Case CX490C Service Manual Download

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Contents

INTRODUCTION

Engine....................................................................................... 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

[10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

Hydraulic systems....................................................................... 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1

[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

[35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

[35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

48098399 20/01/2017

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Summary of Contents for CX490C

Page 2: ...vators 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 EN Find...

Page 3: ...aust manifolds and muffler 10 11 10 501 Exhaust Gas Recirculation EGR exhaust treatment 10 12 10 400 Engine cooling system 10 13 10 414 Fan and drive 10 14 10 310 Aftercooler 10 15 10 304 Engine lubri...

Page 4: ...raulic system 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 Track tension units 4...

Page 5: ...ls 55 17 55 050 Heating Ventilation and Air Conditioning HVAC control system 55 18 55 416 Swing control system 55 19 55 417 Travel control system 55 20 55 530 Camera 55 21 55 518 Wiper and washer syst...

Page 6: ...90 120 Mechanically adjusted operator seat 90 3 90 100 Engine hood and panels 90 4 48098399 20 01 2017 Find manuals at https best manuals com...

Page 7: ...48098399 20 01 2017 Find manuals at https best manuals com...

Page 8: ...INTRODUCTION 48098399 20 01 2017 1 Find manuals at https best manuals com...

Page 9: ...setting 11 Basic instructions Shop and assembly 15 Hydraulic contamination 17 General specification 18 General specification 22 General specification 26 General specification Main equipment 30 Weight...

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: ...or modifications that reduce the functionality of the anchoring part at the left rear of the cab Modifications that effect the strength of the cab with a protective structure Modifications prohibited...

Page 16: ...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 17: ...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 18: ...108 N m 65 80 lb ft 16 Hydraulic pump Pump M20 17 mm hexagon socket head 367 496 N m 270 69 365 83 lb ft 17 Hydraulic tank M16 24 mm 225 6 264 8 N m 166 195 lb ft 18 Fuel tank M16 24 mm 232 4 276 N m...

Page 19: ...INTRODUCTION B2AB1DF6 1 48098399 20 01 2017 12...

Page 20: ...INTRODUCTION YYSJMI 002 2 48098399 20 01 2017 13...

Page 21: ...INTRODUCTION YYSJMI 006 3 48098399 20 01 2017 14...

Page 22: ...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 23: ...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 24: ...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 25: ...ar pump Max oil flow 30 L min 7 925 US gpm Working circuit pressure 3 9 MPa 565 7 psi Control valves With Boom Arm holding valve One 4 spool valve for Right track travel Bucket Boom and Arm accelerati...

Page 26: ...ne touch idle Auto deceleration Auto idle shutdown system Emergency stop Monitor system Message display Caution condition etc Work mode display SP H Auto Machine condition Power boost etc Alarm displa...

Page 27: ...pull 340 kN 76435 041 lb Number of carrier rollers each side 2 Number of carrier rollers each side 8 Number of shoes each side 47 Type of shoe Triple grouser shoe Link pitch 228 6 mm 9 000 in Width o...

Page 28: ...540 mm 21 260 in 540 mm 21 260 in 540 mm 21 260 in Wheel base Center to center of wheels 4040 mm 159 055 in 4040 mm 159 055 in 4040 mm 159 055 in Crawler overall length 5100 mm 200 787 in 5100 mm 200...

Page 29: ...ax oil flow 30 L min 7 925 US gpm Working circuit pressure 3 9 MPa 565 7 psi Control valves With Boom Arm holding valve One 4 spool valve for Right track travel Bucket Boom and Arm acceleration One 5...

Page 30: ...ne touch idle Auto deceleration Auto idle shutdown system Emergency stop Monitor system Message display Caution condition etc Work mode display SP H Auto Machine condition Power boost etc Alarm displa...

Page 31: ...g Travel speeds Low 3 2 km h 1 988 mph Drawbar pull 339 kN 76210 232 lb Number of carrier rollers each side 2 Number of carrier rollers each side 9 Number of shoes each side 50 Type of shoe Triple gro...

Page 32: ...0 mm 52 362 in Minimum ground clearance 540 mm 21 260 in 540 mm 21 260 in 540 mm 21 260 in Wheel base Center to center of wheels 4400 mm 173 228 in 4400 mm 173 228 in 4400 mm 173 228 in Crawler overal...

Page 33: ...r pump Max oil flow 30 L min 7 925 US gpm Working circuit pressure 3 9 MPa 565 7 psi Control valves With Boom Arm holding valve One 4 spool valve for Right track travel Bucket Boom and Arm acceleratio...

Page 34: ...control Dial type throttle control One touch idle Auto deceleration Auto idle shutdown system Emergency stop Monitor system Message display Caution condition etc Work mode display SP H Auto Machine c...

