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1) An overview of the engine specifications and systems such as cooling, fuel, electrical, and emissions control systems.
2) Descriptions of the engine components including the cylinder block, cylinder liner, piston, cylinder head, crankshaft, and EGR system.
3) Identification information for the engine number and static descriptions of key engine features.
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Case cx160 d lc version tier 4b (final) crawler excavator service repair manu...ujjdfjkkskemme
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Case cx160 d lc version tier 4b (final) crawler excavator service repair manualufjjjsefkskem
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Case cx240 c crawler excavator service repair manualfujsjefjskkem
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Case cx210 c crawler excavator service repair manualdfujsjefjkskemm
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Case cx250 c crawler excavator service repair manualhfjsjekfksmem
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Case cx210 d crawler excavator service repair manualfsjefjskekmm
This document provides service information for the CX210D Crawler Excavator, including:
1) An overview of the engine specifications and systems such as cooling, fuel, electrical, and emissions control systems.
2) Descriptions of the engine components including the cylinder block, cylinder liner, piston, cylinder head, crankshaft, and EGR system.
3) Identification information for the engine number and static descriptions of key engine features.
Case cx500 c tier iii crawler excavator service repair manualfsjefjskekmm
The document is a service manual section that provides specifications for the CX490C and CX500C excavator engine. It includes detailed specifications for the engine, cooling system, lubrication system, electrical system, starter, glow plug, and special tools. The engine is a Tier 3 compliant Isuzu 6UZ1 diesel with a displacement of 9.839L and maximum output of 270kW at 2000 RPM.
Case cx160 d lc version tier 4b (final) crawler excavator service repair manu...ujjdfjkkskemme
This service manual section provides specifications and descriptions for the engine and related systems on the CX160D excavator. It details the engine model and main specifications, cooling system specifications, electrical system specifications, engine identification process, and an overview of the engine components and control systems, including the electronic control system, cylinder components, crankshaft, EGR system, fuel system, and preheat system.
Case cx160 d lc version tier 4b (final) crawler excavator service repair manualufjjjsefkskem
This service manual section provides specifications and descriptions for the engine on a Case CX160D excavator. It details the engine components and systems, including the electronic control system, cylinder block, piston, cylinder head, crankshaft, EGR system, fuel system, and preheat system. Identification information and maintenance instructions are also provided.
Case cx130 c crawler excavator service repair manualfusjefjjskekmem
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Case cx240 c crawler excavator service repair manualfujsjefjskkem
The document is a service manual that provides maintenance and repair information for the CX240C crawler excavator. It contains sections covering the engine, hydraulic systems, frames and ballasting, tracks and track suspension, cab climate control, electrical systems, booms/dippers/buckets, and the cab/bodywork. The engine section provides specifications and descriptions of the engine components, cooling system, electrical system, and identification information. It describes the electronic engine control and components like the cylinder block, heads, crankshaft, and common rail fuel injection system.
Case cx210 c crawler excavator service repair manualdfujsjefjkskemm
This document is a service manual for a CX210C crawler excavator. It contains sections covering the engine, hydraulic systems, frames and ballasting, tracks and track suspension, cab climate control, electrical systems, booms dippers and buckets, and the platform, cab, bodywork and decals. Each section contains multiple subsections that provide detailed instructions and part numbers for repair and maintenance of specific components. The introduction emphasizes the importance of qualified dealership personnel strictly following the procedures in the manual and using approved parts for any repair or maintenance work.
Case cx250 c crawler excavator service repair manualhfjsjekfksmem
This document is a service manual for the CX250C Crawler Excavator. It contains sections covering the engine, hydraulic systems, frames and ballasting, tracks and track suspension, cab climate control, electrical systems, booms, dippers, buckets, and the cab, bodywork and decals. Safety is emphasized, with a notice that all repair and maintenance work must be carried out by qualified dealership personnel only. The manual provides instructions and procedures to service the excavator safely and properly.
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This document is a service manual that contains sections on repairing various components of a forklift. It provides:
1) A table of contents listing the document sections by part number, section number, revision date.
2) A description of the forklift frame that includes the hydraulic tank, fuel tank, counterweight, overhead guard, hood, and covers. Safety procedures are provided for when putting the forklift on blocks for maintenance.
3) Instructions for removing the hood, seat, and side covers to access components like the engine and transmission.
