Page 1

CRAWLER EXCAVATOR CX470B SERVICE MANUAL TABLE OF CONTENTS DIVISION/SECTION

SECTION N°

REFERENCE N°

1

GENERAL INFORMATION Safety, general information and standard torque data..................................... 1001 General specifications and special torque setting ........................................... 1002

7-27691EN SM470B1002-1EN

2

ENGINE Removal and installation of the engine............................................................ 2000 Removal and installation of the fuel cooler, engine inter-cooler, radiator and oil cooler ...................................................................................... 2001 Removal and installation of the turbo charger ................................................. 2004 Removal and installation of EGR cooler and EGR valve ................................. 2005 Removal and installation of the engine hood................................................... 2006 Engine specifications..............................................................................................* Disassembly and assembly of the engine ..............................................................*

SM470B2000-0EN SM470B2001-0EN SM470B2004-0EN SM470B2005-0EN SM470B2006-0EN

3

FUEL SYSTEM Removal and installation of the fuel tank......................................................... 3001 Removal and installation of the supply pump and common rail ...................... 3004 Removal and installation of the injectors ......................................................... 3005 Fuel engine system ................................................................................................*

4

ELECTRICAL SYSTEM Service connector kit ....................................................................................... 4000 Electrical and engine functions and service support ....................................... 4001 Removal and installation of the starter motor .................................................. 4004 Removal and installation of the alternator ....................................................... 4005 Electrical equipment & electrical circuit diagrams ........................................... 4020 Engine error code (DTC) ................................................................................. 4021 Main body error code (DTC)............................................................................ 4022 Troubleshooting, 6UZ1 engine......................................................................... 4023

SM350B4000-1EN SM470B4001-0EN SM470B4004-0EN SM470B4005-0EN SM470B4020-0EN SM470B4021-0EN SM470B4022-0EN SM470B4023-0EN

5

UNDERCARRIAGE Removal and installation of tracks ................................................................... 5001 Rollers ............................................................................................................. 5003 Take-up roller................................................................................................... 5005

SM470B5001-0EN SM470B5003-0EN SM470B5005-0EN

6

DRIVE TRAIN Removal and installation of the drive motor and final drive transmission................................................................................ 6001 Disassembly and assembly of the drive motor and final drive transmission................................................................................ 6002 Removal and installation of the swing motor and swing reduction gear ................................................................................... 6003 Disassembly and assembly of the swing reduction gear ................................. 6004

7

UNDERCARRIAGE HYDRAULICS

* Consult the Engine Service Manual

SM470B3001-0EN SM470B3004-0EN SM470B3005-0EN

SM470B6001-0EN SM470B6002-0EN SM470B6003-0EN SM470B6004-0EN


DIVISION/SECTION 8

9

SECTION N°

REFERENCE N°

UPPERSTRUCTURE HYDRAULICS Specifications, troubleshooting, checks and hydraulic pressure settings..........................................................................8001 Removal and installation of the hydraulic reservoir .........................................8002 Removal and installation of the main hydraulic pump......................................8003 Removal and installation of the main hydraulic control valve...........................8004 Removal and installation of the attachment cylinders......................................8005 Removal and installation of the hydraulic swivel ..............................................8006 Removal and installation of the pilot blocs.......................................................8007 Disassembly and assembly of the main hydraulic pump .................................8010 Disassembly and assembly of the main hydraulic control valve ......................8011 Disassembly and assembly of the attachment cylinders .................................8012 Disassembly and assembly of the hand control levers ....................................8013 Disassembly and assembly of the foot control levers ......................................8014 Disassembly and assembly of the cushion valve.............................................8016 Removal and installation of the safety valve ....................................................8017 Disassembly and assembly of the swing motor ...............................................8019 Hydraulic functions ..........................................................................................8020 Hydraulic component functions........................................................................8030

SM470B8001-0EN SM470B8002-0EN SM470B8003-0EN SM470B8004-0EN SM470B8005-0EN SM470B8006-0EN SM470B8007-0EN SM470B8010-0EN SM470B8011-0EN SM130B8012-0EN SM130B8013-0EN SM350B8014-0EN SM130B8016-0EN SM470B8017-0EN SM470B8019-0EN SM470B8020-0EN SM470B8030-0EN

UPPERSTRUCTURE Removal and installation of the counterweight ................................................9002 Removal and installation of the boom, dipper and bucket ...............................9003 Removal and installation of the seat ................................................................9004 Removal and installation of the cab and cab equipment .................................9005 Air conditioner functions and troubleshooting ..................................................9006 Air conditioning unit .........................................................................................9007 Air conditioning components............................................................................9009 Large size hydraulic schematics ................................................................... Pocket Large size electrical schematics ................................................................... Pocket

SM470B9004-0EN SM470B9004-0EN SM130B9004-0EN SM130B9005-0EN SM210B9006-3EN SM130B9007-0EN SM470B9009-0EN KTJ11690-E00 KTR11120-E02

* For electrical schematic option, see section 4020

NOTE: CNH F rance S.A. Company reser ves the right to make changes in the specification and design of the machine without prior notice and without incurring any obligation to modify units previously sold. The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document. All data given in this manual is subject to production variations. Dimensions and w eights are provided with approximate v alues and the machine fitting sho wn in the illustr ations ma y not correspond with st andard models. F or p recise inf ormation on specific mach ine models and v ersions, ple ase cont act y our CASE dealer. Reproduction or tr anlation, e ven pa rtial, is prohib ited without wr itten a uthorization from CN H France SA Company.

Lep SM470BTOC-2EN

Issued 03-2010


1001 SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS

CNH

Lep 7-27691EN

1001

Section


1001-2

TABLE OF CONTENTS GENERAL INFORMATION .......................................................................................................................................3 SAFETY..................................................................................................................................................................... 4 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6

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WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.

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1001-3

GENERAL INFORMATION Cleanning

Gears

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.

Check all gears for wear and damage. Replace gears that have wear or damage.

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.

Lep 7-27691EN

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 Catalog 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.

Issued 02-06


1001-4

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 keyswitch when servicing or repairing the machine. One warning tag is supplied with each machine. Additional tags Part Number 331-4614 are available from your service parts supplier

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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 f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n machine operation, service and to observe pertinent laws and regulations. Operator’s and Service Manuals may be obtained from your Case dealer.

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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.

.

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WARNING: Read the operator’s manual to familiarize yourself with the correct control functions.

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WARNING: Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury.

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WARNING: This is a one man machine, no riders allowed.

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1001-5

!

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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.

WARNING: Use insulated gloves or mittens when working with hot parts.

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.

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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.

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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).

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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.

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1001-6

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the order of tightening.

JS00481A

Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then tighten.

Torque table Tighten cap screws and nuts according to the table below if there are no other special instructions.

Cap Screw Name Size (Size)

M6 [mm]

M8

M10

M12

M14

M16

M18

M20

10

13

17

19

22

24

27

30

[in.]

0.39

0.51

0.67

0.75

0.87

0.95

1.06

1.18

[Nm]

6.9

19.6

39.2

58.8

98.1

156.9

196.1

294.2

[lb-ft]

5.1

14.5

28.9

43.4

72.3

115.7

144.6

217

[mm]

5

6

8

10

12

14

14

17

[in.]

0.20

0.24

0.32

0.39

0.47

0.55

0.55

0.67

[Nm]

8.8

21.6

42.1

78.5

117.7

176.5

245.2

343.2

[lb-ft]

6.5

15.9

31.1

57.9

86.9

130.2

181

253.2

Spanner Cap Screw Tightening torque

Socket Head Cap Screw

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Spanner

Tightening torque

Issued 02-06


1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS

CNH

Lep SM470B1002-1EN

1002

Section


1002-2

TABLE OF CONTENTS

!

WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it.

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 4 Machine ....................................................................................................................................................................... 4 Engine .......................................................................................................................................................................... 4 Serial numbers of the components .............................................................................................................................. 4 FLUIDS AND LUBRICANTS ............................................................................................................................................ 5 Hydraulic fluid .............................................................................................................................................................. 5 Transmission component oil ........................................................................................................................................ 5 Grease ......................................................................................................................................................................... 5 Engine Oil .................................................................................................................................................................... 6 Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 7 Anti-freeze/Anti-corrosion............................................................................................................................................. 9 Environment ................................................................................................................................................................. 9 Plastic and resin parts.................................................................................................................................................. 9 SPECIFICATIONS ......................................................................................................................................................... 10 Main data ................................................................................................................................................................... 10 Performance .............................................................................................................................................................. 10 Main body dimensions ............................................................................................................................................... 10 Engine ........................................................................................................................................................................ 11 Cooling system .......................................................................................................................................................... 11 Capacity of coolant and lubricants ............................................................................................................................. 11 Air conditioning .......................................................................................................................................................... 11 Hydraulic oil filter........................................................................................................................................................ 11 Fuel filter .................................................................................................................................................................... 11 Operating devices ...................................................................................................................................................... 12 Hydraulic system........................................................................................................................................................ 13 Swing unit .................................................................................................................................................................. 16 Travel lower body....................................................................................................................................................... 16 Work Unit ................................................................................................................................................................... 17 New Machine Performance........................................................................................................................................ 18 COMPONENT WEIGHT................................................................................................................................................. 20 Major component weight ............................................................................................................................................ 20 Other component weight ............................................................................................................................................ 21 DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY .................................................................................. 22 Sprocket ..................................................................................................................................................................... 22 Idler wheel.................................................................................................................................................................. 23 Upper roller ................................................................................................................................................................ 24 Lower roller ................................................................................................................................................................ 25 Track .......................................................................................................................................................................... 26 DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ................................................................. 27 1. Boom foot/Frame ................................................................................................................................................... 27 2. Boom cylinder foot/Frame ...................................................................................................................................... 28 3. Boom cylinder head/Boom ..................................................................................................................................... 28 Lep SM470B1002-1EN

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1002-3 4. Arm cylinder foot/Boom ..........................................................................................................................................29 5. Boom/Arm...............................................................................................................................................................29 6. Arm cylinder head/Arm ...........................................................................................................................................29 7. Bucket cylinder foot/Arm.........................................................................................................................................30 8. Connecting rod/Arm................................................................................................................................................30 9. Compensator/Bucket ..............................................................................................................................................30 10. Connecting rod/Compensator/Bucket cylinder head ............................................................................................31 11. Arm/Bucket ...........................................................................................................................................................31 SPECIAL TORQUE SETTINGS......................................................................................................................................32 MACHINE OVERALL DIMENSIONS ..............................................................................................................................35 Standard attachment (6.98 m boom) with fixed side frame ........................................................................................35 Standard attachment (6.98 m boom) with retractable side frame...............................................................................36 Short attachment (6.55 m boom) with fixed side frame ..............................................................................................37 Short attachment (6.55 m boom) with retractable side frame .....................................................................................38

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1002-4

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE For all part orders, request for information or assistance, always specify the type and the serial number of the machine to your Case dealer. Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the serial numbers of the hydraulic and mechanical components.

