Case CX490C Service Manual
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Case CX490C Service Manual

Crawler excavator
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CX490C
CX500C
Crawler Excavator
SERVICE MANUAL
Part number 48098399
English
January 2017
© 2017 CNH Industrial Italia S.p.A. All Rights Reserved.

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  • Page 1 CX490C CX500C Crawler Excavator SERVICE MANUAL Part number 48098399 English January 2017 © 2017 CNH Industrial Italia S.p.A. All Rights Reserved.
  • Page 2 SERVICE MANUAL CX490C Crawler excavators LC version (TIER 3) - Turkish market CX490C Crawler excavators STD version (TIER 3) - Turkish market CX500C Crawler excavator LC Mass excavator version (TIER 3) - Turkish market 48098399 20/01/2017 Find manuals at https://best-manuals.com...
  • Page 3 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.102] Pan and covers .
  • Page 4 [35.752] Hydraulic fan drive cooling system ..........35.8 [35.355] Hydraulic hand control .
  • Page 5 [55.302] Battery................55.7 [55.202] Cold start aid .
  • Page 6 [90.120] Mechanically-adjusted operator seat..........90.3 [90.100] Engine hood and panels .
  • Page 7 48098399 20/01/2017 Find manuals at https://best-manuals.com...
  • Page 8 INTRODUCTION 48098399 20/01/2017 Find manuals at https://best-manuals.com...

  • Page 9: Table Of Contents

    Contents INTRODUCTION Foreword - Important notice regarding equipment servicing ........3 Safety rules .

  • Page 10: Foreword - Important Notice Regarding Equipment Servicing

    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.

  • Page 11: Safety Rules

    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.

  • Page 12: Safety Rules - General Information

    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.

  • Page 13: Safety Rules - Personal Safety

    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.
  • Page 14 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.

  • Page 15: Safety Rules - Cab Protective Structure

    INTRODUCTION Safety rules - Cab protective structure Cab protective structure Modifying the cab main components is prohibited in order to protect the operator. Prohibited items • Modifications that reduce the strength of a platform that has a cab with a protective structure mounted on it. (Actions or modifications that reduce the functionality of the anchoring part at the left-rear of the cab) •...

  • Page 16: Safety Rules - Ecology And The Environment

    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.

  • Page 17: Torque - Bolt And Nut

    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 ®...

  • Page 18: Torque - Special Torque Setting

    INTRODUCTION Torque - Special torque setting Nominal bolt Retightening location Tightening torque Code Wrench diameter 900 – 1051 N·m (664 – 775 lb ft) Travel motor 36 mm Drive sprocket 900 – 1051 N·m (664 – 775 lb ft) 36 mm Take-up roller 24 mm 267 –...
  • Page 19 INTRODUCTION B2AB1DF6 48098399 20/01/2017...
  • Page 20 INTRODUCTION YYSJMI-002 48098399 20/01/2017...
  • Page 21 INTRODUCTION YYSJMI-006 48098399 20/01/2017...

  • Page 22: Basic Instructions - Shop And Assembly

    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.
  • Page 23 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.

  • Page 24: Hydraulic Contamination

    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 •...

  • Page 25: General Specification

    INTRODUCTION General specification CX490C Crawler excavators STD version (TIER 3) - Turkish market APAC Engine Water-cooled, 4-cycle diesel, 6-cylinder in line, High pressure common rail system (electric control), Turbocharger with air Type cooled intercooler, Without cooling fan Model ISUZU GH-6UZ1XKSS-01 270 kW (367.098 Hp) ( 2000 RPM) (without fan-pump)
  • Page 26 INTRODUCTION Fin type Corrugated fin (wavy type) Fin space 2.25 mm (0.0886 in) Cooling fan drive system Pump 1 vane pump Fixed displacement axial piston motor Motor Filters 105 μm Suction filter 6 μm Return filter 8 μm Pilot line filter Hydraulic controls Boom/Arm/Bucket/Swing Pilot pressure control system (ISO control pattern)
  • Page 27 INTRODUCTION Membrane switch on monitor display Windshield wiper & washer Floor mat Polycarbonate roof hatch & Sun shade Auto air-conditioner Top guard OPG level 1 (in CAB structure) Cage type head guard [Limited to the cases the weight is less than or equal to 50.000 kg Roll-over protective structure (ROPS) (110.231 lb)] Operator's seat...
  • Page 28 INTRODUCTION Dimensions [ 2.53 m (8.3005 ft)] HD [ 3.13 m (10.2690 ft)] [ 3.38 m (11.0892 ft)] HD Arm HD Arm Overall length (without attachment) 6270 mm (246.850 in) 6270 mm (246.850 in) 6270 mm (246.850 in) Overall length (with attachment) 12110 mm (476.772 in) 12110 mm (476.772 in) 12070 mm (475.197 in) Overall height (with attachment) 3650 mm (143.701 in)