Yale b875 gdp35 vx lift truck service repair manualfjjksekfksmem
This document provides a service manual for GLP/GDP20VX, GLP/GDP25VX, GLP/GDP30VX, GLP/GDP35VX lift trucks. It contains sections on frame components, engine repair, transmissions, axles, hydraulics and more. The frame includes the counterweight, fuel tank, hydraulic tank and mounts the overhead guard, hood and other parts. Procedures are provided for removing the counterweight, hood, side covers and accessing components. Safety precautions are described for when the lift truck is supported on blocks for maintenance.
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This document contains:
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2. A description of the main frame and its components including the counterweight, overhead guard, hood, and access panels.
3. Descriptions of other frame components including the cowl weldment, side step and fender weldments.
4. Information on battery compartment specifications and overhead guard installation.
Yale a839 erc100 hg lift truck service repair manualfjjksekfksmem
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Yale (d875) gp070 vx lift truck service repair manualfjjksekfksmem
The document provides instructions for removing an operator cab from a forklift. Key steps include:
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2. Disconnecting air filter hoses, removing radiator covers, and draining coolant lines.
3. For models with air conditioning, extracting refrigerant and disconnecting AC lines.
4. Disconnecting wiring harnesses, heater lines, gas springs and removing door assemblies. The cab can then be lifted off as a complete unit.
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The document provides instructions for removing an operator cab from various lift truck models. Key steps include:
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Perkins 400 series 402 d 403d 404d industrial engine (model gm) service repai...fjjksekfksmem
This document provides instructions for disassembling and assembling various components of Perkins 402D-403D-404D industrial diesel engines, including removal and installation procedures for items like the fuel filter base, fuel transfer pump, fuel lines, fuel injection pump, turbocharger, valves, pistons, bearings, and other parts. Safety warnings are provided to prevent injury when performing maintenance on these engines.
New holland t8030 tractor service repair manualfjjksekfksmem
This document provides a master table of contents for a tractor repair manual. It lists sections and chapters covering topics like standard torque specifications, safety information, engine removal and installation, fuel tank removal, hood removal, cooling system removal, transmission system operation, splitting the front frame from the transmission, splitting the transmission, speed transmission repair, splitting the range transmission from the rear frame, and range transmission repair. The document directs the user to other publications for information on engine repair.
New holland kobelco e135 b crawler excavator service repair manualfjjksekfksmem
This document provides an index and overview of safety precautions for operating a Crawler Excavator. It emphasizes reading the operation manual, understanding safety sign meanings, keeping areas clean and clear, and following proper safety equipment protocols like wearing a hard hat and protective clothing. Unauthorized operation and loose clothing that could get caught are forbidden.
Kubota rck54 23 bx-eu tractor service repair manualfjjksekfksmem
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Kioti daedong dk50 s tractor service repair manualfjjksekfksmem
This document contains operation and maintenance instructions for a tractor. It includes:
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2. Specifications for lubricants, fuels, and maintenance schedules. Inspections are to be done daily, every 50 hours of use, every 100 hours, and so on up to every 2 years.
3. Detailed chapters covering the engine, clutch, transmission system, and other components. These chapters describe features, troubleshooting steps, specifications, and procedures for disassembly, inspection, and maintenance.
Kioti daedong ck25 h tractor service repair manualfjjksekfksmem
This document contains operation and maintenance instructions for a tractor. It includes sections on safety, identification and dimensions of the tractor, general precautions for assembly and maintenance, specifications, lubrication requirements, tightening torques, and a maintenance schedule. The maintenance schedule includes daily, 50 hour, 100 hour, 200 hour, 400 hour, 600 hour, 800 hour, yearly, and as-needed checks. Additional sections provide details on tires, implement limitations, the engine system, clutch, and transmission.
Kioti daedong ch27 h tractor service repair manualfjjksekfksmem
- The document provides safety instructions and tips for working on tractors, including wearing proper protective gear, keeping the work area well-ventilated and clean, following procedures for handling hazardous materials and high pressure lines, and taking precautions to prevent fires, scalding, and injury from rotating parts. It emphasizes that most accidents can be avoided by following basic safety regulations and instructions.
Jcb vm146 pd smooth drum roller service repair manualfjjksekfksmem
This document provides information about service tools and consumables for servicing JCB machines. It includes a list of common sealing and retaining compounds with their part numbers and intended uses. Torque specifications are also included for fasteners and hydraulic connections on the machines. The document is intended to aid JCB service engineers in maintaining and repairing hydraulic earthmoving equipment.
