PDF Service Manual Case CX490C CX500C Crawler Excavator - 13 MB
This complete service manual provides in-depth repair and maintenance information for the Case CX490C and CX500C Tier III Crawler Excavators.
It contains step-by-step instructions, detailed diagrams, and technical specifications used by professional Case technicians.
From engine overhauls to hydraulic system troubleshooting, this manual is your go-to guide for any complex repair.
Ensure your excavator performs reliably with the right technical information at your fingertips.
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--- Page 1 ---
SERVICE MANUAL
CX490C
CX490C CX500C
CX500C Tier III
Crawler Excavator Crawler Excavator
1/2 SERVICE MANUAL
Part number 48044249
Part number 48044249
English
September 2016
© 2016 CNH Industrial Italia S.p.A. All Rights Reserved.
--- Page 3 ---
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.
Valve specifications
Maximum flow P→B 25 l/min (6.604 US gpm) Other 5 l/min (1.321 US gpm)
Rated pressure 4.5 MPa (652 psi)
Port size P.T.B port G3/8
C1, C2, C3, C4 C5 ports G1/4
Solenoid specifications
Operating voltage DC 20 - 32 V
Power consumption 17 W max.
Weight 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) primary short type
1,3 port 19 °
Operating angle
2,4 port 25 °
Weight 1.9 kg (4.1888 lb)
Remote control valve for travel operation
Manufacturer Kawasaki Heavy Industries, Ltd.
Operating pressure 3.92 MPa (569 psi)
Secondary pressure 0.49 - 2.89 MPa (71.0745 - 419 psi) primary short type
Operating angle 12.4 °
Weight 4.1 kg (9.0390 lb)
Remote control valve characteristic diagram
Operation remote control valve control dia-
gram
A. Secondary pressure [MPa (psi)]
B. Push rod stroke [mm (in)]
C. Operating angle [deg.]
1 Secondary pressure
2 Independent operating torque (port 1)
3 Independent operating torque (port 3)
SMIL15CEXY883AB 1
48044249 05/09/2016
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--- Page 4 ---
INTRODUCTION
Product identification
CX500C Crawler excavator LC ME version (TIER 3) LA
The CX500C LC are totally hydraulic excavators. They consist of an undercarriage fitted with tracks and a turntable
bearing which supports the upper structure frame. The upper structure frame supports the attachment, at the front end
of the machine, plus the engine, hydraulics and cab. When the operator works the controls, the engine-driven pump
delivers hydraulic fluid to the control valves. The control valves distribute the hydraulic fluid to the various cylinders
and hydraulic motors employed. A cooling system maintains the hydraulic fluid at normal operating temperature.
SMIL16CEX0484EA 1
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.
Machine
(1) Type / Model and Category:
(Hydraulic Excavator) CX500C LC.
(2) Product identification number:
SMIL15CEXY711AB 2
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--- Page 5 ---
Engine - Engine and crankcase
Crankcase - Remove
Battery ground cable disconnect
1. Disengage the battery ground cable from the battery.
NOTICE: Do not disconnect the battery cable for 1 min
after turning OFF the ignition switch.
Coolant drain
WARNING
Burn hazard!
Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system
is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all
pressure to release. Remove the cap only after all pressure has released.
Failure to comply could result in death or serious injury.
W0367A
1. Drain the coolant from the radiator.
NOTICE: After draining the coolant, tighten the drain plug.
2. Drain the coolant from the engine assembly.
NOTE: Loosen the drain plug (1) on the cylinder block side.
XXSHVU-008 1
Engine oil drain
1. Remove the drain plug from the oil pan.
NOTE: Drain engine oil into the drain pan.
2. Install the drain plug to the oil pan.
Tightening torque: 70 N·m (51.63 lb ft)
NOTICE: Be careful not to forget to tighten the drain plug.
Oil level gauge guide tube removal
1. Remove the oil level gauge guide tube from the inlet
duct.
2. Disconnect the oil level gauge guide tube from the oil
pan.
NOTICE: Do not damage the O-ring.
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--- Page 6 ---
Engine - Engine and crankcase
Crankshaft oil seal identification color
Front-side slinger Silver
Rear-side slinger Gray
NOTICE: If flaws are found on the crankshaft, apply Three-
Bond 1207C to the area shown in the diagram below.
R95ZI3-452 12
Crankshaft pulley installation
1. Apply the engine oil to the bolt.
2. Apply engine oil to the washer.
3. Install the crankshaft pulley to the crankshaft.
NOTE: Tighten the bolts in diagonal order.
