CASE CX145CSR Tier 4 Crawler Excavator Service Repair Manual Instant Download

1
CX145CSR Tier 4 Crawler Excavator SERVICE MANUAL
Part number 47395870A 1st edition English July
2012
2
Section
1001
Safety, general information and standard torque
data
47395870A NA - June 2012
3
Safety, general information and standard torque
data
GENERAL INFORMATION CLEANING Clean all metal
parts except bearings, in a suitable cleaning
solvent or by steam cleaning. Do not use caustic
soda for steam cleaning. After cleaning, dry and
put oil on all parts. Clean oil passages with
compressed air. Clean bearings in a suitable
cleaning solvent, dry the bearings completely and
put oil on the bearings. INSPECTION Check all
parts when the parts are disassembled. Replace
all parts that have wear or damage. Small scoring
or grooves can be removed with a hone or crocus
cloth. Complete a visual inspection for
indications of wear, pitting and the replacement
of parts necessary to prevent early
failures. BEARINGS Check bearings for easy
action. If bearings have a loose fit or rough
action replace the bearing. Wash bearings with a
suitable cleaning solvent and permit to air dry.
DO NOT DRY BEARINGS WITH COMPRESSED AIR. NEEDLE
BEARINGS Before you press needle bearings in a
bore always remove any metal protrusions in the
bore or edge of the bore. Before you press
bearings into position put petroleum jelly on the
inside and outside diameter of the
bearings. GEARS Check all gears for wear and
damage. Replace gears that have wear or damage.
Oil seals, O-rings and gaskets. Always install
new oil seals, O-rings and gaskets. Put petroleum
jelly on seals and O-rings. SHAFTS Check all
shafts that have wear or damage. Check the
bearing and oil seal surfaces of the shafts for
damage. SERVICE PARTS Always install genuine
Case service parts. When ordering refer to
the Parts Catalogue for the correct part number
of the genuine Case replacement items. Failures
due to the use of other than genuine Case
replacement parts are not covered by warranty.
LUBRICATION Only use the oils and lubricants
specified in the Operators or Service
Manuals. Failures due to the use of non-specified
oils and lubricants are not covered by warranty.
47395870A NA - June 2012 1001-3
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Safety, general information and standard torque
data Safety
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
symbol contains important information about
safety. Carefully read the message. Make sure
you fully understand the causes of possible
injury or death.
To prevent injury always follow the Warning,
Caution and Danger notes in this section and
throughout the manual. Put the warning tag shown
below on the key for the key switch when
servicing or repairing the machine. One warning
tag is supplied with each machine. Additional
tags are available from your service parts
supplier.
WARNING Read the operator's manual to familiarize
yourself with the correct control functions.
WARNING Operate the machine and equipment
controls from the seat position only. Any other
method could result in serious injury.
WARNING This is a one man machine, no riders
allowed.
WARNING Before starting engine, study Operators
Manual safety messages. Read all safety signs on
machine. Clear the area of other persons. Learn
and practice safe use of controls before
operating. It is your responsibility to
understand and follow manufacturers instructions
on machine operation, ser- vice and to observe
pertinent laws and regulations. Operator's and
Service Manuals may be obtained from your CASE
dealer.
WARNING If you wear clothing that is too loose or
do not use the correct safety equipment for your
job, you can be injured. Always wear clothing
that will not catch on objects. Extra safety
equipment that can be required includes hard hat,
safety shoes, ear protection, eye or face
protection, heavy gloves and reflector clothing.
WARNING When working in the area of the fan belt
with the engine running, avoid loose clothing if
possible, and use extreme caution.
WARNING When doing checks and tests on the
equipment hydraulics, follow the procedures as
they are written. DO NOT change the procedure.
WARNING When putting the hydraulic cylinders on
this machine through the necessary cycles to
check operation or to remove air from a circuit,
make sure all people are out of the way.
WARNING Use insulated gloves or mittens when
working with hot parts.
47395870A NA - June 2012 1001-4
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Safety, general information and standard torque
data
WARNING Lower all attachments to the ground or
use stands to safely support the attachments
before you do any maintenance or service.
WARNING Pin sized and smaller streams of
hydraulic oil under pressure can penetrate the
skin and result in serious infection. If
hydraulic oil under pressure does penetrate the
skin, seek medical treatment immediately. Maintain
all hoses and tubes in good condition. Make
sure all connections are tight. Make a
replacement of any tube or hose that is damaged
or thought to be damaged. DO NOT use your hand to
check for leaks, use a piece of cardboard or wood.
WARNING When removing hardened pins such as a
pivot pin, or a hardened shaft, use a soft head
(brass or bronze) hammer or use a driver made
from brass or bronze and a steel head hammer.
WARNING When using a hammer to remove and install
pivot pins or separate parts using compressed air
or using a grinder, wear eye protection that
completely encloses the eyes (approved goggles or
other approved eye protectors).
WARNING Use suitable floor (service) jacks or
chain hoist to raise wheels or tracks off the
floor. Always block machine in place with
suitable safety stands.
WARNING When servicing or repairing the machine,
keep the shop floor and operator's compartment
and steps free of oil, water, grease, tools,
etc. Use an oil absorbing material and/or shop
cloths as required. Use safe practices at all
times.
WARNING Some components of this machine are very
heavy. Use suitable lifting equipment or
additional help as instructed in this Service
Manual.
WARNING Engine exhaust fumes can cause death. If
it is necessary to start the engine in a closed
place, remove the exhaust fumes from the area
with an exhaust pipe extension. Open the doors
and get outside air into the area.
WARNING When the battery electrolyte is frozen,
the battery can explode if (1), you try to charge
the battery, or (2), you try to jump start and
run the engine. To prevent the battery
electrolyte from freezing, try to keep the
battery at full charge. If you do not follow
these instructions, you or others in the area can
be injured.
47395870A NA - June 2012 1001-5
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Safety, general information and standard torque
data ROPS Judgment Method

