Case CX500C Service Manual
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Case CX500C Service Manual

Crawler excavator
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CX500C
Crawler Excavator
SERVICE MANUAL
Part number 48032547
English
June 2016
© 2016 CNH Industrial Italia S.p.A. All Rights Reserved.

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  • Page 1 CX500C Crawler Excavator SERVICE MANUAL Part number 48032547 English June 2016 © 2016 CNH Industrial Italia S.p.A. All Rights Reserved.
  • Page 2 SERVICE MANUAL CX500C Crawler excavator LC Mass excavator version (TIER 3) - CHINA Market 48032547 22/06/2016 Find manuals at https://best-manuals.com...
  • Page 3 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.102] Pan and covers .
  • Page 4 [35.752] Hydraulic fan drive cooling system ..........35.8 [35.355] Hydraulic hand control .
  • Page 5 [55.202] Cold start aid ............... 55.8 [55.010] Fuel injection system .
  • Page 6 [90.100] Engine hood and panels ............90.4 48032547 22/06/2016 Find manuals at https://best-manuals.com...
  • Page 7 48032547 22/06/2016 Find manuals at https://best-manuals.com...
  • Page 8 INTRODUCTION 48032547 22/06/2016 Find manuals at https://best-manuals.com...

  • Page 9: Table Of Contents

    Contents INTRODUCTION Foreword - Important notice regarding equipment servicing ........3 Safety rules (*) .

  • Page 10: Foreword - Important Notice Regarding Equipment Servicing

    In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

  • Page 11: Safety Rules

    INTRODUCTION Safety rules CX500C Crawler excavator LC Mass excavator version (TIER 3) - CHINA APAC Market CX500C APAC Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

  • Page 12: Safety Rules - General Information

    Service parts Install CASE CONSTRUCTION genuine service parts. When placing an order, check the parts catalog. It contains the CASE CONSTRUCTION genuine part numbers. Any breakdowns arising from the installation of non-genuine parts are not covered by the warranty. Lubricants (fuel, hydraulic oil) Use the oil from the specified company or specified in the operator's manual or service Manual.

  • Page 13: Safety Rules - Personal Safety

    Check the operating methods in a safe location before starting the actual work. Understand the machine operations well, then operate in compliance with all service-related laws and regulations. The operator's manual can be purchased at your CASE CONSTRUCTION dealer. WARNING: Working with sloppy clothes or clothes with which safety cannot be ensured leads to damage to the machine and injury to the operator.
  • Page 14 INTRODUCTION WARNING: Check that there is no one in the surroundings before draining the pressure from hydraulic circuits during machine hydraulic cylinder inspection. WARNING: Use gloves when handling high-temperature parts. WARNING: Bring the lower parts or attachments in contact with the ground before inspecting or repairing them. WARNING: Check that hoses and tubes are securely connected.

  • Page 15: Safety Rules - Cab Protective Structure

    INTRODUCTION Safety rules - Cab protective structure Cab protective structure Modifying the cab main components is prohibited in order to protect the operator. Prohibited items • Modifications that reduce the strength of a platform that has a cab with a protective structure mounted on it. (Actions or modifications that reduce the functionality of the anchoring part at the left-rear of the cab) •...

  • Page 16: Safety Rules - Ecology And The Environment

    Improper disposal of batteries can contaminate the soil, groundwater, and waterways. CASE CONSTRUCTION strongly recommends that you return all used batteries to a CASE CONSTRUCTION dealer, who will dispose of the used batteries or recycle the used batteries properly.

  • Page 17: Torque - Bolt And Nut

    INTRODUCTION Torque - Bolt and nut • Tighten alternating between left and right and top and bottom so that uniform tightening force is applied. LPIL12CX00005EA • If L ® was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the OCTITE old L ®...

  • Page 18: Torque - Special Torque Setting

    INTRODUCTION Torque - Special torque setting Nominal bolt Retightening location Tightening torque Code Wrench diameter 900 - 1051 N·m (664 - 775 lb ft) Travel motor 36 mm Drive sprocket 900 - 1051 N·m (664 - 775 lb ft) 36 mm Take-up roller 24 mm 267 - 312 N·m (196.93 - 230.12 lb ft)
  • Page 19 INTRODUCTION B2AB1DF6 48032547 22/06/2016...
  • Page 20 INTRODUCTION YYSJMI-002 48032547 22/06/2016...
  • Page 21 INTRODUCTION YYSJMI-006 48032547 22/06/2016...

