Case cx350c tier 4 crawler excavator service repair manual by 163561

CX350C Tier 4 Crawler Excavator

SERVICE MANUAL

Part number 84402832 1st edition English August 2011

Section 1001

Safety, general information and standard torque data

84402832 NA - May 2011

CONTENTS GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ROPS Judgment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Standard Torque Data For Cap Screws And Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

84402832 NA - May 2011 1001-1

Safety, general information and standard torque data GENERAL INFORMATION CLEANING Clean all metal parts except bearings, in a suitable cleaning solvent or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning, dry and put oil on all parts. Clean oil passages with compressed air. Clean bearings in a suitable cleaning solvent, dry the bearings completely and put oil on the bearings. INSPECTION Check all parts when the parts are disassembled. Replace all parts that have wear or damage. Small scoring or grooves can be removed with a hone or crocus cloth. Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early failures. BEARINGS Check bearings for easy action. If bearings have a loose fit or rough action replace the bearing. Wash bearings with a suitable cleaning solvent and permit to air dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR. NEEDLE BEARINGS Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings. GEARS Check all gears for wear and damage. Replace gears that have wear or damage. Oil seals, O-rings and gaskets. Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings. SHAFTS Check all shafts that have wear or damage. Check the bearing and oil seal surfaces of the shafts for damage. SERVICE PARTS Always install genuine Case service parts. When ordering refer to the Parts Catalogue for the correct part number of the genuine Case replacement items. Failures due to the use of other than genuine Case replacement parts are not covered by warranty. LUBRICATION Only use the oils and lubricants specified in the Operatorâ&#x20AC;&#x2122;s or Service Manuals. Failures due to the use of non-specified oils and lubricants are not covered by warranty.

84402832 NA - May 2011 1001-3

Safety, general information and standard torque data Safety This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.

To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Put the warning tag shown below on the key for the key switch when servicing or repairing the machine. One warning tag is supplied with each machine. Additional tags are available from your service parts supplier. WARNING Read the operator's manual to familiarize yourself with the correct control functions. WARNING Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury. WARNING This is a one man machine, no riders allowed. WARNING Before starting engine, study Operatorâ&#x20AC;&#x2122;s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturers instructions on machine operation, service and to observe pertinent laws and regulations. Operator's and Service Manuals may be obtained from your CASE dealer. WARNING If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing. WARNING When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution. WARNING When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure. WARNING When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way. WARNING Use insulated gloves or mittens when working with hot parts. 84402832 NA - May 2011 1001-4

Safety, general information and standard torque data WARNING Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. WARNING Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood. WARNING When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. WARNING When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors). WARNING Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands. WARNING When servicing or repairing the machine, keep the shop floor and operator's compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use safe practices at all times. WARNING Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual. WARNING Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area. WARNING When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

84402832 NA - May 2011 1001-5

Safety, general information and standard torque data ROPS Judgment Method 1.

Purpose Check against the ROPS judgment criteria to judge whether the machine satisfies the ROPS criteria or not. The weight and boom of the machine greatly effects whether the ROPS judgment criteria is satisfied or not. The ROPS test assumes that the weight being used is the weight of the machine when the maximum number of selectable options are mounted (as of 2009). However, depending on the derivative machinery or the order details, the weight and boom position may differ from the assumed weight or position. Criteria for judging whether a machine satisfies the ROPS criteria 1)

Weight The weight must not be over the weight shown below for each class. If the weight is exceeded, there is a danger that the cab could be damaged and the operator could die or sustain a serious injury when the machine falls over. If the weight exceeds the stipulated weight, the machine will not satisfy the ROPS criteria. â&#x20AC;˘ Weight (C series model) To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are the weights indicated on the nameplate within the ROPS cab) Machine weight

body

total

Class CX250C CX250CLR CX300C CX370C CX470C

31000 kg or less 40000 kg or less 50000 kg or less

* The ROPS test assumes that the CX470C has a cage guard (alone). â&#x20AC;˘ Weight (B series model) To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are the weights indicated on the nameplate within the ROPS cab) Machine weight

body

25000 kg or less

total

Class CX130B CX160B CX180B CX210B CX230B

84402832 NA - May 2011 1001-6

Safety, general information and standard torque data 2)

Boom position WARNING • If the machine has been modified so that the boom position has been lowered, the machine will not satisfy the ROPS criteria. • It is necessary to consult with our company if it is possible that the boom's position has been lowered by modification. • The extent to which a boom position has moved cannot be determined in the same way for all machines.

Ground point

With the tip of the bucket in contact with the ground surface at maximum work radius, if the position (* in the diagram) that overlaps with the cab when viewed from the side is markedly lower than that of a standard machine (standard arm), the machine will not satisfy the ROPS criteria. Also, with a machine body with a cab mounted that can withstand up to 31 tons, the effect of mounting a 24 ton machine, which is near the restriction weight, and a 21 ton machine to the same cab will not be the same.

84402832 NA - May 2011 1001-7

Safety, general information and standard torque data 3.

Prohibited items â&#x20AC;˘ Modifications that reduce the strength of a platform that has a cab with a ROPS mounted to it. (Actions or modifications that reduce the functionality of the anchoring part at the left-rear of the cab) â&#x20AC;˘ Modifications that effect the strength of the ROPS of a cab. A forbidden all modifications (red part) Allow under specified conditions (gray part)

All modifications (grinding, welding, drilling holes, removing, etc.) are prohibited. Removal of parts is prohibited. Bar welding and making holes (up to diameter 20 mm) by drilling are possible.

[C series Cab]

84402832 NA - May 2011 1001-8

Safety, general information and standard torque data [B series Cab]

â&#x20AC;˘ In general, high cabs do not satisfy the ROPS criteria. (It is necessary to consult with our company to check if the high cab model satisfies the ROPS criteria.)

84402832 NA - May 2011 1001-9

Safety, general information and standard torque data Standard Torque Data For Cap Screws And Nuts BOLT AND NUT TIGHTENING • Tighten alternating between left and right and top and bottom so that uniform tightening force is applied.

