SERVICE MANUAL Crawler Excavator CX180C Part number 48139070 English April 2017 © 2017 CNH Industrial Italia S.p.A. All Rights Reserved.
SER VICE MANUAL
48139070 19/04/2017
CX180C Crawler excavator version (TIER
Contents INTRODUCTION Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] V alve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Crankshaft and flywheel Fuel tanks Fuel filters [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.250] T urbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 1 Intake and exhaust manifolds and muf fler Exhaust Gas Recirculation (EGR) exhaust treatment Engine cooling system Fan and drive Aftercooler [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 Oil cooler and lines Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic systems Reservoir , cooler , and filters Fixed displacement pump V ariable displacement pump Pump control valves [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 48139070 19/04/2017
Hydraulic hand control Hydraulic foot control Hydraulic swing system
travel system
central joint
hydraulic system
hydraulic system
Excavator and backhoe bucket hydraulic system
Hammer and rotating bucket hydraulic system
Frames and ballasting
Ballasts and supports T racks and track suspension
T rack frame and driving wheels
T racks
T rack tension units
T rack rollers
Cab climate control
Pilot system
1 Hydraulic
[35.736] Boom
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 [35.737]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.16
Hydraulic
Dipper
[35.738]
[35.360]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.015] Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.302] Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 48139070 19/04/2017
Heating Air conditioning
Cold start aid Fuel injection system Engine intake and exhaust system Exhaust Gas Recirculation (EGR) electrical system 1 Engine cooling system Engine oil system [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.512] Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 Hydraulic system control [55.051] Cab Heating, V entilation, and (HV AC) controls . . . . . . . . . . . . . . . . . 55.17 [55.050] Heating, V entilation, and Air-Conditioning (HV AC) control system . . . . . . . . . . . . . . . 55.18 [55.416] Swing control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.19 [55.417] T ravel control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.20 Camera [55.518] Wiper and washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.22 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.23 Cab lighting W arning and instruments system F AUL T CODES Booms, dippers, and buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Dipper arm Bucket cab, and decals [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.156] Cab windshield and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.120] operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 48139070 19/04/2017
Engine hood and panels 48139070 19/04/2017
INTRODUCTION 48139070 19/04/2017 1
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 manufacturer reserves the right make improvements design and changes specifications any time without notice and without incurring any obligation install them units previously and illustrative material herein are accurate known time publication but are subject change without notice.
case refer your CASE
CONSTRUCTION Sales and Service
INTRODUCTION
48139070 19/04/2017 3
INTRODUCTION
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 DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .
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
48139070 19/04/2017 4
Safety rules - General information
Cleaning
Clean the metal parts with cleaning solution that meets the standard and steam (except for bearings)
After cleaning, dry well, and inject oil all parts.
Also inject oil into the bearings after
Inspection
When disassembling check all the there are any worn damaged replace Inspect carefully prevent initial
Bearing
Replace any loose
Air dry bearings before installing
Needle bearing
When inserting needle very careful not damage
Apply grease the section where the needle bearing will
Gear
Check that there wear and Oil seal, Oring, gasket
Always install new oil O - and
Apply grease sections where oil seals and O - rings will
Shaft
Check that there wear and
Check the bearings and check for damaged oil seals the shaft.
Service parts
Install CASE CONSTRUCTION genuine service parts.
