6. 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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7. 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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4
8. 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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5
10. Engine - Engine and crankcase
Engine - General specification
Engine main data
Item Engine model D1305-E4B
Number of Cylinder 3
Engine Type Vertical, water-cooled, 4-cycle diesel engine
Bore × Stroke 78.0 – 88.0 mm (3.07 – 3.46 in)
Total Displacement 1261 cm³ (76.95 in³)
ISO Net Continuous 15.5 kW (21.1 Hp) 2600 RPM
ISO/SAE Net Intermittent 17.9 kW (24.3 Hp) 2600 RPM
SAE Gross Intermittent 18.5 kW (25.2 Hp) 2600 RPM
Maximum Bare Speed 2820 RPM
Minimum Bare Idling Speed 1100 RPM
Combustion Chamber Spherical type (E-TVCS)
Fuel Injection Pump Bosch MD type mini pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Mini Nozzle (DNOPD)
Injection Timing 0.2793 rad 16.00 °C before top dead centre
Firing Order 1-2-3
Injection Pressure 13.73 MPa (1992 psi)
Compression Ratio 24 : 1
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (Cartridge type)
Cooling System
Pressurized radiator, forced circulation with water
pump
Starting System Electric Starting with Starter
Starter Motor 12 V, 1.2 kW (1.6 Hp)
Starting Support Device By glow plug in combustion chamber
EGR None
Battery 12 V, 65 A·h, equivalent
Charging Alternator 12 V, 480 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil
Class CF lubricating oil as per API classification is
recommended.
Lubricating Oil Capacity 5.7 L (1.5 US gal)
Weight (Dry) 95 kg (209 lb)
NOTE: the specification described above is of the standard engine of each model.
Conversion Formula: HP = 0.746 kW, PS = 0.7355 kW
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11. Engine - Engine and crankcase
Engine - External view
SMIL16MEX0702GB 1
A 497.6 mm (19.59 in)
B 590.1 mm (23.23 in)
C 396.0 mm (15.59 in)
D 185.3 mm (7.30 in)
E ∅125 mm (4.92 in)
F ∅222.2 mm (8.748 in)
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12. Engine - Engine and crankcase
Engine - Remove
WARNING
Avoid injury!
Shut off the engine, remove the key, and make sure all machine motion stops before you service the
machine.
Failure to comply could result in death or serious injury.
W1128B
WARNING
Chemical hazard!
Use caution when opening the quick coupler cap from the load port. There may be product left in the
port.
Failure to comply could result in death or serious injury.
W1039A
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
Burn hazard!
Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid
temperature should not exceed 40 °C (104 °F).
Failure to comply could result in death or serious injury.
W0241A
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
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
Failure to comply could result in death or serious injury.
W0371A
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13. Engine - Engine and crankcase
1. Remove the counterweight (for details refer to Coun-
terweight - Remove (39.140)).
2. Remove the battery (for details refer to Battery - Re-
move (55.302)).
3. Remove the platform (for details refer to Operator seat
base trim panel - Remove - Platform (90.160)).
4. Drain the fuel.
5. Loosen the clamp to remove the hose (1) from the ex-
pansion tank (2).
6. Pull out the expansion tank (2).
7. Use a wrench [ 13 mm] to remove the bolts (4), then
remove the bracket (3).
SMIL16MEX2843AB 1
8. Disconnect the electrical connector CR-24 (3) of the
timer glow.
9. Use a wrench [ 13 mm] to remove the 2 bolts (1).
10. Use a wrench [ 17 mm] to remove the 2 bolts (4), then
remove the bracket (2).
SMIL16MEX2844BB 2
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14. Engine - Engine and crankcase
11. Use a wrench [ 13 mm] to remove the 2 bolts (1) of
the coolant filling hose bracket (8).
12. Use a wrench [ 13 mm] to remove the 2 bolts (2) of
the engine oil filling hose bracket (7).
13. Use a wrench [ 13 mm] to remove the 2 bolts (3) of
the bracket (6).
