Case CX490D User manual

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CX490D
CX500D
Crawler Excavator
SERVICE MANUAL
CX490D
CX500D
Crawler Excavator
Part number 47937811
English
February 2016
© 2016 CNH Industrial Italia S.p.A. All Rights Reserved.
Part number 47937811
SERVICE MANUAL

SERVICEMANUAL
CX490DCrawlerexcavatorsLCversion(TIER4FINAL)-EUMarket
CX490DCrawlerexcavatorsRTCversion(TIER4FINAL)-EUMarket
CX500DCrawlerexcavatorsLCMassExcavatorversion(TIER4FINAL)-
EUMarket
CX500DCrawlerexcavatorsRTCMassexcavatorversion(TIER4FINAL)
-EUMarket
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.102]Panandcovers....................................................................10.2
[10.106]Valvedriveandgears..............................................................10.3
[10.101]Cylinderheads.....................................................................10.4
[10.105]Connectingrodsandpistons.......................................................10.5
[10.103]Crankshaftandywheel............................................................10.6
[10.216]Fueltanks..........................................................................10.7
[10.206]Fuellters..........................................................................10.8
[10.218]Fuelinjectionsystem...............................................................10.9
[10.202]Aircleanersandlines............................................................10.10
[10.250]Turbochargerandlines...........................................................10.11
[10.254]Intakeandexhaustmanifoldsandmufer.......................................10.12
[10.500]SelectiveCatalyticReduction(SCR)exhausttreatment.........................10.13
[10.501]ExhaustGasRecirculation(EGR)exhausttreatment............................10.14
[10.400]Enginecoolingsystem...........................................................10.15
[10.414]Fananddrive....................................................................10.16
[10.310]Aftercooler........................................................................10.17
[10.304]Enginelubricationsystem........................................................10.18
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.300]Reservoir,cooler,andlters........................................................35.2
[35.104]Fixeddisplacementpump..........................................................35.3
[35.106]Variabledisplacementpump.......................................................35.4
[35.102]Pumpcontrolvalves................................................................35.5
[35.359]Maincontrolvalve..................................................................35.6
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[35.357]Pilotsystem........................................................................35.7
[35.355]Hydraulichandcontrol.............................................................35.8
[35.356]Hydraulicfootcontrol...............................................................35.9
[35.352]Hydraulicswingsystem..........................................................35.10
[35.353]Hydraulictravelsystem..........................................................35.11
[35.354]Hydrauliccentraljoint............................................................35.12
[35.736]Boomhydraulicsystem..........................................................35.13
[35.737]Dipperhydraulicsystem..........................................................35.14
[35.738]Excavatorandbackhoebuckethydraulicsystem................................35.15
[35.360]Hammerandrotatingbuckethydraulicsystem..................................35.16
[35.820]Hydraulicdrivencoolingfans....................................................35.17
Framesandballasting.................................................................39
[39.140]Ballastsandsupports..............................................................39.1
Tracksandtracksuspension........................................................48
[48.130]Trackframeanddrivingwheels....................................................48.1
[48.100]Tracks..............................................................................48.2
[48.134]Tracktensionunits.................................................................48.3
[48.138]Trackrollers........................................................................48.4
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.200]Airconditioning.....................................................................50.2
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.100]Harnessesandconnectors.........................................................55.2
[55.525]Cabenginecontrols................................................................55.3
[55.015]Enginecontrolsystem..............................................................55.4
[55.201]Enginestartingsystem.............................................................55.5
[55.301]Alternator...........................................................................55.6
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[55.302]Battery..............................................................................55.7
[55.202]Coldstartaid.......................................................................55.8
[55.011]Fueltanksystem...................................................................55.9
[55.010]Fuelinjectionsystem.............................................................55.10
[55.014]Engineintakeandexhaustsystem...............................................55.11
[55.988]SelectiveCatalyticReduction(SCR)electricalsystem..........................55.12
[55.989]ExhaustGasRecirculation(EGR)electricalsystem.............................55.13
[55.012]Enginecoolingsystem...........................................................55.14
[55.013]Engineoilsystem................................................................55.15
[55.640]Electronicmodules...............................................................55.16