When placing order , check the parts contains the CASE CONSTRUCTION genuine part
Any breakdowns arising from the installation non - genuine parts are not covered the warranty
Lubricants (fuel, hydraulic oil)
Use the oil from the specified company specified the manual service
Any breakdowns arising from any fuel hydraulic oil other than those specified are not covered the warranty
INTRODUCTION
48139070 19/04/2017 5
SER VICE MANUAL Engine
48139070 19/04/2017
CX180C Crawler excavator version (TIER
Engine - Engine and crankcase
Engine - General specification
Engine main specifications
Item Engine model 4JJ1 T ype Diesel / 4 - cycle / W ater Inline 4 - cylinder DOHC Shape combustion chamber Direct injection type Cylinder liner type liner Cylinder bore x stroke ( ) x ( ) Displacement 2.999 l ( 183 in³ ) Compression ratio Compression pressure 3 MPa ( 435 psi ) 200 RPM Idling rotation speed 800 RPM Intake 0.15 ( 0.006 ) while cool V alve clearance Exhaust 0.15 ( 0.006 ) while cool Ignition method Compression ignition Injection order 2 Lubricant system Lubricating type Pressure type Oil pump type Gear type Lubrication oil amount l ( 4 gal ) Oil filter type Full - flow filter (cartridge type) Oil cooling type Builttype, water cooled Cooling system Cooling type W ater cooling W ater pump type belt type Thermostat type W type unit 76.5 ( 169.70 ) without jiggle valve Open valve temperature the thermostat valve ( 179.6 ) with jiggle valve Coolant container 6 l ( gal ) engine only Fuel system Injection pump type Electronic control common rail type Governor type Electronic type T imer type Electronic type Multi - hole type Injection nozzle type 6 holes Charging system Generator type type Output V / A Regulator type Starting system Starter type Reduction type Output V / ( ) Preheat system Preheat system type Glow plug Glow plug standard voltage / current V / A 48139070 19/04/2017 10.1 [10.001] / 3
Engine - Engine and crankcase
main specifications Item Specifications W ater pump Centrifugal impeller method Pulley ratio Thermostat W type unit 76.5 ( 169.7 ) without jiggle valve Open valve temperature ( ) with jiggle valve ( ) without jiggle valve Full - open temperature ( 203.0 ) with jiggle valve Electrical system main specifications Generator Item Specifications Isuzu parts number 8980921 122 Nominal output V / A Rated rotation count 5000 RPM Regulator type type Regulated voltage – V W eight 9.1 ( 20.1 ) Starter T ype (Manufacturer) Hitachi V oltage V Output 4 Rating T ime s Number pinion teeth 1 1 Rotational direction (facing the pinion) Right W eight 6.3 ( 13.9 ) Current / voltage Less than 120 A / V - load characteristics Revolution speed More than 3500 RPM Current / voltage Less than 250 A / 18.6 V T orque More than 13.2 N·m ( 9.7 ) Load characteristics Revolution speed More than 1590 RPM Current / voltage Less than 1 100 A / V Locking characteristics T orque More than N·m ( ) Glow plug Item T ype Preheat device model Glow plug Glow plug rated voltage / current V / 3.8 A 48139070 19/04/2017 10.1 [10.001] / 4
Cleaning system
Engine - Engine and crankcase
Engine - Identification
Engine number
SMIL14CEX4762FB
1
stamping 48139070 19/04/2017 10.1 [10.001] / 5
Engine number stamping Engine model
Engine - Static description
Engine electronic control
The control provided the control unit applies the range from injection air intake and exhaust including fuel injection injection air intake EGR and idling
Cylinder block
The cylinder block made cast and has the equal center distance for each bore and a high rigidity , and the center the crankshaft matches the center the
Piston
The piston a strut cast thermal flow piston made aluminum alloy , and the combustion chamber the round reentrant
Cylinder head
The cylinder head made cast and has four valves per each cylinder
The angle tightening method has been adopted the cylinder head bolt further improve its reliability and durability
Crankshaft
The crankshaft not polished for has TUFFTRIDE treatment a problem replace with a new
EGR system
The EGR system controlled the engine control module (ECM) according various data including the water temperature, engine RPM, and engine load recirculate the exhaust gas for purification.
The primary components are the EGR EGR cooler , and various
Connecting rod cap bolt
The angle tightening method has been adopted the connecting rod cap bolt further improve its reliability and durability .
Common rail type electronic control injection system
The common rail type electronic control injection system consists the supply pump that sets the target pressure high - pressure fuel supply the the common rail that measures the high - pressure fuel and the fuel injector that injects the fuel the form a fine Each these are controlled the ECM based various signals control the injection timing and injection amount accordance with the driving
Fuel injector
The fuel injector has adopted the 8 - hole and adjusts the fuel injection amount and injection timing opening closing the electromagnetic valve the injector head
The ECM corrects variation the fuel injection amount from fuel injector fuel injector accordance with the code data the memory When adjusting the fuel injector , the code data must recorded the
Fuel filter with sedimenter
The fuel filter with sedimenter removes the water using the dif ference the relative density between diesel oil and water , and notifies the operator through the indicator when becomes full water .