Jcb vibromax vm106 single drum roller service repair manualfjjksekfksmem
This service manual provides maintenance and repair information for a single drum roller model VM 106. It contains 10 sections covering general information, the engine, electrical systems, hydraulics, power train, parking brake, vibration, steering, chassis, and attachments. The manual includes specifications, component identification, maintenance schedules, troubleshooting guides, schematics and diagrams. Procedures are provided for drum removal and installation, bearing replacement, and repair of drive motors, gearboxes and other components. Safety information is also presented.
Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
Yanmar 4 jh4ae marine diesel engine service repair manualfjjksekfksmem
This document is the service manual for Yanmar JH4 series marine engines. It contains safety information, maintenance procedures, troubleshooting steps, and specifications for the JH4, 3JH4E, 4JH4AE, 4JH4-TE, and 4JH4-HTE engines. The manual provides instructions for proper repair and maintenance to ensure quality service. Readers are advised to follow the procedures carefully and use recommended special tools for repairs.
Yamaha outboard 40 vehto, p40th service repair manual l 430386 fjjksekfksmem
This document provides a service manual for 40V, 50H outboard motors. It includes an index listing chapters covering general information, specifications, periodic inspection and adjustment, fuel system, power unit, lower unit, bracket unit, electrical system, and trouble analysis. The general information chapter discusses identification, safety practices, special tools, measuring tools, and tools for removal and installation. It provides guidance on safe work practices and proper use of special tools.
Yamaha g9 ah golf cart service repair manualfjjksekfksmem
This document is a Yamaha service manual that provides information on servicing Yamaha G2-A and G2-E vehicles. It contains chapters covering general information, specifications, periodic inspection and adjustment procedures, engine overhaul, carburetion, power train, chassis, electrical systems, troubleshooting, and special tools required for service. The document provides detailed instructions and specifications to guide technicians in properly servicing and repairing these vehicles.
Yale c875 glp20 vx lift truck service repair manualfjjksekfksmem
The document provides service manual contents and procedures for removing an operator cab from various forklift truck models. It contains the following key points:
- The operator cab is a separate unit that can be removed as a complete module from the forklift frame.
- Steps include tilting the steering column, sliding the seat forward, disconnecting battery and air filter hoses, draining coolant and removing radiator cap, disconnecting heater hoses and refrigerant lines (if equipped), and removing side door assemblies.
- Special precautions are outlined for working with pressurized cooling systems and refrigerants, as well as different cab configurations among the various forklift models.
Yale b888 erp15 vc lift truck service repair manualfjjksekfksmem
This document provides service information for replacing the front window panel on several lift truck models. It describes:
1) Removing nuts, bolts and washers to detach the front window panel from the overhead guard.
2) Removing additional hardware and brackets to fully remove the front window panel.
3) Cleaning and inspecting the front window panel and other components before reinstallation.
4) Noting placement of components during removal to aid in reinstallation.
Yale b875 gp070 vx lift truck service repair manualfjjksekfksmem
This document is a service manual that contains sections on repairing various components of a forklift. It provides:
1) A table of contents listing the document sections by part number, section number, revision date.
2) A description of the forklift frame that includes the hydraulic tank, fuel tank, counterweight, overhead guard, hood, and covers. Safety procedures are provided for when putting the forklift on blocks for maintenance.
3) Instructions for removing the hood, seat, and side covers to access components like the engine and transmission.
Yale b875 gdp35 vx lift truck service repair manualfjjksekfksmem
This document provides a service manual for GLP/GDP20VX, GLP/GDP25VX, GLP/GDP30VX, GLP/GDP35VX lift trucks. It contains sections on frame components, engine repair, transmissions, axles, hydraulics and more. The frame includes the counterweight, fuel tank, hydraulic tank and mounts the overhead guard, hood and other parts. Procedures are provided for removing the counterweight, hood, side covers and accessing components. Safety precautions are described for when the lift truck is supported on blocks for maintenance.
Yale b814 erp16 20 aaf lift truck service repair manualfjjksekfksmem
This document contains:
1. A service manual table of contents listing maintenance sections for various lift truck parts.
2. A description of the main frame and its components including the counterweight, overhead guard, hood, and access panels.
3. Descriptions of other frame components including the cowl weldment, side step and fender weldments.
4. Information on battery compartment specifications and overhead guard installation.
Yale a839 erc100 hg lift truck service repair manualfjjksekfksmem
This document provides a service manual for the ERC070-120HG lift truck models. It contains sections on various parts of the lift truck including the frame, motors, axles, steering, brakes, hydraulics, controls, batteries, masts, cylinders and fasteners. The document describes the frame design and components, provides specifications for battery size and weight, and describes how to adjust spacers in the battery compartment. It also provides instructions for removing and installing the overhead guard.
