INTRODUCTION
[10.001] Engine and crankcase
[10.102] Pan and covers
[10.106] V alve drive and gears
[10.101] Cylinder heads
[10.105] Connecting rods and pistons
Crankshaft and flywheel
Fuel injection system
Throttle linkage Fuel
and lines
Engine cooling system
Engine lubrication system Hydraulic systems
Hydraulic systems
[35.300] Reservoir , cooler , and filters
V ariable displacement pump
Main control valve
Hydraulic hand control
Hydraulic foot control
Hydraulic swing system
Hydraulic travel system
Hydraulic central joint
T rack frame widening system
[35.736] Boom hydraulic system
Dipper hydraulic system
Excavator and backhoe bucket hydraulic system
Swing arm hydraulic system
Dozer blade cylinders
Frames and ballasting
Upper frame
Swing ring assembly
Ballasts and supports
T racks and track suspension
T rack frame and driving wheels
T racks
T rack tension units
T rack rollers
Electrical systems
Electrical system
Harnesses and connectors
Engine starting system
Cold start aid
Alternator
Battery
Booms, dippers, and buckets
14] Boom pivoting support
Boom
Dipper arm
Bucket
Dozer blade and arm
[86.1 10] Dozer blade
[90.150] Cab . . . .
[90.1 14] Operator protections
[90.120] operator seat .
[90.105] Machine shields and guards
[90.1 16] Fenders and guards .
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed this manual must carried out only qualified dealership strictly complying with the instructions and whenever the special
Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall responsible for any subsequent
The manufacturer and all the organizations its distribution chain, including - without limitationnational, regional, local reject any responsibility for damages caused parts and / components not approved the facturer , including those used for the servicing repair the product manufactured marketed the manufacturer any case, warranty given attributed the product manufactured marketed the manufacturer case damages caused parts and / components not approved the manufacturer
The information this manual - - date the date the the policy the manufacturer for continuous Some information could not updated due modifications a technical commercial type, changes the laws and regulations dif ferent countries.
case refer your CASE
CONSTRUCTION Sales and Service
Safety rules
Personal safety
This the safety alert used alert you potential personal injury Obey all safety messages that follow this symbol avoid possible death injury
Throughout this manual you will find the signal words W and CAUTION followed special These precautions are intended for the personal safety you and those working with
Read and understand all the safety messages this manual before you operate service the
DANGER indicates a hazardous situation not will result death serious injury
W ARNING indicates a hazardous situation not could result death serious injury
CAUTION indicates a hazardous situation not could result minor moderate injury
F AILURE T O FOLLOW
Machine safety
NOTICE: Notice indicates a situation that, not avoided, could result machine property damage.
Throughout this manual you will find the signal word Notice followed special instructions prevent machine property damage. The word Notice used address practices not related personal safety .
Information
NOTE: Note indicates additional information that clarifies other information this
Throughout this manual you will find the word Note followed additional information about a step, other information the The word Note not intended address personal safety property
Personal safety
NOTICE: The proper and safe lubrication and maintenance for this recommended Manufacturer , are outlined the OPERA T OR’S MANUAL for the Improper performance lubrication maintenance procedures are dangerous and could result injury Read and understand the MANUAL before performing any lubrication
The serviceman mechanic may unfamiliar with many the systems this machine. This makes a careful use the systems very important when performing maintenance Sound knowledge the system and components important before the removal disassembly any
Because the size some the machine the serviceman mechanic should check the weights noted this Use proper lifting procedures when removing any W eight components table shown this
The following a list basic precautions that must always
Read and understand all W arning plates and decals the machine before Maintaining Repairing this
Always wear protective glasses and protective shoes when working around particular , wear tive glasses when using punches drifts any part the machine Use welders gloves, hood / goggles, apron and the protective clothing appropriate the welding job being performed. not wear loose fitting torn Remove all rings from loose jewellery , confine long hair and loose ing before working this machinery
Disconnect the battery and hang a tag the operator ’ s Remove starter key make all repairs with the machine parked a level and firm Block the machine does not roll while working under the machine. Hang a tag the operator ’ s seat. not work any machine that supported only jacks a Always use blocks stops for the jack before carrying out any disassembly operation.
NOTICE: not operate this machine unless you have read and understood all instructions contained this manual. Improper machine operation dangerous and could result injury
Relieve all pressure air , oil water systems before any lines, fittings related items are disconnected Always make sure all raised components are blocked correctly and alert for possible pressure when disconnecting any device from a system under
Lower the dozer other attachments the ground before performing any work the this cannot make sure the blade other attachment blocked correctly prevent from dropping unexpectedly .
