New Holland E485C Crawler Excavator Service Repair Manual by h0ful7

SERVICE MANUAL

SERVICE MANUAL E485C Crawler Excavator

E485C Crawler Excavator

1/1 Part number 47483341A

Part number 47483341A English January 2013

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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[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

[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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INTRODUCTION

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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 instructions. 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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INTRODUCTION

Personal safety Carefully read this Manual before proceeding with maintenance, repairs, refuelling or other machine operations. Repairs have to be carried out only by authorized and instructed staff; specific precautions have to be taken when grinding, welding or when using mallets or heavy hammers. 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.

TULI12WEX2004AA

TULI12WEX2005AA

TULI12WEX2006AA

Nobody is allowed to seat on the operatorâ&#x20AC;&#x2122;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 repairs or maintenance, do not lift or lower the equipment from any other position than the operatorâ&#x20AC;&#x2122;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. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

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

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.

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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

TULI12WEX2008AA

TULI12WEX2009AA

Equipment Wear close fitting clothing and safety equipment appropriate 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.

Engine - Radiator Never leave the engine run in closed spaces without ventilation and not able to evacuate toxic exhaust gases. Keep the exhaust manifold and tube free from combustion materials. 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 engine is running. Never lubricate the machine with the engine running.

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SERVICE MANUAL Engine

E485C

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Engine - Engine and crankcase

Engine - General specification Performance Maximum climbable gradient Swing speed

70% 7.8 RPM

Travel speed 3.5 km/h (2 mph) 5.6 km/h (3 mph)

Slow Fast

Engine specifications Main specifications – RUSSIAN FEDERATION – MIDDLE EAST –AFRICA Maker Model 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

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 cm³ (642 in³) 17:1 257 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 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

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 cm³ (642 in³) 17:1 257 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

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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

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Engine - Pan and covers

Engine oil pan - Component identification (P11C-UP only)

SMIL13CEX0323GA

12111 12149

Oil pan Drain cock

12151 9659C

Gasket* Gasket*

69 N·m (610.7 lb in) 31 N·m (274.4 lb in)

9191-10451

51 N·m (451.4 lb in)

*Parts not to be reused.

Tightening torque 12149 9191-08452

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Engine - Pan and covers

Engine oil pan - Component identification (P11C-UU only)

SMIL13CEX0515GA

12111 12149

Oil pan Drain cock

12151 9659C

Gasket* Gasket*

69 N·m (610.7 lb in) 31 N·m (274.4 lb in)

9191-10451

51 N·m (451.4 lb in)

*Parts not to be reused.

Tightening torque 12149 9191-08452

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Engine - Pan and covers

Engine oil pan - Remove 1.

Remove bolts and remove the oil pan. Refer to Engine oil pump - Remove (10.304).

ATTENTION: If the gasket is sticking, remove it using a scraper, etc.

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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 between the timing gear case and the cylinder block and between the flywheel housing and the cylinder block.

Replace the gasket with a new one and install the oil pan. Tightening torque : 25 NÂˇm (221.3 lb in)

ATTENTION: Wipe off oil on the oil pan and cylinder block before installation. SMIL13CEX0324AB

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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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Engine - Pan and covers

Timing gear housing - Install Installation of timing gear cover 1.

Replace the gasket and Oâ&#x20AC;&#x201C;ring with new ones and install the timing gear cover.

Tightening torque: 44 NÂˇm (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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Engine - Valve drive and gears

Camshaft gear - Component identification

SMIL13CEX0212GA

13505 13505A 13511 13523 13571 13572 13572A 13572B

Idle gear assembly Main idle gear assembly Camshaft Camshaft gear Thrust plate Thrust plate Thrust plate Thrust plate

13580 13581 13613 900116 900116A 9532-07150 9851A

*Parts not to be reused.

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Idle gear shaft assembly Idle gear shaft Supply pump drive gear Spacer Spacer Key O-ring*

Engine - Valve drive and gears

Tightening torque 900124A 900124

44 N·m (389.4 lb in) +90° +90° 108 N·m (955.9 lb in)

9019A

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137 N·m (1212.6 lb in)

Engine - Valve drive and gears

Get train layout

SMIL13CEX0213GA

(1) (2) (3) (4) (5) (6) (7) (8)

Air compressor idle gear Main idle gear (No. 1) Main idle gear (No. 2) Supply pump drive gear Oil pump drive gear Oil pump driven gear Crankshaft gear Camshaft gear

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Engine - Valve drive and gears

Camshaft - Remove 1.

Remove the push rod cover on the side of the engine.