Engine - Engine and crankcase
48139070
10.1 [10.001] / 6
19/04/2017
Preheat system
The preheat system consists the ECM, glow relay , glow plug and glow indicator light. The preheat system vated when the engine coolant temperature low help engine
Lubricating system
uses and oil filter with a full - flow and cools down the pistons using the water - cooled oil cooler and the oil
Engine - Engine and crankcase
48139070 19/04/2017 10.1 [10.001] / 7
Engine - Prepare W ARNING
Escaping fluid!
Hydraulic fluid diesel fuel leaking under pressure can penetrate the skin and cause infection other injury . T o prevent personal injury: Relieve all pressure before disconnecting fluid lines forming work the hydraulic Before applying make sure all connections are tight and all components are good condition. Never use your hand check for suspected leaks under Use a piece cardboard wood for this injured leaking see your doctor immediately .
Failure comply could result death serious injury .
W ARNING
A void injury!
W0178A
Shut off the engine, remove the key , and make sure all motion stopped before servicing the machine. Failure comply could result death serious injury
128A
W ARNING
Crushing hazard!
The lifting systems must operated qualified personnel who are aware the correct procedures follow . Make sure all lifting equipment good condition, and all hooks are equipped with safety latches.
Failure comply could result death serious injury
W ARNING
Heavy objects!
W0256A
Lift and handle all heavy components using lifting equipment with adequate capacity Always support units parts with suitable slings hooks. Make sure the work area clear all bystanders.
Failure comply could result death serious injury .
W ARNING
Explosion hazard!
W0398A
Batteries emit explosive gases. Always ventilate when using enclosed area when charging. Keep the battery away from open and other ignition
Failure comply could result death serious injury .
NOTICE: Keep away from
W0369A
NOTICE: The air conditioner circuit filled with high pressure gas may spray out dangerously when loosening lines.
Engine - Engine and crankcase
48139070 19/04/2017 10.1 [10.001] / 8
Engine - Engine and crankcase
Items prepare:
• W renches [ 7 , , , , , ]
• Box wrench [ ]
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Lifting equipment (with the required lifting capacity)
• Pliers
• Marking pen
• Cap
• Plug
• W aste oil can
• Rag
• Cleaning fluid
• W ood
48139070 19/04/2017 10.1 [10.001] / 9
Engine - Remove
T urn the battery disconnect switch the "OFF" position disconnect the negative terminal the battery .
• After removing the terminal and fasten them that they not interfere with the frame and other cover with a rubber cap protect against sparks.
Remove the
For see Counterweight - Remove (39.140)
Remove the muf fler
For details, see Exhaust muffler - Remove (10.254) . Remove the pump.
For see Pump - Remove
Use a wrench [ ] remove the bolt (1) , use a wrench [ 7 ] loosen the hose bands (2) and (3) , and then disconnect the intercooler hose (highature side) (4) and hose (5) from the air cleaner
T ightening torque for band (2) installation: –9.8 ( 6.49 –7.23 )
T ightening torque for band (3) installation: –
7.3 N·m ( 4.65 –5.38 )
Loosen the hose bands (1) , and then remove the cooler hose (low - pressure side) (2)
T ightening torque for hose band (2) installation: 8.8 –9.8 ( 6.49 –7.23 )
Engine - Engine and crankcase
LPIL12CX00142AB 1
LPIL12CX00143AB 2 48139070 19/04/2017 10.1 [10.001] /
Use a wrench remove the bolts (1) , (2) , and then remove the fan shroud (3)
Use a wrench remove the bolts (1) , and then remove the fan guard (2)
Engine - Engine and crankcase
LPIL12CX00144BB 3
LPIL12CX00145AB 4 48139070 19/04/2017 10.1 [10.001] / 1 1
Use a wrench [ 7 ] loosen the radiator hose bands (1) 2 and then remove the upper hose (2) and lower hose (3) .
