6. 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 genuine service parts.
When placing an order, check the parts catalog. It contains the CASE 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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7. INTRODUCTION
Safety rules
WARNING:
This symbol indicates the need for caution.
Details are given concerning the safety of the operator and the surroundings.
Read all cautions carefully and understand them well before starting any work.
In order to prevent any accidents, always comply with warnings and cautions.
This section covers overall dangers.
Check if warning labels are installed.
Additional warning labels are available for order as a service part.
WARNING:
Read this operator's manual well to have a thorough understanding of how to control and operate this machine.
WARNING:
Always operate this machine from the seated position.
Any other method of operation has the danger of severe injury.
WARNING:
This machine is for only 1 person to ride on. Do not ride 2 people on this machine.
WARNING:
Before starting the engine, check the safety messages in this operator's manual.
Check all the warning labels on the machine.
Check that there is no one anywhere in or around the work range for the machine.
Check the operation methods in a safe location before starting the actual work.
Understand the operation of this machine well, then operate it according to service-related laws and ordinances.
The operator's manual and service manual can be ordered from any CASE CONSTRUCTION dealer.
WARNING:
Working in untidy work clothes or in clothes with which safety cannot be ensured leads to damage to the machine
and injury of the operator themselves.
Always work dressed for safety.
In order to work more safely, it is recommended to wear additional safety gear.
(Helmet, safety shoes, earplugs, goggles, work clothes, and gloves)
WARNING:
Work with great care when the engine is running.
WARNING:
Check and verify hydraulic equipment.
Work according to the procedure.
Do not change the procedure.
WARNING:
When bleeding the pressure from hydraulic circuits to inspect the machine's hydraulic cylinders, make sure that
there is no one in the vicinity before doing the work.
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4
8. INTRODUCTION
WARNING:
Use gloves when handling hot parts.
WARNING:
Lower the parts to the ground before inspecting or repairing attachments and lower parts.
WARNING:
Check that all hoses and tubes are securely connected.
Replace any damaged hose or tube.
Do not use your hands to check for oil leaks. Use a piece of cardboard or wood.
WARNING:
When removing an attachment pin or other hard pin, use a hammer with a soft head.
WARNING:
When installing a pin with a hammer and working with a grinder, wear protective eyewear.
At this time, use goggles or a protector that meets the standards.
WARNING:
When repairing or inspecting, stop the machine at a safe location.
WARNING:
When repairing the machine, protect the work site.
Check the oil, coolant, grease, and tools.
Collect materials and parts as necessary.
Pay careful attention to work safely.
WARNING:
Some of the machine's parts are extremely heavy.
In this case, use an appropriate crane.
For details on the weights and correct procedures, see the Service Manual.
WARNING:
Exhaust gas is harmful.
When working indoors or in any other enclosed space, always use good ventilation.
WARNING:
If battery solution is frozen, there is a danger of it exploding.
