CASE CX26C Mini Excavator Service Repair Manual

SERVICE MANUAL CX26C

Mini Excavator

1/1

Part number 51422576

CX26C Mini Excavator

SERVICE MANUAL

Part number 51422576 English January 2018

© 2018 CNH Industrial Italia S.p.A. All Rights Reserved.

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.356] Hydraulic foot control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 51422576 22/01/2018

[35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 [35.360] Hammer and rotating bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.11 [35.736] Boom hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.12 [35.737] Dipper hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 [35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14 [35.734] Tool quick coupler hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15 [35.739] Swing arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.16 [35.741] Dozer blade cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.17

Frames and ballasting ................................................................. 39 [39.103] Swing ring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2

Tracks and track suspension ........................................................ 48 [48.100] Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 [48.130] Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2 [48.134] Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.3 [48.138] Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.4

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 51422576 22/01/2018

[55.405] External lighting switches and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.514] Cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16 [55.524] Cab controls (Lift arm, Boom, Dipper, Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17 [55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18

Booms, dippers, and buckets ....................................................... 84 [84.100] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1 [84.114] Boom pivoting support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2 [84.912] Dipper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.3 [84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.4

Dozer blade and arm................................................................... 86 [86.110] Dozer blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86.1

Platform, cab, bodywork, and decals ............................................. 90 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.160] Cab interior trim and panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5 [90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6

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INTRODUCTION

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INTRODUCTION

Foreword - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools.

Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages.

The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, 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 product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

The manufacturer reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication but are subject to change without notice.

In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.

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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 instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation that, if not avoided, could result in death 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 SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.

Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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INTRODUCTION

Safety rules - General information Cleaning Clean the metal parts with cleaning solution that meets the standard and steam cleaning. (except for bearings) After cleaning, dry well, and inject oil in all parts.

Also inject oil into the bearings after drying.

Inspection When disassembling parts, check all the parts.

If there are any worn or damaged parts, replace them.

Inspect carefully to prevent initial breakdowns.

Bearing Replace any loose bearings.

Air dry bearings before installing them.

Needle bearing When inserting needle bearings, be very careful not to damage them.

Apply grease to the section where the needle bearing will be 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.

Shaft Check that there is no wear and no damage.

Check the bearings and check for damaged oil seals on the shaft.

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.

Any breakdowns arising from any fuel or hydraulic oil other than those specified are not covered by the warranty.

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5

SERVICE MANUAL Engine CX26C Cab - Tier IV final engine CX26C Canopy - Tier IV final engine

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Engine - Engine and crankcase

Engine - General specification Engine main data Engine model D1305-E4B

Item Number of Cylinder Engine Type Bore × Stroke Total Displacement ISO Net Continuous ISO/SAE Net Intermittent SAE Gross Intermittent Maximum Bare Speed Minimum Bare Idling Speed Combustion Chamber Fuel Injection Pump Governor Direction of Rotation Injection Nozzle Injection Timing Firing Order Injection Pressure Compression Ratio Lubricating System Oil Pressure Indicating Lubricating Filter Cooling System Starting System Starter Motor Starting Support Device EGR Battery Charging Alternator Fuel Lubricating Oil Lubricating Oil Capacity Weight (Dry)

3 Vertical, water-cooled, 4-cycle diesel engine 78.0 – 88.0 mm (3.07 – 3.46 in) 1261 cm³ (76.95 in³) 15.5 kW (21.1 Hp) 2600 RPM 17.9 kW (24.3 Hp) 2600 RPM 18.5 kW (25.2 Hp) 2600 RPM 2820 RPM 1100 RPM Spherical type (E-TVCS) Bosch MD type mini pump All speed mechanical governor Counter-clockwise (viewed from flywheel side) Mini Nozzle (DNOPD) 0.2793 rad 16.00 °C before top dead centre 1-2-3 13.73 MPa (1992 psi) 24 : 1 Forced lubrication by trochoid pump Electrical type switch Full flow paper filter (Cartridge type) Pressurized radiator, forced circulation with water pump Electric Starting with Starter 12 V, 1.2 kW (1.6 Hp) By glow plug in combustion chamber None 12 V, 65 A·h, equivalent 12 V, 480 W Diesel Fuel No.2-D (ASTM D975) Class CF lubricating oil as per API classification is recommended.