Tightening torque: 200 N·m (148 lb ft)
R95ZI3-453 13
Piston installation
1. Dry the connecting rod bearing using an air splay gun.
2. Install the connecting rod bearing to the connecting rod.
NOTE: Confirm that yellow paint is on the connecting rod
bearing lower side.
NOTICE: Install the connecting rod bearing with its instal-
lation surface dry.
3. Apply the engine oil to the connecting rod bearing.
NOTE: Apply to the sliding surface (1) of the connecting
rod bearing.
R95ZI3-454 14
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--- Page 7 ---
Engine - Engine and crankcase
Generator drive belt adjustment
1. Turn the adjust bolt
Standard: 98.0 N·m (72.28 lb ft)
Specified value: 12.0 - 14.0 mm (0.4724 -
0.5512 in)
NOTE: Conduct adjustment so that the amount of belt flex
that occurs when the belt is pressed at the location indi-
cated by the arrow in the diagram with the specified pres-
sure matches the standard value.
1. Crankshaft pulley
2. Generator
3. Water pump pulley R95ZI3-519 79
NOTICE: Crank the engine for approximately 5 rotations
and readjust the belt tension to the standard value.
2. Securely tighten the adjust plate onto the cylinder
block.
Tightening torque: 50 N·m (37 lb ft)
3. Tighten the penetration bolt with a wrench.
Tightening torque: 157 N·m (116 lb ft)
4. Tighten the lock nut with a wrench.
Tightening torque: 93 N·m (69 lb ft)
Oil level gauge guide tube installation
1. Apply the engine oil to the O-ring.
2. Connect the oil level gauge guide tube to the oil pan.
3. Install the oil level gauge guide tube to the inlet duct.
Tightening torque: 44 N·m (32.45 lb ft)
Engine oil filling
1. Replenish the engine with the engine oil.
NOTE: Add engine oil up to the MAX position of the oil level
gauge.
NOTICE: Check the tightening of the oil drain plug before
adding the engine oil.
Battery ground cable connect
1. Connect the battery ground cable to the battery.
Coolant filling
WARNING
Burn hazard!
Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system
is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all
pressure to release. Remove the cap only after all pressure has released.
Failure to comply could result in death or serious injury.
W0367A
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--- Page 8 ---
Engine - Valve drive and gears
Cylinder head cover (1) installation
1. Install the gasket (2) to the cylinder head cover.
NOTICE: If the gasket has looseness or a slant, repair it
before installation.
2. Install the cylinder head cover (1) to the camshaft car-
rier.
Tightening torque: 15 N·m (11.06 lb ft).
A818C314 5
Ventilation hose connect
1. Connect the ventilation hose to the air breather.
Battery ground cable connect
1. Connect the battery ground cable to the battery.
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--- Page 9 ---
Engine - Valve drive and gears
Injector leak-off pipe installation
1. Install the gasket to the injector leak-off pipe.
NOTICE: Use a new gasket.
2. Install the injector leak-off pipe (1) to the cylinder head
assembly.
Injector leak-off pipe tightening torque
Bolt size Tightening torque
M8 eyebolt (2) 15 N·m (11 lb ft)
M12 eyebolt (3) 34 N·m (25 lb ft)
R95ZI3-488 31
Glow plug installation
1. Install the glow plug to the cylinder head assembly.
Tightening torque: 20 N·m (15 lb ft).
2. Install the glow plug connector to the glow plug.
Cylinder head cover installation
1. Install the gasket (2) to the cylinder head cover.
NOTICE: If the gasket has looseness or a slant, repair it
before installation.
2. Install the cylinder head cover (1) to the camshaft car-
rier.
Tightening torque: 15 N·m (11 lb ft).
A818C314 32
Turbocharger assembly installation
1. Install the gasket to the exhaust pipe adapter.
2. Install the exhaust pipe adapter to the turbocharger.
Tightening torque: 54 N·m (39.83 lb ft)
NOTE: Secure it with double nuts.
3. Replenish the turbocharger assembly with the engine
oil.
NOTE: Apply about 1 cm³ of engine oil to the oil path to
lubricate the turbine bearing portion.
