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, cooling system, electrical system, and preheat system. Identification information and maintenance instructions are also provided.
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This document is a service manual for the CX300D 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 platform, cab, bodywork and decals. The introduction emphasizes that all repair and maintenance work should only be performed by qualified dealership personnel using the proper instructions and tools. It notes that the manufacturer will not be responsible for damages caused by unauthorized parts or repairs.
Case cx210 d, cx210d long reach crawler excavator service repair manualfujsjefjsekkem
1. The document is a service manual that provides specifications and descriptions for key components of the CX210D crawler excavator engine.
2. It includes detailed specifications for the engine, cooling system, electrical system, and descriptions of components like the cylinder block, cylinder head, pistons, crankshaft, and EGR system.
3. The manual explains that many components use techniques like angle tightening of bolts to improve reliability and durability. It provides the information needed to service and repair the engine.
CASE CX160D LC Version Tier 4B (final) Crawler Excavator Service Repair Manua...f8sieokdkdmd
This service manual section provides specifications and descriptions for the key components of the CX160D excavator's engine. The engine uses a common rail electronic fuel injection system that is precisely controlled by the engine control module. It has features like a glow plug preheat system, centrifugal water pump, and EGR system to reduce emissions. Maintenance instructions are provided for proper inspection and replacement of parts like the cylinder head, fuel injectors, and filters.
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The document provides specifications for an ISUZU AQ-6HK1X diesel engine, including its cylinder configuration, displacement, compression ratio, lubrication system details, cooling system details, fuel system details, and charging and starter systems. Key specifications include a 6-cylinder inline configuration with 115mm bore and 125mm stroke for 7.79L displacement and an electronic common rail fuel injection system.
Case cx300 d crawler excavators nlc version (tier4 final) eu market service...fjjskekmsemm
The document provides specifications for an ISUZU AQ-6HK1X diesel engine, including its cylinder configuration, displacement, compression ratio, lubrication system details, cooling system details, fuel system details, and charging and starter systems. Key specifications include a 6-cylinder inline configuration with 115mm bore and 125mm stroke for 7.79L displacement and an electronic common rail fuel injection system.
Case cx160 d crawler excavator service repair manualfusjejfjskekemm
This document is a service manual for CX160D and CX180D crawler excavators. 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. The introduction emphasizes that repair and maintenance should only be performed by qualified dealership personnel according to the procedures in the manual. It notes the manufacturer is not responsible for damages caused by unauthorized parts or repairs.
Case cx290 d crawler excavator service repair manualdfujsjefjkskemm
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Case cx300 d crawler excavators lc version (tier4 final) mea market service...fujsjefjkskekfm
This document is a service manual for the CX300D 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 platform, cab, bodywork and decals. The introduction emphasizes that all repair and maintenance work should only be performed by qualified dealership personnel using the proper instructions and tools. It notes that the manufacturer will not be responsible for damages caused by unauthorized parts or repairs.
Case cx210 d, cx210d long reach crawler excavator service repair manualfujsjefjsekkem
1. The document is a service manual that provides specifications and descriptions for key components of the CX210D crawler excavator engine.
2. It includes detailed specifications for the engine, cooling system, electrical system, and descriptions of components like the cylinder block, cylinder head, pistons, crankshaft, and EGR system.
3. The manual explains that many components use techniques like angle tightening of bolts to improve reliability and durability. It provides the information needed to service and repair the engine.
CASE CX160D LC Version Tier 4B (final) Crawler Excavator Service Repair Manua...f8sieokdkdmd
This service manual section provides specifications and descriptions for the key components of the CX160D excavator's engine. The engine uses a common rail electronic fuel injection system that is precisely controlled by the engine control module. It has features like a glow plug preheat system, centrifugal water pump, and EGR system to reduce emissions. Maintenance instructions are provided for proper inspection and replacement of parts like the cylinder head, fuel injectors, and filters.
Case cx300 d crawler excavators lc version (tier4 final) mea market service...fjjksekfksmem
This document is a service manual for the CX300D Crawler Excavator. It contains instructions for servicing and repairing engine systems, hydraulic systems, frames and ballasting, tracks and track suspension, cab climate control, electrical systems, booms, dippers, buckets, and the platform, cab, bodywork and decals. Any repair or maintenance work must be performed by qualified dealership personnel using the procedures and special tools provided. The manufacturer is not responsible for damages caused by unauthorized parts or components.
Case cx300 d crawler excavators lc version (tier4 final) eu market service ...fjsefksemmm
The document provides specifications for an ISUZU AQ-6HK1X diesel engine, including its cylinder configuration, displacement, compression ratio, lubrication system details, cooling system details, fuel system details, and charging and starter systems. Key specifications include a 6-cylinder inline configuration with 115mm bore and 125mm stroke for 7.79L displacement and an electronic common rail fuel injection system.
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The document provides specifications for an ISUZU AQ-6HK1X diesel engine, including its cylinder configuration, displacement, compression ratio, lubrication system details, cooling system details, fuel system details, and charging and starter systems. Key specifications include a 6-cylinder inline configuration with 115mm bore and 125mm stroke for 7.79L displacement and an electronic common rail fuel injection system.
