CASE CX80C Midi Crawler Excavator Service Repair Manual

CX80C Midi Crawler Excavator

SERVICE MANUAL

Printed in U.S.A. Copyright © 2013 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.

Part number 47575340A 1st edition English July 2013

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.357] Pilot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.525] Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.355] Hydraulic hand control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7 [35.356] Hydraulic foot control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8

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[35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 [35.354] Hydraulic central joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 [35.741] Dozer blade cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15

Frames and ballasting ................................................................. 39 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

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

Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

Electrical systems ....................................................................... 55 [55.416] Swing control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 47575340A 10/07/2013

[55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . 55.16 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . 55.17 [55.524] Cab controls (Lift arm, Boom, Dipper, Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18 [55.417] Travel control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.19 [55.950] Hammer electric system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.20 [55.530] Camera. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.21 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.22 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.23 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.24 [55.992] Anti-theft system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.25 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.26

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

Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.156] Cab glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4

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INTRODUCTION

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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 genuine service parts.

When placing an order, check the parts catalog. It contains the CASE 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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INTRODUCTION

Safety rules WARNING: This symbol indicates the need for caution.

Details are given concerning the safety of the operator and the surroundings.

Read all cautions carefully and understand them well before starting any work.

In order to prevent any accidents, always comply with warnings and cautions.

This section covers overall dangers.

Check if warning labels are installed.

Additional warning labels are available for order as a service part.

WARNING: Read this operator's manual well to have a thorough understanding of how to control and operate this machine.

WARNING: Always operate this machine from the seated position.

Any other method of operation has the danger of severe injury.

WARNING: This machine is for only 1 person to ride on. Do not ride 2 people on this machine.

WARNING: Before starting the engine, check the safety messages in this operator's manual.

Check all the warning labels on the machine.

Check that there is no one anywhere in or around the work range for the machine.

Check the operation methods in a safe location before starting the actual work.

Understand the operation of this machine well, then operate it according to service-related laws and ordinances.

The operator's manual and service manual can be ordered from any CASE CONSTRUCTION dealer.

WARNING: Working in untidy work clothes or in clothes with which safety cannot be ensured leads to damage to the machine and injury of the operator themselves.

Always work dressed for safety.

In order to work more safely, it is recommended to wear additional safety gear.

(Helmet, safety shoes, earplugs, goggles, work clothes, and gloves) WARNING: Work with great care when the engine is running.

WARNING: Check and verify hydraulic equipment.

Work according to the procedure.

Do not change the procedure.

WARNING: When bleeding the pressure from hydraulic circuits to inspect the machine's hydraulic cylinders, make sure that there is no one in the vicinity before doing the work.

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INTRODUCTION

WARNING: Use gloves when handling hot parts.

WARNING: Lower the parts to the ground before inspecting or repairing attachments and lower parts.

WARNING: Check that all hoses and tubes are securely connected.

Replace any damaged hose or tube.

Do not use your hands to check for oil leaks. Use a piece of cardboard or wood.

WARNING: When removing an attachment pin or other hard pin, use a hammer with a soft head.

WARNING: When installing a pin with a hammer and working with a grinder, wear protective eyewear.

At this time, use goggles or a protector that meets the standards.

WARNING: When repairing or inspecting, stop the machine at a safe location.

WARNING: When repairing the machine, protect the work site.

Check the oil, coolant, grease, and tools.

Collect materials and parts as necessary.

Pay careful attention to work safely.

WARNING: Some of the machine's parts are extremely heavy.

In this case, use an appropriate crane.

For details on the weights and correct procedures, see the Service Manual.

WARNING: Exhaust gas is harmful.

When working indoors or in any other enclosed space, always use good ventilation.

WARNING: If battery solution is frozen, there is a danger of it exploding.

