CASE CX220C Hydraulic Excavator Service Repair Manual Instant Download

1
CX220C Hydraulic Excavator
Service Manual
Part Number 71114551 1st Edition English 03/2015
2
SERVICE MANUAL CX220C Standard model
71114551 19/03/2015
EN
3
Link Product / Engine
Product Market Product Engine
CX220C Modelo padrão Latin America F4GE9684EJ615
71114551 19/03/2015
4
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Contents INTRODUCTION Engine.....................
..................................................
................ 10 10.001 Engine and
crankcase . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 10.1 10.202 Air
cleaners and lines . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
10.2 10.216 Fuel tanks . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 10.3 10.254 Intake and
exhaust manifolds and muffler . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 10.4 10.400 Engine cooling system
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 10.5 Hydraulic
systems...........................................
............................ 35 35.000
Hydraulic systems. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
35.1 35.102 Pump control valves. . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 35.2 35.106 Variable displacement
pump . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 35.3 35.300 Reservoir, cooler,
and filters. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 35.4 35.304 Combination
pump units . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 35.5 35.352
Hydraulic swing system . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
35.6 35.353 Hydraulic travel system . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 35.7 35.354 Hydraulic central joint . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 35.8 35.355 Hydraulic hand
control . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 35.9 35.356
Hydraulic foot control. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
35.10 35.359 Main control valve . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 35.11 35.736 Boom hydraulic system
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 35.12 35.737 Dipper hydraulic
system. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 35.13 35.738 Excavator
and backhoe bucket hydraulic system . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
35.14 Frames and ballasting ......................
...........................................
39 39.101 Upper frame . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 39.1 39.103 Swing ring
assembly . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 39.2 39.140
Ballasts and supports . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 39.3
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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 50.200 Air conditioning. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 50.2 Electrical
systems...........................................
............................ 55 55.000
Electrical system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 55.1 55.015 Engine control system. . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 55.2 55.036 Hydraulic system
control . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 55.3 55.051 Cab
Heating, Ventilation, and Air-Conditioning (HVAC)
controls. . . . . . . . . . . . . . . . . . .
55.4 55.302 Battery. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 55.5 55.640
Electronic modules . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
55.6 Booms, dippers, and buckets
..................................................
..... 84 84.910 Boom . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 84.1 84.100
Bucket . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 84.2 Platform, cab, bodywork, and
decals ...........................................
.. 90 90.116 Fenders and guards . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 90.1 90.124 Pneumatically-adjusted
operator seat. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 90.2 90.150 Cab . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 90.3
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INTRODUCTION
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INTRODUCTION Advice - Important notice
regarding equipment servicing All repair and
maintenance work listed in this manual must be
carried out only by qualified dealership
personnel, strictly complying with the
instructions given, and using, whenever possible,
the special tools. Anyone who performs repair and
maintenance operations without complying with the
procedures provided herein shall be responsible
for any subsequent damages. The manufacturer and
all the organizations of its distribution chain,
including - without limitation - national,
regional, or local dealers, reject any
responsibility for damages caused by parts and/or
components not approved by the manu- facturer,
including those used for the servicing or repair
of the product manufactured or marketed by the
manufacturer. In any case, no warranty is given
or attributed on the product manufactured or
marketed by the manufacturer in case of damages
caused by parts and/or components not approved by
the manufacturer. The information in this manual
is up-to-date at the date of the publication. It
is the policy of the manufacturer for continuous
improvement. Some information could not be
updated due to modifications of a technical or
commercial type, or changes to the laws and
regulations of different countries. In case of
questions, refer to your Sales and Service
Networks.
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• INTRODUCTION
• Foreword - Ecology and the environment
• Soil, air, and water are vital factors of
  agriculture and life in general. When legislation
  does not yet rule the treatment of some of the
  substances required by advanced technology, sound
  judgment should govern the use and disposal of
  products of a chemical and petrochemical nature.
• NOTE The following are recommendations that may
  be of assistance
• Become acquainted with and ensure that you
  understand the relative legislation applicable to
  your country.
• Where no legislation exists, obtain information
  from suppliers of oils, filters, batteries,
  fuels, antifreeze, cleaning agents, etc., with
  regard to their effect on man and nature and how
  to safely store, use, and dispose of these
  substances.
• Agricultural consultants will, in many cases, be
  able to help you as well.
• Helpful hints
• Avoid filling tanks using cans or inappropriate
  pressurized fuel delivery systems that may cause
  considerable spillage.
• In general, avoid skin contact with all fuels,
  oils, acids, solvents, etc. Most of them contain
  substances that may be harmful to your health.
• Modern oils contain additives. Do not burn
  contaminated fuels and or waste oils in ordinary
  heating systems.
• Avoid spillage when draining off used engine
  coolant mixtures, engine, gearbox and hydraulic
  oils, brake fluids, etc. Do not mix drained
  brake fluids or fuels with lubricants. Store them
  safely until they can be disposed of in a proper
  way to comply with local legislation and
  available resources.
• Modern coolant mixtures, i.e. antifreeze and
  other additives, should be replaced every two
  years. They should not be allowed to get into
  the soil, but should be collected and disposed of
  properly.
• Do not open the air-conditioning system yourself.
  It contains gases that should not be released
  into the atmosphere. Your CASE CONSTRUCTION
  dealer or air conditioning specialist has a
  special extractor for this purpose and will have
  to recharge the system properly.
• Repair any leaks or defects in the engine cooling
  or hydraulic system immediately.
• Do not increase the pressure in a pressurized
  circuit as this may lead to a component failure.

