CASE CX30C Mini Excavator Service Repair Manual Instant Download

1
CX30C Mini Excavator
SERVICE MANUAL
Part number 48175013 English October 2017
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SERVICE MANUAL CX30C Cab - TIER 4 final engine
CX30C Canopy - TIER 4 final engine
48175013 02/10/2017
EN
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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 10.206
Fuel filters . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 10.8 10.220 Throttle linkage . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 10.9 10.218
Fuel injection system . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
10.10 10.202 Air cleaners and lines . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 10.11 10.254 Intake and exhaust
manifolds and muffler . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
10.12 10.400 Engine cooling system . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10.13 10.414 Fan and drive . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 10.14 10.304 Engine
lubrication system . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 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 35.359 Main control valve . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 35.4 35.357 Pilot
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 35.5 35.355 Hydraulic hand control . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 35.6 35.356 Hydraulic foot control.
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 35.7 35.352 Hydraulic
swing system . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 35.8 35.353
Hydraulic travel system . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 35.9
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35.354 Hydraulic central joint . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. .
35.10
35.736 Boom hydraulic system . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
35.11
35.737 Dipper hydraulic system. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
35.12
35.738 Excavator and backhoe bucket hydraulic
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
35.13
35.734 Tool quick coupler hydraulic system . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
35.14
35.360 Hammer and rotating bucket hydraulic
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
35.15
35.739 Swing arm hydraulic system . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
35.16
35.741 Dozer blade cylinders . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 35.17 Frames and ballasting
..................................................
............... 39 39.103 Swing ring assembly
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 39.1 39.140 Ballasts
and supports . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 39.2 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 Electrical systems........................
...............................................
55 55.000 Electrical system . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 55.1 55.100 Harnesses and
connectors. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 55.2 55.525 Cab engine
controls . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
55.3 55.201 Engine starting system . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 55.4 55.301 Alternator . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 55.5 55.302
Battery. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 55.6 55.202 Cold start aid . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 55.7 55.011
Fuel tank system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 55.8 55.014 Engine intake and exhaust system.
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
55.9 55.012 Engine cooling system . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 55.10 55.013 Engine oil system . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 55.11
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55.512 Cab controls. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
55.12
55.524 Cab controls (Lift arm, Boom, Dipper,
Bucket) . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
55.13
55.518 Wiper and washer system. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
55.14
55.404 External lighting . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . .
55.15
55.405 External lighting switches and relays .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
55.16
55.514 Cab lighting . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
55.17
55.408 Warning indicators, alarms, and
instruments . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 55.18 Booms,
dippers, and buckets .............................
.......................... 84 84.114 Boom
pivoting support . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
84.1 84.910 Boom . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 84.2 84.912 Dipper
arm . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
84.3 84.100 Bucket . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 84.4 Dozer blade
and arm..........................................