• If Loctite was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the old Loctite off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of Loctite to the thread section of the bolt. Torque table Bolt nominal diameter (size) Wrench Hexagon bolt Tightening torque Wrench Hexagon socket Tightening head bolt torque

[mm]

M6 10

M8 13

M10 17

M12 19

M14 22

M16 24

M18 27

M20 30

[N･m]

6.9

19.6

39.2

58.8

98.1

156.9

196.1

294.2

[mm]

[N･m]

8.8

21.6

42.1

78.5

117.7

176.5

245.2

343.2

84402832 NA - May 2011 1001-10

Section 1002A

Specifications

84402832 NA - May 2011

CONTENTS Overall (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 3 3 4 4 4 5 5 6 6 6 6 6 6 6

Specifications Overall (CX350C) Main Data 34700 kg 198 kW/1900 min-1

Operating weight Engine output

Performance Standard weight Swing speed

18.0 kN 9.7 min-1 Low speed 3.2 km/h High speed 5.4 km/h 264 kN 70 ％ (35°) 65 kPa (600 mm grouser 57 kPa (700 mm grouser 50 kPa (800 mm grouser 47 kPa (850 mm grouser 45 kPa (900 mm grouser

Travel speed Maximum pulling force Grade ability

Ground pressure

Standard weight Swing speed

shoe) shoe) shoe) shoe) shoe)

18.0 kN 9.7 min-1 Low speed 3.2 km/h High speed 5.4 km/h 264 kN 70 ％ (35°) 58 kPa (700 mm grouser shoe) 51 kPa (800 mm grouser shoe) 48 kPa (850 mm grouser shoe)

Travel speed Maximum pulling force Grade ability Ground pressure

Main Unit Dimensions Main unit length Main unit width Upper swing body width Cab width Main unit height Swing radius (rear end) Swing body rear end distance Swing body rear section bottom height Distance between tumblers Overall track length Overall track width Distance between tracks Track shoe width Minimum ground clearance

6010 3200 3030 1000 3160 3550 3520

mm mm (600 G shoe) mm mm mm mm mm

1210 mm (not including lug height of 36 mm) 4040 mm 4980 mm 3200 mm (600 G shoe) 2600 mm 600 mm (options 700 mm, 800 mm, 850 mm, 900 mm) 480 mm (to bottom of lower frame) (not including lug height of 36 mm)

Engine Name Model

Isuzu 6HK1X diesel engine 4-cycle, water-cooled, overhead camshaft type Common rail system (electronic control), cooled EGR, with turbocharger (variable displacement type), DPD system

Number of cylinders - bore x 6 - D115 mm x 125 mm stroke 84402832 NA - May 2011 1002A-3

Specifications Total stroke volume Maximum torque Starter Charging generator Battery

7.790 L 1043 NÂˇm/1500 min-1 24 V 5.0 kW reduction type 24 V 50 A AC type 12 V 128 Ah/5 HR x 2

Cooling System Fan type Radiator Fin type Fin pitch Oil cooler Fin type Fin pitch Intercooler Fin type Fin pitch Fuel cooler Fin type Fin pitch

D850 mm, 6 blades, suction Wavy 1.75 mm Wavy 1.75 mm Wavy 2.5 mm Wavy 2.0 mm

Upper Side Work System Model Components, dimensions, working dimensions Bucket capacity (reference) Bucket width Bucket width with side cutter Bucket weight with side cutter Boom length Arm type Arm length Bucket radius Bucket wrist angle Maximum digging radius Maximum digging radius at ground line Maximum digging depth Maximum vertical straight wall digging depth Maximum digging height Maximum dump height Minimum swing radius at front Height for minimum swing radius at front

Backhoe Attachment Heaped 1.40 m3 (Leveled 1.04 1300 mm 1440 mm 1150 kg 6450 mm Standard Long (STD/HD) (4.04 m) (3.25 m) 3250 mm 4040 mm 1680 mm 173Â° 11170 mm 11900 mm

m3)

10980 mm

Short (2.63 m)

Ultra-short (2.21 m)

2630 mm

2210 mm

10670 mm

10200 mm

11720 mm

10470 mm

9990 mm

7340 mm

8140 mm

6730 mm

6300 mm

6350 mm

7150 mm

5970 mm

5080 mm

10370 mm 7230 mm 4500 mm

10670 mm 7540 mm 4560 mm

10320 mm 7140 mm 4630 mm

9850 mm 6770 mm 4660 mm

8480 mm

8490 mm

8540 mm

8650 mm

Operating Device Operator's seat Position Structure Cab Levers and pedals For travel use

Left side Adjustable forward and back and up and down, reclining mechanism, with seat suspension Sealed steel type, all reinforced glass, ROPS, with sunroof Lever and pedal type (hydraulic pilot type) x 2 84402832 NA - May 2011 1002A-4

Specifications For operating machine use Lever type (hydraulic pilot type) x 2 Instruments and switches Work mode switchover 3 modes (SP/H/A) Travel mode switchover Low-speed/high-speed switch type Knob switch type One-touch idle Engine emergency stop Switch type Monitor device Machine status display (TFT color liquid crystal) Message display Work mode select status SP/H/A Instruments Fuel gauge Engine coolant temperature gauge Hydraulic oil temperature gauge Hour meter Rear view camera monitor Warning display and warning alarm * has warning alarm Overheat (*) Battery charge (*) Electrical system abnormality (*) Refill fuel (*) Engine oil pressure (*) Refill coolant (*) Engine pre-heat Auto Warm-up Air cleaner (*) Anti-theft device triggered Engine system abnormality (*) Engine emergency stop (*) Illumination equipment Right front tool Working light box front sur- 24 V 70 W x 1 face: 24 V 70 W x 2 Cab top: Boom side: 24 V 70 W x 1 Interior light 4 V 10 W x 1 Horn Electric horn x 2 Wiper with intermittent function, window washer, air conditioner, 4 rear view mirrors (2 on cab sides, 1 front right stay, 1 CTWT Other rear right), 1 rear view mirror (on CTWT)

Swing Units Swing circle Swing hydraulic motor Reduction gear Swing parking brake

Swing bearing type (with inner gear) Fixed displacement piston motor x 1 Planetary gear 2-stage reduction gear Mechanical lock (operational lever linkage type)

Travel Lower Body Travel hydraulic motor Reduction gear Travel brake Parking brake Track shoe Model Number of shoes (per side) Shoe width Grouser height Link pitch Roller No. of upper rollers (per side) No. of lower rollers (per side) Track belt tension adjuster

Variable displacement piston motor x 2 Planetary gear 2-stage reduction gear(Nabtesco Corporation) Hydraulic lock Mechanical lock (travel lever linkage type) Assembly-type triple grouser shoe 48 600 mm (options 700 mm, 800 mm, 850 mm, 900 mm) 36 mm 216 mm 2 8 Grease cylinder type (with cushion spring) 84402832 NA - May 2011 1002A-5

Specifications Hydraulic Equipment Hydraulic Device Hydraulic pump drive type Hydraulic pump

Direct engine link (no transmission)

Model Discharge volume Pump control method Set pressure of main relief valve Set pressure of overload relief valve

Double variable displacement piston pump x 1 Gear pump x 1 Piston pump 2 x 285 L/min Gear pump 28.5 L/min Simultaneous output full-horsepower control 34.3 MPa (37.3 MPa for pressure boost) 27.4 MPa (boom down) 39.2 MPa (boom up/arm/bucket)

Control Valve and Cylinder Control valve Model Operating method Cylinder Boom cylinder Arm cylinder Bucket cylinder

Quadruple spool + quintuple spool x 1 Hydraulic pilot type: travel, swing, and operating machine No. of cylinders x tube bore - rod diameter - stroke 2 x D145 mm - D100 mm - 1495 mm 1 x D170 mm - D120 mm - 1748 mm 1 x D150 mm - D105 mm - 1210 mm

Capacities, Filters Coolant and Oil Capacities Coolant Fuel Engine lubricating oil (including remote oil filter) Travel reduction gear lubricating oil (one side) Swing reduction gear lubricating oil Hydraulic oil Hydraulic oil tank regulation amount