Yale (d875) gp070 vx lift truck service repair manualfjjksekfksmem
The document provides instructions for removing an operator cab from a forklift. Key steps include:
1. Tilting the steering column up, sliding the seat forward, opening rear doors/windows, and disconnecting the battery.
2. Disconnecting air filter hoses, removing radiator covers, and draining coolant lines.
3. For models with air conditioning, extracting refrigerant and disconnecting AC lines.
4. Disconnecting wiring harnesses, heater lines, gas springs and removing door assemblies. The cab can then be lifted off as a complete unit.
Yale (c875) gtp70 vx lift truck service repair manualfjjksekfksmem
The document provides instructions for removing an operator cab from various lift truck models. Key steps include:
1. Tilting the steering column, sliding the seat forward, and opening doors/windows to access components.
2. Disconnecting the air filter hose, radiator hoses, and extracting refrigerant from air conditioning systems.
3. Removing fasteners and disconnecting electrical connections to fully separate the cab unit for removal. Precautions are listed for high temperature and high pressure components.
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This document provides instructions for disassembling and assembling various components of Perkins 402D-403D-404D industrial diesel engines, including removal and installation procedures for items like the fuel filter base, fuel transfer pump, fuel lines, fuel injection pump, turbocharger, valves, pistons, bearings, and other parts. Safety warnings are provided to prevent injury when performing maintenance on these engines.
New holland t8030 tractor service repair manualfjjksekfksmem
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New holland kobelco e135 b crawler excavator service repair manualfjjksekfksmem
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Kubota rck54 23 bx-eu tractor service repair manualfjjksekfksmem
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Kioti daedong dk50 s tractor service repair manualfjjksekfksmem
This document contains operation and maintenance instructions for a tractor. It includes:
1. Identification and safety information for the tractor.
2. Specifications for lubricants, fuels, and maintenance schedules. Inspections are to be done daily, every 50 hours of use, every 100 hours, and so on up to every 2 years.
3. Detailed chapters covering the engine, clutch, transmission system, and other components. These chapters describe features, troubleshooting steps, specifications, and procedures for disassembly, inspection, and maintenance.
Kioti daedong ck25 h tractor service repair manualfjjksekfksmem
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- The document provides safety instructions and tips for working on tractors, including wearing proper protective gear, keeping the work area well-ventilated and clean, following procedures for handling hazardous materials and high pressure lines, and taking precautions to prevent fires, scalding, and injury from rotating parts. It emphasizes that most accidents can be avoided by following basic safety regulations and instructions.
Jcb vm146 pd smooth drum roller service repair manualfjjksekfksmem
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Jcb vibromax vm106 single drum roller service repair manualfjjksekfksmem
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Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
The Octavia range embodies the design trend of the Škoda brand: a fusion of
aesthetics, safety and practicality. Whether you see the car as a whole or step
closer and explore its unique features, the Octavia range radiates with the
harmony of functionality and emotion
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
7. INTRODUCTION
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.
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8. INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT
IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
47996196 20/05/2016
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9. INTRODUCTION
Safety rules – General information
Cleaning
Clean the metal parts with cleaning solution that meets the standard and steam cleaning. (except for bearings)
After cleaning, dry well, and inject oil in all parts.
Also inject oil into the bearings after drying.
Inspection
When disassembling parts, check all the parts.
If there are any worn or damaged parts, replace them.
Inspect carefully to prevent initial breakdowns.
Bearing
Replace any loose bearings.
Air dry bearings before installing them.
Needle bearing
When inserting needle bearings, be very careful not to damage them.
Apply grease to the section where the needle bearing will be inserted.
Gear
Check that there is no wear and no damage.
Oil seal, O-ring, gasket
Always install new oil seals, O-rings, and gaskets.
Apply grease to sections where oil seals and O-rings will be inserted.
Shaft
Check that there is no wear and no damage.
Check the bearings and check for damaged oil seals on the shaft.
Service parts
Install CASE CONSTRUCTION genuine service parts.
When placing an order, check the parts catalog. It contains the CASE CONSTRUCTION genuine part numbers.
Any breakdowns arising from the installation of non-genuine parts are not covered by the warranty.
Lubricants (fuel, hydraulic oil)
Use the oil from the specified company or specified in the operator's manual or service Manual.
Any breakdowns arising from any fuel or hydraulic oil other than those specified are not covered by the warranty.
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10. INTRODUCTION
Safety rules – Personal safety
WARNING:
This symbol indicates a precaution.