• Purpose
• Check against the ROPS judgment criteria to judge
  whether the machine satisfies the ROPS criteria
  or not. The weight and boom of the machine
  greatly effects whether the ROPS judgment
  criteria is satisfied or not. The ROPS test
  assumes that the weight being used is the weight
  of the machine when the maximum number of
  selectable options are mounted (as of 2009).
• However, depending on the derivative machinery or
  the order details, the weight and boom position
  may differ
• from the assumed weight or position.
• Criteria for judging whether a machine satisfies
  the ROPS criteria
• Weight
• The weight must not be over the weight shown
  below for each class.
• If the weight is exceeded, there is a danger that
  the cab could be damaged and the operator could
  die or sustain a serious injury when the machine
  falls over.
• If the weight exceeds the stipulated weight, the
  machine will not satisfy the ROPS criteria.
• Weight (X3 model)
• To satisfy the ROPS criteria, the weight must not
  be over the indicated weight. (The below weights
  are the weights indicated on the nameplate
  within the ROPS cab)

Machine body total weight Class
16000 kg (35274.146 lb) or less CX75C CX145C
20500 kg (45195.000 lb) or less CX130C CX160C CX180C
28000 kg (61729.756 lb) or less CX235C
31000 kg (68343.658 lb) or less CX210C CX250C CX250C LR CX300C
40000 kg (88185.365 lb) or less CX370C
50000 kg (110231.707 lb) or less CX470C
The ROPS test assumes that the CX470C has a
cage guard (alone).
Machine body total weight Class
16000 kg (35274.146 lb) or less CX75C CX145C
20500 kg (45195.000 lb) or less CX130C CX160C CX180C
28000 kg (61729.756 lb) or less CX235C
31000 kg (68343.658 lb) or less CX210C CX250C CX250C LR CX300C
50000 kg (110231.707 lb) or less CX470C

• The ROPS test assumes that the CX470C has a
  cage guard (alone).
• Weight (X2 model)
• To satisfy the ROPS criteria, the weight must not
  be over the indicated weight. (The below weights
  are the weights indicated on the nameplate
  within the ROPS cab)

Machine body total weight Class
CX130B
CX160B
26600 kg (58643.268 lb) or less CX180B
CX210B
CX240B
47395870A NA - June 2012 1001-6
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Safety, general information and standard torque
data
2) Boom position

