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1. SERVICE MANUAL
E75CSR
Midi Excavator
English
March 2013
Copyright © 2013 CNH Europe Holding S.A. All Rights Reserved.
SERVICE
MANUAL
E75CSR
Midi Excavator
1/2
Part number 47488366A Part number 47488366A

2. SERVICE MANUAL
E75CSR
47488366A 13/03/2013
EN

3. Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.216] Fuel tanks .......................................................................... 10.2
[10.202] Air cleaners and lines .............................................................. 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
[35.300] Reservoir, cooler, and filters........................................................ 35.2
[35.106] Variable displacement pump ....................................................... 35.3
[35.102] Pump control valves................................................................ 35.4
[35.304] Combination pump units ........................................................... 35.5
[35.359] Main control valve.................................................................. 35.6
[35.355] Hydraulic hand control ............................................................. 35.7
[35.356] Hydraulic foot control............................................................... 35.8
[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
[39.101] Upper frame........................................................................ 39.1
[39.103] Swing ring assembly ............................................................... 39.2
[39.140] Ballasts and supports .............................................................. 39.3
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4. 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
[50.200] Air conditioning..................................................................... 50.1
Electrical systems....................................................................... 55
[55.000] Electrical system ................................................................... 55.1
[55.100] Harnesses and connectors......................................................... 55.2
[55.015] Engine control system.............................................................. 55.3
[55.201] Engine starting system ............................................................. 55.4
[55.302] Battery.............................................................................. 55.5
[55.011] Fuel tank system ................................................................... 55.6
[55.640] Electronic modules ................................................................. 55.7
[55.512] Cab controls........................................................................ 55.8
[55.036] Hydraulic system control ........................................................... 55.9
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................. 55.10
[55.404] External lighting .................................................................. 55.11
[55.510] Cab or platform harnesses and connectors...................................... 55.12
[55.408] Warning indicators, alarms, and instruments .................................... 55.13
Booms, dippers, and buckets ....................................................... 84
[84.910] Boom ............................................................................... 84.1
[84.912] Dipper arm ......................................................................... 84.2
[84.100] Bucket.............................................................................. 84.3
Dozer blade and arm................................................................... 86
[86.110] Dozer blade ........................................................................ 86.1
Platform, cab, bodywork, and decals............................................. 90
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5. [90.150] Cab................................................................................. 90.1
[90.160] Cab interior trim and panels........................................................ 90.2
[90.120] Mechanically-adjusted operator seat............................................... 90.3
[90.105] Machine shields and guards ....................................................... 90.4
[90.116] Fenders and guards................................................................ 90.5
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6. INTRODUCTION
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7. INTRODUCTION
International symbols
Introduction
Although this manual uses the SI units system. Outline of
SI units system is described here.
Given here in under are an excerpt of the units that are
related to this manual :
1. Etymology of SI Units
English : International system of units
2. Construction of SI unit system
TULI12EXM0626AB 1
Basic units
Table1-1
Quantities Designation Sign
Length Meter m
Mass Kilogram kg
Time Second s
Current Ampere A
Thermodynamic temperature Kelvin K
Gram molecule Mol mol
Luminous intensity Candela cd
Supplementary units
Table1-2
Quantities Designation Sign
Plain angle Radian rad
Solid angle Steradian sr
Derived units of basic units
Table1-3
Quantities Designation Sign
Area Square meter m2
Volume Cubic meter m3
Velocity Meter per second m/s
Acceleration Meter per second/second m/s2
Density Kilogram per cubic meter kg/m3
Derived units bearing peculiar designations
Table1-4
Quantities Unit Symbol Formula
Frequency Hertz Hz 1Hz = 1/s
Force Newton N kg • m/s2
Pressure and stress Pascal Pa N/m2
Energy, work and quantity of heat Joule J N•m
Power Watt W J/s
Quantity of electricity Coulomb C A•s
Electric potential difference, voltage,
and electromotive force
Volt V W/A
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8. INTRODUCTION
Quantities Unit Symbol Formula
Quantity of static electricity and electric
capacitance
Farad F C/V
Electric resistance Ohm Ω V/A
Celcius temperature
Celcius degree or
degree
°C (t+273.15)K
Illuminance Lux lx l m/m2
Prefixes of SI
Table1-5
Prefix
Designation Sign
Power
Giga G 109
Mega M 106
Kilo k 103
Hecto h 102
Deca da 10
Deci d 10-1
Centi c 10-2
Milli m 10-3
Micro μ 10-6
Nano n 10-9
Pico p 10-12
Unit conversion table
Table1-6
Quantities JIS SI Remarks
Mass kg kg
Force kgf N 1 kgf = 9.807 N
Torque kgm N•m 1 kgm = 9.807 N·m
Pressure Kg/cm² MPa 1 Kg/cm² = 0.09807 MPa
Motive power PS kW 1PS = 0.7355 kW
Revolution RPM min-1 1 RPM = 1 min-1
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9. INTRODUCTION
Safety rules
ATTENTION: Do not operate or perform any maintenance on this machine until all instructions found in the OPERA-
TOR’S MANUAL and this MANUAL have been thoroughly read and understood. Improper operation or maintenance
of this machine may cause accidents and could result in serious injury or death.
