Case cx210c tier 4 crawler excavator service repair manual by 163561

Section 1004

FLUIDS AND LUBRICANTS

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CONTENTS HYDRAULIC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conditions applicable to diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3 3 4 4 4

FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application. IMPORTANT: The conditions of use for individual fluids and lubricants must be respected.

HYDRAULIC FLUID CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system. The type of fluid to be used depends on the ambient temperature.

ENGINE OIL The "CASE Tutela LE ENGINE OIL" is recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions. If the "CASE Tutela LE ENGINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: API CJ-4. ACEA E6.

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FLUIDS AND LUBRICANTS FUEL The fuel must conform to Interim Tier 4/Stage 3B Exhaust Gas Control Regulations. Use grade number 2-D (S15) fuel. Using other types of fuel may lead to stalled engine output or deterioration in fuel economy. During cold weather (lower than -7â&#x201E;&#x192;), it is temporarily acceptable to use a mixture of No. 1-D (S15) and No. 2-D (S15). Consult the fuel supplier or the CASE dealer. If the temperature drops below the fuel cloud point, output deficiency or engine start problems may occur due to wax crystals.

Conditions applicable to diesel fuel The diesel fuel used must: -

be free from dust particles, even minute ones, have the proper viscosity, have a high cetane number, present great fluidity at low temperatures, have low sulphur content, have very little residual carbon.

RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL - JIS (Japanese Industrial Standards): No. 2 - DIN (Deutsche Industrie Normen): DIN 51601 - SAE-J-313C: SAE (Society of Automotive Engineers) based on No. 2-D (S15) - BS (British Standards) based on BS/2869-1970: Class A-1 - EN 590 (less than 10 ppm sulfur) - Or fuel specified by the country using these standards and this machine

IMPORTANT: EPA regulation ultra low sulfur fuel only. IMPORTANT: If a serious problem occurs when other fuels are used, the warranty is invalidated. Using a non-recommended fuel may lead to damage of the fuel injection pump, injector, DPD, and other fuel supply systems or to the engine. CASE assumes no responsibility for these damages. Note that the warranty will not be applied for these damages. It is recommended that the following safety information be considered in order to prevent damage to the engine fuel supply system. - Some fuel suppliers mix old engine oil and diesel fuel. Makers of larger engine permit the use of this kind of fuel. However, do not use diesel fuel contaminated with engine oil in customer's engines. Not only will this fuel damage the engine, it may also have a negative impact on the exhaust gas purification function. Before using diesel fuel, confirm with the supplier whether the fuel complies with the above specifications. IMPORTANT: Consult the supplier or the CASE dealer regarding appropriate use of fuel additives. Do not use fuel oil or gasoline as these may damage the engine. IMPORTANT: In order to prevent condensation during cold weather, fill the fuel tank to full after the completing the day's work.

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Section 1005

Conversion Table

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CONTENTS Metric to U.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 U.S to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Conversion Table Metric to U.S AREA: FORCE: LENGTH: MASS: MASS/AREA: MASS/ENERGY: MASS/VOLUME: POWER: PRESSURE: TEMPERATURE: TORQUE: VELOCITY:

VOLUME:

VOLUME/TIME:

MULTIPLY square meter hectare newton newton millimeter meter kilometer kilogram kilogram/hectare gr/kW/hr. kg/cubic meter kilowatt kilopascal bar megapascal (MPA) degree C newton meter newton meter kilometer/hr cubic centimeter cubic meter cubic meter milliliter litre litre litre litre litre/min. litre/min

BY 10.763 91 2.471 05 3.596 942 2.224 809 0.039 370 3.280 840 0.621 371 2.204 622 0.000 466 0.001 644 1.685 555 1.341 02 0.145 038 14.50385 145.0385 1.8 x C +32 8.850 748 0.737 562 0.621 371 0.061 024 35.314 66 1.307 950 0.033 814 1.056 814 0.879 877 0.264 172 0.219 969 0.264 172 0.219 969

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TO OBTAIN square foot acre ounce force pound force inch foot mile pound ton/acre lbs/hp/hr. lb/cubic yd. horsepower lb/sq. inch lb/sq. inch psi degree F lb/inch lb/foot miles/hr. cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US liquid) gallon (Imperial) gallon/min. (US liquid) gallon/min. (Imperial)

Conversion Table U.S to Metric AREA: FORCE: LENGTH: MASS: MASS/AREA: MASS/ENERGY: MASS/VOLUME: POWER: PRESSURE:

psi TEMPERATURE: TORQUE: VELOCITY:

VOLUME:

VOLUME/TIME:

MULTIPLY square foot acre ounce force pound force inch foot mile pound ounce ton/acre lbs/hp/hr. lb/cubic yd. horsepower lb/sq. inch lb/sq. inch lb/sq. inch psi degree F lb/inch lb/foot miles/hr. cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US) gallon (Imperial) gallon/min.

