CASE CX220C Hydraulic Excavator Service Repair Manual

Service Manual CX220C

Hydraulic Excavator

CX220C

Hydraulic Excavator

1/1 Part Number 71114551 1st Edition English 03/2015

Printed in Brazil Copyright © 2015 – CNH Industrial Latin America LTDA. All Rights Reserved..

Service Manual

Part Number 71114551 1st Edition English 03/2015

SERVICE MANUAL CX220C Standard model

71114551 19/03/2015 EN

Link Product / Engine Product CX220C Modelo padrão

Market Product Latin America

71114551 19/03/2015

Engine F4GE9684E*J615

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.304] Combination pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8 [35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.356] Hydraulic foot control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Frames and ballasting ................................................................. 39 [39.101] Upper frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 [39.103] Swing ring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.3

71114551 19/03/2015

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

Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . 55.4 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

Booms, dippers, and buckets ....................................................... 84 [84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1 [84.100] Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.2

Platform, cab, bodywork, and decals ............................................. 90 [90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

71114551 19/03/2015

INTRODUCTION

71114551 19/03/2015

1

INTRODUCTION

Advice - 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 information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries.

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

71114551 19/03/2015

3

INTRODUCTION

Foreword - Ecology and the environment Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

NOTE: The following are recommendations that may be of assistance: • Become acquainted with and ensure that you understand the relative legislation applicable to your country.

• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these substances.

• Agricultural consultants will, in many cases, be able to help you as well.

Helpful hints • Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable spillage.

• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may be harmful to your health.

• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.

Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources.

• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil, but should be collected and disposed of properly.

• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere.

Your CASE CONSTRUCTION dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly.

• Repair any leaks or defects in the engine cooling or hydraulic system immediately.

• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.

• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

71114551 19/03/2015

4

INTRODUCTION

Safety rules DANGER Improper operation or service of this machine can result in an accident.

Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information.

Failure to comply will result in death or serious injury.

D0010A

WARNING Maintenance hazard!

Always perform all service procedures punctually at the intervals stated in this manual. This ensures optimum performance levels and maximum safety during machine operation.

Failure to comply could result in death or serious injury.

W0132A

WARNING Pressurized system!

Before attempting any service procedure, it is your responsibility to know the number of accumulators on the machine, and the correct procedure for releasing the pressure of each accumulator.

Failure to comply could result in death or serious injury.

W0136A

NOTICE: Extreme working and environmental conditions require shortened service intervals.

Use Case fluids, lubricants, and filters for the best protection and performance of your machine. All fluids, lubricants, and filters must be disposed of in compliance with environmental standards and regulations. Contact your dealer with any questions regarding the service and maintenance of this machine.

Read the safety decals and information decals on the machine. Read the Operator’s Manual and safety manual.

Understand the operation of the machine before you start any service.

Before you service the machine, put a 'Do Not Operate' tag on the steering wheel or over the key switch. Ensure the tag is at a location where everyone who might operate or service the machine may see clearly. One tag is included with your new machine. Additional tags are available from your dealer.

Plastic and resin parts • Avoid using gasoline, paint thinner, etc. when cleaning plastic parts, console, instrument cluster, etc.

• Use only water, mild soap, and a soft cloth when you clean these parts.

• Using gasoline, thinners, etc. can cause discoloration, cracking, or deformation of the part being cleaned.

71114551 19/03/2015

5

INTRODUCTION

Safety rules Standard safety precautions Be informed and notify personnel of the laws in force regulating safety, and provide documentation available for consultation.

• Keep working areas as clean as possible.

• Ensure that working areas are provided with emergency boxes. They must be clearly visible and always contain adequate sanitary equipment.

• Fire extinguishers must be properly identified and always be clear of obstructions. Their efficiency must be checked on a regular basis and personnel must be trained on proper interventions and priorities.

• Keep all emergency exits free of obstructions and clearly marked.

• Smoking in working areas subject to fire danger must be strictly prohibited.

Prevention of injury • Wear suitable work attire and safety glasses with no jewelry such as rings and chains when working close to engines and equipment in motion.

• Wear safety gloves and goggles when performing the following operations: • Topping off or changing lubrication oils.

• Using compressed air or liquids at a pressure greater than 2 bar (29 psi).

• Wear a safety helmet when working close to hanging loads or equipment working at head level.

• Always wear safety shoes and fitting clothes.

• Use protection cream for hands.

• Change wet clothes as soon as possible.

• In the presence of voltages exceeding 48 - 60 V, verify the efficiency of the ground and mass electrical connections.