  • Page 22: Basic Instructions - Shop And Assembly

    Only use CNH Original Parts or CASE CONSTRUCTION Original Parts. Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same parts that are assembled during standard production. Only CNH Original Parts or CASE CONSTRUCTION Original Parts can offer this guarantee.
  • Page 23 W0111A Special tools The special tools that CASE CONSTRUCTION suggests and illustrate in this manual have been specifically re- searched and designed for use with CASE CONSTRUCTION machines. The special tools are essential for reliable repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting oper- ation.

  • Page 24: Hydraulic Contamination

    INTRODUCTION Hydraulic contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways: • When you drain the oil or disconnect any line •...

  • Page 25: General Specification

    INTRODUCTION General specification Engine Water-cooled, 4-cycle diesel, 6-cylinder in line, high pressure common rail system (electric control), Type turbocharger with air cooled intercooler, without cooling fan Model ISUZU GH-6UZ1XKSS-01 (without fan-pump) 270 kW (362.08 Hp) at 2000 RPM Rated flywheel horse power (ISO 14396) (with fan-pump) 245 kW (328.55 Hp) at 2000 RPM...
  • Page 26 INTRODUCTION fin space 2.0 mm (0.08 in) Fuel cooler capacity 3.72 kW fin type Corrugated fin (wavy type) fin space 2.25 mm (0.09 in) Cooling fan drive system Pump 1 vane pump Motor Fixed displacement axial piston motor Filters Suction filter 105 μm Return filter 6 μm...
  • Page 27 INTRODUCTION Sliding front window with auto lock Built-in type full-color LCD monitor display Membrane switch on monitor display Windshield wiper & washer AM/FM Radio with auto-tuner Floor mat Hinged skylight Auto air-conditioner Top guard OPG level 1 (in CAB structure) Operator's seat Cloth upholstered type seat with suspension Reclining and sliding seat...
  • Page 28 INTRODUCTION Overall height (with attachment) 3770 mm (148.425 in) Cab height 3290 mm (129.528 in) Upper structure overall width (without catwalks) 3060 mm (120.472 in) Upper structure overall width (with catwalks) 3590 mm (141.339 in) Swing (rear end) radius 3730 mm (146.850 in) Clearance height under upper structure 1330 mm (52.362 in) Minimum ground clearance...

  • Page 29: General Specification - Main Equipment

    INTRODUCTION General specification - Main equipment Lower component Travel unit Manufacturer Nabtesco Corporation Motor type Variable displacement piston motor Automatic 2-speed switchover with parking brake Intake amount 290.7 - 170.1 cm³/rev (17.740 - 10.380 in³/rev) Operating pressure 34.3 MPa (4975 psi) Operating flow 360.4 l/min (360.4000 US gpm) Brake torque...
  • Page 30 INTRODUCTION Weight or Quantity Bolt Upper component Swing unit Swing motor assembly Swing motor Manufacturer Hyest Corporation Motor type Fixed displacement piston motor With parking brake Intake amount 250 cm³/rev (15.26 in³/rev) Operating pressure 29.4 MPa (4264 psi) Operating flow 360 l/min (360.0000 US gpm) Mechanical brake torque 1288 N·m (949.980 lb ft) min.
  • Page 31 INTRODUCTION Weight 17 kg (37.4786 lb) Radiator Manufacturer T.RAD CO.,LTD. Weight 42 kg (92.594 lb) Oil cooler Oil volume 18.5 L (4.887 US gal) Weight 34.5 kg (76.059 lb) Radiator Coolant capacity 18.6 L (4.914 US gal) Weight 30 kg (66.139 lb) Air cooler —...
  • Page 32 INTRODUCTION Operating pressure 20.6 MPa (2988.03 psi) Operating flow 69.8 L/min (18.4392 US gpm) Maximum operating speed 2000 RPM Minimum operating speed 900 RPM Shaft input horsepower 27.9 kW (37.9 Hp) Shaft input torque 133.1 N·m (98.17 lb ft) Operating temperature range -20 - 100 °C (-4 - 212 °F) Hydraulic fluid used ISO viscosity grade VG46-equivalent hydraulic fluid...
  • Page 33 INTRODUCTION Straight travel circuit Boom-up/arm 2 pumps internal flow Boom and arm load holding circuit Boom-down regenerative circuit Function Bucket-close regenerative circuit Arm-in forced regenerative circuit Boom-up priority variable orifice (for arm operation) 2 pumps flow Weight 424 kg (934.760 lb) Solenoid valve (5 stack) Manufacturer Yuken Kogyo Co., Ltd.
  • Page 34 INTRODUCTION A. Secondary pressure [MPa (psi)] B. Push rod stroke [mm (in)] C. Operating angle [deg.] Secondary pressure Independent operating torque SMIL15CEXY884AB Travel remote control valve control diagram A. Secondary pressure [MPa (psi)] B. Push rod stroke [mm (in)] C. Pedal operating angle [deg.] Secondary pressure Operating torque SMIL15CEXY885AB...
  • Page 35 INTRODUCTION Boom cylinder Weight 400 kg (881.8490 lb) Arm cylinder Cylinder bore ∅ 200 mm (7.874 in) Rod diameter ∅ 140 mm (5.512 in) Maximum retracted length 2588 mm (101.890 in) Stroke 1820 mm (71.654 in) Weight 695 kg (1532.2127 lb) Bucket cylinder Cylinder bore ∅...