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10. Engine - Engine and crankcase
Engine - General specification
Main data
Engine main specifications
Item Engine model 4LE2
Type
Diesel/4-cycle/water-cooled, inline 4 cylinder
overhead valve
Shape of combustion chamber Direct injection type
Cylinder liner type No liner
Cylinder bore x stroke 85 mm (3.35 in) x 96 mm (3.78 in)
Displacement 2.179 l (133 in³)
Compression ratio 17.6
Compression pressure 3.04 MPa (441 psi) 250 RPM
Idling rotation speed 1000 RPM
Intake 0.4 mm (0.016 in) while cool
Valve clearance
Exhaust 0.4 mm (0.016 in) while cool
Ignition type Compression ignition
Injection order 1-3-4-2
Lubricant system
Lubricating type Compression type
Oil pump type Gear type
10.4 l (3 US gal) MAX
Lubrication oil amount
7.6 l (2 US gal) MIN
Oil filter type Combined type
Oil cooling type Built-in type, water cooled
Cooling system
Cooling type Water cooling
Water pump type Centrifugal, belt type
Thermostat type Wax type unit
Thermostat valve opening temperature 82 °C (180 °F)
Coolant capacity 4.1 l (1.1 US gal) engine only
Fuel system
Injection pump type Electronic control common rail (fuel rail) type
Governor type Electronic type
Timer type Electronic type
Multi-hole type
Injection nozzle type
7 holes
Battery system
Generator type AC type
Output 24 V / 50 A
Regulator type IC
Start system
Starter type Reduction type
Output 24 V / 3.2 kW (4.4 Hp)
Preheat system
Preheat system type Glow plug
Glow plug standard voltage/current 23 V / 3.0 A (Reference)
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11. Engine - Engine and crankcase
Primary specifications of cooling system
Item Specifications
Water pump Centrifugal impeller method
Pulley ratio 1.03
Thermostat Wax pellet type
Valve opening temperature 85 °C (185 °F) with jiggle valve
Fully open temperature 100 °C (212 °F) with jiggle valve
Valve lift amount when fully open 10 mm (0.394 in)
Primary specifications of electrical system
Generator
Item Specifications
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) Mitsubishi
Voltage 24 V
Output 3.2 kW (4.4 Hp)
Rating
Time 30 s
Number of pinion gears 11
Direction of rotation (toward pinion) Right
Weight (approx.) 5.8 kg (12.8 lb)
Current/voltage Less than 80 A / 23 V
No-load characteristics
Revolution speed 3750 RPM / min or more
Current/voltage 250 A / 18.6 V
Torque More than 12.9 N·m (9.5 lb ft)
Load characteristics
Speed 1550 RPM / min or more
Current/voltage Less than 760 A / 8 V
Locking characteristics
Torque More than 47 N·m (34.7 lb ft)
Glow plug
Item Type
Preheat device model Glow plug
Glow plug rated voltage/current 23 V / 3.0 A (Reference)
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12. Engine - Engine and crankcase
Engine - Prepare
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)
• Liftcrane (with the required lifting capacity)
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Wood planks, etc.
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13. Engine - Engine and crankcase
Engine - Remove
WARNING:
• Keep away from flames.
• Be sure to release hydraulic pressure before begin-
ning work.
• The air-conditioner circuit is filled with high pressure
gas, so there is the danger of gas spraying out when
loosening lines.
• Do not use flames near the battery or expose it to
sparks.
CAUTION:
• Be sure to stop the engine before beginning work.
• Be sure to inspect the wire rope and other lifting
equipment before beginning work.
• Do not let anyone go under a suspended load.
1. Use a wrench [ 17 mm] to remove the bolt (1), and then
remove the battery cable (2) on the negative side.
• After removing terminals or harnesses, fix them to
the frame or a similar location so they do not interfere
with the work.
Also, cover with a rubber cap to protect against
sparks.
Tightening torque for bolt installation: 10.6 -
13.0 N·m (7.82 - 9.59 lb ft)
2. Remove the engine hood.
For details, see Hood - Remove (90.100).
3. Remove the counterweight.
For details, see Counterweight - Remove (39.140).
4. Remove the muffler.
For details, see Diesel Oxidation Catalyst (DOC) - Re-
move (10.501).
5. Remove the pump.
For details, see Pump - Remove (35.106).
SMIL13CEX4344BB 1
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14. Engine - Engine and crankcase
6. Use a wrench [ 7 mm] to loosen the hose bands (1),
(2), and then remove the intercooler hose (high-tem-
perature side) (3) and hose from the air cleaner (4).
Tightening torque for band (1) installation: 8.8 -
9.8 N·m (6.49 - 7.23 lb ft)
Tightening torque for band (2) installation: 6.3 -
7.3 N·m (4.65 - 5.38 lb ft)
SMIL13CEX4663AB 2
7. Loosen the hose bands (1), and then remove the inter-
cooler hose (low-pressure side) (2).
Tightening torque for hose band (1) installation: 8.8
- 9.8 N·m (6.49 - 7.23 lb ft)
SMIL13CEX4561AB 3
8. Use a wrench to remove the bolts (1) and (2), and then
remove the hose band (3) and fan guard (4).