Ensure that hands and feet are dry and use isolating foot boards. Workers should be properly trained to work with electricity.

• Do not smoke or start an open flame close to batteries and any fuel material.

• Place soiled rags with oil, diesel fuel or solvents in specially provided anti-fire containers.

• Do not use any tool or equipment for any use other than what it was originally intended for. Serious injury may occur.

• If running an engine indoors, make sure there is a sufficient exhaust fan in use to eliminate exhaust fumes.

During maintenance • Never open the filler cap of the cooling system when the engine is hot. High temperature liquid at operating pressure could result in serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F).

• Never add coolant to an overheated engine and use only appropriate liquids.

• Always work when the engine is turned off. Certain circumstances require maintenance on a running engine. Be aware of all the risks involved with such an operation.

• Always use adequate and safe containers for engine fluids and used oil.

• Keep engine clean of any spilled fluids such as oil, diesel fuel, and or chemical solvents.

• Use of solvents or detergents during maintenance may emit toxic vapors. Always keep working areas aerated.

Wear a safety mask if necessary.

• Do not leave soiled rags that may contain any flammable substances close to the engine.

• Always use caution when starting an engine after any work has been performed. Be prepared to cut off intake air in case of engine runaway.

• Never disconnect the batteries while the engine is running.

• Disconnect the batteries prior to performing any work on the equipment.

71114551 19/03/2015

6

INTRODUCTION

• Disconnect the batteries to place a load on them with a load tester.

• After any work is performed, verify that the battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation.

• Before disconnecting any pipelines (pneumatic, hydraulic, fuel pipes, etc.), verify that all pressure has been released. Take all necessary precautions bleeding and draining residual pressure. Always wear the proper safety equipment.

• Do not alter the lengths of any wires.

• Do not connect any electronic service tool to the engine electrical equipment unless specifically approved by CASE CONSTRUCTION. • Do not modify the fuel system or hydraulic system unless approved by CASE CONSTRUCTION. Any unauthorized modification will compromise warranty assistance and may affect engine operation and life span.

For engine equipped with an electronic control unit • Do not weld on any part of the equipment without removing the control unit.

• Remove the in case of work requiring heating over 80 °C (176 °F).

• Do not paint the components and the electronic connections.

• Do not alter any data filed in the electronic control unit driving the engine. Any manipulation or alteration of electronic components will void engine warranty assistance and may affect the correct working order and life span of the engine.

Respect of the Environment • Respect of the environment should be of primary importance. Take all necessary precautions to ensure personnel's safety and health.

• Inform the personnel of the laws regarding the dispensing of used engine fluids.

• Handle batteries with care, storing them in a well ventilated environment and within anti-acid container.

71114551 19/03/2015

7

SERVICE MANUAL Engine CX220C Standard model

71114551 19/03/2015

10

Engine - Engine and crankcase

Engine - General specification Performance Road speed 3.7 km/h (2 mph) 5.7 km/h (4 mph)

Slow Fast

Motor Specifications Main specifications Manufacturer Model Type Number of cylinders Bore Stroke Total displacement Compression ratio Rated output power (at 2000 RPM) ( ISO 14396: Without fan) Maximum torque (at 1400 RPM) ( ISO 14396) High idling Low idling Fuel consumption rate Total engine oil volume Volume of oil in the filter Volume of oil in the line Volume of oil in the engine chambers Weight without oil

FPT Tier 3 F4GE9684E*J615 Water-cooled, 4 cycle direct injection type diesel engine with intercooler turbo-charger 6 in-line 104 mm (4.09 in) 132 mm (5.20 in) 6728 cm³ (411 in³) 17 : 1 118 kW (160 Hp) 670 N·m (494 lb ft) 2200 RPM 800 RPM 212 g/kWh 17.8 L (4.7 US gal) 0.90 L (0.24 US gal) 0.85 L (0.22 US gal) 1.50 L (0.40 US gal) 510.0 kg (1124.4 lb)

Feed Injection Sequence

1-5-3-6-2-4

Battery Voltage Capacity

2 x 12 V 2 x 100 A·h

Starter Motor Manufacturer Voltage Output

BOSCH 24 V 4 kW (5 Hp)

Alternator Manufacturer Voltage Output

BOSCH 24 V 90 A

71114551 19/03/2015

10.1 [10.001] / 3

Engine - Engine and crankcase

Engine - Prepare Preparation for removing 1.

Remove battery ground.

2.

Remove bonnet and guard. Remove under cover.

3.

Remove air cleaner hose.

