PDF Service Repair Manual Case Cx15B Cx18B Series 2 Mini Excavator - 12 MB
This service repair manual covers the Case CX15B and CX18B Series 2 Mini Excavators in complete detail.
It is the definitive guide for technicians, offering step-by-step procedures for all maintenance and repair tasks.
From the engine to the hydraulic system, every component is covered with clear instructions and illustrations.
Use this manual to troubleshoot problems and perform professional-quality repairs.
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SERVICE MANUAL
CX15B CX15B
CX18B CX18B
Series 2 Series 2
Mini Excavator Mini Excavator
1/1 SERVICE MANUAL
Part number 84533370B
Part number 84533370B
English
May 2014
Copyright © 2014 CNH Industrial Italia S.p.A. All Rights Reserved.
--- Page 3 ---
INTRODUCTION
15. Repairs which require welding should be performed only with the benefit of the appropriate reference informa-
tion and by personnel adequately trained and skilled in welding procedures. Determine the type of metal being
welded and select the correct welding procedure and electrodes, rods or wires to provide a metal weld strength
at least equivalent to that of the parent metal. Make sure to disconnect the battery before any welding operation
is performed.
16. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged
in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do
not connect wiring to a line containing fluid.
17. Be sure all protective devices, including guards and shields, are properly installed and functioning correctly before
starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace
the guard or shield after repair is complete.
18. Performing maintenance and repair operations while the bucket is lifted is dangerous, because there is the pos-
sibility of a device falling. Do not fail to lower such device and place the bucket to the ground before starting the
operation.
19. Loose or dirty fuel, lubrication and hydraulic systems, pipes and hoses may cause fires. Do not bend or strike
high-pressure lines, do not install bent or damaged lines. Inspect lines, tubes and hoses carefully. Do not check
for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil jet that will be invisible close
to the hose.
This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks.
20. Tighten connections to the correct torque. Make sure that all protections against burns, the clamps and the oper-
ator’s protective devices are correctly installed in order to prevent excessive heat, vibrations or rubbing against
other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a
line, tube or seal failure must be installed correctly.
21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high
speed rotating component that has been damaged or altered should be checked for balance before reusing.
22. Be careful when servicing or separating the tracks. Chips can fly when removing or installing a track pin. Wear
safety glasses and long sleeve protective clothing. Tracks can unroll very quickly when separated. Keep away
from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged
from the sprockets. Block the machine to prevent it from moving.
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INTRODUCTION
Torque specifications for sleeve type tube fitting
Sleeve type tube fittings
Tube size
Outside Tightening
Wrench size
diameter x torque
thickness
10 mm (0.4 in) 44 N·m (32.5 lb
x 1.5 mm 19 mm ft) ± 4.9 N·m
(0.1 in) (3.6 lb ft)
147 N·m
15 mm (0.6 in)
(108.4 lb ft) ±
x 2.0 mm 27 mm
20 N·m (14.8 lb
(0.1 in)
ft)
177 N·m
18 mm (0.7 in)
(130.5 lb ft) ± SMIL13MEX0050XA 6
x 2.5 mm 32 mm
20 N·m (14.8 lb
(0.1 in)
ft)
216 N·m
22 mm (0.9 in)
(159.3 lb ft) ±
x 3.0 mm 36 mm
20 N·m (14.8 lb
(0.1 in)
ft)
275 N·m
28 mm (1.1 in)
(202.8 lb ft) ±
x 4.0 mm 41 mm
29 N·m (21.4 lb
(0.2 in)
ft)
441 N·m
35 mm (1.4 in)
(325.3 lb ft) ±
x 5.0 mm 55 mm
44 N·m (32.5 lb
(0.2 in)
ft)
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INTRODUCTION
Product identification - Machine orientation
The terms right-hand, left-hand, front, and rear are used
in this manual to indicate the sides as they are seen from
the operator seat when the travel motors are positioned at
the rear and the operator is facing the direction in which
the machine advances (forward).
A Front of machine
B Rear of machine
C Left side of machine
D Right side of machine
E Travel motor
SMIL13MEX0315AB 1
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Engine - Engine and crankcase
Engine - Special tools
Name Shape Function
For pulling out and press fitting piston
Piston pin setting tool.
pins.
Compression gauge adapter. For measuring compression.