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--- Page 10 ---
Engine - Cylinder heads
Cylinder head - Special tools
Isuzu reference 5-8840-2626-0
CASE CONSTRUCTION tool
Common tool
number
Description Bridge guide setting
tool
SMIL14CEX2689AA 1
Isuzu reference 5-8840-2628-0
CASE CONSTRUCTION tool
380300014
number
Description Valve guide replacer
SMIL14CEX2690AA 2
Isuzu reference 5-8840-2627-0
CASE CONSTRUCTION tool
Common tool
number
Description Oil seal installer
SMIL14CEX3037AA 3
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--- Page 11 ---
Engine - Cylinder heads
Cylinder head assembly inspection
1. Measure the cylinder head assembly using a feeler
gauge.
1. Measurement point
2. Measurement point
3. Measurement point
4. Measurement point
5. Measurement point
6. Measurement point
NOTE: Apply a simple straight ruler extending from section
1 to section 6 in the following diagram and measure the
deformation of the cylinder head. JEIJ51-196 20
Cylinder head distortion
Limit for use less than 0.2 mm (0.0079 in)
NOTICE: Replace the cylinder head if it exceeds the use
limit.
Do not repair the cylinder head because the backlash of
the timing gear will change.
NOTE: Inspect the cylinder head while referring to the fol-
lowing table, as necessary.
Cylinder head inspection
Inspection method Supplement
The magnetic flaw detection method
Dye penetrant check Crack and damage inspection
can also be used.
Water pressure tester Water jacket crack inspection 490 kPa (71 psi)
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--- Page 12 ---
Contents
Engine - 10
Connecting rods and pistons - 105
TECHNICAL DATA
Piston
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Piston
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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--- Page 13 ---
Engine - Connecting rods and pistons
4. Align the alignment mark with the camshaft carrier.
5. Apply engine oil to the cam holder.
NOTE: Apply it on the cam holder journal surface.
NOTICE: In tightening, if attached oil is found, thoroughly
remove oil from each seat surface and threaded portion of
the bolt, camshaft carrier, and cam holder.
6. Align the cam holder with the camshaft carrier.
NOTICE: Confirm the identification code and front mark of
the cam holder.
R95ZI3-480 19
7. Temporarily tighten the cam holder onto the camshaft
carrier.
NOTE: Temporarily tighten the bolts in the numerical order
indicated in the diagram.
Tightening order.
8. Securely tighten the cam holder onto the camshaft car-
rier.
NOTE: Securely tighten them in the numerical order indi-
cated in the diagram.
Tightening torque: 53 N·m (39 lb ft) M8 bolt.
NOTICE: After tightening the cam holder, confirm the align- R95ZI3-481 20
ment mark of the camshaft gear again.
Bridge installation
1. Apply the engine oil to the bridge guide.
2. Loosen the adjust screw using the wrench.
NOTICE: Be sure the adjust screw does not loosen too
much because it may fall off of the bridge.
3. Install the bridge to the bridge guide.
NOTICE: Install it in the same position as it was removed.
R95ZI3-482 21
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--- Page 14 ---
Engine - Crankshaft and flywheel
11. Remove the EGR cooler bracket (1) from the cylinder
head.
NOTE: Remove the inlet side bracket.
PAWF1HSH002101 6
EGR valve removal
1. Disconnect the connector from the EGR valve (1).
2. Remove the EGR valve (1) from both EGR cooler duct
B and EGR cooler duct A (2).
3. Remove EGR cooler duct B (4) from the inlet duct (3).
PAWF1HSH001601 7
Inlet duct removal
1. Remove the inlet duct (1) from the inlet cover.
2. Remove the O-ring from the inlet cover.
NOTICE: Seal the inlet cover opening to prevent intrusions
of foreign material.
PAWF1BSH002101 8
Ventilation hose removal
1. Disconnect the ventilation hose from the cylinder head
cover.
2. Remove the ventilation hose from the bracket.
Fuel suction pipe removal
1. Remove the fuel suction pipe from the fuel supply
pump.
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--- Page 15 ---
Engine - Crankshaft and flywheel
EGR valve installation
NOTICE: When assembling the EGR devices, temporarily
tighten in the following order before performing securely
tightening.
Use a new gasket.
Securely tighten after assembling the EGR cooler.
1. Temporarily tighten the EGR valve (1) to EGR cooler
duct A.
Tightening torque: 5 N·m (3.69 lb ft)
NOTE: Referring to the diagram, align with the gasket iden-
tification mark (2).
PAWF1HSH001901 45
2. Temporarily tighten EGR cooler duct B (1) to the EGR
valve (1) and inlet duct.
