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CX490CCrawlerexcavatorLCversion(TIER3)

CX500CCrawlerexcavatorLCMEversion(TIER3)

SERVICEMANUAL

4804424905/09/2016

Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.102]Panandcovers....................................................................10.2 [10.106]Valvedriveandgears..............................................................10.3 [10.101]Cylinderheads.....................................................................10.4 [10.105]Connectingrodsandpistons.......................................................10.5 [10.218]Fuelinjectionsystem...............................................................10.9 [10.250]Turbochargerandlines...........................................................10.10 [35.300]Reservoir,cooler,andfilters........................................................35.2 4804424905/09/2016

[35.352]Hydraulicswingsystem..........................................................35.11

[35.353]Hydraulictravelsystem..........................................................35.12 [35.354]Hydrauliccentraljoint............................................................35.13

[35.356]Hydraulicfootcontrol.............................................................35.10

Framesandballasting.................................................................39 Tracksandtracksuspension........................................................48 Cabclimatecontrol.....................................................................50 [50.100]Heating.............................................................................50.1 [50.200]Airconditioning.....................................................................50.2 Electricalsystems.......................................................................55 4804424905/09/2016

[35.736]Boomhydraulicsystem..........................................................35.14 [35.737]Dipperhydraulicsystem..........................................................35.15 [35.738]Excavatorandbackhoebuckethydraulicsystem................................35.16 [35.360]Hammerandrotatingbuckethydraulicsystem..................................35.17

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[55.640]Electronicmodules...............................................................55.14 [55.512]Cabcontrols......................................................................55.15 [55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.17 [55.416]Swingcontrolsystem............................................................55.19 [55.417]Travelcontrolsystem............................................................55.20 [55.518]Wiperandwashersystem........................................................55.22 [55.404]Externallighting..................................................................55.23 [55.992]Anti-theftsystem.................................................................55.26 Booms,dippers,andbuckets.......................................................84 [90.150]Cab.................................................................................90.1 [90.156]Cabwindshieldandwindows......................................................90.2 [90.120]Mechanically-adjustedoperatorseat...............................................90.3 4804424905/09/2016

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INTRODUCTION

Contents

Safetyrules(*)..................................................................................4 Hydrauliccontamination......................................................................17 Generalspecification-Mainequipment......................................................18 Weight(*).....................................................................................25 Weight(*).....................................................................................27 Conversionfactors............................................................................29 Consumables.................................................................................41 Productidentification(*)......................................................................48 Productidentification(*)......................................................................50 Productidentification-Machineorientation..................................................52 4804424905/09/2016 2

INTRODUCTION

INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing

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Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.

INTRODUCTION Safetyrules CX490CCrawlerexcavatorLCversion(TIER3) CX500C

Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine. DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury. FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor Information NOTE: 4804424905/09/2016 4

Personalsafety

INTRODUCTION Safetyrules-Generalinformation Cleaning Aftercleaning,drywell,andinjectoilinallparts. Inspection Bearing Needlebearing Gear Alwaysinstallnewoilseals,O-rings,andgaskets. Shaft Checkthebearingsandcheckfordamagedoilsealsontheshaft. Serviceparts InstallCASECONSTRUCTIONgenuineserviceparts. Lubricants(fuel,hydraulicoil) Usetheoilfromthespecifiedcompanyorspecifiedintheoperator'smanualorserviceManual. 4804424905/09/2016 5

INTRODUCTION Safetyrules-Personalsafety WARNING: Itgivesinformationconcerningthesafetyoftheoperatorandthoseinthesurroundings. Alwayscomplywithwarningsandprecautionssoastoavoidanyaccidents. Checkwhetherallwarninglabelsareinplace. WARNING: Readtheoperator'smanualtogainathoroughunderstandingofmachinecontroloperations. WARNING: WARNING: WARNING: Checkthesafetymessagesintheoperator'smanualbeforestartingtheengine. Checkthatnooneiswithinthemachine’soperatingrange. Theoperator'smanualcanbepurchasedatyourCASECONSTRUCTIONdealer. WARNING: Workingwithsloppyclothesorclotheswithwhichsafetycannotbeensuredleadstodamagetothemachine andinjurytotheoperator. Inordertoworkmoresafely,itisrecommendedtowearadditionalsafetyequipment. WARNING: WARNING: 4804424905/09/2016 6