For removing and installing oil
Oil pressure switch key (26).
pressure switch.
Range applicable for removing and
Piston ring pliers. installing piston rings: 60 - 95 mm
(2.36 - 3.74 in)
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Engine - Engine and crankcase
Engine serial number
The engine serial number (No.) is stamped on the injec-
tion pump mount (upper side of tie rod cover) of the cylin-
der block.
TULI12EXN3145AB 2
Engine model and total displacement
The engine type and displacement are stamped on the
side of the injection pump mount of the cylinder block.
TULI12EXN3146AA 3
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Engine - Engine and crankcase
Bleeding fuel system
NOTICE: Completely wipe off any spilled fuel from air vent screws with a cloth or the like, as spilled fuel can cause a
fire.
Bleeding of the fuel system must be carried out closest to
the fuel tank: bleed the fuel filter first, then the injection
pump.
Air bleeding from fuel filter
1. Deliver fuel by solenoid pump.
2. Place the cock of the fuel filter in the “OPEN” position
(O).
3. Press (P) and hold the button until the filter body cup
(1) is filled with fuel.
4. Stop the fuel supply.
TULI12EXN3519AB 9
Air bleeding from water separator
1. Loosen the water separator’s bleed plug for fuel supply
(1).
2. Deliver fuel by solenoid pump.
3. Tighten air bleed plug for fuel inlet when the fuel flow
from the air bleed plug becomes free of bubbles.
4. Loosen air bleed plug for fuel outlet (2).
5. Tighten air bleed plug for fuel outlet when the fuel flow
from the air bleed plug becomes free of bubbles.
6. Stop the fuel supply.
TULI12EXN3520AB 10
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Engine - Engine and crankcase
Overheating
Check items before troubleshooting
Quantity and leakage of coolant
Loosening of fan belt
Clogging of radiator fins
Concentration of LLC
Clogging of muffler
Quantity and degradation of engine oil
Swirling of cooling air
Thermostat malfunction
Problem: Overheating
Overheating is caused by a disalignment of engine load
during engine setting.
If the engine itself is normal and overheat occurs, measure
the ambient and coolant temperatures in the loaded condi-
tion (thermostat full open).
If the temperature difference is greater than 60 °C (140 °F),
the investigation into other components as well as the en-
gine is suggested.
TULI12EXN3498EA 3
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Engine - Pan and covers
Engine oil pan - Assemble
Installation of oil filter
1. Turn the engine upside down to face up the oil pan
mounting surface.
2. Install the oil screen so that the tip of the screen does
not contact the oil pan.
TULI12EXN3355AA 1
Installation of oil pan
1. Install new oil pan gasket.
2. Tighten oil pan bolts evenly and diagonally.
TULI12EXN3356AA 2
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Engine - Valve drive and gears
Camshaft - Disassemble
Disassembly of idler gear
1. Remove the snap ring (36).
2. Remove the idler gear (19).
TULI12EXN3176AB 1
Disassembly of camshaft
NOTICE: When pulling out the camshaft, be careful not to
cause damage to the cam lobe of the camshaft and the
camshaft hole of the cylinder block.
1. Remove the stop screws of the camshaft (37).
TULI12EXN3177AB 2
2. Extract the camshaft (21) with the gear (20) and the
bearings (21).
TULI12EXN3178AB 3
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Engine - Valve drive and gears
Camshaft gear - Disassemble
1. Loosen and remove the screws (33) and a stud (32).
2. Screw in a screw in the threaded hole of the stud and
remove the flange (3) from the gear pump.
TULI12EXN3169AB 1
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Engine - Cylinder heads
Retouching valve face
1. Grind remarkably worn valve faces with a valve rectifier.
NOTE: Grind the valve face with a rectifier (1) at the spec-
ified angle.
Secure the valve margin width equal to or greater than the
limit. Replace valves with new ones if their dimensions
after refacing do not meet the standard.
2. (A) Set the valve face angle at the specified angle.
TULI12EXN3200AB 8
Measuring perpendicularity and free length of valve spring
Measure the perpendicularity and free length of the valve
spring. Replace the valve spring if the limit is exceeded.