BY 0.092 903 0.404 686 0.278 014 4.448 222 25.4 0.304 8 1.609 344 0.453 592 28.35 2241 702 608.277 4 0.593 276 0.745 700 6.894 757 0.069 0.070 303 0.006 895 1.8 F - 32 0.112 985 1.355 818 1.609 344 16.387 06 0.028 317 0.764.555 29.573 53 0.946 353 1.136 523 3.785 412 4.546 092 3.785 412

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TO OBTAIN square meter hectare newton newton millimeter meter kilometer kilogram gram kilogram/hectare gr/kW/hr. kg/cubic meter kilowatt kilopascal bar kg/sq. cm megapascal (Mpa) degree C newton meter newton meter kilometer/hr cubic centimeter cubic meter cubic meter milliliter litre litre litre litre litre/min.

Section 1900

Abbreviations

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CONTENTS Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Abbreviations Abbreviations Abbreviation AC A/D ABDC AC ACC ACG ACT API ASM ATDC ATF drilled head B eye B full threaded B hexagon socket head B high-strength B reamer B B+ BAT BBDC BKT BRG BTDC C/B C/U CAL CAN CFG CHK CKP CMP CO CPU DC DI DIAG DLC DMM DPD DTC ECM ECT ECU EEPROM EGR EMI EMPS ENG EPF EVRV EXH F/B F/C F/L FLW FRT

description air conditioner analog/digital after bottom dead center alternating current accessory alternating current generator actuator american petroleum industry assembly after top dead center automatic transmission fluid drilled head bolt eye bolt full threaded bolt hexagon socket head bolt high-strength bolt reamer bolt battery + terminal battery before bottom dead center bracket bearing before the top dead center circuit breaker control unit calibration a control unit communication method (control area network) config check crankshaft position camshaft position carbon monoxide central processing unit direct current direct injection type diagnosis data link connector digital multiâ&#x20AC;&#x201C;meter diesel particulate diffuser self-diagnosis code engine control module engine coolant temperature electronic control unit electrically erasable/programmable ROM exhaust gas recirculation electromagnetic interference engine module programing system engine engine protection feature electric vacuum regulating valve exhaust feedback fuel cut fusible link fusible link wire front 84402826 - May 2011 1900-3

Abbreviations Abbreviation FT FWD GEN GND HBCV HC HO2S HR HRD IAC IAT IC ID Plate IMT INL INJ ISO ISP ITP J/C JIS KW LED LH LLC LM M/V MAF MAP Max MIL milli-amp Min MPU high-strength N NC NO NOx N-TDC PM O2S OBD OEM OPT OT P/L PCV P-I PM PTO PWM QOS QWS R/L RAM REF RH ROM

description fuel temperature front generator ground hose burst check valves hydrocarbon superheat O2 sensor hour high reach idle air control intake air temperature integrated circuit ID plate (Name plate) intake manifold temperature intake injection international organization for standardization intake shutter position intake throttle position joint connector japan Industrial Standard a communication method (Keyword) light emitting diode left long life coolant lifting magnet electromagnetic valve mass air flow manifold air pressure maximum warning light (diagnostic) milli-amperage minimum micro processing unit high-strength nut normally closed normally open nitrogen oxide top dead center revolution speed particle material O2 sensor on-board diagnosis original equipment manufacturer option oil temperature pilot light pump control valve/positive crankcase ventilation proportion-integration particle material power take-off pulse width modulation wave quick on start system quick warming up system relay RAM (random access memory) reference right ROM (read only memory) 84402826 - May 2011 1900-4

Abbreviations Abbreviation RP Rr RWD flush head S phillips pan head S truss head S subassembly SAE SBF SCV SIG SLD SP pin ST STD SW TDC TEMP TP TEMP UART VB VGS Turbo high-strength W toothed W W/H W/L W/S WOT

description rail pressure rear rear flush head screw phillips pan head screw truss head screw sub assembly society of atomotive engineers slow blow fuse suction control valve signal shield special pin starter/start standards switch top dead center temperature throttle position temperature universal asynchronous receiver transmitter battery voltage variable geometry system turbo high-strength washer toothed washer wire/harness warning light weld splice wide open throttle

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Section 2000

Removal and Installation of Engine Assembly

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CONTENTS Removal of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Removal and Installation of Engine Assembly Removal of Engine Assembly

WARNING • Keep away from fire. • Be sure to release hydraulic pressure before beginning work. • The air conditioner circuit is filled with highpressure gas, so beware of the gas released when loosening lines. • Do not use open flames and do not allow sparks near the battery.

