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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18. 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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