Case CX160D Service Manual Download

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CX490D

CX500D

Crawler Excavator

SERVICE MANUAL

CX490D

CX500D

Crawler Excavator

Part number 47937811

English

February 2016

Part number 47937811

SER
VICE MANU

Summary of Contents for CX160D

Page 1: ...90D CX500D Crawler Excavator SERVICE MANUAL CX490D CX500D Crawler Excavator Part number 47937811 English February 2016 2016 CNH Industrial Italia S p A All Rights Reserved Part number 47937811 SERVICE...

Page 2: ...t CX490D Crawler excavators RTC version TIER4 FINAL EU Market CX500D Crawler excavators LC Mass Excavator version TIER4 FINAL EU Market CX500D Crawler excavators RTC Mass excavator version TIER4 FINAL...

Page 3: ...Intake and exhaust manifolds and muffler 10 12 10 500 Selective Catalytic Reduction SCR exhaust treatment 10 13 10 501 Exhaust Gas Recirculation EGR exhaust treatment 10 14 10 400 Engine cooling syst...

Page 4: ...5 820 Hydraulic driven cooling fans 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...

Page 5: ...18 55 051 Cab Heating Ventilation and Air Conditioning HVAC controls 55 19 55 050 Heating Ventilation and Air Conditioning HVAC control system 55 20 55 524 Cab controls Lift arm Boom Dipper Bucket 55...

Page 6: ...cals 90 90 150 Cab 90 1 90 156 Cab glazing 90 2 90 118 Protections and footboards 90 3 90 120 Mechanically adjusted operator seat 90 4 90 100 Engine hood and panels 90 5 47937811 29 02 2016 Find manua...

Page 7: ...47937811 29 02 2016 Find manuals at https best manuals com...

Page 8: ...INTRODUCTION 47937811 29 02 2016 1 Find manuals at https best manuals com...

Page 9: ...ic instructions Shop and assembly 20 Hydraulic contamination 22 General specification 23 General specification 27 General specification 31 General specification 35 General specification Main equipment...

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: ...h or serious injury CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury FAILURE TO FOLLOW DANGER WARNING AND CAUTION MESSAGES COULD RESULT IN DEATH OR...

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: ...onditions 2 ROPS criteria Weight For each class the following weight shall not be exceeded If the weight is exceeded a cab may become damaged in case of a rollover causing the operator to die or becom...

Page 16: ...ground Moreover it cannot be said that the 24 ton model close to the limit weight with a cab that can bear up to 31 tons and the 21 ton model with the same cab are the same in the degree of influence...

Page 17: ...INTRODUCTION Cab CX130D CX160D CX180D SMPH15CEX5805FA 2 47937811 29 02 2016 10...

Page 18: ...INTRODUCTION Cab CX210D CX230D CX250D CX300D SMIL14CEX2002FA 3 47937811 29 02 2016 11...

Page 19: ...ION Cab CX350D CX370D The large sized model CX350D CX370D cab consists of the medium sized model CX210D CX230D CX250D CX300D cab in the figure plus seven reinforcements SMIL14CEX2003FA 4 47937811 29 0...

Page 20: ...D CX500D The irregularly shaped steel line also contains reinforcements CAF7CBDF 5 The high cab is not supported basically Since it varies for each model consultation with us is required in each case...

Page 21: ...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 22: ...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 23: ...3 33 lb ft 12 Front bracket M10 17 mm 63 8 73 6 N m 47 06 54 28 lb ft 13 Engine Rear bracket M16 24 mm 245 2 274 6 N m 180 85 202 53 lb ft 14 Radiator M16 24 mm 147 2 176 6 N m 108 57 130 25 lb ft 15...

Page 24: ...INTRODUCTION 8023766E 1 47937811 29 02 2016 17...

Page 25: ...INTRODUCTION 97815A48 2 47937811 29 02 2016 18...

Page 26: ...INTRODUCTION E9BCB5F5 3 47937811 29 02 2016 19...

Page 27: ...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 28: ...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 29: ...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 30: ...4975 psi Pilot pump 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 a...

Page 31: ...ck left side tilt console Fan reverse rotation system Electrical system Engine control Dial type throttle control One touch idle Auto deceleration Auto idle shutdown system Emergency stop Monitor syst...

Page 32: ...y of seat Others Rear view mirror Cab side Right side Rear view Camera Undercarriage Travel motor Variable displacement axial piston motor Brake Mechanical disc brake Hydraulic service brake Brake val...

Page 33: ...339 in 3590 mm 141 339 in Swing rear end radius 3730 mm 146 850 in 3730 mm 146 850 in Clearance height under upper structure 1330 mm 52 362 in 1330 mm 52 362 in Minimum ground clearance 535 mm 21 063...