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10
INTRODUCTION
Safety rules
DANGER Improper operation or service of this
machine can result in an accident. Do not operate
this machine or perform any lubrication,
maintenance, or repair on it until you have read
and understood the operation, lubrication,
maintenance, and repair information. Failure to
comply will result in death or serious
injury. D0010A
WARNING Maintenance hazard! Always perform all
service procedures punctually at the intervals
stated in this manual. This ensures optimum
performance levels and maximum safety during
machine operation. Failure to comply could result
in death or serious injury. W0132A
WARNING Pressurized system! Before attempting any
service procedure, it is your responsibility to
know the number of accumulators on the machine,
and the correct procedure for releasing the
pressure of each accumulator. Failure to comply
could result in death or serious injury. W0136A

• NOTICE Extreme working and environmental
  conditions require shortened service intervals.
• Use Case fluids, lubricants, and filters for the
  best protection and performance of your machine.
  All fluids, lubricants, and filters must be
  disposed of in compliance with environmental
  standards and regulations. Contact your dealer
  with any questions regarding the service and
  maintenance of this machine.
• Read the safety decals and information decals on
  the machine. Read the Operators Manual and
  safety manual. Understand the operation of the
  machine before you start any service.
• Before you service the machine, put a 'Do Not
  Operate' tag on the steering wheel or over the
  key switch. Ensure the tag is at a location
  where everyone who might operate or service the
  machine may see clearly. One tag is included
  with your new machine. Additional tags are
  available from your dealer.
• Plastic and resin parts
• Avoid using gasoline, paint thinner, etc. when
  cleaning plastic parts, console, instrument
  cluster, etc.
• Use only water, mild soap, and a soft cloth when
  you clean these parts.
• Using gasoline, thinners, etc. can cause
  discoloration, cracking, or deformation of the
  part being cleaned.

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11

• INTRODUCTION
• Safety rules
• Standard safety precautions
• Be informed and notify personnel of the laws in
  force regulating safety, and provide
  documentation available for consultation.
• Keep working areas as clean as possible.
• Ensure that working areas are provided with
  emergency boxes. They must be clearly visible and
  always contain adequate sanitary equipment.
• Fire extinguishers must be properly identified
  and always be clear of obstructions. Their
  efficiency must be checked on a regular basis
  and personnel must be trained on proper
  interventions and priorities.
• Keep all emergency exits free of obstructions and
  clearly marked.
• Smoking in working areas subject to fire danger
  must be strictly prohibited.
• Prevention of injury
• Wear suitable work attire and safety glasses with
  no jewelry such as rings and chains when working
  close to engines and equipment in motion.
• Wear safety gloves and goggles when performing
  the following operations
• Topping off or changing lubrication oils.
• Using compressed air or liquids at a pressure
  greater than 2 bar (29 psi).
• Wear a safety helmet when working close to
  hanging loads or equipment working at head level.
• Always wear safety shoes and fitting clothes.