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This document provides parts information for a PC200LC-3 excavator with serial numbers 20001 and up. It includes 380 line items grouped into 10 categories: Engine Related Parts and Electrical System, Travel and Final Drive, Undercarriage, Swing and Control System, Revolving Frame and Cab, Work Equipment Control System, Work Equipment, Optional Parts, Special Application Parts, and Mark Plate/Tool and Kit. Each line item lists the part name, number, and applicable serial number range.
Komatsu pc138 us 2 crawler excavator parts catalogue manual - sn 4501 and upfujsjefkkkemme
This document provides parts information for a PC138US-2 excavator with serial numbers 4501 and up for overseas versions. It includes a parts list and part numbers for the engine and its related parts, cooling system, and other systems. The parts are organized by category and subcategories with references to other documents providing more detailed part specifications and diagrams.
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This document provides parts information for a Komatsu PC138US-2 excavator with serial numbers 1001 and up. It includes sections covering the engine and related parts, cooling system, fuel tank, electrical system, hydraulics, frames, operator controls, guards, undercarriage, work equipment, markings and plates, accessories, special products, and service kits. The document lists part numbers, descriptions, quantities and applicable serial number ranges for each component.
Komatsu hm350 1 articulated dump truck parts catalogue manual - sn 1001 and upfujsjefkkkemme
This document provides parts information for an HM350-1 excavator with serial numbers 1001 and up. It includes a list of major systems and subsystems with 3-digit codes for easy part identification (e.g. B0150 refers to the air conditioning system). For each part, the document provides the part number, name, quantity, and applicable serial number range. The level of detail in the parts listings provides a complete resource for technicians to identify replacement components for this excavator model.
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This document provides parts information for an HM300-3 excavator with serial numbers 3001 and up. It includes sections for the engine, cooling system, fuel system, electrical system, and other components. The cooling system section lists units for the radiator, aftercooler, coolant piping, brake oil cooler, and brake oil cooler piping. Parts are identified by index number, part number, description, and quantity. Diagrams and part numbers are provided for individual components.
Case cx490 c crawler excavators std version (tier 3) turkish market service...fujsjefkkkemme
This service manual section provides specifications for the Isuzu 6UZ1 diesel engine, including its cooling system, lubrication system, and electrical system. The engine is an inline 6-cylinder overhead cam design with a displacement of 9.839 liters. Maximum output is 270 kW at 2000 RPM with maximum torque of 1435 Nm at 1500 RPM. Coolant capacity is 22.5 liters and oil capacity ranges from 30-41 liters. The generator is a 24V/50A unit and the starter is a 24V/5.5kW unit designed to crank the engine at over 3100 RPM.
Case cx250 d long reach crawler excavator service repair manualfujsjefkkkemme
This document is the service manual for CX250D Crawler excavators. It contains sections on 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. The introduction emphasizes that all repair and maintenance work must only be done by qualified dealership personnel using the proper tools and procedures. Liability is disclaimed for damages caused by unapproved parts or improper servicing.
Case cx160 b crawler excavator service repair manualfujsjefkkkemme
This document provides a service manual table of contents for a crawler excavator. It lists 9 sections covering general information, the engine, fuel system, electrical system, undercarriage, drive train, undercarriage hydraulics, upperstructure hydraulics, upperstructure, and includes large size hydraulic and electrical schematics. Safety topics and standard torque specifications are also included in section 1. The document provides part numbers and references for removal, installation, disassembly and assembly procedures for various components of the excavator.
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This document is a service manual that contains information for servicing and repairing CX130D crawler excavators. It includes sections covering the engine, hydraulic systems, frames and ballasting, tracks and track suspension, cab climate control, electrical systems, booms, dippers, buckets, dozer blades, and the platform, cab, bodywork and decals. The introduction emphasizes that all repair and maintenance work must only be done by qualified dealership personnel using the proper instructions and tools, and unauthorized repairs will void any warranty.
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The document provides instructions for removing the engine from an excavator by removing components connected to the engine like hoses, wires, and shields. Specific components that must be removed include the radiator hoses, fuel lines, battery cables, and other connecting parts. Safety precautions are noted such as draining fluids before removing components and capping open ports to prevent contamination.
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This document contains instructions for removing and installing an engine from a Case 9010 excavator. It describes disconnecting hoses, wires, and other components to separate the engine from the machine. It also provides details on installing the engine, including bleeding air from the cooling system. The torque specifications for reinstalling components like engine mounts and hydraulic pump mounting bolts are referenced.
Case 2050 m tier 4a (interim) crawler dozer service repair manual (pin nedc20...fujsjefkkkemme
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This document is a service manual for a 1850K Crawler Dozer that contains important safety information and identifies key components. It provides warnings about performing unauthorized repairs and using unapproved parts. The summary lists safety symbols used in the manual and directs the reader to carefully follow all safety instructions to avoid risks and protect their health and safety. It also provides an overview of the manual's contents, which includes sections on the engine, transmission, brakes, undercarriage, dozing equipment, and electrical and hydraulic systems.
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Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
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Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
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Practical Tips: Gain actionable insights and tips to effectively prevent catalytic converter theft.
Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
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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.
47896678 24/07/2015
3
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.
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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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11. 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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12. 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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13. Engine - Engine and crankcase
Engine - Identification
SMIL15CEX8993FB 1
1. Engine number stamping
2. Engine model stamping
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14. 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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15. 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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16. 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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17. 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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18. 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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19. 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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20. 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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21. 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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22. 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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23. 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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24. 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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your reading. Please Click
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26. 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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27. 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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28. 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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29. 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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