1. 2. 3.

Remove the counterweight.(For details, see "Removal and Installation of Counterweight".) Remove the pump.(For details, see "Removal and Installation of Hydraulic Pump".) Use a wrench （14 mm） to remove the bolts (1) and (2), and then remove the fan shroud (3).

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 stand or pass under the suspended load. Items to prepare • Wrenches (7 mm, 8 mm, 10 mm, 12 mm, 13 mm, 14 mm, 17 mm, 36 mm) • Box wrench (24 mm) • Shackle (with the required lifting capacity) x 2 • Wire rope (with the required breaking load) • Crane (with the required lifting capacity) • Marking pen • Caps • Plugs • Waste oil can • Rag • Cleaning fluid • Wood plank

Use a wrench to remove the bolts (1), and then remove the fan guard (2).

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Removal and Installation of Engine Assembly 5.

Use a wrench (7 mm) to loosen the hose band (1) on the radiator, and then remove the upper hose (2).

Use a wrench (8 mm) to loosen the hose band (1) on the inter cooler, and then remove the hose (2). • Use caps to cover the line and hose to prevent the entry of water, dust or dirt.

Use a wrench (7 mm) to loosen the hose band (1) on the radiator, and then remove the lower hose (2). • Use caps to cover the radiator and hoses to prevent the entry of water, dust or dirt. • Before removing the radiator hoses, completely drain the coolant.

Remove the hose bands (1) in the 3 locations.

10. Prepare a waste oil can (1). 7.

Use a wrench (12 mm) to loosen the line bolts (1) in 2 locations, and then remove the 2 lines (2) and (3) from the compressor.

• Drain the engine oil before removing the engine oil hose.

• Always remove the low-pressure (suction side) line (2) first. • Attach caps or plugs to the compressor and lines to prevent any entry of water, dust or dirt.

11. Use a wrench (36 mm) to remove the 2 engine oil remote hoses (1).

Line (discharge side)

• Mark the engine and hoses so that the connectors match at the time of assembly. • Attach 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.

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Removal and Installation of Engine Assembly 14. Use a wrench (14 mm) to remove the 1 nut (1), and then remove the wiring (2) from the starter motor.

12. Use a wrench (17 mm) to remove the bolt (1), and then remove the negative-side battery cable (2). â&#x20AC;˘ When removing the terminal and harness, secure them so that they do not interfere with the frame. Also, cover with a rubber cap to protect against sparks.

15. Remove the hose band (1), and then remove the fuel hose (2).

13. Use a wrench (8 mm) to remove the 1 nut (1), and then remove the wiring (2) from the starter motor.

16. Remove the hose band (1), and then remove the fuel hose (2).

â&#x20AC;˘ Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

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Removal and Installation of Engine Assembly 17. Use a wrench (13 mm) to remove the 2 bolts (1), and then remove the connector bracket (2).

20. Loosen the hose band (1), and then remove the heater hose (2). • Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

18. Use a wrench (13 mm) to remove the hose band (1) from the bracket, and then remove the connectors (2). • Wrap the removed connectors in plastic after tying them together.

19. Loosen the hose band (1), and then remove the heater hose (2). • Attach caps or plugs to the engine and hose to prevent any entry of water, dust or dirt.

21. Use a wrench (7 mm) to loosen the hose band (1), and then remove the radiator hose (2). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

22. Use a wrench (7 mm) to loosen the hose band (1), and then remove the air hose (2). • Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

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Removal and Installation of Engine Assembly 23. Use a wrench (9.5 mm) to loosen the hose band (1), and then remove the air hose (2).

26. Use a wrench (13 mm) to remove the bolt (1), and then remove the radiator hose clamp (2).

â&#x20AC;˘ Use caps to cover the line and hose to prevent any entry of water, dust or dirt.

27. Install the 2 shackles (1), and then use the wire rope (2) and crane to secure the engine. 24. Remove the connectors (1) from the alternator.