Machine 1 2

3

CT04A171A

(1) Type ....................................................................................................................................................................... (2) Serial number......................................................................................................................................................... (3) Year of manufacture ...............................................................................................................................................

Engine Make and type ............................................................................................................................................................. Serial number ..............................................................................................................................................................

Serial numbers of the components Hydraulic pump ........................................................................................................................................................... Swing reduction gear................................................................................................................................................... Travel reduction gears ................................................................................................................................................. Control valve................................................................................................................................................................

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1002-5

FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application.

!

WARNING: The conditions of use for individual fluids and lubricants must be respected.

Hydraulic fluid CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system. The type of fluid to be used depends on the ambient temperature. Temperate climates: -20°C to +40°C (-4° to 104° F) CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) Hot climates: 0°C to +50°C (32° to 122° F) CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP) Cold climates: -25°C to +20°C (-13° to 68° F) CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2) Biodegradable fluid: -30°C to +40°C (-22° to 104° F) This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit completely before refilling with this fluid. CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

Transmission component oil Extreme pressure oil used for enclosed transmission components. CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)

Grease CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide. CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and calcium. CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap.

Hydraulic breakers CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

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1002-6

Engine Oil THE CASE/AKCELA No. 1 engine oil is recommended for y our en gine. This o il ensures pr oper lu brication of your engine for all operating conditions. If the CASE /AKCELA Multigrade "N o. 1 E NGINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: ACEA E7. API CI-4.

CP02N001

Oil viscosity / Oil range

1 2 3 3

2

CT02M001

1) With mineral base (2) With semi-synthetic base (3) With synthetic base

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1002-7

Engine fuel, maintenance of fuel filters and fuel storage In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and they are to be used under high-pressure conditions. Therefore, the specified fuel must be used for the engine. As a matter of course, not only the guar antee will not be giv en for the use of a fuel other than the sp ecified but also it may invite a serious breakdown. In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the genuine filter is essential. The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel and the fuel elements.

Fuel to be applied Selection of fuel Following conditions must be met for the diesel engines, that is the one; 1 In which no dust even fine one is mixed, 2 With proper viscosity, 3 With high cetane rating, 4 With good flow properties in lower temperature, 5 With not much sulfur content, and 6 With less content of carbon residue Applicable standards for diesel fuel Applicable Standard

Recommendation

JIS (Japanese Industrial Standard)

NO.2

DIN (Deutsche Industrie Normen)

DIN 51601

SAE (Society of Automotive Engineers) Based on SAE-J-313C

NO. 2-D

BS (British Standard) Based on BS/2869-197

Class A-1

EN590 If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details. Requirements for diesel fuel Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big influence on its service durability and service life. Be sure to observe the following requirements for selecting fuel. Sulfur content .............................................................................. 2500 ppm or less HFRR* ......................................................................................... 460 mm or less Water content .............................................................................. 0.05 wt% or less * HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel. Sulfur content reacts to moisture to change into sulfuric acid after combustion. Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear. In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be worse which results in acceleration of wear of sliding portions. HFRR is an index that indicates lubricating property of a fuel. Large value of the index means poor lubrication so that seizure of the machine components may result if such a fuel is used. Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out. Lep SM470B1002-1EN

Issued 03-2010


1002-8 If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in acceleration of wear. Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter. IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation. This may also cause wear and seizure of the machine components. If atmospheric temperature goes below the freezing point, moisture content in t he fuel forms fine particle of ice allowing the fuel line to be clogged. IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the criteria described above. IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine or an accident may be invited. Guarantee will not be given to a breakdown caused by the use of a improper fuel. Some fuels are used with engine oil or additives mixed together with diesel engine fuel. In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated. It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not meet the specifications and the requirements is used. Use the specified fuel for compliance of the exhaust gas control. IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to fol- low the items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns caused by not to follow these items. 1 Selection of engine oil Use API grade CF-4 or JASO grade DH-1. 2 Exchange the engine oil an d engine oil f ilter element by the periodical interval reported on the Operator’s Manual. 3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use. * EGR: Exhaust Gas Recircultion

Maintenance of fuel filters Be sure to use the genuine fuel filters. The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional filters to improve protection of machine equipment. If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine equipment can wear out in a short period of time. IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the use of a wrong filter. Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine. Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Manual. IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine. Time to replace filters may be advanced according to properties of the fuel being supplied. • Therefore, take measures to prevent dust or water from being entered in the fuel tank when sup- plying fuel. • When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply clean fuel standing above a precipitate. • If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel tank of the machine to supply clean fuel. Water drain cock is provided on the bottom side of the fuel tank. • Drain water before starting the engine every morning. • In addition, remove the cover under the tank once a year to clean up inside of the tank.

Lep SM470B1002-1EN

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1002-9

Fuel storage Long st orage can lead t o the a ccumulation o f impurities and con densation in the fuel. Eng ine trouble can o ften be traced to the presence of water in the fuel. The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710) For areas where the temperature goes down to -38°C (-36.4°F), mix 50/50 with water. IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the system.

Environment Before car rying ou t any ma intenance operation o n t his m achine a nd before dispo sing of used f luids or lub ricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles. Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of disposing of these lubricants.

Plastic and resin parts When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint solvents etc... Use only water, soap and a soft cloth. The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.

Lep SM470B1002-1EN

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1002-10

SPECIFICATIONS Main data Model name.......................................................................................................................... CX470B Hydraulic Excavator Operating weight Standard attachment, fixed side frame .......................................................................................46600 kg (102735 lbs) Standard attachment, retractable side frame ..............................................................................48100 kg (106042 lbs) Short attachment, fixed side frame .............................................................................................47100 kg (103838 lbs) Short attachment, retractable side frame ....................................................................................48600 kg (107145 lbs) Engine output ....................................................................................................................................... 270 kW / 1950 rpm

Performance

Swing speed.......................................................................................................................................................9.0 Tr/min. Travel speed: Low Speed ..................................................................................................................................... 3.1 km/h (1.93 mph) High Speed .................................................................................................................................... 5.3 km/h (3.29 mph) Maximum drawbar pull ..........................................................................................................................341 kN (76660 lbf) Grade ability ....................................................................................................................................................... 70% (35°) Ground pressure with 600 mm (23.62 in) grouser shoe Standard attachment, fixed side frame ............................................................................................................... 80 kPa Standard attachment, retractable side frame ...................................................................................................... 82 kPa Short attachment, fixed side frame ..................................................................................................................... 81 kPa Short attachment, retractable side frame ............................................................................................................ 83 kPa Ground pressure with 750 mm (29.53 in) grouser shoe Standard attachment, fixed side frame ............................................................................................................... 65 kPa Standard attachment, retractable side frame ...................................................................................................... 67 kPa Short attachment, fixed side frame ..................................................................................................................... 66 kPa Short attachment, retractable side frame ............................................................................................................ 68 kPa Ground pressure with 900 mm (35.43 in) grouser shoe Standard attachment, fixed side frame ............................................................................................................... 55 kPa Standard attachment, retractable side frame ...................................................................................................... 57 kPa Short attachment, fixed side frame ..................................................................................................................... 55 kPa Short attachment, retractable side frame ............................................................................................................ 57 kPa

Main body dimensions

Main body width ..............................................................................................................See machine overall dimensions Main unit length ................................................................................................................................. 6395 mm (251.77 in) Main unit width, fixed side frame ....................................................................................................... 3350 mm (131.89 in) Main unit width, retractable side frame........... 3700 mm (145.67 in) (maximum track retraction for transport = 3200 mm) Upper swing body width ........................................................... 3060 mm (120.47 in) (3590 mm (141.34 in) with catwalk) Cab width ............................................................................................................................................ 1000 mm (39.37 in) Main unit height, fixed side frame...................................................................................................... 3290 mm (129.53 in) Main unit height, retractable side frame ............................................................................................ 3440 mm (134.43 in) Swing radius (rear end) ..................................................................................................................... 3680 mm (144.88 in) Swing body rear end distance ........................................................................................................... 3670 mm (144.49 in) Swing body rear section bottom height, fixed side frame .................................................................... 1330 mm (52.36 in) Swing body rear section bottom height, retractable side frame........................................................... 1480 mm (58.27 in) Overall track length............................................................................................................................ 5450 mm (214.57 in) Overall track width, fixed side frame.................................................................................................. 3350 mm (131.89 in) Overall track width, retractable side frame ..................................................... 3490 mm (137.40 in) (maximum track retraction for transport = 2990 mm (117.72 in)) Distance between tracks fixed side frame ......................................................................................... 2750 mm (108.27 in) Distance between tracks, retractable side frame ......................................................2890 mm (113.78 in) (maximum track retraction for transport = 2390 mm) (94.09 in)) Width of track shoe......................................................600 mm (23.2 in) (Option: 750 mm (29.53 in), 900 mm (35.43 in)) Minimum ground clearance (To bottom of lower frame), fixed side frame ............................................. 540 mm (21.26 in) Minimum ground clearance (To bottom of lower frame), retractable side frame.................................... 740 mm (29.13 in)