12

• INTRODUCTION
• Disconnect the batteries to place a load on them
  with a load tester.
• After any work is performed, verify that the
  battery clamp polarity is correct and that the
  clamps are tight and safe from accidental short
  circuit and oxidation.
• Before disconnecting any pipelines (pneumatic,
  hydraulic, fuel pipes, etc.), verify that all
  pressure has been re- leased. Take all necessary
  precautions bleeding and draining residual
  pressure. Always wear the proper safety
  equipment.
• Do not alter the lengths of any wires.
• Do not connect any electronic service tool to the
  engine electrical equipment unless specifically
  approved by CASE CONSTRUCTION.
• Do not modify the fuel system or hydraulic system
  unless approved by CASE CONSTRUCTION. Any
  unauthorized modification will compromise
  warranty assistance and may affect engine
  operation and life span.
• For engine equipped with an electronic control
  unit
• Do not weld on any part of the equipment without
  removing the control unit.
• Remove the in case of work requiring heating over
  80 C (176 F).
• Do not paint the components and the electronic
  connections.
• Do not alter any data filed in the electronic
  control unit driving the engine. Any manipulation
  or alteration of electronic components will void
  engine warranty assistance and may affect the
  correct working order and life span of the
  engine.
• Respect of the Environment
• Respect of the environment should be of primary
  importance. Take all necessary precautions to
  ensure personnel's safety and health.
• Inform the personnel of the laws regarding the
  dispensing of used engine fluids.
• Handle batteries with care, storing them in a
  well ventilated environment and within anti-acid
  container.

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SERVICE MANUAL Engine CX220C Standard model
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Engine - Engine and crankcase Engine - General
specification Performance Road speed
Slow 3.7 km/h (2 mph)
Fast 5.7 km/h (4 mph)
Motor Specifications Main specifications
Manufacturer FPT Tier 3
Model F4GE9684EJ615
Type Water-cooled, 4 cycle direct injection type diesel engine with intercooler turbo-charger
Number of cylinders 6 in-line
Bore 104 mm (4.09 in)
Stroke 132 mm (5.20 in)
Total displacement 6728 cm³ (411 in³)
Compression ratio 17 1
Rated output power (at 2000 RPM) ( ISO 14396 Without fan) 118 kW (160 Hp)
Maximum torque (at 1400 RPM) ( ISO 14396) 670 Nm (494 lb ft)
High idling 2200 RPM
Low idling 800 RPM
Fuel consumption rate 212 g/kWh
Total engine oil volume 17.8 L (4.7 US gal)
Volume of oil in the filter 0.90 L (0.24 US gal)
Volume of oil in the line 0.85 L (0.22 US gal)
Volume of oil in the engine chambers 1.50 L (0.40 US gal)
Weight without oil 510.0 kg (1124.4 lb)
Feed
Injection Sequence
1-5-3-6-2-4
Battery
Voltage 2 x 12 V
Capacity 2 x 100 Ah
Starter Motor
Manufacturer BOSCH
Voltage 24 V
Output 4 kW (5 Hp)
Alternator
Manufacturer BOSCH
Voltage 24 V
Output 90 A
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15

• Engine - Engine and crankcase
• Engine - Prepare
• Preparation for removing
• Remove battery ground.
• Remove bonnet and guard. Remove under cover.
• Remove air cleaner hose.
• Remove counterweight.
• Remove radiator hose and inter-cooler hose.
• Remove fuel hose and heater hose, and if neces-
  sary disconnect air-con hose.
• If necessary, remove pump, muffler and radiator.
• Remove harness connector.
• Remove E/G ground cable.
• Starter cable-starter B terminal.
• Remove the connector that connects the upper
  harness with the engine and ECU harness.
• Upper harness
• P1 Alternator B terminal CN-160 E/G speed sensor
• CN-141, CN142 P1, P2 pump proportional

TULI12ECX3380FB 1
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Engine - Engine and crankcase
TULI12ECX1634FB 2
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17
Engine - Engine and crankcase
Engine - Remove
TULI12ECX3418HA 1
1. Remove hose of engine oil filter.
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Engine - Engine and crankcase