SMIL13CEX4127AB 4
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15. Engine - Engine and crankcase
9. Use a wrench [ 7 mm] to loosen the radiator hose
bands (1) in 4 locations, and then remove the upper
hose (2) and lower hose (3).
• Use caps to cover the radiator and hoses to prevent
any entry of water, dust or dirt.
• Before removing the radiator hose, completely drain
the coolant.
Tightening torque for band (1) installation: 4.9 -
5.9 N·m (3.61 - 4.35 lb ft)
SMIL13CEX4680BB 5
10. Remove the connectors (1) in the 5 locations.
• Wrap the removed connectors in plastic after tying
them together.
SMIL13CEX4233AB 6
11. Remove the connector (1) from the air-conditioner
compressor.
SMIL13CEX4245AB 7
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16. Engine - Engine and crankcase
12. Use a wrench [ 13 mm] to remove the bolt (1) , and
then remove the terminal cap (2).
Use a wrench to remove the lines (3) (4) from the starter.
Use a wrench [ 17 mm] to remove the bolt (5), and then
remove the line (6) from the frame.
SMIL13CEX4477AB 8
13. Use a wrench [ 10 mm] to remove the bolts (1).
Remove the connector (2) from the alternator.
Use a wrench to remove the line (3) from the alternator.
SMIL13CEX4490AB 9
14. Use a wrench [ 13 mm] to loosen the line bolts (1) in 2
locations, and then remove the lines (2) and (3) from
the compressor.
• Always remove the low-pressure (suction side) line
(2) first.
• Install caps or plugs to the compressor and lines to
prevent any entry of water, dust or dirt.
Tightening torque for bolt installation: [ 20 - 25 N·m
(14.751 - 18.439 lb ft)]
SMIL13CEX4271AB 10
15. Loosen the hose bands (1) in 2 locations, and then
remove the heater hoses (2) and (3).
• Install caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
SMIL13CEX4817AB 11
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17. Engine - Engine and crankcase
16. Prepare the waste oil can (1). Use a wrench [ 36 mm]
to remove the 2 engine oil remote hoses (2).
• Drain the engine oil before removing the engine oil
hose.
• Mark the engine and hoses so that the connectors
match at the time of assembly.
• Install caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
Tightening torque for bolt installation: [ 54.1 -
63.9 N·m (39.90 - 47.13 lb ft)]
SMIL13CEX4518BB 12
17. Remove the hose bands (1), and then remove the fuel
hoses (2) and (3).
• Install caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
SMIL13CEX4306AB 13
18. Remove the hose band (1), and then remove the hose
(2).
• Install caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
SMIL13CEX4819AB 14
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18. Engine - Engine and crankcase
19. Install the 2 shackles (1), and then use the wire rope
(2) and liftcrane to secure the engine main unit.
SMIL13CEX5233AB 15
20. Use a box wrench [ 24 mm] to remove the 4 bolts (1)
from the mount.
Tightening torque for bolt installation: [ 364.9 -
313.9 N·m (269.14 - 231.52 lb ft)]
SMIL13CEX5285BB 16
21. Use the wire rope (1) and liftcrane to lift the engine
main unit.
• Always check if the hoses and connectors are all
disconnected before lifting the engine.
Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.
• Thoroughly fasten the engine so that it does not fall
over.
SMIL13CEX4986AB 17
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19. Engine - Engine and crankcase
Engine - Install
1. To install the engine, perform the reverse of the removal
procedure.
For details, see the individual explanations for each proce-
dure.
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 proce-
dure.
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20. Engine - Engine and crankcase
Crankcase - Remove
Battery ground cable disconnect
1. Disconnect the battery ground cable from the battery.
Coolant drain
1. Drain coolant from the radiator.
CAUTION:
• After draining the coolant, do not forget to tighten the
drain plug.
Engine oil drain
1. Drain the engine oil from the oil pan.
NOTE: After draining the oil, tighten the drain plug to the
specified torque.
Tightening torque: 78.5 N·m (57.899 lb ft)
CAUTION:
• Do not forget to tighten the drain plug.
