service repair manual

1. SERVICE MANUAL
E485C
Crawler Excavator
Part number 47483341A
English
January 2013
Copyright © 2013 CNH Europe Holding S.A. All Rights Reserved.
SERVICE
MANUAL
E485C
Crawler Excavator
1/1
Part number 47483341A

2. 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
[10.114] Pump drives ........................................................................ 10.7
[10.216] Fuel tanks .......................................................................... 10.8
[10.210] Lift pump and lines ................................................................. 10.9
[10.206] Fuel filters ........................................................................ 10.10
[10.218] Fuel injection system............................................................. 10.11
[10.202] Air cleaners and lines ............................................................ 10.12
[10.250] Turbocharger and lines........................................................... 10.13
[10.254] Intake and exhaust manifolds and muffler ....................................... 10.14
[10.400] Engine cooling system ........................................................... 10.15
[10.414] Fan and drive .................................................................... 10.16
[10.304] Engine lubrication system........................................................ 10.17
[10.408] Oil cooler and lines............................................................... 10.18
[10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust
treatment .................................................................................. 10.19
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems.................................................................. 35.1
[35.300] Reservoir, cooler, and filters........................................................ 35.2
[35.106] Variable displacement pump ....................................................... 35.3
[35.102] Pump control valves................................................................ 35.4
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3. [35.359] Main control valve.................................................................. 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
[35.736] Boom hydraulic system .......................................................... 35.10
[35.737] Dipper hydraulic system.......................................................... 35.11
[35.738] Excavator and backhoe bucket hydraulic system................................ 35.12
[35.354] Hydraulic central joint ............................................................ 35.13
Frames and ballasting ................................................................. 39
[39.101] Upper frame........................................................................ 39.1
[39.103] Swing ring assembly ............................................................... 39.2
[39.140] Ballasts and supports .............................................................. 39.3
Tracks and track suspension........................................................ 48
[48.100] Tracks .............................................................................. 48.1
[48.134] Track tension units ................................................................. 48.2
[48.138] Track rollers ........................................................................ 48.3
Cab climate control ..................................................................... 50
[50.200] Air conditioning..................................................................... 50.1
Electrical systems....................................................................... 55
[55.000] Electrical system ................................................................... 55.1
[55.100] Harnesses and connectors......................................................... 55.2
[55.015] Engine control system.............................................................. 55.3
[55.201] Engine starting system ............................................................. 55.4
[55.301] Alternator........................................................................... 55.5
[55.302] Battery.............................................................................. 55.6
[55.010] Fuel injection system............................................................... 55.7
[55.012] Engine cooling system ............................................................. 55.8
[55.013] Engine oil system .................................................................. 55.9
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4. [55.640] Electronic modules ............................................................... 55.10
[55.036] Hydraulic system control ......................................................... 55.11
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................. 55.12
[55.DTC] FAULT CODES.................................................................. 55.13
Lubrication system...................................................................... 71
[71.460] Grease lubrication system ......................................................... 71.1
Booms, dippers, and buckets ....................................................... 84
[84.910] Boom ............................................................................... 84.1
[84.100] Bucket.............................................................................. 84.2
Platform, cab, bodywork, and decals............................................. 90
[90.150] Cab................................................................................. 90.1
[90.124] Pneumatically-adjusted operator seat.............................................. 90.2
[90.105] Machine shields and guards ....................................................... 90.3
[90.116] Fenders and guards................................................................ 90.4
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5. INTRODUCTION
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6. 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 which, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, 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 which, 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 which 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.
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7. INTRODUCTION
Personal safety
Carefully read this Manual before proceeding with main-
tenance, repairs, refuelling or other machine operations.
Repairs have to be carried out only by authorized and in-
structed staff; specific precautions have to be taken when
grinding, welding or when using mallets or heavy ham-
mers.
Not authorized persons are not allowed to repair or carry
out maintenance on this machine. Do not carry out any
work on the equipment without prior authorization.
Ask your employer about the safety instructions in force
and safety equipment.
Nobody is allowed to seat on the operator’s place during
machine maintenance unless he is a qualified operator
helping with the maintenance work.
If it is necessary to move the equipment to carry out re-
pairs or maintenance, do not lift or lower the equipment
from any other position than the operator’s seat.
TULI12WEX2004AA 1
Never carry out any operation on the machine when the
engine is running, except when specifically indicated.
Stop the engine and ensure that all pressure is relieved
from hydraulic circuits before removing caps, covers,
valves, etc.