• Place oil pan under the connection of filter (1),
  and dis- connect hoses (2), (3).
• 41 mm (1.6 in)
• Put a protection cap on the opened hoses.
• Remove hoses of fuel injection pump (4) and water
  sep- arator.
• Place fuel pan under the connections (4) and
  discon-
• nect hoses (5).
• Loosen engine mounting bolt of frame.
• Loosen 4 nuts (6) M18
• 27 mm (1.1 in)
• Loosen 4 capscrews (7) M18 X 150.
• 27 mm (1.1 in)
• Remove 4 plates (8).
• Remove upper rubber mounts (9) and (10) 2 each.
• Slinging engine body
• Sling engine hooking wire to lifting lugs on the
  front and rear sides.
• Weight Approx. 544 kg (1199 lb)
• Wire dia. 6 mm (0.2 in)x 1 m (3.3 ft) - 2 pcs.
• ATTENTION Prepare a stand, which withstands the
  weight of the engine assy. and can place the
  removed engine firmly.

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Engine - Engine and crankcase

• Engine - Install
• Installation of engine
• Installing is done in the reverse order of
  removing.
• Tightening torque.

No. Name Tightening torque Remarks
7 Capscrew M18 X 150 202.5 - 247.5 Nm (149.36 - 182.55 lb ft) Apply LOCTITE 271
11 Capscrew M12 X 80 104 - 126 Nm (76.71 - 92.93 lb ft) Apply LOCTITE 262
12 Capscrew M12 X 40 104 - 126 Nm (76.71 - 92.93 lb ft) Apply LOCTITE 262
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Engine - Engine and crankcase Engine -
Measure Warming up of engine Start engine to
raise the coolant temperature of engine to 60 -
90 C (140 - 194 F) at surface of radiator upper
tank. The E/G coolant temperature gauge is used
to mea- sure. The range in white color shows the
temperature of approx. 65 - 105 C (149 - 221
F), so confirm that the pointer indicates the
temperature within the white range.
TULI12ECX0098AA 1
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• Engine - Engine and crankcase
• Engine speed measured value through service
  diagnosis
• Turn On the starter switch with the buzzer stop
  switch pressed.
• A program number and an actual engine revolution
  are displayed as item No. 2.
• The screen advances in the sequence number 2,
  num- ber 3 etc. each time you press the "up
  arrow button" on the gauge assembly.
• The screen goes back in the sequence number 45,
  number 44 etc. each time you press the "down
  arrow button".
• The display does not disappear unless the starter
  switch is turned to Off.