25. Use a wrench (10 mm) to remove the nut (1), and then remove the wiring from the alternator (2).

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Removal and Installation of Engine Assembly 28. Use a box wrench (24 mm) to remove the 4 bolts (1) from the mount.

29. Use the wire rope (1) and crane to lift the engine. Thoroughly check that the location is safe before lowering the engine on wood planks, etc.

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Removal and Installation of Engine Assembly Installation of Engine Assembly

To install the engine, perform the reverse of the removal procedure. 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.

Run the engine at no-load idling and check for any water or oil leaks. Attach the hydraulic pump, covers, and counterweight. For details, see the individual explanations for each procedure.

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Section 2001

Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler

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CONTENTS Removal and Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal and Installation of Engine Intercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal of Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation of Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal and Installation of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation of Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal and Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal and Installation of Fuel Cooler CAUTION • Be sure to stop the engine before beginning work. • As the fuel hose will be removed, strictly prohibit open flames. Items to prepare • • • • • • • • •

Wrenches (12 mm) Screwdriver Pliers Marking pen Cap Plug Rag Cleaning fluid Drip pan

Removal of Fuel Cooler 1.

Mark the fuel cooler (5) and hoses (1) (2) so that the connectors match at the time of assembly. • Remove the fuel hose clamp (6). • Use pliers to loosen the hose bands (3) (4), and then remove the hoses. • Fuel will spill out, so place a drip pan directly below the area. • Install caps or plugs to the fuel cooler and hoses to prevent any entry of water, dust or dirt. • Tightening torque for bolt (1) installation: 25.0 N·m

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 2.

Use a wrench (12 mm) to remove the 4 bolts (1), and then remove the fuel cooler (2).

Installation of Fuel Cooler Perform the reverse of the removal procedure. After connecting the hoses, carefully check for any fuel leaks. When installing the bolts, tighten them to the specified torque. If the torque is not specified for a bolt or other part, see the "Bolt Size and Torque Table".

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal and Installation of Engine Intercooler

Removal of Intercooler 1.

CAUTION

Use a wrench (8 mm) or flathead screwdriver to loosen the hose bands (1) in the 2 locations, and then remove the 2 hoses (2) (3).

• Be sure to stop the engine before beginning work. • As the fuel hose will be removed, strictly prohibit open flames.

• Use caps to cover the intercooler and hoses to prevent the entry of water, dust or dirt. Tightening torque for band (1) installation: 8.8 9.8 N·m

Items to prepare • • • • •

Wrenches (8 mm, 14 mm) Flathead screwdriver Cap Rag Cleaning fluid

Use a wrench (14 mm) to remove the 4 bolts (1), and then remove the intercooler (2). • Tightening torque for bolt (1) installation: 55.0 N·m

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Installation of Intercooler To install, perform the reverse of the removal procedure. Check for any air leaks. When installing the bolts, tighten them to the specified torque. If the torque is not specified for a bolt or other part, see the "Bolt Size and Torque Table".

Removal and Installation of Radiator WARNING • Do not remove the radiator cap when the radiator coolant temperature is high. Hot liquid could spray out. CAUTION • Be sure to release hydraulic pressure before beginning work. • 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 stand or pass under the suspended load. Items to prepare • • • • • • • • • • • • •

Wrenches (7 mm, 8 mm, 13 mm, 14 mm, 19 mm) Box wrench (12 mm) Pliers Shackles (with the required lifting capacity) x 2 Wire rope (with the required breaking load) Liftcrane (with the required lifting capacity) Cap Plug Drain tank Drain hose Rag Cleaning fluid Wood planks, etc.

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal of Radiator 1.

Loosen the drain plug (1), and then drain the coolant.

Use a wrench (13 mm) to remove the high-strength bolt (1), plain washer (2), and seal retainer (3), and then remove the cushion seal. Remove the 4 sems bolts (4), and then remove the bracket.

Use a wrench (13 mm) to remove the 5 bolts (1), and then remove the cover (2).

Use a wrench (19 mm) to remove the 3 bolts (1), and then remove the under cover (2).

Install the drain hose (1), and then prepare the drain tank (2).

To make it easier to drain the coolant, remove the radiator cap (1).

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 7.

Use a wrench (7 mm) to loosen the hose band (1), and then remove the upper hose (2) and lower hose (3) from the radiator. • Use caps to cover the radiator and hoses to prevent the entry of water, dust or dirt. • Tightening torque for band (1) installation: 4.9 5.9 N·m

Loosen the hose band (2), and then remove the hose (1) from the radiator cap. • Install caps or plugs to the hoses to prevent any entry of water, dust or dirt.