Lep SM470B1002-1EN

Issued 03-2010


1002-11

Engine

Name............................................................................................................................................................. ISUZU, 6UZ1 Type: 4- cycle, w ater-cooled, o verhead cam shaft, v ertical in-line, direct injec tion ty pe (electric cont rol), with turbocharger, without cooling fan. No. of cylinders - bore x stroke........................................................................... 6-dia. 120 mm x 145 mm (4.72 x 5.71 in) Displacement .................................................................................................................................... 9839 cc (600.4 cu.in) Compression ratio ........................................................................................................................................................17.5 Rated output ...................................................................................................................................... 270 kW / 1950 min-1 Maximum torque ........................................................................................................... 1435 Nm (1058 lb-ft) / 1500 min-1 Engine dimensions (LxWxH)................................................................ 1235 x 953 x 1272 mm (48.62 x 37.52 x 50.08 in) Oil pan.......................................................................................................................................All direction 35°, inclinable Starter, reduction type.....................................................................................................................................24 V, 5.5 kW Alternator, AC type ............................................................................................................................................. 24 V, 50 A Battery.......................................................................................................................................... 2x 12V/24V,128 Ah/5 Hr

Cooling system

Fan type .................................................Hydraulic drive, diameter 1016 mm (40 in), suction type-6blades plastic & steel Pulley ratio ...................................................................................................................................................................... . Direction of rotation ................................................................................................................ Right (viewed from fan side) Radiator Fin type ...................................................................................................................................................................wavy Fin space ............................................................................................................................................. 2.0 mm (0.08 in) Oil cooler Fin type ..................................................................................................................................................................wawy Fin space ........................................................................................................................................... 1.75 mm (0.07 in) Inter-cooler Fin type ...............................................................................................................................................triangular straight Fin space ............................................................................................................................................. 2.0 mm (0.08 in) Fuel cooler Fin type ...................................................................................................................................................................wavy Fin space ........................................................................................................................................... 2.25 mm (0.09 in)

Capacity of coolant and lubricants

Coolant...................................................................................................................................................... 38 L (10.04 gal) Fuel ....................................................................................................................................................... 650 L (171.71 gal) Lubricant for engine .................................................................................................................................... 36 L (9.51 gal) Lubricant for travel reduction gear (per side) .............................................................................................. 15 L (3.96 gal) Lubricant for swing reduction gear ........................................................................................................... 10.5 L (2.77 gal) Hydraulic oil........................................................................................................................................... 460 L (121.52 gal) Capacity of hydraulic oil tank .................................................................................................................. 230 L (60.76 gal)

Air conditioning

R134 gas load .............................................................................................................................................. 1Kg (2.20 Ibs)

Hydraulic oil filter

Suction filter (inside tank).......................................................................................................................................105 μ m Return filter (inside tank)............................................................................................................................................6 μ m Pilot line filter (inside housing) ...................................................................................................................................8 μ m

Fuel filter

Main filter.....................................................................................................................................................................4 µm Pre-filter.......................................................................................................................................................................7 µm

Lep SM470B1002-1EN

Issued 03-2010


1002-12

Operating devices

Operator's seat Location: left side Structure: Adjustable forward and back and up and down, reclining mechanism, with seat suspension. Cab Sealed steel type, all reinforced glass. Levers and pedals For travel use: Lever and pedal type (hydraulic pilot type) (x2) For operating machine use: Lever type (hydraulic pilot type) (x2) Instruments and switches Work mode select switch: 3 modes (SP / super power, H / heavy duty, A / automatic) Travel mode select switch: Low-speed / high-speed switch type One-touch idle: Knob switch type Engine emergency stop: Switch type Monitor device Machine status display (full-dot liquid crystal) Work mode selection status: SP / H / A Instruments (full-dot liquid crystal, except for hour meter) Fuel gauge: bar graph indicator Engine coolant temperature gauge: bar graph indicator Hydraulic oil temperature gauge: bar graph indicator Hour meter: digital type Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm Over heat* Fan reverse operation* Anti-theft device triggered Refill fuel*

Battery charge*

Electrical system abnormality*

Engine preheat

Engine oil pressure*

Refill coolant*

Air cleaner*

Auto warm-up

Engine system abnormality*

Service due

Engine emergency stop*

Idling

Lighting Working light

Interior light

Boom up:

24V, 70W (x2)

Cab top:

24V, 70W (x2)

Tank top surface

24V, 70W (x1) 24V, 10W (x1)

Horn: electric horn (x2) Other Wiper with intermittent function, Window washer, Air conditioner, Rear view mirrors (left and right), Clock, DC-DC converter

Lep SM470B1002-1EN

Issued 03-2010


1002-13

Hydraulic system Hydraulic pump drive system, directly coupled to the engine (no transmission) Main pump Manufacturer .............................................................................................................................................. Kawasaki Pump type ..............................................................................................double variable displacement piston pump Displacement volume ..................................................................................................182 cm3 (11.11 cu in) x 2 /rev Rated operating pressure .......................................................................................................... 31.4 MPa (4555 psi) Maximum operating pressure .................................................................................................... 34.3 MPa (4975 psi) Input revolution speed ..............................................................................................................................1980 min-1 Maximum discharge flow ........................................................................... 360 L/min (95.11 gpm) x 2 at 1980 min-1 Pilot pump Pump type ...............................................................................................................................................Gear pump Displacement volume .............................................................................................................15 cm3 (0.91 cu in)/rev Operating pressure...................................................................................................................... 3.92 MPa (569 psi) Maximum flow.................................................................................................29.7 L/min (7.85 gpm) (at 1980 min-1) Control method Hydraulic simultaneous constant output control. Maximum flow adjustment control through external commands (negative control). Maximum flow adjustment control through external command (negative control, front side). Setting horsepower adjustment control through external command milli-amp. Control Valve Model; 4-spool section: integrated (1) or 5-spool section: integrated (1) Operation method: hydraulic pilot method: travel, swing and operating machine Maximum flow .................................................................................................... 360 L / min (95.11 gpm) at 1980 min-1 Main relief set pressure ...........................................standard; 31.4 MPa (4555 psi), power boost 34.3 MPa (4975 psi) Overload set pressure ..................................................................................... when boom down; 24.5 MPa (3553 psi) ............................................................................................................................................. other: 36.3 MPa (5265 psi) Foot relief set pressure ................................................................................................................. 3.38 MPa (490.2 psi) Functions Straight travel circuit Boom up / arm 2 pumps internal flow Boom and arm load holding circuit Boom-down regenerative circuit Arm-in forced regenerative circuit Swing priority variable orifice (for arm operation) Boom-up priority variable orifice (for arm operation) Reserve 2 pumps flow Bucket - close regenerative circuit

Lep SM470B1002-1EN

Issued 03-2010


1002-14 Hydraulic Cylinders Boom cylinder (x2) Cylinder bore .............................................................................................................................Ø170 mm (Ø6.69 in) Rod diametre .............................................................................................................................Ø115 mm (Ø4.53 in) Maximum retracted lenghth ........................................................................................................ 2230 mm (87.80 in) Stroke ......................................................................................................................................... 1550 mm (61.02 in) Arm (dipper) cylinder Cylinder bore .............................................................................................................................Ø200 mm (Ø7.87 in) Rod diametre .............................................................................................................................Ø140 mm (Ø5.51 in) Maximum retracted lenghth ...................................................................................................... 2588 mm (101.89 in) Stroke ......................................................................................................................................... 1820 mm (71.65 in) Bucket cylinder with standard boom Cylinder bore .............................................................................................................................Ø165 mm (Ø6.50 in) Rod diametre ...........................................................................................................................Ø115 mm (Ø44.53 in) Maximum retracted lenghth ........................................................................................................ 1972 mm (77.64 in) Stroke ......................................................................................................................................... 1285 mm (50.59 in) Bucket cylinder with short boom Cylinder bore .............................................................................................................................Ø170 mm (Ø6.69 in) Rod diametre ...........................................................................................................................Ø115 mm (Ø44.53 in) Stroke ......................................................................................................................................... 1335 mm (52.56 in) Cushion Valve Port size A-P ports.............................................................................................................................................................G3/8 Q-V ports ............................................................................................................................................................G1/4 Rotating Joint Operating pressure High pressure passage (ABCD) ............................................................................................... 51.5 MPa (7469 psi) Drain port (T) ................................................................................................................................. 2.0 MPa (290 psi) Pilot port (P)................................................................................................................................... 5.9 MPa (856 psi) With stand pressure test pressure High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi) Drain port (T) ................................................................................................................................. 1.0 MPa (145 psi) Pilot port (P)................................................................................................................................... 3.9 MPa (566 psi) Flow High pressure passage (ABCD) ............................................................................................ 360 L/min (95.11 gpm) Drain port (T) ........................................................................................................................... 40 L/min (10.57 gpm) Pilot port (P)............................................................................................................................... 31 L/min (8.19 gpm) Speed............................................................................................................................................................... 15 min-1 Rotation torque When pressurizing 2 ports....................................................................................................... 196 Nm (144.56 lb-ft) Port A; forward right ...................................................................................................................................................G1 Port B; forward left .....................................................................................................................................................G1 Port C; backward right................................................................................................................................................G1 Port D; backward left ..................................................................................................................................................G1 Port T; drain port ....................................................................................................................................................G1/2 Port P; pilot port .....................................................................................................................................................G1/4 Solenoid Valve Maximum flow ..........................................................................P -> B: 25 L/min (6.60 gpm) Other: 5 L/min (1.32 gpm) Rated pressure ............................................................................................................................. 4.5 MPa (652.67 psi) Port size P, T, B port...........................................................................................................................................................G3/8 C1, C2, C3, C4, C5 ports....................................................................................................................................G1/4 Solenoid specifications Operating voltage ................................................................................................................................DC 20 to 32 V Power consumption .................................................................................................................................. 17 W max.