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

a
Ground point

• With the tip of the bucket in contact with the
  ground surface at maximum work radius, if the
  position ( in the diagram) that overlaps with
  the cab when viewed from the side is markedly
  lower than that of a standard machine (standard
  arm), the machine will not satisfy the ROPS
  criteria.
• Also, with a machine body with a cab mounted that
  can withstand up to 31 tons, the effect of
  mounting a
• 24 ton machine, which is near the restriction
  weight, and a 21 ton machine to the same cab will
  not be the same.
• Prohibited items
• Modifications that reduce the strength of a
  platform that has a cab with a ROPS mounted to
  it. (Actions or modifications that reduce the
  functionality of the anchoring part at the
  left-rear of the cab)
• Modifications that effect the strength of the
  ROPS of a cab.

A forbidden all modifications (red part) All modifications (grinding, welding, drilling holes, removing, etc.) are prohib- ited.
Allow under spec- ified conditions (gray part) Removal of parts is prohibited. Bar welding and making holes up to diameter 20 mm (0.787 in) by drilling are possible.
47395870A NA - June 2012 1001-7
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Section
2000
Removal and Installation of Engine Assembly
47395870A NA - June 2012
10
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.

• Use a wrench 17 mm (0.699 in) to remove the
  bolt (1), and then remove the battery cable (2)
  on the negative side.
• After removing the terminal and harness, secure
  them so that they do not interfere with the frame
  and other parts.
• Also, cover with a rubber cap to protect against
  sparks.
• Tightening torque for bolt installation 10.6 -
  13.0 Nm (7.82 - 9.59 lbfft)

• 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 (0.276 in), 10 mm (0.394 in), 13
  mm
• (0.512 in), 14 mm (0.551 in), 17 mm (0.669 in),
  19 mm
• (0.748 in), 36 mm (1.417 in)
• Box wrench 24 mm (0.945 in)
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Crane (with the required lifting capacity)
• Pliers
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Wood planks, etc.

• Remove the counterweight.
• For details, see "Removal and Installation of
  Coun- terweight".
• Remove the muffler.
• For details, see "Removal and Installation of
  Muf- fler".
• Remove the pump.
• For details, see "Removal and Installation of Hy-
  draulic Pump".
• Use a wrench 19 mm (0.748 in) to remove the
  bolt
• , use a wrench 7 mm (0.276 in) to loosen the
  hose bands (2) (3), and then remove the
  intercooler hose (high-temperature side) (4) and
  hose (5) from the air cleaner.
• Tightening torque for band (2) installation 8.8
  - 9.8 Nm (6.49 - 7.23 lbfft)
• Tightening torque for band (3) installation 6.3
  - 7.3 Nm (4.65 - 5.39 lbfft)

47395870A NA - June 2012 2000-3
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Removal and Installation of Engine Assembly

• Loosen the hose bands (1), and then remove the
  intercooler hose (low-pressure side) (2).
• Tightening torque for hose band (2) installation
  8.8 - 9.8 Nm (6.49 - 7.23 lbfft)

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

• Use a wrench 7 mm (0.276 in) to loosen the
  radia- tor hose bands (1) in 2 locations, and
  then remove the upper hose (2) and lower hose
  (3).
• Use caps to cover the radiator and hoses to pre-
  vent 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 (3.615 - 4.352 lbfft)

• Use a wrench 14 mm (0.551 in) to remove the
  bolts
• (2), and then remove the fan shroud (3).

47395870A NA - June 2012 2000-4
12
Removal and Installation of Engine Assembly
10. Use a wrench 13 mm (0.512 in) to remove the
2 bolts (1), and then remove the connector
brackets (2).
13. Use a wrench 13 mm (0.512 in) to remove the
bolt (1), and then remove the terminal cap
(2). Use a wrench to remove the wiring (3) (4)
from the starter. Use a wrench 17 mm (0.669 in)
to remove the bolt (5), and then remove the
wiring (6) from the frame.