4.

Remove counterweight.

5.

Remove radiator hose and inter-cooler hose.

6.

Remove fuel hose and heater hose, and if necessary disconnect air-con hose.

7.

If necessary, remove pump, muffler and radiator.

8. Remove harness connector.

1.

Remove E/G ground cable.

2.

Starter cable-starter B terminal.

3.

Remove the connector that connects the upper harness with the engine and ECU harness.

4.

Upper harness P1 Alternator B terminal CN-160 E/G speed sensor CN-141, CN142 P1, P2 pump proportional valve CN-139, CN-140 P1, P2 pump pressure sensor M-1 starter motor C terminal

NOTE: Prepare a stand, which withstands the weight of the engine assy. and can place the removed engine firmly.

TULI12ECX3380FB

1

71114551 19/03/2015

10.1 [10.001] / 5

Engine - Engine and crankcase

TULI12ECX1634FB

2

71114551 19/03/2015

10.1 [10.001] / 6

Engine - Engine and crankcase

Engine - Remove

TULI12ECX3418HA

1

1. Remove hose of engine oil filter.

71114551 19/03/2015

10.1 [10.001] / 7

Engine - Engine and crankcase

Place oil pan under the connection of filter (1), and disconnect hoses (2), (3). : 41 mm (1.6 in) 2. Put a protection cap on the opened hoses.

3. Remove hoses of fuel injection pump (4) and water separator.

Place fuel pan under the connections (4) and disconnect hoses (5).

4. Loosen engine mounting bolt of frame.

1.

Loosen 4 nuts (6) M18 : 27 mm (1.1 in)

2.

Loosen 4 capscrews (7) M18 X 150. : 27 mm (1.1 in)

3.

Remove 4 plates (8).

4.

Remove upper rubber mounts (9) and (10) 2 each.

5. Slinging engine body 1. Sling engine hooking wire to lifting lugs on the front and rear sides.

Weight: Approx. 544 kg (1199 lb) Wire: dia. 6 mm (0.2 in)x 1 m (3.3 ft) - 2 pcs.

ATTENTION: Prepare a stand, which withstands the weight of the engine assy. and can place the removed engine firmly.

6. Position engine on the stand stably.

7. Remove 4 rubber mounts (9), (10).

71114551 19/03/2015

10.1 [10.001] / 8

Engine - Engine and crankcase

Engine - Install Installation of engine 1. Installing is done in the reverse order of removing.

2. Tightening torque.

No. 7 11 12

Name Capscrew M18 X 150 Capscrew M12 X 80 Capscrew M12 X 40

Tightening torque 202.5 - 247.5 N·m (149.36 - 182.55 lb ft) 104 - 126 N·m (76.71 - 92.93 lb ft) 104 - 126 N·m (76.71 - 92.93 lb ft)

71114551 19/03/2015

10.1 [10.001] / 9

Remarks Apply LOCTITE® 271™ Apply LOCTITE® 262™ Apply LOCTITE® 262™

Engine - Engine and crankcase

Engine - Measure Warming up of engine Start engine to raise the coolant temperature of engine to 60 - 90 °C (140 - 194 °F) at surface of radiator upper tank.

The E/G coolant temperature gauge is used to measure.

The range in white color shows the temperature of approx. 65 - 105 °C (149 - 221 °F), so confirm that the pointer indicates the temperature within the white range.

TULI12ECX0098AA

71114551 19/03/2015

10.1 [10.001] / 10

1

Engine - Engine and crankcase

Engine speed measured value through service diagnosis 1. Turn On the starter switch with the buzzer stop switch pressed.

2. A program number and an actual engine revolution are displayed as item No. 2.

3. The screen advances in the sequence number 2, number 3 etc. each time you press the "up arrow button" on the gauge assembly.

4. The screen goes back in the sequence number 45, number 44 etc. each time you press the "down arrow button".

5. The display does not disappear unless the starter switch is turned to Off.

71114551 19/03/2015

10.1 [10.001] / 11

TULI12ECX0099BA

2

TULI12ECX0100AA

3

Engine - Engine and crankcase

Engine - Service instruction Engine Factors 1*

2*

Filters 3* 4*

Poor starting ability (takes a long time) Faulty engine starting/engine does not rotate Faulty engine starting/engine rotates Ο but no exhaust gas (no fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (with fuel injection)