35.4 L 580 L 49 L 11 L 5L 350 L 175 L

Hydraulic Oil Filters Suction filter (inside tank) Return filter (inside tank) Pilot line filter (inside pump chamber)

105 μm 6 μm 8 μm

Fuel Filter Main filter Pre-filter

2 μm 7 μm

84402832 NA - May 2011 1002A-6

Section 1002B

Main Equipment Table

84402832 NA - May 2011

CONTENTS Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lower Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Travel Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Recoil Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Shoe (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Upper Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Swing Unit (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air Cleaner (double element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Control-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Solenoid Valve (4 stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remote Control Valve (left/right, travel operations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remote Control Valve for Left/Right Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remote Control Valve for Travel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remote Control Valve Characteristic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operation Remote Control Valve Control Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Travel Remote Control Valve Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cushion Valve (heat circuit, with shuttle valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Backhoe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

84402832 NA - May 2011 1002B-2

Main Equipment Table Main Equipment Table Lower Component Travel Unit Manufacturer Motor type Intake amount Operating pressure Operating flow Brake torque Relief valve set pressure Automatic 2-speed switchover pressure Reduction gear Reduction gear type Reduction ratio Dry weight

Nabtesco Corporation Variable displacement piston motor Automatic 2-speed switchover with parking brake 290.7/170.1 cm3/rev 34.3 MPa 285 L/min 47.39 kNÂˇm min. (including reduction gear) 35.8 - 37.8 MPa 26.5 MPa Planetary gear 2-stage reduction gear 40.467 399 kg

Take-up Roller Sumitomo part No. Weight

LH5146 164.6 kg

Upper Roller Weight

43 kg

Lower Roller Weight

61 kg

Recoil Spring Item Yoke Sems B M16 x 50 Threaded rod Groove height N M64 SP pin 10 x 100 Recoil spring Grease cylinder assembly Sems B M16 x 65 Assembly (Total) Mounting length of spring

Weight (kg) 39.8 0.5 49.1 1.9 0.1 119.4 41.1 0.3 252.2 779 mm

Q'ty 1 4 1 1 1 1 1 2

84402832 NA - May 2011 1002B-3

Main Equipment Table Shoe (CX350C) 600 grouser Link Shoe Bolt Nut 700 grouser Link Shoe Bolt Nut 800 grouser Link Shoe Bolt Nut 850 grouser Link Shoe Bolt Nut 900 grouser Link Shoe Bolt Nut

Weight or Q'ty 2217 kg 1 set 48 192 192 2473 kg 1 set 48 192 192 2618 kg 1 set 48 192 192 2735 kg 1 set 48 192 192 2817 kg 1 set 48 192 192

84402832 NA - May 2011 1002B-4

Main Equipment Table Upper Component Swing Unit (CX350C) Swing motor assembly Swing motor Manufacturer Motor type Intake amount Operating pressure Operating flow Mechanical brake torque Brake off pressure Relief valve set pressure Swing reduction gear Reduction gear type Reduction ratio Dry weight Turntable bearing No. of teeth Weight Counterweight Weight

Kawasaki Precision Machinery Ltd. Fixed displacement piston motor With parking brake 180.1 cm3/rev 30.4 MPa 285 L/min 1010.8 Nă&#x192;ťm min. 3.1 MPa max. 30.4 MPa Planetary gear 2-stage reduction gear 27.143 437 kg 92 540 kg 6400 kg

84402832 NA - May 2011 1002B-5

Main Equipment Table Engine-related Engine Sumitomo part No. Engine model name

KSH11600 Isuzu 6HK1X diesel engine 4-cycle, water-cooled, overhead camshaft type, common rail system Engine type (electronic control), cooled EGR, with turbocharger (variable displacement type), DPD system No. of cylinders - bore - stroke 6 - D115 mm - 125 mm Total displacement 7.79 L 17.5 Compression ratio Rated output 198 kW/1900 min-1 Maximum torque 1043 NÂˇm/about 1500 min-1 Fuel consumption ratio 221 - 241 g/kWÂˇh at 1900 min-1 Engine dry weight About 640 kg Engine dimension L 1388 - W 1047 - H 1194 mm D850 mm - suction type - 6 vanes, plastic and steel Cooling fan With bell mouth-type fan guide Pulley ratio 0.9 (reduction) Charging generator 24 V 50 A AC type 24 V 5 kW reduction type Starter motor Coolant capacity 14.5 L Oil pan capacity Max: 46 L Min: 36 L (not including oil filter) Right (viewed from fan side) Direction of rotation Compliant with JISD 0006-2000.

DPD Isuzu Motors, Ltd. 38 kg

Manufacturer Weight

Air Cleaner (double element) Nippon Donaldson, Ltd.

Manufacturer Element (outer) Element (inner) Weight

13 kg

Radiator Manufacturer Oil cooler Radiator Air cooler Fuel cooler Total weight

Weight Oil volume Weight Coolant capacity Weight Capacity Weight Capacity

Tokyo Radiator MFG. Co.,Ltd. 39.0 kg 12.9 L 11.9 kg 9.4 L 12.6 kg 1.0 kg x 2 0.3 L x 2 159 kg

84402832 NA - May 2011 1002B-6

Main Equipment Table Hydraulic Device Hydraulic Pump Manufacturer Main pump Pump type Displacement capacity Operating pressure Input revolution speed Maximum discharge flow Pilot pump Pump type Displacement capacity Operating pressure Maximum discharge flow Control method

Dry weight

Kawasaki Precision Machinery Ltd.

Rated Maximum

Double variable displacement piston pump 150 x 2 cm3/rev 34.3 MPa 37.3 MPa 1900 min-1 289 x 2 L/min (at Pd = 3.0 MPa. 1900 min-1) 285 x 2 L/min (at Pd = 8.0 MPa. 1900 min-1) Gear pump 15 cm3/rev 3.9 MPa 28.5 L/min (at 1900 min-1) Hydraulic simultaneous constant output control Maximum flow adjustment control through external commands (negative control) Maximum flow adjustment control through external command milli-amp (negative control, front side) Setting horsepower adjustment control through external command milli-amp 188 kg

84402832 NA - May 2011 1002B-7

Main Equipment Table Control-related Control Valve STD (with 2nd option add-on valve) Manufacturer Maximum flow Overload set pressure

Main relief set pressure (at boosting) Foot relief set pressure Function

Weight

KYB Corporation 285 L/min (at 1900 min-1) 27.4 MPa boom down 39.2 MPa boom up, arm, bucket 22.6 MPa attachment 2 34.3 MPa 37.3 MPa 2.55 MPa Straight travel circuit Boom-up/arm 2 pumps internal flow Boom and arm load holding circuit Boom-down regenerative circuit Bucket-close regenerative circuit Arm-in forced regenerative circuit Swing priority variable orifice 2 pumps flow (external flow merging) 199 kg 215 kg

Solenoid Valve (4 stack) Manufacturer Valve specifications Maximum flow Rated pressure Port size Solenoid specifications Operating voltage Power consumption Weight

Yuken Kogyo Co., Ltd.