5.7 L (1.5 US gal) 95 kg (209 lb)

NOTE: the specification described above is of the standard engine of each model.

Conversion Formula: HP = 0.746 kW, PS = 0.7355 kW

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Engine - Engine and crankcase

Engine - External view

SMIL16MEX0702GB

A B C D E F

1

497.6 mm (19.59 in) 590.1 mm (23.23 in) 396.0 mm (15.59 in) 185.3 mm (7.30 in) ∅125 mm (4.92 in) ∅222.2 mm (8.748 in)

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Engine - Engine and crankcase

Engine - Remove WARNING Avoid injury!

Shut off the engine, remove the key, and make sure all machine motion stops before you service the machine.

Failure to comply could result in death or serious injury.

W1128B

WARNING Chemical hazard!

Use caution when opening the quick coupler cap from the load port. There may be product left in the port.

Failure to comply could result in death or serious injury.

W1039A

WARNING Crushing hazard!

The lifting systems must be operated by qualified personnel who are aware of the correct procedures to follow. Make sure all lifting equipment is in good condition, and all hooks are equipped with safety latches.

Failure to comply could result in death or serious injury.

W0256A

WARNING Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W0398A

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

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Engine - Engine and crankcase

1. Remove the counterweight (for details refer to Counterweight - Remove (39.140)).

2. Remove the battery (for details refer to Battery - Remove (55.302)).

3. Remove the platform (for details refer to Operator seat base trim panel - Remove - Platform (90.160)).

4. Drain the fuel.

5. Loosen the clamp to remove the hose (1) from the expansion tank (2).

6. Pull out the expansion tank (2).

7. Use a wrench [ 13 mm] to remove the bolts (4), then remove the bracket (3).

SMIL16MEX2843AB

1

SMIL16MEX2844BB

2

8. Disconnect the electrical connector CR-24 (3) of the timer glow.

9. Use a wrench [ 13 mm] to remove the 2 bolts (1).

10. Use a wrench [ 17 mm] to remove the 2 bolts (4), then remove the bracket (2).

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Engine - Engine and crankcase

11. Use a wrench [ 13 mm] to remove the 2 bolts (1) of the coolant filling hose bracket (8).

12. Use a wrench [ 13 mm] to remove the 2 bolts (2) of the engine oil filling hose bracket (7).

13. Use a wrench [ 13 mm] to remove the 2 bolts (3) of the bracket (6).

14. Use a wrench [ 13 mm] to remove the 2 bolts (4) of the battery connect and disconnect switch (5).

SMIL16MEX2845AB

3

SMIL16MEX2846AB

4

SMIL16MEX2847AB

5

SMIL16MEX2848AB

6

15. Use a wrench [ 19 mm] to remove the 2 bolts (2) and the 2 bolts (3) of the cab support bracket (1).

16. Use a wrench [ 13 mm] to remove the 2 bolts (1) of the air cleaner inlet hose.

17. Use a wrench [ 19 mm] to remove the 2 bolts (2) of the cab support bracket (3).

18. Use a wrench [ 13 mm] to remove the 2 bolts (4) of the cab support bracket (3).

19. Remove the cab support bracket (1).

20. Loosen the clamp (1) to remove the hose (2) from the radiator.

21. Loosen the clamp (4) to remove the hose (3) from the cylinder head cover.

22. Remove the coolant filling assembly (5).

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Engine - Engine and crankcase

23. Loosen the clamp (1) to remove the engine oil filling assembly (2) from the cylinder head cover.

SMIL16MEX2849AB

7

SMIL16MEX2850AB

8

SMIL16MEX2851AB

9

SMIL16MEX2852AB

10

24. Loosen the clamps and remove the fuel hoses (1) and (2) from the fuel filter support (3).

25. Loosen the clamp and remove the fuel hose (1) from the fuel filter water separator (2).

26. Use a wrench [ 17 mm] to remove the bolt (4), and then disconnect the earth strap (3) from the engine.

27. Cut the tie (1) and disconnect the electrical connector CD-10 (2) from the air cleaner pressure switch (3).

28. Loosen the clamp (5) to remove the hose (4) from the intake manifold.

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Engine - Engine and crankcase

29. Use a wrench [ 17 mm] to remove the bolts (1) with relative washers and remove the clamps (3) that fix the electrical cables to the bracket (1).

