Case CX500C Service Manual Download Page 3

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Contents

INTRODUCTION

Engine....................................................................................... 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

Hydraulic systems....................................................................... 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

48032547 22/06/2016

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Summary of Contents for CX500C

Page 1: ...1 2 CX500C Crawler Excavator SERVICE MANUAL Crawler Excavator CX500C Part number 48032547 English June 2016 2016 CNH Industrial Italia S p A All Rights Reserved SERVICE MANUAL Part number 48032547...

Page 2: ...SERVICE MANUAL CX500C Crawler excavator LC Mass excavator version TIER 3 CHINA Market 48032547 22 06 2016 EN Find manuals at https best manuals com...

Page 3: ...aust manifolds and muffler 10 11 10 501 Exhaust Gas Recirculation EGR exhaust treatment 10 12 10 400 Engine cooling system 10 13 10 414 Fan and drive 10 14 10 310 Aftercooler 10 15 10 304 Engine lubri...

Page 4: ...ydraulic system 35 17 Frames and ballasting 39 39 140 Ballasts and supports 39 1 Tracks and track suspension 48 48 130 Track frame and driving wheels 48 1 48 100 Tracks 48 2 48 134 Track tension units...

Page 5: ...n and Air Conditioning HVAC control system 55 18 55 416 Swing control system 55 19 55 417 Travel control system 55 20 55 530 Camera 55 21 55 518 Wiper and washer system 55 22 55 404 External lighting...

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 1 Find manuals at https best manuals com...

Page 9: ...nment 9 Torque Bolt and nut 10 Torque Special torque setting 11 Basic instructions Shop and assembly 15 Hydraulic contamination 17 General specification 18 General specification Main equipment 22 Weig...

Page 10: ...nts not approved by the manu facturer including those used for the servicing or repair of the product manufactured or marketed by the manufacturer In any case no warranty is given or attributed on the...

Page 11: ...ion that if not avoided could result in death or serious injury CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AN...

Page 12: ...e inserted Gear Check that there is no wear and no damage Oil seal O ring gasket Always install new oil seals O rings and gaskets Apply grease to sections where oil seals and O rings will be inserted...

Page 13: ...it WARNING Check the safety messages in the operator s manual before starting the engine Check all the warning labels on the machine Check that no one is within the machine s operating range Check the...

Page 14: ...a soft head WARNING Wear eye protection when using a hammer to install a pin or when working with a grinder At this time use goggles or eye protectors that meet standards WARNING Park the machine in a...

Page 15: ...or modifications that reduce the functionality of the anchoring part at the left rear of the cab Modifications that effect the strength of the cab with a protective structure Modifications prohibited...

Page 16: ...w coolant mixtures to get into the soil Collect and dispose of coolant mixtures properly The air conditioning system contains gases that should not be released into the atmosphere Consult an air condi...

Page 17: ...meter size M6 M8 M10 M12 M14 M16 M18 M20 Wrench 10 mm 13 mm 17 mm 19 mm 22 mm 24 mm 27 mm 30 mm Hexagon bolt Tighten ing torque 6 9 N m 5 089 lb ft 19 6 N m 14 456 lb ft 39 2 N m 28 912 lb ft 58 8 N m...

Page 18: ...108 N m 65 80 lb ft 16 Hydraulic pump Pump M20 17 mm hexagon socket head 367 496 N m 270 69 365 83 lb ft 17 Hydraulic tank M16 24 mm 225 6 264 8 N m 166 195 lb ft 18 Fuel tank M16 24 mm 232 4 276 N m...

Page 19: ...INTRODUCTION B2AB1DF6 1 48032547 22 06 2016 12...

Page 20: ...INTRODUCTION YYSJMI 002 2 48032547 22 06 2016 13...

Page 21: ...INTRODUCTION YYSJMI 006 3 48032547 22 06 2016 14...

Page 22: ...n tool Do not tap the seal with a hammer or mallet 6 While you insert the seal check that the seal is perpendicular to the seat When the seal settles make sure that the seal makes contact with the thr...

Page 23: ...ground cable from the machine battery The electronic monitoring system and charging system will be damaged if this is not done 5 Remove the battery ground cable Reconnect the cable when you complete w...

Page 24: ...lief valves or check valves held open by dirt Quick failure of components that have been repaired Slow cycle times are slow The machine does not have enough power If your machine has any of these prob...

Page 25: ...1 gear pump Max oil flow 30 L 7 9 US gal Working circuit pressure 3 9 MPa 566 psi Control valves With Boom Arm holding valve One 4 spool valve for Right track travel Bucket Boom and Arm acceleration O...