G3/8 G1/4

P â&#x2020;&#x2019; B 20 L/min Other 5 L/min 4.5 MPa P.T.B. port C1, C2, C3, C4, C5 ports DC 20 - 32 V 17 W max. 5 kg

84402832 NA - May 2011 1002B-8

Main Equipment Table Remote Control Valve (left/right, travel operations) Remote Control Valve for Left/Right Operations Manufacturer Operating pressure Secondary pressure Operating

Kawasaki Precision Machinery Ltd. 3.92 MPa 0.64 - 2.45 MPa primary short type 19° 25° 1.9 kg

1, 3 port 2, 4 port

Weight

Remote Control Valve for Travel Operations Kawasaki Precision Machinery Ltd. 3.92 MPa 0.64 - 2.45 MPa primary short type 12.4° 5.5 kg

Manufacturer Operating pressure Secondary pressure Operating angle Weight

Remote Control Valve Characteristic Diagram Operation Remote Control Valve Control Diagram Ports 1, 3

Secondary pressure [MPa]

Push rod stroke [mm]

Operating angle [deg.]

Secondary pressure 1

84402832 NA - May 2011 1002B-9

Main Equipment Table Ports 2, 4

Secondary pressure [MPa]

Push rod stroke [mm]

Operating angle [deg.]

Secondary pressure 1

Travel Remote Control Valve Control Diagram

Secondary pressure [MPa]

Push rod stroke [mm]

Pedal operating angle [deg.]

Secondary pressure 1 84402832 NA - May 2011 1002B-10

Main Equipment Table Cushion Valve (heat circuit, with shuttle valve) Yanagisawa Seiki MFG. Co., Ltd. G 3/8 (A - P ports) G 1/4 (Q - V ports) 12.5 kg

Manufacturer Port size Weight

Center Joint Operating pressure

Flow

Port A Port B Port C Port D Port T Port P Weight

High-pressure passage (ABCD) Drain port (T) Pilot port (P) High-pressure passage (ABCD) Drain port (T) Pilot port (P) Forward right Forward left Backward right Backward left Drain port Pilot port 55.5 kg

Backhoe Attachment Cylinder Boom Cylinder Cylinder bore Rod diameter Maximum retracted length Stroke Weight

D145 mm D100 mm 2090 mm 1495 mm 279 kg

Arm Cylinder Cylinder bore Rod diameter Maximum retracted length Stroke Weight

D170 mm D120 mm 2445 mm 1748 mm 462 kg

Bucket cylinder Cylinder bore Rod diameter Maximum retracted length Stroke Weight

D150 mm D105 mm 1870 mm 1210 mm 276 kg

84402832 NA - May 2011 1002B-11

34.3 MPa 1.0 MPa 3.9 MPa 360 L/min 40 L/min 31 L/min G1 G1 G1 G1 G1/2 G1/4

Main Equipment Table

84402832 NA - May 2011 1002B-12

Section 1002C

Main Unit Weight

84402832 NA - May 2011

CONTENTS Main Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Divided Weight (standard specifications) CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stand Alone Part Weight (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe Weight (per side) CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm Weight (CX350C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 4 4

Main Unit Weight Main Unit Weight Divided Weight (standard specifications) CX350C

Weight (kg) 34700

Code

Component name

Operating weight Upper component (including counterweight and turntable 15370 bearing) Counterweight 6420 Lower component (with grouser shoe) 12290 Main unit weight 27700 Attachments 7000 Boom (including cylinders) 3920 Arm (including cylinders and linkage) 1800

B C D E F G H

84402832 NA - May 2011 1002C-3

Main Unit Weight * The weights displayed are approximate weights.

Stand Alone Part Weight (CX350C) Component name 1

Travel unit

2 3 4 5 6 7 8 9 10 11 12 13

Take-up roller Upper roller Lower roller Swing unit Turntable bearing Engine Radiator Hydraulic pump Fuel tank Hydraulic oil tank Control valve Center joint

Boom

Nabtesco KYB

Standard HD

Weight (kg) 505 500 165 43 61 467 541 785 187 222 244 203 211 58 2427 2720

Shoe Weight (per side) CX350C 1 2 3 4 5

Component name 600mm grouser shoe 700mm grouser shoe 800mm grouser shoe 850mm grouser shoe 900mm grouser shoe

Weight (kg) 2220 2470 2620 2740 2820

Arm Weight (CX350C) 1 2 3 4

Component name Standard arm Ultra-short Arm Short Arm Long Arm

Weight (kg) 1112 1102 1209 1447

84402832 NA - May 2011 1002C-4

Section 1002D

Maintenance Standards

84402832 NA - May 2011

CONTENTS Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Track Shoe (grouser shoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Attachment (backhoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1. Boom and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2. Boom Cylinder and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3. Boom and Boom Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4. Boom and Arm Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 5. Boom and Arm Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6. Arm and Arm Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7. Arm and Bucket Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 8. Arm and Arm Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 9. Bucket and Bucket Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 10. Bucket Link and Bucket Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 11. Bucket and Arm Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspection Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 For Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 For Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 For Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 For Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

84402832 NA - May 2011 1002D-2

Maintenance Standards Drive Sprocket

* See the gauge list for measurement gauges.

Part name

Code

Measurement di- Standard mensions value (mm) (mm)

Usage limit (mm)

D660.7

D650.7

D748

D738

D732.5

215.9

Drive sprocket

84402832 NA - May 2011 1002D-3

Judgment

Solution

Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Cladding by welding or replacement Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable

Maintenance Standards Take-up Roller

* See the gauge list for measurement gauges.

Part name

Take-up roller

Shaft

Code

Measurement di- Standard mensions value (mm) (mm)

Usage limit (mm)

D560

22.5

25.5

102

100

D85

D84

D85

D86

23.6

Bushing

Hub

84402832 NA - May 2011 1002D-4

Judgment Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable

Solution

Cladding by welding or replacement

Replacement

Maintenance Standards Upper Roller

* See the gauge list for measurement gauges.

Part name

Carrier roller

Code

Measurement di- Standard mensions value (mm) (mm)

Usage limit (mm)

D150

D138

104

Shaft

D65

D64

Bushing

D65

D66

Bushing

Thrust plate

8.5

Cover

84402832 NA - May 2011 1002D-5

Judgment Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable

Solution

Cladding by welding or replacement

Replacement Replacement Replacement Replacement Replacement

Maintenance Standards Lower Roller

* See the gauge list for measurement gauges.