......................... 86 86.110 Dozer
blade . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
86.1 Platform, cab, bodywork, and decals
.............................................
90 90.150 Cab . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 90.1 90.160 Cab
interior trim and panels. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 90.2 90.118
Protections and footboards. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
90.3 90.120 Mechanically-adjusted operator
seat. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
90.4 90.100 Engine hood and panels . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 90.5 90.105 Machine shields and guards .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 90.6
48175013 02/10/2017
7
INTRODUCTION
48175013 02/10/2017 1
8
INTRODUCTION Foreword - 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 manufacturer reserves the
right to make improvements in design and changes
in specifications at any time without notice and
without incurring any obligation to install them
on units previously sold. Specifications,
descriptions, and illustrative material herein
are as accurate as known at time of publication
but are subject to change without notice. In case
of questions, refer to your CASE CONSTRUCTION
Sales and Service Networks.
48175013 02/10/2017 3
9
INTRODUCTION
Safety rules
Personal safety This is the safety alert symbol.
It is used to alert you to potential personal
injury hazards. Obey all safety messages that
follow this symbol to avoid possible death or
injury.
Throughout this manual you will find the signal
words DANGER, WARNING, and CAUTION followed by
special in- structions. These precautions are
intended for the personal safety of you and those
working with you. Read and understand all the
safety messages in this manual before you operate
or service the machine.
DANGER indicates a hazardous situation that, if
not avoided, will result in death or serious
injury. WARNING indicates a hazardous situation
that, if not avoided, could result in death or
serious injury. CAUTION indicates a hazardous
situation that, if not avoided, could result in
minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION
MESSAGES COULD RESULT IN DEATH OR SERIOUS
INJURY. Machine safety NOTICE Notice indicates a
situation that, if not avoided, could result in
machine or property damage. Throughout this
manual you will find the signal word Notice
followed by special instructions to prevent
machine or property damage. The word Notice is
used to address practices not related to personal
safety. Information NOTE Note indicates
additional information that clarifies steps,
procedures, or other information in this
manual. Throughout this manual you will find the
word Note followed by additional information
about a step, procedure, or other information in
the manual. The word Note is not intended to
address personal safety or property damage.
48175013 02/10/2017 4
10
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 CONSTRUCTION genuine service
parts. When placing an order, check the parts
catalog. It contains the CASE CONSTRUCTION
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.
48175013 02/10/2017 5
11
SERVICE MANUAL Engine CX30C Cab - TIER 4 final
engine CX30C Canopy - TIER 4 final engine
48175013 02/10/2017 10
12
Engine - Engine and crankcase Engine - General
specification Engine main data
Item Engine model D1305-E4B
Number of Cylinder 3
Engine Type Vertical, water-cooled, 4-cycle diesel engine
Bore Stroke 78.0 88.0 mm (3.07 3.46 in)
Total Displacement 1261 cm³ (76.95 in³)
ISO Net Continuous 15.5 kW (21.1 Hp) 2600 RPM
ISO/SAE Net Intermittent 17.9 kW (24.3 Hp) 2600 RPM
SAE Gross Intermittent 18.5 kW (25.2 Hp) 2600 RPM
Maximum Bare Speed 2820 RPM
Minimum Bare Idling Speed 1100 RPM
Combustion Chamber Spherical type (E-TVCS)
Fuel Injection Pump Bosch MD type mini pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Mini Nozzle (DNOPD)
Injection Timing 0.2793 rad 16.00 C before top dead centre
Firing Order 1-2-3
Injection Pressure 13.73 MPa (1992 psi)
Compression Ratio 24 1
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (Cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starter Motor 12 V, 1.2 kW (1.6 Hp)
Starting Support Device By glow plug in combustion chamber
EGR None
Battery 12 V, 65 Ah, equivalent
Charging Alternator 12 V, 480 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Lubricating Oil Class CF lubricating oil as per API classification is recommended.
Lubricating Oil Capacity 5.7 L (1.5 US gal)
Weight (Dry) 95 kg (209 lb)
NOTE the specification described above is of the
standard engine of each model. Conversion
Formula HP 0.746 kW, PS 0.7355 kW
48175013 02/10/2017 10.1 10.001 / 3
13
Engine - Engine and crankcase Engine -
Overview Engine main components
SMIL17MEX1213G 1
48175013 02/10/2017 10.1 10.001 / 12
14
Engine - Engine and crankcase
Component Reference
Fuel injection system - Overview (10.218) Fuel
injection system - Timing check (10.218)
1. Fuel injectors
2. Fuel pump