Always keep the manual in storage.
If it is missing or damaged, place an order with an authorized our Distributor for a replacement. If you have any
questions, please consult an authorized our Distributor.
1. Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules.
Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance ser-
vices are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures,
NOTES, DANGERS, WARNINGS and CAUTIONS contained in the manual and on the machine should be read
and understood by all personnel before starting any work with or on the machine.
2. Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority.
Messages of safety are indicated with marks. The safety information contained in the manual is intended only to
supplement safety codes, insurance requirements, local laws, rules and regulations.
3. Messages of safety appear in the manual and on the machine : All messages of safety are identified by either
word of "DANGER", "WARNING" and "CAUTION".
1. Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury and is represented as follows:
2. Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury and is represented as follows:
3. Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against possible damage to the machine and
its components and is represented as follows:
4. It is very difficult to forecast every danger that may occur during operation. However,
safety can be ensured by fully understanding proper operating procedures for this
machine according to methods recommended by Manufacturer.
5. While operating the machine, be sure to perform work with great care, so as not to
damage the machine, or allow accidents to occur.
6. Continue studying the manual until all Safety, Operation and Maintenance procedures
are completely understood by all persons working with the machine.
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10. INTRODUCTION
Safety precautions
ATTENTION: The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are
outlined in the OPERATOR’S MANUAL for the machine.
Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death.
Read and understand the MANUAL before performing any lubrication or maintenance.
The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important
to use caution when performing service work. A knowledge of the system and or components is important before the
removal or disassembly of any component.
Because of the size of some of the machine components, the serviceman or mechanic should check the weights
noted in this manual. Use proper lifting procedures when removing any components.
The following is a list of basic precautions that must always be observed.
1. Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing
this machine.
2. Always wear protective glasses and protective shoes when working around machines. In particular, wear pro-
tective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders
gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not
wear loose fitting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose cloth-
ing before working on this machinery.
3. Disconnect the battery and hang a "Do Not Operate" tag in the Operators Compartment. Remove ignition keys.
4. If possible, make all repairs with the machine parked on a firm level surface. Block the machine so it does not
roll while working on or under the machine. Hang a "Do Not Operate" tag in the Operators Compartment.
5. Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands,
capable of supporting the machine, before performing any disassembly.
ATTENTION: Do not operate this machine unless you have read and understand the instructions in the OPER-
ATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death.
6. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or
removed. Always make sure all raised components are blocked correctly and be alert for possible pressure
when disconnecting any device from a system that utilizes pressure.
7. Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this
cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from
dropping unexpectedly.
8. Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps,
walkways or work platforms before using. Always face to the machine when using steps, ladders and walkways.
When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to per-
form safe repair operations.
9. To avoid back injury, use a hoist when lifting components which weigh 20kg (45lbs) or more. Make sure all chains,
hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly.
Lifting eyes are not to be side loaded during a lifting operation.
10. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes
and compartments.
11. Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite
ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing
the last two capscrews or nuts completely.
12. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to
prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just
been stopped because fluids can be hot.
13. Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you
understand how to use them before performing any service work.
14. Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are nec-
essary.
15. Repairs which require welding should be performed only with the benefit of the appropriate reference informa-
tion and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal
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11. INTRODUCTION
being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength
equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures
are attempted.
16. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged
in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do
not connect wiring to a line containing fluid.
17. Be sure all protective devices including guards and shields are properly installed and functioning correctly before
starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace
the guard or shield after repair is completed.
18. The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling
attachment. Don’t fail to lower the attachment and place the bucket to the ground before starting the work.
19. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike
high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully.
Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or
paper to locate pinhole leaks.
20. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed cor-
rectly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect
against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.
21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high
speed rotating component that has been damaged or altered should be checked for balance before reusing.