TULI12EXN3301AA 9
Item Standard Allowable limit
Free length H 40 mm (1.575 in) 38.5 mm (1.516 in)
θ = 2.0° or less
D (gap) = 1.4 mm
Perpendicularity (0.055 in) total length 2 mm (0.079 in)
or less
Lf = 40 mm (1.575 in)
35.5 mm (1.398 in)/ 64.1 - 71.0 N (14.4 -
16.0 lb)
Setting length/load -0.15%
28 mm (1.102 in)/ 170.1 - 189.4 N (38.2 -
42.6 lb)
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Engine - Connecting rods and pistons
Measurement of clearance between connecting rod bearing and pin
NOTICE: When grinding crank pins, be sure to grind all the
pins to the same size.
Finish the fillet radius to the specified dimension.
1. Reassemble the bearing into the big end of the con-
necting rod.
2. Tighten the connecting rod cap bolts to the specified
torque.
3. Measure the inner diameter of the connecting rod bear-
ing.
4. Measure the outer diameter of the crank pin.
TULI12EXN3326AA 10
5. Calculate the clearance between the inner diameter of
the connecting rod bearing and the outer diameter of
the crank journal.
6. Replace the connecting rod bearing if the clearance
exceeds the limit.
7. Measure the clearance between the connecting rod
bearing and the crank pin again. Use the undersize
bearing if the limit is exceeded.
8. If an undersize bearing is used, grind the crank pin to
the specified undersize.
A. Measuring directions
TULI12EXN3327AA 11
B. Measuring points
TULI12EXN3328AA 12
Item Nominal Standard Allowable limit
39.965 - 39.98 mm
Pin outer diameter (STD) ø40 mm (1.575 in) -0.7 mm (-0.028 in)
(1.573 - 1.574 in)
Clearance between
0.028 - 0.071 mm (0.001
connecting rod pin and - 0.15 mm (0.006 in)
- 0.003 in)
bearing
Item Undersize Finish dimension
0.25 mm (0.010 in) ø39.715 - 39.73 mm (1.564 - 1.564 in)
Pin undersize
0.50 mm (0.020 in) ø39.465 - 39.48 mm (1.554 - 1.554 in)
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Engine - Crankshaft and flywheel
Disassembly of valves and valve springs
NOTICE: Be careful not to cut your hands with the ring gear
when pulling out the flywheel.
Pay attention not to drop or hit the flywheel while removing
it.
TULI12EXN3163AB 2
1. Firmly hold the pulley with a wrench (W) to prevent the
flywheel from turning.
2. Loosen and remove one screw from the flywheel.
3. Screw in a guide screw (G) in the threaded hole of the
removed screw.
4. Loosen and remove the remaining screws from the fly-
wheel (1).
5. Hold the flywheel (1) firmly with both hands and, by
moving it back and forth, pull it out straight.
NOTE: The ring gear is shrink fitted to the flywheel. Do not
remove it unless defective. TULI12EXN3164AB 3
Disassembly of rear plate
Loosen and remove the screw of the rear plate. Remove
the rear plate (2).
NOTE: When removing the rear plate (2), firmly hold it with
both hands and pull the rear plate straight out by moving it
back and forth, as the rear plate is located near the bush-
ing.
TULI12EXN3165AB 4
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Engine - Crankshaft and flywheel
Measurement of the distortion of the cylinder block top surface
NOTE: Limit the depth of surface grinding of cylinder block
to a necessary minimum. If the surface of cylinder block is
ground more than specified, it may result in defects such
as defective combustion and stamping (contact between
piston and valve).
1. Apply a straight edge to the top surface of the cylinder
block and measure its distortion with a feeler gauge.
2. If the distortion exceeds the limit, grind the cylinder
block with a surface grinder.
TULI12EXN3334AA 6
Item Standard Allowable limit
Distortion of cylinder block
0.05 mm (0.002 in) or less 0.1 mm (0.004 in)
top surface
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Engine - Fuel injection system
Injection pump - Remove
NOTE: Check thickness of the fuel injection timing adjusting shim.
(1) Screw
(2) Fuel pump
(3) Gasket
TULI12EXN3401BB 1
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Engine - Fuel injection system
2. Place the stamped side of the piston (8) to the opposite
side of the protrusion of the sleeve (11) (opposite side
to the crosspiece side). Assemble the spring lower seat
on the piston and insert it into the control sleeve.
TULI12EXN3422AB 6
Pusher installation
1. Install the shim (6).
2. Install the pusher (5) so that its groove is oriented to-
wards the pin hole (4).