  • Page 36: Weight

    INTRODUCTION Weight Divided weight ( LC Standard undercarriage) P73R4C-001 Code Part name Weight Operating weight 48500 kg (106924.197 lb) Upper component (including counterweight and 19800 kg (43651.528 lb) turntable bearing) Counterweight 9200 kg (20282.528 lb) Lower component (with grouser shoe) 17460 kg (38492.711 lb) Main unit weight 37310 kg (82254.470 lb)
  • Page 37 INTRODUCTION Stand alone part weight Weight Part name 757.4 kg (1669.781 lb) Travel unit Take-up roller 262.9 kg (579.595 lb) Upper roller 42.1 kg (92.815 lb) 82.3 kg (181.440 lb) Lower roller Swing unit 580.2 kg (1279.122 lb) Turntable bearing 656.4 kg (1447.114 lb) Engine 873.842 kg (1926.492 lb)

  • Page 38: Dimension

    INTRODUCTION Dimension Short arm [ 2.53 m (8.30 ft) ] NOTE: The values used in this document are subject to change without notice due to a design change or other rea- sons. NOTE: The values indicated in the diagram include the shoe lug height (a) [ 36 mm (1.417 in) ]. 638B83C1 (b) With catwalk - option 1570 mm (61.811 in)

  • Page 39: Conversion Factors

    INTRODUCTION Conversion factors Unit conversion rate - x → Gravitational unit SI unit ← ÷ - 9.807 4.448 kgf•cm 0.0981 N•m lbf•ft 1.356 N•m lbf•in 0.113 N•m kgf/cm 0.0981 0.1013 lbf/in 0.0069 mm Hg 133.3 in Hg 3386 kgf・m/s 0.00981 lbf•ft/s 0.00136 0.7355...
  • Page 40 INTRODUCTION Inches to millimeters 1/64 0.3969 17/64 6.7469 33/64 13.0969 49/64 19.4469 1/32 0.7938 9/32 7.1438 17/32 13.4938 25/32 19.8438 3/64 1.1906 19/64 7.5406 35/64 13.8906 51/64 20.2406 1/16 1.5875 5/16 7.9375 9/16 14.2875 13/16 20.6375 5/64 1.9844 21/64 8.3344 37/64 14.6844 53/64...
  • Page 41 INTRODUCTION Miles to kilometers miles miles 　 　 　 　 　 　 ---- 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 ---- 16.093 17.703 19.312 20.921 22.531 24.140 25.750 27.359 28.968 30.578 32.187 33.796 35.406 37.015 38.624 40.234 41.843 43.452 45.062 46.671...
  • Page 42 INTRODUCTION Square centimeters to square inches 　 　 　 　 　 　 ---- 　 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 ---- 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340...
  • Page 43 INTRODUCTION Gallons (U.S) to liters U.S- U.S- .gal. .gal. 　 　 　 　 　 　 liters liters liters liters liters liters liters liters liters liters ---- 3.7853 7.5707 11.3560 15.1413 18.9266 22.7120 26.4973 30.2826 34.0680 ---- 37.8533 41.6386 45.4239 49.2093 52.9946 56.7799 60.5653 64.3506 68.1359 71.9213 10 102.203 105.989 109.774...
  • Page 44 INTRODUCTION Gallons (Imp.) to liters Imp- p.g- .gal. 　 　 　 　 　 　 liters liters liters liters liters liters liters liters liters liters ---- 　 4.5455 9.0909 13.6364 18.1818 22.7273 27.2727 31.8182 36.3636 40.9091 ---- 45.4545 50.0000 54.5455 59.0909 63.6364 68.1818 72.7273 77.2727 81.8182 86.3636 10 100.000 104.545 109.090...

  • Page 45: Kgf

    INTRODUCTION Kilograms to pounds 　 　 　 　 　 　 lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. ---- 2.205 4.409 6.614 8.819 11.023 13.228 15.432 17.637 19.842 ---- 22.046 24.251 26.456 28.660 30.865 33.069 35.274 37.479 39.683 41.888 44.093 46.297...