Part name

Track roller

Shaft

Code

Standard Measurement divalue mensions (mm) (mm)

Usage Judgment limit (mm)

D180

D168

216

224

D75

D74

D75

D76

D82

D81

17.5

17.0

Bushing

Collar

84402832 NA - May 2011 1002D-6

Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable

Solution

Cladding by welding or replacement

Replacement

Maintenance Standards Track Shoe (grouser shoe)

Measurement di- Standard mensions value (mm) (mm)

Usage limit (mm)

Part name

Code

Shoe plate

Link

129

123

D71.4

D67.4

D47.9

D47.3

216.2

220.7

864.6

882.6

Master bushing

Master pin Link pitch 4 linked sections

D71.4

D67.4

D48.4

D47.6

Track bushing

Track pin

84402832 NA - May 2011 1002D-7

Solution Replacement Cladding by welding or replacement Replacement

Replacement

Maintenance Standards Attachment (backhoe)

84402832 NA - May 2011 1002D-8

Maintenance Standards 1. Boom and Swing Frame Installation Section

Usage limits Judgment (mm) Acceptable/ 861.5 869.5 Unacceptable Acceptable/ 857 855 Unacceptable Shim ad- Acceptable/ 1 mm max. justment Unacceptable Acceptable/ D110 D109 Unacceptable Acceptable/ D110 D111.5 Unacceptable

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Swing frame

Boom

Clearance

Bushing (boom)

84402832 NA - May 2011 1002D-9

Solution Replacement Adjustment shims Replacement Replacement

with

Maintenance Standards 2. Boom Cylinder and Swing Frame Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Swing frame

131

Boom cylinder (foot section)

130

Clearance

1.0 - 2.5

D90

Bushing (boom cylinder)

D90

Usage limits Judgment (mm) Acceptable/ 137 Unacceptable Acceptable/ 128 Unacceptable Shim ad- Acceptable/ justment Unacceptable Acceptable/ D89 Unacceptable Acceptable/ D91.5 Unacceptable

84402832 NA - May 2011 1002D-10

Solution Replacement Adjustment shims Replacement Replacement

with

Maintenance Standards 3. Boom and Boom Cylinder Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Boom cylinder (top section)

123

Boom

669

Clearance

1.2 max.

D110

Bushing (boom cylinder)

D110

Usage limits Judgment (mm) Acceptable/ 121 Unacceptable Acceptable/ 665 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ D109 Unacceptable Acceptable/ D111.5 Unacceptable

84402832 NA - May 2011 1002D-11

Solution Replacement Replacement Adjustment shims Replacement Replacement

with

Maintenance Standards 4. Boom and Arm Cylinder Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Boom

146

Arm cylinder (foot section)

145

Clearance

1.2 max.

D100

Bushing (arm cylinder)

D100

Usage limits Judgment (mm) Acceptable/ 152 Unacceptable Acceptable/ 143 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ D99 Unacceptable Acceptable/ D101.5 Unacceptable

84402832 NA - May 2011 1002D-12

Solution Replacement Replacement Adjustment shims Replacement Replacement

with

Maintenance Standards 5. Boom and Arm Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Boom

Arm

Clearance

Bushing (arm)

Boom

Usage limits Judgment (mm) Acceptable/ 392 395 Unacceptable Acceptable/ 387.7 385.7 Unacceptable Shim ad- Acceptable/ 1 mm max. justment Unacceptable Acceptable/ D115 D114 Unacceptable Acceptable/ D115 D116.5 Unacceptable Acceptable/ D115 D116.5 Unacceptable Acceptable/ 89 87.5 Unacceptable

84402832 NA - May 2011 1002D-13

Solution Replacement Replacement Adjustment shims Replacement Replacement Replacement Replacement

with

Maintenance Standards 6. Arm and Arm Cylinder Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Arm

146

Arm cylinder (top section)

145

Clearance

0.5 - 3.0

D100

Bushing (arm cylinder)

D100

Usage limits Judgment (mm) Acceptable/ 152 Unacceptable Acceptable/ 143 Unacceptable Shim ad- Acceptable/ justment Unacceptable Acceptable/ D99 Unacceptable Acceptable/ D101.5 Unacceptable

84402832 NA - May 2011 1002D-14

Solution Replacement Replacement Adjustment shims Replacement Replacement

with

Maintenance Standards 7. Arm and Bucket Cylinder Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Arm

146

Bucket cylinder (foot b section)

145 1.2 max.

Clearance

D95

Bushing (bucket cylinder)

D95

Usage limits Judgment (mm) Acceptable/ 152 Unacceptable Acceptable/ 143 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ D94 Unacceptable Acceptable/ D96.5 Unacceptable

84402832 NA - May 2011 1002D-15

Solution Replacement Replacement Adjustment shims Replacement Replacement

with

Maintenance Standards 8. Arm and Arm Link Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Arm link

Arm

375

Clearance

1.2 max.

D85

Bushing (arm)

D85

Usage limits Judgment (mm) Acceptable/ 48 Unacceptable Acceptable/ 373 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ D84 Unacceptable Acceptable/ D86.5 Unacceptable

84402832 NA - May 2011 1002D-16

Solution Replacement Replacement Adjustment shims Replacement Replacement

with

Maintenance Standards 9. Bucket and Bucket Link Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Bucket

401

Bucket link

400

Clearance

1.0 - 3.5

D90

Bushing (bucket link)

D90

Usage limits Judgment (mm) Acceptable/ 406 Unacceptable Acceptable/ 398 Unacceptable Shim ad- Acceptable/ justment Unacceptable Acceptable/ D89 Unacceptable Acceptable/ D91.5 Unacceptable

84402832 NA - May 2011 1002D-17

Solution Replacement Replacement Adjustment shims Replacement Replacement

with

Maintenance Standards 10. Bucket Link and Bucket Cylinder Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Arm link

Bucket link

Clearance

Bucket link

Bucket cylinder (top section)

Clearance

Bushing (bucket link) Bushing (bucket cylinder)

Usage limits Judgment (mm) Acceptable/ 50 48 Unacceptable Acceptable/ 375 373 Unacceptable 1.2 mm Shim ad- Acceptable/ max. justment Unacceptable Acceptable/ 121 123 Unacceptable Acceptable/ 120 118 Unacceptable Shim ad- Acceptable/ 1.0 - 2.0 justment Unacceptable Acceptable/ D105 D104 Unacceptable Acceptable/ D105 D106.5 Unacceptable Acceptable/ D105 D106.5 Unacceptable

84402832 NA - May 2011 1002D-18

Solution Replacement Replacement Adjustment shims

with

Replacement Replacement Adjustment shims Replacement Replacement Replacement

with

Maintenance Standards 11. Bucket and Arm Installation Section

Measurement di- Standard mensions value (mm) (mm)

Part name

Code

Bucket

401

Arm

400

Clearance

1.2 max.

