CASE CX75C SR Midi Excavator Service Repair Manual Instant Download

1
CX75C SR Midi Excavator SERVICE MANUAL
Part number 47575334A 1st edition English July
2013
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Contents INTRODUCTION Engine......................
..................................................
............... 10 10.001 Engine and crankcase
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 10.1 10.102 Pan and
covers . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
10.2 10.106 Valve drive and gears . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 10.3 10.101 Cylinder heads . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 10.4 10.105
Connecting rods and pistons. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
10.5 10.103 Crankshaft and flywheel. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 10.6 10.216 Fuel tanks . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 10.7 10.218
Fuel injection system . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
10.8 10.250 Turbocharger and lines. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 10.9 10.254 Intake and exhaust
manifolds and muffler . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
10.10
10.501 Exhaust Gas Recirculation (EGR) -
Diesel Particulate Filter (DPF) exhaust
treatment . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 10.400 Engine cooling
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 10.414 Fan and drive
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 10.310
Aftercooler. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10.304 Engine lubrication system . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. .
10.11 10.12 10.13 10.14 10.15
Hydraulic systems................................
.......................................
35 35.000 Hydraulic systems. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 35.1 35.300 Reservoir, cooler, and
filters. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 35.2 35.106 Variable
displacement pump . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 35.3 35.102 Pump
control valves. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
35.4 35.359 Main control valve . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 35.5 35.357 Pilot system . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
35.6 35.525 Auxiliary hydraulic valves and
lines . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 35.7 35.355 Hydraulic hand control . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 35.8
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35.356 Hydraulic foot control. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 35.9
35.352 Hydraulic swing system . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. 35.353 Hydraulic travel system . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 35.354 Hydraulic central joint . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35.736 Boom hydraulic system . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 35.737 Dipper hydraulic system. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 35.738 Excavator and backhoe bucket hydraulic
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 35.739 Swing arm
hydraulic system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 35.741 Dozer blade
cylinders . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
35.10 35.11 35.12 35.13 35.14 35.15 35.16 35.17
Frames and ballasting ..........................
.......................................
39 39.140 Ballasts and supports . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 39.1 Tracks and track suspension
..................................................
...... 48 48.130 Track frame and driving
wheels . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 48.1 48.100 Tracks . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
48.2 48.134 Track tension units . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 48.3 48.138 Track rollers . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 48.4 Cab
climate control .................................
....................................
50 50.100 Heating . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 50.1 50.104 Ventilation
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
50.2 50.200 Air conditioning . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 50.3 Electrical
systems...........................................
............................ 55 55.416 Swing
control system . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
55.1 55.000 Electrical system . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 55.2 55.100 Harnesses and
connectors. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 55.3 55.015 Engine
control system. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
55.4 55.201 Engine starting system . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 55.5 55.301 Alternator . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 55.6 55.302
Battery. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 55.7 55.202 Cold start aid . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 55.8
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55.010 Fuel injection system . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 55.9 55.014 Engine intake and exhaust
system. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
55.10 55.989 Exhaust Gas Recirculation (EGR)
electrical system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 55.11 55.012 Engine
cooling system . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 55.12 55.013