[55.512]Cabcontrols......................................................................55.17
[55.036]Hydraulicsystemcontrol.........................................................55.18
[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.19
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem...............55.20
[55.524]Cabcontrols(Liftarm,Boom,Dipper,Bucket)...................................55.21
[55.416]Swingcontrolsystem............................................................55.22
[55.417]Travelcontrolsystem............................................................55.23
[55.530]Camera...........................................................................55.24
[55.518]Wiperandwashersystem........................................................55.25
[55.404]Externallighting..................................................................55.26
[55.514]Cablighting......................................................................55.27
[55.408]Warningindicators,alarms,andinstruments....................................55.28
[55.992]Anti-theftsystem.................................................................55.29
[55.DTC]FAULTCODES..................................................................55.30
Booms,dippers,andbuckets.......................................................84
[84.910]Boom...............................................................................84.1
[84.912]Dipperarm.........................................................................84.2
[84.100]Bucket..............................................................................84.3
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Platform,cab,bodywork,anddecals.............................................90
[90.150]Cab.................................................................................90.1
[90.156]Cabglazing........................................................................90.2
[90.118]Protectionsandfootboards.........................................................90.3
[90.120]Mechanically-adjustedoperatorseat...............................................90.4
[90.100]Enginehoodandpanels...........................................................90.5
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INTRODUCTION
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Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing....................................3
Safetyrules.....................................................................................4
Safetyrules–Generalinformation.............................................................5
Safetyrules–Personalsafety..................................................................6
Safetyrules–ROPSjudgment.................................................................8
Safetyrules-Ecologyandtheenvironment..................................................14
Torque–Boltandnut.........................................................................15
Torque-Specialtorquesetting...............................................................16
Basicinstructions-Shopandassembly......................................................20
Hydrauliccontamination......................................................................22
Generalspecication(*)......................................................................23
Generalspecication(*)......................................................................27
Generalspecication(*)......................................................................31
Generalspecication(*)......................................................................35
Generalspecication-Mainequipment......................................................39
Weight(*).....................................................................................52
Weight(*).....................................................................................56
Dimension(*).................................................................................60
Dimension(*).................................................................................62
Dimension(*).................................................................................64
Dimension(*).................................................................................65
Consumables.................................................................................66
Conversionfactors............................................................................70
Abbreviation..................................................................................82
Productidentication..........................................................................85
Productidentication-Machineorientation..................................................88
(*)Seecontentforspecicmodels
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INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecicationsatanytimewithout
noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specications,descriptions,and
illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
Incaseofquestions,refertoyourCASECONSTRUCTIONSalesandServiceNetworks.
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY .
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Safetyrules–Generalinformation
Cleaning
Cleanthemetalpartswithcleaningsolutionthatmeetsthestandardandsteamcleaning.(exceptforbearings)
Aftercleaning,drywell,andinjectoilinallparts.
Alsoinjectoilintothebearingsafterdrying.
Inspection
Whendisassemblingparts,checkalltheparts.
Ifthereareanywornordamagedparts,replacethem.
Inspectcarefullytopreventinitialbreakdowns.
Bearing
Replaceanyloosebearings.
Airdrybearingsbeforeinstallingthem.
Needlebearing
Wheninsertingneedlebearings,beverycarefulnottodamagethem.
Applygreasetothesectionwheretheneedlebearingwillbeinserted.
Gear
Checkthatthereisnowearandnodamage.
Oilseal,O-ring,gasket
Alwaysinstallnewoilseals,O-rings,andgaskets.
ApplygreasetosectionswhereoilsealsandO-ringswillbeinserted.