All repair and maintenance operations should be carried
out with the greatest care and attention.
Service stairs and platforms used in a workshop or in the
field should be built in compliance with the safety rules in
force.
Any functional disorders, especially those affecting the
safety of the machine, should therefore be rectified im-
mediately.
DANGER
Unexpected movement!
Make sure parking brake is applied. Secure
machine with wheel chocks.
Failure to comply will result in death or serious
injury.
D0013A
TULI12WEX2005AA 2
Before performing any work on the machine, attach a
maintenance in progress tag. This tag can be applied on
the left-hand control lever, safety lever or cab door.
TULI12WEX2006AA 3
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8. INTRODUCTION
Emergency
Be prepared for emergencies. Always keep at disposal on
the machine a first aid kit and a fire extinguisher. Make
sure that the fire extinguisher is serviced in accordance
with the manufacturer’s instructions.
SMIL12WEX0174AA 4
Equipment
Wear close fitting clothing and safety equipment appropri-
ate for the job:
• Safety helmet
• Safety shoes
• Heavy gloves
• Reflective clothing
• Wet weather clothing
If environment condition require it following personal
safety equipment should be at hand:
• Respirators (or dust proof masks)
• Ear plugs or acoustic ears protections
• Goggles with lateral shield or masks for eyes protection
Do not wear rings, wristwatches, jewels, unbuttoned or
flapping clothing such as ties, torn clothes, scarves, open
jackets or shirts with open zips which could get caught into
moving parts.
TULI12WEX2008AA 5
Engine - Radiator
Never leave the engine run in closed spaces without venti-
lation and not able to evacuate toxic exhaust gases. Keep
the exhaust manifold and tube free from combustion ma-
terials.
Do not refuel with the engine running, especially if hot, as
this increases fire hazard in case of fuel spillage.
Never attempt to check or adjust the belts when the en-
gine is running.
Never lubricate the machine with the engine running.
TULI12WEX2009AA 6
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9. SERVICE MANUAL
Engine
E485C
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10. Engine - Engine and crankcase
Engine - General specification
Performance
Maximum climbable gradient 70%
Swing speed 7.8 RPM
Travel speed
Slow 3.5 km/h (2 mph)
Fast 5.6 km/h (3 mph)
Engine specifications
Main specifications – RUSSIAN FEDERATION – MIDDLE EAST –AFRICA
Maker HINO MOTORS
Model P11CUU
Type
Water-cooled, 4 cycle direct injection type diesel engine with
intercooler turbo-charger
Number of cylinders 6 in-line
Bore 122 mm (4.80 in)
Stroke 150 mm (5.91 in)
Total displacement 10520 cm³ (642 in³)
Compression ratio 17:1
Rated output power (at 1850 RPM) ( ISO 14396:
without fan)
257 kW (349 Hp)
Maximum torque (at 1400 RPM) ( ISO 14396) 1400 N·m (1032.6 lb ft)
High idling 2050 RPM
Low idling 800 RPM
Fuel consumption rate 213 g/kWh ±6
Engine oil quantity 42.5 l (11.23 US gal)
Weight 1150 kg (2535.3 lb)
Main specifications - TURKEY
Maker HINO MOTORS
Model P11CUP
Type
Water-cooled, 4 cycle direct injection type diesel engine with
intercooler turbo-charger
Number of cylinders 6 in-line
Bore 122 mm (4.80 in)
Stroke 150 mm (5.91 in)
Total displacement 10520 cm³ (642 in³)
Compression ratio 17:1
Rated output power (at 1850 RPM) ( ISO 14396:
without fan)
257 kW (349 Hp)
Maximum torque (at 1400 RPM) ( ISO 14396) 1400 N·m (1032.6 lb ft)
High idling 2050 RPM
Low idling 800 RPM
Fuel consumption rate 213 g/kWh ±6
Engine oil quantity 42.5 l (11.2 US gal)
Weight 1150 kg (2535.3 lb)
Feeding
Type Electron type
Injection sequence 1-4-2-6-3-5
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11. Engine - Engine and crankcase
Battery (RUSSIAN FEDERATION – MIDDLE EAST – AFRICA)
Voltage 2 x 12 V
Capacity 2 x 176 A·h
Battery (TURKEY)
Voltage 2 x 12 V
Capacity 2 x 160 A·h
Starter motor
Maker SAWAFUJI
Voltage 24 V
Output 6 kW (8 Hp)
Alternator
Maker SAWAFUJI
Voltage 24 V
Output 60 A
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12. Engine - Pan and covers
Engine oil pan - Component identification (P11C-UP only)
SMIL13CEX0323GA 1
12111 Oil pan 12151 Gasket*
12149 Drain cock 9659C Gasket*
*Parts not to be reused.