Engine oil system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
55.13 55.640 Electronic modules . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 55.14 55.512 Cab controls. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 55.15 55.051 Cab
Heating, Ventilation, and Air-Conditioning (HVAC)
controls. . . . . . . . . . . . . . . . . 55.16
55.050 Heating, Ventilation, and
Air-Conditioning (HVAC) control system. . . . . .
. . . . . . . . . 55.17 55.524 Cab controls
(Lift arm, Boom, Dipper, Bucket) . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 55.18 55.417 Travel control system . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 55.19 55.950 Hammer electric
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 55.20
55.530 Camera. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 55.518 Wiper and washer system.
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 55.404 External lighting . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 55.408 Warning indicators,
alarms, and instruments . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
55.992 Anti-theft system . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . .
55.21 55.22 55.23 55.24 55.25
55.DTC FAULT CODES. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 55.26 Booms, dippers, and buckets
..................................................
..... 84 84.910 Boom . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 84.1 84.912
Dipper arm . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 84.2 84.100 Bucket . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
84.3 Platform, cab, bodywork, and decals
.............................................
90 90.150 Cab . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 90.1 90.156 Cab
glazing . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 90.2 90.120 Mechanically-adjusted operator
seat. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
90.3 90.100 Engine hood and panels . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 90.4
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INTRODUCTION
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INTRODUCTION Safety rules General
information Cleaning Clean the metal parts with
cleaning solution that meets the standard and
steam cleaning. (except for bearings) After
cleaning, dry well, and inject oil in all
parts. Also inject oil into the bearings after
drying. Inspection When disassembling parts,
check all the parts. If there are any worn or
damaged parts, replace them. Inspect carefully to
prevent initial breakdowns. Bearing Replace any
loose bearings. Air dry bearings before
installing them. Needle bearing When inserting
needle bearings, be very careful not to damage
them. Apply grease to the section where the
needle bearing will be inserted. Gear Check that
there is no wear and no damage. Oil seal,
O-ring, gasket Always install new oil seals,
O-rings, and gaskets. Apply grease to sections
where oil seals and O-rings will be
inserted. Shaft Check that there is no wear and
no damage. Check the bearings and check for
damaged oil seals on the shaft. Service
parts Install CASE genuine service parts. When
placing an order, check the parts catalog. It
contains the CASE genuine part numbers. Any
breakdowns arising from the installation of
non-genuine parts are not covered by the
warranty. Lubricants (fuel, hydraulic oil) Use
the oil from the specified company or specified
in the operator's Manual or service Manual. Any
breakdowns arising from any fuel or hydraulic oil
other than those specified are not covered by the
warranty.
47575334A 09/07/2013 3
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INTRODUCTION
Safety rules
WARNING This symbol indicates the need for
caution. Details are given concerning the safety
of the operator and the surroundings. Read all
cautions carefully and understand them well
before starting any work. In order to prevent any
accidents, always comply with warnings and
cautions. This section covers overall
dangers. Check if warning labels are
installed. Additional warning labels are
available for order as a service
part. WARNING Read this operator's manual well
to have a thorough understanding of how to
control and operate this machine. WARNING Always
operate this machine from the seated
position. Any other method of operation has the
danger of severe injury. WARNING This machine
is for only 1 person to ride on. Do not ride 2
people on this machine. WARNING Before starting
the engine, check the safety messages in this
operator's manual. Check all the warning labels
on the machine. Check that there is no one
anywhere in or around the work range for the
machine. Check the operation methods in a safe
location before starting the actual
work. Understand the operation of this machine
well, then operate it according to
service-related laws and ordinances. The
operator's manual and service manual can be
ordered from any CASE CONSTRUCTION
dealer. WARNING Working in untidy work clothes
or in clothes with which safety cannot be ensured
leads to damage to the machine and injury of the
operator themselves. Always work dressed for
safety. In order to work more safely, it is
recommended to wear additional safety gear.
(Helmet, safety shoes, earplugs, goggles, work
clothes, and gloves) WARNING Work with great
care when the engine is running. WARNING Check
and verify hydraulic equipment. Work according to
the procedure. Do not change the
procedure. WARNING When bleeding the pressure
from hydraulic circuits to inspect the machine's
hydraulic cylinders, make sure that there is no
one in the vicinity before doing the work.
