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Copyright © 2012 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.
Part number 47370128A
1st edition English
April 2012
SERVICE MANUAL
CX160C
Tier 4
Crawler Excavator
Section
1001
Safety, general information and standard torque data
47370128A NA - April 2012
CONTENTS
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ROPS Judgment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bolt and Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
47370128A NA - April 2012
1001-1
Copyright © 2011 CNH FRANCE
PRINTED IN FRANCE
Safety, general information and standard torque data
GENERAL INFORMATION
CLEANING
Clean all metal parts except bearings, in a suitable cleaning solvent or by steam cleaning.
Do not use caustic soda for steam cleaning.
After cleaning, dry and put oil on all parts.
Clean oil passages with compressed air.
Clean bearings in a suitable cleaning solvent,
dry the bearings completely and put oil on the bearings.
INSPECTION
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage.
Small scoring or grooves can be removed with a hone or crocus cloth.
Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early
failures.
BEARINGS
Check bearings for easy action.
If bearings have a loose fit or rough action replace the bearing.
Wash bearings with a suitable cleaning solvent and permit to air dry.
DO NOT DRY BEARINGS WITH COMPRESSED AIR.
NEEDLE BEARINGS
Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore.
Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.
GEARS
Check all gears for wear and damage.
Replace gears that have wear or damage.
Oil seals, O-rings and gaskets.
Always install new oil seals, O-rings and gaskets.
Put petroleum jelly on seals and O-rings.
SHAFTS
Check all shafts that have wear or damage.
Check the bearing and oil seal surfaces of the shafts for damage.
SERVICE PARTS
Always install genuine Case service parts.
When ordering refer to the
Parts Catalogue for the correct part number of the genuine Case replacement items.
Failures due to the use of other than genuine Case replacement parts are not covered by warranty.
LUBRICATION
Only use the oils and lubricants specified in the Operator’s or Service Manuals.
Failures due to the use of non-specified oils and lubricants are not covered by warranty.
47370128A NA - April 2012
1001-3
Safety, general information and standard torque data
Safety
This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.
The message that follows the symbol contains important information about safety.
Carefully read the message.
Make sure you fully understand the causes of possible injury or death.
To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual.
Put the warning tag shown below on the key for the key switch when servicing or repairing the machine.
One warning tag is supplied with each machine.
Additional tags are available from your service parts supplier.
WARNING
Read the operator's manual to familiarize yourself with the correct control functions.
WARNING
Operate the machine and equipment controls from the seat position only.
Any other method could result in serious injury.
WARNING
This is a one man machine, no riders allowed.
WARNING
Before starting engine, study Operator’s Manual safety messages.
Read all safety signs on machine.
Clear the area of other persons.
Learn and practice safe use of controls before operating.
It is your responsibility to understand and follow manufacturers instructions on machine operation, ser-
vice and to observe pertinent laws and regulations.
Operator's and Service Manuals may be obtained from your CASE dealer.
WARNING
If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can
be injured.
Always wear clothing that will not catch on objects.
Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face
protection, heavy gloves and reflector clothing.
WARNING
When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and
use extreme caution.
WARNING
When doing checks and tests on the equipment hydraulics, follow the procedures as they are written.
DO NOT change the procedure.
WARNING
When putting the hydraulic cylinders on this machine through the necessary cycles to check operation
or to remove air from a circuit, make sure all people are out of the way.
WARNING
Use insulated gloves or mittens when working with hot parts.
47370128A NA - April 2012
1001-4
Safety, general information and standard torque data
WARNING
Lower all attachments to the ground or use stands to safely support the attachments before you do any
maintenance or service.
WARNING
Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious
infection.
If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately.
Maintain all hoses and tubes in good condition.
Make sure all connections are tight.
Make a replacement of any tube or hose that is damaged or thought to be damaged.
DO NOT use your hand to check for leaks, use a piece of cardboard or wood.
WARNING
When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze)
hammer or use a driver made from brass or bronze and a steel head hammer.
WARNING
When using a hammer to remove and install pivot pins or separate parts using compressed air or using
a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved
eye protectors).
WARNING
Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor.
Always block machine in place with suitable safety stands.
WARNING
When servicing or repairing the machine, keep the shop floor and operator's compartment and steps
free of oil, water, grease, tools, etc.
Use an oil absorbing material and/or shop cloths as required.
Use safe practices at all times.
WARNING
Some components of this machine are very heavy.
Use suitable lifting equipment or additional help as instructed in this Service Manual.
WARNING
Engine exhaust fumes can cause death.
If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an
exhaust pipe extension.
Open the doors and get outside air into the area.
WARNING
When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2),
you try to jump start and run the engine.
To prevent the battery electrolyte from freezing, try to keep the battery at full charge.
If you do not follow these instructions, you or others in the area can be injured.
47370128A NA - April 2012
1001-5
Safety, general information and standard torque data
ROPS Judgment Method
1. Purpose
Check against the ROPS judgment criteria to judge whether the machine satisfies the ROPS criteria or not.
The weight and boom of the machine greatly effects whether the ROPS judgment criteria is satisfied or not.
The ROPS test assumes that the weight being used is the weight of the machine when the maximum number of
selectable options are mounted (as of 2009).
However, depending on the derivative machinery or the order details, the weight and boom position may differ
from the assumed weight or position.
2. Criteria for judging whether a machine satisfies the ROPS criteria
1) Weight
The weight must not be over the weight shown below for each class.
If the weight is exceeded, there is a danger that the cab could be damaged and the operator could die or
sustain a serious injury when the machine falls over.
If the weight exceeds the stipulated weight, the machine will not satisfy the ROPS criteria.
