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SERVICE MANUAL CX490D Crawler excavators LC version (TIER4 FINAL) - EU Market 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)
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Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.102] Pan and covers .
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[35.357] Pilot system ............... . 35.7 [35.355] Hydraulic hand control .
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[55.302] Battery................55.7 [55.202] Cold start aid .
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.
INTRODUCTION Safety rules 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. Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in- structions.
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.
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.
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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.
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 become severely disabled. It is not applicable beyond the criterion.
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INTRODUCTION Boom position Warning • If you make such modification as lowers the boom position, ROPS is not applicable. • Consultation with us is required whenever it is assumed that the boom position is lowered by modification. • The range of change in the boom position cannot be determined uniformly. SMIL14CEX2001EA (a) Ground point It is not applicable if the position overlapping with a cab on the side view (mark * in the figure) is lowered significantly...
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INTRODUCTION 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 47937811 29/02/2016...
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INTRODUCTION Cab (CX490D/CX500D) The irregularly shaped steel line also contains reinforcements. CAF7CBDF The high cab is not supported basically. (Since it varies for each model, consultation with us is required in each case.) 47937811 29/02/2016...
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.
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 ®...
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.
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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.
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 •...
INTRODUCTION General specification CX490D Crawler excavators LC version (TIER4 FINAL) - EU Market Engine Water-cooled, 4-cycle diesel, 6-cylinder in line, High Type pressure common rail system (electric control), Turbocharger with air cooled intercooler, SCR system Model ISUZU AQ-6UZ1X ( ISO 14396)
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INTRODUCTION fin type Straight fin 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 gear pump Fixed displacement axial piston motor Motor Filters 105 μm...
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INTRODUCTION Safety glass for all windows Shock-less cab suspension by 4-point fluid mounting Sliding front window with auto lock Built-in type full-color LCD monitor display Membrane switch on monitor display Windshield wiper & washer Floor mat Polycarbonate roof hatch and Sun shade Auto air-conditioner Rain deflector Sun visor...
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INTRODUCTION Digging force (with 2.0 m³ bucket) ( ISO 6015 ) 3.38 m (11.0892 ft) Arm 2.53 m (8.3005 ft) Arm Arm digging force 201 kN (45187 lb) 246 kN (55303 lb) With auto power up 220 kN (49458 lb) 269 kN (60474 lb) Bucket digging force 247 kN (55528 lb)
INTRODUCTION General specification CX490D Crawler excavators RTC version (TIER4 FINAL) - EU Market Engine Water-cooled, 4-cycle diesel, 6-cylinder in line, High Type pressure common rail system (electric control), Turbocharger with air cooled intercooler, SCR system Model ISUZU AQ-6UZ1X ( ISO 14396)
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INTRODUCTION fin type Straight fin 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 gear pump Fixed displacement axial piston motor Motor Filters 105 μm...
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INTRODUCTION Safety glass for all windows Shock-less cab suspension by 4-point fluid mounting Sliding front window with auto lock Built-in type full-color LCD monitor display Membrane switch on monitor display Windshield wiper & washer Floor mat Polycarbonate roof hatch and Sun shade Auto air-conditioner Rain deflector Sun visor...
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INTRODUCTION Digging force (with 2.0 m³ bucket) ( ISO 6015 ) 3.38 m (11.0892 ft) Arm 2.53 m (8.3005 ft) Arm Arm digging force 201 kN (45187 lb) 246 kN (55303 lb) With auto power up 220 kN (49458 lb) 269 kN (60474 lb) Bucket digging force 247 kN (55528 lb)
INTRODUCTION General specification CX500D Crawler excavators LC Mass Excavator version (TIER4 FINAL) - EU Market Engine Water-cooled, 4-cycle diesel, 6-cylinder in line, High Type pressure common rail system (electric control), Turbocharger with air cooled intercooler, SCR system Model ISUZU AQ-6UZ1X ( ISO 14396) 270 kW (367 Hp) at 2000 RPM Rated flywheel horse power...
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INTRODUCTION Intercooler capacity 40.0 kW fin type Straight fin 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 gear pump Fixed displacement axial piston motor Motor Filters...
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INTRODUCTION Operator environment Operator's cab Smooth and round shape design cab, fabricated by press work Safety glass for all windows Shock-less cab suspension by 4-point fluid mounting Sliding front window with auto lock Built-in type full-color LCD monitor display Membrane switch on monitor display Windshield wiper &...
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INTRODUCTION with 2.53 m (8.3005 ft) Arm, 2.0 m³ Bucket, 600 mm (23.622 in) grouser shoe 0.085 MPa (12.329 psi) Digging force (with 3.0 m³ bucket) 2.53 m (8.3005 ft) Arm Arm digging force 245 kN (55078 lb) With auto power up 267 kN (60024 lb) Bucket digging force 287 kN (64520 lb)
INTRODUCTION General specification CX500D Crawler excavators RTC Mass excavator version (TIER4 FINAL) - EU Market Engine Water-cooled, 4-cycle diesel, 6-cylinder in line, High Type pressure common rail system (electric control), Turbocharger with air cooled intercooler, SCR system Model ISUZU AQ-6UZ1X ( ISO 14396) 270 kW (367 Hp) at 2000 RPM Rated flywheel horse power...