Shaft
Checkthatthereisnowearandnodamage.
Checkthebearingsandcheckfordamagedoilsealsontheshaft.
Serviceparts
InstallCASECONSTRUCTIONgenuineserviceparts.
Whenplacinganorder,checkthepartscatalog.ItcontainstheCASECONSTRUCTIONgenuinepartnumbers.
Anybreakdownsarisingfromtheinstallationofnon-genuinepartsarenotcoveredbythewarranty.
Lubricants(fuel,hydraulicoil)
Usetheoilfromthespeciedcompanyorspeciedintheoperator'smanualorserviceManual.
Anybreakdownsarisingfromanyfuelorhydraulicoilotherthanthosespeciedarenotcoveredbythewarranty.
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INTRODUCTION
Safetyrules–Personalsafety
WARNING:
Thissymbolindicatesaprecaution.
Itgivesinformationconcerningthesafetyoftheoperatorandthoseinthesurroundings.
Readandunderstandtheseprecautionsthoroughlybeforeperformingthework.
Alwayscomplywithwarningsandprecautionssoastoavoidanyaccidents.
Thissectioncoversinformationrelatedtooverallsafety.
Checkwhetherallwarninglabelsareinplace.
AdditionallabelscanbeorderedfromServiceParts.
WARNING:
Readtheoperator'smanualtogainathoroughunderstandingofmachinecontroloperations.
WARNING:
Performanymachineoperationsfromtheseatingposition.
Anyothermethodmaycausesevereinjuries.
WARNING:
Onlytheoneoperatoristorideonthemachine.Nooneelseistorideonit.
WARNING:
Checkthesafetymessagesintheoperator'smanualbeforestartingtheengine.
Checkallthewarninglabelsonthemachine.
Checkthatnooneiswithinthemachine’soperatingrange.
Checktheoperatingmethodsinasafelocationbeforestartingtheactualwork.
Understandthemachineoperationswell,thenoperateincompliancewithallservice-relatedlawsandregulations.
Theoperator'smanualcanbepurchasedatyourCASECONSTRUCTIONdealer.
WARNING:
Workingwithsloppyclothesorclotheswithwhichsafetycannotbeensuredleadstodamagetothemachine
andinjurytotheoperator.
Alwayswearclothesthatensuressafety.
Inordertoworkmoresafely,itisrecommendedtowearadditionalsafetyequipment.
Helmet,safetyshoes,earprotection,goggles,workclothes,andgloves
WARNING:
Paycarefulattentionwhenworkingwiththeenginerunning.
WARNING:
Checkhydraulicequipment.
Workaccordingtotheprocedure.
Donotchangetheprocedure.
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INTRODUCTION
WARNING:
Checkthatthereisnooneinthesurroundingsbeforedrainingthepressurefromhydrauliccircuitsduring
machinehydrauliccylinderinspection.
WARNING:
Usegloveswhenhandlinghigh-temperatureparts.
WARNING:
Bringthelowerpartsorattachmentsincontactwiththegroundbeforeinspectingorrepairingthem.
WARNING:
Checkthathosesandtubesaresecurelyconnected.
Ifthereisanydamagetoahoseortube,replaceit.
Donotcheckforoilleaksbyhand.Usecardboardorwood.
WARNING:
Whenremovinganattachmentpinorotherhardenedpin,useahammerthathasasofthead.
WARNING:
Weareyeprotectionwhenusingahammertoinstallapinorwhenworkingwithagrinder.
Atthistime,usegogglesoreyeprotectorsthatmeetstandards.
WARNING:
Parkthemachineinasafelocationwhenrepairingorinspectingit.
WARNING:
Useworksiteprotectionwhenrepairingthemachine.
Checktheoil,coolant,grease,andtools.
Recovermaterialsandpartsasnecessary.
Payenoughattentiontosafety.
WARNING:
Someofthemachine'spartsareextremelyheavy.
