SERVICE MANUAL Mini Excavator CX57C Part number 51452080 English March 2018 © 2018 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICEMANUAL CX57CCab-TierIVfinalengine 5145208020/06/2018
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.106]Valvedriveandgears..............................................................10.2 [10.101]Cylinderheads.....................................................................10.3 Hydraulicsystems.......................................................................35 [35.300]Reservoir,cooler,andfilters........................................................35.2 5145208020/06/2018
[35.741]Dozerbladecylinders............................................................35.17 Pneumaticsystem......................................................................36 [36.100]Pneumaticsystem..................................................................36.1 Framesandballasting.................................................................39 Tracksandtracksuspension........................................................48 Cabclimatecontrol.....................................................................50 [50.100]Heating.............................................................................50.1 [50.200]Airconditioning.....................................................................50.2 Electricalsystems.......................................................................55 5145208020/06/2018
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[55.514]Cablighting......................................................................55.18 [55.408]Warningindicators,alarms,andinstruments....................................55.19 [55.DTC]FAULTCODES..................................................................55.20 Booms,dippers,andbuckets.......................................................84 [84.910]Boom...............................................................................84.1 [84.912]Dipperarm.........................................................................84.2 [84.100]Bucket..............................................................................84.3 Dozerbladeandarm...................................................................86 Platform,cab,bodywork,anddecals.............................................90 [90.120]Mechanically-adjustedoperatorseat...............................................90.2
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INTRODUCTION 5145208020/06/2018 1
Contents INTRODUCTION Safetyrules.....................................................................................4 Machinespecifications........................................................................15 Weights.......................................................................................17 Dimensions...................................................................................18 Conversionfactors............................................................................20 Consumables-Engineoilrecommendedoperatingtemperaturerange.....................39 Productidentification-Machineorientation..................................................43 5145208020/06/2018 2
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing
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INTRODUCTION
Safetyrules
Personalsafety
ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY.
Machinesafety
NOTICE: Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:
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4
Cleaning
Safetyrules-Generalinformation
Aftercleaning,drywell,andinjectoilinallparts.
Inspection
Bearing Needlebearing
Gear
Alwaysinstallnewoilseals,O-rings,andgaskets.
Shaft
Checkthebearingsandcheckfordamagedoilsealsontheshaft.
Serviceparts
InstallCASECONSTRUCTIONgenuineserviceparts.
Lubricants(fuel,hydraulicoil)
Usetheoilfromthespecifiedcompanyorspecifiedintheoperator'smanualorserviceManual.
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INTRODUCTION
5
INTRODUCTION Safetyrules-Personalsafety Preliminarywarningstomaintenanceoperation WARNING Avoidinjury! Shutofftheengine,removethekey,andmakesureallmachinemotionstopsbeforeyouservicethe machine. W1128B WARNING Improperoperationorserviceofthismachinecanresultinanaccident. suitablehandsignals. Failuretocomplycouldresultindeathorseriousinjury. W0287A CAUTION Pinchhazard! Alwaysusesuitabletoolstoalignmatingparts.DONOTuseyourhandorfingers. C0044A PersonalProtectiveEquipment(PPE) WARNING Avoidinjury! UsePersonalProtectiveEquipment(PPE),includingprotectivegoggles,gloves,andsafetyfootwear. Failuretocomplycouldresultindeathorseriousinjury. W1036A Liftingoperation WARNING Crushinghazard! Theliftingsystemsmustbeoperatedbyqualifiedpersonnelwhoareawareofthecorrectprocedures tofollow.Makesureallliftingequipmentisingoodcondition,andallhooksareequippedwithsafety latches. W0256A WARNING Heavyobjects! unitsorpartswithsuitableslingsorhooks.Makesuretheworkareaisclearofallbystanders. W0398A WARNING Improperoperationorserviceofthismachinecanresultinanaccident. Raisedequipmentormachinemovementwithoutanoperatorcancauseseriousinjury.Alwaysdothe followingbeforeperforminganymaintenance: Parkthemachineonflat,levelground. Shutdowntheengineandremovetheignitionkey. Lockthetracks. W0944D 5145208020/06/2018 6
INTRODUCTION WARNING Tip-overhazard! Onlyraisethetrackaslittleasnecessary. W0276A Hydraulicsystem WARNING Burnhazard! Beforeperforminganyserviceonthehydraulicsystem,youmustallowittocool.Hydraulicfluid temperatureshouldnotexceed40°C(104°F). W0241A WARNING Pressurizedfluidcanpenetratetheskinandcausesevereinjuries. inordertospeeduptheflowofgrease. W0261A WARNING Pressurizedsystem! Beforeattemptinganyserviceprocedure,itisyourresponsibilitytoknowthenumberofaccumulators Failuretocomplycouldresultindeathorseriousinjury. W0136A Battery WARNING Batteryacidcausesburns.Batteriescontainsulfuricacid. Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):flush withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge quantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately. W0111A WARNING Batterygascanexplode! notweld,grind,orsmokenearabattery. W0011A
WARNING Hazardouschemicals! Coolantcanbetoxic.Avoidcontactwithskin,eyes,andclothing.Antidotes: W0282A 5145208020/06/2018 7
Fluids
INTRODUCTION WARNING Burnhazard! Hotcoolantcansprayandscaldifyouremovetheradiatorordeaerationtankcapwhilethesystem pressuretorelease.Removethecaponlyafterallpressurehasreleased. W0367A WARNING Escapingfluid! Hydraulicfluidordieselfuelleakingunderpressurecanpenetratetheskinandcauseinfectionor formingworkonthehydraulicsystem.Beforeapplyingpressure,makesureallconnectionsaretight pressure.Useapieceofcardboardorwoodforthispurpose.Ifinjuredbyleakingfluid,seeyour doctorimmediately. W0178A WARNING Chemicalhazard! Whenhandlingfuel,lubricants,andotherservicechemicals,followthemanufacturer'sinstructions. WearPersonalProtectiveEquipment(PPE)asinstructed.Donotsmokeoruseopenflame.Collect Failuretocomplycouldresultindeathorseriousinjury. W0371A 5145208020/06/2018 8