Page 34: ...4975 psi Pilot pump 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 a...

Page 35: ...ck left side tilt console Fan reverse rotation system Electrical system Engine control Dial type throttle control One touch idle Auto deceleration Auto idle shutdown system Emergency stop Monitor syst...

Page 36: ...y of seat Others Rear view mirror Cab side Right side Rear view Camera Undercarriage Travel motor Variable displacement axial piston motor Brake Mechanical disc brake Hydraulic service brake Brake val...

Page 37: ...arance height under upper structure 1480 mm 58 268 in 1480 mm 58 268 in Minimum ground clearance 720 mm 28 346 in 720 mm 28 346 in Wheel base Center to center of wheels 4400 mm 173 228 in 4400 mm 173...

Page 38: ...ravel circuit 34 3 MPa 4975 psi Pilot pump 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 trac...

Page 39: ...speed travel Attachment cushion control Hydraulic lock gate lock left side tilt console Fan reverse rotation system Electrical system Engine control Dial type throttle control One touch idle Auto dece...

Page 40: ...adrest Retractable seat belt Adjustable lumbar support Control consoles adjust independently of seat Others Rear view mirror Cab side Right side Rear view Camera Undercarriage Travel motor Variable di...

Page 41: ...h 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 M...

Page 42: ...ravel circuit 34 3 MPa 4975 psi Pilot pump 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 trac...

Page 43: ...speed travel Attachment cushion control Hydraulic lock gate lock left side tilt console Fan reverse rotation system Electrical system Engine control Dial type throttle control One touch idle Auto dece...

Page 44: ...adrest Retractable seat belt Adjustable lumbar support Control consoles adjust independently of seat Others Rear view mirror Cab side Right side Rear view Camera Undercarriage Travel motor Variable di...

Page 45: ...catwalks 3590 mm 141 339 in Swing rear end radius 3730 mm 146 850 in Clearance height under upper structure 1480 mm 58 268 in Minimum ground clearance 720 mm 28 346 in Wheel base Center to center of...

Page 46: ...26 5 MPa 3843 825 psi Reduction gear Reduction gear type Planetary gear 2 stage reduction gear Reduction ratio 60 652 Dry weight 652 kg 1437 414 lb Take up roller Weight 263 kg 579 82 lb Upper roller...

Page 47: ...ntity 600 grouser 2585 kg 5698 949 lb Link 1 set Shoe 50 Bolt 200 Nut 200 750 grouser 2930 kg 6459 544 lb Link 1 set Shoe 50 Bolt 200 Nut 200 900 grouser 3280 kg 7231 162 lb Link 1 set Shoe 50 Bolt 20...

Page 48: ...a 4264 470 psi Operating flow 360 L min 95 102 US gpm Mechanical brake torque 1288 N m 949 980 lb ft Brake off pressure 2 9 MPa 420 645 psi max Relief valve set pressure 29 4 MPa 4264 470 psi Swing re...

Page 49: ...Hp 2000 RPM Maximum torque 1435 N m 1058 40 lb ft 1500 RPM Fuel consumption ratio Engine dry weight About 940 kg 2072 345 lb Engine dimension L 1235 mm 48 622 in W 1181 mm 46 496 in H 1366 mm 53 780...

Page 50: ...diator MFG Co Ltd Weight 42 0 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 0 kg 66 139 lb Air cooler Capacity...

Page 51: ...96 16 US gpm x 2 at Pd 2 0 MPa 290 10 psi 2000 RPM Maximum discharge flow 234 L min 61 82 US gpm x 2 at Pd 7 85 MPa 1138 64 psi 2000 RPM Pilot pump Pump type Gear pump Displacement 15 cm rev 0 92 in r...

Page 52: ...harge volume 86 0 L min 22 72 US gpm x 2 at Pd 22 5 MPa 3263 63 psi 2300 RPM oil temperature of 40 C 104 0 F Negative suction pressure 0 02 MPa 2 90 psi 0 20 MPa 29 01 psi Direction of rotation Left r...

Page 53: ...wer 27 9 kW Shaft input torque 133 1 N m 98 2 lb ft Operating temperature range 20 0 C 68 0 F 100 0 C 212 0 F Hydraulic fluid used ISO viscosity grade VG46 equivalent hydraulic fluid Dry weight 5 4 kg...

Page 54: ...0 10 MPa 14 51 psi Crack pressure 19 6 MPa 2843 0 psi at 5 0 L min 1 3 US gpm Safety valve performance Reseat pressure 14 7 MPa 2132 2 psi at 5 0 L min 1 3 US gpm Rated pressure 17 8 MPa 2581 9 psi R...