Page 26: ...rotation system Electrical system Engine control Dial type throttle control One touch idle Auto deceleration Auto idle shutdown system Emergency stop Monitor system Message display Caution condition e...

Page 27: ...ch side 9 Number of shoes each side 50 Type of shoe Triple grouser shoe Link pitch 228 6 mm 9 000 in Width of shoe 600 mm 23 622 in S T D Grade ability 70 35 Mass Operating mass 49500 kg 109128 8 lb w...

Page 28: ...21 260 in Wheel base Center to center of wheels 4400 mm 173 228 in Crawler overall length 5450 mm 214 567 in Track gauge 2750 mm 108 268 in Undercarriage overall width with 600 mm 23 622 in shoes 3350...

Page 29: ...ction ratio 60 652 Dry weight 613 kg 1351 434 lb Take up roller Weight 262 9 kg 579 5953 lb Upper roller Weight 42 1 kg 92 8146 lb Lower roller Weight 82 3 kg 181 4404 lb Recoil spring Item Weight Qua...

Page 30: ...le water cooled overhead camshaft type vertical in line direct injection type electronic control Number of cylinders bore stroke 6 120 mm 4 72 in 145 mm 5 71 in Total displacement 9 839 L 2 599 US gal...

Page 31: ...t pump Pump type Gear pump Displacement capacity 15 cm rev 0 92 in rev Operating pressure 3 92 MPa 568 596 psi Maximum discharge flow 30 L min 7 925 US gpm at 2000 RPM Hydraulic simultaneous constant...

Page 32: ...283 US gpm at 0 10 MPa 14 51 psi Crack pressure 19 6 MPa 2842 98 psi at 5 0 L min 1 321 US gpm Safety valve performance Reseat pressure 14 7 MPa 2132 24 psi at 5 0 L min 1 321 US gpm Rated pressure 17...

Page 33: ...6 7 kg 14 7710 lb Remote control valve for left right operations Manufacturer Kawasaki Heavy Industries Ltd Operating pressure 3 92 MPa 569 psi Secondary pressure 0 49 2 89 MPa 71 0745 419 psi primar...

Page 34: ...Weight 12 5 kg 27 5578 lb Center joint High pressure passage ABCD 34 3 MPa 4975 psi Drain port T 1 0 MPa 145 psi Operating pressure Pilot port P 3 9 MPa 566 psi High pressure passage ABCD 360 L min 95...

Page 35: ...er 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 170 mm 6 693 in Rod diameter 115 mm 4 528 in Maximum re...

Page 36: ...9800 kg 43651 528 lb C Counterweight 9200 kg 20282 528 lb D Lower component with grouser shoe 17460 kg 38492 711 lb E Main unit weight 37310 kg 82254 470 lb F Attachment 11180 kg 24647 681 lb G Boom i...

Page 37: ...3 842 kg 1926 492 lb 8 Radiator 291 kg 641 545 lb 9 Hydraulic pump 230 kg 507 063 lb 10 Fuel tank 337 009 kg 742 978 lb 11 Hydraulic oil tank 225 601 kg 497 365 lb 12 Control valve 424 kg 934 760 lb 1...

Page 38: ...ent 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 1 b With catwalk option...

Page 39: ...5 2 1654 80 3 1496 6 0 2362 31 1 2205 56 2 2047 81 3 1890 7 0 2756 32 1 2598 57 2 2441 82 3 2283 8 0 3150 33 1 2992 58 2 2835 83 3 2677 9 0 3543 34 1 3386 59 2 3228 84 3 3071 10 0 3937 35 1 3780 60 2...

Page 40: ...3 50 60 18 288 18 593 18 898 19 202 19 507 19 812 20 117 20 422 20 726 21 031 60 70 21 336 21 641 21 946 22 250 22 555 22 860 23 165 23 470 23 774 24 079 70 80 24 384 24 689 24 994 25 298 25 603 25 90...

Page 41: ...98 26 719 27 340 27 962 28 583 29 204 29 826 30 447 40 50 31 069 31 690 32 311 32 933 33 554 34 175 34 797 35 418 36 040 36 661 50 60 37 282 37 904 38 525 39 146 39 768 40 389 41 010 41 632 42 253 42...

Page 42: ...7 770 194 786 581 802 968 40 50 819 355 835 742 852 129 868 516 884 904 901 291 917 678 934 065 950 452 966 839 50 60 983 226 999 613 1016 00 0 1032 38 7 1048 77 5 1065 16 2 1081 54 9 1097 93 6 1114 3...