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9
INTRODUCTION
WARNING Use gloves when handling hot
parts. WARNING Lower the parts to the ground
before inspecting or repairing attachments and
lower parts. WARNING Check that all hoses and
tubes are securely connected. Replace any damaged
hose or tube. Do not use your hands to check for
oil leaks. Use a piece of cardboard or
wood. WARNING When removing an attachment pin
or other hard pin, use a hammer with a soft
head. WARNING When installing a pin with a
hammer and working with a grinder, wear
protective eyewear. At this time, use goggles or
a protector that meets the standards. WARNING Wh
en repairing or inspecting, stop the machine at a
safe location. WARNING When repairing the
machine, protect the work site. Check the oil,
coolant, grease, and tools. Collect materials and
parts as necessary. Pay careful attention to work
safely. WARNING Some of the machine's parts are
extremely heavy. In this case, use an appropriate
crane. For details on the weights and correct
procedures, see the Service Manual. WARNING Exha
ust gas is harmful. When working indoors or in
any other enclosed space, always use good
ventilation. WARNING If battery solution is
frozen, there is a danger of it exploding.
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SERVICE MANUAL Engine CX75C SR
47575334A 09/07/2013 10
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Engine - Engine and crankcase Engine - General
specification Main data Engine main specifications
Item Item Engine model 4LE2
Type Type Diesel/4-cycle/water-cooled, inline 4 cylinder overhead valve
Shape of combustion chamber Shape of combustion chamber Direct injection type
Cylinder liner type Cylinder liner type No liner
Cylinder bore x stroke Cylinder bore x stroke 85 mm (3.35 in) x 96 mm (3.78 in)
Displacement Displacement 2.179 l (133 in³)
Compression ratio Compression ratio 17.6
Compression pressure Compression pressure 3.04 MPa (441 psi) 250 RPM
Idling rotation speed Idling rotation speed 1000 RPM
Valve clearance Intake 0.4 mm (0.016 in) while cool
Valve clearance Exhaust 0.4 mm (0.016 in) while cool
Ignition type Ignition type Compression ignition
Injection order Injection order 1-3-4-2
Lubricant system Lubricant system Lubricant system
Lubricating type Lubricating type Compression type
Oil pump type Oil pump type Gear type
Lubrication oil amount Lubrication oil amount 10.4 l (3 US gal) MAX
Lubrication oil amount Lubrication oil amount 7.6 l (2 US gal) MIN
Oil filter type Oil filter type Combined type
Oil cooling type Oil cooling type Built-in type, water cooled
Cooling system Cooling system Cooling system
Cooling type Cooling type Water cooling
Water pump type Water pump type Centrifugal, belt type
Thermostat type Thermostat type Wax type unit
Thermostat valve opening temperature Thermostat valve opening temperature 82 C (180 F)
Coolant capacity Coolant capacity 4.1 l (1.1 US gal) engine only
Fuel system Fuel system Fuel system
Injection pump type Injection pump type Electronic control common rail (fuel rail) type
Governor type Governor type Electronic type
Timer type Timer type Electronic type
Injection nozzle type Injection nozzle type Multi-hole type
Injection nozzle type Injection nozzle type 7 holes
Battery system Battery system Battery system
Generator type Generator type AC type
Output Output 24 V / 50 A
Regulator type Regulator type IC
Start system Start system Start system
Starter type Starter type Reduction type
Output Output 24 V / 3.2 kW (4.4 Hp)
Preheat system Preheat system Preheat system
Preheat system type Preheat system type Glow plug
Glow plug standard voltage/current Glow plug standard voltage/current 23 V / 3.0 A (Reference)
47575334A 09/07/2013 10.1 10.001 / 12
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Engine - Engine and crankcase Primary
specifications of cooling system
Item Specifications
Water pump Centrifugal impeller method
Pulley ratio 1.03
Thermostat Wax pellet type
Valve opening temperature 85 C (185 F) with jiggle valve
Fully open temperature 100 C (212 F) with jiggle valve
Valve lift amount when fully open 10 mm (0.394 in)
Primary specifications of electrical system
Generator Generator
Item Specifications
Isuzu parts number 8980921122
Nominal output 24 V / 50 A
Rated speed 5000 RPM
Regulator type IC type
Regulated voltage 28 - 29 V
Weight 9.1 kg (20.1 lb)
Starter Starter Starter
Type (Manufacturer) Type (Manufacturer) Mitsubishi
Rating Voltage 24 V
Rating Output 3.2 kW (4.4 Hp)
Rating Time 30 s
Number of pinion gears Number of pinion gears 11
Direction of rotation (toward pinion) Direction of rotation (toward pinion) Right
Weight (approx.) Weight (approx.) 5.8 kg (12.8 lb)
No-load characteristics Current/voltage Less than 80 A / 23 V
No-load characteristics Revolution speed 3750 RPM / min or more
Load characteristics Current/voltage 250 A / 18.6 V
Load characteristics Torque More than 12.9 Nm (9.5 lb ft)
Load characteristics Speed 1550 RPM / min or more
Locking characteristics Current/voltage Less than 760 A / 8 V
Locking characteristics Torque More than 47 Nm (34.7 lb ft)
Glow plug Glow plug
Item Type
Preheat device model Glow plug
Glow plug rated voltage/current 23 V / 3.0 A (Reference)
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13
Engine - Engine and crankcase Engine -
Prepare Items to prepare
Wrenches 7 mm, 10 mm, 13 mm, 17 mm, 19 mm, 36
mm Box wrench 24 mm Shackle (with the
required lifting capacity) x 2 Wire rope (with
the required breaking load) Liftcrane (with the
required lifting capacity) Pliers Marking pen
Cap Plug Rag Cleaning fluid Wood planks, etc.