10. Use a wrench (14 mm) to remove the 3 bolts (1), and then remove the brackets (2).

11. Use a wrench (14 mm) to remove the 2 bolts (1), and then remove the fan guard (2). 8.

Remove the drain plug (1), loosen the hose band (2), and then remove the hose (3).

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 12. Use a wrench (14 mm) to remove the 3 bolts (1), and then remove the brackets (2).

15. Remove the 2 one-touch clips (1), and then remove the front anti-insect net (2).

13. Use a wrench (14 mm) to remove the 3 bolts (1), and then remove the brackets (2).

16. Use a wrench (17 mm) to remove the 4 bolts (1), the 8 washers (2) and the 4 rubber cushions (3).

14. Use a box wrench (12 mm) to remove the 8 bolts (2) from the fan shroud (1), and then move the fan shroud (1) towards the engine.

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 17. Install the 2 shackles (1) to the top of the radiator, and then use the wire rope (2) and liftcrane to lift the radiator.

Installation of Radiator To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. If the torque is not specified, see the "Bolt Size and Torque Table". Coolant capacity is 30.2 L. Finally, check that the level of coolant is correct.

18. Lift until the fixtures (1) at the bottom of the radiator become disconnected.

19. Thoroughly check that the location is safe before lowering the radiator on square wooden piece. When laying down the radiator, be careful not to bend or crush the bottom fixtures (1).

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal and Installation of Oil Cooler

Removal of Oil Cooler

WARNING

• Drain the hydraulic oil from the hydraulic oil tank. See "Draining Oil from Hydraulic Oil Tank" for details of the procedure.

• Keep away from fire.

Use a wrench (19 mm) to remove the 3 bolts (1), and then remove the under cover (2).

Prepare the waste oil can (1).

Use a wrench (13 mm) to remove the 5 bolts (1), and then remove the cover (2).

Wrenches (13 mm, 17 mm, 19 mm) Hexagon wrench (10 mm) Pliers Screwdriver Eyebolts (M12 x 2) Shackles (with the required lifting capacity) x 2 Wire rope (with the required breaking load) Liftcrane (with the required lifting capacity) Cap Waste oil can Rag Cleaning fluid Wood planks, etc.

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 4.

Remove the 2 one-touch clips (1), and then remove the anti-insect net (2).

Use a wrench (14 mm) to remove the 3 bolts (1), and then remove the brackets (2).

Use a hexagon wrench (10 mm) to remove the 2 upper hexagon socket head bolts (1) and 2 lower bolts (1), and then use a wrench (8 mm) to loosen the hose bands (2) and remove the lines (3) (4).

Use a wrench (14 mm) to remove the 2 bolts (1), and then remove the fan guard (2).

Use a wrench (14 mm) to remove the 3 bolts (1), and then remove the brackets (2).

â&#x20AC;˘ Use caps to cover the oil cooler and lines to prevent the entry of water, dust or dirt.

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 9.

Use a wrench (14 mm) to remove the 3 bolts (1), and then remove the brackets (2).

11. Use a wrench (17 mm) to remove the 4 bolts (1).

10. Use a box wrench (12 mm) to remove the 8 bolts (2) from the fan shroud (1), and then move the fan shroud (1) towards the engine.

12. Install the 2 eyebolts (M12) (1) on the top of the oil cooler. â&#x20AC;˘ Fully tighten the eyebolts, and then loosen them by a half turn.

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 13. Install the 2 shackles (1) to the eyebolts, and then use the wire rope (2) and liftcrane to lift the oil cooler main unit.

Installation of Oil Cooler 1.

Use a liftcrane to lift the oil cooler (1) main unit.

14. Thoroughly check that the location is safe before lowering the oil cooler on wood planks, etc.

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 2.

Mount the oil cooler (1), and then remove the shackles (2), wire ropes (3), and eyebolts (4).

Use a wrench (17 mm) to secure the oil cooler (1) with the 4 bolts (2). • Bolt (2) tightening torque: 88.0 N·m

Use a box wrench (12 mm) to install the 8 bolts (2) and install the fan shroud (1). • Bolt (2) tightening torque: 25.0 N·m

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 5.

Use a wrench (14 mm) to install the 3 bolts (1) and install the bracket (2).

Use a wrench (14 mm) to install the 2 bolts (1) and install the fan guard (2).

Use a wrench (14 mm) to install the 3 bolts (1) and install the bracket (2).

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 9.