22. Be careful when servicing or separating the tracks (crawlers). Chips can fly when removing or installing a track
(crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly
when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both
tracks (crawlers) are disengaged from the sprockets. Block the machine to prevent it from moving.
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12. INTRODUCTION
Part identification
Machine main components
SMIL13CEX1700HA 1
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13. SERVICE MANUAL
Engine
E75CSR
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10

14. Engine - Engine and crankcase
Engine - General specification
Engine model ISUZU 4LE2X-S
Water-cooled, 4-cycle, direct injection type diesel engine with inter
Type
cooler turbo-charger
Number of cylinder-bore X stroke 4-85 mm (3.35 in) X 96 mm (3.78 in)
Total displacement 2179 cm³ (133 in³)
Compression ratio 17.6
Rated out put net 42 kW (57 Hp) / 2000 RPM
Maximum torque 211 N·m (156 lb ft) / 1800 RPM
High idling 2000 RPM
Low idling 1000 RPM
Thermostat action Start 82 °C (180 °F) / Full open 95 °C (203 °F)
Firing order 1-3-4-2
Compression pressure 3.04 MPa (441 psi) at 200 RPM
Fuel injection timing Electronic control type
Valve clearance Open Close
Intake
valve
0.4 mm (0.016 in) in
cold condition
15 ° before top
dead point
29 ° after bottom
dead pointValve clearance
Exhaust
valve
0.4 mm (0.016 in) in
cold condition
40 ° before top
dead point
16 ° after top
dead point
Starter capacity 3.2 kW X 24 V
Generator capacity (alternator) 50 A X 24 V
Cooling fan drive method
475 dia. ( 18.7 in) suction type seven fans
V-belt drive, pulley ratio Crank / Fan=1.12
Full level Max: 11.0 l (2.9 US gal), Min: 8.0 l (2.1 US gal)
Engine oil quantity Oil pan
only
Max: 10.4 l (2.7 US gal), Min: 7.3 l (1.9 US gal)
Dry weight Approx. 217 kg (478 lb)
Fuel consumption ratio 225 g/kWh (225 g/kWh)
Allowable inclination Front / Rear and Right / Left: 35 °
Dimension (L X W X H) 739 mm (29 in) X 601 mm (24 in) X 771 mm (30 in)
Rotating direction Counterclockwise seeing from flywheel side
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15. Engine - Engine and crankcase
Engine characteristic curve (ISUZU 4LE2X-S)
Condition to be measured : Without fan
SMIL13CEX1871HA 1
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16. Engine - Engine and crankcase
Engine - Special tools
Engine mounting pedestal
SMIL13CEX1880GA 1
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17. Engine - Engine and crankcase
Rear housing pedestal (17. PVC plate is proved)
SMIL13CEX1881GA 2
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18. Engine - Engine and crankcase
Front oil pan pedestal (140X180X540)
SMIL13CEX1882FA 3
Detail of front sandwich bar (70X70X400)
SMIL13CEX1883EA 4
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19. Engine - Engine and crankcase
Detail of rear sandwich bar (70X70X400)
SMIL13CEX1884EA 5
Woody materials
No Parts Qty Remarks
1 Crossbar 2 70 mm x 70 mm x 925 mm ( 0.0093 m³)
2 Base 2 70 mm x 70 mm x 540 mm ( 0.0053 m³)
3 Front oil pan pedestal (With notch) 1
140 mm x 180 mm x 540 mm ( 0.0136
m³) (with notch)
4 Right prevention interference bar 1 50 mm x 50 mm x 650 mm ( 0.0016 m³)
5 Front sandwich bar 1
70 mm x 70 mm x 400 mm ( 0.0020 m³)
(with notch)
6 Rear housing pedestal 1
95 mm x 140 mm x 540 mm ( 0.0060
m³) (with notch)
7 Rear sandwich bar 1 70 mm x 70 mmx 400 mm ( 0.0020 m³)
8 Left prevention interference bar 1 70 mm x 70 mm x 585 mm ( 0.0029 m³)
9 Bar for stopper 1 30t x 140 mm x 540 mm
Bolts, Nails, Wood screws
No Parts Qty Remarks
11 Bolt 4
12 dia x 255 mm (Top and bottom
counterbore)
12 Bolt 2
12 dia x 185 mm (Top and bottom
counterbore)
13 Wood screw 21
3.1 dia x 35 mm (12 dia. Counter
sinking)
14 Coach screw 10 9 dia x 90 mm (Top counterbore)
15 Screw nail 20
2.2 dia x 50 - 60 mm (Drive nail at
connection points appropriately)
16 Coach screw 2 9 dia x 90 mm
PVG plates
No Parts Qty Remarks
17 PVG plate 1
5t x 90 mm x 564 mm (Wood screw
cramp)
18 PVG plate 3
5t x 50 mm x 130 mm (Wood screw
cramp)
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20. Engine - Engine and crankcase
Engine - Prepare
1. Remove battery ground. (See Battery - Remove
(55.302) )
2. Remove bonnet and guard. (See Machine shields
and guards - Remove (90.105) )