Lep SM470B1002-1EN

Issued 03-2010


1002-15 Hand control valve Manufacturer................................................................................................................................................... Kawasaki Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.07 to 419.16 psi) Operating angle Ports 1, 3 .............................................................................................................................................................. 19° Ports 2, 4 .............................................................................................................................................................. 25° Port 1, 3

4.0 Secondary pressure

3.0 2.0 1.0 0

5

10

4.0 3.0 2.0

Secondary pressure

1.0 0

2 4 6 7 Push rod stroke (mm) 0

Port 2, 4

5.0 Secondary pressure (MPa)

Secondary pressure (MPa)

5.0

Push rod stroke (mm)

15 19

0

Operating angle (deg.)

5

10

15

20

Operating angle (deg.)

25 WC01014-004

Foot control valve Manufacturer................................................................................................................................................... Kawasaki Operating pressure .......................................................................................................................... 3.92 MPa (569 psi) Secondary pressure, primary short type .......................................................... 0.49 to 2.89 MPa (71.07 to 419.16 psi) Operating angle ..................................................................................................................................................... 12.4°

Secondary pressure (MPa)

3.9 3.0

2.0

1.0

Secondary pressure

0

2

5.5

4

Push rod stroke (mm) 0

5

10

12.4

Pedal operating angle (deg.) WC01014-005

Lep SM470B1002-1EN

Issued 03-2010


1002-16

Swing unit

Swing circle; swing bearing type (with internal gears) Swing hydraulic motor (x1) ..................... fixed displacement piston motor (with parking brake reverse prevention valve). Intake amount ........................................................................................................................ 250 cm3/(15.26 cu in)/rev Operating pressure ........................................................................................................................ 29.4 MPa (4264 psi) Operating flow ............................................................................................................................. 360L/min (95.11 gpm) Mechanical brake torque................................................................................................................. 1288 Nm (950 lb-ft) Brake off pressure................................................................................................................ 2.9 MPa max. (420.61 psi) Relief valve set pressure .......................................................................... 29.4 MPa (4264 psi) at 50L/min (13.21 gpm) Reduction gears ................................................................................................ planetary gear 2-stage reduction system Reduction ratio .................................................................................................................................................... 27.143 Swing parking brake ................................................................................ Mechanical lock (operational lever linkage type)

Travel lower body

Travel hydraulic motor (x2) .......... Variable displacement piston motor, automatic 2-speed switchover with parking brake Displacement .................................................................................................. 290.7/170.1 cm3 (17.74/10.38 cu in)/rev Operating pressure ........................................................................................................................ 34.3 MPa (4975 psi) Operating flow ......................................................................................................................... 360.4 L/min (95.21 gpm) Brake torque................................................................................ 71 KNm (52367 Ib-ft) min. (including reduction gear) Relief valve set pressure ............................................................................................... 35.8/37.8 MPa (5192/5482 psi) Automatic 2-speed switch-over pressure (with parking brake)....................................................... 26.5 MPa (3843 psi) Reduction gear .......................................................................................................Planetary gear 2-stage reduction gear Reduction ratio .................................................................................................................................................... 60.652 Travel brake .................................................................................................................................................. Hydraulic lock Parking brake ................................................................................................... Mechanical lock (travel lever linkage type) Track shoe Model .................................................................................................................... Assembly type double grouser shoe Number of shoes (per side)........................................................................................................................................ 50 Shoe width ..........................................................600 mm (23.62 in), (optional 750 mm (29.53 in), 900 mm (35.43 in)) Grouser height ...................................................................................................................................... 36 mm (1.42 in) Link pitch .......................................................................................................................................... 228.6 mm (9.00 in) Roller Number of upper rollers (per side), fixed side frame .................................................................................................... 2 Number of upper rollers (per side), retractable side frame .......................................................................................... 3 Number of lower rollers (per side)................................................................................................................................ 9 Track belt tension adjuster............................................................................... Grease cylinder type (with cushion spring) Mounting length of spring ...................................................................................................................... 740 mm (29.13 in)

Lep SM470B1002-1EN

Issued 03-2010


1002-17

Work Unit

Model ................................................................................................................................................. Backhoe attachment Standard Boom 6980 mm (274.80 in) CX470B

Fixed side frame

Arm (dipper) length

Short boom 6550 mm (257.87 in)

Retractable side frame

Fixed side frame

Retractable side frame

Standard arm

Short arm

Standard arm

Short arm

Short arm

3380 mm (133.07 in)

2530 mm (99.61 in)

3380 mm (133.07 in)

2530 mm (99.61 in)

2530 mm (99.61 in)

Bucket radius Bucket wrist angle

1840 mm (72.44 in)

1850 mm ( in)

176°

161°

Maximum digging radius

12000 mm (472.44 in)

11230 mm (442.12 in)

12000 mm (472.44 in)

11230 mm (442.12 in)

Maximum digging radius at ground line

11770 mm (463.38 in)

10990 mm (432.68 in)

11740 mm (462.20 in)

10950 mm (431.10 in)

10560 mm (415.75 in)

10520 mm (414.17 in)

Maximum digging depth

7720 mm (303.94 in)

6870 mm (270.47 in)

7570 mm (298.03 in)

6720 mm (264.57 in)

6490 mm (255.51 in)

6340 mm (249.61 in)

Maximum v ertical straight w all digging depth

6570 mm (258.66 in)

5670 mm (223.23 in)

6420 mm (252.76 in)

5520 mm (217.32 in)

4920 mm (193.70 in)

4770 mm (187.79 in)

Maximum digging height

11140 mm (438.58 in)

10820 mm (425.98 in)

11290 mm (444.49 in)

10970 mm (431.89 in)

10520 mm (414.17 in)

10670 mm (420.08 in)

Maximum d height

ump

7740 mm (304.72 in)

7420 mm (292.13 in)

7890 mm (310.63 in)

7570 mm (298.03 in)

7180 mm (282.68 in)

7340 mm (288.98 in)

Minimum s radius at front

wing

4990 mm (196.46 in)

5130 mm (201.97 in)

4990 mm (196.46 in)

5130 mm (201.97 in)

Height f or minimum swing radius at front

9250 mm (364.17 in)

9320 mm (366.93 in)

9400 mm (370.08 in)

9470 mm (372.83 in)

Lep SM470B1002-1EN

10810 mm (425.59 in)

4800 mm (188.98 in) 9050 mm (356.30 in)

9200 mm (362.20 in)

Issued 03-2010


1002-18

New Machine Performance SP Mode (with standard bucket) Item

Unit

Idling 1

Engine speed

900 ± 10

No load A mode

min-1

No load H mode No load SP mode

30.6 ± 2.0

Boosted pressure

33.8 ± 2.0

Up

40.5 ± 2.0

Down

28.0 ± 2.0

Out

Arm relief

Open

Bucket relief

Close

40.5 ± 2.0 30.6 ± 2.0 33.8 ± 2.0

front and back

4th pump relief

20.6 ± 2.0

Pilot pump

3.9 ± 1.0

Natural fall distance

Boom cylinder retraction

(position change)

Arm cylinder extension

for each cylinder with no load

Bucket cylinder retraction

(in 10 min.)

Overall bucket tip falling Boom (bucket open) Arm Bucket

Lep SM470B1002-1EN

MPa

Left and right,

Option relief

Attachment speed

39.5 ± 2.0

Left and right

Travel r elief

4

40.5 ± 2.0

In

Swing relief

3

1900 ± 10

Standard

Boom relief

Pressure in each section

1750 ± 10 2000 ± 10

Main relief

2

Reference value

For crusher

-

For breaker

13 max. mm

19 max. 22 max. 250 max.

Up (stroke 941)

4.5 ± 0.6

Down (stroke 941)

3.7 ± 0.6

Out In

sec.

3.6 ± 0.6 4.5 ± 0.6

Open

3.0 ± 0.6

Close

4.3 ± 0.6

Issued 03-2010


1002-19 SP Mode (with standard bucket) Item 5

Swing speed (one rotation)

Left and right

6

Swing brake angle (180°)

Left and right

7

Swing motor leakage amount

8

9

Travel speed

Forwards and bac-

(6 m travel speed)

kwards

Low speed

Travel sprocket speed

High speed

(10 rotations)

Low speed

Travel turning amount 10

High speed

(20 m travel meandering amount)

11

Shoe tension amount

12

Travel motor leakage amount

Forwards and backwards

Reference value

sec./rev.

6.7 ± 0.6

min-1

9.0 ± 0.6

deg.

40 ° max.

L/min

2.5

sec./6 m

4.1 ± 0.6

km/h

5.3 ± 0.6

sec./6 m

6.8 ± 0.6

km/h

3.2 ± 0.4

sec.