Bushing (bucket)

D90

Bushing (arm)

D90

Bushing (bucket)

D90

Usage limits Judgment (mm) Acceptable/ 406 Unacceptable Acceptable/ 398 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ 7 Unacceptable Acceptable/ D89 Unacceptable Acceptable/ D91.5 Unacceptable Acceptable/ D91.5 Unacceptable

84402832 NA - May 2011 1002D-19

Solution Replacement Replacement Adjustment shims Replacement Replacement Replacement Replacement

with

Maintenance Standards Inspection Gauge For Drive Sprocket

84402832 NA - May 2011 1002D-20

Maintenance Standards For Take-up Roller

84402832 NA - May 2011 1002D-21

Maintenance Standards For Upper Roller

84402832 NA - May 2011 1002D-22

Maintenance Standards For Lower Roller

84402832 NA - May 2011 1002D-23

Maintenance Standards

84402832 NA - May 2011 1002D-24

Section 1002E

Bolt Size and Torque Table

84402832 NA - May 2011

CONTENTS Special Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Bolt Size and Torque Table Special Torque Settings Code

Retightening location

1* 2* 3* 4* 5* 6* 7 8 9* 10* 11* 12* 13* 14* 15*

Travel motor Drive sprocket Take-up roller Upper roller Lower roller Track guard Shoe Counterweight Turntable bearing Swing unit

16*

Hydraulic pump

17* 18* 19* 20* 21* 22 23

Hydraulic oil tank Fuel tank Control valve

Engine

Flange

Bolt nominal diameter M24 M20 M16 M20 M24 M24 M24 M33 M24 M24 M20 M10 M12 M16 M10

Pump

M20

Mount Front bracket Rear bracket

Radiator

Center joint

M16 M16 M16 M16 M12 M16 M10

Lock bar Joint

Cab Battery

Wrench 36 mm 30 mm 24 mm 30 mm 36 mm 36 mm 32 mm 50 mm 36 mm 36 mm 30 mm 17 mm 19 mm 24 mm 17 mm 17 mm hexagon socket head 24 mm 24 mm 24 mm 24 mm 19 mm 24 mm 17 mm

Tightening torque [N•m] 900 - 1051 521 - 608 267 - 312 521 - 608 902 - 1049 902 - 1049 1236 - 1510 1862 - 2058 900 - 1050 900 - 1050 289 - 337 64 - 73 109 - 127 147 - 176 64 - 73 367 - 496 233 - 276 233 - 276 267 - 312 267 - 312 109 - 127 149 - 173 20 - 29

CAUTION For items marked with *, always apply Loctite #262 or the equivalent and tighten to the specified torque. The tightening torque in kgf•m is determined with N•m ÷ 9.8. The tightening for bolts and nuts not otherwise specified in the table above is as follows. Bolt nominal diameter (size) Wrench Hexagon bolt Tightening torque Wrench Hexagon socket head Tightening bolt torque

[mm]

M6 10

M8 13

M10 17

M12 19

M14 22

M16 24

M18 27

M20 30

[N・m]

6.9

19.6

39.2

58.8

98.1

156.9

196.1

294.2

[mm]

[N・m]

8.8

21.6

42.1

78.5

117.7

176.5

245.2

343.2

84402832 NA - May 2011 1002E-3

Bolt Size and Torque Table

84402832 NA - May 2011 1002E-4

Bolt Size and Torque Table

84402832 NA - May 2011 1002E-5

Bolt Size and Torque Table

84402832 NA - May 2011 1002E-6

Section 1002F

Overall View

84402832 NA - May 2011

CONTENTS CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Arm (3.25 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short Arm (2.63 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Long Arm (4.04 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ultra-short Arm (2.21 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 4 5 6

Overall View CX350C Standard Arm (3.25 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).

84402832 NA - May 2011 1002F-3

Overall View Short Arm (2.63 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).

84402832 NA - May 2011 1002F-4

Overall View Long Arm (4.04 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).

84402832 NA - May 2011 1002F-5

Overall View Ultra-short Arm (2.21 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).

84402832 NA - May 2011 1002F-6

Section 1003

List of special tools

84402832 NA - May 2011

CONTENTS Tools to purchase or to make locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Travel Motor Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Take-up Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Upper Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Lower Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Grease Cylinder Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Center Joint Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Swing Motor Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Remote Control Valve Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Gas Filling Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 CX250C/CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CASE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Isuzu Engine Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4HK1X-6HK1X Tier 4 Isuzu Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Attachment Special Tool (for Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Special Jigs Part Number List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 CNH-EST DIAGNOSTIC TOOL (SCAN TOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

84402832 NA - May 2011 1003-2

List of special tools Tools to purchase or to make locally Note: Dimensions in the drawings are shown in mm

Travel Motor Special Tool CX350C/CX370C

Code 1 2 3

Order No.

4 5 6

84402832 NA - May 2011 1003-3

Jig name Remarks Holder fitting Rear cover guide pin Brake piston removal jig Shim thickness adjustNo diagram ment jig Oil seal insertion jig Rear bearing insertion jig

List of special tools

Code 7 8

Order No.

Jig name Remarks Brake piston insertion jig Piston and shoe mea- When the rear cover bolts are used as is: D1: 2-20 drill, D2: 10 - Plain surement jig flat washer with rounded finish 18 mm

84402832 NA - May 2011 1003-4

List of special tools

Code 9 10 11

Order No.

Jig name Motor assembly pedestal Snap ring removal and installation (removal) jig Ball bearing removal and installation jig

84402832 NA - May 2011 1003-5

Remarks *1: Welding (8 locations)

List of special tools

Code

Order No.

12 13

84402832 NA - May 2011 1003-6

Jig name Remarks Holder A subassembly lifting jig Holder B subassembly lifting jig

List of special tools

Code 14 15 16

Order No.

Jig name

Remarks *1: Socket head bolt (1) Holder C subassembly lift- *2: M10 nut (1) *3: JIS B1354 Type A equiving jig alent (2) Motor assembly disassembly and assembly rod Angular bearing press-fit jig

84402832 NA - May 2011 1003-7

List of special tools

84402832 NA - May 2011 1003-8

List of special tools Code

Order No.

Jig name

Floating seal press-fit jig 1

Floating seal press-fit jig 2

Code 19 20

Order No.

84402832 NA - May 2011 1003-9

Jig name Floating seal press-fit jig 3 Oil seal press-fit jig

Remarks *1: 4 - M6 x 1.0 equipartition *2: 4 - 7 mm equipartition *3: 4 - 11 mm equipartition *1: 4 - M6 x 1.0 equipartition *2: 4 - 11 mm equipartition *3: 4 - 7 mm equipartition

Remarks

List of special tools Code 21

Order No.

84402832 NA - May 2011 1003-10

Jig name Remarks Bearing press-fit jig M12 x 1.75 x L45 socket head bolt

List of special tools Take-up Roller Special Tool CX350C/CX370C

Code 1 2 3

Order No.

84402832 NA - May 2011 1003-11

Jig name Remarks Bushing removal jig Bushing press-fit jig Floating seal installation jig

List of special tools Upper Roller Special Tool CX350C/CX370C

Code 1 2 3 4

Order No.

84402832 NA - May 2011 1003-12

Jig name Remarks Bushing removal jig Bushing press-fit jig 1 Bushing press-fit jig 2 Floating seal installation jig

List of special tools Lower Roller Special Tool CX350C/CX370C

Code 1 2 3

Order No.