Cooling fan removal
1. Remove the cooling fan (1) from the fan pulley.
2. Adapter
3. Spacer
SMIL13CEX4383AB 1
Cooling fan belt removal
1. Remove the cooling fan belt from the pulley.
NOTE: Loosen the generator adjust bolt and remove the
belt.
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21. Engine - Engine and crankcase
Fan pulley removal
1. Remove the fan pulley (1) from the water pump assem-
bly (2).
SMIL13CEX4195AB 2
Generator removal
1. Disconnect the harness connector from the generator.
2. Remove the generator (3) from the generator bracket.
3. Remove the adjust plate (1) from the water pump as-
sembly (2).
4. Bolt
SMIL13CEX4034AB 3
Engine coolant temperature sensor disconnect
1. Disconnect the harness connector from the engine
coolant temperature sensor.
Water hose disconnect
1. Disconnect the water hose from the water pump as-
sembly.
NOTE: Remove the hose clip.
Water pump assembly removal
1. Remove the water pump assembly from the cylinder
block and the cylinder head.
NOTE: Remove the water pump assembly and the gasket.
SMIL13CEX4353AA 4
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22. Engine - Engine and crankcase
Pressure sensor/boost temperature sensor disconnect
1. Disconnect the harness connector from the boost pres-
sure sensor/boost temperature sensor.
NOTE: Remove the harness clip.
Turbocharger heat protector removal
1. Remove the turbocharger heat protector from the tur-
bocharger.
SMIL13CEX4396AA 5
Integrated oxidation catalyst silencer removal
1. Remove the integrated oxidation catalyst silencer from
the exhaust pipe (1).
2. Remove the exhaust pipe (1) from the turbocharger as-
sembly.
NOTE: Remove together with the bracket (2).
SMIL13CEX4144AB 6
3. Remove the support bracket (1) from the silencer
bracket (2).
SMIL13CEX4733AB 7
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23. Engine - Engine and crankcase
Turbocharger assembly removal
1. Remove the exhaust pipe adapter from the tur-
bocharger assembly.
SMIL13CEX5312AA 8
2. Remove the oil feed pipe (2) from the turbocharger as-
sembly (1)Turbocharger assembly removal
3. Remove the oil return pipe (3) from the turbocharger
assembly and the cylinder block.
SMIL13CEX5438AB 9
4. Remove the turbocharger assembly from the exhaust
manifold.
SMIL13CEX5437AA 10
EGR valve removal
1. Disconnect the harness connector from the EGR valve.
2. Disconnect the harness clip from the EGR pipe.
3. Disconnect the water rubber hose (1) from the EGR
cooler assembly.
SMIL13CEX5266AB 11
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24. Engine - Engine and crankcase
4. Remove the EGR valve from the intake chamber.
SMIL13CEX4342AA 12
5. Remove the EGR pipe from the EGR cooler.
SMIL13CEX5443AA 13
6. Remove the EGR cooler from the EGR pipe.
SMIL13CEX4393AA 14
7. Remove the EGR pipe from the exhaust manifold.
SMIL13CEX4998AA 15
PCV hose removal
1. Remove the PCV hose from the intake chamber.
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25. 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.
26. Engine - Engine and crankcase
IMT sensor removal
1. Disconnect the harness connector from the IMT sensor.
2. Remove the IMT sensor from the intake chamber.
Intake chamber removal
1. Remove the intake chamber from the cylinder head
cover.
SMIL13CEX4646AA 16
Cylinder head cover removal
1. Remove the cylinder head cover from the rocker arm
bracket.
SMIL13CEX4879AA 17
Harness bracket removal
1. Disconnect the engine harness from the harness
bracket.
2. Remove the harness bracket from the cylinder head.
SMIL13CEX4073AA 18
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27. Engine - Engine and crankcase
Fuel leak-off hose removal
1. Remove the fuel leak-off hose from the injector.
NOTE: Do not reuse the leak-off pipe clip.
1. Clip
SMIL13CEX4402BA 19
SMIL13CEX4693AB 20
Injection pipe removal
1. Remove the injection pipe from the injector and the
common rail (fuel rail) assembly.