  • Page 29: General Specification

    INTRODUCTION General specification CX490C Crawler excavators LC version (TIER 3) - Turkish market APAC Engine Water-cooled, 4-cycle diesel, 6-cylinder in line, High pressure common rail system (electric control), Turbocharger with air Type cooled intercooler Model ISUZU GH-6UZ1XKSS-01 270 kW (367.098 Hp) ( 2000 RPM) (without fan-pump) Rated flywheel horse power (ISO 14396) 245 kW (333.107 Hp) ( 2000 RPM) (with fan-pump)
  • Page 30 INTRODUCTION Fin type Corrugated fin (wavy type) Fin space 2.25 mm (0.0886 in) Cooling fan drive system Pump 1 vane pump Fixed displacement axial piston motor Motor Filters 105 μm Suction filter 6 μm Return filter 8 μm Pilot line filter Hydraulic controls Boom/Arm/Bucket/Swing Pilot pressure control system (ISO control pattern)
  • Page 31 INTRODUCTION Membrane switch on monitor display Windshield wiper & washer Floor mat Polycarbonate roof hatch & Sun shade Auto air-conditioner Sun visor Cage type head guard Roll-over protective structure (ROPS) Roll-over protective structure (ROPS) [Limited to the cases the weight is less than or equal to 50.000 kg (110.231 lb) Top guard OPG level 2 Operator's seat...
  • Page 32 INTRODUCTION With auto power up 266 kN (59799.179 lb) 266 kN (59799.179 lb) 266 kN (59799.179 lb) Dimensions [ 2.53 m (8.3005 ft)] HD [ 3.13 m (10.2690 ft)] [ 3.38 m (11.0892 ft)] HD Arm HD Arm Overall length (without attachment) 6445 mm (253.740 in) 6445 mm (253.740 in) 6445 mm (253.740 in)

  • Page 33: General Specification

    INTRODUCTION General specification CX500C Crawler excavator LC Mass excavator version (TIER 3) - Turkish APAC market Engine Water-cooled, 4-cycle diesel, 6-cylinder in line, High pressure Type common rail system (electric control) Model ISUZU GH-6UZ1XKSS-01 270 kW (367.098 Hp) ( 2000 RPM) (without fan-pump) Rated flywheel horse power (ISO 14396) 245 kW (333.107 Hp) ( 2000 RPM) (with fan-pump) Piston displacement...
  • Page 34 INTRODUCTION Fuel cooler capacity 3.72 kW Fin type Corrugated fin (wavy type) Fin space 2.25 mm (0.0886 in) Cooling fan drive system Pump 1 vane pump Fixed displacement axial piston motor Motor Filters 105 μm Suction filter 6 μm Return filter 8 μm Pilot line filter Hydraulic controls...
  • Page 35 INTRODUCTION Built-in type full-color LCD monitor display Membrane switch on monitor display Windshield wiper & washer Floor mat Polycarbonate roof hatch & Sun shade Auto air-conditioner Sun visor Cage type head guard [Limited to the cases the weight is less than or equal to 50.000 kg Roll-over protective structure (ROPS) (110.231 lb) Top guard OPG level 2...
  • Page 36 INTRODUCTION With auto power up 266 kN (59799.18 lb) 266 kN (59799.18 lb) 266 kN (59799.18 lb) Dimensions [ 2.53 m (8.3005 ft)] HD [ 3.13 m (10.2690 ft)] [ 3.38 m (11.0892 ft)] HD Arm HD Arm Overall length (without attachment) 6445 mm (253.740 in) 6445 mm (253.740 in) 6445 mm (253.740 in)