84402832 NA - May 2011 1003-13

Jig name Remarks Bushing removal jig Bushing press-fit jig Floating seal installation jig

List of special tools Grease Cylinder Special Tool Jig Dimension Diagram

A B

Dust seal press-fit jig Removal jig

84402832 NA - May 2011 1003-14

List of special tools Center Joint Special Tool CX350C/CX370C Axle removal jig

a *1 *2 *3

Axle removal jig

M16 - M20 full threaded bolt L = 370 - 420 mm M16 - M20 female thread Cover (9) installation dimensions

Removal jig (for O-ring and V-ring)

84402832 NA - May 2011 1003-15

Hexagon socket head bolt (7) M10 x 25 Backing plate Axle (1) outer diameter - about 5 mm t = about 5 mm

List of special tools Swing Motor Special Tool CX350C/CX370C

Code 1 2

Order No.

84402832 NA - May 2011 1003-16

Jig name Remarks Oil seal assembly jig Pinion shaft assembly jig

List of special tools

Code 3

Order No.

84402832 NA - May 2011 1003-17

Jig name Remarks Brake piston removal jig

List of special tools Remote Control Valve Special Tool CX350C/CX370C

a b c *1 *2

SCM415N carburized S45C

*4 *5

Bolt width

Hole *7 Shaft *8 *1 and *2 are inserted by tightening. Code 1 84402832 NA - May 2011 1003-18

Order No.

Detailed diagram of jig main unit Joint installation state Detailed diagram of bushing Bushing 2

Jig name Remarks Joint disassembly jig

List of special tools

*1 Code

Order No.

84402832 NA - May 2011 1003-19

Center hole possible (Ď&#x2020; 2 or less)

Jig name Remarks Special jig 1 (for bushing removal)

List of special tools Gas Filling Special Tool CX250C/CX350C/CX370C

Code 1 2 3 4 5 6 7

Jig name Gauge manifold Charging hose Quick joint 27.5 Quick joint 23.5 T joint Service can valve Vacuum pump adapter

Remarks

84402832 NA - May 2011 1003-20

List of special tools Hydraulic Circuit

1 2 3 4

Vacuum pump and power supply (for vacuum pump) Pressure gauge (10 MPa-1) Pressure gauge (60 MPa-2) Hexagon wrench (8 mm, 6 mm)

5 6 7 8

Wrenches (17, 19, 24, 27 x 2, 32, 36 x 2) Rag Extension cable Hydraulic oil tank lid (for vacuum pump)

84402832 NA - May 2011 1003-21

Recording sheet

10 11

Pen Cleaning fluid

List of special tools CASE SPECIAL TOOLS Isuzu Engine Special Tools 4HK1X-6HK1X Tier 4 Isuzu Engine Illustration

Description

Isuzu Reference

CASE Tool Number

8-9439-6856-0

380001712

Oil seal setting tool kit

5-8840-2627-0

380001719

Oil seal Installer

5-8840-2623-0

380001720

Remover; Nozzle sleeve

5-8840-2624-0

380001721

Installer; Nozzle sleeve

5-8840-2626-0

380001722

Installer; Bridge guide

5-8840-2360-0

380002574

Slinger puller

5-8840-2826-0

380002601

Fuel Injector Remover

5-8840-0019-0

380002602

Sliding Hammer

84402832 NA - May 2011 1003-22

List of special tools Illustration

Description

Isuzu Reference

CASE Tool Number

5-8840-2222-0

380002604

Sealing cup Installer

5-8840-9061-0

380002611

Oil seal installer kit

5-8840-2675-0 (5-85317002-0)

380002626

Compression Gauge (adapter)

8980131700

380002630

Main filter wrench

5-8840-0266-0

380300009

Angle gauge

5-8840-2625-0

380300013

Installer; Valve guide oil seal

5-8840-2628-00

380300014

Remover/Installer; Valve guide

5-8840-2815-0

380300015

Compression Gauge Adaptor

8–9439–6818–0

Common tool

84402832 NA - May 2011 1003-23

Crankshaft gear puller

List of special tools Illustration

Not Illustrated

Description

Isuzu Reference

CASE Tool Number

8–9439–6819–0

380002613

Crankshaft gear installer

5-8840–9018–0

380300022

Piston setting tool

1-8522–1029–0

380300005

Piston ring setting tool

5-8840-2835-0

Common Probes

5-8840-2621-0

Common Tool

Remover; Valve spring

5-8840-2691-0

Common Tool

Digital multimeter with an input impedance of 10MΩ

5-8840-2674-1

Not needed

Scissors gear spring wrench

8-9439-6862-0

Not needed

Pivot ASM

84402832 NA - May 2011 1003-24

Connector test adapter kit

List of special tools Attachment Special Tool (for Cylinder Assembly) Special Jigs Part Number List â&#x20AC;˘ Select jigs for the cylinder head according to the rod diameter. â&#x20AC;˘ Select jigs for the piston according to the cylinder bore. CASE Tool Number KHV0511 KHV0512 KHV0513 KHV0514 KHV0515 KHV0516 KHV0517 KHV0518 KHV0519 KHV0520 KHV0521 KHV0522 CASE Tool Number KHV0526 KHV0527 KHV0528 KHV0529 KHV0530 KHV0531 KHV0532 KHV0533 KHV0534 KHV0535 KHV0536 KHV0537 KHV0539

Description (applicable rod diameter in mm)

Illustration

Cylinder head assembly and disassembly jig (65) Cylinder head assembly and disassembly jig (70) Cylinder head assembly and disassembly jig (75) Cylinder head assembly and disassembly jig (80) Cylinder head assembly and disassembly jig (85) Cylinder head assembly and disassembly jig (90) Cylinder head assembly and disassembly jig (95) Cylinder head assembly and disassembly jig (100) Cylinder head assembly and disassembly jig (105) Cylinder head assembly and disassembly jig (110) Cylinder head assembly and disassembly jig (115) Cylinder head assembly and disassembly jig (120) Description (applicable cylinder bore diameter in mm) Seal ring insertion and calibration jig (100) Seal ring insertion and calibration jig (105) Seal ring insertion and calibration jig (110) Seal ring insertion and calibration jig (115) Seal ring insertion and calibration jig (120) Seal ring insertion and calibration jig (125) Seal ring insertion and calibration jig (130) Seal ring insertion and calibration jig (135) Seal ring insertion and calibration jig (140) Seal ring insertion and calibration jig (145) Seal ring insertion and calibration jig (150) Seal ring insertion and calibration jig (160) Seal ring insertion and calibration jig (170)

84402832 NA - May 2011 1003-25

Illustration

List of special tools CNH-EST DIAGNOSTIC TOOL (SCAN TOOL) The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating parameters of electronic control components (control units, sensors etc.). It is also capable of reading fault codes. To use this tool, please refer to the book provided during the CXC series training sessions. Y-Cable 380060269 is required to connect the EST to the controllers.

84402832 NA - May 2011 1003-26

Section 1004

FLUIDS AND LUBRICANTS

84402832 NA - May 2011

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

84402832 NA - May 2011 1004-1

3 3 3 3 3

84402832 NA - May 2011 1004-2

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.

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.