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SERVICE MANUAL Engine CX80C

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Engine - Engine and crankcase

Engine - General specification Main data Engine main specifications Item Type Shape of combustion chamber Cylinder liner type Cylinder bore x stroke Displacement Compression ratio Compression pressure Idling rotation speed Valve clearance Ignition type Injection order Lubricant system Lubricating type Oil pump type Lubrication oil amount Oil filter type Oil cooling type Cooling system Cooling type Water pump type Thermostat type Thermostat valve opening temperature Coolant capacity Fuel system Injection pump type Governor type Timer type Injection nozzle type Battery system Generator type Output Regulator type Start system Starter type Output Preheat system Preheat system type Glow plug standard voltage/current

Intake Exhaust

Engine model 4LE2 Diesel/4-cycle/water-cooled, inline 4 cylinder overhead valve Direct injection type No liner 85 mm (3.35 in) x 96 mm (3.78 in) 2.179 l (133 in³) 17.6 3.04 MPa (441 psi) 250 RPM 1000 RPM 0.4 mm (0.016 in) while cool 0.4 mm (0.016 in) while cool Compression ignition 1-3-4-2 Compression type Gear type 10.4 l (3 US gal) MAX 7.6 l (2 US gal) MIN Combined type Built-in type, water cooled Water cooling Centrifugal, belt type Wax type unit 82 °C (180 °F) 4.1 l (1.1 US gal) engine only Electronic control common rail (fuel rail) type Electronic type Electronic type Multi-hole type 7 holes AC type 24 V / 50 A IC Reduction type 24 V / 3.2 kW (4.4 Hp) Glow plug 23 V / 3.0 A (Reference)

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Engine - Engine and crankcase

Primary specifications of cooling system Specifications Centrifugal impeller method 1.03 Wax pellet type 85 °C (185 °F) with jiggle valve 100 °C (212 °F) with jiggle valve 10 mm (0.394 in)

Item Water pump Pulley ratio Thermostat Valve opening temperature Fully open temperature Valve lift amount when fully open

Primary specifications of electrical system Generator Specifications

Item Isuzu parts number Nominal output Rated speed Regulator type Regulated voltage Weight

8980921122 24 V / 50 A 5000 RPM IC type 28 - 29 V 9.1 kg (20.1 lb) Starter

Type (Manufacturer) Voltage Output Time

Rating Number of pinion gears Direction of rotation (toward pinion) Weight (approx.)

Current/voltage Revolution speed Current/voltage Torque Speed Current/voltage Torque

No-load characteristics Load characteristics Locking characteristics

Mitsubishi 24 V 3.2 kW (4.4 Hp) 30 s 11 Right 5.8 kg (12.8 lb) Less than 80 A / 23 V 3750 RPM / min or more 250 A / 18.6 V More than 12.9 N·m (9.5 lb ft) 1550 RPM / min or more Less than 760 A / 8 V More than 47 N·m (34.7 lb ft)

Glow plug Item Preheat device model Glow plug rated voltage/current

Type Glow plug 23 V / 3.0 A (Reference)

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Engine - Engine and crankcase

Engine - Prepare Items to prepare • Wrenches [ 7 mm, 10 mm, 13 mm, 17 mm, 19 mm, 36 mm] • Box wrench [ 24 mm] • Shackle (with the required lifting capacity) x 2 • Wire rope (with the required breaking load) • Liftcrane (with the required lifting capacity) • Pliers • Marking pen • Cap • Plug • Rag • Cleaning fluid • Wood planks, etc.

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Engine - Engine and crankcase

Engine - Remove WARNING: • Keep away from flames.

• Be sure to release hydraulic pressure before beginning work.

• The air-conditioner circuit is filled with high pressure gas, so there is the danger of gas spraying out when loosening lines.

• Do not use flames near the battery or expose it to sparks.

CAUTION: • Be sure to stop the engine before beginning work.

• Be sure to inspect the wire rope and other lifting equipment before beginning work.

• Do not let anyone go under a suspended load.

1. Use a wrench [ 17 mm] to remove the bolt (1), and then remove the battery cable (2) on the negative side.

• After removing terminals or harnesses, fix them to the frame or a similar location so they do not interfere with the work.