• Weight (X3 model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)
Machine body total weight Class
16000 kg (35274.146 lb) or less
CX75C
CX145C
20500 kg (45195.000 lb) or less
CX130C
CX160C
CX180C
28000 kg (61729.756 lb) or less CX235C
31000 kg (68343.658 lb) or less
CX210C
CX250C
CX250C LR
CX300C
40000 kg (88185.365 lb) or less CX370C
50000 kg (110231.707 lb) or less CX470C
* The ROPS test assumes that the CX470C has a cage guard (alone).
Machine body total weight Class
16000 kg (35274.146 lb) or less
CX75C
CX145C
20500 kg (45195.000 lb) or less
CX130C
CX160C
CX180C
28000 kg (61729.756 lb) or less CX235C
31000 kg (68343.658 lb) or less
CX210C
CX250C
CX250C LR
CX300C
50000 kg (110231.707 lb) or less CX470C
* The ROPS test assumes that the CX470C has a cage guard (alone).
• Weight (X2 model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)
Machine body total weight Class
26600 kg (58643.268 lb) or less
CX130B
CX160B
CX180B
CX210B
CX240B
47370128A NA - April 2012
1001-6
Safety, general information and standard torque data
2) Boom position
WARNING
• If the machine has been modified so that the boom position has been lowered, the machine
will not satisfy the ROPS criteria.
• It is necessary to consult with our company if it is possible that the boom's position has been
lowered by modification.
• The extent to which a boom position has moved cannot be determined in the same way for
all machines.
a Ground point
With the tip of the bucket in contact with the ground surface at maximum work radius, if the position (* in the
diagram) that overlaps with the cab when viewed from the side is markedly lower than that of a standard
machine (standard arm), the machine will not satisfy the ROPS criteria.
Also, with a machine body with a cab mounted that can withstand up to 31 tons, the effect of mounting a
24 ton machine, which is near the restriction weight, and a 21 ton machine to the same cab will not be the
same.
3. Prohibited items
• Modifications that reduce the strength of a platform that has a cab with a ROPS mounted to it. (Actions or
modifications that reduce the functionality of the anchoring part at the left-rear of the cab)
• Modifications that effect the strength of the ROPS of a cab.
A forbidden all
modifications
(red part)
All modifications (grinding, welding, drilling holes, removing, etc.) are prohib-
ited.
Allow under spec-
ified conditions
(gray part)
Removal of parts is prohibited.
Bar welding and making holes [up to diameter 20 mm (0.787 in)] by drilling
are possible.
47370128A NA - April 2012
1001-7
Safety, general information and standard torque data
[X3 Cab (CX130C/CX160C/CX180C)]
[X3 Cab (CX210C/CX240C/CX290C)]
47370128A NA - April 2012
1001-8
Safety, general information and standard torque data
[X2 Cab (CX210B/CX240B/CX290B)]
• In general, high cabs do not satisfy the ROPS criteria. (It is necessary to consult with our company to check if
the high cab model satisfies the ROPS criteria.)
47370128A NA - April 2012
1001-9
Safety, general information and standard torque data
Bolt and Nut Tightening
• Tighten alternating between left and right and top and bottom so that uniform tightening force is applied.
• If Loctite was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the
old Loctite off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of Loctite to the thread section of the bolt.
Torque table
Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench
mm
(in)
10
(0.394)
13
(0.512)
17
(0.669)
19
(0.748)
22
(0.866)
24
(0.945)
27
(1.063)
30
(1.181)
Hexagon
bolt Tightening
torque
N・m
(lbf・ft)
6.9
(5.090)
19.6
(14.459
)
39.2
(28.917
)
58.8
(43.376
)
98.1
(72.367
)
156.9
(115.74
3)
196.1
(144.66
1)
294.2
(217.02
8)
Wrench
mm
(in)
5
(0.197)
6
(0.236)
8
(0.315)
10
(0.394)
12
(0.472)
14
(0.551)
14
(0.551)
17
(0.669)Hexagon
socket
head bolt Tightening
torque
N・m
(lbf・ft)
8.8
(6.492)
21.6
(15.934
)
42.1
(217.02
8)
78.5
(57.909
)
117.7
(86.826
)
176.5
(130.20
2)
245.2
(180.88
1)
343.2
(253.17
5)
47370128A NA - April 2012
1001-10
Section
2000
Removal and Installation of Engine Assembly
47370128A NA - April 2012
Removal and Installation of Engine Assembly
WARNING
• Keep away from fire.
• Be sure to release hydraulic pressure before
beginning work.
• The air conditioner circuit is filled with high-
pressure gas, so beware of the gas released
when loosening lines.
• Do not use open flames and do not allow
sparks near the battery.
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 stand or pass under the suspended
load.
Items to prepare
• Wrenches [7 mm (0.276 in), 10 mm (0.394 in), 13 mm
(0.512 in), 14 mm (0.551 in), 17 mm (0.669 in), 19 mm
(0.748 in), 36 mm (1.417 in)]
• Box wrench [24 mm (0.945 in)]
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Crane (with the required lifting capacity)
• Pliers
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Wood planks, etc.
Removal of Engine Assembly
1. Use a wrench [17 mm (0.699 in)] to remove the bolt
(1), and then remove the battery cable (2) on the
negative side.
• After removing the terminal and harness, secure
them so that they do not interfere with the frame
and other parts.
Also, cover with a rubber cap to protect against
sparks.
• Tightening torque for bolt installation: [10.6 - 13.0
N·m (7.82 - 9.59 lbf·ft)]
2. Remove the counterweight.
For details, see "Removal and Installation of Coun-
terweight".