It gives information concerning the safety of the operator and those in the surroundings.
Read and understand these precautions thoroughly before performing the work.
Always comply with warnings and precautions so as to avoid any accidents.
This section covers information related to overall safety.
Check whether all warning labels are in place.
Additional labels can be ordered from Service Parts.
WARNING:
Read the operator's manual to gain a thorough understanding of machine control operations.
WARNING:
Perform any machine operations from the seating position.
Any other method may cause severe injuries.
WARNING:
Only the one operator is to ride on the machine. No one else is to ride on it.
WARNING:
Check the safety messages in the operator's manual before starting the engine.
Check all the warning labels on the machine.
Check that no one is within the machine’s operating range.
Check the operating methods in a safe location before starting the actual work.
Understand the machine operations well, then operate in compliance with all service-related laws and regulations.
The operator's manual can be purchased at your CASE CONSTRUCTION dealer.
WARNING:
Working with sloppy clothes or clothes with which safety cannot be ensured leads to damage to the machine
and injury to the operator.
Always wear clothes that ensures safety.
In order to work more safely, it is recommended to wear additional safety equipment.
Helmet, safety shoes, ear protection, goggles, work clothes, and gloves
WARNING:
Pay careful attention when working with the engine running.
WARNING:
Check hydraulic equipment.
Work according to the procedure.
Do not change the procedure.
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12. Engine - Engine and crankcase
Engine - General specification
Engine main specifications
Item Engine model AR-4JJ1X
Type
Diesel/4-cycle/water-cooled, inline 4 cylinder
OHC
Shape of combustion chamber Direct injection type
Cylinder liner type Dry type
Cylinder bore x stroke 95.4 mm (3.76 in) x 104.9 mm (4.13 in)
Displacement 2.999 L (183 in³)
Compression ratio 17.5
Compression pressure 3 MPa (435 psi) 200 RPM
Idling speed 800 RPM
Intake 0.15 mm (0.006 in) While cool
Valve clearance
Exhaust 0.15 mm (0.006 in) While cool
Ignition method Compression ignition
Injection order 1, 3, 4, 2
Lubrication system
Lubrication type Compression type
Oil pump type Gear type
Lubrication oil amount 15 L (4 US gal)
Oil filter type Full-flow filter (Cartridge type)
Oil cooling type Built-in type, water cooling
Cooling system
Cooling type Water cooling
Radiator type Corrugated fin (Pressure type)
Water pump type Centrifugal type, belt type
Thermostat type Wax type unit
Coolant capacity 14.5 L (3.8 US gal)
Fuel system
Injection pump type Electronic control common rail (fuel rail) type
Governor type Electronic type
Timer type Electronic type
Injection nozzle type Multi-hole type 8 holes
Charging system
Generator type AC type
Output 24 V 50 A
Regulator type IC
Starter system
Starter type Reduction type
Output 24 V 4.0 kW
Preheat system type Glow plug
Glow plug standard voltage/current 23 V 3.8 A
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13. Engine - Engine and crankcase
Cooling system main specifications
Item Specifications
Water pump Centrifugal impeller method
Pulley ratio 1.03
Thermostat Wax pellet type
Full open temperature 95 °C (203 °F)
Electrical system main specifications
Generator
Item Data
Isuzu parts number 8980921122
Nominal output 24 V/ 50 A
Rated speed 5000 RPM
Regulator type IC type
Regulated voltage 28 - 29 V
Weight 9.1 kg (20.1 lb)
Starter
Type (Manufacturer) Hitachi
Voltage 24 V
Output 4 kW (5.4 Hp)Rated
Time 30 s
No. of pinion gears 11
Direction of rotation (toward pinion) Clockwise
Weight (approx.) 6.3 kg (13.9 lb)
Current/voltage 120 A or less/ 24 V
No-load characteristics
Speed 3500 RPM or more
Current/voltage 250 A/ 18.6 V
Torque 13.2 N·m (9.74 lb ft) or moreLoad characteristics
Speed 1590 RPM or more
Current/voltage 1100 A or less/ 10 V
Locking characteristics
Torque 47 N·m (34.67 lb ft) or more
Glow plug
Preheat device model Glow plug
Glow plug rated voltage/current 23 V / 3.5 A
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14. Engine - Engine and crankcase
Engine - Identification
SMIL15CEX8993FB 1
1. Engine number stamping
2. Engine model stamping
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15. Engine - Engine and crankcase
Engine - Static description
Engine electronic control
The control provided by the control unit applies to the range from injection to air intake and exhaust, including fuel
injection quantity, injection timing, air intake restriction, EGR, and idling speed.