  • Page 37: General Specification - Main Equipment

    INTRODUCTION General specification - Main equipment Lower component Travel unit Manufacturer Nabtesco Corporation Motor type Variable displacement piston motor Automatic 2-speed switchover with parking brake Intake amount 290.7 – 170.1 cm³/rev (17.740 – 10.380 in³/rev) Operating pressure 34.3 MPa (4975 psi) Operating flow 360.4 l/min (360.4000 US gpm) Brake torque...
  • Page 38 INTRODUCTION Shoe Applicability CX490C (LC), CX500C Weight or Quantity (LC) (MASS Excavator) 600 grouser 2581 kg (5690.131 lb) Link 1 set Shoe Bolt 750 grouser 2930 kg (6459.544 lb) Link 1 set Shoe Bolt Upper component Swing unit Swing motor assembly...
  • Page 39 INTRODUCTION Charging generator 24 V 50 A AC type Starter motor 24 V 5.5 kW (7.5 Hp) reduction type Coolant capacity 22.5 l (22.500 US gal) Max: 36 l (36.000 US gal)　Min: 25 l (25.000 US gal) (not including Oil pan capacity oil filter) Direction of rotation Right (viewed from fan side)
  • Page 40 INTRODUCTION Hydraulically-operated fan pump Manufacturer SHIMADZU CORPORATION Pump type Gear pump Displacement 40.6 cm³/rev (2.5 in³/rev) Allowable peak pressure 24.5 MPa (3553.73 psi) Maximum speed 2300 RPM 86.0 L/min (22.719 US gpm) at 22.5 MPa (3263.63 psi), 2300 RPM, Maximum discharge volume oil temperature of 40 °C (104 °F) Negative suction pressure -0.02 –...
  • Page 41 INTRODUCTION Control-related Control valve Manufacturer KYB Corporation Maximum flow 400 L/min (105.669 US gpm) (at 2000 RPM) 24.5 MPa (3554 psi) boom down Overload set pressure 36.3 MPa (5265 psi) other 31.4 MPa (4555 psi) Main relief set pressure (at boosting) 34.3 MPa (4975 psi) Foot relief set pressure 3.38 MPa (490 psi)
  • Page 42 INTRODUCTION 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.] Secondary pressure Independent operating torque (port 1) Independent operating torque (port 3) SMIL15CEXY883AB A.
  • Page 43 INTRODUCTION Port B Forward left Port C Backward right Port D Backward left Port T Drain port G1/2 Port P Pilot port G1/4 Weight 55.5 kg (122.357 lb) Backhoe attachment Cylinder Boom cylinder Cylinder bore ∅ 170 mm (6.693 in) Rod diameter ∅...

  • Page 44: Weight (*)

    INTRODUCTION Weight CX490C Crawler excavators STD version (TIER 3) - Turkish market APAC Divided weight ( LC Standard type) P73R4C-001 Code Part name Weight Operating weight 47600 kg (104940.037 lb) Upper component (including counterweight and 20900 kg (46076.613 lb) turntable bearing) Counterweight 9200 kg (20282.528 lb)
  • Page 45 INTRODUCTION NOTE: The bucket weight is not included. The weights shown here are approximate values. Stand alone part weight Part name Weight Travel unit (travel motor + drive sprocket) 792 kg (1746.061 lb) Take-up roller 263 kg (579.816 lb) Upper roller 42 kg (92.594 lb) Lower roller 82 kg (180.779 lb)

  • Page 46: Weight (*)

    INTRODUCTION Weight CX490C Crawler excavators LC version (TIER 3) - Turkish market APAC Divided weight ( LC Standard type) P73R4C-001 Code Part name Weight Operating weight 48500 kg (106924.197 lb) Upper component (including counterweight and 20900 kg (46076.613 lb) turntable bearing) Counterweight 9200 kg (20282.528 lb)
  • Page 47 INTRODUCTION NOTE: The bucket weight is not included. The weights shown here are approximate values. Stand alone part weight Part name Weight Travel unit (travel motor + drive sprocket) 792 kg (1746.061 lb) Take-up roller 263 kg (579.816 lb) Upper roller 42 kg (92.594 lb) Lower roller 82 kg (180.779 lb)

  • Page 48: Weight

    INTRODUCTION Weight CX500C Crawler excavator LC Mass excavator version (TIER 3) - Turkish APAC market Divided weight ( LC Standard type) P73R4C-001 Code Part name Weight Operating weight 49900 kg (110010.669 lb) Upper component (including counterweight and 21700 kg (47840.311 lb) turntable bearing) Counterweight 10020 kg (22090.319 lb)
  • Page 49 INTRODUCTION NOTE: The bucket weight is not included. The weights shown here are approximate values. Stand alone part weight Part name Weight Travel unit (travel motor + drive sprocket) 792 kg (1746.061 lb) Take-up roller 263 kg (579.816 lb) Upper roller 42 kg (92.594 lb) Lower roller 82 kg (180.779 lb)