Tightening torque
12149 69 N·m (610.7 lb in) 9191-10451 51 N·m (451.4 lb in)
9191-08452 31 N·m (274.4 lb in)
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13. Engine - Pan and covers
Engine oil pan - Component identification (P11C-UU only)
SMIL13CEX0515GA 1
12111 Oil pan 12151 Gasket*
12149 Drain cock 9659C Gasket*
*Parts not to be reused.
Tightening torque
12149 69 N·m (610.7 lb in) 9191-10451 51 N·m (451.4 lb in)
9191-08452 31 N·m (274.4 lb in)
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14. Engine - Pan and covers
Engine oil pan - Remove
1. Remove bolts and remove the oil pan. Refer to En-
gine oil pump - Remove (10.304).
ATTENTION: If the gasket is sticking, remove it using a
scraper, etc.
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15. Engine - Pan and covers
Engine oil pan - Install
1. Apply a small amount of liquid gasket (G) [Threebond
TB1211 (white)] to the step of the joint surface be-
tween the timing gear case and the cylinder block
and between the flywheel housing and the cylinder
block.
2. Replace the gasket with a new one and install the oil
pan.
Tightening torque :
25 N·m (221.3 lb in)
ATTENTION: Wipe off oil on the oil pan and cylinder block
before installation.
SMIL13CEX0324AB 1
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16. Engine - Pan and covers
Timing gear housing - Remove
Removal of crankshaft front oil seal
1. Reference: "Engine mechanical, Timing gear cover
and flywheel housing. Refer to Crankshaft oil seal -
Remove (10.103) for the removal of crankshaft front
oil seal.
Removal of timing gear case cover
2. Remove bolts and remove the timing gear cover.
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17. Engine - Pan and covers
Timing gear housing - Install
Installation of timing gear cover
1. Replace the gasket and O–ring with new ones and
install the timing gear cover.
Tightening torque: 44 N·m (389.4 lb in)
2. Cut the gasket projecting to the engine lower surface
so that it becomes a flat surface.
Installation of crankshaft front oil seal
1. Reference: "Engine mechanical, Timing gear cover
and flywheel housing. Refer to Crankshaft oil seal -
Install (10.103) for the installation of crankshaft front
oil seal.
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18. Engine - Valve drive and gears
Camshaft gear - Component identification
SMIL13CEX0212GA 1
13505 Idle gear assembly 13580 Idle gear shaft assembly
13505A Main idle gear assembly 13581 Idle gear shaft
13511 Camshaft 13613 Supply pump drive gear
13523 Camshaft gear 900116 Spacer
13571 Thrust plate 900116A Spacer
13572 Thrust plate 9532-07150 Key
13572A Thrust plate 9851A O-ring*
13572B Thrust plate
*Parts not to be reused.
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19. Engine - Valve drive and gears
Tightening torque
900124A 44 N·m (389.4 lb in) +90°
+90°
9019A 137 N·m (1212.6 lb in)
900124 108 N·m (955.9 lb in)
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20. Engine - Valve drive and gears
Get train layout
SMIL13CEX0213GA 2
(1) - Air compressor idle gear
(2) - Main idle gear (No. 1)
(3) - Main idle gear (No. 2)
(4) - Supply pump drive gear
(5) - Oil pump drive gear
(6) - Oil pump driven gear
(7) - Crankshaft gear
(8) - Camshaft gear
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21. Engine - Valve drive and gears
Camshaft - Remove
1. Remove the push rod cover on the side of the engine.
2. Hold the roller tappet so that it does not fall using a
special tool.
Special tool : Stopper
SMIL13CEX0214AA 1
3. Turn the camshaft gear, align the camshaft gear hole
with the thrust plate mounting bolt position, remove
the bolt and remove the shaft.
ATTENTION: Pull out the cam bearing so that it is not dam-
aged.
NOTICE: Refer to the following for installation of the
camshaft. Reference: Camshaft - Install (10.106).
SMIL13CEX0215AA 2
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22. Engine - Valve drive and gears
Camshaft - Disassemble
1. Fix the camshaft through an aluminum plate, etc.
with a vice and remove the camshaft gear bolt.
ATTENTION: Prevent faulty conditions on the gear such
as deformation, impact, scratch, etc.