NOTE: Do not reuse the injection pipe.
SMIL13CEX4572AA 21
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28. Engine - Engine and crankcase
Injector removal
1. Disconnect the harness connector from the injector.
2. Remove the injector (2) from the cylinder head assem-
bly.
3. Remove the injector gasket (4) from the injector.
4. Remove the O-ring (3) from the injector.
NOTE: Do not reuse the injector gasket or the O-ring.
1. Injector clamp
• Absolutely never touch the injector solenoid because
doing so can hinder performance or cause damage.
• Store the removed injector with the cylinder number
on it.
SMIL13CEX4248AB 22
Glow plug connector removal
1. Remove the glow plug connector from the glow plug.
Glow plug removal
1. Remove the glow plug from the cylinder head.
SMIL13CEX5078AA 23
Engine hanger removal
1. Remove the engine hanger (1) from the cylinder head.
SMIL13CEX4995AB 24
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29. Engine - Engine and crankcase
Rocker arm bracket removal
1. Remove the rocker arm bracket from the cylinder head.
CAUTION:
• Be careful not to damage the rocker arm bracket
when removing.
SMIL13CEX5330AA 25
Push rod removal
1. Remove the push rod from the cylinder block.
Cylinder head assembly removal
1. Remove the cylinder head assembly from the cylinder
block.
NOTE: Gradually loosen the bolts in the numerical order
shown in the diagram and remove.
2. Remove the cylinder head gasket from the cylinder
block.
SMIL13CEX5331AA 26
Tappet removal
1. Remove the tappet from the cylinder block.
Crankshaft pulley removal
1. Remove the crankshaft pulley from the crankshaft.
NOTE: Remove after stopping the crankshaft from turning.
NOTICE: Do not reuse the bolt and the washer.
SMIL13CEX4030AA 27
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30. Engine - Engine and crankcase
CMP sensor removal
1. Disconnect the harness connector from the CMP sen-
sor.
2. Remove the CMP sensor from the timing gear case.
3. Remove the O-ring from the CMP sensor.
Timing gear case removal
1. Remove the idle gear cover (1) from the front oil pump
plate.
2. Remove the timing gear case (2) from the front oil pump
plate.
SMIL13CEX4492AB 28
Fuel pipe (1) removal
1. Remove the fuel pipe (1) from the fuel supply pump and
the common rail (fuel rail) assembly.
SMIL13CEX4007AB 29
Fuel return pipe removal
1. Remove the fuel return pipe from the fuel supply pump.
Fuel supply pump removal
1. Disconnect the harness connector from the fuel supply
pump.
2. Remove the fuel supply pump from the front oil pump
plate.
NOTE: Remove the tightening bolts, and remove together
with the bracket.
SMIL13CEX4656AA 30
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![Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase ............................................................. 10.1
[10.102] Pan and covers .................................................................... 10.2
[10.106] Valve drive and gears .............................................................. 10.3
[10.101] Cylinder heads ..................................................................... 10.4
[10.105] Connecting rods and pistons....................................................... 10.5
[10.103] Crankshaft and flywheel............................................................ 10.6
[10.216] Fuel tanks .......................................................................... 10.7
[10.218] Fuel injection system............................................................... 10.8
[10.250] Turbocharger and lines............................................................. 10.9
[10.254] Intake and exhaust manifolds and muffler ....................................... 10.10
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust
treatment .................................................................................. 10.11
[10.400] Engine cooling system ........................................................... 10.12
[10.414] Fan and drive .................................................................... 10.13
[10.310] Aftercooler........................................................................ 10.14
[10.304] Engine lubrication system........................................................ 10.15
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.300] Reservoir, cooler, and filters........................................................ 35.2
[35.106] Variable displacement pump ....................................................... 35.3
[35.359] Main control valve.................................................................. 35.4
[35.357] Pilot system ........................................................................ 35.5
[35.525] Auxiliary hydraulic valves and lines ................................................ 35.6
[35.355] Hydraulic hand control ............................................................. 35.7
[35.356] Hydraulic foot control............................................................... 35.8
47575340A 10/07/2013](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)