3. Remove the muffler.
For details, see "Removal and Installation of Muf-
fler".
4. Remove the pump.
For details, see "Removal and Installation of Hy-
draulic Pump".
5. Use a wrench [19 mm (0.748 in)] to remove the bolt
(1), use a wrench [7 mm (0.276 in)] to loosen the
hose bands (2) (3), and then remove the intercooler
hose (high-temperature side) (4) and hose (5) from
the air cleaner.
• Tightening torque for band (2) installation: [8.8 -
9.8 N·m (6.49 - 7.23 lbf·ft)]
• Tightening torque for band (3) installation: [3.9 -
4.9 N・m (2.877 - 3.615 lbf・ft)]
47370128A NA - April 2012
2000-3
Removal and Installation of Engine Assembly
6. Loosen the hose bands (1), and then remove the
intercooler hose (low-pressure side) (2).
• Tightening torque for hose band (2) installation:
[8.8 - 9.8 N·m (6.49 - 7.23 lbf·ft)]
7. Use a wrench [14 mm (0.551 in)] to remove the bolts
(1) (2), and then remove the fan shroud (3).
8. Use a wrench to remove the bolts (1), and then re-
move the fan guard (2).
9. Use a wrench [7 mm (0.276 in)] to loosen the radia-
tor hose bands (1) in 2 locations, and then remove
the upper hose (2) and lower hose (3).
• Use caps to cover the radiator and hoses to pre-
vent 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 (3.615 - 4.352 lbf·ft)]
47370128A NA - April 2012
2000-4
Removal and Installation of Engine Assembly
10. Use a wrench [13 mm (0.512 in)] to remove the 2
bolts (1), and then remove the connector brackets
(2).
11. Use a wrench [13 mm (0.512 in)] to remove the hose
bands (1) in 2 locations from the bracket, and then
remove the 5 connectors (2).
• Wrap the removed connectors in plastic after tying
them together.
• Tightening torque for bolt installation: [21.6 - 37.2
N·m (15.93 - 27.44 lbf·ft)]
12. Remove the connector (1) from the air conditioner
compressor.
13. Use a wrench [13 mm (0.512 in)] to remove the bolt
(1), and then remove the terminal cap (2).
Use a wrench to remove the wiring (3) (4) from the
starter.
Use a wrench [17 mm (0.669 in)] to remove the bolt
(5), and then remove the wiring (6) from the frame.
14. Use a wrench [10 mm (0.394 in)] to remove the bolts
(1).
Remove the connector (2) from the alternator.
Use a wrench to remove the wiring (3) from the al-
ternator.
15. Use a wrench [13 mm (0.512 in)] to loosen the line
bolts (1) in 2 locations, and then remove the lines
(2) (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 (1) installation: [20 - 25
N·m (14.75 - 18.44 lbf·ft)]
47370128A NA - April 2012
2000-5
Removal and Installation of Engine Assembly
16. Loosen the hose bands (1) in 2 locations, and then
remove the heater hoses (2) (3).
• Install caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
17. Prepare the waste oil can (1).
• Drain the engine oil before removing the engine
oil hose.
Use a wrench [36 mm (1.417 in)] to remove the 2
engine oil remote hoses (1).
• 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 pre-
vent dirt from accumulating on the connectors.
• Tightening torque for installation: [54.1 - 63.9 N·m
(39.91 - 47.14 lbf·ft)]
18. Remove the hose bands (1), and then remove the
fuel hoses (2).
• Install caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
19. Install the 2 shackles (1), then use the wire rope (2)
and liftcrane to secure the engine main unit.
47370128A NA - April 2012
2000-6
Removal and Installation of Engine Assembly
20. Use a box wrench [24 mm (0.945 in)] to remove the
4 bolts (1) from the mount.
• Tightening torque for bolt installation: [264.9 -
313.9 N·m (195.41 - 231.56 lbf·ft)]
21. Use the wire rope (1) and liftcrane to lift the engine
main unit.
• Be sure to check all hoses and connectors for any
disconnections before lifting.
Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.
• Thoroughly secure the engine so that it does not
fall over.
Installation of Engine Assembly
1. To install the engine, perform the reverse of the re-
moval procedure.
After installing the engine, resupply coolant and en-
gine oil, perform fuel line air bleeding, and perform
filling for the air conditioner gas.
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 counter-
weight.
For details, see the individual explanations for each
procedure.
47370128A NA - April 2012
2000-7
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Fuel
Cooler
CAUTION
• Be sure to stop the engine before beginning
work.
• As the fuel hose will be removed, strictly pro-
hibit open flames.
Items to prepare
• Wrenches [13 mm (0.512 in)]
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan
Removal of Fuel Cooler
1. Mark the fuel cooler (5) and hoses (1) (2) so that the
connectors match at the time of assembly.
• Use pliers to loosen the hose bands (3) (4), and
then remove the hoses.
• Fuel will spill out, so place a drip pan directly be-
low the area.
• Install caps or plugs to the fuel cooler and hoses
to prevent any entry of water, dust or dirt.
2. Use a wrench [13 mm (0.512 in)] to remove the 4
bolts (1), and then remove the fuel cooler (2).
47370128A NA - April 2012
2001-3
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Installation of Fuel Cooler
Perform the reverse of the removal procedure.
After connecting the hoses, carefully check for any fuel
leaks.
When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for a bolt or other part, see
the Bolt Size and Torque Table.
Removal and Installation of Engine
Intercooler
CAUTION
• Be sure to stop the engine before beginning
work.
• As the fuel hose will be removed, strictly pro-
hibit open flames.