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11

SMIL16MEX2853BB

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30. Disconnect the electrical connector CN-145 (6) of the electrical fuel feed pump (7).

31. Use a wrench [ 13 mm] to remove the bolts (5) of the bracket (1).

32. Remove the bracket (1) includes air filter (2), fuel filter (3), fuel filter water separator (4) and feed pump (7).

33. Disconnect the electrical connector CD-8 (2) from the engine coolant temperature sensor (1).

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Engine - Engine and crankcase

34. Loosen the clamp (2) and remove the cab heating hose (1).

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SMIL16MEX2856AB

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SMIL16MEX2857AB

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SMIL16MEX2868AB

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35. Loosen the clamp (3) and remove the cab heating hose (1) from the coolant cock (2).

36. Use a wrench [ 7 mm] to remove the nut (4), and then disconnect the glows electrical connector CN-80.

37. Disconnect the electrical connector CN-74 (2) from the alternator (1).

38. Remove the nut (6) to disconnect the wiring CN-74 (3) from the alternator (1).

39. Remove the nut (4) to disconnect the electrical connector CD-18 from the engine oil pressure switch (5).

40. Loosen the clamp (1) and remove the radiator coolant hose (2).

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Engine - Engine and crankcase

41. Disconnect the electrical connector CN-45 (2) from the starter motor (1).

42. Remove the nut (5) to disconnect the cable (4) and the wire (3) from the starter motor (1).

SMIL16MEX2858AB

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SMIL16MEX2859AB

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43. Use a wrench [ 11 mm] to loosen the clamp (1), and then remove the hydraulic oil suction hose (2) from the pump flange (3).

44. Use a wrench [ 19 mm] to remove the T hose (1).

45. Use a wrench [ 24 mm] to remove the P1 hose (3) and the P2 hose (2).

46. Use a wrench [ 22 mm] to remove the P3 hose (4) and the P4 hose (5).

47. Disconnect the electrical connector CN-79 (2) from the fuel solenoid (1).

48. Loosen the clamp and remove the fuel supply hose (3) from the fuel injection pump (4).

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Engine - Engine and crankcase

49. Disconnect the electrical connector CD-9 (3) from the coolant high temperature sensor switch (2).

50. Loosen the clamp and remove the fuel injectors overflow hose (1).

SMIL16MEX2862AB

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SMIL16MEX2863BB

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SMIL16MEX2864AB

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51. Use a wrench [ 13 mm] to remove the 2 bolts (2) for separate the bracket (3) and the hose (4) from the right-hand support (1).

52. Use a wrench [ 13 mm] to remove the 4 bolts (4), and then remove the right-hand support (1).

53. Use a wrench [ 19 mm] to loosen the 2 bolts (2) of the radiator (1).

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Engine - Engine and crankcase

54. Install the 2 hooks (1) into the engine lift bracket, and then use the wire rope or chain and lift-crane to secure the engine.

55. Install the lift strap (3) around the pump (4) and insert it into the hook (2).

SMIL16MEX2865AB

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SMIL16MEX2866BB

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56. Use a box wrench [ 19 mm] to remove the 4 bolts (1).

NOTICE: if necessary, remove the bracket (5) to access to the bolt (1).

57. Remove the washers (2) .and the silent blocks (3).

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Engine - Engine and crankcase

58. Tilt the radiator (1) as shown in the figure and by means of the lift-crane remove the engine.

59. Remove the washers (2) .and the silent blocks (3).

60. Thoroughly check that the location is safe before lowering the engine on wood planks, etc.

SMIL16MEX2867BB

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27

Engine - Engine and crankcase

Engine - Install WARNING Avoid injury!

Shut off the engine, remove the key, and make sure all machine motion stops before you service the machine.

