17-21 Pound-Feet (23-28 Newton metres) | p. 6 |
| Cylinder Block ID | 102.00 to 102.04 mm | p. 36 |
| Cylinder Block Maximum Service Limit | 102.116 mm | p. 36 |
| Track deflection | 2.0 to 2.8 inches (51 to 70 mm) | p. 367 |
| Bolts that hold the track shoes | 362 to 434 pound-feet (490 to 588 Nm) | p. 367 |
| Cap screws that hold the end caps for the track roller to the track frame | 197 to 230 pound-feet (267 to 312 Nm) | p. 367 |
| Track roller lubricant capacity | 6.3 ounces (190 cc) | p. 367 |
| Cap screws that hold the brackets for the carrier roller to the track frame | 384 to 448 pound-feet (520 to 607 Nm) | p. 367 |
| Cap screws that hold the retainer | 20 to 23 pound-feet (27.1 to 31.2 Nm) | p. 367 |
| Idler wheel lubricant capacity | 5.5 ounces (170 cc) | p. 367 |
| Cap screws that hold the yoke to the brackets on the idler wheel | 197 to 230 pound-feet (267 to 312 Nm) | p. 367 |
Case 9020 Common Problems This Manual Covers
Case 9020 hydraulic power weak, boom and arm slow, all functions erratic under load
Check hydraulic oil level first and fill the reservoir if low; it holds 21.9 U.S. gallons (83 litres). Test main relief pressure with the procedure on page 421; spec is 4200 to 4350 psi (290 to 300 bar). If pressure checks good but functions stay slow, flow test each pump against its 41 gpm rating before condemning it.
Manual Section: Hydraulic Specifications, Troubleshooting, and Pressure Checks p. 421Grinding noise from one final drive, track drags or loses power when turning
Drain the final drive and check the oil for metal; refill with 2.8 U.S. quarts (2.5 litres). Inspect the sprocket cap screws for looseness, apply Loctite 262 to the threads, and torque them to 384 to 448 pound-feet (520 to 607 Nm) per page 392. Replace the final drive if debris keeps appearing.
Manual Section: Power Train p. 392Track loose on one side, chain jumps the sprocket or throws off on slopes
Measure track sag between the carrier roller and idler; adjust the tension cylinder until deflection reads 2.0 to 2.8 inches (51 to 70 mm) per page 367. Inspect the idler, rollers, and sprocket for uneven wear. Retorque loose track shoe bolts to 362 to 434 pound-feet (490 to 588 Nm).
Manual Section: Tracks p. 367Swing brake slow to release, upper structure drifts or swings weak against grade
Test swing circuit relief pressure; the spec on page 407 is 3200 to 3350 psi. If pressure is in range, check the swing brake solenoid with the electrical procedures starting. Drain the swing gearbox, look for metal, and refill with 1.8 U.S. quarts (1.7 litres) if the reduction gear whines.
Manual Section: Hydraulic Specifications, Troubleshooting, and Pressure Checks p. 407Engine bogs down under load, loses power when digging, runs fine at idle
Replace both fuel filters and bleed the system, following the fuel system procedures that begin on page 229. Inspect rubber suction lines for internal collapse; a soft line chokes flow only under load. Drain water and sediment from the tank; it holds 63.4 U.S. gallons (240 litres), so contamination settles at the bottom.
Manual Section: Fuel System p. 229Frequently Asked Questions
What is the torque specification for the track shoe bolts on the Case 9020 excavator?
The torque specification for the bolts that hold the track shoes is 362 to 434 pound-feet (490 to 588 Nm). p. 367
What is the torque specification for steel hydraulic fittings on the Case 9020?
The torque for 37 degree flare fittings ranges from 6-12 pound-feet (8-16 Nm) for 1/4 inch tubes up to 210-250 pound-feet (285-338 Nm) for 1-1/2 inch tubes. For straight threads with O-ring, the torque ranges from 12-19 pound-feet (16-26 Nm) to 250-400 pound-feet (339-542 Nm). p. 8
What are the replacement specifications for the hydraulic pump on the Case 9020?
The main hydraulic pump weighs 201 pounds (91 kg). The cap screws that hold the hydraulic pump to the flywheel housing must be tightened to 46 to 54 pound-feet (62 to 73 Nm). p. 441
What is the torque spec for the main control valve mounting bolts on a Case 9020 excavator?
The cap screws that hold the main control valve to the mounting bracket must be tightened to 178 to 208 pound-feet (242 to 282 Nm). p. 467
What is the engine oil capacity of the 4-390 diesel engine in the Case 9020 excavator?
The engine oil capacity with filter change is 11.6 U.S. quarts (11 litres). p. 13
How will I receive this Case 9020 Service Manual?
All 542 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Can I print this Case 9020 manual?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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