Also, cover with a rubber cap to protect against sparks.

Tightening torque for bolt installation: 13.0 N·m (7.82 - 9.59 lb ft)

10.6 -

2. Remove the engine hood.

For details, see Hood - Remove (90.100).

3. Remove the counterweight.

For details, see Counterweight - Remove (39.140).

4. Remove the muffler.

For details, see Diesel Oxidation Catalyst (DOC) - Remove (10.501).

5. Remove the pump.

For details, see Pump - Remove (35.106).

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Engine - Engine and crankcase

6. Use a wrench [ 7 mm] to loosen the hose bands (1), (2), and then remove the intercooler hose (high-temperature side) (3) and hose from the air cleaner (4).

Tightening torque for band (1) installation: 8.8 9.8 N·m (6.49 - 7.23 lb ft) Tightening torque for band (2) installation: 6.3 7.3 N·m (4.65 - 5.38 lb ft)

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2

SMIL13CEX4561AB

3

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7. Loosen the hose bands (1), and then remove the intercooler hose (low-pressure side) (2).

Tightening torque for hose band (1) installation: 8.8 - 9.8 N·m (6.49 - 7.23 lb ft)

8. Use a wrench to remove the bolts (1) and (2), and then remove the hose band (3) and fan guard (4).

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Engine - Engine and crankcase

9. Use a wrench [ 7 mm] to loosen the radiator hose bands (1) in 4 locations, and then remove the upper hose (2) and lower hose (3).

• Use caps to cover the radiator and hoses to prevent any entry of water, dust or dirt.

• Before removing the radiator hose, completely drain the coolant.

Tightening torque for band (1) installation: 4.9 5.9 N·m (3.61 - 4.35 lb ft)

SMIL13CEX4680BB

5

SMIL13CEX4233AB

6

SMIL13CEX4245AB

7

10. Remove the connectors (1) in the 5 locations.

• Wrap the removed connectors in plastic after tying them together.

11. Remove the connector (1) from the air-conditioner compressor.

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Engine - Engine and crankcase

12. Use a wrench [ 13 mm] to remove the bolt (1) , and then remove the terminal cap (2).

Use a wrench to remove the lines (3) (4) from the starter.

Use a wrench [ 17 mm] to remove the bolt (5), and then remove the line (6) from the frame.

SMIL13CEX4477AB

8

SMIL13CEX4490AB

9

13. Use a wrench [ 10 mm] to remove the bolts (1).

Remove the connector (2) from the alternator.

Use a wrench to remove the line (3) from the alternator.

14. Use a wrench [ 13 mm] to loosen the line bolts (1) in 2 locations, and then remove the lines (2) and (3) from the compressor.

• Always remove the low-pressure (suction side) line (2) first.

• Install caps or plugs to the compressor and lines to prevent any entry of water, dust or dirt.

Tightening torque for bolt installation: [ 20 - 25 N·m (14.751 - 18.439 lb ft)]

SMIL13CEX4271AB

10

SMIL13CEX4817AB

11

15. Loosen the hose bands (1) in 2 locations, and then remove the heater hoses (2) and (3).

• Install caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.

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Engine - Engine and crankcase

16. Prepare the waste oil can (1). Use a wrench [ 36 mm] to remove the 2 engine oil remote hoses (2).

• Drain the engine oil before removing the engine oil hose.

• Mark the engine and hoses so that the connectors match at the time of assembly.

• Install caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.

• Clean the engine and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

Tightening torque for bolt installation: 63.9 N·m (39.90 - 47.13 lb ft)]

[ 54.1 -

SMIL13CEX4518BB

12

SMIL13CEX4306AB

13

SMIL13CEX4819AB

14

17. Remove the hose bands (1), and then remove the fuel hoses (2) and (3).

• Install caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.

18. Remove the hose band (1), and then remove the hose (2).

• Install caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.