Page 55: ...22 kg 930 351 lb Solenoid valve 5 stack Manufacturer Yuken Kogyo Co Ltd Valve specifications Maximum flow SP 30 L min 7 925 US gpm Others 5 L min 1 321 US gpm Rated pressure 4 5 MPa 652 psi G3 8 Port...

Page 56: ...torque Port 3 4 Operating torque Nm SMIL15CEXY354EB 3 1 Push rod stroke mm in 4 Operating torque Nm 2 Operating angle deg 5 Secondary pressure 3 Secondary pressure MPa psi 6 Independent operating torq...

Page 57: ...ize G3 8 Weight 4 kg 8 8185 lb Center joint High pressure passage ABCD 34 3 MPa 4975 psi Drain port T 1 0 MPa 145 05 psi Operating pressure Pilot port P 3 9 MPa 566 psi High pressure passage ABCD 360...

Page 58: ...Arm cylinder Manufacturer KYB Corporation Cylinder bore 190 mm 7 480 in Rod diameter 130 mm 5 118 in Maximum retracted length 2688 mm 105 827 in Stroke 1920 mm 75 591 in Weight 631 kg 1391 117 lb Buc...

Page 59: ...ght A Operating weight 47299 kg 104276 445 lb B Upper component including counterweight and turntable bearing 22224 kg 48995 533 lb C Counterweight 10022 kg 22094 728 lb D Lower component with grouser...

Page 60: ...lic oil tank 237 kg 522 496 lb 12 Control valve 264 kg 582 020 lb 13 Center joint 59 kg 130 073 lb 14 Boom Standard 2561 kg 5646 039 lb Shoe weight per side Part name Weight 1 600 mm 23 62 in grouser...

Page 61: ...ts Capacity ISO 7451 Heaped Width Mass 1 04 m 1 36 yd 900 mm 35 in 1775 kg 3913 lb 1 35 m 1 77 yd 1100 mm 43 in 1949 kg 4297 lb 1 50 m 1 96 yd 1200 mm 47 in 2082 kg 4590 lb 1 75 m 2 29 yd 1350 mm 53 i...

Page 62: ...yd 1800 mm 71 in 2640 kg 5820 lb 2 78 m 3 64 yd 2000 mm 79 in 2900 kg 6393 lb Extreme Rock buckets Capacity ISO 7451 Heaped Width Mass 1 75 m 2 29 yd 1350 mm 53 in 2450 kg 5401 lb 2 00 m 2 62 yd 1500...

Page 63: ...Weight A Operating weight 48591 kg 107124 818 lb B Upper component including counterweight and turntable bearing 22229 kg 49006 556 lb C Counterweight 10022 kg 22094 728 lb D Lower component with grou...

Page 64: ...lic oil tank 237 kg 522 496 lb 12 Control valve 264 kg 582 020 lb 13 Center joint 59 kg 130 073 lb 14 Boom Standard 2561 kg 5646 039 lb Shoe weight per side Part name Weight 1 600 mm 23 62 in grouser...

Page 65: ...ets Capacity ISO 7451 Heaped Width Mass 1 04 m 1 36 yd 900 mm 35 in 1775 kg 3913 lb 1 35 m 1 77 yd 1100 mm 43 in 1949 kg 4297 lb 1 50 m 1 96 yd 1200 mm 47 in 2082 kg 4590 lb 1 75 m 2 29 yd 1350 mm 53...

Page 66: ...kg 5820 lb 2 78 m 3 64 yd 2000 mm 79 in 2900 kg 6393 lb Extreme Rock buckets Capacity ISO 7451 Heaped Width Mass 1 75 m 2 29 yd 1350 mm 53 in 2450 kg 5401 lb 2 00 m 2 62 yd 1500 mm 59 in 2570 kg 5666...

Page 67: ...tandard arm 3 38 m 11 09 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 sho...

Page 68: ...alues 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 BB4CBE6E...

Page 69: ...ues 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 NOTE The d...

Page 70: ...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 NOTE The dimension between brackets indicates t...

Page 71: ...arket WE 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 t...

Page 72: ...e 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 NOTE...

Page 73: ...E AKCELA UNITEK 10W 40 MAT3521 SAE 10W40 ACEA E9 API CJ 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 Travel reduction unit 15 L 4 0 US gal CASE...

Page 74: ...s proper performance of the engine cooling system in the above mentioned operating temper ature range of the machine CASE AKCELA ACTIFULL OT EXTENDED LIFE COOLANT is available as 50 50 PREMIXED coolan...

Page 75: ...ratures have low sulphur content have very little residual carbon It is recommended that the following safety information be considered in order to prevent damage to the engine fuel supply system Some...

Page 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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...

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