  • Page 46: Lbf

    INTRODUCTION Pressure Weight pounds/square inch to weight kilograms/square centimeter lbf/in lbf/in (psi) kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm (psi) ---- 　 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5624 0.6327 ---- 0.7030 0.7733 0.8436 0.9139 0.9842 1.0545 1.1248 1.1951...

  • Page 47: Lbf.ft

    INTRODUCTION Kilopascals to weight kilograms/square centimeter 　 　 　 　 　 　 kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm kgf/cm ---- 　 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 ---- 1000 10.197 11.217 12.237 13.256 14.276 15.296 16.315 17.335...
  • Page 48 INTRODUCTION Weight kilogram meters to Newton meters kgf·m kgf·m 　 　 　 　 　 　 N·m N·m N·m N·m N·m N·m N·m N·m N·m N·m ---- 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 ---- 98.07 107.87 117.68 127.49 137.29 147.10 156.91...
  • Page 49 INTRODUCTION Temperature Fahrenheit to centigrade °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C -51.1 -18.9 13.3 45.6 77.8 142.2 174.4 -17.8 14.4 46.7 78.9 111.1 143.3 175.6 -48.9 -16.7 15.6 47.8 80.0 112.2 144.4 176.7...
  • Page 50 INTRODUCTION Centigrade to fahrenheit °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F -58.0 -0.4 57.2 114.8 172.4 230.0 287.6 345.2 -56.2 59.0 116.6 174.2 231.8 289.4 347.0 -54.4 60.8 118.4 176.0 233.6 291.2 348.8 -52.6...

  • Page 51: Consumables

    (5 °F) to 40 °C (104 °F). Refer to the list of fluids and lubricants contained in this manual. NOTICE: When operating the machine in ambient temperatures outside the above mentioned range, consult your CASE CONSTRUCTION Dealer for specific machine provision and for specific fluids and lubricants to be used. CASE CON-...
  • Page 52 FREEZE. NOTICE: Never mix CASE AKCELA PREMIUM ORGANIC ANTI-FREEZE coolant with conventional coolant. Mix- ing organic based coolant with conventional coolant will reduce the effectiveness of CASE AKCELA PREMIUM OR- GANIC ANTI-FREEZE coolant. NOTICE: If only conventional coolant is available, a complete changeover of the fluid into the cooling system shall be carried out.
  • Page 53 CASE CONSTRUCTION may not be responsible to any of such damages. NOTICE: If operating in severe winter climate, consult the fuel supplier or the CASE CONSTRUCTION dealer for specific diesel fuel to be used.
  • Page 54 Never throw oil or fluid on the ground and never place it in leaking receptacles. Consult your local ecological recycling center or your CASE CONSTRUCTION Dealer to obtain information on the correct method of disposing of these lubricants.

  • Page 55: Abbreviation

    INTRODUCTION Abbreviation Abbreviation Explanation Air-conditioner Analog/digital ABDC After bottom dead center Alternating current Accessories Alternating current generator Actuator American Petroleum Institute Assembly ATDC After top dead center Automatic transmission fluid Drilled hole B Notch hole bolt Eye B Eyebolt Full threaded B Full threaded bolt Hexagon socket head B Hexagon socket head bolt...
  • Page 56 INTRODUCTION Abbreviation Explanation Fuel temperature Forward Generator Ground HBCV Hose burst check valve Hydrocarbons HO2S Heated O2 sensor Time High reach demolition machine Idle air control Suction air temperature Integrated circuit Nameplate, ID plate ID Plate Intake manifold temperature Suction air Injection International Organization for Standardization Intake shutter position...
  • Page 57 INTRODUCTION Abbreviation Explanation Right hand Read-only memory Rail pressure Rear Rearward + Flush head S + Flush head Screw + Phillips pan head S + Phillips pan head Screw + Screw tapping S + Screw tapping Screw Subassembly Society of Automotive Engineers Slow blow fuse Suction control valve Signal...

  • Page 58: Product Identification

    Product identification SMIL16CEX0484EA When ordering parts, obtaining information or assistance, always supply your CASE CONSTRUCTION Dealer with the type and serial number of your machine or accessories. Write the following in the spaces below: the type, serial number and year of manufacture of your machine, accessories and the serial numbers of the various hydraulic and mechanical components.
  • Page 59 INTRODUCTION Component serial numbers Hydraulic pump: Swing reduction gear: Travel reduction gears: Travel control valve: Attachment control valve: Swing control valve: 48032547 22/06/2016...

  • Page 60: Product Identification - Machine Orientation

    INTRODUCTION Product identification - Machine orientation The terms "Right-hand", "Left-hand", "Front" and "Rear" are used in this manual to indicate the sides as they are seen from the operator's seat when the cab is over the idler wheels. NOTICE: the illustration opposite shows the machine in normal travel position.
  • Page 61 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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