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
INTRODUCTION
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INTRODUCTION Torque-Standardtorquesettings BOLTANDNUT Coarsethread Boltsize 8t 10t 1.15–1.69N·m ( ) 1.55–2.36N·m ( ) 2.71–4.07N·m ( ) 3.66–5.56N·m ( ) M10x1.5 5.42–8.13N·m ( ) 7.46–11.25N·m ( ) ( ) ( ) 16.54–22.51N·m ( ) 22.64–30.51N·m ( ) 25.22–34.17N·m ( ) 34.17–46.37N·m ( ) M18x2.5 34.98–47.45N·m ( ) 47.59–64.40N·m ( ) ( ) ( ) 65.49–85.82N·m ( ) 89.21–132.87N·m ( ) 84.74–114.57N·m ( ) 115.24–155.92N·m ( ) ( ) ( ) ( ) ( ) Finethread Boltsize 8t 10t 2.98–4.61N·m ( ) 4.07–5.97N·m ( ) 6.10–9.08N·m ( ) 8.00–12.07N·m ( ) M12x1.25 10.58–15.73N·m ( ) 14.37–21.69N·m ( ) ( ) ( ) 26.98–36.47N·m ( ) 36.06–48.81N·m ( ) 38.78–59.11N·m ( ) 52.06–70.50N·m ( ) M20x1.5 54.23–73.21N·m ( ) 72.40–97.89N·m ( ) ( ) ( ) 92.06–124.60N·m ( ) 123.24–166.77N·m ( ) 185.75–250.83N·m ( ) 246.76–336.24N·m ( ) ( ) ( ) Pipeandhose(FLAREtype) Threadsize(PF) Widthacrossflat Torque 1/4" 19mm ( 0.75in ) 39.18N·m ( 28.90lbft ) 3/8" 22mm ( 0.87in ) ( 36.20lbft ) 1/2" 27mm ( ) 93.14N·m ( ) 3/4" 36mm ( 1.42in ) 176.26N·m ( 130.00lbft ) 41mm ( 1.61in ) 206.08N·m ( 152.00lbft ) 50mm ( 1.97in ) ( 253.00lbft ) Pipeandhose(ORFStype) Threadsize(UNF) Widthacrossflat Torque 19mm ( 0.75in ) ( 28.90lbft ) 22mm ( ) 49.08N·m ( ) 27mm ( 1.06in ) 93.14N·m ( 68.70lbft ) 36mm ( 1.42in ) 176.26N·m ( 130.00lbft ) 1-7/16-12 41mm ( 1.61in ) ( 152.00lbft ) 50mm ( ) 343.02N·m ( ) 5145208020/06/2018
Fitting Threadsize Widthacrossflat Torque 1/4" 19mm ( ) 39.18N·m ( ) 3/8" 22mm ( 0.87in ) 49.08N·m ( 36.20lbft ) 1/2" 27mm ( 1.06in ) 93.14N·m ( 68.70lbft ) 3/4" 36mm ( 1.42in ) ( 130.00lbft ) 41mm ( ) 206.08N·m ( ) 1-1/4" 50mm ( 1.97in ) 343.02N·m ( 253.00lbft ) 5145208020/06/2018 11
INTRODUCTION
INTRODUCTION Torque-Specialtorquesettings Component Boltsize Tighteningtorque Engine Enginemountingbolt ( ) Enginemountingbolt ( ) Coolingfanmountingbolt ( ) Radiatormountingboltandnut ( ) Couplingmountingbolt 127.2–146.7N·m ( ) Mainpumpmountingbolt 94.9–154.6N·m ( ) Maincontrolvalvemountingbolt ( ) Fueltankmountingbolt 246.8–336.2N·m ( ) Hydraulicoiltankmountingbolt 246.8–336.2N·m ( ) Hydraulic system Hydraulicswivelmountingboltand nut ( ) Swingmotormountingbolt 246.8–336.2N·m ( ) Swingbearinguppermountingbolt ( ) Swingbearinglowermountingbolt 246.8–336.2N·m ( ) Powertrain system Travelmotormountingbolt 176.9–216.3N·m ( ) Sprocketmountingbolt ( ) Trackrollersupportmountingbolt andnut 366.2–444.6N·m ( ) Trackrollermountingbolt 366.2–444.6N·m ( ) Idlerwheeltorecoilspring assemblymountingbolt 94.9–154.6N·m ( ) 171.5–210.8N·m ( ) Undercarriage Trackguardmountingbolt 259.0–321.3N·m ( ) Counterweightmountingbolt 504–629.5N·m ( ) Cabmountingboltandnut ( ) Cabanchorbolt 247.4–335.6N·m ( ) Others 10.6–12.5N·m ( ) 5145208020/06/2018
Shimming Rotatingshaftseals
NOTE:
O-ringseals Sealingcompounds
Spareparts
INTRODUCTION
Basicinstructions-Shopandassembly
andthedustlipondoublelipsealswithgrease.
compound,preparethesurfacesasdirectedbytheproductcontainer.