• Use a wrench 13 mm (0.512 in) to remove the
  hose bands (1) in 2 locations from the bracket,
  and then remove the 5 connectors (2).
• Wrap the removed connectors in plastic after
  tying them together.
• Tightening torque for bolt installation 21.6 -
  37.2 Nm (15.93 - 27.44 lbfft)

14. Use a wrench 10 mm (0.394 in) to remove the
bolts (1). Remove the connector (2) from the
alternator. Use a wrench to remove the wiring (3)
from the al- ternator.
12. Remove the connector (1) from the air
conditioner compressor.

• 15. Use a wrench 13 mm (0.512 in) to loosen the
  line bolts (1) in 2 locations, and then remove
  the lines
• (2) (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 (1) installation 20
  - 25 Nm (14.75 - 18.44 lbfft)

47395870A NA - June 2012 2000-5
13
Removal and Installation of Engine Assembly

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

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

• Prepare the waste oil can (1).
• Drain the engine oil before removing the engine
  oil hose.
• Use a wrench 36 mm (1.417 in) to remove the 2
  engine oil remote hoses (1).
• 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 pre-
  vent dirt from accumulating on the connectors.
• Tightening torque for installation 54.1 - 63.9
  Nm (39.91 - 47.14 lbfft)

19. Install the 2 shackles (1), then use the wire
rope (2) and liftcrane to secure the engine main
unit.
47395870A NA - June 2012 2000-6
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Removal and Installation of Engine Assembly
Installation of Engine Assembly

• Use a box wrench 24 mm (0.945 in) to remove the
  4 bolts (1) from the mount.
• Tightening torque for bolt installation 264.9 -
  313.9 Nm (195.41 - 231.56 lbfft)

• 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.
• 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.

• Use the wire rope (1) and liftcrane to lift the
  engine main unit.
• Be sure to check all hoses and connectors for any
  disconnections before lifting.
• Thoroughly check that the location is safe before
  lowering the engine on wood planks, etc.
• Thoroughly secure the engine so that it does not
  fall over.

47395870A NA - June 2012 2000-7
15
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.
• 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.

• 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 13 mm (0.512 in)
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan

2. Use a wrench 13 mm (0.512 in) to remove the
4 bolts (1), and then remove the fuel cooler (2).
47395870A NA - June 2012 2001-3
16
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.
Removal and Installation of Engine Intercooler

• CAUTION
• Be sure to release the pressure within the cir-
  cuit 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 (0.276 in), 8 mm (0.315 in), 13 mm
• (0.512 in), 14 mm (0.551 in), 19 mm (0.748 in)
• Box wrench 13 mm (0.512 in)
• Pliers
• Shackles (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Rag
• Cleaning fluid
• Wood planks, etc.

47395870A NA - June 2012 2001-4
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Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler

• Removal of Intercooler
• Remove the counterweight.(For details, see
  "Removal and Installation of Counterweight".)

• Use a wrench 7 mm (0.276 in) to loosen the hose
  band (1) in the 2 locations, and then remove the
  upper hose (2) and lower hose (3) from the inter
  cooler.
• 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 (6.492 - 7.229 lbfft)

1. Use a wrench 13 mm (0.512 in) to remove the
4 bolts (1), and then remove the cover (2) (3).
2. Use a box wrench 13 mm (0.512 in) to remove
the 7 bolts (1) from the radiator cover.
4. Use a wrench 14 mm (0.551 in) to remove the
3 bolts (1), and then remove the brackets (2).
47395870A NA - June 2012 2001-5
18
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
5. Use a wrench 14 mm (0.551 in) to remove the
2 8. bolts (1), and then remove the fan guard
(2).
Use a wrench 13 mm (0.512 in) to remove the
bolt (1), and washer (2).
9. Install the shackle (1) to the top of the
radiator, and then use the wire rope (2) and
liftcrane to lift the inter cooler.
6. Use a wrench 14 mm (0.551 in) to remove the
3 bolts (1), and then remove the brackets (2).
Remove the bracket on the opposite side using the
same procedure.
10. Lift until the fixtures (1) at the bottom of
the inter cooler become disconnected.
7. Remove the 4 one-touch clips (1), and then
remove the front anti-insect net (2).
47395870A NA - June 2012 2001-6
19
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.
11. Thoroughly check that the location is safe
before lowering the inter cooler on square
wooden piece. When laying down the radiator, be
careful not to bend or crush the bottom fixtures
(1).
47395870A NA - June 2012 2001-7
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Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler

• Removal of Radiator
• Remove the counterweight.(For details, see
  "Removal and Installation of Counterweight".)