17.0 ± 2.0 29.1 ± 2.0

High speed Low speed

Swing ball race bearing move-

Up and down

ment distance

Left and right

14

Bucket tip movement amount

Left and right

15

Recoil spring dimensions

13

Unit

Compression ratio Free

mm

1000 max.

mm

360 - 380

L/min

3.0

mm mm mm

2.5 max. 6.0 max. 110 max. 740 914.6

Travel high speed 16

Coil resistance of each sole-

Coil resistance tem-

noid valve

perature 20 °C

Boosted pressure Swing brake

Ω

35

Lever lock Power save

17

electromagnetic proportional valve

Lep SM470B1002-1EN

490 ± 20

SP mode

Milli- amp for hydraulic pump No load

H mode A mode

mA

460 ± 20 420 ± 20

Issued 03-2010


1002-20

COMPONENT WEIGHT Major component weight

B A

C

E D

F

G

H

RST-11-01-001a

Weight information is approximate A) Operating weight Standard attachment, fixed side frame ...................................................................................46600 kg (102735 lbs) Standard attachment, retractable side frame..........................................................................48100 kg (106042 lbs) Short attachment, fixed side frame .........................................................................................47100 kg (103838 lbs) Short attachment, retractable side frame................................................................................48600 kg (107145 lbs) B) Upper mechanism (including counterweight and turntable bearing) ........................................19900 kg (43872 lbs) C) Counterweight ............................................................................................................................9200 kg (20283 lbs) D) Lower mechanism (with standard grouser shoe) Fixed side frame ......................................................................................................................16400 kg (645.67 lbs) Retractable side frame.............................................................................................................17900 kg (704.72 lbs) E) Main Unit Weight Fixed side frame ....................................................................................................................36300 kg (1429.13 lbs) Retractable side frame...........................................................................................................37800 kg (1488.18 lbs) F) Attachments Standard attachment ...............................................................................................................10300 kg (405.51 lbs) Short attachment .....................................................................................................................10800 kg (425.20 lbs) Lep SM470B1002-1EN

Issued 03-2010


1002-21 G) Boom (including cylinders)........................................................................................................ 5630 kg (221.65 lbs) H) Arm (dipper) (including cylinders and linkage) Standard attachment ................................................................................................................. 2690 kg (105.91 lbs) Short attachment ........................................................................................................................ 2610 kg (102.76lbs)

Other component weight

Engine ........................................................................................................................ Approximately 869 kg (1915.81 lbs) Air cleaner .............................................................................................................................................17.6 kg (38.80 lbs) Hydraulic pump ....................................................................................................................................245 kg (540.13 lbs) Control valve ........................................................................................................................................424 kg (934.76 lbs) Cushion valve........................................................................................................................................12.5 kg (27.56 lbs) Swing motor and reduction gear assembly ........................................................................................ 581 kg (1280.88 lbs) Travel motor and reduction gear assembly ........................................................................................ 613 kg (1351.43 lbs) Rotary joint............................................................................................................................................. 56 kg (123.46 lbs) Turtable bearing ................................................................................................................................. 656 kg (1446.23 lbs) 5 solenoid valve bank..............................................................................................................................6.7 kg (14.77 lbs) Hand control valve .................................................................................................................................... 1.9 kg (4.19 lbs) Foot control valve ....................................................................................................................................5.5 kg (12.13 lbs) Cab ......................................................................................................................................................255 kg (562.18 lbs) Muffler ......................................................................................................................................................21 kg (46.30 lbs) Radiator total weight ............................................................................................................................211 kg (465.17 lbs) Oil cooler..............................................................................................................................................34 kg (74.96 lbs) Radiator ...............................................................................................................................................24 kg (52.91 lbs) Air cooler..............................................................................................................................................29 kg (63.93 lbs) Fuel cooler ............................................................................................................................................. 6 kg (13.23 lbs) Idler wheel............................................................................................................................................251 kg (553.36 lbs) Upper roller ..............................................................................................................................................44 kg (97.00 lbs) Lower roller ............................................................................................................................................ 82 kg (180.78 lbs) Tension damper assembly ...................................................................................................................343 kg (756.18 lbs) Recoil spring assembly....................................................................................................................141 kg (310.85 lbs) Grease cylinder assembly ................................................................................................................. 62 kg (136.69 lbs) Track chains 600 mm (23.62 in) (50 shoe) ....................................................................................................... 2585 kg (5698.94 lbs) 750 mm (29.53 in) (50 shoe) ...................................................................................................... 2930 kg (6459.54 lbs) 900 mm (35.43 in) (50 shoe) ...................................................................................................... 3280 kg (7231.15 lbs) Boom cylinder ......................................................................................................................................400 kg (881.85 lbs) Arm (dipper) cylinder.......................................................................................................................... 695 kg (1532.21 lbs) Bucket cylinder .....................................................................................................................................390 kg (859.80 lbs) Fuel tank .............................................................................................................................................. 255 kg (562.18 lbs) Hydraulic oil tank..................................................................................................................................219 kg (482.81 lbs) Standard boom................................................................................................................................. 3540 kg (7804.35 lbs) Short boom ...................................................................................................................................... 3570 kg (7870.49 lbs) Standard arm ................................................................................................................................... 1711 kg (3772.10 lbs) Short arm With standard boom..................................................................................................................... 1511 kg (3331.18 lbs) With short boom .......................................................................................................................... 1580 kg (3483.30 lbs)

Lep SM470B1002-1EN

Issued 03-2010


1002-22

DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY Sprocket Dimensions a

P

e

Øb Øc

Ød

330-6-10-00-13A

Dimension

Mark a Øb Øc

Standard Limit Standard Limit Standard Limit

mm

in

90 78 773.6 763.6 867.5 854.5

3.54 3.07 30.45 30.06 34.15 33.64

Dimension

Mark Ød e P

Standard Limit Standard Limit Standard Limit

mm

in

847.3 43.4 48.4 228.6 -

33.35 1.70 1.90 8.99 -

Gauge unit in mm

TI14011-014

Lep SM470B1002-1EN

Issued 03-2010


1002-23

Idler wheel Dimensions c b

a f

e d

330-6-10-00-13B

Dimension mm in

Mark Øa b c Ø d (shaft)

Standard Limit Standard Limit Standard Limit Standard Limit

676 665 22.5 25.5 102 92 95 94

26.61 26.18 0.88 1.00 4.01 3.62 3.74 3.70

Dimension mm in

Mark Ø d (bushing) e (bushing) f

Standard Limit Standard Limit Standard Limit

95 96 100 99 15 -

3.74 3.77 3.93 3.89 0.59 -

Gauge unit in mm

TI14011-015

Lep SM470B1002-1EN

Issued 03-2010


1002-24

Upper roller Dimensions c b

d

a

g

e f 330-6-10-00-13C

Dimension

Mark Øa b c Ø d (shaft)

Standard Limit Standard Limit Standard Limit Standard Limit

mm

in

150 138 15 104 65 64

5.90 5.43 0.59 4.09 2.55 2.51

Mark Standard Ø d (bushing) Limit Standard e (bushing) Limit Standard f Limit Standard g Limit

Dimension mm

in

65 66 69 68 9 8.5 15 -

2.55 2.59 2.71 2.67 0.35 0.33 0.59 -

Gauge unit in mm

Lep SM470B1002-1EN

Issued 03-2010


1002-25

Lower roller Dimensions d

g

f a e

b

330-6-10-00-13D

Dimension

Mark Øa b d Ø e (shaft)

Standard Limit Standard Limit Standard Limit Standard Limit

mm

in

200 188 25 20 223 233 85 84

7.87 7.40 0.98 0.78 8.77 9.17 3.34 3.30

Dimension

Mark Ø e (bushing) f g

Standard Limit Standard Limit Standard Limit

mm

in

85 86 93 92 24.5 23.9

3.34 3.38 3.66 3.62 0.96 0.94

Gauge unit in mm

TI14011-016

Lep SM470B1002-1EN

Issued 03-2010


1002-26

Track

c

c’

d

d’

e

e’

f

f

f’ (4 pieces)

b a

330-6-10-00-13E

Dimension mm in

Mark Standard Limit Standard b Limit Standard Ø c (bushing) Limit Standard Ø d (bushing) Limit Standard

a

Ø e (Pin) f

Limit Standard Limit

Lep SM470B1002-1EN

52 32 129 124 73.33 69.7 49.2 48.3

2.04 1.25 5.07 4.88 2.88 2.74 1.93 1.90

-

-

228.6

8.99

-

-

Mark Standard Limit Standard Ø d’ (bushing) Limit Standard Ø e’ (Pin) Limit Standard f’ (4 pieces) Limit

Ø c’ (bushing)

Dimension mm in 73.33 69.7 49.5 48.83 914.4 934.4

2.88 2.74 1.94 1.92 35.99 36.78

Issued 03-2010


1002-27

DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS 4 7

9

6 1

10 3 5 2 8

11

CRIL06C002F

1. Boom foot/Frame

a b

d

c

e

SI14004-001A

Dimension mm in

Mark a (frame) b (boom) c (clearance) Ø d (shaft) Ø e (bushing)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

Lep SM470B1002-1EN

875.5 34.46 883 34.76 871 34.29 868 34.17 4.5 to 5.5 0.17 to 0.21 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

Issued 03-2010


1002-28

2. Boom cylinder foot/Frame a b

c

e

d

330.6.10.00.12C2

Dimension mm in

Mark a (boom) b (cylinder) c (clearance) Ø d (shaft) Ø e (bushing)

Standard Limit Standard Limit Standard Limit Standard Limit Standard Limit

126 4.96 132 5.19 125 4.92 122 4.80 1.5 to 3.5 0.05 to 0.13 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

3. Boom cylinder head/Boom a

b

a

c d

e TI14011-005a

Mark Standard a (boom cylinder) Limit Standard b (boom) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Ø e (bushing boom Standard Limit cylinder)

Lep SM470B1002-1EN

mm

Dimension

in

140 5.51 137 5.39 679 26.73 675 26.57 1.5 to 3.0 0.05 to 0.11 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

Issued 03-2010


1002-29

4. Arm cylinder foot/Boom Mark

a b

c

Standard Limit Standard b (cylinder) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

a (boom)

e

d

Dimension mm in 156 6.14 162 6.37 155 6.10 153 6.02 1.0 to 3.0 0.039 to 0.11 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

SI14004-002B

5. Boom/Arm g

a

Mark

g

b

c

e

d f

330.6.10.00.12E1

Standard Limit Standard b (arm) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit Standard f (boom) Limit Standard g (boom) Limit

a (boom)

Dimension mm in 437 17.20 440 17.32 432.7 17.03 429.7 16.91 4.5 to 5.5 0.17 to 0.21 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78 120 4.72 121.5 4.78 98 3.85 96 3.77

6. Arm cylinder head/Arm Mark

a b

e

Standard Limit Standard b (cylinder) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

a (arm)

c

d

Dimension mm in 156 6.14 161 6.33 155 6.10 153 6.02 1.0 to 3.0 0.039 to 0.11 Shim adjustment 120 4.72 119 4.68 120 4.72 121.5 4.78