Items to prepare
• Wrenches [8 mm (0.315 in), 13 mm (0.512 in), 19 mm
(0.748 in)]
• Flathead screwdriver
• Cap
• Rag
• Cleaning fluid
Removal of Intercooler
1. Use a wrench [13 mm (0.512 in)] to remove the 3
bolts (1), and then remove the cover (2).
2. Use a wrench [8 mm (0.315 in)] or flathead screw-
driver to loosen the 2 hose bands (1) and remove
the hose (2).
• Use caps to cover the intercooler and hoses to
prevent the entry of water, dust or dirt.
Tightening torque for band (1) installation: 8.8 -
9.8 N·m (6.492 - 7.229 lbf·ft)
3. Use a wrench [8 mm (0.315 in)] or flathead screw-
driver to loosen the 2 hose bands (1) and remove
the hose (2).
• Use caps to cover the intercooler and hoses to
prevent the entry of water, dust or dirt.
Tightening torque for band (1) installation: 8.8 -
9.8 N·m (6.492 - 7.229 lbf·ft)
47370128A NA - April 2012
2001-4
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
4. Use a wrench [19 mm (0.748 in)] to remove the bolt
(1).
5. Attach a wire to the top section of the inter cooler
using a shackle, and lift the inter cooler to remove
it.
Installation of Intercooler
To install, perform the reverse of the removal procedure.
Check for any air leaks.
When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for a bolt or other part, see
the Bolt Size and Torque Table.
47370128A NA - April 2012
2001-5
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of
Radiator
WARNING
• Do not remove the radiator cap when the ra-
diator coolant temperature is high.
Hot liquid could spray out.
CAUTION
• Be sure to release the pressure within the cir-
cuit before beginning work.
• 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 stand or pass under the suspended
load.
Items to prepare
• Wrenches [7 mm (0.276 in), 13 mm (0.512 in), 19 mm
(0.748 in)]
• Pliers
• Shackles (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
• Wood planks, etc.
Removal of Radiator
1. Use a wrench [19 mm (0.748 in)] to remove the 4
bolts (1), and then remove the under cover (2).
2. Install the drain hose (1), and then prepare the drain
tank (2).
3. To make it easier to drain the coolant, remove the
radiator cap (1).
47370128A NA - April 2012
2001-6
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
4. Loosen the drain plug (1), and then drain the
coolant.
5. Use a wrench [13 mm (0.512 in)] to remove the 5
bolts (1), and then remove the covers (2) (3).
6. Use a box wrench [13 mm (0.512 in)] to remove the
6 bolts (1) from the radiator cover.
7. Use a wrench [7 mm (0.276 in)] to loosen the hose
band (1) in the 2 locations, and then remove the
upper hose (2) and lower hose (3) from the radiator.
• Use caps to cover the radiator and hoses to pre-
vent the entry of water, dust or dirt.
• Tightening torque for band (1) installation: 4.9 -
5.9 N·m (3.615 - 4.352 lbf·ft)
8. Remove the drain plug (1), loosen the hose band
(2), and then remove the hose (3).
47370128A NA - April 2012
2001-7
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Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
9. Loosen the hose band (2), and then remove the
hose (1) from the radiator cap.
• Install caps or plugs to the hoses to prevent any
entry of water, dust or dirt.
10. Use a wrench to remove the 3 bolts (1), and then
remove the brackets (2).
11. Use a wrench to remove the 2 bolts (1), and then
remove the fan guard (2).
12. Use a wrench to remove the 3 bolts (1), and then
remove the brackets (2).
Remove the bracket on the opposite side using the
same procedure.
13. Remove the 2 one-touch clips (1), and then remove
the front anti-insect net (2).
14. Use a wrench [19 mm (0.748 in)] to remove the 2
bolts (1), the 2 washers (2).
47370128A NA - April 2012
2001-8
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
15. Install the 2 shackles (1) to the top of the radiator,
and then use the wire rope (2) and liftcrane to lift the
radiator.
16. Lift until the fixtures (1) at the bottom of the radiator
become disconnected.
17. Thoroughly check that the location is safe before
lowering the radiator on square wooden piece.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (1).
Installation of Radiator
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Bolt Size and
Torque Table".
Coolant capacity is 16.2 L (4.280 gal).
Finally, check that the level of coolant is correct.
47370128A NA - April 2012
2001-9
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Oil
Cooler
WARNING
• Keep away from fire.
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 stand or pass under the suspended
load.
Items to prepare
• Wrenches [7 mm (0.276 in), 13 mm (0.512 in), 19 mm
(0.748 in)]
• Hexagon wrench [6 mm (0.236 in)]
• Pliers
• Screwdriver
• Eyebolts x 2
• Shackles (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.
Removal of Oil Cooler
• Drain the hydraulic oil from the hydraulic oil tank.
See Draining Oil from Hydraulic Oil Tank for details of
the procedure.
1. Use a wrench [19 mm (0.748 in)] to remove the 3
bolts (1), and then remove the under cover (2).
2. Prepare the waste oil can (1).
3. Use a wrench [13 mm (0.512 in)] to remove the 5
bolts (1), and then remove the cover (2) (3).
47370128A NA - April 2012
2001-10
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
4. Remove the 2 one-touch clips (1), and then remove
the anti-insect net (2).
5. Use a wrench [7 mm (0.276 in)] to loosen the hose
band (1), and then remove the hose (2).
• Use caps to cover the oil cooler and lines to pre-
vent the entry of water, dust or dirt.
6. Use a hexagon wrench [6 mm (0.236 in)] to remove
the 4 bolts (1), and then remove the lines (2).