Cylinder block
The cylinder block is made of cast iron, and it has an equal center distance for each bore and a high rigidity, and the
center of the crankshaft matches the center of the block.
Piston
The piston is a strut cast thermal flow piston made of aluminum alloy, and the combustion chamber is the round
re-entrant type.
Cylinder head
The cylinder head is made of cast iron and has four valves per cylinder. The angle tightening method has been
adopted for the cylinder head bolt to further improve its reliability and durability.
Crankshaft
The crankshaft is not fit to be reused, as it has tufftride treatment applied. In case of any defects, replace with a new
one.
EGR system
The EGR system is controlled by the engine control module (ECM) according to various data, including the water
temperature, engine speed, and engine load, to recirculate the exhaust gas for purification. The primary components
are the EGR valve, EGR cooler, and various sensors.
Connecting rod cap bolt
The angle tightening method has been adopted for the connecting rod cap bolt to further improve its reliability and
durability.
Common rail type electronic control injection system
The common rail type electronically controlled injection system consists of a fuel supply pump that sets the target
pressure of high-pressure fuel to supply the fuel, a common rail to measure high-pressure fuel, and a fuel injector
to emit a fine spray of fuel. Each of these is controlled by the ECM based on various signals to control the injection
timing and injection amount in accordance with the driving condition.
Fuel injector
An 8-hole nozzle has been adopted for the fuel injector, and fuel injection quantity or injection timing is adjusted by
opening and closing the electromagnetic valve of injector head.
The ECM corrects the differences in fuel injection quantity between fuel injectors based on the ID code data in the
memory. The ID code data must be recorded in ECM when adjusting fuel injector.
Fuel filter with sedimenter
The fuel filter with sedimenter makes use of the difference in specific gravity of diesel oil and water to removes water
and notifies the operator through an indicator when the water reaches its full capacity.
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16. Engine - Engine and crankcase
Preheat system
The preheat system consists of ECM, glow relay, glow plug, and glow indicator lamp. To help start the engine at low
coolant temperature, the preheat system is activated when engine coolant temperature is low.
Lubricating system
It uses the full flow bypass oil filter, and cools the piston with water-cooled oil cooler and oil jet.
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17. Engine - Engine and crankcase
Engine - Prepare
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
Failure to comply could result in death or serious injury.
W0178A
WARNING
Avoid injury!
Shut off the engine, remove the key, and make sure all motion is stopped before servicing the machine.
Failure to comply could result in death or serious injury.
W1128A
WARNING
Crushing hazard!
The lifting systems must be operated by qualified personnel who are aware of the correct procedures
to follow. Make sure all lifting equipment is in good condition, and all hooks are equipped with safety
latches.
Failure to comply could result in death or serious injury.
W0256A
WARNING
Heavy objects!
Lift and handle all heavy components using lifting equipment with adequate capacity. Always support
units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
Failure to comply could result in death or serious injury.
W0398A
WARNING
Explosion hazard!
Batteries emit explosive gases. Always ventilate when using in an enclosed area or when charging.
Keep the battery away from sparks, open flames, and other ignition sources.
Failure to comply could result in death or serious injury.
W0369A
NOTICE: Keep away from flames.
NOTICE: The air conditioner circuit is filled with high pressure gas, gas may spray out dangerously when loosening
lines.
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18. Engine - Engine and crankcase
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)
• Lifting equipment (with the required lifting capacity)
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Wood plank, etc.
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19. Engine - Engine and crankcase
Engine - Remove
1. Remove the 2 bolts (1) to remove the battery cover (2).
SMIL15CEX4657AB 1
2. Remove the bolt (1) with a wrench [ 17 mm] to remove
the negative battery cable (2).
• Secure the terminal and harness in order to prevent
them from touching the frame or other parts when
they have been removed.
Moreover, protect them with rubber caps etc. to pre-
vent sparks.
• Bolt tightening torque: 10.6 - 13.0 N·m (7.8 - 9.6 lb
ft)
SMIL15CEX6714AB 2
3. Remove the counterweight. (For details, See " Coun-
terweight - Remove (39.140) and Counterweight - In-
stall (39.140)").
4. Remove the SCR (For details, See " Selective Cat-
alytic Reduction (SCR) muffler and catalyst - Re-
move (10.500)” and “ Selective Catalytic Reduction
(SCR) muffler and catalyst - Install (10.500)”).