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14
Engine - Engine and crankcase
Engine - Remove
WARNING Keep away from flames. Be sure to
release hydraulic pressure before begin- ning
work. The air-conditioner circuit is filled with
high pressure gas, so there is the danger of gas
spraying out when loosening lines. Do not use
flames near the battery or expose it to sparks.

• CAUTION
• Be sure to stop the engine before beginning work.
• Be sure to inspect the wire rope and other
  lifting equipment before beginning work.
• Do not let anyone go under a suspended load.
• Use a wrench 17 mm to remove the bolt (1), and
  then remove the battery cable (2) on the
  negative side.
• After removing terminals or harnesses, fix them
  to the frame or a similar location so they do
  not interfere with the work.
• Also, cover with a rubber cap to protect against
• sparks.

Tightening torque for bolt installation 13.0 Nm
(7.82 - 9.59 lb ft) 2. Remove the engine hood.
10.6 -
For details, see Hood - Remove (90.100). 3.
Remove the counterweight.

• For details, see Counterweight - Remove (39.140).
• Remove the muffler.
• For details, see Diesel Oxidation Catalyst (DOC)
  - Re- move (10.501).
• Remove the pump.
• For details, see Pump - Remove (35.106).

SMIL13CEX4344BB 1
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15
Engine - Engine and crankcase
6. Use a wrench 7 mm to loosen the hose bands
(1), (2), and then remove the intercooler hose
(high-tem- perature side) (3) and hose from the
air cleaner (4). Tightening torque for band (1)
installation 8.8 - 9.8 Nm (6.49 - 7.23 lb
ft) Tightening torque for band (2) installation
6.3 - 7.3 Nm (4.65 - 5.38 lb ft)
SMIL13CEX4663AB 2
7. Loosen the hose bands (1), and then remove the
inter- cooler hose (low-pressure side)
(2). Tightening torque for hose band (1)
installation 8.8 - 9.8 Nm (6.49 - 7.23 lb ft)
SMIL13CEX4561AB 3
8. Use a wrench to remove the bolts (1) and (2),
and then remove the hose band (3) and fan guard
(4).
SMIL13CEX4127AB 4
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16
Engine - Engine and crankcase

• Use a wrench 7 mm to loosen the radiator hose
  bands (1) in 4 locations, and then remove the
  upper hose (2) and lower hose (3).
• Use caps to cover the radiator and hoses to
  prevent any entry of water, dust or dirt.
• Before removing the radiator hose, completely
  drain the coolant.
• Tightening torque for band (1) installation 4.9
  -
• 5.9 Nm (3.61 - 4.35 lb ft)

SMIL13CEX4680BB 5
10. Remove the connectors (1) in the 5 locations.
Wrap the removed connectors in plastic after
tying them together.