• Use caps to cover the oil cooler and lines to pre-
vent the entry of water, dust or dirt.
7. Use a wrench [19 mm (0.748 in)] to remove the 2
bolts (1).
8. Install the 2 eyebolts (1) on the top of the oil cooler.
• Fully tighten the eyebolts, and then loosen them
by a half turn.
9. Install the 2 shackles (1) to the eyebolts, and then
use the wire rope (2) and liftcrane to lift the oil cooler
main unit.
• When lifting the oil cooler unit, be careful not to
let the line on the bottom of the oil cooler catch on
the fan shroud.
47370128A NA - April 2012
2001-11

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Case cx160 c tier 4 crawler excavator service repair manual

  • 1. Printed in U.S.A. Copyright © 2012 CNH America LLC. All Rights Reserved. Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A. Part number 47370128A 1st edition English April 2012 SERVICE MANUAL CX160C Tier 4 Crawler Excavator
  • 2. Section 1001 Safety, general information and standard torque data 47370128A NA - April 2012
  • 3. CONTENTS GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ROPS Judgment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bolt and Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 47370128A NA - April 2012 1001-1 Copyright © 2011 CNH FRANCE PRINTED IN FRANCE
  • 4. Safety, general information and standard torque data GENERAL INFORMATION CLEANING Clean all metal parts except bearings, in a suitable cleaning solvent or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning, dry and put oil on all parts. Clean oil passages with compressed air. Clean bearings in a suitable cleaning solvent, dry the bearings completely and put oil on the bearings. INSPECTION Check all parts when the parts are disassembled. Replace all parts that have wear or damage. Small scoring or grooves can be removed with a hone or crocus cloth. Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early failures. BEARINGS Check bearings for easy action. If bearings have a loose fit or rough action replace the bearing. Wash bearings with a suitable cleaning solvent and permit to air dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR. NEEDLE BEARINGS Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings. GEARS Check all gears for wear and damage. Replace gears that have wear or damage. Oil seals, O-rings and gaskets. Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings. SHAFTS Check all shafts that have wear or damage. Check the bearing and oil seal surfaces of the shafts for damage. SERVICE PARTS Always install genuine Case service parts. When ordering refer to the Parts Catalogue for the correct part number of the genuine Case replacement items. Failures due to the use of other than genuine Case replacement parts are not covered by warranty. LUBRICATION Only use the oils and lubricants specified in the Operator’s or Service Manuals. Failures due to the use of non-specified oils and lubricants are not covered by warranty. 47370128A NA - April 2012 1001-3
  • 5. Safety, general information and standard torque data Safety This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death. To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Put the warning tag shown below on the key for the key switch when servicing or repairing the machine. One warning tag is supplied with each machine. Additional tags are available from your service parts supplier. WARNING Read the operator's manual to familiarize yourself with the correct control functions. WARNING Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury. WARNING This is a one man machine, no riders allowed. WARNING Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturers instructions on machine operation, ser- vice and to observe pertinent laws and regulations. Operator's and Service Manuals may be obtained from your CASE dealer. WARNING If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing. WARNING When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution. WARNING When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure. WARNING When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way. WARNING Use insulated gloves or mittens when working with hot parts. 47370128A NA - April 2012 1001-4
  • 6. Safety, general information and standard torque data WARNING Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. WARNING Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood. WARNING When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. WARNING When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors). WARNING Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands. WARNING When servicing or repairing the machine, keep the shop floor and operator's compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use safe practices at all times. WARNING Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual. WARNING Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area. WARNING When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured. 47370128A NA - April 2012 1001-5
  • 7. Safety, general information and standard torque data ROPS Judgment Method 1. Purpose Check against the ROPS judgment criteria to judge whether the machine satisfies the ROPS criteria or not. The weight and boom of the machine greatly effects whether the ROPS judgment criteria is satisfied or not. The ROPS test assumes that the weight being used is the weight of the machine when the maximum number of selectable options are mounted (as of 2009). However, depending on the derivative machinery or the order details, the weight and boom position may differ from the assumed weight or position. 