  • Page 50: Dimension

    INTRODUCTION Dimension CX490C Crawler excavators STD version (TIER 3) - Turkish market APAC Standard arm [ 3.38 m (11.0892 ft)] NOTE: Numbers are subject to change without notice due to design change or other reason. The diagrams give values that include the shoe lug height “a” [ 36 mm (1.417 in)].
  • Page 51 INTRODUCTION Medium-short Arm [ 3.13 m (10.2690 ft)] NOTE: Numbers are subject to change without notice due to design change or other reason. The diagrams give values that include the shoe lug height “a” [ 36 mm (1.417 in)]. 36600B7D With catwalk - option 540 mm (21.260 in) 1570 mm (61.811 in)
  • Page 52 INTRODUCTION Short Arm [ 2.53 m (8.3005 ft)] NOTE: Numbers are subject to change without notice due to design change or other reason. The diagrams give values that include the shoe lug height “a” [ 36 mm (1.417 in)]. 14BB71E3 With catwalk - option 540 mm (21.260 in) 1570 mm (61.811 in)

  • Page 53: Dimension

    INTRODUCTION Dimension CX490C Crawler excavators LC version (TIER 3) - Turkish market APAC Standard arm [ 3.38 m (11.0892 ft)] NOTE: Numbers are subject to change without notice due to design change or other reason. The diagrams give values that include the shoe lug height “a” [ 36 mm (1.417 in)].
  • Page 54 INTRODUCTION Medium-short Arm [ 3.13 m (10.2690 ft)] NOTE: Numbers are subject to change without notice due to design change or other reason. The diagrams give values that include the shoe lug height “a” [ 36 mm (1.417 in)]. C918054B With catwalk - option 540 mm (21.260 in) 1570 mm (61.811 in)
  • Page 55 INTRODUCTION Short Arm [ 2.53 m (8.3005 ft)] NOTE: Numbers are subject to change without notice due to design change or other reason. The diagrams give values that include the shoe lug height “a” [ 36 mm (1.417 in)]. DFC9959E With catwalk - option 540 mm (21.260 in) 1570 mm (61.811 in)

  • Page 56: Dimension

    INTRODUCTION Dimension CX500C Crawler excavator LC Mass excavator version (TIER 3) - Turkish APAC market Short Arm [ 2.53 m (8.3005 ft)] NOTE: Numbers are subject to change without notice due to design change or other reason. The diagrams give values that include the shoe lug height “a” [ 36 mm (1.417 in)]. C2BC0153 With catwalk - option 540 mm (21.260 in)

  • Page 57: Conversion Factors

    INTRODUCTION Conversion factors Unit conversion rate - x → Gravitational unit SI unit ← ÷ - 9.807 4.448 kgf•cm 0.0981 N•m lbf•ft 1.356 N•m lbf•in 0.113 N•m kgf/cm 0.0981 0.1013 lbf/in 0.0069 mm Hg 133.3 in Hg 3386 kgf・m/s 0.00981 lbf•ft/s 0.00136 0.7355...
  • Page 58 INTRODUCTION Inches to millimeters 1/64 0.3969 17/64 6.7469 33/64 13.0969 49/64 19.4469 1/32 0.7938 9/32 7.1438 17/32 13.4938 25/32 19.8438 3/64 1.1906 19/64 7.5406 35/64 13.8906 51/64 20.2406 1/16 1.5875 5/16 7.9375 9/16 14.2875 13/16 20.6375 5/64 1.9844 21/64 8.3344 37/64 14.6844 53/64...
  • Page 59 INTRODUCTION Miles to kilometers miles miles 　 　 　 　 　 　 ---- 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 ---- 16.093 17.703 19.312 20.921 22.531 24.140 25.750 27.359 28.968 30.578 32.187 33.796 35.406 37.015 38.624 40.234 41.843 43.452 45.062 46.671...
  • Page 60 INTRODUCTION Square centimeters to square inches 　 　 　 　 　 　 ---- 　 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 ---- 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340...
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