Ο

Ο

Trouble

5*

6*

Checking Leak, clogging Liquid 7* 8* 9* 10* 11* 12* 13* 14* 15*

Faulty starting Ο

Ο

Ο Ο

Ο

Ο

Ο

Ο

Ο

Ο

Ο

Ο

Ο

Ο

Ο

Ο

Insufficient rotation Engine poor run-up (low follow-up ability) Rotation in bad condition (hunting)

Ο

Poor output Engine stalled during operation Output is lowered Overheating

Ο Ο

Ο Ο

Ο Ο

Ο Ο

Ο

Ο

Other failures Exhaust smoke is black Exhaust smoke is white Larger oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (monitor lights up) Oil quantity increased (intruding of water and fuel) Vibration 1* 2* 3*

Shortage of fuel level Air cleaner clogged Fuel filter clogged

4*

Oil filter clogged

5*

Fan belt slipped, fan pulley worn

6*

Breather hose crushed or clogged

7* 8*

Improper fuel in use Coolant level

Ο

Ο Ο Ο Ο

Ο

Ο

Ο

Ο Ο

Ο Ο

Ο

Ο

Ο

Ο

Ο Ο

Ο Ο

9* 10* 11* 12* 13* 14* 15*

71114551 19/03/2015

10.1 [10.001] / 12

Oil level of oil pan Contamination of water and fuel with oil Poor or deteriorated battery Leak, clogging of fuel system and intruding of air Engine oil leak Air leak between turbocharger and intake manifold Muffler clogged

Engine - Engine and crankcase

Factors

Checking shovel side

Trouble

1*

2*

3*

4*

5*

6*

Electric equipment Engine side Shovel side 7* 8* 9* 10* 11* 12* 13* 14* 15* 16*

Faulty starting Poor starting ability (takes a long time) Faulty engine starting/engine does not rotate Faulty engine starting/engine rotates but no exhaust gas (no fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (with fuel injection)

Ο Ο

Ο Ο

Ο

Ο

Ο

Ο

Ο

Ο Ο

Ο

Ο

Ο

Insufficient rotation Engine poor run-up (low follow-up ability) Rotation in bad condition (hunting)

Poor output Engine stalled during operation Output is lowered Overheating

Ο Ο Ο

Ο

Ο

Other failures Exhaust smoke is black Exhaust smoke is white Larger oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (monitor lights up) Oil quantity increased (intruding of water and fuel) Vibration 1* 2* 3* 4* 5* 6* 7* 8*

Ο

Ο

Loose mounting bolts, damage of mounting rubber Failure of radiator pressure cap Radiator core clogged/fin clogged and crushed Peeling of space insulation around radiator Failure of hydraulic system Malfunction of unload valve and low pressure sensor Startup circuit wiring Starter key switch

9*

Loose connection of battery cable terminal

10* 11* 12* 13*

Battery relay Alternator Glow plug Glow relay

14*

Starter motor

15* 16*

Safety relay Hydraulic switch

71114551 19/03/2015

10.1 [10.001] / 13

Engine - Engine and crankcase

Fuel system

Factors Trouble

1*

2*

Poor starting ability (takes a long time) Ο Faulty engine starting/engine does not rotate Faulty engine starting/engine rotates but no exhaust gas (no fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (with fuel Ο injection)

Ο

3*

4*

Intake and exhaust system 5* 6* 7* 8*

Lubrication Cooling system system 9* 10* 11* 12* 13* 14*

Faulty starting

Ο

Insufficient rotation Engine poor run-up (low follow-up ability) Rotation in bad condition (hunting)

Ο

Ο

Ο

Ο Ο

Ο

Poor output Engine stalled during operation Output is lowered Overheating

Ο Ο

Ο Ο

Other failures Exhaust smoke is black Exhaust smoke is white Larger oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (monitor lights up) Oil quantity increased (intruding of water and fuel) Vibration 1* 2* 3* 4* 5* 6* 7*

Ο Ο

Ο

Ο Ο

Ο

Ο

Ο Ο

Ο

Ο

Ο

Ο

Ο

Ο Ο

Ο Ο Ο Ο Ο

Ο

Ο

Ο

Ο

Ο

Ο

Ο

Failure of injector Failure of supply pump Improper fuel injection time Fuel leak into the head cover Turbocharger oil drain tube clogged Seal of turbocharger worn, damaged Seizing and interference of turbocharger

8* 9* 10* 11* 12* 13* 14*

71114551 19/03/2015

10.1 [10.001] / 14

Damage of EGR cooler Failure oil pump Failure of relief valve Failure of regulation valve Leak and crush of hydraulic piping Damage of water pump Failure of thermostat (not open)