2. Criteria for judging whether a machine satisfies the ROPS criteria 1) Weight The weight must not be over the weight shown below for each class. If the weight is exceeded, there is a danger that the cab could be damaged and the operator could die or sustain a serious injury when the machine falls over. If the weight exceeds the stipulated weight, the machine will not satisfy the ROPS criteria. • Weight (X3 model) To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are the weights indicated on the nameplate within the ROPS cab) Machine body total weight Class 16000 kg (35274.146 lb) or less CX75C CX145C 20500 kg (45195.000 lb) or less CX130C CX160C CX180C 28000 kg (61729.756 lb) or less CX235C 31000 kg (68343.658 lb) or less CX210C CX250C CX250C LR CX300C 40000 kg (88185.365 lb) or less CX370C 50000 kg (110231.707 lb) or less CX470C * The ROPS test assumes that the CX470C has a cage guard (alone). Machine body total weight Class 16000 kg (35274.146 lb) or less CX75C CX145C 20500 kg (45195.000 lb) or less CX130C CX160C CX180C 28000 kg (61729.756 lb) or less CX235C 31000 kg (68343.658 lb) or less CX210C CX250C CX250C LR CX300C 50000 kg (110231.707 lb) or less CX470C * The ROPS test assumes that the CX470C has a cage guard (alone). • Weight (X2 model) To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are the weights indicated on the nameplate within the ROPS cab) Machine body total weight Class 26600 kg (58643.268 lb) or less CX130B CX160B CX180B CX210B CX240B 47370128A NA - April 2012 1001-6
  • 8. Safety, general information and standard torque data 2) Boom position WARNING • If the machine has been modified so that the boom position has been lowered, the machine will not satisfy the ROPS criteria. • It is necessary to consult with our company if it is possible that the boom's position has been lowered by modification. • The extent to which a boom position has moved cannot be determined in the same way for all machines. a Ground point With the tip of the bucket in contact with the ground surface at maximum work radius, if the position (* in the diagram) that overlaps with the cab when viewed from the side is markedly lower than that of a standard machine (standard arm), the machine will not satisfy the ROPS criteria. Also, with a machine body with a cab mounted that can withstand up to 31 tons, the effect of mounting a 24 ton machine, which is near the restriction weight, and a 21 ton machine to the same cab will not be the same. 3. Prohibited items • Modifications that reduce the strength of a platform that has a cab with a ROPS mounted to it. (Actions or modifications that reduce the functionality of the anchoring part at the left-rear of the cab) • Modifications that effect the strength of the ROPS of a cab. A forbidden all modifications (red part) All modifications (grinding, welding, drilling holes, removing, etc.) are prohib- ited. Allow under spec- ified conditions (gray part) Removal of parts is prohibited. Bar welding and making holes [up to diameter 20 mm (0.787 in)] by drilling are possible. 47370128A NA - April 2012 1001-7
  • 9. Safety, general information and standard torque data [X3 Cab (CX130C/CX160C/CX180C)] [X3 Cab (CX210C/CX240C/CX290C)] 47370128A NA - April 2012 1001-8
  • 10. Safety, general information and standard torque data [X2 Cab (CX210B/CX240B/CX290B)] • In general, high cabs do not satisfy the ROPS criteria. (It is necessary to consult with our company to check if the high cab model satisfies the ROPS criteria.) 47370128A NA - April 2012 1001-9
  • 11. Safety, general information and standard torque data Bolt and Nut Tightening • Tighten alternating between left and right and top and bottom so that uniform tightening force is applied. • If Loctite was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the old Loctite off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of Loctite to the thread section of the bolt. Torque table Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20 Wrench mm (in) 10 (0.394) 13 (0.512) 17 (0.669) 19 (0.748) 22 (0.866) 24 (0.945) 27 (1.063) 30 (1.181) Hexagon bolt Tightening torque N・m (lbf・ft) 6.9 (5.090) 19.6 (14.459 ) 39.2 (28.917 ) 58.8 (43.376 ) 98.1 (72.367 ) 156.9 (115.74 3) 196.1 (144.66 1) 294.2 (217.02 8) Wrench mm (in) 5 (0.197) 6 (0.236) 8 (0.315) 10 (0.394) 12 (0.472) 14 (0.551) 14 (0.551) 17 (0.669)Hexagon socket head bolt Tightening torque N・m (lbf・ft) 8.8 (6.492) 21.6 (15.934 ) 42.1 (217.02 8) 78.5 (57.909 ) 117.7 (86.826 ) 176.5 (130.20 2) 245.2 (180.88 1) 343.2 (253.17 5) 47370128A NA - April 2012 1001-10
  • 12. Section 2000 Removal and Installation of Engine Assembly 47370128A NA - April 2012
  • 13. Removal and Installation of Engine Assembly WARNING • Keep away from fire. • Be sure to release hydraulic pressure before beginning work. • The air conditioner circuit is filled with high- pressure gas, so beware of the gas released when loosening lines. • Do not use open flames and do not allow sparks near the battery. 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 stand or pass under the suspended load. Items to prepare • Wrenches [7 mm (0.276 in), 10 mm (0.394 in), 13 mm (0.512 in), 14 mm (0.551 in), 17 mm (0.669 in), 19 mm (0.748 in), 36 mm (1.417 in)] • Box wrench [24 mm (0.945 in)] • Shackle (with the required lifting capacity) x 2 • Wire rope (with the required breaking load) • Crane (with the required lifting capacity) • Pliers • Marking pen • Caps • Plugs • Rag • Cleaning fluid • Wood planks, etc. Removal of Engine Assembly 1. Use a wrench [17 mm (0.699 in)] to remove the bolt (1), and then remove the battery cable (2) on the negative side. • After removing the terminal and harness, secure them so that they do not interfere with the frame and other parts. Also, cover with a rubber cap to protect against sparks. • Tightening torque for bolt installation: [10.6 - 13.0 N·m (7.82 - 9.59 lbf·ft)] 2. Remove the counterweight. For details, see "Removal and Installation of Coun- terweight". 3. Remove the muffler. For details, see "Removal and Installation of Muf- fler". 4. Remove the pump. For details, see "Removal and Installation of Hy- draulic Pump". 5. Use a wrench [19 mm (0.748 in)] to remove the bolt (1), use a wrench [7 mm (0.276 in)] to loosen the hose bands (2) (3), and then remove the intercooler hose (high-temperature side) (4) and hose (5) from the air cleaner. • Tightening torque for band (2) installation: [8.8 - 9.8 N·m (6.49 - 7.23 lbf·ft)] • Tightening torque for band (3) installation: [3.9 - 4.9 N・m (2.877 - 3.615 lbf・ft)] 47370128A NA - April 2012 2000-3