5. Remove the pump. (For details, See " Pump - Remove
(35.106) and Pump - Install (35.106)").
6. Remove the 4 bolts (1) with a wrench [ 19 mm] to re-
move the bracket (2).
SMIL15CEX4460AB 3
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20. Engine - Engine and crankcase
7. Loosen the hose band to disconnect the rubber hoses
(1) and (2) from the air cleaner.
Loosen the hose bands (3) and (4) with a wrench [
7 mm] to disconnect the intercooler hose (on high tem-
perature side) (5) and the hose from the air cleaner (6).
• Band (3) tightening torque: 8.8 - 9.8 N·m (6.5 - 7.2 lb
ft)
• Band (4) tightening torque: 6.3 - 7.3 N·m (4.6 - 5.4 lb
ft)
SMIL15CEX6715AB 4
8. Loosen the hose band (1) to disconnect the intercooler
hose (on low temperature side) (2).
• Hose band (1) tightening torque: 8.8 - 9.8 N·m (6.5
- 7.2 lb ft)
NOTE: The arrow indicates the left side of the vehicle.
SMIL15CEX4462AB 5
9. Remove the bolts (1) (2) with a wrench to remove the
fan shroud (3).
LPIL12CX00144BB 6
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21. Engine - Engine and crankcase
10. Remove the bolt (1) with a wrench to remove the fan
guard (2).
LPIL12CX00145AB 7
11. Loosen the 2 hose bands (1) of the radiator with a
wrench [ 7 mm] to disconnect the upper hose (2) and
the lower hose (3).
• Attach caps to each location of the radiator and
hoses to prevent the entry of water, dust, and dirt.
• Completely drain coolant before removing the radi-
ator hose.
• Band (1) tightening torque: 4.9 - 5.9 N·m (3.6 -
4.4 lb ft)
SMIL15CEX4463BB 8
12. Remove the 2 bolts (1) with a wrench [ 13 mm] to
remove the connector bracket (2).
SMIL15CEX4464AB 9
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22. Engine - Engine and crankcase
13. Remove the bolt with a wrench [ 13 mm] to remove the
2 clamps (1), and then disconnect the 5 connectors
(2).
• Wrap the disconnected connectors with a plastic
sheet after bundling them.
• Bolt tightening torque: 21.6 - 37.2 N·m (15.9 -
27.4 lb ft)
SMIL15CEX4465AB 10
14. Disconnect the connector (1) of the air conditioner
compressor.
SMIL15CEX4466AB 11
15. Remove the bolt (1) with a wrench [ 13 mm] to remove
the terminal cap (2).
Remove the wiring (3) (4) from the starter with a
wrench.
Remove the bolt (5) with a wrench [ 17 mm ] to remove
the wiring (6) from the frame.
SMIL15CEX4467AB 12
16. Remove the bolts (1) with a wrench [ 10 mm].
Remove the connector (2) of the alternator.
Remove the harness (3) from the alternator.
SMIL15CEX4468AB 13
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23. Engine - Engine and crankcase
17. Remove the 2 bolts (1) of lines with a wrench [ 13 mm]
to disconnect the lines (2) (3) of the compressor.
• Make sure that the piping (2) on the lowpressure
(suction) side is removed first.
• Attach caps and plugs to each location of the com-
pressor and piping to prevent the entry of water,
dust, and dirt.
• Bolt (1) tightening torque: 20.0 - 25.0 N·m (14.8 -
18.4 lb ft)
SMIL15CEX4469AB 14
18. Loosen the 2 hose bands (1) to disconnect the heater
hoses (2) (3) .
• Attach caps and plugs to the engine and the hoses
to prevent the entry of water, dust, and dirt.
NOTE: The arrows indicate the left side of the vehicle.
SMIL15CEX4470BB 15
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24. Engine - Engine and crankcase
19. Prepare a waste oil can (1) .
• Drain engine oil in advance to remove the hose for
engine oil.
• Disconnect the 2 engine oil remote hoses (1) with
a wrench [ 36 mm ].
• Apply marking to each location of the engine and
hoses so as to match connections at assembling.
• Attach caps and plugs to each location of the en-
gine and hoses to prevent the entry of water, dust,
and dirt.
• Wash each location of the engine and hoses by
blowing parts cleaner so as to prevent adhering dirt
at connections and not to damage them.
• Tightening torque: 54.1 - 63.9 N·m (39.9 - 47.1 lb
ft)
NOTE: The arrow indicates the front side of the vehicle.