3. Engine oil filler cap
4. Coolant thermostat
Coolant thermostat - Test (10.400)
Engine lubrication system - Check - Engine oil
level (10.304)
5. Engine oil dipstick
Electrical system - Component identification -
Alternator (55.000)
6. Alternator
Electrical system - Component identification -
Fuel feed pump (55.000)
7. Fuel filler pump
8. Engine oil filter
Engine - Change fluid - Engine oil and oil filter
(10.001)
Fuel-water separator filter - Cleaning (10.206)
Fuel-water separator filter - Replace (10.206)
9. Fuel filter water separator
Electrical system - Component identification -
Engine starter (55.000)
10. Engine starter

11. Muffler
12. Fuel filter
Fuel filters - Replace (10.206)
Air cleaner - Cleaning (10.202) Air cleaner -
Replace (10.202)
13. Air cleaner
14. Belt
Belt - Inspect (10.414)
48175013 02/10/2017 10.1 10.001 / 13
15
Engine - Engine and crankcase
Engine sensors
SMIL17MEX1212G 2
Component Reference
1. Coolant high temperature sensor
Electrical system - Component identification -
Coolant high temperature sensor (55.000)
2. Air-heater
Electrical system - Component identification -
Air heater (55.000) Glow plug system - Test
(55.202)
3. Coolant temperature sensor
Electrical system - Component identification -
Engine coolant temperature sensor (55.000)
Electrical system - Component identification -
Engine oil pressure switch (55.000) Engine
lubrication system - Check - Engine oil pressure
(10.304)
4. Engine oil pressure switch
5. Glow timer
Electrical system - Component identification -
Glow timer (55.000)
6. Engine stop solenoid
Electrical system - Component identification -
Engine stop solenoid (55.000)
48175013 02/10/2017 10.1 10.001 / 14
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Engine - Engine and crankcase
Generality Topic Reference
General specification
Engine - General specification (10.001)
Engine identification
Engine - Identification (10.001)
Consumables - Engine oil recommended operating
temperature range ()
Engine oil recommended operating temperature range
48175013 02/10/2017 10.1 10.001 / 15
17

• Engine - Engine and crankcase
• Engine - Identification
• You must identify engine model name and serial
  number before you start servicing.
• Engine label
• Emission label
• Engine model
• Serial number

SMIL16MEX0703AB 1
Engine series
Number Series Number Series
1 05 series (include WG) 5 Air cooled gasoline
2 V3 series 6 GZ, OC, AC, EA and E series
3 08 series 7 03 series
4 SM series (include WG) 8 07 series
Year of manufacture
Alphabet or Number Year Alphabet or Number Year
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
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18
Engine - Engine and crankcase Month of
manufacture
Month Engine lot number Engine lot number
January A0001 A9999 B0001 BZ999
February C0001 C9999 D0001 DZ999
March E0001 E9999 F0001 FZ999
April G0001 G9999 H0001 HZ999
May J0001 J9999 K0001 KZ999
June L0001 L9999 M0001 MZ999
July N0001 N9999 P0001 PZ999
August Q0001 Q9999 R0001 RZ999
September S0001 S9999 T0001 TZ999
October U0001 U9999 V0001 VZ999
November W0001 W9999 X0001 XZ999
December Y0001 Y9999 Z0001 ZZ999

• Engine serial number
• The engine serial number is an identified number
  for the engine.
• It appears after the engine model number. It
  shows the
• month and year of manufacture as below.
• Alphabetical letters "I" and "O" are not used.
• Engine model name D1305
• Engine series 1 indicates 05 series
• Year D indicates 2013
• Month L or M indicates June
• Lot number (0001 9999 or A001 Z999)