330.6.10.00.12F1

Lep SM470B1002-1EN

Issued 03-2010


1002-30

7. Bucket cylinder foot/Arm a

Mark

b

e

Standard Limit Standard b (cylinder) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

a (arm)

c d

330.6.10.00.12F2

Dimension mm in 141 5.55 146 5.74 140 5.51 138 5.43 1.0 to 3.0 0.039 to 0.11 Shim adjustment 110 4.33 109 4.29 110 4.33 111.5 4.38

8. Connecting rod/Arm c

Mark

a

Standard Limit Standard b Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

a

b

e a d

Dimension mm in 50 1.96 47 1.85 441 17.36 437 17.20 1.5 to 2.0 0.059 to 0.078 Shim adjustment 95 3.74 94 3.70 95 3.74 96.5 3.79

330.6.10.00.12G1

9. Compensator/Bucket c

Mark Standard Limit Standard b (link) Limit Standard c (clearance) Limit Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit

a (bucket)

b a e

d

Dimension mm in 480 18.89 485 19.09 479 18.85 476 18.74 1.5 to 3.5 0.059 to 0.137 Shim adjustment 100 3.93 99 3.89 100 3.93 101.5 3.99

330.6.10.00.12G2

Lep SM470B1002-1EN

Issued 03-2010


1002-31

10. Connecting rod/Compensator/Bucket cylinder head c

Mark

f i

a

Standard Limit Standard b Limit Standard c (clearance) Limit Standard d (link) Limit Standard e (cylinder) Limit Standard f (clearance) Limit Standard Ø g (shaft) Limit Standard Ø h (bushing) Limit Standard Ø i (bushing) Limit

a

d e b

h a g 330.6.10.00.12H1

Dimension mm in 50 1.96 48 1.88 441 17.36 436 17.16 1.5 to 2.5 0.059 to 0.098 Shim adjustment 141 5.55 143 5.62 140 5.51 138 5.43 1.5 to 2.0 0.059 to 0.078 Shim adjustment 110 4.33 109 4.29 110 4.33 111.5 4.38 110 4.33 111.5 4.38

11. Arm/Bucket c d

Mark

g f

a b

e 330.6.10.00.12I1

Lep SM470B1002-1EN

Standard Limit Standard b (arm) Limit Standard c (clearance) Limit Standard d Limit Standard Ø e (shaft) Limit Standard Ø f (bushing) Limit Standard Ø g (bushing) Limit

a (bucket)

Dimension mm in 480 18.89 479 18.85 476 18.74 1.5 to 4.0 0.059 to 0.157 Shim adjustment 16 0.62 10 0.39 100 3.93 99 3.89 100 3.93 101.5 3.99 100 3.93 101.5 3.99

Issued 03-2010


1002-32

SPECIAL TORQUE SETTINGS No.

Component

Torque setting

Screw (Ă˜)

Wrench (mm)

Nm

lb-ft

1*

Travel motor

M24

36

900-1051

664-775

2*

Sprocket

M24

36

900-1051

664-775

3 Id

ler wheel

M16

34

267-312

197-230

4*

Upper roller

M20

30

521-608

384-448

5*

Lower roller

M24

36

902-1049

665-774

902-1049

665-774

353-431

260-318

6*

Track guard

7

Shoe

Frame Guard

M24

36

M24

36

1236-1510

912-1114

8

Counterweight

M30

46

1765-2010

1302-1482

9*

Turntable bearing

M24

36

952-1050

702-774

10 *

Swing unit

M24

36

952-1050

702-774

M20

30

324-373

239-275

Front Bracket

M10

17

64-73

128-149

Rear Bracket

M16

24

245-274

181-202

M16

24

147-176

108-130

M12

19

88-108

65-80

11 * 12 *

Mount Engine

13 * 14 * 15 * 16 * 17 * 18 Fue 19 * 20 * 21* 22 23*

Radiator Hydraulic pump

Flange

M20

17

367-496

271-366

Hydraulic reservoir

Pump

M16

24

226-264

167-195

l reservoir

M16

24

226-264

167-195

M20

30

333-392

246-289

Control valve Center Joint Cab

Lock bar

M16

24

267-312

197-230

Joint

M12

19

54-64

40-47

Floor

M16

24

78-80

57-59

Mount

M12

19

54-64

40-47

24

Battery

M10

17

20-29

15-21

25

Lower frame joint

M30

46

1470-1920

1084-1416

NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

Lep SM470B1002-1EN

Issued 03-2010


1002-33

17

15 16

19

11 12 13

10 18

8

14 24 7

20 21

1 2

9

5

22, 23

6 3

1

25

4

6

2 1

6

2

3

4

5

7

8

7

4 5 3

8 TI08010-001

Lep SM470B1002-1EN

Issued 03-2010


1002-34

9 10

15 16

10

9

15

9

11 12 13 14

16

17

17 14

12

11

18

13 20 21

19

20

21

19

18 22 23

24

25

22 24 23

25 TI08010-002

Lep SM470B1002-1EN

Issued 03-2010


1002-35

MACHINE OVERALL DIMENSIONS Standard attachment (6.98 m boom) with fixed side frame

Dippers 2,53 m 3,38 m (A) ................................................................................ ...................3,64 m ................3,60 m (B) ................................................................................ ...................3,29 m ................3,29 m (C) ................................................................................ .................12,06 m ..............12,01 m (D) ................................................................................ ...................6,39 m ................6,39 m (E) ................................................................................ ...................3,06 m ................3,06 m (E) (with catwalks)........................................................ ...................3,59 m ................3,59 m (F)................................................................................. ...................1,33 m ................1,33 m (G) ................................................................................ ...................3,67 m ................3,67 m (H) ................................................................................ ...................5,45 m ................5,45 m (I).................................................................................. ...................4,40 m ................4,40 m (J) ................................................................................. ...................2,75 m ................2,75 m (K) (standard pads) ...................................................... ...................0,60 m ................0,60 m (L) (with 600 mm pads) ................................................ ...................3,35 m ................3,35 m (L) (with 750 mm pads) ................................................ ...................3,50 m ................3,50 m (L) (with 900 mm pads) ................................................ ...................3,65 m ................3,65 m (M)................................................................................ ...................0,54 m ................0,54 m

Lep SM470B1002-1EN

Issued 03-2010


1002-36

Standard attachment (6.98 m boom) with retractable side frame

Dippers 2,53 m 3,38 m (A)................................................................................. .................. 3,71 m................ 3,66 m (B)................................................................................. .................. 3,44 m................ 3,44 m (C) ................................................................................ ................ 12,04 m.............. 11,98 m (D) ................................................................................ .................. 6,39 m................ 6,39 m (E)................................................................................. .................. 3,06 m................ 3,06 m (E) (with catwalks) ........................................................ .................. 3,59 m................ 3,59 m (F)................................................................................. .................. 1,48 m................ 1,48 m (G) ................................................................................ .................. 3,67 m................ 3,67 m (H) ................................................................................ .................. 5,45 m................ 5,45 m (I) .................................................................................. .................. 4,40 m................ 4,40 m (J)*................................................................................ .................. 2,89 m................ 2,89 m (J)** .............................................................................. .................. 2,39 m................ 2,39 m (K) (standard pads) ...................................................... .................. 0,60 m................ 0,60 m (L)* (with 600 mm pads) ............................................... .................. 3,49 m................ 3,49 m (L)** (with 600 mm pads).............................................. .................. 2,99 m................ 2,99 m (L)* (with 750mm pads) ................................................ .................. 3,64 m................ 3,64 m (L)** (with 750mm pads)............................................... .................. 3,14 m................ 3,14 m (L)* (with 900 mm pads) ............................................... .................. 3,79 m................ 3,79 m (L)** (with 900mm pads)............................................... .................. 3,29 m................ 3,29 m (M) ................................................................................ .................. 0,74 m................ 0,74 m (N) ................................................................................ .................. 0,11 m................ 0,11 m NOTE: * (working position) ** (transport position)

Lep SM470B1002-1EN

Issued 03-2010


1002-37

Short attachment (6.55 m boom) with fixed side frame

Dipper 2.53 m (A).......................................................................................................................................................................... 3,76 m (B).......................................................................................................................................................................... 3,29 m (C) ....................................................................................................................................................................... 11,64 m (D) ......................................................................................................................................................................... 6,39 m (E).......................................................................................................................................................................... 3,06 m (E) (with catwalks) ............................................................................................................................................... 3,59 m (F).......................................................................................................................................................................... 1,33 m (G) ......................................................................................................................................................................... 3,67 m (H) ......................................................................................................................................................................... 5,45 m (I) ........................................................................................................................................................................... 4,40 m (J) .......................................................................................................................................................................... 2,75 m (K) (standard pads).............................................................................................................................................. 0,60 m (L) (with 600 mm pads) ....................................................................................................................................... 3,35 m (L) (with 750 mm pads) ....................................................................................................................................... 3,50 m (L) (with 900 mm pads) ....................................................................................................................................... 3,65 m (M)......................................................................................................................................................................... 0,54 m

Lep SM470B1002-1EN

Issued 03-2010


1002-38

Short attachment (6.55 m boom) with retractable side frame

Dipper 2.53 m (A) ..........................................................................................................................................................................3,81 m (B) ..........................................................................................................................................................................3,44 m (C)........................................................................................................................................................................11,61 m (D)..........................................................................................................................................................................6,39 m (E) ..........................................................................................................................................................................3,06 m (E) (with catwalks .................................................................................................................................................3,59 m (F) ..........................................................................................................................................................................1,48 m (G)..........................................................................................................................................................................3,67 m (H)..........................................................................................................................................................................5,45 m (I)............................................................................................................................................................................4,40 m (J)* .........................................................................................................................................................................2,89 m (J)**........................................................................................................................................................................2,39 m (K) (standard pads) ..............................................................................................................................................0,60 m (L)* (with 600 mm pads) ......................................................................................................................................3,49 m (L)** (with 600 mm pads).....................................................................................................................................2,99 m (L)* (with 750 mm pads) ......................................................................................................................................3,64 m (L)** (with 750 mm pads).....................................................................................................................................3,14 m (L)* (with 900 mm pads) ......................................................................................................................................3,79 m (L)** (with 900 mm pads).....................................................................................................................................3,29 m (M)..........................................................................................................................................................................0,74 m (N)..........................................................................................................................................................................0,11 m NOTE: * (working position) ** (transport position)

Lep SM470B1002-1EN

Issued 03-2010


Section 2000

CNH

Lep SM470B2000-0EN

2000

REMOVAL AND INSTALLATION OF THE ENGINE


2000-2

TABLE OF CONTENTS REMOVAL AND INSTALLATION OF THE ENGINE ASSEMBLY ......................................................................... 3 REMOVAL OF THE ENGINE ...................................................................................................................................... 3 INSTALLATION OF THE ENGINE ............................................................................................................................. 10

Lep SM470B2000-0EN

Issued 03-09


2000-3

REMOVAL AND INSTALLATION OF THE ENGINE ASSEMBLY

Caution:

Keep away from fire. Be sure to release hydraulic pressure before beginning work. The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas splaying out 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.