Failure to comply could result in death or serious injury.

W1128B

WARNING Chemical hazard!

Use caution when opening the quick coupler cap from the load port. There may be product left in the port.

Failure to comply could result in death or serious injury.

W1039A

WARNING Crushing hazard!

The lifting systems must be operated by qualified personnel who are aware of the correct procedures to follow. Make sure all lifting equipment is in good condition, and all hooks are equipped with safety latches.

Failure to comply could result in death or serious injury.

W0256A

WARNING Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W0398A

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

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Engine - Engine and crankcase

NOTICE: For bolts for which the torque is not specified, see Torque - Standard torque settings () .

1. Install the washers (2) and the silent blocks (3).

2. Tilt the radiator (1) as shown in the figure and by means of the lift-crane install the engine.

SMIL16MEX2867BB

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SMIL16MEX2866BB

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3. Install the silent blocks (3) and the washers (2).

4. Use a box wrench [ 19 mm] to install the bolts (1) and (4).

5. Tightening torque for bolts (1) installation: 137 N·m (87 – 101 lb ft)

118 –

6. Tightening torque for bolts (4) installation: 137 N·m (87 – 101 lb ft)

118 –

NOTICE: if removed, install the bracket (5).

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Engine - Engine and crankcase

7. Remove the 2 hooks (1) from the engine lift bracket.

8. Remove the lift strap (3) from the hook (2) and the pump (4).

SMIL16MEX2865AB

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SMIL16MEX2864AB

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SMIL16MEX2863BB

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9. Use a wrench [ 19 mm] to tighten the 2 bolts (2) of the radiator (1).

Tightening torque for bolts (2) installation: 96.3 – 155.9 N·m (71.0 – 115.0 lb ft)

10. Install the right-hand support (1) and use a wrench [ 13 mm] to install the 4 bolts (4).

11. Install the bracket (3) and the hose (4) on the righthand support (1).

12. Use a wrench [ 13 mm] to install the 2 bolts (2).

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13. Install the fuel injectors overflow hose (1).

14. Connect the electrical connector CD-9 (3) to the coolant high temperature sensor switch (2).

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SMIL16MEX2861AB

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SMIL16MEX2860AB

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15. Install the fuel supply hose (3) on the fuel injection pump (4).

16. Connect the electrical connector CN-79 (2) to the fuel solenoid (1).

17. Use a wrench [ 24 mm] to install the P1 hose (3) and the P2 hose (2).

18. Use a wrench [ 19 mm] to install the T hose (1).

19. Use a wrench [ 22 mm] to install the P3 hose (4) and the P4 hose (5).

20. Install the hydraulic oil suction hose (2) on the pump flange (3).

21. Use a wrench [ 11 mm] to tighten the clamp (1).

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22. Connect the electrical connector CN-45 (2) to the starter motor (1).

23. Connect the wire (3) and the cable (4) to the starter motor (1).

24. Install the nut (5).

SMIL16MEX2858AB

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SMIL16MEX2868AB

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SMIL16MEX2857AB

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SMIL16MEX2856AB

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25. Install the radiator coolant hose (2) and tighten the clamp (1).

26. Connect the electrical connector CN-74 (2) to the alternator (1).

27. Connect the wiring CN-74 (3) to the alternator (1) and fix it with the nut (6).

28. Connect the electrical connector CD-18 to the engine oil pressure switch (5) and fix it with the nut (4).

29. Connect the glows electrical connector CN-80 and use a wrench [ 7 mm] to fix it with the nut (4).

30. Install the cab heating hose (1) on the coolant cock (2) and fix it with the clamp (3).

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31. Install the cab heating hose (1) and fix it with the clamp (2).

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SMIL16MEX2854AB

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32. Connect the electrical connector CD-8 (2) on the engine coolant temperature sensor (1).

33. Install the bracket (1) includes air filter (2), fuel filter (3), fuel filter water separator (4) and feed pump (7).

34. Use a wrench [ 13 mm] to install the bolts (5) of the bracket (1).

35. Connect the electrical connector CN-145 (6) of the electrical fuel feed pump (7).

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