TULI12ECX0099BA 2
TULI12ECX0100AA 3
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Engine - Engine and crankcase
Engine - Service instruction Engine
Factors Checking Checking Checking Checking Checking Checking Checking Checking Checking Checking Checking Checking Checking Checking Checking
Trouble Filters Filters Filters Filters Filters Filters Liquid Liquid Liquid Liquid Liquid Leak, clogging Leak, clogging Leak, clogging Leak, clogging
Trouble 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting
Poor starting ability (takes a long time) ? ? ? ?
Faulty engine starting/engine does not rotate ?
Faulty engine starting/engine rotates but no exhaust gas (no fuel injection) ? ? ? ?
Faulty engine starting/exhaust gas is emitted but engine does not start (with fuel injection) ? ? ? ? ?
Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation
Engine poor run-up (low follow-up ability) ? ? ?
Rotation in bad condition (hunting) ? ? ?
Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output
Engine stalled during operation ? ? ?
Output is lowered ? ? ? ? ?
Overheating ? ?
Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures
Exhaust smoke is black ? ? ? ?
Exhaust smoke is white ? ?
Larger oil consumption (or blue exhaust gas) ? ?
Early contamination of oil ? ? ? ? ?
Larger fuel consumption ? ? ? ?
Intruding of oil in coolant, back flow, reduction of coolant quantity
Hydraulic pressure down (monitor lights up) ? ?
Oil quantity increased (intruding of water and fuel) ?
Vibration
1 Shortage of fuel level 9 Oil level of oil pan
2 Air cleaner clogged 10 Contamination of water and fuel with oil
3 Fuel filter clogged 11 Poor or deteriorated battery
4 Oil filter clogged 12 Leak, clogging of fuel system and intruding of air
5 Fan belt slipped, fan pulley worn 13 Engine oil leak
6 Breather hose crushed or clogged 14 Air leak between turbocharger and intake manifold
7 Improper fuel in use 15 Muffler clogged
8 Coolant level
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Engine - Engine and crankcase
Factors Checking shovel side Checking shovel side Checking shovel side Checking shovel side Checking shovel side Electric equipment Electric equipment Electric equipment Electric equipment Electric equipment Electric equipment Electric equipment Electric equipment Electric equipment Electric equipment Electric equipment
Factors Checking shovel side Checking shovel side Checking shovel side Checking shovel side Checking shovel side Shovel side Shovel side Shovel side Shovel side Shovel side Engine side Engine side Engine side Engine side Engine side Engine side
Trouble 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting
Poor starting ability (takes a long time) ? ? ? ?
Faulty engine starting/engine does not rotate ? ? ? ? ? ? ? ?
Faulty engine starting/engine rotates but no exhaust gas (no fuel injection)
Faulty engine starting/exhaust gas is emitted but engine does not start (with fuel injection) ? ?
Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation
Engine poor run-up (low follow-up ability)
Rotation in bad condition (hunting)
Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output
Engine stalled during operation ?
Output is lowered ?
Overheating ? ? ?
Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Early contamination of oil
Larger fuel consumption
Intruding of oil in coolant, back flow, reduction of coolant quantity
Hydraulic pressure down (monitor lights up) ?
Oil quantity increased (intruding of water and fuel)
Vibration ?
1 Loose mounting bolts, damage of mounting rubber 9 Loose connection of battery cable terminal
2 Failure of radiator pressure cap 10 Battery relay
3 Radiator core clogged/fin clogged and crushed 11 Alternator
4 Peeling of space insulation around radiator 12 Glow plug
5 Failure of hydraulic system 13 Glow relay
6 Malfunction of unload valve and low pressure sensor 14 Starter motor
7 Startup circuit wiring 15 Safety relay
8 Starter key switch 16 Hydraulic switch
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24
Engine - Engine and crankcase
Factors Fuel system Fuel system Fuel system Fuel system Intake and exhaust system Intake and exhaust system Intake and exhaust system Intake and exhaust system Lubrication system Lubrication system Lubrication system Lubrication system Cooling system Cooling system
Trouble 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting
Poor starting ability (takes a long time) ? ?
Faulty engine starting/engine does not rotate
Faulty engine starting/engine rotates but no exhaust gas (no fuel injection)
Faulty engine starting/exhaust gas is emitted but engine does not start (with fuel injection) ? ?
Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation
Engine poor run-up (low follow-up ability) ? ? ?
Rotation in bad condition (hunting)
Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output
Engine stalled during operation ?
Output is lowered ? ? ? ?
Overheating ? ? ?
Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures
Exhaust smoke is black ? ? ?
Exhaust smoke is white ? ? ? ? ?
Larger oil consumption (or blue exhaust gas) ? ? ?
Early contamination of oil ? ? ? ?
Larger fuel consumption ? ? ?
Intruding of oil in coolant, back flow, reduction of coolant quantity ? ?
Hydraulic pressure down (monitor lights up) ? ? ? ?
Oil quantity increased (intruding of water and fuel) ? ? ?
Vibration ?
1 Failure of injector 8 Damage of EGR cooler
2 Failure of supply pump 9 Failure oil pump
3 Improper fuel injection time 10 Failure of relief valve
4 Fuel leak into the head cover 11 Failure of regulation valve
5 Turbocharger oil drain tube clogged 12 Leak and crush of hydraulic piping
6 Seal of turbocharger worn, damaged 13 Damage of water pump
7 Seizing and interference of turbocharger 14 Failure of thermostat (not open)
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25
Engine - Engine and crankcase
Factors Engine body Engine body Engine body Engine body Engine body Engine body Engine body Engine body Engine body Engine body Engine body
Trouble 1 2 3 4 5 6 7 8 9 10 11
Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting Faulty starting
Poor starting ability (takes a long time) ? ?
Faulty engine starting/engine does not rotate ?
Faulty engine starting/engine rotates but no exhaust gas (no fuel injection)
Faulty engine starting/exhaust gas is emitted but engine does not start (with fuel injection) ? ?
Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation Insufficient rotation
Engine poor run-up (low follow-up ability) ? ?
Rotation in bad condition (hunting)
Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output Poor output
Engine stalled during operation ?
Output is lowered ? ?
Overheating ? ?
Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures Other failures
Exhaust smoke is black ? ?
Exhaust smoke is white ? ? ? ?
Larger oil consumption (or blue exhaust gas) ? ? ? ? ?
Early contamination of oil ? ?
Larger fuel consumption ?
Intruding of oil in coolant, back flow, reduction of coolant quantity ? ? ? ?
Hydraulic pressure down (monitor lights up) ?
Oil quantity increased (intruding of water and fuel) ? ? ? ?
Vibration ? ?
1 Damage of engine oil cooler core and O-ring 7 Wear of piston ring and liner, ring stick
2 Strainer clogged, damage of oil pipe 8 Hole due to cavitation
3 Damage of cylinder head and head gasket 9 Wear and damage of rear oil seal and seal surface
4 Failure of injection holder sleeve 10 Damage of dumper
5 Wear and failure of valve and valve guide 11 Damage of flywheel gear
6 Damage and seizing of piston and connecting rod
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26
Engine - Air cleaners and lines
Air cleaner - Prepare