14. Use a wrench [ 13 mm] to remove the 2 bolts (4) of
the battery connect and disconnect switch (5).
SMIL16MEX2845AB 3
15. Use a wrench [ 19 mm] to remove the 2 bolts (2) and
the 2 bolts (3) of the cab support bracket (1).
SMIL16MEX2846AB 4
16. Use a wrench [ 13 mm] to remove the 2 bolts (1) of
the air cleaner inlet hose.
17. Use a wrench [ 19 mm] to remove the 2 bolts (2) of
the cab support bracket (3).
18. Use a wrench [ 13 mm] to remove the 2 bolts (4) of
the cab support bracket (3).
19. Remove the cab support bracket (1).
SMIL16MEX2847AB 5
20. Loosen the clamp (1) to remove the hose (2) from the
radiator.
21. Loosen the clamp (4) to remove the hose (3) from the
cylinder head cover.
22. Remove the coolant filling assembly (5).
SMIL16MEX2848AB 6
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15. Engine - Engine and crankcase
23. Loosen the clamp (1) to remove the engine oil filling
assembly (2) from the cylinder head cover.
SMIL16MEX2849AB 7
24. Loosen the clamps and remove the fuel hoses (1) and
(2) from the fuel filter support (3).
SMIL16MEX2850AB 8
25. Loosen the clamp and remove the fuel hose (1) from
the fuel filter water separator (2).
26. Use a wrench [ 17 mm] to remove the bolt (4), and
then disconnect the earth strap (3) from the engine.
SMIL16MEX2851AB 9
27. Cut the tie (1) and disconnect the electrical connector
CD-10 (2) from the air cleaner pressure switch (3).
28. Loosen the clamp (5) to remove the hose (4) from the
intake manifold.
SMIL16MEX2852AB 10
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16. Engine - Engine and crankcase
29. Use a wrench [ 17 mm] to remove the bolts (1) with
relative washers and remove the clamps (3) that fix
the electrical cables to the bracket (1).
SMIL17MEX2987AB 11
30. Disconnect the electrical connector CN-145 (6) of the
electrical fuel feed pump (7).
31. Use a wrench [ 13 mm] to remove the bolts (5) of the
bracket (1).
32. Remove the bracket (1) includes air filter (2), fuel filter
(3), fuel filter water separator (4) and feed pump (7).
SMIL16MEX2853BB 12
33. Disconnect the electrical connector CD-8 (2) from the
engine coolant temperature sensor (1).
SMIL16MEX2854AB 13
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17. Engine - Engine and crankcase
34. Loosen the clamp (2) and remove the cab heating
hose (1).
SMIL16MEX2855AB 14
35. Loosen the clamp (3) and remove the cab heating
hose (1) from the coolant cock (2).
36. Use a wrench [ 7 mm] to remove the nut (4), and then
disconnect the glows electrical connector CN-80.
SMIL16MEX2856AB 15
37. Disconnect the electrical connector CN-74 (2) from
the alternator (1).
38. Remove the nut (6) to disconnect the wiring CN-74 (3)
from the alternator (1).
39. Remove the nut (4) to disconnect the electrical con-
nector CD-18 from the engine oil pressure switch (5).
SMIL16MEX2857AB 16
40. Loosen the clamp (1) and remove the radiator coolant
hose (2).
SMIL16MEX2868AB 17
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18. Engine - Engine and crankcase
41. Disconnect the electrical connector CN-45 (2) from
the starter motor (1).
42. Remove the nut (5) to disconnect the cable (4) and
the wire (3) from the starter motor (1).
SMIL16MEX2858AB 18
43. Use a wrench [ 11 mm] to loosen the clamp (1), and
then remove the hydraulic oil suction hose (2) from the
pump flange (3).
SMIL16MEX2859AB 19
44. Use a wrench [ 19 mm] to remove the T hose (1).
45. Use a wrench [ 24 mm] to remove the P1 hose (3) and
the P2 hose (2).