Useanappropriateliftingequipmentforsuchparts.
Forweightsandprocedures,seetheServiceManual.
WARNING:
Exhaustgasesaretoxic.
Alwaysprovidegoodventilationwhenworkingindoorsorinanyotherenclosedspace.
WARNING:
Iftheelectrolyticbatterysolutionfreezes,itmayexplode.
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INTRODUCTION
Safetyrules–ROPSjudgment
1.Purpose
JudgewhetherornotthemodeliscompliantwithROPSbytheROPScriteria.
CompliancewithROPSishighlydependentonitsdeadweightandboom.
ThemodelhaspassedtheROPStestforitsdeadweightwithallselectableoptionsinstalled(asof2014).
However,thejudgmentisrequiredbecauseitsdeadweightorboompositionmaygobeyondtheassumptionde-
pendingonderivativeororderconditions.
2.ROPScriteria
Weight
Foreachclass,thefollowingweightshallnotbeexceeded.
Iftheweightisexceeded,acabmaybecomedamagedincaseofarollover,causingtheoperatortodieorbecome
severelydisabled.
Itisnotapplicablebeyondthecriterion.
TheROPS-compliantmodelshallnotexceedtheweightshowninthetable.
(ThefollowingweightisshownonthedecalintheROPScab.)
GrossbodyweightClass
CX130D
CX160D
20500kg(45194.76lb)orless
CX180D
CX210D
CX230D
CX250D
32000kg(70547.92lb)orless
CX300D
CX350D
40000kg(88184.90lb)orlessCX370D
CX490D
50000kg(110231.13lb)orlessCX500D
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INTRODUCTION
Boomposition
Warning
•Ifyoumakesuchmodicationaslowerstheboomposition,ROPSisnotapplicable.
•Consultationwithusisrequiredwheneveritisassumedthattheboompositionisloweredbymodication.
•Therangeofchangeintheboompositioncannotbedetermineduniformly.
SMIL14CEX2001EA1
(a)Groundpoint
Itisnotapplicableifthepositionoverlappingwithacabonthesideview(mark*inthegure)isloweredsignicantly
ascomparedwiththestandardmodel(standardarm),withinthemaximumdiggingradiuswiththebuckettiponthe
surfaceoftheground.
Moreover,itcannotbesaidthatthe24-tonmodel,closetothelimitweight,withacabthatcanbearupto31-tonsand
the21-tonmodelwiththesamecabarethesameinthedegreeofinuence.
3.Prohibitions
•SuchmodicationasreducesthestrengthoftheplatformwheretheROPScabisinstalled.(Suchactionormodi-
cationasreducesthefunctionoftheretaininganchorintheleftrearofthecab)
•SuchmodicationasaffectstheROPSstrengthoftheROPScab.
Modicationprohibited(Redcomponents)Allchanges(grinding,welding,drilling,removal,etc.)
areprohibited.
Conditionalmodicationpermitted(Graycomponents)
Removalofcomponentsisprohibited.
Weldinganddrillingofbars(limitedto20mm(0.79in)
orlessindiameter)areallowed.
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INTRODUCTION
Cab(CX130D/CX160D/CX180D)
SMPH15CEX5805FA2
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INTRODUCTION
Cab(CX210D/CX230D/CX250D/CX300D)
SMIL14CEX2002FA3
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INTRODUCTION
Cab(CX350D/CX370D)
Thelarge-sizedmodel(CX350D/CX370D)cabconsistsofthemedium-sizedmodel(CX210D/CX230D/CX250D/
CX300D)cabinthegureplussevenreinforcements.
SMIL14CEX2003FA4
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INTRODUCTION
Cab(CX490D/CX500D)
Theirregularlyshapedsteellinealsocontainsreinforcements.
CAF7CBDF5
Thehighcabisnotsupportedbasically.(Sinceitvariesforeachmodel,consultationwithusisrequiredineachcase.)
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