1. Open panel assembly (A) and (B).
2. Open bonnet assembly (C).

TULI12ECX1479AB 1
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27
Engine - Air cleaners and lines
Air cleaner - Remove

• Unplug terminals on indicator (7) wiring.
• Loosen clips (1), (2) on both sides of hose (3).
• Pull out hose (3).
• Tools flat-blade screwdriver
• Remove 4 sems bolts (4) M10 X 25.
• 17 mm
• Remove air cleaner assembly (5) from bracket (6).

TULI12ECX1483AB 1
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28
Engine - Air cleaners and lines
Air cleaner - Install

• Attach air cleaner (5) using sems bolts (4) M10 X
  25 to bracket (6).
• 17 mm
• 39.2 Nm (29 lb ft)
• Attach hose (3) to the end of the air cleaner.
• Tighten clip (1) and (2) on both sides of hose
  (3).
• 5.9 Nm (4.4 lb ft)
• Connect wire harness to indicator (7) on the air
  cleaner.

3.9 Nm (2.9 lb ft)
TULI12ECX1483AB 1
TULI12ECX1488AB 2
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29
Engine - Fuel tanks
Fuel tank - Prepare

1. Unlock cap (1) with the starter key and open it.
2. Loosen valve (2) under the tank (3) and drain the
   fuel. Capacity of tank 320 l (84.5 US gal)
3. Loosen 5 machine screw (4) and remove the
   connector for the level sensor (5).
4. Loosen the clip and pull out the hoses (6) and
   (7).
5. Plug the ends of the hoses to prevent fuel
   leakage.

TULI12ECX1432AB 1
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30
Engine - Fuel tanks
Fuel tank - Remove

• Remove 4 capscrews (8) M16 X 40.
• 24 mm
• Hook the lifting cable to the lifting eye on the
  fuel tank
• (3) and remove the fuel tank. Weight 113 kg
  (249.1 lb)
• Remove shims (9).
• NOTE Record the shim locations before removing
  them.

TULI12ECX1437AB 1
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31
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Engine - Fuel tanks Fuel tank - Install 1.
Attach fuel tank (3) to the frame using 4
capscrews (8) M16 X 40. Apply LOCTITE 262 on
the threads. 24 mm NOTE If the gap (looseness)
between the tank mount and the frame exceeds 1
mm (0.04 in), adjust the gap with shim (9) and
tighten capscrews (8) to install the tank.
TULI12ECX1437AB 1
2. Tightening torque
Tightening position Tightening torque
Capscrew M16 - (8) 196.4 - 235.6 Nm (144.86 - 173.77 lb ft)
Machine screw M5 - (4) 1.76 - 2.16 Nm (1.30 - 1.59 lb ft)
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33
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