Page 43: ...348 250 3 352 035 6 355 820 9 359 606 3 363 391 6 367 176 9 370 962 2 374 747 6 90 100 378 532 9 382 318 2 386 103 6 389 888 9 393 674 2 397 459 5 401 244 9 405 030 2 408 815 5 412 600 9 100 Liters t...

Page 44: ...000 3 5200 3 7400 3 9600 4 1800 10 20 4 4000 4 6200 4 8400 5 0600 5 2800 5 5000 5 7200 5 9400 6 1600 6 3800 20 30 6 6000 6 8200 7 0400 7 2600 7 4800 7 7000 7 9200 8 1400 8 3600 8 5800 30 40 8 8000 9 0...

Page 45: ...62 85 372 65 382 46 30 40 392 27 402 07 411 88 421 69 431 49 441 30 451 11 460 91 470 72 480 53 40 50 490 33 500 14 509 95 519 75 529 56 539 37 549 17 558 98 568 79 578 59 50 60 588 40 598 21 608 01 6...

Page 46: ...84 07 398 30 412 52 20 30 426 75 440 97 455 20 469 42 483 65 497 87 512 10 526 32 540 55 554 77 30 40 569 00 583 22 597 45 611 67 625 90 640 12 654 35 668 57 682 80 697 02 40 50 711 25 725 47 739 70 7...

Page 47: ...843 4 981 5 119 5 258 5 396 30 40 5 534 5 673 5 811 5 949 6 088 6 226 6 365 6 503 6 641 6 780 40 50 6 918 7 056 7 195 7 333 7 471 7 610 7 748 7 887 8 025 8 163 50 60 8 302 8 440 8 578 8 717 8 855 8 9...

Page 48: ...990 47 1000 28 1010 08 1019 89 1029 70 1039 5 1049 31 1059 12 1068 92 100 Newton meters to weight kilogram meters N m 0 10 20 30 40 50 60 70 80 90 N m kgf m kgf m kgf m kgf m kgf m kgf m kgf m kgf m...

Page 49: ...6 370 187 8 34 36 7 24 4 4 82 27 8 140 60 198 92 2 256 124 4 314 156 7 372 188 9 32 35 6 26 3 3 84 28 9 142 61 1 200 93 3 258 125 6 316 157 8 374 190 0 30 34 4 28 2 2 86 30 0 144 62 2 202 94 4 260 12...

Page 50: ...4 60 140 0 92 197 6 124 255 2 156 312 8 188 370 4 35 31 0 3 26 6 29 84 2 61 141 8 93 199 4 125 257 0 157 314 6 189 372 2 34 29 2 2 28 4 30 86 0 62 143 6 94 201 2 126 258 8 158 316 4 190 374 0 33 27 4...

Page 51: ...US gal ASTM D975 Engine oil 36 L 9 5 US gal CASE AKCELA NO 1 ENGINE OIL MAT3507 SAE 15W40 API CI 4 Swing reduction unit 10 5 L 2 8 US gal CASE AKCELA GEAR 135 H EP 80W 90 MS 1316 SAE 80W 90 API GL 5 T...

Page 52: ...IUM ORGANIC ANTI FREEZE a 50 50 mixture of antifreeze and distilled deionized water grants proper performance of the engine cooling system in the above mentioned operating temperature range of the mac...

Page 53: ...ittle residual carbon It is recommended that the following safety information be considered in order to prevent damage to the engine fuel supply system Some fuel suppliers mix old engine oil and diese...

Page 54: ...mation on the correct method of disposing of these lubricants The following are recommendations which may be of assistance Become acquainted with and ensure that you understand the relative legislatio...

Page 55: ...B Circuit breaker C U Control unit CAL Calibration CAN A type of control unit communication technique controller area network CFG Config CHK Check CKP Crankshaft position CMP Camshaft position CO Car...

Page 56: ...ord LED Light emitting diode LH Left LLC Long life coolant LM Lifting magnet M V Magnet valve MAF Mass air flow MAP Manifold air pressure Max Maximum MIL Malfunction indicator lamp diagnostic milli am...

Page 57: ...neers SBF Slow blow fuse SCV Suction control valve SIG Signal SLD Shield SP pin Special pin ST Starter start STD Standard SW Switch TDC Top dead center TEMP Temperature TP Throttle position UART Unive...

Page 58: ...el and Category Hydraulic Excavator CX500C 2 Product identification number SMIL15CEX5777AA 2 Engine Make and type ISUZU GH 6UZ1X Serial number NOTICE The engine and fuel system on your machine is desi...

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 52...

Page 60: ...e operator s seat when the cab is over the idler wheels NOTICE the illustration opposite shows the machine in normal travel position In normal travel position the cab is over the idler wheels The trav...

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