Set the O-rings (2) on the oil cooler (1) side and install the lines (3) (4) with 2 hexagon socket head bolts (5) each.

10. Use a wrench (8 mm) to install the hose bands (1) and install the hoses (2).

â&#x20AC;˘ The O-rings cannot be reused.Replace them with new parts.

11. Install the anti-insect net (1) with the 2 one-touch clips (2).

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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 12. Use a wrench (13 mm) to install the cover (1) with the 5 bolts (2).

13. Use a wrench (19 mm) to install the under cover (1) with the 3 bolts (2).

Tighten bolts being installed to the specified torque. If the torque is not specified, see the "Bolt Size and Torque Table".

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Section 2004

Removal and Installation of Turbo Charger

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CONTENTS Turbocharger assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbocharger assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Removal and Installation of Turbo Charger Turbocharger assembly Removal

WARNING The engine is extremely hot just after stopping. Wait for them to sufficiently cool before beginning work.

1) 2.

CAUTION

Battery ground cable Disconnect

Coolant Drain 1)

• Be sure to stop the engine before beginning work.

Wrenches (8 mm, 10 mm, 13 mm, 14 mm, 17 mm) Cap Plug Rag Cleaning fluid

Drain the coolant from the radiator. CAUTION • After the coolant is discharged, make sure to tighten the drain plug.

Items to prepare • • • • •

Disengage the battery ground cable from the battery.

Turbocharger assembly Removal 1) 2) 3) 4)

Remove the air cleaner duct from the air cleaner assembly and the turbocharger assembly. Remove the air intake hose from the turbocharger assembly and the intercooler. Remove the exhaust pipe from the turbocharger assembly. Disengage the oil feed pipe from the turbocharger assembly. ANNOTATION: • Remove the clip.

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Removal and Installation of Turbo Charger 5)

Disengage the oil return pipe from the turbocharger assembly.

Disengage the water feed pipe from the turbocharger assembly. ANNOTATION: â&#x20AC;˘ Remove the clip.

1 2 3 6)

Turbocharger assembly Oil feed pipe Oil return pipe 1 2

Disengage the water return pipe from the turbocharger assembly.

Remove the exhaust manifold stay from the cylinder block and the turbocharger assembly.

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Water return pipe Water feed pipe

Turbocharger assembly Exhaust manifold Exhaust manifold stay

Removal and Installation of Turbo Charger 9) 10)

Disengage the harness connector from the turbocharger assembly. Remove the turbocharger assembly from the exhaust manifold.

Turbocharger assembly Installation 1.

Turbocharger assembly Installation 1)

1 2

Temporarily tighten the turbocharger assembly to the exhaust manifold.

Exhaust manifold Turbocharger assembly 1 2 2)

Temporarily tighten the exhaust manifold stay to the cylinder block and the turbocharger assembly.

1 2 3 3)

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Exhaust manifold Turbocharger assembly

Turbocharger assembly Exhaust manifold Exhaust manifold stay

Securely tighten the turbocharger assembly to the exhaust manifold. Tightening torque： 52 N・m { 5.3 kgf・m / 38 lb・ft }

Removal and Installation of Turbo Charger 4)

Securely tighten the exhaust manifold stay to the cylinder block and the turbocharger assembly. Tightening torque： 52 N・m { 5.3 kgf・m / 38 lb・ft } Nut Tightening torque： 50 N・m { 5.1 kgf・m / 37 lb・ft } Bolt

Connect the water return pipe to the turbocharger assembly.

ANNOTATION: • Tightening order

Connect the water feed pipe to the turbocharger assembly. CAUTION • Use new gaskets. Tightening torque： 35 N・m { 3.5 kgf・m / 25 lb・ft } Eyebolt Tightening torque： 14 N・m { 1.4 kgf・m / 119 lb・in } Clip

1 2

Water return pipe Water feed pipe

Tightening torque： 35 N・m { 3.5 kgf・m / 25 lb・ft } Eyebolt Connect the oil return pipe to the turbocharger assembly. CAUTION • Use new gaskets. Tightening torque： 9 N・m { 0.9 kgf・m / 78 lb・in }

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Removal and Installation of Turbo Charger 8)

10)

Connect the oil feed pipe to the turbocharger assembly.

11) CAUTION 12)

・ Use new gaskets. Tightening torque： 17 N・m { 1.7 kgf・m / 12 lb・ft } Eyebolt Tightening torque： 24 N・m { 2.4 kgf・m / 17 lb・ft } Clip

Install the air intake hose to the turbocharger assembly and the intercooler. Install the air cleaner duct to the air cleaner assembly and the turbocharger assembly. Connect the harness connector to the turbocharger assembly.