Use steps and grab handles when mounting dismounting a Remove any debris mud from walkways work platforms before using Always face the machine when using ladders and When not possible use the designed access provide scaf platforms perform safe repair
T o avoid back injury , use a hoist when lifting components which weigh lb) Make sure all are good condition and are the correct capacity sure hooks are positioned correctly Lifting eyes are not side loaded during a lifting
T o avoid alert for hot parts and surfaces immediately after stopping the machine such hot fluids tubes and compartment
1 careful when removing cover Gradually back f the last two capscrews nuts located opposite ends the cover device and carefully pry the cover loose relieve any spring other before removing the last two capscrews nuts completely .
Be careful when removing filler breathers and plugs the Hold a rag over the cap plug prevent being sprayed splashed liquids under Danger even greater the machine has just been liquids might boiling
Always use the proper tools that are good condition and that are suited for the job sure you understand how use them before performing any service
Reinstall all clamps with the same spare part number not use clamps inferior quality replacement necessary .
Repairs which require welding should performed only with the benefit the appropriate reference tion and personnel adequately trained and skilled welding Determine the type metal being welded and select the correct welding procedure and rods wires provide a metal weld strength least equivalent that the parent Make sure disconnect the battery before any welding operation performed.
not damage wiring during removal
Reinstall the wiring not damaged nor will damaged operation the machine contacting sharp rubbing against some object hot not connect wiring a line containing sure all protective including guards and are properly installed and functioning correctly before starting a repair . a guard shield must removed perform the repair work, use extra caution and replace the guard shield after repair
18. Performing maintenance and repair operations while the bucket lifted dangerous, because there the sibility a device not fail lower such device and place the bucket the ground before starting the
Loose dirty lubrication and hydraulic pipes and hoses may cause not bend strike high - pressure not install bent damaged Inspect tubes and hoses carefully not check for leaks with your hands. V ery small (pinhole) leaks can result a high velocity oil jet that will invisible close the
This oil can penetrate the skin and cause personal injury Use card - board paper locate pinhole T ighten connections the correct Make sure that all protections against the clamps and the ator ’ s protective devices are correctly installed order prevent excessive vibrations rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components event a tube seal failure must installed correctly
not operate a machine any rotating part damaged contacts any other part during Any high speed rotating component that has been damaged altered should checked for balance before careful when servicing separating the Chips can fly when removing installing a track W ear safety glasses and long sleeve protective T racks can unroll very quickly when Keep away from front and rear The machine can move unexpectedly when both tracks (crawlers) are disengaged from the Block the machine prevent from
Part identification
TULI12E1B0042GB
SER VICE MANUAL
CX15B CX18B
Engine - General specification
Model
L3E - 31KBSA
T ypeline, water cooled, 4 - cycle diesel engine
Number 3
Combustion type
V alve mechanism
Swirl chamber type
Overhead valve type
Cylinder bore x stroke ( 2.99 ) x ( 2.76 )
T otal displacement
Main data Dry weight ( )
0.952 l ( 0.25 gal )
Compression ratio 23: 1
Fuel Diesel oil (EN590)
Order ignition 1 - 3 - 2
Rotating direction
Piston ring Number
Main components
V alve timing (when warm)
Starting system
Intake valve
Exhaust valve
Counterclockwise viewed from flywheel side
Compression ring: 2
Oil rings (with expander): 1
Open BTDC 18°
Close ABDC 46°
Open BBDC 46°
Close A TDC 18°
Centrifugal mass start T ype Bosch Manufacturer DENSO CORPORA TION
Fuel injection pump Cam lift 6 ( 0.24 )
Fuel system
Piston diameter ø 5.5 ( 0.22 )
Governor Speed governing type
Centrifugal weight system T ype Nozzle Manufacturer DENSO CORPORA TION
Spray angle 15° Fuel injection nozzle
V alve opening pressure MPa ( psi )
Fuel filter T ype
Paper filter element T ype
Solenoid fuel pump (compact type)
Fuel pump Discharge rate l ( 1 gal ) / min higher (at V - A )
Engine Model
Specification Class above oil (API service classification)
Engine - Service instruction
Break - operation
After the engine couple the engine the dynamometer , and run the engine for break - operation and
Starting
Before starting the engine, check the level coolant, gine oil and
Bleed air from the fuel system and cooling
Stop fuel supply and start the engine with the starter motor for about s lubricate the
Move the control lever slightly the fuel increase direction (but not the and then turn the starter switch key the “ST position start the
After the engine adjust the control lever let the engine operate a minimum - load speed (low idle speed).
T urn the starter switch key the “OFF” position and make sure that the engine
Inspecting engine condition after starting
During the break - check the any abnormality stop the investigate the cause, and take appropriate
The oil pressure must within the specified
The coolant temperature must within the specified
The engine must free from any leakages such oil, coolant and Pay special attention oil leakage from the fitting face turbocharger lube oil
Check for abnormal
NOTE: Knocking noise will disappear the coolant perature rises.