Tightening torque: 5 N·m (3.69 lb ft)
PAWF1HSH002001 46
EGR cooler installation
1. Install the EGR cooler bracket (1) to the cylinder head.
Tightening torque: 97 N·m (71.54 lb ft)
NOTE: Install the inlet side bracket.
2. Install the EGR cooler bracket (1) to the cylinder head.
Tightening torque: 97 N·m (71.54 lb ft)
NOTE: Install the exhaust side bracket.
PAWF1HSH002101 47
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Engine - Crankshaft and flywheel
9. Measure the cylinder block using a cylinder gauge.
60B2F22B 6
10. Calculate the clearance from the measured value.
NOTE: Calculate the clearance from the inner diameter of
the crankshaft bearing and the outer diameter of the crank-
shaft journal.
Clearance between the bearing and the journal:
Standard value: 0.045 - 0.080 mm (0.0018 -
0.0031 in)
Limit: 0.09 mm (0.0035 in)
1. Measurement point
2. Measurement point
E4BFFBF0 7
3. Measurement point
4. Measurement point
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--- Page 17 ---
Engine - Crankshaft and flywheel
Common rail assembly installation
1. Install the common rail bracket to the cylinder block.
Tightening torque: 44 N·m (32 lb ft).
2. Install the common rail assembly to the bracket.
Tightening torque: 44 N·m (32 lb ft).
Fuel filter installation
1. Install the fuel filter to the cylinder head assembly.
NOTE: It varies depending on the machine.
Fuel feed pipe installation
1. Temporarily tighten the fuel field pipe (4) to the fuel
supply pump and the fuel filter.
2. Securely tighten the fuel feed pipe (4) onto the fuel
supply pump.
Tightening torque: 17 N·m (13 lb ft) .
3. Securely tighten the fuel feed pipe (4) onto the fuel filter.
Tightening torque: 50 N·m (37 lb ft) .
1. Fuel pipe
2. Fuel leak-off pipe
3. Fuel pipe
B7485782 67
5. Fuel suction pipe
Fuel pipe installation
1. Temporarily tighten the fuel pipe to the fuel supply pump
and the fuel filter.
NOTICE: Use new fuel pipes.
2. Securely tighten the fuel pipe onto the fuel supply
pump.
Tightening torque: 17 N·m (13 lb ft) Fuel temper-
ature sensor adapter
3. Securely tighten the fuel pipe onto the fuel filter.
Tightening torque: 50 N·m (37 lb ft) Fuel temper-
ature sensor adapter
4. Install the clip to the fuel feed pipe.
Tightening torque: 9 N·m (80 lb in).
Fuel pipe installation
1. Temporarily tighten the fuel pipe onto the common rail
assembly and the fuel supply pump.
2. Securely tighten the fuel pipe onto the common rail as-
sembly and the fuel supply pump.
Tightening torque: 44 N·m (32 lb ft) Sleeve nut.
Tightening torque: 9 N·m (80 lb in) Clip.
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--- Page 18 ---
Engine - Fuel filters
Fuel filters - Install
Fuel filter installation
1. Install the fuel filter to the cylinder head assembly.
NOTE: It varies depending on the machine.
Fuel feed pipe installation
2. Securely tighten the fuel feed pipe (4) onto the fuel filter.
Tightening torque: 50 N·m (37 lb ft) .
1. Fuel pipe
2. Fuel leak-off pipe
3. Fuel pipe
5. Fuel suction pipe
B7485782 1
Fuel leak-off pipe installation
1. Completely tighten the fuel leak-off pipe to the fuel filter
bracket.
Tightening torque: 41 N·m (30.24 lb ft)
Battery ground cable connect
1. Connect the battery ground cable to the battery.
Fuel air bleed
NOTICE: Always perform air bleeding to prevent engine
failure after removing or installing fuel system parts.
NOTE: The following applies to types equipped with a prim-
ing pump.
1. Prepare a pan.
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--- Page 19 ---
Engine - Fuel injection system
11. Remove the EGR cooler bracket (1) from the cylinder
head.
NOTE: Remove the inlet side bracket.
PAWF1HSH002101 5
EGR valve removal
1. Disconnect the connector from the EGR valve (1).
2. Remove the EGR valve from both EGR cooler duct B
and EGR cooler duct A (2).