Coolant Filling 1) 2)

Loosen the valve using a wrench. Replenish the coolant with the radiator. CAUTION • Be careful not to let coolant overflow splash on the exhaust system parts. • Coolant overflow should be wiped off.

Tighten the valve using a wrench. CAUTION • Use new gaskets.

1 2 3 9)

Turbocharger assembly Oil feed pipe Oil return pipe

Tightening torque： 28 N・m { 2.8 kgf・m / 20 lb・ft } Replenish the coolant with the radiator.

1 2 3.

Install the exhaust pipe to the turbocharger assembly.

Valve Gasket

Battery ground cable Connect 1)

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Connect the battery ground cable to the battery.

Section 2005

Removal and Installation of EGR Valve

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CONTENTS EGR valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 EGR valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Removal and Installation of EGR Valve EGR valve Removal 1.

Remove the EGR pipe A from the EGR cooler A and exhaust manifold.

Battery ground cable Disconnect 1)

Disengage the battery ground cable from the battery.

Coolant Drain 1)

Drain the coolant from the radiator. CAUTION â&#x20AC;˘ After the coolant is discharged, make sure to tighten the drain plug.

EGR cooler assembly Removal 1)

Disengage the water rubber hose from the EGR cooler assembly. 1 2 3

4) 5) 6) 7)

1 2)

EGR cooler A EGR pipe A Exhaust manifold

Remove the EGR cooler A from the EGR pipe B. Remove the EGR pipe B from the EGR cooler B. Remove the EGR cooler B from the EGR pipe C. Remove the EGR pipe C from the EGR valve.

Water rubber hose

Remove the EGR heat protector from the EGR pipe A.

1 2 3 4 5 6

EGR heat protector

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EGR EGR EGR EGR EGR EGR

valve pipe C cooler B pipe B cooler A pipe D

Removal and Installation of EGR Valve 4.

EGR valve Removal

EGR valve Installation

Disengage the harness connector from the EGR valv.e Remove the EGR valve from the EGR pipe D.

1 2 3 4

EGR EGR EGR EGR

EGR valve Installation 1)

cooler C pipe C valve pipe D

Install the EGR valve to the EGR pipe D. Tightening torque： 24 N・m { 2.4 kgf・m / 17 lb・ft }

1 2 3 4

EGR EGR EGR EGR

cooler C pipe C valve pipe D

CAUTION • Use new gaskets. 2) 2.

Connect the harness connector to the EGR valve.

EGR cooler assembly Installation 1) 2) 3)

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Temporarily tighten the EGR pipe C to the EGR valve. Temporarily tighten the EGR cooler B to the EGR pipe C. Temporarily tighten the EGR pipe B to the EGR cooler B.

Removal and Installation of EGR Valve 4)

Temporarily tighten the EGR cooler A to the EGR pipe B.

1 2 3 4 5 6 5)

EGR EGR EGR EGR EGR EGR

valve pipe C cooler B pipe B cooler A pipe B

Temporarily tighten the EGR pipe A to the EGR cooler A and the exhaust manifold.

1 2 3

EGR cooler A EGR pipe A Exhaust manifold

10) ANNOTATION: • Complete tightening order of the EGR cooler assembly

11)

12)

13)

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Securely tighten the EGR pipe C to the EGR valve. Tightening torque： 24 N・m { 2.4 kgf・m / 17 lb・ft } No.1 in the diagram Completely tighten the EGR pipe C to the engine hanger bracket. Tightening torque： 48 N・m { 4.9 kgf・m / 35 lb・ft } No.2 in the diagram Securely tighten the EGR pipe B to the bracket. Tightening torque： 48 N・m { 4.9 kgf・m / 35 lb・ft } No.3 in the diagram Securely tighten the EGR cooler B to the EGR pipe C. Tightening torque： 24 N・m { 2.4 kgf・m / 17 lb・ft } No.4 in the diagram Securely tighten the EGR pipe B to the EGR cooler B. Tightening torque： 24 N・m { 2.4 kgf・m / 17 lb・ft } No.5 in the diagram Securely tighten the EGR cooler A to the EGR pipe B. Tightening torque： 24 N・m { 2.4 kgf・m / 17 lb・ft } No.6 in the diagram Securely tighten the EGR pipe A to the exhaust manifold. Tightening torque： 28 N・m { 2.9 kgf・m / 21 lb・ft } No.7 in the diagram Securely tighten the EGR pipe A to the EGR cooler A. Tightening torque： 28 N・m { 2.9 kgf・m / 21 lb・ft } No.8 in the diagram

Removal and Installation of EGR Valve 14)

1) 2)

Install the EGR heat protector to the EGR pipe A.