TULI12EXN3423AB 7
3. Push down the pusher (5) and install the pin (4).
TULI12EXN3424AB 8
Crosspiece assembly
1. Align the sleeve (11) so that the protrusion (P) of the
control sleeve matches the fork (F) of the control cross-
piece (3).
2. Install the control crosspiece (3).
3. Install the stop wire bracket.
4. Tighten the screws to the specified torque.
TULI12EXN3425AB 9
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Contents
Engine - 10
Air cleaners and lines - 202
SERVICE
Air cleaner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - Intake and exhaust manifolds and muffler
Intake and exhaust manifolds and muffler - Inspect
1. Suction pipe
2. Inlet cover
3. Exhaust manifold
TULI12EXN3470AB 1
Checks
A. Cracks, damage, contamination, dirt, corrosion
B. Cracks, damage, corrosion
Measurement of deformation of inlet cover and exhaust manifold
Using a level (1) and a thickness gauge (2), measure the
deformation on the cylinder head mounting sur-faces of the
inlet cover and exhaust manifold. If the measured deforma-
tion exceeds the limit, grind or re-place the part.
TULI12EXN3471AB 2
Item Allowable limit
Distortion on mounting surfaces of inlet cover and
0.15 mm (0.006 in)
exhaust manifold
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Engine - Engine cooling system
Engine cooling system - Install
Installation of pulley, belt, thermostat, switch and water pump
1. Fan
2. Spacer
3. Pulley
4. Belt
5. Thermostat body
6. Switch
7. Pipe
8. Water pump
For switch assembly (6), tighten it to the prescribed tight-
ening torque of 19.6 - 29.4 N·m (14.5 - 21.7 lb ft).
TULI12EXN3463BB 1
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--- Page 25 ---
Contents
Engine - 10
Engine lubrication system - 304
TECHNICAL DATA
Engine lubrication system
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Engine lubrication system
Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Engine lubrication system
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - Engine lubrication system
Installation of relief valve
Insert the piston and the spring into the gear case and
tighten the plug (2) to the specified tightening torque of 39.2
- 28.9 N·m (28.9 - 21.3 lb ft).
TULI12EXN3460AB 5
Oil filter installation
1. Apply a light coating of engine oil to the filter gasket.
2. Tighten the filter (1) by hand. When the filter gasket
contacts the support surface, tighten the filter.
TULI12EXN3461AB 6
(A) Apply engine oil.
TULI12EXN3462AB 7
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Hydraulic systems - Hydraulic systems
1. Pump
2. Control valve
3. Slewing motor
4/A. Right travel motor
4/B. Left travel motor
5. Boom cylinder
6. Arm cylinder
7. Bucket cylinder
8. Swing cylinder
9. Dozer cylinder
10. Swivel joint
11/A. Right control lever valve
11/B. Left control lever valve
12. Travel pedals valves
13. Solenoid valve
14. Return filter
15. Suction filter
16. Check valve
17. Oil tank
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Hydraulic systems - Hydraulic systems
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Hydraulic systems - Hydraulic systems
BOOM OPERATION
Hydraulic pilot system allows to operate, through the right control lever, the boom.
Boom raising
Pilot circuit
• Boom control spool
When the right control lever is put at boom raising position, the pilot valve (11/A) controls the pressurized oil entering into
the Pb8 port on control valve (2) and allows the activation of boom control spool.
Main circuit
• Boom cylinder (5) circuit, head side
Oil flow coming from P1 port of pump (1) enters to P1 port of control valve (2) and, through the boom control spool, reaches
the B8 port. Oil flow coming from port B8 flows to head side of boom cylinder (5) to activate the boom raising function.
Boom lowering
Pilot circuit
• Boom control spool
When the right control lever is put at boom lowering position, the pilot valve (11/A) control the pressurized oil entering into
the Pa8 port on control valve (2) and allows the activation of boom control spool.
Main circuit
• Boom cylinder (5) circuit, bottom side and return oil circuit
Oil flow coming from P1 port of pump (1) flows to the boom control spool of control valve (2) and supplies bottom side of
boom cylinder (5) to lower the boom. Boom cylinder (5) head side return flow enters into B8 port of control valve (2),
passes through boom control spool and reaches the discharge port of control valve. To avoid a non-controlled boom
lowering, the lowering control of boom spool is provided with a flow cocking of cylinder bottom side delivery flow and an
adjusted restriction on cylinder head side return circuit.
