CASE CX210C TIER 4 CRAWLER EXCAVATOR Service Repair Manual Instant Download

1
Section
1004
FLUIDS AND LUBRICANTS
84402826 - May 2011
2
CONTENTS
HYDRAULIC FLUID. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 3 ENGINE OIL . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 3 FUEL . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 4 Conditions applicable to diesel fuel.
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 4 RECOMMENDED
CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4
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Copyright 2011 CNH FRANCE S.A. PRINTED IN FRANCE
3
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 cate-
gories API CJ-4. ACEA E6.
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FLUIDS AND LUBRICANTS

• FUEL
• The fuel must conform to Interim Tier 4/Stage 3B
  Ex- haust Gas Control Regulations.
• Use grade number 2-D (S15) fuel.
• Using other types of fuel may lead to stalled
  engine out- put or deterioration in fuel
  economy.
• During cold weather (lower than -7?), 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, out- put 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

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 dam- ages. 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 en- gine 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 ap- propriate 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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6
Section
1005
Conversion Table
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CONTENTS
Metric to U.S . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 3 U.S to
Metric . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 4
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Copyright 2011 CNH FRANCE S.A. PRINTED IN FRANCE
8
Conversion Table Metric to U.S
MULTIPLY BY TO OBTAIN
AREA square meter 10.763 91 square foot
AREA hectare 2.471 05 acre
FORCE newton 3.596 942 ounce force
FORCE newton 2.224 809 pound force
LENGTH millimeter 0.039 370 inch
LENGTH meter 3.280 840 foot
LENGTH kilometer 0.621 371 mile
MASS kilogram 2.204 622 pound
MASS/AREA kilogram/hectare 0.000 466 ton/acre
MASS/ENERGY gr/kW/hr. 0.001 644 lbs/hp/hr.
MASS/VOLUME kg/cubic meter 1.685 555 lb/cubic yd.
POWER kilowatt 1.341 02 horsepower
kilopascal 0.145 038 lb/sq. inch
PRESSURE bar megapascal (MPA) 14.50385 145.0385 lb/sq. inch psi
TEMPERATURE degree C 1.8 x C 32 degree F
TORQUE newton meter 8.850 748 lb/inch
TORQUE newton meter 0.737 562 lb/foot
VELOCITY kilometer/hr 0.621 371 miles/hr.
cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
VOLUME milliliter litre 0.033 814 1.056 814 ounce (US fluid) quart (US liquid)
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
VOLUME/TIME litre/min. 0.264 172 gallon/min. (US liquid)
VOLUME/TIME litre/min 0.219 969 gallon/min. (Imperial)
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Conversion Table U.S to Metric
MULTIPLY BY TO OBTAIN
AREA square foot 0.092 903 square meter
AREA acre 0.404 686 hectare
FORCE ounce force 0.278 014 newton
FORCE pound force 4.448 222 newton
LENGTH inch 25.4 millimeter
LENGTH foot 0.304 8 meter
LENGTH mile 1.609 344 kilometer
MASS pound 0.453 592 kilogram
MASS ounce 28.35 gram
MASS/AREA ton/acre 2241 702 kilogram/hectare
MASS/ENERGY lbs/hp/hr. 608.277 4 gr/kW/hr.
MASS/VOLUME lb/cubic yd. 0.593 276 kg/cubic meter
POWER horsepower 0.745 700 kilowatt
PRESSURE psi lb/sq. inch lb/sq. inch 6.894 757 0.069 kilopascal bar
PRESSURE psi lb/sq. inch psi 0.070 303 0.006 895 kg/sq. cm megapascal (Mpa)
TEMPERATURE degree F 1.8 F - 32 degree C
TORQUE lb/inch 0.112 985 newton meter
TORQUE lb/foot 1.355 818 newton meter
VELOCITY miles/hr. 1.609 344 kilometer/hr
cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yd. 0.764.555 cubic meter
VOLUME ounce (US fluid) quart (US liquid) 29.573 53 0.946 353 milliliter litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallon (Imperial) 4.546 092 litre
VOLUME/TIME gallon/min. 3.785 412 litre/min.
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Section
1900
Abbreviations
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CONTENTS
Abbreviations . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 3
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Copyright 2011 CNH FRANCE S.A. PRINTED IN FRANCE
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Abbreviations
Abbreviations
Abbreviation description
AC air conditioner
A/D analog/digital
ABDC after bottom dead center
AC alternating current
ACC accessory
ACG alternating current generator
ACT actuator
API american petroleum industry
ASM assembly
ATDC after top dead center
ATF automatic transmission fluid
drilled head B drilled head bolt
eye B eye bolt
full threaded B full threaded bolt
hexagon socket head B hexagon socket head bolt
high-strength B high-strength bolt
reamer B reamer bolt
B battery terminal
BAT battery
BBDC before bottom dead center
BKT bracket
BRG bearing
BTDC before the top dead center
C/B circuit breaker
C/U control unit
CAL calibration
CAN a control unit communication method (control area network)
CFG config
CHK check
CKP crankshaft position
CMP camshaft position
CO carbon monoxide
CPU central processing unit
DC direct current
DI direct injection type
DIAG diagnosis
DLC data link connector
DMM digital multimeter
DPD diesel particulate diffuser
DTC self-diagnosis code
ECM engine control module
ECT engine coolant temperature
ECU electronic control unit
EEPROM electrically erasable/programmable ROM
EGR exhaust gas recirculation
EMI electromagnetic interference
EMPS engine module programing system
ENG engine
EPF engine protection feature
EVRV electric vacuum regulating valve
EXH exhaust
F/B feedback
F/C fuel cut
F/L fusible link
FLW fusible link wire
FRT front
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Abbreviations
Abbreviation description
FT fuel temperature
FWD front
GEN generator
GND ground
HBCV hose burst check valves
HC hydrocarbon
HO2S superheat O2 sensor
HR hour
HRD high reach
IAC idle air control
IAT intake air temperature
IC integrated circuit
ID Plate ID plate (Name plate)
IMT intake manifold temperature
INL intake
INJ injection
ISO international organization for standardization
ISP intake shutter position
ITP intake throttle position
J/C joint connector
JIS japan Industrial Standard
KW a communication method (Keyword)
LED light emitting diode
LH left
LLC long life coolant
LM lifting magnet
M/V electromagnetic valve
MAF mass air flow
MAP manifold air pressure
Max maximum
MIL warning light (diagnostic)
milli-amp milli-amperage
Min minimum
MPU micro processing unit
high-strength N high-strength nut
NC normally closed
NO normally open
NOx nitrogen oxide
N-TDC top dead center revolution speed
PM particle material
O2S O2 sensor
OBD on-board diagnosis
OEM original equipment manufacturer
OPT option
OT oil temperature
P/L pilot light
PCV pump control valve/positive crankcase ventilation
P-I proportion-integration
PM particle material
PTO power take-off
PWM pulse width modulation wave
QOS quick on start system
QWS quick warming up system
R/L relay
RAM RAM (random access memory)
REF reference
RH right
ROM ROM (read only memory)
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Abbreviations
Abbreviation description
RP rail pressure
Rr rear
RWD rear
flush head S flush head screw
phillips pan head S phillips pan head screw
truss head S truss head screw
subassembly sub assembly
SAE society of atomotive engineers
SBF slow blow fuse
SCV suction control valve
SIG signal
SLD shield
SP pin special pin
ST starter/start
STD standards
SW switch
TDC top dead center
TEMP temperature
TP throttle position
TEMP temperature
UART universal asynchronous receiver transmitter
VB battery voltage
VGS Turbo variable geometry system turbo
high-strength W high-strength washer
toothed W toothed washer
W/H wire/harness
W/L warning light
W/S weld splice
WOT 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 high-
  pressure gas, so beware of the gas released when
  loosening lines.
• Do not use open flames and do not allow sparks
  near the battery.