Tighten the valve using a wrench. CAUTION • Use new gaskets

1 15)

EGR heat protector

Tightening torque： 28 N・m { 2.8 kgf・m / 20 lb・ft } Replenish the coolant with the radiator.

Connect the water rubber hose to the EGR cooler assembly.

1 2 1

Water rubber hose

Battery ground cable Connect 1)

Valve Gasket

Coolant Filling

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Connect the battery ground cable to the battery.

Section 2006

Removal and Installation of Engine Hood

84402826 - May 2011

CONTENTS Removal of Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Engine Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Removal and Installation of Engine Hood Removal of Engine Hood

CAUTION • Be sure to stop the engine before beginning work. • Do not perform this operation in strong wind. • Be sure to inspect the nylon sling and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. • When removing the gas damper, be sure to do so while the lock is applied, because the hood holding force may be reduced and the hood may drop. • Be careful not to let the hood fall and catch fingers. • The damper’s rod may fly out suddenly. Completely extend the gas dumper when removing it. • Operate the liftcrane slowly and gently.

Open the engine hood (1) until the lock is engaged. Wrap the nylon sling (2) around the engine hood (1), and then gently lift with the liftcrane until there is no force on the open lock stay (3). Remove the pin (1) and washer (2) that are on the engine hood side of the open lock stay, and then remove the open rock stay (3) from the guide.

Items to prepare • Wrench (13 mm, 17 mm, 19 mm) • Nylon sling (with the required breaking load) • Liftcrane (with the required lifting capacity)

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Removal and Installation of Engine Hood 2.

Use the liftcrane and lift up the engine hood (2) until the damper (1) is completely extended and there is no force on it. Loosen the ring (3) of the damper’s head section, and then remove the gas damper (1).

Wrap the nylon sling (2) around the engine hood (1), and then use the liftcrane to lift the engine hood (1).

Installation of Engine Hood 3.

After closing the engine hood (1), use a wrench (19 mm) to remove the 6 bolts (2) from the engine hood.

To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, check of the "About This Shop Manual Section • Tightening Torque • Retightening Torque Table" in the explanation in the materials.

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Section 2007

Removal and Installation of Muffler

84402826 - May 2011

CONTENTS Removal of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Removal and Installation of Muffler Removal of Muffler

WARNING • Keep fire away. • The machine is extremely hot just after the engine has been stopped. Wait for it to sufficiently cool before beginning work.

Use a wrench (13 mm) to loosen the nut (1); remove the bolt (2), washers (3), and gasket (4); and then remove the exhaust pipe (5).

Remove the connectors (1).

Use a wrench (10 mm) to loosen the bolt (1), and then remove the cord clamp.

CAUTION • Be sure to stop the engine before beginning work. Items to prepare • • • • • •

Wrench (10 mm) Wrench (13 mm) Wrench (14 mm) Cap Rag Cleaning fluid

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Removal and Installation of Muffler 4.

Use a wrench (19 mm) to loosen the 4 bolts (1), and then remove the muffler.

Installation of Muffler 1.

When installing the bolts, tighten them to the specified torque. When the tightening torque is not specified for a bolt or other part, see "Materials Explanation - Tightening Torque - Torque Table (one page)". Place the DPD muffler (1) in the bracket, and install the gasket (2), bolt (3), nut (4), and washers (5) on the flanges. Move the DPD muffler over until the DPD muffler flange touches the exhaust pipe (6) flange surface, and then use a wrench (13 mm) to temporarily tighten the flanges together. CAUTION â&#x20AC;˘ Use caution when handling the DPD muffler (1), DPD pressure sensor (7), and DPD thermo-sensors (8) (9) and do not subject them to any impacts etc. â&#x20AC;˘ Do not reuse these parts if they are dropped or fall.

Use a wrench (19 mm) to tighten the 4 bolts (1) to secure the muffler.

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Removal and Installation of Muffler 4.

Use a wrench (13 mm) to fully tighten the bolt (1), nut (2), and washers (3) temporarily tightened in Step 2.

Install the connectors (1).

After installation, run the engine at no-load idling and check for any abnormalities.

Use a wrench (10 mm) to tighten the bolt (1) to install the cord clamp.

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