SMIL16MEX0704AA 2
Emission decal The emission decal is affixed on
the cylinder head cover. It describes important
details for using the engine. Make sure to read
before using the engine. Also, the emission decal
describes details regarding the engine only.
SMIL16MEX0444AA 3
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19
Engine - Engine and crankcase Cylinder
number You can see the cylinder numbers of KUBOTA
diesel en- gine in the figure. The sequence of
cylinder numbers is No.1, No.2, No.3 and No.4 and
it starts from the gear case side.
SMIL16MEX0706AA 4
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20
Engine - Engine and crankcase
Engine - External view
SMIL16MEX0702GB 1
A 497.6 mm (19.59 in)
B 590.1 mm (23.23 in)
C 396.0 mm (15.59 in)
D 185.3 mm (7.30 in)
E ?125 mm (4.92 in)
F ?222.2 mm (8.748 in)
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21
Engine - Engine and crankcase
Engine - Remove
WARNING Avoid injury! Shut off the engine, remove
the key, and make sure all machine motion stops
before you service the machine. Failure to comply
could result in death or serious injury. W1128B
WARNING Chemical hazard! Use caution when opening
the quick coupler cap from the load port. There
may be product left in the port. Failure to
comply could result in death or serious
injury. W1039A
WARNING Crushing hazard! The lifting systems must
be operated by qualified personnel who are aware
of the correct procedures to follow. Make sure
all lifting equipment is in good condition, and
all hooks are equipped with safety
latches. Failure to comply could result in death
or serious injury. W0256A
WARNING Heavy objects! Lift and handle all heavy
components using lifting equipment with adequate
capacity. Always support units or parts with
suitable slings or hooks. Make sure the work area
is clear of all bystanders. Failure to comply
could result in death or serious injury. W0398A
WARNING Burn hazard! Before performing any
service on the hydraulic system, you must allow
it to cool. Hydraulic fluid temperature should
not exceed 40 C (104 F). Failure to comply
could result in death or serious injury. W0241A
WARNING Escaping fluid! Hydraulic fluid or diesel
fuel leaking under pressure can penetrate the
skin and cause infection or other injury. To
prevent personal injury Relieve all pressure
before disconnecting fluid lines or per- forming
work on the hydraulic system. Before applying
pressure, make sure all connections are tight and
all components are in good condition. Never use
your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for
this purpose. If injured by leaking fluid, see
your doctor immediately. Failure to comply could
result in death or serious injury. W0178A
WARNING Chemical hazard! When handling fuel,
lubricants, and other service chemicals, follow
the manufacturer's instructions. Wear Personal
Protective Equipment (PPE) as instructed. Do not
smoke or use open flame. Collect fluids in proper
containers. Obey all local and environmental
regulations when disposing of chemi-
cals. Failure to comply could result in death or
serious injury. W0371A
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22
Engine - Engine and crankcase

1. Remove the counterweight (for details refer to
   Coun- terweight - Remove (39.140)).
2. Remove the battery (for details refer to Battery
   - Re- move (55.302)).
3. Remove the platform (for details refer to
   Operator seat base trim panel - Remove -
   Platform (90.160)).
4. Drain the fuel.
5. Loosen the clamp to remove the hose (1) from the
   ex- pansion tank (2).
6. Pull out the expansion tank (2).
7. Use a wrench 13 mm to remove the bolts (4),
   then remove the bracket (3).

SMIL16MEX2843AB 1

1. Disconnect the electrical connector CR-24 (3) of
   the timer glow.
2. Use a wrench 13 mm to remove the 2 bolts (1).
3. Use a wrench 17 mm to remove the 2 bolts (4),
   then remove the bracket (2).

SMIL16MEX2844BB 2
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23
Engine - Engine and crankcase

1. Use a wrench 13 mm to remove the 2 bolts (1)
   of the coolant filling hose bracket (8).
2. Use a wrench 13 mm to remove the 2 bolts (2)
   of the engine oil filling hose bracket (7).
3. Use a wrench 13 mm to remove the 2 bolts (3)
   of the bracket (6).
4. Use a wrench 13 mm to remove the 2 bolts (4)
   of the battery connect and disconnect switch (5).

SMIL16MEX2845AB 3
15. Use a wrench 19 mm to remove the 2 bolts
(2) and the 2 bolts (3) of the cab support
bracket (1).
SMIL16MEX2846AB 4

1. Use a wrench 13 mm to remove the 2 bolts (1)
   of the air cleaner inlet hose.
2. Use a wrench 19 mm to remove the 2 bolts (2)
   of the cab support bracket (3).
3. Use a wrench 13 mm to remove the 2 bolts (4)
   of the cab support bracket (3).
4. Remove the cab support bracket (1).

SMIL16MEX2847AB 5

1. Loosen the clamp (1) to remove the hose (2) from
   the radiator.
2. Loosen the clamp (4) to remove the hose (3) from
   the cylinder head cover.
3. Remove the coolant filling assembly (5).