SMIL13CEX4233AB 6
11. Remove the connector (1) from the
air-conditioner compressor.
SMIL13CEX4245AB 7
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17
Engine - Engine and crankcase
12. Use a wrench 13 mm to remove the bolt (1)
, and then remove the terminal cap (2). Use a
wrench to remove the lines (3) (4) from the
starter. Use a wrench 17 mm to remove the bolt
(5), and then remove the line (6) from the frame.
SMIL13CEX4477AB 8
13. Use a wrench 10 mm to remove the bolts
(1). Remove the connector (2) from the
alternator. Use a wrench to remove the line (3)
from the alternator.
SMIL13CEX4490AB 9

• Use a wrench 13 mm to loosen the line bolts
  (1) in 2 locations, and then remove the lines
  (2) and (3) from the compressor.
• Always remove the low-pressure (suction side)
  line
• (2) first.
• Install caps or plugs to the compressor and lines
  to prevent any entry of water, dust or dirt.
• Tightening torque for bolt installation 20 -
  25 Nm
• (14.751 - 18.439 lb ft)

SMIL13CEX4271AB 10

• Loosen the hose bands (1) in 2 locations, and
  then remove the heater hoses (2) and (3).
• Install caps or plugs to the engine and hoses to
  prevent any entry of water, dust or dirt.

SMIL13CEX4817AB 11
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18
Engine - Engine and crankcase
16. Prepare the waste oil can (1). Use a wrench
36 mm to remove the 2 engine oil remote hoses
(2).

• Drain the engine oil before removing the engine
  oil hose.
• Mark the engine and hoses so that the connectors
  match at the time of assembly.
• Install caps or plugs to the engine and hoses to
  prevent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying them with
  a parts cleaner to prevent scratches and prevent
  dirt from accumulating on the connectors.
• Tightening torque for bolt installation 54.1
  -
• 63.9 Nm (39.90 - 47.13 lb ft)

SMIL13CEX4518BB 12

• Remove the hose bands (1), and then remove the
  fuel hoses (2) and (3).
• Install caps or plugs to the engine and hoses to
  prevent any entry of water, dust or dirt.

SMIL13CEX4306AB 13

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

SMIL13CEX4819AB 14
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19
Engine - Engine and crankcase
19. Install the 2 shackles (1), and then use the
wire rope (2) and liftcrane to secure the engine
main unit.
SMIL13CEX5233AB 15
20. Use a box wrench 24 mm to remove the 4
bolts (1) from the mount. Tightening torque for
bolt installation 364.9 - 313.9 Nm (269.14 -
231.52 lb ft)
SMIL13CEX5285BB 16
21. Use the wire rope (1) and liftcrane to lift
the engine main unit.

• Always check if the hoses and connectors are all
  disconnected before lifting the engine.
• Thoroughly check that the location is safe before
• lowering the engine on wood planks, etc.
• Thoroughly fasten the engine so that it does not
  fall over.

SMIL13CEX4986AB 17
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20

• Engine - Engine and crankcase
• Engine - Install
• To install the engine, perform the reverse of the
  removal procedure.
• After installing the engine, resupply coolant and
  engine oil, perform fuel line air bleeding, and
  perform filling for the air-conditioner gas.
• For details, see the individual explanations for
  each proce- dure.
• Run the engine at no-load idling and check for
  any wa- ter or oil leaks.
• Attach the hydraulic pump, covers, and
  counterweight.
• For details, see the individual explanations for
  each proce- dure.

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21
Engine - Engine and crankcase Crankcase -
Remove Battery ground cable disconnect 1.
Disconnect the battery ground cable from the
battery. Coolant drain 1. Drain coolant from the
radiator.
CAUTION After draining the coolant, do not
forget to tighten the drain plug.