1 Removal of the engine [1] Drain the coolant from the radiator. (For details, see "Operator’s Manual".) [2] Remove the engine hood. (For details, see "Removal and Installation of Engine Hood".) [3] Remove the pump. (For details, see "Removal and Installation of Pump") [4] Use a wrench (19 mm) to remove the 7 bolts (1), and then remove the radiator cover (2).

2 1 1 1 1

TF11006-029

[5] Use a wrench (7 mm) to loosen the hose band (3) on the radiator, and then remove the lower hose (4). • Use caps to cover the radiator and hose to prevent the entry of water, dust or dirt. • Before removing the radiator hose, completely drain the coolant.

4

3 TF11006-001

Lep SM470B2000-0EN

Issued 03-09


2000-4 [6] Use a wrench (7 mm) to loosen the hose band (5) on the radiator, and then remove the upper hose (6).

6 5

TF11006-002

[7] Use a wrench to loosen the 2 line bolts (7), and then remove the 2 compressor lines (8) and (9). • Before removing the compressor lines, recover the air conditioner gas. • Always remove the low-pressure (suction side) line (8) first. • Attach caps or plugs to the compressor and lines to prevent any entry of water, dust or dirt. • The O-ring cannot be reused. Always replace it with a new one.

8

9

7

TF11006-003

[8] Use a wrench (8 mm) to loosen the hose band (10) on the inter cooler, and then remove the hose (11). • Use caps to cover the line and hose to prevent the entry of water, dust or dirt.

10

11

TF11006-004

Lep SM470B2000-0EN

Issued 03-09


2000-5 [9] Prepare the waste oil can (12). • Drain the engine oil before removing the engine oil hose. [10]Use a wrench to remove the 2 engine oil remote hoses (13). • Mark the engine and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt. • Clean the engine and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

13

12

TF11006-005

[11]Use a wrench (17 mm) to loosen the nut (14), and then remove the battery cable (15) on the negative side. • When removing the terminal and harness, secure them so that they do not interfere with the frame. Also, cover with a rubber cap to protect against sparks.

15

14

TF11006-006

[12]Use a wrench to remove the 3 nuts (16), and then remove the starter motor wiring (17).

16

16

17 16

TF11006-007

Lep SM470B2000-0EN

Issued 03-09


2000-6 [13]Use a wrench to remove the 1 bolt (18), and then remove the ground wiring (19).

19

18 TF11006-008

[14]Use a wrench to loosen the hose band (20), and then remove the fuel hose (21). • Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

20 21

TF11006-009

[15]Use a wrench to loosen the hose band (22), and then remove the fuel hose (23). • Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

23

22 TF11006-010

Lep SM470B2000-0EN

Issued 03-09


2000-7 [16]Use a wrench to remove the 4 bolts (24), and then remove the box cover (25). [17]Remove the connectors (26) in the box. • Wrap the removed connectors in plastic after tying them together.

24

26 25

24

TF11006-011

[18]Use a wrench (7 mm) to loosen the 2 hose bands (27), and then remove the 2 heater hoses (28). • Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

27

28 TF11006-012

[19]Use a wrench to remove the 2 bolts (29). [20]Use a wrench (7 mm) to loosen the 2 hose bands (30), and then remove the air hose (31). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

32

33 30

[21]Use a wrench (8 mm) to loosen the 2 hose bands (32), and then remove the air hose (33). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

30

31

29 32

TF11006-013

Lep SM470B2000-0EN

Issued 03-09


2000-8 [22]Remove the connector (34) from the alternator. [23]Use a wrench (10 mm) to remove the nut (35). [24]Use a wrench to remove the bolt (36), and then remove the alternator wiring (37).

34

36 35 37

TF11006-014

[25]Use a wrench to remove the 4 bolts (38), and then remove the step (39).

38

39 38

TF11006-015

[26]Install the 4 shackles (40), and then use the wire ropes (41) and liftcrane to secure the engine main unit.

40

40 41

TF11006-016

Lep SM470B2000-0EN

Issued 03-09


2000-9 [27]Use a box wrench (30 mm) to remove the 4 bolts (42) from the mount.

42 42

42

42

TF11006-017

[28]Use the wire ropes (41) and liftcrane to lift the engine main unit. [29]Thoroughly check that the location is safe before lowering the engine on wood planks, etc.

41

41

TF11006-018

Lep SM470B2000-0EN

Issued 03-09


2000-10

2 Installation of the engine [1] To install the engine, perform the reverse of the removal procedure. After installing the engine, resupply coolant and engine 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 counterweight. For details, see the individual explanations for each procedure.

Lep SM470B2000-0EN

Issued 03-09


2001 REMOVAL AND INSTALLATION OF THE FUELCOOLER, ENGINE INTER-COOLER, RADIATOR AND OIL-COOLER

CNH

Lep SM470B2001-0EN

2001

Section


2001-2

TABLE OF CONTENTS REMOVAL AND INSTALLATION OF FUEL COOLER .......................................................................................... 3 REMOVAL OF FUEL COOLER .................................................................................................................................. 3 INSTALLATION THE FUEL COOLER .......................................................................................................................... 3 REMOVAL AND INSTALLATION OF INTER COOLER......................................................................................... 4 REMOVAL OF INTER COOLER ................................................................................................................................. 4 INSTALLATION OF INTER COOLER ........................................................................................................................... 4 REMOVAL AND INSTALLATION OF RADIATOR ................................................................................................. 5 REMOVAL OF RADIATOR ........................................................................................................................................ 5 INSTALLATION OF RADIATOR................................................................................................................................ 13 REMOVAL AND INSTALLATION OF OIL COOLER............................................................................................ 14 REMOVAL OF OIL COOLER ................................................................................................................................... 14 INSTALLATION OF OIL COOLER............................................................................................................................. 14

Lep SM470B2001-0EN

Issued 03-09


2001-3

REMOVAL AND INSTALLATION OF FUEL COOLER Caution:

Be sure to stop the engine before beginning work. As the fuel hose will be removed, strictly prohibit open flames.

1 Removal of fuel cooler [1] Use a wrench (7 mm) to loosen the 2 hose bands (1), and then remove the 2 hoses (2). • Mark the fuel cooler (3) and hoses (2) so that the connectors match at the time of assembly. • Fuel will spill out, so place a drip pan directly below the area. • Attach caps or plugs to the fuel cooler and hoses to prevent any entry of water, dust or dirt.

2

2

1

1

3 TF11006-030

[2] Use a wrench (12 mm) to remove the 4 bolts (4), and then remove the fuel cooler (3).

4

4

4 3 TF11006-031

2 Installation the fuel cooler Perform the reverse of the removal procedure. • After connecting the hoses, carefully check for any fuel leaks.

Lep SM470B2001-0EN

Issued 03-09


2001-4

REMOVAL AND INSTALLATION OF INTER COOLER Caution:

Be sure to stop the engine before beginning work. As the fuel hose will be removed, strictly prohibit open flames.

1 Removal of inter cooler [1] Remove the fuel cooler. (For details, see "Removal and Installation of Fuel Cooler") [2] Use a wrench (8 mm) or flathead screwdriver to loosen the 2 hose bands (1), and then remove the 2 hoses (2). • Use caps to cover the inter cooler and hoses to prevent the entry of water, dust or dirt.

2

2

1

1

TF11006-032

[3] Use a wrench (14 mm) to remove the 6 bolts (3), then remove the inter cooler (4).

4

3

3

TF11006-033

2 Installation of inter cooler Perform the reverse of the removal procedure. Check for any air leaks.

Lep SM470B2001-0EN

Issued 03-09


2001-5

REMOVAL AND INSTALLATION OF RADIATOR Caution:

Do not remove the radiator cap when the radiator coolant temperature is high. Hot liquid could spray out.

Caution:

Be sure to release hydraulic pressure before beginning work. 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.

1 Removal of radiator [1] Open the engine hood. [2] Drain the hydraulic oil from the hydraulic oil tank. (See Operator’s Manual for details of this procedure). [3] Use a wrench (19 mm) to remove the 5 bolts (1), and then remove the under cover (2).

2

1

TM13006-001

[4] To make it easier to drain the coolant, remove the radiator cap (3).

3

TM13006-002

Lep SM470B2001-0EN

Issued 03-09


2001-6 [5] Install the drain hose (4), and then prepare the drain tank (5). [6] Loosen the drain plug (6), and then drain the coolant.

6

4

5

TM13006-003

[7] Use a wrench (19 mm) to remove the 7 bolts (7), and then remove the radiator cover (8).

8 7 7 7 7

TM13006-004

Lep SM470B2001-0EN

Issued 03-09


2001-7 [8] Remove the connector (9). [9] Use a wrench to remove the bolt (10). [10]Use a wrench (8 mm) to remove the 3 sleeve nuts (11), and then remove the hoses (12). • Use caps to cover the line and fan motor to prevent any entry of water, dust or dirt.