• Use caps cover the radiator and hoses prevent any entry water , dust
• Before removing the radiator completely drain the
T ightening torque for band (1) installation: 4.9 –N·m ( – )
Use a wrench [ ] remove the 2 bolts (1) , and then remove the connector brackets (2)
1 Use a wrench [ ] remove the hose bands (1) 2 locations from the and then remove the 5 connectors (2)
• W rap the removed connectors plastic after tying them together
T ightening torque for bolt installation: 21.6 –
37.2 ( 15.93 –27.44 )
Engine - Engine and crankcase
LPIL12CX00146BB 5
6
LPIL12CX00147AB
7 48139070 19/04/2017 10.1 [10.001] /
LPIL12CX00148AB
12. Disconnect the connectors (1) from the air - conditioner compressor
13. Use a wrench [ ] remove the bolt (1) , and then remove the terminal cap (2)
Use a wrench remove the wirings (3) and (4) from the starter
Use a wrench [ ] remove the bolt (5) , and then remove the wiring (6) from the
Use a wrench [ ] remove the bolt (1) Disconnect the connector (2) from the alternator
Use a wrench remove the wiring (3) from the nator .
Use a wrench [ ] loosen the 2 line bolts (1) the and then remove the lines (2) and (3) from the compressor
• Always remove the low - pressure (suction side) line (2)
• Install caps plugs the compressor and lines prevent any entry water , dust
T ightening torque for bolt (1) installation: –N·m ( 14.75 –18.44 )
Engine
crankcase
Engine -
and
LPIL12CX00149AB 8
LPIL12CX00150AB 9
LPIL12CX00151AB
LPIL12CX00152AB 1 1 48139070 19/04/2017 10.1 [10.001] /
Engine - Engine and crankcase
16. Loosen the 2 hose bands (1) , and then remove the heater hoses (2) , (3)
• Install caps plugs the engine and hoses prevent any entry water , dust dirt.
Prepare the waste oil can (1)
• Drain the engine oil before removing the engine oil
Use a wrench [ ] disconnect the 2 engine oil remote hoses (1) .
• Mark the engine and hoses that the connectors match the time assembly .
• Install caps plugs the engine and hoses vent any entry water , dust
• Clean the engine and hoses spraying them with a parts cleaner prevent scratches and prevent dirt from accumulating the connectors.
T ightening torque for installation: – N·m ( 39.90 –47.13 )
LPIL12CX00153BB
48139070 19/04/2017 10.1 [10.001] /
LPIL12CX00154BB
18. Remove the hose bands (1) , and then disconnect the fuel hoses (2)
• Install caps plugs the engine and hoses prevent any entry water , dust dirt.
19. Install the 2 shackles (1) , and then use the wire ropes (2) and liftcrane fasten the engine main
Use a box wrench [ ] remove the 4 bolts (1) from the
Engine - Engine and crankcase
LPIL12CX00155AB
LPIL12CX00156AB
T ightening torque for bolt installation: –313.9 N·m ( 195.38 –231.52 ) LPIL12CX00157BB 48139070 19/04/2017 10.1 [10.001] /
21. Use the wire ropes (1) and lifting equipment lift the engine main
• Always check the hoses and connectors are all disconnected before lifting the engine. Thoroughly check that the location safe before lowering the engine wood
• Thoroughly fasten the engine that does not fall over
Engine - Engine and crankcase
LPIL12CX00158AB 48139070 19/04/2017 10.1 [10.001] /
Engine - Engine and crankcase
Engine - Install
T o install the perform the reverse the removal procedure.
When installing each tighten them the specified
For bolts for which the torque not see " T orque - Bolt and nut
After installing the engine, resupply coolant and engine perform fuel line air and perform filling for the air conditioner
For details, see the individual explanations for each
Run the engine - load idling and check for any ter oil
Attach the hydraulic and For see the individual explanations for each
48139070 19/04/2017 10.1 [10.001] /
Engine - Engine and crankcase
Engine - Check - Engine oil
W ARNING
Burn hazard! not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) temperatures that exceed (120 °F). Allow fluids cool before proceeding.