• Engine oil drain
• Drain the engine oil from the oil pan.
• NOTE After draining the oil, tighten the drain
  plug to the specified torque.
• Tightening torque 78.5 Nm (57.899 lb ft)
• CAUTION
• Do not forget to tighten the drain plug.
• Cooling fan removal
• Remove the cooling fan (1) from the fan pulley.
• Adapter
• Spacer

SMIL13CEX4383AB 1
Cooling fan belt removal 1. Remove the cooling
fan belt from the pulley. NOTE Loosen the
generator adjust bolt and remove the belt.
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22
Engine - Engine and crankcase Fan pulley
removal 1. Remove the fan pulley (1) from the
water pump assem- bly (2).
SMIL13CEX4195AB 2

• Generator removal
• Disconnect the harness connector from the
  generator.
• Remove the generator (3) from the generator
  bracket.
• Remove the adjust plate (1) from the water pump
  as- sembly (2).
• Bolt

SMIL13CEX4034AB 3
Engine coolant temperature sensor disconnect 1.
Disconnect the harness connector from the engine
coolant temperature sensor. Water hose
disconnect 1. Disconnect the water hose from the
water pump as- sembly. NOTE Remove the hose
clip. Water pump assembly removal 1. Remove the
water pump assembly from the cylinder block and
the cylinder head. NOTE Remove the water pump
assembly and the gasket.
SMIL13CEX4353AA 4
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23
Engine - Engine and crankcase Pressure
sensor/boost temperature sensor disconnect 1.
Disconnect the harness connector from the boost
pres- sure sensor/boost temperature sensor. NOTE
Remove the harness clip. Turbocharger heat
protector removal 1. Remove the turbocharger heat
protector from the tur- bocharger.
SMIL13CEX4396AA 5

• Integrated oxidation catalyst silencer removal
• Remove the integrated oxidation catalyst silencer
  from the exhaust pipe (1).
• Remove the exhaust pipe (1) from the turbocharger
  as- sembly.
• NOTE Remove together with the bracket (2).

SMIL13CEX4144AB 6
3. Remove the support bracket (1) from the
silencer bracket (2).
SMIL13CEX4733AB 7
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24
Engine - Engine and crankcase Turbocharger
assembly removal 1. Remove the exhaust pipe
adapter from the tur- bocharger assembly.
SMIL13CEX5312AA 8

1. Remove the oil feed pipe (2) from the
   turbocharger as- sembly (1)Turbocharger assembly
   removal
2. Remove the oil return pipe (3) from the
   turbocharger assembly and the cylinder block.

SMIL13CEX5438AB 9
4. Remove the turbocharger assembly from the
exhaust manifold.
SMIL13CEX5437AA 10

• EGR valve removal
• Disconnect the harness connector from the EGR
  valve.
• Disconnect the harness clip from the EGR pipe.
• Disconnect the water rubber hose (1) from the EGR
  cooler assembly.

SMIL13CEX5266AB 11
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25
Engine - Engine and crankcase
4. Remove the EGR valve from the intake chamber.
SMIL13CEX4342AA 12
5. Remove the EGR pipe from the EGR cooler.
SMIL13CEX5443AA 13
6. Remove the EGR cooler from the EGR pipe.
SMIL13CEX4393AA 14
7. Remove the EGR pipe from the exhaust manifold.
SMIL13CEX4998AA 15
PCV hose removal 1. Remove the PCV hose from the
intake chamber.
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26

• Engine - Engine and crankcase
• IMT sensor removal
• Disconnect the harness connector from the IMT
  sensor.
• Remove the IMT sensor from the intake chamber.
• Intake chamber removal
• Remove the intake chamber from the cylinder head
  cover.

SMIL13CEX4646AA 16
Cylinder head cover removal 1. Remove the
cylinder head cover from the rocker arm bracket.
SMIL13CEX4879AA 17

• Harness bracket removal
• Disconnect the engine harness from the harness
  bracket.
• Remove the harness bracket from the cylinder head.