Ο

Engine - Engine and crankcase

Factors Trouble

1*

2*

3*

4*

Engine body 5* 6* 7*

8*

9*

10* 11*

Faulty starting Poor starting ability (takes a long time) Faulty engine starting/engine does not rotate Faulty engine starting/engine rotates but no exhaust gas (no fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (with fuel injection)

Ο

Ο Ο

Ο

Ο

Ο

Ο

Insufficient rotation Engine poor run-up (low follow-up ability) Rotation in bad condition (hunting)

Poor output Engine stalled during operation Output is lowered Overheating

Ο Ο

Ο

Ο

Ο

Other failures Exhaust smoke is black Exhaust smoke is white Larger oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (monitor lights up) Oil quantity increased (intruding of water and fuel) Vibration 1* 2* 3* 4* 5* 6*

Damage of engine oil cooler core and O-ring Strainer clogged, damage of oil pipe Damage of cylinder head and head gasket Failure of injection holder sleeve Wear and failure of valve and valve guide Damage and seizing of piston and connecting rod

Ο Ο Ο

Ο Ο

Ο

Ο

Ο

Ο

Ο

Ο Ο Ο

Ο Ο Ο Ο Ο

Ο

Ο

Ο Ο

Ο Ο

7* 8* 9* 10* 11*

Ο

Wear of piston ring and liner, ring stick Hole due to cavitation Wear and damage of rear oil seal and seal surface Damage of dumper Damage of flywheel gear

71114551 19/03/2015

10.1 [10.001] / 15

Engine - Air cleaners and lines

Air cleaner - Prepare 1. Open panel assembly (A) and (B).

2. Open bonnet assembly (C).

TULI12ECX1479AB

71114551 19/03/2015

10.2 [10.202] / 3

1

Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

Engine - Air cleaners and lines

Air cleaner - Remove 1. Unplug terminals on indicator (7) wiring.

2. Loosen clips (1), (2) on both sides of hose (3).

3. Pull out hose (3).

Tools: flat-blade screwdriver 4. Remove 4 sems bolts (4) M10 X 25. : 17 mm 5. Remove air cleaner assembly (5) from bracket (6).

TULI12ECX1483AB

71114551 19/03/2015

10.2 [10.202] / 4

1

Engine - Air cleaners and lines

Air cleaner - Install 1. Attach air cleaner (5) using sems bolts (4) M10 X 25 to bracket (6). : 17 mm : 39.2 N·m (29 lb ft) 2. Attach hose (3) to the end of the air cleaner.

3. Tighten clip (1) and (2) on both sides of hose (3). : 5.9 N·m (4.4 lb ft) 4. Connect wire harness to indicator (7) on the air cleaner. : 3.9 N·m (2.9 lb ft)

71114551 19/03/2015

10.2 [10.202] / 5

TULI12ECX1483AB

1

TULI12ECX1488AB

2

Engine - Fuel tanks

Fuel tank - Prepare 1. Unlock cap (1) with the starter key and open it.

2. Loosen valve (2) under the tank (3) and drain the fuel.

Capacity of tank: 320 l (84.5 US gal) 3. Loosen 5 machine screw (4) and remove the connector for the level sensor (5).

4. Loosen the clip and pull out the hoses (6) and (7).

5. Plug the ends of the hoses to prevent fuel leakage.

TULI12ECX1432AB

71114551 19/03/2015

10.3 [10.216] / 3

1

Engine - Fuel tanks

Fuel tank - Remove 1. Remove 4 capscrews (8) M16 X 40. : 24 mm 2. Hook the lifting cable to the lifting eye on the fuel tank (3) and remove the fuel tank.

Weight: 113 kg (249.1 lb) 3. Remove shims (9).

NOTE: Record the shim locations before removing them.

TULI12ECX1437AB

71114551 19/03/2015

10.3 [10.216] / 4

1

Engine - Fuel tanks

Fuel tank - Install 1. Attach fuel tank (3) to the frame using 4 capscrews (8) M16 X 40.

Apply LOCTITE® 262™ on the threads. : 24 mm NOTE: If the gap (looseness) between the tank mount and the frame exceeds 1 mm (0.04 in), adjust the gap with shim (9) and tighten capscrews (8) to install the tank.

TULI12ECX1437AB

2. Tightening torque: Tightening position Capscrew M16 - (8) Machine screw M5 - (4)

Tightening torque 196.4 - 235.6 N·m (144.86 - 173.77 lb ft) 1.76 - 2.16 N·m (1.30 - 1.59 lb ft)

71114551 19/03/2015

10.3 [10.216] / 5

1