3. Remove EGR cooler duct B (4) from the inlet duct (3).
PAWF1HSH001601 6
Inlet duct removal
1. Remove the inlet duct (1) from the inlet cover.
2. Remove the O-ring from the inlet cover.
NOTICE: Seal the inlet cover opening to prevent intrusions
of foreign material.
PAWF1BSH002101 7
Fuel pipe removal
1. Disconnect the fuel pipe from the common rail assem-
bly.
2. Remove the fuel pipe from the fuel supply pump.
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--- Page 20 ---
Index
Engine - 10
Fuel injection system - 218
Common rail - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Common rail - Install - Pressure limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Common rail - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Common rail - Remove - Pressure limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fuel injection system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel injection system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel injectors - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel injectors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fuel injectors - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
High pressure pump - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
High pressure pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High pressure pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High pressure pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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--- Page 21 ---
Engine - Exhaust Gas Recirculation (EGR) exhaust treatment
5. Replenish the radiator with the coolant.
1. Plug
PAWF1DSH001001 11
Battery ground cable connect
1. Connect the battery ground cable to the battery.
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--- Page 22 ---
Engine - Engine cooling system
Water pump - Inspect
Impeller inspection
1. Inspect the impeller.
NOTE: Inspect the impeller for corrosion, and the oil seal
unit contact surface for wear or damage.
SMIL13CEX7061AA 1
Water pump pulley inspection
1. Inspect the bearing.
NOTE: Check to see from the ball clearance to the lace for
scratching or flaking (full circumference).
Inspect the ball and race for any abnormal looseness.
Check if you can feel anything unusual in your hand when
rotating the bearing.
Shaft inspection
1. Inspect the shaft.
NOTE: Inspect the contact surface of the oil seal of the
shaft for worn and damage.
SMIL13CEX7062AA 2
2. Measure the shaft using the micrometer.
Specified value: 0.023 - 0.051 mm (0.000906 -
0.002008 in)
NOTE: Measure the interference of the impeller and shaft.
Specified value: 0.048 - 0.082 mm (0.001890 -
0.003228 in)
NOTE: Measure the interference of the impeller and water
pump pulley.
SMIL13CEX7063AA 3
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--- Page 23 ---
Contents
Engine - 10
Aftercooler - 310
SERVICE
Aftercooler
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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--- Page 24 ---
Engine - Oil cooler and lines
Engine oil cooler - Disassemble
Oil cooler assembly disassembly
1. Remove the water guide from the oil cooler assembly.
2. Remove the oil cooler element from the oil cooler as-
sembly.
NOTE: Loosen the nut on the oil cooler front side to remove
it.
NOTICE: Seal the oil gallery to prevent foreign matter from
entering the gallery.
NOTE: Pour cleaning solution into the element and soak
the inside for approx. 10 h.
NOTICE: Keep sparks, flames and smoking materials
away from cleaning solutions. Wear safety glasses and a
mask, and provide sufficient ventilation.
NOTE: Clean the oil cooler element using the cleaning fluid
below.
Manufacturer Product name
Nippon Oil Corporation Hi-arpmu 2S
Maruzen Suwazoru 310
Showa Hi-zoru
Mobil Oil Mobile Zol A
NOTE: Drain approx. 1/3 of the cleaning solution.
Apply compressed air from the oil port to discharge the
cleaning fluid.
Air pressure: 200 kPa (29.01 psi)
NOTE: When the oil cooler element is significantly dirty,
repeat the work above for a few times.
3. Remove the oil thermo valve from the oil cooler assem-
bly.
NOTICE: The oil thermo valve cannot be disassembled.
4. Remove the oil relief valve from the oil cooler assembly.
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--- Page 25 ---
Hydraulic systems - Hydraulic systems
Pressure line Pilot tank line
Tank line Electric line
Pilot pressure line
1. Travel motor 11. Hydraulic pump
2. Travel high-speed select switch 12. Travel remote control valve
3. Computer A 13. Oil cooler
4. Control valve 14. Backward left
5. Travel (left) 15. Forward left
6. Travel (right) 16. Backward right
7. Travel high speed 17. Forward right
8. Lever lock 18. Computer B
9. 5 stack solenoid valve 19. Swash plate
10. Console lever lock switch
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--- Page 26 ---
Hydraulic systems - Hydraulic systems
Pressure line Pilot tank line
Tank line Electric line
Pilot pressure line
1. Swing motor 10. 5 stack solenoid valve
2. Cushion valve 11. Console lever lock switch
3. Right swing 12. Computer A
4. Left swing 13. Control valve