46. Use a wrench [ 22 mm] to remove the P3 hose (4) and
the P4 hose (5).
SMIL16MEX2860AB 20
47. Disconnect the electrical connector CN-79 (2) from
the fuel solenoid (1).
48. Loosen the clamp and remove the fuel supply hose
(3) from the fuel injection pump (4).
SMIL16MEX2861AB 21
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19. Engine - Engine and crankcase
49. Disconnect the electrical connector CD-9 (3) from the
coolant high temperature sensor switch (2).
50. Loosen the clamp and remove the fuel injectors over-
flow hose (1).
SMIL16MEX2862AB 22
51. Use a wrench [ 13 mm] to remove the 2 bolts (2) for
separate the bracket (3) and the hose (4) from the
right-hand support (1).
52. Use a wrench [ 13 mm] to remove the 4 bolts (4), and
then remove the right-hand support (1).
SMIL16MEX2863BB 23
53. Use a wrench [ 19 mm] to loosen the 2 bolts (2) of the
radiator (1).
SMIL16MEX2864AB 24
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20. Engine - Engine and crankcase
54. Install the 2 hooks (1) into the engine lift bracket, and
then use the wire rope or chain and lift-crane to secure
the engine.
55. Install the lift strap (3) around the pump (4) and insert
it into the hook (2).
SMIL16MEX2865AB 25
56. Use a box wrench [ 19 mm] to remove the 4 bolts (1).
NOTICE: if necessary, remove the bracket (5) to access to
the bolt (1).
57. Remove the washers (2) .and the silent blocks (3).
SMIL16MEX2866BB 26
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21. Engine - Engine and crankcase
58. Tilt the radiator (1) as shown in the figure and by
means of the lift-crane remove the engine.
59. Remove the washers (2) .and the silent blocks (3).
60. Thoroughly check that the location is safe before low-
ering the engine on wood planks, etc.
SMIL16MEX2867BB 27
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22. Engine - Engine and crankcase
Engine - Install
WARNING
Avoid injury!
Shut off the engine, remove the key, and make sure all machine motion stops before you service the
machine.
Failure to comply could result in death or serious injury.
W1128B
WARNING
Chemical hazard!
Use caution when opening the quick coupler cap from the load port. There may be product left in the
port.
Failure to comply could result in death or serious injury.
W1039A
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
Burn hazard!
Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid
temperature should not exceed 40 °C (104 °F).
Failure to comply could result in death or serious injury.
W0241A
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
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
Failure to comply could result in death or serious injury.
W0371A
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23. Engine - Engine and crankcase
NOTICE: For bolts for which the torque is not specified, see
Torque - Standard torque settings () .
1. Install the washers (2) and the silent blocks (3).
2. Tilt the radiator (1) as shown in the figure and by means
of the lift-crane install the engine.
SMIL16MEX2867BB 1
3. Install the silent blocks (3) and the washers (2).
4. Use a box wrench [ 19 mm] to install the bolts (1) and
(4).
5. Tightening torque for bolts (1) installation: 118 –
137 N·m (87 – 101 lb ft)
6. Tightening torque for bolts (4) installation: 118 –
137 N·m (87 – 101 lb ft)
NOTICE: if removed, install the bracket (5).
SMIL16MEX2866BB 2
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25. Engine - Engine and crankcase
7. Remove the 2 hooks (1) from the engine lift bracket.
8. Remove the lift strap (3) from the hook (2) and the pump
(4).
SMIL16MEX2865AB 3
9. Use a wrench [ 19 mm] to tighten the 2 bolts (2) of the
radiator (1).
Tightening torque for bolts (2) installation: 96.3 –
155.9 N·m (71.0 – 115.0 lb ft)
SMIL16MEX2864AB 4
10. Install the right-hand support (1) and use a wrench [
13 mm] to install the 4 bolts (4).
11. Install the bracket (3) and the hose (4) on the right-
hand support (1).