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INTRODUCTION Intercooler capacity 40.0 kW fin type Straight fin 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 gear pump Fixed displacement axial piston motor Motor Filters...
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INTRODUCTION Operator environment Operator's cab Smooth and round shape design cab, fabricated by press work Safety glass for all windows Shock-less cab suspension by 4-point fluid mounting Sliding front window with auto lock Built-in type full-color LCD monitor display Membrane switch on monitor display Windshield wiper &...
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INTRODUCTION with 2.53 m (8.3005 ft) Arm, 2.0 m³ Bucket, 600 mm (23.622 in) grouser shoe 0.087 MPa (12.619 psi) Digging force (with 3.0 m³ bucket) 2.53 m (8.3005 ft) Arm Arm digging force 245 kN (55078 lb) With auto power up 267 kN (60024 lb) Bucket digging force 287 kN (64520 lb)
INTRODUCTION General specification - Main equipment Lower component Travel unit Manufacturer Nabtesco Corporation Motor type Variable displacement piston motor Automatic 2-speed switch over with parking brake Intake amount 290.0 - 170.1 cm³/rev (17.7 - 10.4 in³/rev) Operating pressure 34.3 MPa (4975 psi) Operating flow 360.4 L/min (95.208 US gpm) Brake torque...
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INTRODUCTION Shoes Weight or quantity 600 grouser 2585 kg (5698.949 lb) Link 1 set Shoe Bolt 750 grouser 2930 kg (6459.544 lb) Link 1 set Shoe Bolt 900 grouser 3280 kg (7231.162 lb) Link 1 set Shoe Bolt 47937811 29/02/2016...
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INTRODUCTION Upper component Swing unit Swing motor assembly Swing motor Manufacturer Hyest Corporation Fixed displacement piston motor Motor type With parking brake Intake amount 250 cm³/rev (15.26 in³/rev) Operating pressure 29.4 MPa (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...
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INTRODUCTION Engine-related Engine Engine model name Isuzu 6HK1X diesel engine 4-cycle, water-cooled, overhead camshaft, vertical in-line, direct Engine type injection type (electronics control type) Number of cylinders - diameter - stroke 6 - Æ 120 mm (4.53 in) x 145 mm (5.71 in) Total displacement 9.839 L (2.599 US gal) 16.2...
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INTRODUCTION Air cleaner (double element) Nippon Donaldson, Ltd. Manufacturer Filtering area size Element (outer) 14.7 m² (158.23 ft²) Element (inner) Filtering area size 1.85 m² (19.91 ft²) Weight 17.6 kg (38.801 lb) Radiator Manufacturer Tokyo Radiator MFG. Co.,Ltd. Weight 42.0 kg (92.594 lb) Oil cooler Oil volume 18.5 L (4.887 US gal)
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INTRODUCTION Hydraulic device Hydraulic pump Manufacturer Kawasaki Heavy Industries, Ltd. Main pump Pump type Double variable displacement piston pump Displacement 182 cm³/rev (11.106 in³/rev) x 2 Rating 31.4 MPa (4555 psi) Operating pressure Maximum 34.3 MPa (4975 psi) Input revolution speed 2000 RPM 364 L/min (96.16 US gpm) x 2 (at Pd = 2.0 MPa (290.10 psi) 2000 RPM)
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INTRODUCTION C32763E0 PQ diagram Hydraulically-operated fan pump Manufacturer SHIMADZU CORPORATION Pump type Gear pump Displacement 40.6 cm³/rev (2.478 in³/rev) x 2 Allowable peak pressure 24.5 MPa (3554 psi) Maximum speed 2300 RPM 86.0 L/min (22.72 US gpm) x 2 (at Pd = 22.5 MPa (3263.63 psi) Maximum discharge volume 2300 RPM), oil temperature of 40 °C (104.0 °F) Negative suction pressure...
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INTRODUCTION Shaft input horsepower 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 (11.9 lb) 47937811 29/02/2016...
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INTRODUCTION Hydraulically-operated fan motor Manufacturer KOMATSU LTD. (DEALT IN BY KOMATSU ZENOAH LTD.) Absorption amount 40 cm³/rev Allowable peak pressure 31.9 MPa (4627 psi) Normal operation 2.0 MPa (290.1 psi) or less T port pressure pressure Peak pressure 4.4 MPa (638.2 psi) or less Normal operation 0.10 MPa (14.5 psi) or less...