• Remove the counterweight.(For details, see "Re-
  moval 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

4. Use a wrench to remove the bolts (1), and then
re- move 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 pre-
  vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely
  drain the coolant.

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

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

• 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.
• 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.

• 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.
• Clean the engine and hoses by spraying them with
  a parts cleaner to prevent scratches and pre-
  vent dirt from accumulating on the connectors.

3
Line (discharge side)
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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.

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

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

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

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

• 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.

• 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.

• 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.

• 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.

• 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

• Use a wrench (9.5 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.

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

• Use a box wrench (24 mm) to remove the 4 bolts
• 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

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

1. To install the engine, perform the reverse of
the re- moval procedure. After installing the
engine, resupply coolant and en- gine oil,
perform fuel line air bleeding, and perform
filling for the air conditioner gas. 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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26
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
Removal and Installation of Fuel Cooler
Removal of Fuel Cooler

• 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
  be- low 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
  Nm

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

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

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Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
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".
2. Use a wrench (12 mm) to remove the 4 bolts
(1), and then remove the fuel cooler (2).
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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

• 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).
• 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 Nm

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

• 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
  Nm

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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 ra-
  diator 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.

84402826 - May 2011 2001-6
30
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
Removal of Radiator
4. Loosen the drain plug (1), and then drain the
coolant.
1. Use a wrench (19 mm) to remove the 3 bolts
(1), and then remove the under cover (2).
5. 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.
2. Install the drain hose (1), and then prepare
the drain tank (2).
3. To make it easier to drain the coolant, remove
the radiator cap (1).
6. Use a wrench (13 mm) to remove the 5 bolts
(1), and then remove the cover (2).
84402826 - May 2011 2001-7
31
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 pre-
  vent the entry of water, dust or dirt.
• Tightening torque for band (1) installation 4.9
  -
• 5.9 Nm

• 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).
84402826 - May 2011 2001-8
32
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.
84402826 - May 2011 2001-9
33
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
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.
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.
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).
84402826 - May 2011 2001-10
34
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler

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

Removal and Installation of Oil Cooler

• WARNING
• Keep away from fire.

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

• 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 (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.

2. Prepare the waste oil can (1).
3. Use a wrench (13 mm) to remove the 5 bolts
(1), and then remove the cover (2).
84402826 - May 2011 2001-11
35
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36
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 6. 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 caps to cover the oil cooler and lines to
  pre- vent the entry of water, dust or dirt.

7. Use a wrench (14 mm) to remove the 2 bolts
(1), and then remove the fan guard (2).
8. Use a wrench (14 mm) to remove the 3 bolts
(1), and then remove the brackets (2).
84402826 - May 2011 2001-12
37
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