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Hydraulic systems - Hydraulic systems
NIBBLER / BREAKER OPERATION (OPTIONAL)
Operation is controlled by pedal which drives the cable to operate the valve. This function is activated regardless to
the safety lock lever.
NIBBLER (CLOSE) OPERATING CIRCUIT
Put the nibbler/breaker selector valve to nibbler position.
Nibbler operation
Pressing the left side of the control pedal, the cable is pulled and consequently the nibbler valve spool of control valve (2)
is activated.
Main circuit
Supply circuit for nibbler cylinder: Oil flows coming from P1 and P2 ports of variable pump flow into P1 and P2 port of
control valve (2), pass through independent travel valve and join together upwards of nibbler/breaker section, supplying the
head side of nibbler cylinder (closing of nibbler).
Return: Return flow coming from nibbler cylinder enters into A1 port of control valve (2), flows through the nibbler/breaker
spool and reaches the discharge port of control valve.
HYDRAULIC BREAKER ACTIVATION
Put the nibbler/breaker selector valve to breaker position.
Breaker operation
Pressing the right side of the control pedal, the cable is pushed and it activates the nibbler/breaker section of control
valve (2).
Main circuit
Supply circuit for breaker: Operation is similar to nibbler operation.
Return: Breaker return oil flow directly reaches the valve (18) and, then, the hydraulic oil tank but it does not flow through
the control valve (2).
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Hydraulic systems - Hydraulic systems
BUCKET OPERATION
Hydraulic pilot system allows to operate, through the right control lever, the bucket.
Bucket digging operation circuit
Pilot circuit
• Bucket control spool
When the right control lever is put at bucket digging position, the pilot valve (12/A) controls the pressurized oil entering
into the Pa9 port of control valve (2) and allows the activation of bucket control spool.
Main circuit
• Bucket cylinder (7) circuit, head side
Oil flow coming from P1 port of pump (1) enters into P1 port of control valve (2) and, through the bucket control spool,
reaches the A9 port. Oil flow coming from port A9 flows to head side of bucket cylinder (7) to activate the digging
function. The return oil flow coming from bottom side of bucket cylinder (7) flows through the bucket spool and reaches
the discharge port of control valve.
Bucket dumping operation
Pilot circuit
• Bucket control spool
When the right control lever is put at bucket dumping position, the pilot valve (12/A) controls the pressurized oil entering
into the Pb9 port of control valve (2) and allows the activation of bucket control spool.
Bucket spool shifting.
Main circuit
• Bucket cylinder (7) circuit, bottom side
Oil flow coming from P1 port of pump (1) enters into P1 port of control valve (2) and, through the bucket control spool,
reaches the B9 port. Oil flow coming from B9 port flows to the bottom side of bucket cylinder (7) to activate the dumping
function. The return oil flow coming from head side of bucket cylinder (7), flows through the bucket spool and reaches the
discharge port of control valve.
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Hydraulic systems - Hydraulic systems
TRAVEL / DOZER COMBINED OPERATION
When travel/dozer combined function is activated, straight travel is not activated.
Travel/dozer lowering operation
Pilot circuit
Travel is controlled by the pilot hydraulic system and the dozer is controlled by operating cable.
Main circuit
The flows coming from P1 and P2 ports of the variable pump enter into P1 and P2 ports on the control valve (2) and reach
the travel motors (4/A) and (4/B) through the travel motor spool and through the swivel joint (11). Flow coming from P3
port of fixed pump enters into P3 port of control valve (2) and reaches the dozer cylinder (9) through the dozer spool
and the swivel joint (11).
Dozer is operated by the pressurized oil supplied by the third pump: in this way, there is no flow adjustment on (right and
left) travel motors and the independent travel and flow conflux valve is not activated.
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Hydraulic systems - Hydraulic systems
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Hydraulic systems - Hydraulic systems
MEASURING TRAVEL PERFORMANCE
Test procedures
Make 3 test measurements.
Use average resulting values for the evaluation.
Machine travel
Travel speed (5 complete revolutions)
Engine: High idle.
Hydraulic oil temperature: 50 - 60 °C (122 - 140 °F).
Measuring position: The machine body is lifted using both
the hoe attachment and the dozer.