INTRODUCTION WARNING: Checkthatthereisnooneinthesurroundingsbeforedrainingthepressurefromhydrauliccircuitsduring WARNING: Usegloveswhenhandlinghigh-temperatureparts. WARNING: WARNING: WARNING: WARNING: Weareyeprotectionwhenusingahammertoinstallapinorwhenworkingwithagrinder. WARNING: WARNING: Checktheoil,coolant,grease,andtools. Payenoughattentiontosafety. WARNING: Someofthemachine'spartsareextremelyheavy. Forweightsandprocedures,seetheServiceManual. WARNING: Exhaustgasesaretoxic. WARNING: 4804424905/09/2016 7

INTRODUCTION Safetyrules-Cabprotectivestructure Cabprotectivestructure Prohibiteditems • • Modificationsprohibited(redpart) Modificationspermittedunderconditions(gray part) todiameter 20mm ( 0.787in ))bydrillingarepossible. SMPH15CEX6544FA 1 4804424905/09/2016 8

INTRODUCTION Safetyrules-Ecologyandtheenvironment Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,filters,batteries,fuels,anti-freeze, cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use, Helpfulhints • • • • etc.Donotmixdrainedbrakefluidsorfuelswithlubricants.Storealldrainedfluidssafelyuntilyoucandisposeof • Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly. • • • • Batteryrecycling Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful CONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoaCASE batteriesproperly.Insomecountries,thisisalegalrequirement. Mandatorybatteryrecycling NOTE: Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead, CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany Pointsofsaleareobligedto: • Acceptthereturnofyourusedbatteries • Storethereturnedbatteriesinasuitablelocation • Sendthereturnedbatteriestothebatterymanufacturerforrecycling 4804424905/09/2016 9

6.9N·m ( )

19.6N·m ( )

39.2N·m ( )

58.8N·m ( )

98.1N·m ( )

156.9N· m ( 3lbft )

196.1N· m ( 6lbft )

294.2N· m ( 1lbft ) Wrench 5mm 6mm8mm10mm12mm14mm14mm17mm Hexagon socket headbolt ingtorque

8.8N·m ( 6.491lb )

21.6N·m ( 15.931lb )

42.1N·m ( 31.051lb )

78.5N·m ( 57.899lb )

117.7N·m ( 86.811lb ) 4804424905/09/2016

176.5N· m ( 130.18 0lbft )

245.2N· m ( 180.85 0lbft )

343.2N· m ( 253.13 1lbft )

INTRODUCTION Torque-Boltandnut •

diameter(size)

LPIL12CX00005EA 1 • L OCTITE ® old L OCTITE ® L OCTITE ® Torquetable Boltnominal

M6M8M10M12M14M16M18M20

Wrench 10mm13mm17mm19mm22mm24mm27mm30mm Hexagon bolt ingtorque

INTRODUCTION Torque-Specialtorquesetting Code Retighteninglocation Nominalbolt diameter Wrench Tighteningtorque Travelmotor M2436mm ( 664-775lbft ) Drivesprocket M2436mm ( ) M1624mm ( ) Upperroller M2030mm ( ) Lowerroller M2436mm ( ) Trackguard M2436mm ( ) 7 Shoe M2436mm ( ) 8 Counterweight M3350mm ( ) Turntablebearing M2436mm ( ) 10* Swingunit M2436mm ( ) 11* Mount M2741mm ( 622-723lbft ) 12* Frontbracket M1017mm 63.8-73.6N·m ( 47-54lbft ) 13* Engine Rearbracket M1624mm 245.2-274.6N·m ( ) 14* Radiator M1624mm 147.2-176.6N·m ( ) 15* Flange M1219mm ( 65-80lbft ) 16* Hydraulic pump Pump M20 17mm hexagon socket head ( ) 17* Hydraulictank M1624mm 225.6-264.8N·m ( ) 18* Fueltank M1624mm 232.4-276N·m ( 171-204lbft ) M2030mm ( ) 20* Lockbar M1624mm ( ) 21* Centerjoint Joint M1219mm ( ) Cab M1624mm ( ) Battery M1017mm ( ) NOTE: Makesuretoapply L OCTITE ®262™ orequivalenttothelocationswiththe*mark,andtightenaccordingto Nominalboltdiameter(Size) M6M8M10M12M14M16M18M20 Wrench 10mm13mm17mm19mm22mm24mm27mm30mm Hexagonbolt Tightening torque 19.6N· m 39.2N· m 58.8N· m 98.1N· m 156.9N· m N·m 294.2N· m Wrench 5mm 6mm8mm10mm12mm14mm14mm17mm Hexagonsocket headbolt Tightening torque 8.8N·m 21.6N· m 42.1N· m 78.5N· m 117.7N· m 176.5N· m 245.2 N·m 343.2N· m 4804424905/09/2016 11

INTRODUCTION B2AB1DF6 1 4804424905/09/2016

INTRODUCTION 2 4804424905/09/2016

INTRODUCTION 3 4804424905/09/2016