3. Remove air cleaner hose.
4. Remove counterweight. (See Counterweight - Re-
move (39.140) )
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. (Refer to Electrical
system - Check (55.000) )
1. Remove E/G ground cable
2. Starter cable-starter B terminal
3. Upper harness
CN–6, CN-7, CN-12
CN-53
E/G control harness
P5 Alternator B terminal
CN-136 E/G speed sensor
CN–212 Glow
CN–456 Starter motor S terminal
NOTE: prepare a stand, which withstands the weight of the engine assy. and can place the removed engine firmly.
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21. Engine - Engine and crankcase
Outside view of engine
SMIL13CEX2047FA 1
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22. Engine - Engine and crankcase
Engine - Remove
SMIL13CEX2048FA 1
1. Remove hose of engine oil filter
Place oil pan under the connection of filter (1), and
disconnect 2 hoses (4).
Tools: Spanner 27 mm
2. Plug connector of filter side and hose
3. Loosen engine mounting bolt of frame
1. Loosen 2 nuts (6) M12 .
Tool: Socket 19 mm
2. Loosen 4 capscrews (12) M12 x 110
3. Remove 4 plates (6).
4. Remove upper rubber mounts (5) 4 each.
4. Slinging engine body
ATTENTION: prepare a stand, which withstands the weight of the engine assy and can place the removed engine
firmly.
1. Sling engine hooking wire to lifting lugs on the
front and rear sides.
Weight approx 232 kg (511 lb)
Wire: 6 dia ( 0.236 in) x 1 m (3.3 ft) 2 pcs
5. Position engine on the stand stably.
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23. Engine - Engine and crankcase
Engine - Install
Installing is done in the reverse order of removing.
Tightening torque
No. Name Tightening torque Remarks
12 Capscrew 80 N·m (59 lb ft) Apply LOCTITE® 271
13 Sems bolt 70.6 N·m (52 lb ft) Apply LOCTITE® 262
Tightening torque of Separated engine oil filter piping
ORS joint Hose
Thread size Tightening torque Tightening torque
PF 1/2 — 78.5 N·m (58 lb ft)
PF 3/4 162 N·m (119 lb ft) —
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24. Engine - Engine and crankcase
Engine - Service instruction
Engine related troubleshooting
Factors Checking
Filters Liquid Leak, clogging
Trouble
1* 2* 3* 4* 5* 6* 7* 8* 9* 10* 11* 12* 13* 14* 15*
Faulty starting
Poor start ability (take a long time) Ο Ο Ο Ο
Faulty engine starting/engine does not
rotate
Ο
Faulty engine starting/engine rotates
but no exhaust gas (no fuel injection)
Ο Ο Ο Ο
Faulty engine starting/exhaust gas is
emitted but engine does not start (with
fuel injection)
Ο Ο Ο Ο Ο
Insufficient rotation
Engine poor run-up (low follow-up
ability)
Ο Ο Ο
Rotation in bad condition (hunting) Ο Ο Ο
Poor output
Engine stalled during operation Ο Ο Ο
Output is lowered Ο Ο Ο Ο Ο
Overheating Ο Ο
Other failures
Exhaust smoke is black Ο Ο Ο Ο
Exhaust smoke is white Ο Ο
Lager oil consumption (or blue exhaust
gas)
Ο Ο
Early contamination of oil Ο Ο Ο Ο Ο
Larger fuel consumption Ο Ο Ο Ο
Intruding of oil in coolant, back flow,
reduction of coolant quantity
Hydraulic pressure down (monitor
lights up)
Ο Ο
Oil quantity increased (intruding of
water and fuel)
Ο
Vibration
1* Shortage of fuel level 9* Oil level of oil pan
2* Air cleaner clogged 10* Contamination of water and fuel with oil
3* Fuel filter clogged 11* Poor or deteriorated battery
4* Oil filter clogged
12* Leak, clogging of fuel system and intruding of
air
5* Fan belt slipped, fan pulley worn 13* Engine oil leak
6* Breather hose crushed or clogged
14* Air leak between turbocharger and intake
manifold
7* Improper fuel in use 15* Muffler clogged
8* Coolant level
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25. Engine - Engine and crankcase
Checking Electric equipment
Factors
Shovel side Shovel side Engine side
Trouble 1* 2* 3* 4* 5* 6* 7* 8* 9* 10* 11* 12* 13* 14* 15* 16* 17* 18* 19*
Faulty starting
Poor start ability
(take a long time)
Ο Ο Ο
Faulty engine
starting/engine
does not rotate
Ο Ο Ο Ο Ο Ο Ο O
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 O
Insufficient rotation
Engine poor
run-up (low
follow-up ability)
Rotation in
bad condition
(hunting)
Poor output
Engine stalled
during operation.