12. Use a wrench [ 13 mm] to install the 2 bolts (2).
SMIL16MEX2863BB 5
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26. Engine - Engine and crankcase
13. Install the fuel injectors overflow hose (1).
14. Connect the electrical connector CD-9 (3) to the
coolant high temperature sensor switch (2).
SMIL16MEX2862AB 6
15. Install the fuel supply hose (3) on the fuel injection
pump (4).
16. Connect the electrical connector CN-79 (2) to the fuel
solenoid (1).
SMIL16MEX2861AB 7
17. Use a wrench [ 24 mm] to install the P1 hose (3) and
the P2 hose (2).
18. Use a wrench [ 19 mm] to install the T hose (1).
19. Use a wrench [ 22 mm] to install the P3 hose (4) and
the P4 hose (5).
SMIL16MEX2860AB 8
20. Install the hydraulic oil suction hose (2) on the pump
flange (3).
21. Use a wrench [ 11 mm] to tighten the clamp (1).
SMIL16MEX2859AB 9
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27. Engine - Engine and crankcase
22. Connect the electrical connector CN-45 (2) to the
starter motor (1).
23. Connect the wire (3) and the cable (4) to the starter
motor (1).
24. Install the nut (5).
SMIL16MEX2858AB 10
25. Install the radiator coolant hose (2) and tighten the
clamp (1).
SMIL16MEX2868AB 11
26. Connect the electrical connector CN-74 (2) to the al-
ternator (1).
27. Connect the wiring CN-74 (3) to the alternator (1) and
fix it with the nut (6).
28. Connect the electrical connector CD-18 to the engine
oil pressure switch (5) and fix it with the nut (4).
SMIL16MEX2857AB 12
29. Connect the glows electrical connector CN-80 and
use a wrench [ 7 mm] to fix it with the nut (4).
30. Install the cab heating hose (1) on the coolant cock (2)
and fix it with the clamp (3).
SMIL16MEX2856AB 13
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28. Engine - Engine and crankcase
31. Install the cab heating hose (1) and fix it with the clamp
(2).
SMIL16MEX2855AB 14
32. Connect the electrical connector CD-8 (2) on the en-
gine coolant temperature sensor (1).
SMIL16MEX2854AB 15
33. Install the bracket (1) includes air filter (2), fuel filter
(3), fuel filter water separator (4) and feed pump (7).
34. Use a wrench [ 13 mm] to install the bolts (5) of the
bracket (1).
35. Connect the electrical connector CN-145 (6) of the
electrical fuel feed pump (7).
SMIL16MEX2853BB 16
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![Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.101] Cylinder heads ..................................................................... 10.2
[10.102] Pan and covers .................................................................... 10.3
[10.103] Crankshaft and flywheel............................................................ 10.4
[10.105] Connecting rods and pistons....................................................... 10.5
[10.106] Valve drive and gears .............................................................. 10.6
[10.304] Engine lubrication system.......................................................... 10.7
[10.400] Engine cooling system ............................................................. 10.8
[10.216] Fuel tanks .......................................................................... 10.9
[10.202] Air cleaners and lines ............................................................ 10.10
[10.206] Fuel filters ........................................................................ 10.11
[10.218] Fuel injection system............................................................. 10.12
[10.220] Throttle linkage................................................................... 10.13
[10.254] Intake and exhaust manifolds and muffler ....................................... 10.14
[10.414] Fan and drive .................................................................... 10.15
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.106] Variable displacement pump ....................................................... 35.2
[35.300] Reservoir, cooler, and filters........................................................ 35.3
[35.359] Main control valve.................................................................. 35.4
[35.355] Hydraulic hand control ............................................................. 35.5
[35.352] Hydraulic swing system ............................................................ 35.6
[35.353] Hydraulic travel system ............................................................ 35.7
[35.354] Hydraulic central joint .............................................................. 35.8
[35.356] Hydraulic foot control............................................................... 35.9
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