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.

1. Use a wrench 17 mm (0.669 in) to remove the
4 bolts (1), and then remove the under cover (2).

• CAUTION
• Be sure to release the pressure within the cir-
  cuit 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 (0.276 in), 13 mm (0.512 in), 14
  mm
• (0.551 in), 17 mm (0.669 in)
• Box wrench 13 mm (0.512 in)
• 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.

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).
47395870A NA - June 2012 2001-8
21
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
4. Loosen the drain plug (1), and then
drain the 7. coolant.

• Use a wrench 7 mm (0.267 in) to loosen the hose
  bands (1) in the 2 locations, use a wrench 13
  mm (0.512 in) to remove the bolt (2), and then
  remove the upper hose (3) and lower hose (4)
  from the ra- diator.
• 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 (3.615 - 4.352 lbfft)

5. Use a wrench 13 mm (0.512 in) to remove the
4 bolts (1), and then remove the covers (2) (3).
6. Use a box wrench 13 mm (0.512 in) to remove
the 7 bolts (1) from the radiator cover.
8. Remove the drain plug (1), loosen the hose
band (2), and then remove the hose (3).
47395870A NA - June 2012 2001-9
22
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler

• 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.

12. Use a wrench 14 mm (0.551 in) to remove the
3 bolts (1), and then remove the brackets (2).
Remove the bracket on the opposite side using the
same procedure.
13. Remove the 4 one-touch clips (1), and then
remove the front anti-insect net (2).
10. Use a wrench 14 mm (0.551 in) to remove the
3 bolts (1), and then remove the brackets (2).
14. Use a wrench 13 mm (0.512 in) to remove the
2 bolts (1), the 2 washers (2).
11. Use a wrench 14 mm (0.551 in) to remove the
2 bolts (1), and then remove the fan guard (2).
47395870A NA - June 2012 2001-10
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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 16.2 L
(4.280 gal). Finally, check that the level of
coolant is correct.
15. Install the 2 shackles (1) to the top of the
radiator, and then use the wire rope (2) and
liftcrane to lift the radiator.
16. Lift until the fixtures (1) at the bottom of
the radiator become disconnected.
17. 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).
47395870A NA - June 2012 2001-11
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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 17 mm (0.669 in) to remove the
4 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 7 mm (0.276 in), 13 mm (0.512 in), 17
  mm
• (0.669 in)
• Hexagon wrench 6 mm (0.236 in)
• Pliers
• Screwdriver
• Eyebolts 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 (0.512 in) to remove the
4 bolts (1), and then remove the cover (2) (3).
47395870A NA - June 2012 2001-12
25
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 7. the anti-insect net (2).
Use a wrench 13 mm (0.512 in) to remove the 4
bolts (1).

• Use a wrench 7 mm (0.276 in) to loosen the hose
  band (1), and then remove the hose (2).
• Use caps to cover the oil cooler and lines to
  pre- vent the entry of water, dust or dirt.

• Install the 2 eyebolts (1) on the top of the oil
  cooler.
• Fully tighten the eyebolts, and then loosen them
  by a half turn.
• Use a hexagon wrench 6 mm (0.236 in) to remove
• the 4 bolts (1), and then remove the lines (2).
• Use caps to cover the oil cooler and lines to
  pre- vent the entry of water, dust or dirt.

47395870A NA - June 2012 2001-13
26
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27
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
Installation of oil cooler 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". The O-rings cannot be reused.
Replace them with new parts.

• Install the 2 shackles (1) to the eyebolts, and
  then use the wire rope (2) and liftcrane to lift
  the oil cooler main unit.
• When lifting the oil cooler unit, be careful not
  to let the line on the bottom of the oil cooler
  catch on the fan shroud.

10. Thoroughly check that the location is safe
before lowering the oil cooler on wood planks,
etc.
47395870A NA - June 2012 2001-14
28
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