SMIL16MEX2848AB 6
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24
Engine - Engine and crankcase
23. Loosen the clamp (1) to remove the engine oil
filling assembly (2) from the cylinder head cover.
SMIL16MEX2849AB 7
24. Loosen the clamps and remove the fuel hoses
(1) and (2) from the fuel filter support (3).
SMIL16MEX2850AB 8

1. Loosen the clamp and remove the fuel hose (1)
   from the fuel filter water separator (2).
2. Use a wrench 17 mm to remove the bolt (4), and
   then disconnect the earth strap (3) from the
   engine.

SMIL16MEX2851AB 9

• Cut the tie (1) and disconnect the electrical
  connector
• CD-10 (2) from the air cleaner pressure switch
  (3).
• Loosen the clamp (5) to remove the hose (4) from
  the intake manifold.

SMIL16MEX2852AB 10
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25
Engine - Engine and crankcase

• Disconnect the electrical connector CN-145 (6) of
  the electrical fuel feed pump (7).
• Use a wrench 13 mm to remove the bolts (5) of
  the bracket (1).
• Remove the bracket (1) includes air filter (2),
  fuel filter
• (3), fuel filter water separator (4) and feed
  pump (7).

SMIL16MEX2853BB 11
32. Disconnect the electrical connector CD-8 (2)
from the engine coolant temperature sensor (1).
SMIL16MEX2854AB 12
33. Loosen the clamp (2) and remove the cab
heating hose (1).
SMIL16MEX2855AB 13
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26
Engine - Engine and crankcase

1. Loosen the clamp (3) and remove the cab heating
   hose (1) from the coolant cock (2).
2. Use a wrench 7 mm to remove the nut (4), and
   then disconnect the glows electrical connector
   CN-80.

SMIL16MEX2856AB 14

• Disconnect the electrical connector CN-74 (2)
  from the alternator (1).
• Remove the nut (6) to disconnect the wiring CN-74
  (3)
• from the alternator (1).
• Remove the nut (4) to disconnect the electrical
  con- nector CD-18 from the engine oil pressure
  switch (5).

SMIL16MEX2857AB 15
39. Loosen the clamp (1) and remove the radiator
coolant hose (2).
SMIL16MEX2868AB 16

1. Disconnect the electrical connector CN-45 (2)
   from the starter motor (1).
2. Remove the nut (5) to disconnect the cable (4)
   and the wire (3) from the starter motor (1).

SMIL16MEX2858AB 17
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27
Engine - Engine and crankcase
42. Use a wrench 11 mm to loosen the clamp
(1), and then remove the hydraulic oil suction
hose (2) from the pump flange (3).
SMIL16MEX2859AB 18

1. Use a wrench 19 mm to remove the T hose (1).
2. Use a wrench 24 mm to remove the P1 hose (3)
   and the P2 hose (2).
3. Use a wrench 22 mm to remove the P3 hose (4)
   and the P4 hose (5).

SMIL16MEX2860AB 19

• Disconnect the electrical connector CN-79 (2)
  from the fuel solenoid (1).
• Loosen the clamp and remove the fuel supply hose
• (3) from the fuel injection pump (4).

SMIL16MEX2861AB 20

1. Disconnect the electrical connector CD-9 (3) from
   the coolant high temperature sensor switch (2).
2. Loosen the clamp and remove the fuel injectors
   over- flow hose (1).

SMIL16MEX2862AB 21
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28
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29
Engine - Engine and crankcase

1. Use a wrench 13 mm to remove the 2 bolts (2)
   for separate the bracket (3) and the hose (4)
   from the right-hand support (1).
2. Use a wrench 13 mm to remove the 4 bolts (4),
   and then remove the right-hand support (1).

SMIL16MEX2863BB 22
52. Use a wrench 19 mm to loosen the 2 bolts
(2) of the radiator (1).
SMIL16MEX2864AB 23

1. Install the 2 hooks (1) into the engine lift
   bracket, and then use the wire rope or chain and
   lift-crane to secure the engine.
2. Install the lift strap (3) around the pump (4)
   and insert it into the hook (2).

SMIL16MEX2865AB 24
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30
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