  • 14. Removal and Installation of Engine Assembly 6. Loosen the hose bands (1), and then remove the intercooler hose (low-pressure side) (2). • Tightening torque for hose band (2) installation: [8.8 - 9.8 N·m (6.49 - 7.23 lbf·ft)] 7. Use a wrench [14 mm (0.551 in)] to remove the bolts (1) (2), and then remove the fan shroud (3). 8. Use a wrench to remove the bolts (1), and then re- move the fan guard (2). 9. Use a wrench [7 mm (0.276 in)] to loosen the radia- tor hose bands (1) in 2 locations, and then remove the upper hose (2) and lower hose (3). • Use caps to cover the radiator and hoses to pre- vent 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 (3.615 - 4.352 lbf·ft)] 47370128A NA - April 2012 2000-4
  • 15. Removal and Installation of Engine Assembly 10. Use a wrench [13 mm (0.512 in)] to remove the 2 bolts (1), and then remove the connector brackets (2). 11. Use a wrench [13 mm (0.512 in)] to remove the hose bands (1) in 2 locations from the bracket, and then remove the 5 connectors (2). • Wrap the removed connectors in plastic after tying them together. • Tightening torque for bolt installation: [21.6 - 37.2 N·m (15.93 - 27.44 lbf·ft)] 12. Remove the connector (1) from the air conditioner compressor. 13. Use a wrench [13 mm (0.512 in)] to remove the bolt (1), and then remove the terminal cap (2). Use a wrench to remove the wiring (3) (4) from the starter. Use a wrench [17 mm (0.669 in)] to remove the bolt (5), and then remove the wiring (6) from the frame. 14. Use a wrench [10 mm (0.394 in)] to remove the bolts (1). Remove the connector (2) from the alternator. Use a wrench to remove the wiring (3) from the al- ternator. 15. Use a wrench [13 mm (0.512 in)] to loosen the line bolts (1) in 2 locations, and then remove the lines (2) (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 (1) installation: [20 - 25 N·m (14.75 - 18.44 lbf·ft)] 47370128A NA - April 2012 2000-5
  • 16. Removal and Installation of Engine Assembly 16. Loosen the hose bands (1) in 2 locations, and then remove the heater hoses (2) (3). • Install caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt. 17. Prepare the waste oil can (1). • Drain the engine oil before removing the engine oil hose. Use a wrench [36 mm (1.417 in)] to remove the 2 engine oil remote hoses (1). • 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 pre- vent dirt from accumulating on the connectors. • Tightening torque for installation: [54.1 - 63.9 N·m (39.91 - 47.14 lbf·ft)] 18. Remove the hose bands (1), and then remove the fuel hoses (2). • Install caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt. 19. Install the 2 shackles (1), then use the wire rope (2) and liftcrane to secure the engine main unit. 47370128A NA - April 2012 2000-6
  • 17. Removal and Installation of Engine Assembly 20. Use a box wrench [24 mm (0.945 in)] to remove the 4 bolts (1) from the mount. • Tightening torque for bolt installation: [264.9 - 313.9 N·m (195.41 - 231.56 lbf·ft)] 21. Use the wire rope (1) and liftcrane to lift the engine main unit. • Be sure to check all hoses and connectors for any disconnections before lifting. Thoroughly check that the location is safe before lowering the engine on wood planks, etc. • Thoroughly secure the engine so that it does not fall over. Installation of Engine Assembly 1. To install the engine, perform the reverse of the re- moval procedure. After installing the engine, resupply coolant and en- gine oil, perform fuel line air bleeding, and perform filling for the air conditioner gas. 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 counter- weight. For details, see the individual explanations for each procedure. 47370128A NA - April 2012 2000-7
  • 18. Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal and Installation of Fuel Cooler CAUTION • Be sure to stop the engine before beginning work. • As the fuel hose will be removed, strictly pro- hibit open flames. Items to prepare • Wrenches [13 mm (0.512 in)] • Screwdriver • Pliers • Marking pen • Cap • Plug • Rag • Cleaning fluid • Drip pan Removal of Fuel Cooler 1. Mark the fuel cooler (5) and hoses (1) (2) so that the connectors match at the time of assembly. • Use pliers to loosen the hose bands (3) (4), and then remove the hoses. • Fuel will spill out, so place a drip pan directly be- low the area. • Install caps or plugs to the fuel cooler and hoses to prevent any entry of water, dust or dirt. 2. Use a wrench [13 mm (0.512 in)] to remove the 4 bolts (1), and then remove the fuel cooler (2). 47370128A NA - April 2012 2001-3
  • 19. Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Installation of Fuel Cooler Perform the reverse of the removal procedure. After connecting the hoses, carefully check for any fuel leaks. When installing the bolts, tighten them to the specified torque. If the torque is not specified for a bolt or other part, see the Bolt Size and Torque Table. Removal and Installation of Engine Intercooler CAUTION • Be sure to stop the engine before beginning work. • As the fuel hose will be removed, strictly pro- hibit open flames. Items to prepare • Wrenches [8 mm (0.315 in), 13 mm (0.512 in), 19 mm (0.748 in)] • Flathead screwdriver • Cap • Rag • Cleaning fluid Removal of Intercooler 1. Use a wrench [13 mm (0.512 in)] to remove the 3 bolts (1), and then remove the cover (2). 2. Use a wrench [8 mm (0.315 in)] or flathead screw- driver to loosen the 2 hose bands (1) and remove the hose (2). • Use caps to cover the intercooler and hoses to prevent the entry of water, dust or dirt. Tightening torque for band (1) installation: 8.8 - 9.8 N·m (6.492 - 7.229 lbf·ft) 3. Use a wrench [8 mm (0.315 in)] or flathead screw- driver to loosen the 2 hose bands (1) and remove the hose (2). • Use caps to cover the intercooler and hoses to prevent the entry of water, dust or dirt. Tightening torque for band (1) installation: 8.8 - 9.8 N·m (6.492 - 7.229 lbf·ft) 47370128A NA - April 2012 2001-4