OnlyuseCNHOriginalPartsorCASECONSTRUCTIONOriginalParts. partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorCASECONSTRUCTIONOriginal Whenorderingspareparts,alwaysprovidethefollowinginformation:
Machinemodel(commercialname)andProductIdentificationNumber(PIN) • 5145208020/06/2018
•
INTRODUCTION Protectingtheelectronicand/orelectricalsystemsduringchargingandwelding Toavoiddamagetotheelectronicand/orelectricalsystems,alwaysobservethefollowingpractices: • • • weld. NOTICE: Ifyoumustweldontheunit,youmustdisconnectthebatterygroundcablefromthemachinebattery. WARNING Batteryacidcausesburns.Batteriescontainsulfuricacid. withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge Failuretocomplycouldresultindeathorseriousinjury. W0111A Specialtools Byusingthesetools,repairpersonnelwillbenefitfrom: • Operatinginoptimaltechnicalconditions • Obtainingthebestresults • Savingtimeandeffort • Workinginsafeconditions 5145208020/06/2018
Machinespecifications
INTRODUCTION
Engine Model Yanmar4TNV98C Type Coolingmethod Watercooling Numberofcylindersandarrangement Firingorder Combustionchambertype Directinjectiontype Cylinderborexstroke 98mm ( )x 110mm ( ) Pistondisplacement 3319cm³ ( 203in³ ) Compressionratio Ratedgrosshorsepower(SAEJ1995) 49.9kW ( 67.8Hp )at 2400RPM Maximumtorqueat 1550RPM 235.4N·m ( ) Engineoilquantity 11.6L ( 3.1USgal ) Dryweight 270kg ( 595lb ) Highidlingspeed Lowidlingspeed Ratedfuelconsumption 2400RPM Startingmotor 12V , 3.0kW Alternator 12V , 100A Battery 1x 12V x Mainpump Type Variabledisplacementtandemaxispistonpumps Capacity 2x 27.5cm³/rev ( 1.7in³/rev ) Maximumpressure 21581kPa ( 3130psi ) Ratedoilflow 2x 57.8L/min ( 15.3USgpm ) Ratedspeed 2100RPM Gearpump Type Fixeddisplacementgearpumpsinglestage Capacity 18.3–22.8cm³/rev ( 1.1–0.3in³/rev ) Maximumpressure 21581kPa ( 3130psi ) Ratedoilflow ( ) Maincontrolvalve Type Sectional,9spools Operatingmethod Hydraulicpilotsystem Mainreliefvalvepressure 21581kPa ( 3130psi ) Overloadreliefvalvepressure 23511kPa ( 3410psi ) 5145208020/06/2018
Swingmotor Type Fixeddisplacementaxialpistonmotor Capacity 32.3cm³/rev ( 2.0in³/rev ) Reliefpressure 21581kPa ( 3130psi ) Brakingsystem Brakingtorque ( 101.30lbft ) Brakereleasepressure ( ) Reductiongeartype Travelmotor Type Variabledisplacementaxialpistonmotor Reliefpressure 21581kPa ( 3130psi ) Reductiongeartype Brakingsystem Automatic,springappliedhydraulicreleased Brakereleasepressure 883kPa ( 128psi ) Brakingtorque ( 60.78lbft ) Cylinder BorediameterxRoddiameterxStroke Ø 110mm ( 4.3in )xØ 65mm ( 2.6in )x 715mm ( ) Boomcylinder Cushion Extendonly BorediameterxRoddiameterxStroke Ø 90mm ( 3.5in )xØ 55mm ( 2.2in )x 850mm ( 33.5in ) Armcylinder Cushion Extendandretract BorediameterxRoddiameterxStroke Ø 80mm ( 3.1in )xØ 50mm ( 2.0in )x 660mm ( 26.0in ) Bucketcylinder Cushion Extendonly BorediameterxRoddiameterxStroke Ø 110mm ( 4.3in )xØ 60mm ( 2.4in )x 219mm ( ) Dozerblade Cushion Extendonly NOTE:
surface. Shoe Steel 380mm ( 15.0in ) Shoewidth Rubber 400mm ( 15.7in ) Steel 0.34Kg/cm² ( ) Groundpressure Rubber 0.33Kg/cm² ( 4.7psi ) Steel 1880mm ( 74.0in ) Overallwidth Rubber 1900mm ( 74.8in ) Numberofrollersandshoeoneachside Carrierrollers:1
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INTRODUCTION
discolorationofcylinderrodcanoccurwhenthefrictionreductionadditiveoflubricationoilspreadsontherod
Trackrollers:5 Trackshoes(steel):40