Check for the colour smoke and odours.
Break - operation time
The relationship between the load break - operation and the operation time shown below
NOTICE: The table above provided solely for reference Run the engine appropriate speed and load for the break - operation your sure perform break - operation after overhaul installation.
Inspection and adjustment after break - operation
V alve clearance
Ignition timing
Exterior bolt and nut tightness
Performance test (standard jis)
The following describes the procedures specified moving machinery - Engines - Part T est code net power ( JIS D0006 - 1 and moving machinery - Engines - Part Standard format specifications and testing methods diesel engines ( JIS D0006 - 2 )”.
Other test items may required some applications. All test results should evaluated comprehensively order determine the engine
Engine equipment condition
The engine must equipped with standard auxiliary vices such cooling air cleaner and alternator
T est items and purposes
Operation load test
Conduct this test evaluate the engine fuel consumption rate and governor performance under various load
Continuous load test
Operate the engine continuously for h 90% load (continuous load application) nominal net brake power while the engine speed maintained revolutions ing the nominal brake power this evaluate the fuel consumption rate and operating condition, and confirm that the engine capable continuous
Low idle test
Conduct this test confirm that the engine can operate stably the specified low idle
Other inspections
Check for coolant oil anomalousodours and Make adjustment
Engine output adjustment
Diesel engine output fected atmospheric temperature and humidity correction calculations must performed obtain the value engine put under the standard atmospheric
Standard atmospheric conditions:
Base temperature: ( )
T otal pressure: 100 kPa ( psi )
Dry pressure: kPa ( psi )
Calculation corrected power
Multiply the measured braking power braking torque value for the diesel engine correction coef the applicable range the correction formula ceeded, indicate the corrected values and record the test conditions the test
Calculation output = Correction factor c ) x measured brake power
Atmospheric conditions during test
T emperature (Τ): ( ) ≤ (Τ) ( 104 ) )
Dry atmospheric pressure d kPa ( psi ) ≤ d ) ≤ 1 kPa ( psi )
α c =(f a ) f m f a :atmospheric factor f m : engine factor
Range correction equation use
The range correction factor c ) follows: ≤ α c ≤
Calculation correction factor a ) Calculation engine factor m )
Natural aspiration engine and engine with mechanically driven air charger f m = 0.036 q c1.14 q c : corrected fuel supply volume q
f a = (99 / P d ) • / 298) 0 7 q c = r (z) x (Fuel flow rate g /
T urbocharged engine without air cooler with air - - air cooler q = (Stroke volume x (Engine speed RPM)
f a = (99 / P d ) 0 7 • / 298) 1 2
120000 - cycle engine) ratio between turbocharger pressure air cooling outlet and atmospheric pressure (r=1 for natural suction engine)
T urbocharged engine with air - - liquid cooler Applicable range engine factor m ) ≤ q c : ≤ ( 0.023 ) / x cycle)
f a = (99 / P d ) 0 7 • / 298) 0 7 q c ≤ ( ) / x cycle): f m = (constant) ( 0.023 ) / x cycle) ≤ q c : f m = (constant)
Engine - Adjust
Inspection and adjustment valve clearance
Preparation for valve clearance adjustment
Inspect and adjust the valve clearance when the engine cold.
Slightly loosen the cylinder head screws main screw) and secondary screws) and tighten them the ified torque the order shown the figure (following the
NOTE: careful that the tightening torque cylinder head bolts different between main bolts and sub
Screws (1) = tightening torque - N·m (61.5 )
Screws (2) = tightening torque 19.629.4 ( 14.5)
V alve clearance check
Set cylinder 1 the top dead center sion
This position where the TDC mark (M2) the shaft pulley aligns with the mark the gear case (M1)
NOTE: The compression top where the rocker arm does not move when the crankshaft rotated the forward and backward direction both 20° approximately the rocker arm the top dead center exhaust
Rotate the crankshaft another full turn set the 1 cylinder the top dead center compression Order ignition: 1 - 3 - 2 T urning angle: 240°
Start adjusting the valve clearance from the 1 der and adjust the valve clearance other cylinders according the ignition order .
NOTE: T o set the next cylinder the compression top after adjustment 1 cylinder , rotate the crankshaft the forward direction (clockwise toward the timing gear case) the angle corresponding the number
Insert a thickness gauge between the rocker arm and bridge T urn the adjusting screw while ing the and adjust the clearance that the thickness gauge can move with slight stif
After tighten the lock nut firmly check the clearance again.