SMIL15CEX4471BB 16
20. Remove the hose bands (1) to disconnect the fuel
hoses (2) and (3).
• Attach caps and plugs to the engine and the hoses
to prevent the entry of water, dust, and dirt.
SMIL15CEX4472AB 17
21. Loosen the hose bands (1) to disconnect the cooling
hoses (2) (3).
SMIL15CEX4473AB 18
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25. Engine - Engine and crankcase
22. Attach the 2 shackles (1), and secure the engine main
unit with wire ropes (2) and a liftcrane.
SMIL15CEX4474AB 19
23. Remove the 4 bolts (1) of the mount with a box wrench
[ 24 mm].
• Bolt tightening torque: 264.9 - 313.9 N·m (195.4 -
231.5 lb ft).
NOTE: The arrows indicate the front side of the vehicle.
SMIL15CEX4475BB 20
24. Lift the engine main unit with wire ropes (1) and a
liftcrane.
• Before lifting, be sure to check that hoses and con-
nectors are all disconnected.
• Make sure that the area is safe, and then place the
engine on wood planks.
• Fully secure the engine so that it may not topple.
SMIL15CEX4476AB 21
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26. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
27. Engine - Engine and crankcase
Engine - Install
1. To install the engine, perform the reverse of the removal
procedure.
When installing each bolt, tighten them to the specified
torque.
For bolts for which the torque is not specified, see
Torque – Bolt and nut ().
After installing the engine, resupply coolant and engine
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 wa-
ter or oil leaks.
3. Attach the hydraulic pump, covers, and counterweight.
For details, see the individual explanations for each
procedure.
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28. Engine - Engine and crankcase
Engine - Check - Engine oil
WARNING
Burn hazard!
Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that
exceed 49 °C (120 °F). Allow fluids to cool before proceeding.
Failure to comply could result in death or serious injury.
W0330B
NOTICE: The engine should be in a horizontal position.
NOTICE: Wait at least 5 min before starting the engine and after stopping the engine.
Engine oil inspection
1. Remove the oil level gauge from the oil level gauge
guide tube.
NOTE: Wipe off the engine oil remaining on the oil level
gauge.
2. Install the oil level gauge to the oil level gauge guide
tube.
3. Remove the oil level gauge from the oil level gauge
guide tube.
4. Inspect the engine oil.
NOTE: Check the engine oil remaining on the oil level
gauge to inspect the engine oil level.
1. MAX
2. MIN
3. Acceptable oil amount
4. Requires replenishment
NOTE: If the oil level is under the lower limit, add engine
oil. Replace the engine oil if engine oil is dirty.
LPIL12CX009 1
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29. Engine - Engine and crankcase
Engine - Test - Engine oil
Sampling of engine oil
1. Open the side door (1).
At this time, make sure to apply the lock (2).
SMIL15CEX4477AB 1
2. Place a sampling container under the sampling port (1).
3. Open the valve (2) to drain a proper amount of oil.
4. Close the valve (2) to check that there is no leakage.
5. If necessary, add the same amount of oil as the drained
oil.
SMIL15CEX6716AB 2
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30. Engine - Engine and crankcase
Engine - Compression test
NOTE: Warm up the engine.
1. Remove the glow plug from the cylinder head assem-
bly.
NOTE: Remove all the glow plugs.
2. Remove the injector harness connectors (1) from the
lower cover.
SMIL14CEX5667AB 1
3. Install the special tool on the cylinder head assembly.
Special tool: Compression gauge adapter (Refer
to Cylinder head - Special tools (10.101))
SMIL14CEX3445AA 2
Special tool: Compression gauge (adapter) (Refer
to Cylinder head - Special tools (10.101))
SMIL14CEX3446AA 3
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31. Engine - Engine and crankcase
4. Insert the compression gauge adapter (2) into the glow
plug installation hole to install the compression gauge
(1).
SMIL14CEX3447BB 4
5. To measure the compression pressure proceed as fol-
lows:
• Turn the starter and read the compression pressure
when the compression gauge indicator is stable at
about 200 RPM.
• Measure the compression pressure for all cylinders.
Standard value: 2840 - 3240 kPa (412 - 470 psi) .
Limit value: 1960 kPa (284 psi).
Difference between each cylinder: 294 kPa
(43 psi)
NOTE: Be careful of the streaming air blowing out from the
glow plug hole while rotating.
NOTE: If the key switch is turned ON with the injector har-
ness connector removed, the ECM judges that it is a mal-
function and a diagnostic trouble code is set. Be sure to
clear DTCs after the inspection is complete.
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