New Holland E485C Crawler Excavator Service Repair Manual Instant Download

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

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 47483341A 14/02/2013

[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 47483341A 14/02/2013

https://www.ebooklibonline.com Hello dear friend! Thank you very much for reading. Enter the link into your browser. The full manual is available for immediate download. https://www.ebooklibonline.com

[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 47483341A 14/02/2013

INTRODUCTION 47483341A 14/02/2013 1

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. 47483341A 14/02/2013 3

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. 1 TULI12WEX2004AA 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. 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. 2 TULI12WEX2005AA 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. Failuretocomplywillresultindeathorserious injury. D0013A 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. 3 TULI12WEX2006AA 47483341A 14/02/2013 4

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. 4 SMIL12WEX0174AA 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: 5 Respirators (or dust proof masks) Ear plugs or acoustic ears protections Goggles with lateral shield or masks for eyes protection TULI12WEX2008AA Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jacketsorshirtswithopenzipswhichcouldgetcaughtinto moving parts. Engine - Radiator Neverleavetheengineruninclosedspaceswithoutventi- 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. 6 TULI12WEX2009AA 47483341A 14/02/2013 5

SERVICE MANUAL Engine E485C 47483341A 14/02/2013 10

Engine - Engine and crankcase Engine - General specification Performance Maximum climbable gradient Swing speed 70% 7.8 RPM Travel speed Slow Fast 3.5 km/h (2 mph) 5.6 km/h (3 mph) Engine specifications Main specifications RUSSIAN FEDERATION MIDDLE EAST AFRICA Maker Model HINO MOTORS P11CUU Water-cooled, 4 cycle direct injection type diesel engine with intercooler turbo-charger 6 in-line 122 mm (4.80 in) 150 mm (5.91 in) 10520 cm (642 in ) 17:1 Type Number of cylinders Bore Stroke Total displacement Compression ratio Rated output power (at 1850 RPM) ( ISO 14396: without fan) Maximum torque (at 1400 RPM) ( ISO 14396) High idling Low idling Fuel consumption rate Engine oil quantity Weight 257 kW (349 Hp) 1400 N m (1032.6 lb ft) 2050 RPM 800 RPM 213 g/kWh 6 42.5 l (11.23 US gal) 1150 kg (2535.3 lb) Main specifications - TURKEY Maker Model HINO MOTORS P11CUP Water-cooled, 4 cycle direct injection type diesel engine with intercooler turbo-charger 6 in-line 122 mm (4.80 in) 150 mm (5.91 in) 10520 cm (642 in ) 17:1 Type Number of cylinders Bore Stroke Total displacement Compression ratio Rated output power (at 1850 RPM) ( ISO 14396: without fan) Maximum torque (at 1400 RPM) ( ISO 14396) High idling Low idling Fuel consumption rate Engine oil quantity Weight 257 kW (349 Hp) 1400 N m (1032.6 lb ft) 2050 RPM 800 RPM 213 g/kWh 6 42.5 l (11.2 US gal) 1150 kg (2535.3 lb) Feeding Type Injection sequence Electron type 1-4-2-6-3-5 47483341A 14/02/2013 10.1 [10.001] / 3

Engine - Engine and crankcase Battery (RUSSIAN FEDERATION MIDDLE EAST AFRICA) Voltage Capacity 2 x 12 V 2 x 176 A h Battery (TURKEY) Voltage Capacity 2 x 12 V 2 x 160 A h Starter motor Maker Voltage Output SAWAFUJI 24 V 6 kW (8 Hp) Alternator Maker Voltage Output SAWAFUJI 24 V 60 A 47483341A 14/02/2013 10.1 [10.001] / 4

Engine - Pan and covers Engine oil pan - Component identification (P11C-UP only) 1 SMIL13CEX0323GA 12111 12149 12151 9659C Oil pan Drain cock Gasket* Gasket* *Parts not to be reused. Tightening torque 12149 9191-08452 9191-10451 69 N m (610.7 lb in) 31 N m (274.4 lb in) 51 N m (451.4 lb in) 47483341A 14/02/2013 10.2 [10.102] / 3

Engine - Pan and covers Engine oil pan - Component identification (P11C-UU only) 1 SMIL13CEX0515GA 12111 12149 12151 9659C Oil pan Drain cock Gasket* Gasket* *Parts not to be reused. Tightening torque 12149 9191-08452 9191-10451 69 N m (610.7 lb in) 31 N m (274.4 lb in) 51 N m (451.4 lb in) 47483341A 14/02/2013 10.2 [10.102] / 4

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. 47483341A 14/02/2013 10.2 [10.102] / 5

Engine - Pan and covers Engine oil pan - Install 1. Applyasmallamountofliquidgasket(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. 1 SMIL13CEX0324AB 47483341A 14/02/2013 10.2 [10.102] / 6

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. 47483341A 14/02/2013 10.2 [10.102] / 7

Suggest: If the above button click is invalid. Please download this document first, and then click the above link to download the complete manual. Thank you so much for reading

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. 47483341A 14/02/2013 10.2 [10.102] / 8

https://www.ebooklibonline.com Hello dear friend! Thank you very much for reading. Enter the link into your browser. The full manual is available for immediate download. https://www.ebooklibonline.com