Failure comply could result death serious injury
NOTICE: The engine should a horizontal position.
NOTICE: W ait least 5 min before starting the engine and after stopping the
Engine oil inspection
Remove the oil level gauge from the oil level gauge guide
NOTE: W ipe off the engine oil adhered the oil level
Install the oil level gauge the oil level gauge guide
Remove the oil level gauge from the oil level gauge guide
Inspect the engine
NOTE: Check for the engine oil adhered the oil level gauge and inspect the engine oil level.
MAX MIN
Acceptable oil amount
Refilling required
W0330B
LPIL12CX009 1 48139070 19/04/2017 10.1 [10.001] /
Engine - Engine and crankcase
Engine - Compression test
Start the
• W arm - the T urn “OFF” the starter
Disconnect the battery ground cable from the battery
• not disconnect the battery cable least for 1 min after turning the starter switch “OFF”. Remove the glow plug from the cylinder
• Remove all glow
Connect the battery ground cable the battery
Rotate the starter
• Crank the engine discharge foreign matter from inside the cylinders.
Install the special tool the cylinder head.
• Insert the compression gauge adapter into the lation hole the glow plug install the compression
Special tool: Compression gauge adapter (Refer Cylinder head - Special tools (10.101) )
Special tool: Compression gauge (Refer Cylinder head - Special tools (10.101) )
LPIL12CX00522AA 1
LPIL12CX00523AA 2 48139070 19/04/2017 10.1 [10.001] /
Measure the compression
• Rotate the starter , and read the indication the compression pressure when the compression gauge needle
• Measure the compression pressure all
V alues: 2840 – 3240 kPa ( 412 – 470 psi ) Engine speed: 200 RPM
Limit: 1960 kPa ( 284 psi ) Engine speed: 200 RPM
Dif ference between each cylinder: 294 kPa ( psi ) Engine speed: 200 RPM
NOTICE: Use a fully charged battery
Note that air will burst out through the glow plug hole during rotation.
sure clear the DTC after completing the because a DTC stored the starter switch turned “ON” while the injector harness connector
Remove the special tool from the cylinder
10. Disconnect the battery ground cable from the battery .
• not disconnect the battery cable least for 1 min after turning the starter switch “OFF”.
1 Install the glow plug the cylinder head assembly .
• Install the all glow
T ightening torque: N·m ( )
Connect the harness connector the injector
Connect the battery ground cable the battery
Engine - Engine and crankcase
LPIL12CX00524AA 3
48139070 19/04/2017 10.1 [10.001] /
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Engine - Service instruction
Precautions maintenance
T o prevent the engine from being damaged and sure the reliability engine careful the following points when performing maintenance works.
When placing the engine the make sure that the bearing surface the oil pan does not directly tact the
Use appropriate wood support the gine the engine foot portion and the flywheel housing portion. There only a small gap between the oil pan and oil pump strainer , careful not damage the oil pan and oil strainer
• When maintaining the sure disconnect the negative battery Failure this may cause the harness electrical components energizing required for careful not cause a
• Before assembly , apply the engine oil the slide contact surface the engine. This work ensures appropriate lubrication when first starting the
• When the valve train piston connecting connecting rod and / crankshaft journal bearing are removed, line them the correct order that their original positions are clear
• When install the same position when was
• When assembling the replace the oil and O - ring with new
• For a component with the liquid gasket applied, fully remove the old liquid gasket and clean the ponent that water , and / dust Thereafter , apply the specified liquid gasket each component before assembly
• Assemble components with the liquid gasket applied within 5 min applying the liquid 5 min have remove the old liquid gasket and apply liquid gasket
• When assembling installing a make sure tighten them the specified torque ensure secure
Important precautions for handling this engine
The holes and gaps the fuel system including inside the injector where the fuel passes through are factured with high
these are extremely sensitive any foreign matter , and may severely damaged due foreign matter accidentally For this extreme care must taken prevent any foreign matter from entering.
Engine - Engine and crankcase
48139070 19/04/2017 10.1 [10.001] /