2. Pull out the main bearing from the crankshaft using
a special tool.
Special tool : Timing gear puller
NOTICE: Refer to the following for inspection and as-
sembly of the camshaft. Reference: Camshaft - Inspect
(10.106), Reference: Camshaft - Install (10.106).
SMIL13CEX0216AA 1
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23. Engine - Valve drive and gears
Camshaft - Inspect
1. Measure the cam height using a micrometer. If it is
beyond the operation limit, replace the camshaft.
SMIL13CEX0217AA 1
Standard value Operation limit
IN 56.03 mm (2.2059 in) 55.23 mm (2.1744 in)
Cam height
EX 53.72 mm (2.1150 in) 52.92 mm (2.0835 in)
IN 6.63 mm (0.2610 in) 6.48 mm (0.2551 in)
Cam lift
EX 8.72 mm (0.3433 in) 8.57 mm (0.3374 in)
Inspection of camshaft bearing oil clearance
1. Measure the outer diameter of the camshaft journal
using a micrometer.
SMIL13CEX0218AA 2
Standard value
Journal No. 1 65.0 mm (2.5591 in)
Journal No. 2 64.6 mm (2.5433 in)
Journal No. 3 64.2 mm (2.5276 in)
Journal No. 4 63.8 mm (2.5118 in)
Journal No. 5 63.4 mm (2.4961 in)
Journal No. 6 63.0 mm (2.4803 in)
Journal No. 7 62.6 mm (2.4646 in)
2. Measure the camshaft bearing inner diameter using
a cylinder gauge.
3. Calculate the difference between the outer diameter
of the camshaft journal and the inner diameter of the
camshaft bearing. If it is beyond the operation limit,
replace the camshaft or camshaft bearing.
Standard value Repair limit
0.030 mm (0.0012 in) - 0.120 mm (0.0047 in) 0.30 mm (0.0118 in)
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24. Engine - Valve drive and gears
Inspection of camshaft runout
1. Hold the camshaft with the V-block, measure the ro-
tation runout of the camshaft using a dial gauge. If it
is beyond the operation limit, replace the camshaft.
Operation limit: 0.05 mm (0.0020 in)
SMIL13CEX0219AA 3
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25. Engine - Valve drive and gears
Camshaft - Install
Installation of ring gear
1. Insert the spacer and thrust plate into the camshaft.
2. Warm the cam gear to approx. 180 °C (356 °F) using
a heater (piston heater, etc.).
ATTENTION: Do not touch parts with bare hand because
they are hot.
3. Apply engine oil to the bolt seating and thread, fix the
cam gear using a vice with the part number stamp
surface facing outside, and tighten the bolt.
Tightening torque : 137 N·m (1212.6 lb in)
ATTENTION: Prevent faulty conditions on the gear such
as deformation, impact, scratch, etc.
4. Tighten the bolt again to the specified torque after the
cam gear decreases to room temperature.
SMIL13CEX0220AA 1
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26. Engine - Valve drive and gears
Camshaft - Inspect
1. Measure the camshaft end play (1) using a thickness
gauge and measure the thrust plate thickness (2) us-
ing calipers. If it is beyond the operation limit, replace
the thrust plate.
SMIL13CEX0221AB 1
SMIL13CEX0222AB 2
Standard value Operation limit
End play
0.10 mm (0.0039 in) - 0.23 mm
(0.0091 in)
0.3 mm (0.0118 in)
Thrust plate thickness 8 mm (0.315 in) —
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28. Engine - Valve drive and gears
Camshaft - Install
Tappet installation
1. Insert the tappet coated with engine oil.
ATTENTION: Check the tappet visually for absence of ec-
centric wear, cracks, scratches, etc.
2. Use the special tool and secure the tappet.
Special tool: Stopper
SMIL13CEX0223AA 1
3. Apply engine oil to the camshaft journal and insert it
into the cylinder block while turning the camshaft.
ATTENTION: Do not damage the camshaft bearing.
4. Install the camshaft using 4 bolts.
5. Make sure that the camshaft end play is the standard
value.
Standard value: 0.10 mm (0.0039 in) - 0.23 mm
(0.0091 in)
SMIL13CEX0215AA 2
6. Apply the liquid gasket [Threebond TB1207C (red) or
equivalent] and install the push rod cover.
ATTENTION: Apply it continuously.
Apply the liquid gasket at the width of 1.5 mm (0.0591 in)
to 2.5 mm (0.0984 in).