Page 35: ...ed shifting Travel speeds Low 3 2 km h 1 988 mph Drawbar pull 339 kN 76210 232 lb Number of carrier rollers each side 2 Number of carrier rollers each side 9 Number of shoes each side 50 Type of shoe...

Page 36: ...mm 52 362 in Minimum ground clearance 540 mm 21 260 in 540 mm 21 260 in 540 mm 21 260 in Wheel base Center to center of wheels 4400 mm 173 228 in 4400 mm 173 228 in 4400 mm 173 228 in Crawler overall...

Page 37: ...on gear Reduction ratio 60 652 Dry weight 613 kg 1351 434 lb Take up roller Weight 262 9 kg 579 5953 lb Upper roller Weight 42 1 kg 92 8146 lb Lower roller Weight 82 3 kg 181 4404 lb Recoil spring Ite...

Page 38: ...age reduction gear Dry weight 537 kg 1183 882 lb Turntable bearing No of teeth 92 Weight 656 kg 1446 232 lb Counterweight Weight CX500C LC MASS Excavator 10000 kg 22046 226 lb Weight CX490C CX490C LC...

Page 39: ...lic pump Manufacturer Kawasaki Heavy Industries Ltd Main pump Pump type Double variable displacement piston pump Displacement capacity 200 cm rev 12 205 in rev x 2 Rated 31 4 MPa 4555 psi Operating pr...

Page 40: ...MATSU ZENOAH LTD Absorption amount 40 0 cm rev 2 4 in rev Allowable peak pressure 31 9 MPa 4627 10 psi Normal operation pressure 2 0 MPa 290 10 psi or less T port pressure Peak pressure 4 4 MPa 638 22...

Page 41: ...k 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 G...

Page 42: ...Travel remote control valve control diagram A Secondary pressure MPa psi B Push rod stroke mm in C Pedal operating angle deg 1 Secondary pressure 2 Operating torque SMIL15CEXY885AB 3 Cushion valve he...

Page 43: ...n Maximum retracted length 2230 mm 87 795 in Stroke 1550 mm 61 024 in Weight 400 kg 881 8490 lb Arm cylinder Cylinder bore 200 mm 7 874 in Rod diameter 140 mm 5 512 in Maximum retracted length 2588 mm...

Page 44: ...7 lb B Upper component including counterweight and turntable bearing 20900 kg 46076 613 lb C Counterweight 9200 kg 20282 528 lb D Lower component with grouser shoe 16190 kg 35692 840 lb E Main unit we...

Page 45: ...Center joint 56 kg 123 459 lb 14 Boom 3570 kg 7870 503 lb Shoe weight per side Part name Weight 1 600 mm 23 62 in grouser shoe 2427 kg 5350 619 lb 2 750 mm 29 53 in grouser shoe 2754 kg 6071 531 lb Ar...

Page 46: ...7 lb B Upper component including counterweight and turntable bearing 20900 kg 46076 613 lb C Counterweight 9200 kg 20282 528 lb D Lower component with grouser shoe 16970 kg 37412 446 lb E Main unit we...

Page 47: ...lb 13 Center joint 56 kg 123 459 lb 14 Boom 3570 kg 7870 503 lb Shoe weight per side Part name Weight 1 600 mm 23 62 in grouser shoe 2581 kg 5690 131 lb 2 750 mm 29 53 in grouser shoe 2930 kg 6459 544...

Page 48: ...010 669 lb B Upper component including counterweight and turntable bearing 21700 kg 47840 311 lb C Counterweight 10020 kg 22090 319 lb D Lower component with grouser shoe 16970 kg 37412 446 lb E Main...

Page 49: ...6 kg 1446 232 lb 7 Engine 873 kg 1924 636 lb 8 Radiator 291 kg 641 545 lb 9 Hydraulic pump 230 kg 507 063 lb 10 Fuel tank 337 kg 742 958 lb 11 Hydraulic oil tank 226 kg 498 245 lb 12 Control valve 424...

Page 50: ...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 F8877C5D 1 b With catwalk o...

Page 51: ...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 2 b With catwalk option e 540 mm 21 260 in c 1570 mm 6...

Page 52: ...hange 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 3 b With catwalk option e 540 mm 21 260 in c 1570 mm 61 81...

Page 53: ...1 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 6948EAB3 1 b With catwalk op...

Page 54: ...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 2 b With catwalk option e 540 mm 21 260 in c 1570 mm 6...

Page 55: ...hange 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 3 b With catwalk option e 540 mm 21 260 in c 1570 mm 61 81...

Page 56: ...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 1 b With catwa...

Page 57: ...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 58: ...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 59: ...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 60: ...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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