84402832 NA - May 2011 1004-3

FLUIDS AND LUBRICANTS

84402832 NA - May 2011 1004-4

Section 1005

Conversion Table

84402832 NA - May 2011

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

84402832 NA - May 2011 1005-1

84402832 NA - May 2011 1005-2

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

84402832 NA - May 2011 1005-3

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

84402832 NA - May 2011 1005-4

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

84402832 NA - May 2011

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

84402832 NA - May 2011 1900-1

84402832 NA - May 2011 1900-2

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 84402832 NA - 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) 84402832 NA - 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

84402832 NA - May 2011 1900-5

Abbreviations

84402832 NA - May 2011 1900-6

Section 2000

Removal and Installation of Engine Assembly

84402832 NA - May 2011

CONTENTS Removal of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

84402832 NA - May 2011 2000-1

84402832 NA - May 2011 2000-2

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 there is the danger of gas spraying out when loosening lines. • Do not use open flames and do not allow sparks near the battery.

1. 2. 3. 4. 5.

Drain the engine oil.(For details, see "Engine Oil Replacing".) Drain the coolant from the radiator.(For details, see "Removal and Installation of Radiator".) Remove the engine hood.(For details, see "Removal and Installation of Engine Hood".) Remove the hydraulic pump.(For details, see "Removal and Installation of Hydraulic Pump".) Use a wrench (13 mm) to remove the 3 bolts (1).

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, 13 mm, 17 mm, 19 mm, 36 mm) • Box wrench (30 mm) • Shackle (with the required lifting capacity) x 2 • Wire ropes (with the required breaking load) • Liftcrane (with the required lifting capacity) • Marking pen • Cap • Plug • Waste oil can • Rag • Cleaning fluid • Wood planks, etc.

84402832 NA - May 2011 2000-3

Removal and Installation of Engine Assembly 6.

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

Use a wrench (8 mm) to loosen the hose band (1) on the radiator, and then remove the upper hose (2).

Remove the cushion seal on the side of the radiator, use a wrench (8 mm) to loosen the hose band (1) of 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 fan guard (1).

10. Use a wrench (13 mm) to loosen the line bolts (1) in 2 locations, and then remove the 2 lines (2) and (3) from the compressor. • 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. Tightening torque for bolt installation: 19.6 - 24.5 N•m

84402832 NA - May 2011 2000-4

Removal and Installation of Engine Assembly 12. Use a wrench (17 mm) to remove the 5 bolts (1), and then remove the under cover (2). • Use caution when removing as the parts are heavy. Tightening torque for bolt installation: 63.7 - 73.5 N•m

13. Prepare the waste oil can (1). • Drain the engine oil before removing the engine oil hose.

11. 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 lines and hoses to prevent the entry of water, dust or dirt.

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

84402832 NA - May 2011 2000-5

Removal and Installation of Engine Assembly • Clean the engine and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

16. Use a wrench (17 mm) to remove the 5 bolts (1), and then remove the under cover (2). Tightening torque for bolt installation: 63.7 - 73.5 N•m

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

15. Use a wrench (17 mm) to remove the bolt (1), and then remove the battery cable (2) on the negative side. • 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.

18. Remove the hose band (1), and then remove the fuel hose (2). • Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.

84402832 NA - May 2011 2000-6

Removal and Installation of Engine Assembly 19. Remove the hose band (1), and then remove the fuel hose (2). • Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.

20. Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the box cover (2).

22. Use a wrench (8 mm) to loosen the hose band (1), and then remove the heater hose (2). Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.

23. Use a wrench (8 mm) to loosen the hose band (1), and then remove the heater hose (2). • Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.

21. Remove the connectors (1) in the box. • Wrap the removed connectors in plastic after tying them together to prevent any entry of water, dust or dirt.

24. Use a wrench (8 mm) to loosen the hose band (1), and then remove the radiator hose (2). • Use caps to cover the lines and hoses to prevent any entry of water, dust or dirt.

84402832 NA - May 2011 2000-7

Removal and Installation of Engine Assembly 25. Use a wrench (8 mm) to loosen the hose band (1), and then remove the air hose (2).

27. Remove the connectors (1) from the alternator.

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

28. Remove the cap (1), use the wrench (10 mm) to remove the nut (2), and then remove the alternator wiring (3). 26. Use a wrench (8 mm) to loosen the hose band (1), and then remove the air hose (2). â&#x20AC;˘ Use caps to cover the lines and hoses to prevent any entry of water, dust or dirt. Tightening torque for bolt installation: 8.8 - 9.8 Nâ&#x20AC;˘m

29. Install the 2 shackles (1), and then use the wire rope (2) and liftcrane to secure the engine main unit.

84402832 NA - May 2011 2000-8

Removal and Installation of Engine Assembly 30. Use a box wrench (30 mm) to remove the 4 bolts (1) from the mount. Tightening torque for bolt installation: 289 - 337 Nâ&#x20AC;˘m

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

84402832 NA - May 2011 2000-9

Removal and Installation of Engine Assembly Installation of Engine Assembly

To install the engine, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts". 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.

84402832 NA - May 2011 2000-10

Section 2001

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

84402832 NA - May 2011

CONTENTS Removal and Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal and Installation of Engine Inter Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal of Inter Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation of Inter Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal and Installation of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation of radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal and Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

84402832 NA - May 2011 2001-1

84402832 NA - May 2011 2001-2

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

Removal of Fuel Cooler 1.

Mark the fuel cooler and hoses (1) and (2) so that the connectors match at the time of assembly. Use pliers to loosen the hose bands (3) and (4), and then remove the hoses. Fuel will spill out, so place a drip pan directly below the area. Attach caps or plugs to the fuel cooler and hoses to prevent any entry of water, dust or dirt.

Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the fuel cooler (2).

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

Wrench (13 mm) Screwdriver Pliers Marking pen Cap Plug Rag Cleaning fluid Drip pan

Installation of Fuel Cooler To installation, perform the reverse of the removal procedure. After connecting the hoses, carefully check for any fuel leaks. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".

84402832 NA - May 2011 2001-3

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

Removal of Inter Cooler 1.

Remove the fuel cooler.(For details, see "Removal and Installation of Fuel Cooler".) Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the bracket (2) from the fuel cooler.

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) and (3). Use caps to cover the inter cooler and hoses to prevent the entry of water, dust or dirt.

Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the inter cooler (2).

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 (8 mm, 13 mm) Flathead screwdriver Wire cutters Cap Rag Cleaning fluid

84402832 NA - May 2011 2001-4

Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Installation of Inter Cooler To install, perform the reverse of the removal procedure. Check for any air leaks. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".

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 (8 mm, 14 mm, 19 mm) Box wrenches (8 mm, 10 mm) Pliers Shackle (with the required lifting capacity) x 2 Wire ropes (with the required breaking load) Liftcrane (with the required lifting capacity) Caps Plugs Drain tank Drain hose Rag Cleaning fluid Wood planks, etc.

84402832 NA - May 2011 2001-5

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 (8 mm) to loosen the hose band (1), and then remove the hose (2).

Use a wrench (19 mm) to remove the 5 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).

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

Use a box wrench (13 mm) to remove the 1 nut (1) and the 3 bolts (2) of the radiator cover.

84402832 NA - May 2011 2001-6

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