Ο
Output is
lowered.
Ο
Overheating Ο Ο Ο
Other failures
Exhaust smoke is
black
O O O
Exhaust smoke is
white
O
Lager 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)
Ο
Oil quantity
increased
(intruding of water
and fuel)
Vibration Ο
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26. Engine - Engine and crankcase
1* Loose mounting bolts, damage of mounting
rubber
11* Glow plug
2* Failure of radiator pressure cap 12* Glow relay
3* Radiator core clogged/fin clogged and crushed 13* Starter motor
4* Peeling of space insulation around radiator 14* Safety relay
5* Failure of hydraulic system 15* Hydraulic switch
6* Startup circuit wiring 16* Glow timer
7* Starter switch key 17* EGR cut controller
8* Loose connection of battery cable terminal 18* EGR valve
9* Battery rely 19* Boost sensor
10* Alternator
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27. Engine - Engine and crankcase
Factors Fuel system
Intake and
exhaust system
Lubrication
system
Cooling
system
Trouble 1* 2* 3* 4* 5* 6* 7* 8* 9* 10* 11* 12* 13*
Faulty starting
Poor start ability (take 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 injection)
Ο
Insufficient rotation
Engine poor run-up (low follow-up ability) Ο Ο
Rotation in bad condition (hunting)
Poor output
Engine stalled during operation.
Output is lowered. Ο Ο Ο
Overheating O Ο Ο
Other failures
Exhaust smoke is black Ο Ο
Exhaust smoke is white Ο O Ο Ο Ο
Lager oil consumption (or blue exhaust gas) Ο Ο Ο
Early contamination of oil O Ο Ο Ο
Larger fuel consumption Ο O Ο
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Ο Ο
Hydraulic pressure down (monitor lights up) Ο Ο Ο Ο
Oil quantity increased (intruding of water and
fuel)
Ο O
Vibration Ο
1* Failure of injector (nozzle, pump) 8* Failure of oil pump
2* Improper fuel injection time 9* Failure of relief valve
3* Fuel leak into the head cover 10* Failure of regulator valve
4* Turbocharger oil drain tube clogged 11* Leak and crush of hydraulic piping
5* Seal of turbocharger worn, damaged 12* Damage of water pump
6* Seizing and interference of turbocharger 13* Failure of thermostat (Not open)
7* Damage of EGR cooler
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28. Engine - Engine and crankcase
Factors Engine body
Trouble 1* 2* 3* 4* 5* 6* 7* 8* 9* 10* 11*
Faulty starting
Poor start ability (take a long time) Ο Ο
Faulty engine starting/engine does not rotate Ο
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
Insufficient rotation
Engine poor run-up (low follow-up ability) Ο Ο
Rotation in bad condition (hunting)
Poor output
Engine stalled during operation Ο
Output is lowered Ο Ο
Overheating Ο Ο
Other failures
Exhaust smoke is black Ο Ο
Exhaust smoke is white Ο Ο Ο Ο
Lager oil consumption (or blue exhaust gas) Ο Ο Ο Ο Ο
Early contamination of oil Ο Ο
Larger fuel consumption Ο
Intruding of oil in coolant, back flow, reduction of coolant
quantity
Ο Ο Ο Ο
Hydraulic pressure down (monitor lights up) Ο
Oil quantity increased (intruding of water and fuel) Ο Ο Ο Ο
Vibration Ο Ο
1* Damage of engine oil cooler core and O-ring 7* Wear of piston ring and liner, ring stick
2* Strainer clogged, damage of oil pipe 8* Hole due to cavitation
3* Damage of cylinder head and head gasket 9* Wear and damage of rear oil seal and seal surface