Install it within 20 minutes after application of the liquid gas-
ket.
SMIL13CEX0214AA 3
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29. Engine - Valve drive and gears
Camshaft gear - Remove
Removal of supply pump drive gear
1. Refer to: Pump drives - Remove (10.114).
Removal of idle gear and main idle gear
1. Remove the idle gear shaft mounting bolts of the idle
gear and main idle gear.
2. Remove the thrust plate and main idle gear at the
main idle gear side.
SMIL13CEX0226AA 1
Removal of idle gear shaft
1. Pull out each idle gear shaft using the special tool.
Special tool :
Sliding hammer
Idle gear shaft puller adapter
ATTENTION: Do not remove the idle gear shaft unless nec-
essary.
ATTENTION: Refer to the following for installation of the
timing gear. Reference: Camshaft gear - Install (10.106).
SMIL13CEX0227AA 2
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30. Engine - Valve drive and gears
Camshaft gear - Inspect
Inspection of idle gear oil clearance
1. Measure the idle gear shaft outer diameter using a
micrometer and measure the idle gear bushing inner
diameter using a cylinder gauge.
SMIL13CEX0228BA 1
Standard value
Shaft outer diameter 64 mm (2.520 in)
Main idle gear
Bushing inner diameter 64 mm (2.520 in)
Shaft outer diameter 52 mm (2.047 in)
Idle gear
Bushing inner diameter 52 mm (2.047 in)
2. Calculate the difference between the idle gear shaft
outer diameter and the idle gear bushing inner diam-
eter. If it is beyond the operation limit, replace the
idle gear shaft and the idle gear bushing.
Standard value Operation limit
Main idle gear
0.030 mm (0.0012 in) - 0.090 mm
(0.0035 in)
0.20 mm (0.0079 in)
Idle gear
0.030 mm (0.0012 in) - 0.090 mm
(0.0035 in)
0.20 mm (0.0079 in)
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31. Engine - Valve drive and gears
Camshaft gear - Install
Temporary tightening of air compressor idle gear shaft
1. Apply engine oil to the idle gear shaft.
2. Direct the identification hole (1) of the idle gear shaft
to the lower part of the engine and fix the idle gear
shaft, gear and thrust plate temporarily.
Special tools :
Plate
Guide
ATTENTION: Press-fit vertically so that the idle gear shaft
does not hit the timing gear case.
3. Remove the special tool, apply engine oil to the bolt
seating and the bolt thread and fix it temporarily.
SMIL13CEX0229AB 1
Installation of idle gear
1. Align the gear mark and install each idle gear (2) and
(3).
Tightening torque:
Main idle gear (2)
44 N·m (389.4 lb in)
Idle gear (3)
108 N·m (955.9 lb in)
2. Make sure that each backlash and end play are
within the standard value after installation. "Refer-
ence: Camshaft gear - Inspect (10.106).
SMIL13CEX0230BB 2
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32. Engine - Valve drive and gears
Camshaft gear - Inspect
Inspection of backlash for each gears
1. Measure backlash between gears using a dial
gauge. If it is beyond the operation limit, replace the
gear.
SMIL13CEX0231AA 1
Standard value Operation limit
Between supply pump drive gear and
main idle gear (No.2)
0.05 mm (0.0020 in) - 0.19 mm
(0.0075 in)
0.30 mm (0.0118 in)
Between camshaft gear and main
idle gear (No.2)
0.07 mm (0.0028 in) - 0.19 mm
(0.0075 in)
0.30 mm (0.0118 in)
Between camshaft gear and idle gear
0.06 mm (0.0024 in) - 0.19 mm
(0.0075 in)
0.30 mm (0.0118 in)
Between main idle gear (No. 2) and
crankshaft gear
0.07 mm (0.0028 in) - 0.19 mm
(0.0075 in)
0.30 mm (0.0118 in)
Between oil pump drive gear and oil
pump driven gear
0.06 mm (0.0024 in) - 0.19 mm
(0.0075 in)
0.40 mm (0.0157 in)
Inspection of idle gear end play
2. Measure the end play of the main idle gear and idle
gear using a thickness gauge. If it is beyond the
operation limit, replace the gear and shaft.
SMIL13CEX0232AA 2
Standard value Operation limit
Main idle gear
0.065 mm (0.0026 in) - 0.149 mm
(0.0059 in)
0.30 mm (0.0118 in)
Idle gear
0.070 mm (0.0028 in) - 0.125 mm
(0.0049 in)
0.30 mm (0.0118 in)
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