Hold the roller tappet so that it does not fall using a special tool. Special tool : Stopper

SMIL13CEX0214AA

SMIL13CEX0215AA

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 damaged. NOTICE: Refer to the following for installation of the camshaft. Reference: Camshaft - Install (10.106).

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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 assembly of the camshaft. Reference: Camshaft - Inspect (10.106), Reference: Camshaft - Install (10.106). SMIL13CEX0216AA

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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

Standard value 56.03 mm (2.2059 in) 53.72 mm (2.1150 in) 6.63 mm (0.2610 in) 8.72 mm (0.3433 in)

IN EX IN EX

Cam height Cam lift

Operation limit 55.23 mm (2.1744 in) 52.92 mm (2.0835 in) 6.48 mm (0.2551 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

Journal Journal Journal Journal Journal Journal Journal

No. No. No. No. No. No. No.

Standard value 65.0 mm (2.5591 in) 64.6 mm (2.5433 in) 64.2 mm (2.5276 in) 63.8 mm (2.5118 in) 63.4 mm (2.4961 in) 63.0 mm (2.4803 in) 62.6 mm (2.4646 in)

1 2 3 4 5 6 7

Measure the camshaft bearing inner diameter using a cylinder gauge.

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 0.030 mm (0.0012 in) - 0.120 mm (0.0047 in)

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Repair limit 0.30 mm (0.0118 in)

Engine - Valve drive and gears

Inspection of camshaft runout 1.

Hold the camshaft with the V-block, measure the rotation 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

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Engine - Valve drive and gears

Camshaft - Install Installation of ring gear 1.

Insert the spacer and thrust plate into the camshaft.

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

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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) using calipers. If it is beyond the operation limit, replace the thrust plate.

End play Thrust plate thickness

Standard value 0.10 mm (0.0039 in) - 0.23 mm (0.0091 in) 8 mm (0.315 in)

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SMIL13CEX0221AB

SMIL13CEX0222AB

Operation limit 0.3 mm (0.0118 in) â&#x20AC;&#x201D;

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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 eccentric wear, cracks, scratches, etc. 2.

Use the special tool and secure the tappet. Special tool: Stopper

SMIL13CEX0223AA

SMIL13CEX0215AA

SMIL13CEX0214AA

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.

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)

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 gasket.

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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.

Remove the thrust plate and main idle gear at the main idle gear side.

SMIL13CEX0226AA

SMIL13CEX0227AA

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 necessary. ATTENTION: Refer to the following for installation of the timing gear. Reference: Camshaft gear - Install (10.106).

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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

Main idle gear Idle gear 2.

Shaft outer diameter Bushing inner diameter Shaft outer diameter Bushing inner diameter

Standard value 64 mm (2.520 in) 64 mm (2.520 in) 52 mm (2.047 in) 52 mm (2.047 in)

Calculate the difference between the idle gear shaft outer diameter and the idle gear bushing inner diameter. If it is beyond the operation limit, replace the idle gear shaft and the idle gear bushing.

Main idle gear Idle gear

Standard value 0.030 mm (0.0012 in) - 0.090 mm (0.0035 in) 0.030 mm (0.0012 in) - 0.090 mm (0.0035 in)

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Operation limit 0.20 mm (0.0079 in) 0.20 mm (0.0079 in)

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.

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

SMIL13CEX0230BB

Installation of idle gear 1.

Align the gear mark and install each idle gear (2) and (3). Tightening torque: Main idle gear (2) 44 NÂˇm (389.4 lb in) Idle gear (3) 108 NÂˇm (955.9 lb in)

Make sure that each backlash and end play are within the standard value after installation. "Reference: Camshaft gear - Inspect (10.106).

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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

Standard value 0.05 mm (0.0020 in) - 0.19 (0.0075 in) 0.07 mm (0.0028 in) - 0.19 (0.0075 in) 0.06 mm (0.0024 in) - 0.19 (0.0075 in) 0.07 mm (0.0028 in) - 0.19 (0.0075 in) 0.06 mm (0.0024 in) - 0.19 (0.0075 in)

Between supply pump drive gear and main idle gear (No.2) Between camshaft gear and main idle gear (No.2) Between camshaft gear and idle gear Between main idle gear (No. 2) and crankshaft gear Between oil pump drive gear and oil pump driven gear

Operation limit mm mm mm mm mm

0.30 mm (0.0118 in) 0.30 mm (0.0118 in) 0.30 mm (0.0118 in) 0.30 mm (0.0118 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

Main idle gear Idle gear

Standard value 0.065 mm (0.0026 in) - 0.149 mm (0.0059 in) 0.070 mm (0.0028 in) - 0.125 mm (0.0049 in)

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Operation limit 0.30 mm (0.0118 in) 0.30 mm (0.0118 in)