  • 20. Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 4. Use a wrench [19 mm (0.748 in)] to remove the bolt (1). 5. Attach a wire to the top section of the inter cooler using a shackle, and lift the inter cooler to remove it. Installation of Intercooler To install, perform the reverse of the removal procedure. Check for any air leaks. When installing the bolts, tighten them to the specified torque. If the torque is not specified for a bolt or other part, see the Bolt Size and Torque Table. 47370128A NA - April 2012 2001-5
  • 21. Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal and Installation of Radiator WARNING • Do not remove the radiator cap when the ra- diator coolant temperature is high. Hot liquid could spray out. CAUTION • Be sure to release the pressure within the cir- cuit before beginning work. • 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 stand or pass under the suspended load. Items to prepare • Wrenches [7 mm (0.276 in), 13 mm (0.512 in), 19 mm (0.748 in)] • Pliers • Shackles (with the required lifting capacity) x 2 • Wire rope (with the required breaking load) • Liftcrane (with the required lifting capacity) • Cap • Plug • Drain tank • Drain hose • Rag • Cleaning fluid • Wood planks, etc. Removal of Radiator 1. Use a wrench [19 mm (0.748 in)] to remove the 4 bolts (1), and then remove the under cover (2). 2. Install the drain hose (1), and then prepare the drain tank (2). 3. To make it easier to drain the coolant, remove the radiator cap (1). 47370128A NA - April 2012 2001-6
  • 22. Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 4. Loosen the drain plug (1), and then drain the coolant. 5. Use a wrench [13 mm (0.512 in)] to remove the 5 bolts (1), and then remove the covers (2) (3). 6. Use a box wrench [13 mm (0.512 in)] to remove the 6 bolts (1) from the radiator cover. 7. Use a wrench [7 mm (0.276 in)] to loosen the hose band (1) in the 2 locations, and then remove the upper hose (2) and lower hose (3) from the radiator. • Use caps to cover the radiator and hoses to pre- vent the entry of water, dust or dirt. • Tightening torque for band (1) installation: 4.9 - 5.9 N·m (3.615 - 4.352 lbf·ft) 8. Remove the drain plug (1), loosen the hose band (2), and then remove the hose (3). 47370128A NA - April 2012 2001-7
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  • 24. Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 9. Loosen the hose band (2), and then remove the hose (1) from the radiator cap. • Install caps or plugs to the hoses to prevent any entry of water, dust or dirt. 10. Use a wrench to remove the 3 bolts (1), and then remove the brackets (2). 11. Use a wrench to remove the 2 bolts (1), and then remove the fan guard (2). 12. Use a wrench to remove the 3 bolts (1), and then remove the brackets (2). Remove the bracket on the opposite side using the same procedure. 13. Remove the 2 one-touch clips (1), and then remove the front anti-insect net (2). 14. Use a wrench [19 mm (0.748 in)] to remove the 2 bolts (1), the 2 washers (2). 47370128A NA - April 2012 2001-8
  • 25. Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 15. Install the 2 shackles (1) to the top of the radiator, and then use the wire rope (2) and liftcrane to lift the radiator. 16. Lift until the fixtures (1) at the bottom of the radiator become disconnected. 17. Thoroughly check that the location is safe before lowering the radiator on square wooden piece. When laying down the radiator, be careful not to bend or crush the bottom fixtures (1). Installation of Radiator To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. If the torque is not specified, see the "Bolt Size and Torque Table". Coolant capacity is 16.2 L (4.280 gal). Finally, check that the level of coolant is correct. 47370128A NA - April 2012 2001-9
  • 26. Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal and Installation of Oil Cooler WARNING • Keep away from fire. 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 stand or pass under the suspended load. Items to prepare • Wrenches [7 mm (0.276 in), 13 mm (0.512 in), 19 mm (0.748 in)] • Hexagon wrench [6 mm (0.236 in)] • Pliers • Screwdriver • Eyebolts x 2 • Shackles (with the required lifting capacity) x 2 • Wire rope (with the required breaking load) • Liftcrane (with the required lifting capacity) • Cap • Waste oil can • Rag • Cleaning fluid • Wood planks, etc. Removal of Oil Cooler • Drain the hydraulic oil from the hydraulic oil tank. See Draining Oil from Hydraulic Oil Tank for details of the procedure. 1. Use a wrench [19 mm (0.748 in)] to remove the 3 bolts (1), and then remove the under cover (2). 2. Prepare the waste oil can (1). 3. Use a wrench [13 mm (0.512 in)] to remove the 5 bolts (1), and then remove the cover (2) (3). 47370128A NA - April 2012 2001-10
  • 27. Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 4. Remove the 2 one-touch clips (1), and then remove the anti-insect net (2). 5. Use a wrench [7 mm (0.276 in)] to loosen the hose band (1), and then remove the hose (2). • Use caps to cover the oil cooler and lines to pre- vent the entry of water, dust or dirt. 6. Use a hexagon wrench [6 mm (0.236 in)] to remove the 4 bolts (1), and then remove the lines (2). • Use caps to cover the oil cooler and lines to pre- vent the entry of water, dust or dirt. 7. Use a wrench [19 mm (0.748 in)] to remove the 2 bolts (1). 8. Install the 2 eyebolts (1) on the top of the oil cooler. • Fully tighten the eyebolts, and then loosen them by a half turn. 9. Install the 2 shackles (1) to the eyebolts, and then use the wire rope (2) and liftcrane to lift the oil cooler main unit. • When lifting the oil cooler unit, be careful not to let the line on the bottom of the oil cooler catch on the fan shroud. 47370128A NA - April 2012 2001-11