SMIL13CEX4073AA 18
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27
Engine - Engine and crankcase Fuel leak-off
hose removal 1. Remove the fuel leak-off hose
from the injector. NOTE Do not reuse the
leak-off pipe clip. 1. Clip
SMIL13CEX4402BA 19
SMIL13CEX4693AB 20
Injection pipe removal 1. Remove the injection
pipe from the injector and the common rail (fuel
rail) assembly. NOTE Do not reuse the injection
pipe.
SMIL13CEX4572AA 21
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28
Engine - Engine and crankcase

• Injector removal
• Disconnect the harness connector from the
  injector.
• Remove the injector (2) from the cylinder head
  assem- bly.
• Remove the injector gasket (4) from the injector.
• Remove the O-ring (3) from the injector.
• NOTE Do not reuse the injector gasket or the
  O-ring.
• 1. Injector clamp

Absolutely never touch the injector solenoid
because doing so can hinder performance or cause
damage. Store the removed injector with the
cylinder number on it.


SMIL13CEX4248AB 22
Glow plug connector removal 1. Remove the glow
plug connector from the glow plug. Glow plug
removal 1. Remove the glow plug from the cylinder
head.
SMIL13CEX5078AA 23
Engine hanger removal 1. Remove the engine hanger
(1) from the cylinder head.
SMIL13CEX4995AB 24
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29
Engine - Engine and crankcase Rocker arm
bracket removal 1. Remove the rocker arm bracket
from the cylinder head.
CAUTION Be careful not to damage the rocker arm
bracket when removing.

SMIL13CEX5330AA 25

• Push rod removal
• Remove the push rod from the cylinder block.
• Cylinder head assembly removal
• Remove the cylinder head assembly from the
  cylinder block.
• NOTE Gradually loosen the bolts in the numerical
  order shown in the diagram and remove.
• Remove the cylinder head gasket from the cylinder
  block.

SMIL13CEX5331AA 26
Tappet removal 1. Remove the tappet from the
cylinder block. Crankshaft pulley removal 1.
Remove the crankshaft pulley from the
crankshaft. NOTE Remove after stopping the
crankshaft from turning. NOTICE Do not reuse the
bolt and the washer.
SMIL13CEX4030AA 27
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30
Engine - Engine and crankcase

• CMP sensor removal
• Disconnect the harness connector from the CMP
  sen- sor.
• Remove the CMP sensor from the timing gear case.
• Remove the O-ring from the CMP sensor.
• Timing gear case removal
• Remove the idle gear cover (1) from the front oil
  pump plate.
• Remove the timing gear case (2) from the front
  oil pump plate.

SMIL13CEX4492AB 28
Fuel pipe (1) removal 1. Remove the fuel pipe
(1) from the fuel supply pump and the common rail
(fuel rail) assembly.
SMIL13CEX4007AB 29

• Fuel return pipe removal
• Remove the fuel return pipe from the fuel supply
  pump.
• Fuel supply pump removal
• Disconnect the harness connector from the fuel
  supply pump.
• Remove the fuel supply pump from the front oil
  pump plate.
• NOTE Remove the tightening bolts, and remove
  together with the bracket.

SMIL13CEX4656AA 30
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31
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• Engine - Engine and crankcase
• Common rail assembly removal
• Disconnect the harness connector from the common
  rail (fuel rail) assembly (1).
• Remove the fuel leak-off pipe (2) from the common
  rail (fuel rail) assembly (1).
• Remove the common rail (fuel rail) assembly (1)
  from the common rail (fuel rail) bracket.

SMIL13CEX4716AB 31
Housing cover (1) removal 1. Remove the housing
cover (1) from the cylinder block.
CAUTION Be careful not to deform when removing.

SMIL13CEX4028AB 32
Idle gear A measurement
1. Measure the backlash using a dial
gauge. Specified value 0.04 mm (0.002 in) crank
gear, idle gear Limit 0.2 mm (0.008 in) crank
gear, idle gear Specified value 0.03 mm (0.002
in) crank gear, idle gear Limit 0.2 mm (0.008
in) crank gear, idle gear
CAUTION Before removing the idle gear, measure
the end play of the gear.

SMIL13CEX4118AA 33
NOTE
Install the dial gauge as shown in the diagram,
and measure by turning the gear left and
right. If the measured value exceeds the limit,
replace the thrust collar or the idle gear.


47575334A 09/07/2013 10.1 10.001 / 32
33
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