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INTRODUCTION Control-related Control valve Manufacturer KYB Corporation Maximum flow 364 L/min (96.159 US gpm) (at 2000 RPM) Overload set pressure 24.5 MPa (3553.725 psi), boom down 36.3 MPa (5265.315 psi) boom up, arm, bucket Main relief set pressure 31.4 MPa (4555 psi) (Upon pressure 34.3 MPa (4975 psi) boost)
INTRODUCTION Weight CX490D Crawler excavators LC version (TIER4 FINAL) - EU Market CX500D Crawler excavators LC Mass Excavator version (TIER4 FINAL) - EU Market Divided weight ( LC Standard undercarriage) C156F60E Code Part name Weight Operating weight 47299 kg (104276.445 lb) Upper component (including counterweight and 22224 kg (48995.533 lb)
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INTRODUCTION NOTE: The bucket weight is not included. The weights shown here are approximate values. Stand alone part weight Part name Weight Travel unit 1002 kg (2209.032 lb) Take-up roller 335 kg (738.549 lb) Upper roller 175 kg (385.809 lb) Lower roller 993 kg (2189.190 lb) Swing unit...
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INTRODUCTION Bucket weight (CX490D LC) Heavy Duty buckets Capacity Width Mass ISO 7451 (Heaped) 1.04 m³ (1.36 yd³) 900 mm (35 in) 1634 kg (3602 lb) 1.35 m³ (1.77 yd³) 1100 mm (43 in) 1803 kg (3975 lb) 1.50 m³ (1.96 yd³)
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INTRODUCTION Bucket weight (CX500D LC) Rock buckets Capacity Width Mass ISO 7451 (Heaped) 1.75 m³ (2.29 yd³) 1350 mm (53 in) 2270 kg (5004 lb) 2.00 m³ (2.62 yd³) 1500 mm (59 in) 2380 kg (5247 lb) 2.33 m³ (3.05 yd³) 1700 mm (67 in) 2500 kg (5512 lb) 2.50 m³...
INTRODUCTION Weight CX490D Crawler excavators RTC version (TIER4 FINAL) - EU Market CX500D Crawler excavators RTC Mass excavator version (TIER4 FINAL) - EU Market Divided weight ( RTC Retractable undercarriage) C156F60E Code Part name Weight Operating weight 48591 kg (107124.818 lb) Upper component (including counterweight and 22229 kg (49006.556 lb)
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INTRODUCTION NOTE: The bucket weight is not included. The weights shown here are approximate values. Stand alone part weight Part name Weight Travel unit 1002 kg (2209.032 lb) Take-up roller 335 kg (738.549 lb) Upper roller 175 kg (385.809 lb) Lower roller 993 kg (2189.190 lb) Swing unit...
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INTRODUCTION Bucket weight (CX490D RTC) Heavy Duty buckets Capacity Width Mass ISO 7451 (Heaped) 1.04 m³ (1.36 yd³) 900 mm (35 in) 1634 kg (3602 lb) 1.35 m³ (1.77 yd³) 1100 mm (43 in) 1803 kg (3975 lb) 1.50 m³ (1.96 yd³)
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INTRODUCTION Bucket weight (CX500D RTC) Rock buckets Capacity Width Mass ISO 7451 (Heaped) 1.75 m³ (2.29 yd³) 1350 mm (53 in) 2270 kg (5004 lb) 2.00 m³ (2.62 yd³) 1500 mm (59 in) 2380 kg (5247 lb) 2.33 m³ (3.05 yd³) 1700 mm (67 in) 2500 kg (5512 lb) 2.50 m³...
INTRODUCTION Dimension CX490D Crawler excavators LC version (TIER4 FINAL) - EU Market Standard 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.
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INTRODUCTION 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) ]. BB4CBE6E (b) With catwalk - option 47937811 29/02/2016...
INTRODUCTION Dimension CX490D Crawler excavators RTC version (TIER4 FINAL) - EU Market Standard 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.
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INTRODUCTION Standard 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) ]. NOTE: The dimension between brackets [ ] indicates the minimum dimension for transport.
INTRODUCTION Dimension CX500D Crawler excavators LC Mass Excavator version (TIER4 FINAL) - EU Market 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.
INTRODUCTION Dimension CX500D Crawler excavators RTC Mass excavator version (TIER4 FINAL) - EU Market 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.
(-4 °F) to 45 °C (113 °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-...
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INTRODUCTION Engine coolant CASE CONSTRUCTION requires the use of a fully formulated Organic Acid Technology (OAT) based coolant. CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT is the reference genuine product. NOTICE: Use of different coolant brands is not recommended. NOTICE: Never add Supplemental Coolant Additives (SCA) when using CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT.
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If the temperature drops below the fuel cloud point, output deficiency or engine start problems may occur due to wax crystals. NOTICE: If operating in severe winter climate, consult the fuel supplier or the CASE CONSTRUCTION dealer for specific diesel fuel according to the EN 590 to be used.
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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.
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