4* Failure of injection holder sleeve 10* Damage of dumper
5* Wear and failure of valve and valve guide 11* Damage of flywheel gear
6* Damage and seizing of piston and connecting rod
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29. Engine - Fuel tanks
Fuel tank - Prepare
1. Draining fuel.
1. Unlock cap (B1) with a starter key and open it.
2. Loosen valve (A16) under the tank.
3. Draining fuel
Capacity of tank: 120 l (32 US gal)
2. Remove panel assy.
3. Remove the connector for fuel level sensor (A4)
4. Remove fuel hose.
1. Loosen clip (27) and draw out hoses (11) and
(12).
2. Put in plugs that match the hose bore.
SMIL13CEX2011BA 1
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30. Engine - Fuel tanks
Fuel tank - Remove
1. Remove 2 capscrews (A1) M16 X 40 and remove 2
capscrews (A17) M16X60.
Tools: Socket: 24 mm
2. Hook the wire to the lifting eye on the fuel tank assy.
(B6) and remove the fuel tank.
Weight: 63 kg (139 lb)
3. Remove shim (A3).
NOTE: record the shim locations.
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31. Thank you very much for
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32. Engine - Fuel tanks
Fuel tank - Install
Installing is done in the reverse order of removing.
Tank attaching 2 bolt (A1) M16 X 40 and 2 bolts (A17)
M16X60.
Tools: Socket: 24 mm, apply LOCTITE® 262
Tightening torque: 191 N·m (141 lb ft)
ATTENTION: if the gap (looseness) between tank mount
and frame exceeds 1 mm (0.04 in), adjust the gap with
shim (A3) and tighten capscrew (A1), (A17) to install the
tank.
SMIL13CEX2012BB 1
Tightening torque
NO. Name Qty. Tightening torque
A1, A17 Capscrew 4 191 N·m (141 lb ft)
A5 Machine screw 5 1.96 N·m (1.45 lb ft)
A16 Cock 1 34 N·m (25 lb ft)
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33. Engine - Air cleaners and lines
Air cleaners and lines - Prepare
1. Opening bonnet assy. (2).
1. Unlock it with starter key.
2. Open bonnet (2).
2. Unplug terminals on indicator lines (2–5)
(see Fig Pulling out hose (4)).
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34. Engine - Air cleaners and lines
Air cleaners and lines - Remove
1. Pulling out hose (3).
1. Loosen clips (10) on air cleaner side.
2. Pulling out hose (3).
Tools: Flat-blade screw driver
SMIL13CEX2028AA 1
2. Pulling out hose (4).
1. Loosen clip (10) on air cleaner side.
2. Pulling out hose (4).
Tools: Flat-blade screw driver
3. Remove air cleaner assy (2).
1. Loosen 2 sems bolts (12) M10 X 25.
2. Remove air cleaner assy. (2) together with
bracket (7).
Tools: Socket: 13 mm
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35. Engine - Air cleaners and lines
Air cleaners and lines - Install
1. Installing is done in the reverse order of removing.
2. Spare parts for deteriorated elements.
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36. Engine - Intake and exhaust manifolds and muffler
Intake and exhaust manifolds and muffler - Prepare
1. Remove 4 sems-bolts (3) M10 X 20.
2. Remove exhaust tube (2).
3. Remove 4 sems-bolts (A17).
4. Remove cover assy (A3).
5. Open right hand cover (B2).
SMIL13CEX2031AA 1
SMIL13CEX2032BA 2
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37. Engine - Intake and exhaust manifolds and muffler
Intake and exhaust manifolds and muffler - Remove
1. Remove exhaust tube (3)
1. Remove 4 sems-bolts (4) M8 X 25.
Tools: Socket: 13 mm
2. Remove exhaust tube (3).
2. Remove cover (C2)
1. Remove 5 bolts (C3).
Tools: Socket:
2. Remove cover (C2).
SMIL13CEX2032BA 1
3. Remove harness connector of sensor (C4).
4. Remove 2 bolts (C7) and remove 2 clips (C5).
Tools: Socket
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38. Engine - Intake and exhaust manifolds and muffler
5. Loosen a clip (12) and pull out hose (11).
6. Remove 4 bolts (C6).
7. Remove 4 capscrews (7) M10 X 35.
Tools: Socket: 17 mm
8. Remove muffler.
9. Remove 4 bolts (8).
Tools: Socket
10. Remove bracket.
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