9

12

10

11

12 11

12

TM13006-005

[11]Use a wrench (7 mm) to loosen the hose band (13) on the radiator, and then remove the lower hose (14). • Use caps to cover the hose and radiator to prevent any entry of water, dust or dirt.

14

13 TM13006-006

[12]Use a wrench (7 mm) to loosen the hose band (15) on the radiator, and then remove the upper hose (16). • Use caps to cover the hose and radiator to prevent any entry of water, dust or dirt.

16 15

TM13006-007

Lep SM470B2001-0EN

Issued 03-09


2001-8 [13]Use a wrench (7 mm) to loosen the hose bands (17) of the oil cooler. Use a box wrench to remove the 2 bolts (18), and then remove the oil cooler pipe (19). • Use caps to cover the oil cooler and hose to prevent any entry of water, dust or dirt. [14]Use a wrench (7 mm) to loosen the oil cooler hose bands (20), and then remove the hose (21). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

21

20

19 18 17

TM13006-008

[15]Remove the connector (22) from the sensor. [16]Use a wrench to remove the 2 bolts (23), and then remove the oil cooler pipe (24). • Use caps to cover the oil cooler and line to prevent any entry of water, dust or dirt.

22

23

24

TM13006-012

[17]Use a wrench (7 mm) to loosen the 2 hose bands (25), and then remove the 2 hoses (26). • Fuel will spill out, so place a drip pan directly below the area. • Mark the fuel cooler and hoses so that the connectors match at the time of assembly. • Use caps to cover the fuel cooler and hoses to prevent any entry of water, dust or dirt. [18]Use a wrench (8 mm) to loosen the 2 hose bands (27), and then remove the 2 hoses (28). • Use caps to cover the inter cooler and hoses to prevent any entry of water, dust or dirt.

28

27

27

26 25

28

25 26

TM13006-009

[19]Close the drain plug (29), loosen the hose band (30), and then remove the hose (31).

29

30 31 Lep SM470B2001-0EN

TM13006-010

Issued 03-09


2001-9 [20]Loosen the hose band (33), and then remove the hose (32) from the radiator cap. • Attach caps or plugs to the hose to prevent any entry of water, dust or dirt.

32

33

TM13006-011

[21]Use a wrench to loosen the nut (34). Use a wrench to remove the bolt (35), and then remove the engine hood opener cable (36).

34

36

35

TM13006-013

[22]Use a wrench to remove the 4 bolts (37), and then remove the frame (38).

37

38 37

TM13006-014

Lep SM470B2001-0EN

Issued 03-09


2001-10 [23]Install the 2 shackles (39) to the top of the radiator cover, and then use the wire rope (40) and liftcrane to secure the radiator and oil cooler assembly.

40 39

39

TM13006-015

[24]Use a wrench (19 mm) to remove the 2 bolts (41).

41

TM13006-016

[25]Use a wrench (19 mm) to remove the 4 bolts (42), and then remove the 2 radiator stays (43).

43

42

43 42

TM13006-017

Lep SM470B2001-0EN

Issued 03-09


2001-11 [26]Use a wrench to remove the 4 bolts (44).

44

44

TM13006-018

[27]Use a box wrench to remove the 4 bolts (45).

45

45 TM13006-019

[28]Use the wire rope (40) and liftcrane to lift the radiator and oil cooler assembly. [29]Thoroughly check that the location is safe before lowering the radiator and oil cooler assembly on wood planks, etc.

40

TM13006-020

Lep SM470B2001-0EN

Issued 03-09


2001-12 [30]Use a wrench to remove the 8 bolts (47), and then remove the fan assemblies (48).

47

47

48 48

47

47 TM13006-021

[31]Use a wrench to remove the 10 bolts (49), and then remove the shroud assembly (50).

50

49

49

49

TM13006-022

Lep SM470B2001-0EN

Issued 03-09


2001-13 [32]Use a wrench (14 mm) to remove the 4 bolts (51), the 8 washers (52) and the 4 rubber cushions (53). • Be careful not to drop the bottom side washers.

51 52 53 52

51

51

TM13006-023

[33]Lift the radiator (55) until the fixtures (54) at the bottom of the radiator become disconnected. [34]Thoroughly check that the location is safe before lowering the radiator on square wooden piece. When laying down the radiator, be careful not to bend or crush the bottom fixtures (54).

55

54 TM13006-025

2 Installation of radiator To install, perform the reverse of the removal procedure. For details on the method for coolant filling, see the Operator’s Manual. Coolant capacity is 38 L. Finally, check that the level of coolant is correct.

Lep SM470B2001-0EN

Issued 03-09


2001-14

REMOVAL AND INSTALLATION OF OIL COOLER Caution:

Keep away from fire

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.

1 Removal of oil cooler [1] Remove the radiator and oil cooler assembly and also the fan assembly and shroud assembly. See "Removal and Installation of Radiator" for details of this procedure.

1

[2] Use a wrench (17 mm) to remove the 4 bolts (1) and 8 washers (2), and then remove the rubbers cushions (3) and remove the oil cooler. • Be careful not to drop the bottom side washers.

2

3

2

1

[3] Thoroughly check that the location is safe before lowering the oil cooler on wood planks, etc.

1

TM13006-024

2 Installation of oil cooler Perform the reverse of the removal procedure.

Lep SM470B2001-0EN

Issued 03-09


Section

REMOVAL AND INSTALLATION OF THE TURBO CHARGER

CNH

Lep SM470B2004-0EN

2004

2004


2004-2

TABLE OF CONTENTS REMOVAL AND INSTALLATION OF TURBO CHARGER .................................................................................... 3 REMOVAL OF TURBO CHARGER.............................................................................................................................. 3 INSTALLATION OF TURBO CHARGER ....................................................................................................................... 5 Tightening torque .............................................................................................................................................. 5

Lep SM470B2004-0EN

Issued 03-09


2004-3

REMOVAL AND INSTALLATION OF TURBO CHARGER Caution:

The turbo charger is extremely hot just after stopping the engine. Wait for them to sufficiently cool before beginning work.

Caution:

Be sure to stop the engine before beginning work.

1 Removal of turbo charger The engine oil line and coolant line will be removed, so either drain the engine oil and coolant beforehand or use stoppers on the ends of the lines to prevent leaking. [1] Remove the muffler. [2] Use a wrench (7 mm) to loosen the 2 hose bands (1), and then remove the intercooler hose (2). • Use caps to cover the turbo charger and the hose to prevent any entry of water, dust or dirt.

4

3

[3] Use a wrench (7 mm) to loosen the hose band (3), and then remove the intake hose (4). • Use caps to cover the turbo charger and the hose to prevent any entry of water, dust or dirt.

1 2

1

TF11006-024

[4] Use a wrench (14 mm) to remove the eyebolt (5), and then remove the oil feed pipe (6). • Use caps and plugs to cover the turbo charger and oil feed pipe to prevent any entry of water, dust or dirt. • When removing the oil feed pipe, be very careful not to damage or lose the packing.

6 5

TF11006-025

[5] Use a wrench (10 mm) to remove the 2 bolts (7), and then remove the oil return pipe (8). • Use caps and plugs to cover the turbo charger and oil return pipe to prevent any entry of water, dust or dirt.

7

8

TF11006-026

Lep SM470B2004-0EN

Issued 03-09


2004-4 [6] Use a wrench (14 mm) to remove the 4 nuts (9), and then remove the turbo charger (10).

9 10 TF11006-027

[7] Use a wrench (13 mm) to remove the 8 nuts (11), and then remove the line (12) from the turbo charger main unit.

11

12 TF11006-028

Lep SM470B2004-0EN

Issued 03-09


2004-5

2 Installation of turbo charger To install, perform the reverse of the removal procedure. During installation, replace each gasket and the packing with new ones. Make sure to check the engine oil and coolant levels and resupply as necessary. Each of the installation tightening torque values are indicated below. Check carefully for exhaust leaks, water leaks, and oil leaks. 1 Tightening torque Unit: Nm

4

3

2

1

Oil feed pipe

2

Exhaust manifold

3

Turbo charger assembly

4

Exhaust adapter

5

Oil return pipe

34.3 Nm 40 Nm Bolt 50 Nm Nut 40 Nm 43.8 Nm

1

5

3 2

4 TF11006-092

Lep SM470B2004-0EN

Issued 03-09


2004-6

NOTES ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ ........................................................................................................................................................................................ Lep SM470B2004-0EN

Issued 03-09


Section

REMOVAL AND INSTALLATION OF THE EGR COOLER AND EGR VALVE

CNH

Lep SM470B2005-0EN

2005

2005


2005-2

TABLE OF CONTENTS REMOVAL AND INSTALLATION OF EGR COOLER AND EGR VALVE ............................................................. 3 REMOVAL OF EGR COOLER AND EGR VALVE ........................................................................................................ 3 INSTALLATION OF EGR COOLER AND EGR VALVE ................................................................................................. 5 Tightening torque for each section .................................................................................................................... 5

Lep SM470B2005-0EN

Issued 03-09


2005-3

REMOVAL AND INSTALLATION OF EGR COOLER AND EGR VALVE Caution:

The EGR cooler and EGR valve are extremely hot just after stopping the engine. Wait for them to sufficiently cool before beginning work.

Caution:

Be sure to stop the engine before beginning work. Be sure to drain coolant before beginning work.

1 Removal of EGR cooler and EGR valve [1] Use a wrench (12 mm) to remove the 6 bolts (1).

1

1 1 TF11006-069

[2] Use pliers to loosen the 4 hose bands (2), and then remove the 4 hoses (3). • Use caps and plugs to cover the line hoses to prevent any entry of water, dust or dirt.

2 3 3

3 2

TF11006-070

[3] Use a wrench (12 mm) to remove the 7 bolts (4), and then remove the EGR duct C (5).

4 4

5 TF11006-071

Lep SM470B2005-0EN

Issued 03-09


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Case cx470b crawler excavator service repair manual  
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