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Engine - Engine and crankcase

19. Install the 2 shackles (1), and then use the wire rope (2) and liftcrane to secure the engine main unit.

SMIL13CEX5233AB

15

SMIL13CEX5285BB

16

SMIL13CEX4986AB

17

20. Use a box wrench [ 24 mm] to remove the 4 bolts (1) from the mount.

Tightening torque for bolt installation: [ 364.9 313.9 N·m (269.14 - 231.52 lb ft)]

21. Use the wire rope (1) and liftcrane to lift the engine main unit.

• Always check if the hoses and connectors are all disconnected before lifting the engine.

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

• Thoroughly fasten the engine so that it does not fall over.

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Engine - Engine and crankcase

Engine - Install 1. To install the engine, perform the reverse of the removal procedure.

For details, see the individual explanations for each procedure.

2. Run the engine at no-load idling and check for any water or oil leaks.

3. Attach the hydraulic pump, covers, and counterweight.

For details, see the individual explanations for each procedure.

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Engine - Engine and crankcase

Crankcase - Remove Battery ground cable disconnect 1. Disconnect the battery ground cable from the battery.

Coolant drain 1. Drain coolant from the radiator.

CAUTION: • After draining the coolant, do not forget to tighten the drain plug.

Engine oil drain 1. Drain the engine oil from the oil pan.

NOTE: After draining the oil, tighten the drain plug to the specified torque.

Tightening torque: 78.5 N·m (57.899 lb ft) CAUTION: • Do not forget to tighten the drain plug.

Cooling fan removal 1. Remove the cooling fan (1) from the fan pulley.

2. Adapter 3. Spacer

SMIL13CEX4383AB

Cooling fan belt removal 1. Remove the cooling fan belt from the pulley.

NOTE: Loosen the generator adjust bolt and remove the belt.

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1

Engine - Engine and crankcase

Fan pulley removal 1. Remove the fan pulley (1) from the water pump assembly (2).

SMIL13CEX4195AB

2

SMIL13CEX4034AB

3

SMIL13CEX4353AA

4

Generator removal 1. Disconnect the harness connector from the generator.

2. Remove the generator (3) from the generator bracket.

3. Remove the adjust plate (1) from the water pump assembly (2).

4. Bolt

Engine coolant temperature sensor disconnect 1. Disconnect the harness connector from the engine coolant temperature sensor.

Water hose disconnect 1. Disconnect the water hose from the water pump assembly.

NOTE: Remove the hose clip.

Water pump assembly removal 1. Remove the water pump assembly from the cylinder block and the cylinder head.

NOTE: Remove the water pump assembly and the gasket.

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Engine - Engine and crankcase

Pressure sensor/boost temperature sensor disconnect 1. Disconnect the harness connector from the boost pressure sensor/boost temperature sensor.

NOTE: Remove the harness clip.

Turbocharger heat protector removal 1. Remove the turbocharger heat protector from the turbocharger.

SMIL13CEX4396AA

5

SMIL13CEX4144AB

6

SMIL13CEX4733AB

7

Integrated oxidation catalyst silencer removal 1. Remove the integrated oxidation catalyst silencer from the exhaust pipe (1).

2. Remove the exhaust pipe (1) from the turbocharger assembly.

NOTE: Remove together with the bracket (2).

3. Remove the support bracket (1) from the silencer bracket (2).

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Turbocharger assembly removal 1. Remove the exhaust pipe adapter from the turbocharger assembly.

SMIL13CEX5312AA

8

SMIL13CEX5438AB

9

2. Remove the oil feed pipe (2) from the turbocharger assembly (1)Turbocharger assembly removal 3. Remove the oil return pipe (3) from the turbocharger assembly and the cylinder block.

4. Remove the turbocharger assembly from the exhaust manifold.

SMIL13CEX5437AA

10

SMIL13CEX5266AB

11

EGR valve removal 1. Disconnect the harness connector from the EGR valve.