Inspecting fuel injection timing
NOTICE: T o prevent the outflow stop the fuel supply before removing the delivery
The fuel injection timing varies with the speed and other engine sure check the s specification
Remove the 1 fuel injection
Remove the 1 delivery valve the fuel injection and install the holder
Remove the cover
Remove the clip (1) and disconnect the rod (2) from the control crosspiece (3)
Place the control crosspiece (3) medium position with respect the operating
Feed fuel from the fuel hose and check that the fuel flows out from the delivery holder
Rotate the crankshaft forward (clockwise). The fuel jection timing the moment when the fuel stops flowing from the delivery valve holder
TULI12EXN3514AA
TULI12EXN3515AB
Adjusting fuel injection timing
Check that the fuel injection timing (T) meets the ified fuel injection timing the position where the jection timing mark (M2) the crank pulley aligned with the mark (M1) the gear
the fuel injection timing does not meet the specified value, increase decrease the thickness the fuel injection pump adjusting shim adjust the
NOTE: A change thickness the shim ( 0.004 ) results a change the fuel injection timing approximately 1°.
There are nine kinds shims from 0.21.0 ( 0.010.04 ) .
Adjusting value
With the delivery valve check the fuel ejection timing follows:
Remove the tie rod cover and disconnect the tie rod from the control
Set the control rack the medium position the erating range and then remove the 1 fuel injection pipe the nozzle side.
When the crankshaft gradually fuel begins swell the tip the This timing the fuel injection timing. this case, the timing delayed compared the normal fuel injection
Standard value ± 1.5°
TULI12EXN3516AB 6
TULI12EXN3517AA 7
RPM check and adjustment
NOTICE: The minimum - load speed (low idle speed) and the maximum - load speed (high idle speed) each gine have been checked test bench and then their ting bolts have been sealed the factory Only the service shops designated Mitsubishi are authorized perform checking and adjusting these sure seal all the external stoppers the same ner they were sealed the factory adjustments have been made the governor
Whether the seals are intact not has important effect the validity claims under warranty sure seal all the specified
When inspecting and adjusting the governor , prepared operate the engine stop lever manually anticipation engine
Adjust speed after engine preheating (coolant temperature ( 140 ) higher).
T o adjust the engine remove the cooling fan and pay attention the rotating
During engine operation for speed check for leakages water , oil and
Adjust the high idling speed with the high - speed set bolt (2)
. Note that the high - speed set bolt (2) sealed the factory before not make adjustment unless absolutely necessary not remove the torque spring set from the front plate unless necessary
Adjust the engine low idling speed with the low idle set bolt (1)
not remove the sealing cap adjust the torque spring
After perform acceleration and ation test check for hunting and smoke condition.
NOTE: If there is no response to click on the link above, please download the PDF document first and then clickonit.
Bleeding fuel system
NOTICE: Completely wipe off any spilled fuel from air vent screws with a cloth the spilled fuel can cause a fire.
Bleeding the fuel system must carried out closest the fuel tank: bleed the fuel filter then the injection
Air bleeding from fuel filter
Deliver fuel solenoid pump.
Place the cock the fuel filter the “OPEN” position
Press (P) and hold the button until the filter body cup (1) filled with fuel.
Stop the fuel supply .
Air bleeding from water separator
Loosen the water separator ’ s bleed plug for fuel supply (1)
Deliver fuel solenoid
T ighten air bleed plug for fuel inlet when the fuel flow from the air bleed plug becomes free
Loosen air bleed plug for fuel outlet (2)
T ighten air bleed plug for fuel outlet when the fuel flow from the air bleed plug becomes free bubbles.
Stop the fuel supply .
TULI12EXN3520AB
Belt tension adjustment
Loosen the adjusting screw (4) and the screw (6) Loop the belt (7) around the water pump pulley (2) , the nator pulley (5) and the crankshaft pulley (1) .
Adjust the adjusting screw (4) that the belt (7) sion meets the specified
Belt deflection (with push force approximatelyN·m ( - )
Approximately ( 0.39 )
TULI12EXN3521AB
1
Engine - Remove
Remove the side guard and the engine
Remove the battery
Remove the counterweight.
Remove the air filter .
Remove the exhaust gas muf fler
Remove the radiator
Remove the pump disconnect the hoses connected the
Disconnect the hoses the fuel
Disconnect any hose connected the engine.
10. Disconnect the cable the starter motor1).
Disconnect the connector from the generator -
Disconnect the terminals for the water temperature sensor (SW - and oil pressure switch (SW -
Disconnect the terminal the glow plugs -
Disconnect the terminal the ground cable -
15. Loosen and remove the nuts (1) with the relevant washers (2) fastening the engine (5) the rubber ports (3) and (4)
Pass a steel wire rope through the two lifting located the top the engine and lift the Engine weight: approximately ( 157 )
Engine - Install
Install the engine reverse order the T ightening torque nuts (1) = ( )
TULI12EXN2577BB 1