2. Disconnect the harness clip from the EGR pipe.

3. Disconnect the water rubber hose (1) from the EGR cooler assembly.

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Engine - Engine and crankcase

4. Remove the EGR valve from the intake chamber.

SMIL13CEX4342AA

12

SMIL13CEX5443AA

13

SMIL13CEX4393AA

14

SMIL13CEX4998AA

15

5. Remove the EGR pipe from the EGR cooler.

6. Remove the EGR cooler from the EGR pipe.

7. Remove the EGR pipe from the exhaust manifold.

PCV hose removal 1. Remove the PCV hose from the intake chamber.

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Engine - Engine and crankcase

IMT sensor removal 1. Disconnect the harness connector from the IMT sensor.

2. Remove the IMT sensor from the intake chamber.

Intake chamber removal 1. Remove the intake chamber from the cylinder head cover.

SMIL13CEX4646AA

16

SMIL13CEX4879AA

17

SMIL13CEX4073AA

18

Cylinder head cover removal 1. Remove the cylinder head cover from the rocker arm bracket.

Harness bracket removal 1. Disconnect the engine harness from the harness bracket.

2. Remove the harness bracket from the cylinder head.

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Engine - Engine and crankcase

Fuel leak-off hose removal 1. Remove the fuel leak-off hose from the injector.

NOTE: Do not reuse the leak-off pipe clip.

1. Clip

SMIL13CEX4402BA

19

SMIL13CEX4693AB

20

SMIL13CEX4572AA

21

Injection pipe removal 1. Remove the injection pipe from the injector and the common rail (fuel rail) assembly.

NOTE: Do not reuse the injection pipe.

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Injector removal 1. Disconnect the harness connector from the injector.

2. Remove the injector (2) from the cylinder head assembly.

3. Remove the injector gasket (4) from the injector.

4. Remove the O-ring (3) from the injector.

NOTE: Do not reuse the injector gasket or the O-ring.

1. Injector clamp • Absolutely never touch the injector solenoid because doing so can hinder performance or cause damage. • Store the removed injector with the cylinder number on it.

SMIL13CEX4248AB

22

SMIL13CEX5078AA

23

SMIL13CEX4995AB

24

Glow plug connector removal 1. Remove the glow plug connector from the glow plug.

Glow plug removal 1. Remove the glow plug from the cylinder head.

Engine hanger removal 1. Remove the engine hanger (1) from the cylinder head.

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Engine - Engine and crankcase

Rocker arm bracket removal 1. Remove the rocker arm bracket from the cylinder head.

CAUTION: • Be careful not to damage the rocker arm bracket when removing.

SMIL13CEX5330AA

25

SMIL13CEX5331AA

26

SMIL13CEX4030AA

27

Push rod removal 1. Remove the push rod from the cylinder block.

Cylinder head assembly removal 1. Remove the cylinder head assembly from the cylinder block.

NOTE: Gradually loosen the bolts in the numerical order shown in the diagram and remove.

2. Remove the cylinder head gasket from the cylinder block.

Tappet removal 1. Remove the tappet from the cylinder block.

Crankshaft pulley removal 1. Remove the crankshaft pulley from the crankshaft.

NOTE: Remove after stopping the crankshaft from turning.

NOTICE: Do not reuse the bolt and the washer.

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Engine - Engine and crankcase

CMP sensor removal 1. Disconnect the harness connector from the CMP sensor.

2. Remove the CMP sensor from the timing gear case.

3. Remove the O-ring from the CMP sensor.

Timing gear case removal 1. Remove the idle gear cover (1) from the front oil pump plate.

2. Remove the timing gear case (2) from the front oil pump plate.

SMIL13CEX4492AB

28

SMIL13CEX4007AB

29

SMIL13CEX4656AA

30

Fuel pipe (1) removal 1. Remove the fuel pipe (1) from the fuel supply pump and the common rail (fuel rail) assembly.

Fuel return pipe removal 1. Remove the fuel return pipe from the fuel supply pump.

Fuel supply pump removal 1. Disconnect the harness connector from the fuel supply pump.

2. Remove the fuel supply pump from the front oil pump plate.

NOTE: Remove the tightening bolts, and remove together with the bracket.

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