MANUAL E85CMSR Midi Excavator English April 2013 Copyright © 2013 CNH Europe Holding S.A. All Rights Reserved.
SERVICE
Part number 47516729A
E85CMSR 47516729A 05/04/2013
SER VICE MANUAL
Contents INTRODUCTION Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine and crankcase [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Air cleaners and lines Intake and exhaust manifolds and muf fler [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic systems Reservoir , cooler , and filters [35.106] V ariable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 Pump control valves Combination pump units [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 Hydraulic hand control Hydraulic foot control [35.352] Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.9 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 Hydraulic central joint 1 Boom hydraulic system [35.737] Dipper hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 [35.738] Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.14 Dozer blade cylinders Frames and ballasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper frame [39.103] Swing ring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.3 47516729A 05/04/2013
T rack frame and driving wheels
T rack tension units
T rack rollers
Cab climate control
Air conditioning
system
racks and
suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T
track
[48.100] T
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.2
racks
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [55.000] Electrical
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 Engine control system [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.302] Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 Fuel tank system Electronic modules [55.512] Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 Hydraulic system control Cab V and (HV AC) controls [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 1 [55.510] Cab platform harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12 W arning and instruments Booms, dippers, and buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [84.910] Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1 Dipper arm Bucket Dozer blade and arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10] Dozer blade Platform, cab, bodywork, and decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47516729A 05/04/2013
Electrical systems
Cab Cab interior trim and panels [90.120] Mechanically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 Machine shields and guards 16] Fenders and guards 47516729A 05/04/2013
INTRODUCTION 47516729A 05/04/2013 1
International symbols
Introduction
Although this manual uses the units Outline units system described
Given here under are excerpt the units that are related this manual :
Etymology Units
English : International system units
unit system
Derived units basic units
Derived units bearing peculiar designations T
INTRODUCTION
Construction
TULI12EXM0626AB 1 Basic units T able1 - 1 Quantities Designation Sign Length Meter m Mass Kilogram T ime Second s Current Ampere A Thermodynamic temperature Kelvin K Gram molecule Mol mol Luminous intensity Candela Supplementary units T able1 - 2 Quantities Designation Sign Plain angle Radian rad Solid angle Steradian
T able1 - 3 Quantities Designation Sign Area Square meter m 2 V olume Cubic meter m 3 V elocity Meter per second m / s Acceleration Meter per second / second m / s 2 Density Kilogram per cubic meter / m 3
4 Quantities Unit Symbol Formula Frequency Hertz 1Hz = 1 / s Force Newton N • m / s 2 Pressure and stress Pascal N / m 2 Energy , work and quantity heat Joule J N•m Power W att W J / s Quantity electricity Coulomb C A•s Electric potential dif and electromotive force V olt V W / A 47516729A 05/04/2013 3
able1 -
Quantities Unit Symbol Formula Quantity static electricity and electric capacitance Farad F C / V Electric resistance Ohm Ω V / A Celcius temperature Celcius degree degree Illuminance Lux l m / m 2 Prefixes T able1 - 5 Prefix Designation Sign Power Giga G 9 Mega M 6 Kilo k 3 Hecto h 2 Deca Deci d - 1 Centi c - 2 Milli m - 3 Micro μ - 6 Nano n - 9 Pico p - 1 2 Unit conversion table T able1 - 6 Quantities JIS Remarks Mass Force kgf N 1 kgf = N T orque kgm N•m 1 kgm = 9.807 Pressure / cm² MPa 1 / cm² = 0.09807 MPa Motive power 1PS = Revolution RPM min - 1 1 RPM = 1 min - 1 47516729A 05/04/2013 4
INTRODUCTION
Safety rules
A TTENTION: not operate perform any maintenance this machine until all instructions found the T OR’S MANUAL and this MANUAL have been thoroughly read and Improper operation maintenance this machine may cause accidents and could result serious injury
Always keep the manual missing place order with authorized our Distributor for a you have any please consult authorized our Distributor
Most which occur during are due neglect precautionary measures and safety Suf ficient care should taken avoid these Erroneous lubrication maintenance vices are very dangerous and may cause injury death Therefore all precautionary
NOTES, DANGERS, W ARNINGS and CAUTIONS contained the manual and the machine should read and understood all personnel before starting any work with the and maintenance should carefully carried and safety must given the first priority Messages safety are indicated with The safety information contained the manual intended only supplement safety insurance local rules and Messages safety appear the manual and the machine : All messages safety are identified either word "DANGER", ARNING" and "CAUTION".
Indicates imminently hazardous situation not will result death serious injury and represented follows:
Indicates a potentially hazardous situation not could result death serious injury and represented follows:
Indicates a potentially hazardous situation not may result minor moderate injury may also used alert against possible damage the machine and its components and represented follows: very dif ficult forecast every danger that may occur during However , safety can ensured fully understanding proper operating procedures for this machine according methods recommended Manufacturer While operating the sure perform work with great not damage the allow accidents occur Continue studying the manual until all Safety , Operation and Maintenance procedures are completely understood all persons working with the machine.
INTRODUCTION
47516729A 05/04/2013 5
INTRODUCTION
Safety precautions
A TTENTION: The proper and safe lubrication and maintenance for this machine, recommended Manufacturer , are outlined the OPERA T OR’S MANUAL for the Improper performance lubrication maintenance procedures are dangerous and could result injury Read and understand the MANUAL before performing any lubrication
The serviceman mechanic may unfamiliar with many the systems this This makes important use caution when performing service A knowledge the system and components important before the removal disassembly any
Because the size some the machine components, the serviceman mechanic should check the weights noted this Use proper lifting procedures when removing any
The following a list basic precautions that must always
Read and understand all W arning plates and decal the machine before Maintaining Repairing this
Always wear protective glasses and protective shoes when working around particular , wear tective glasses when using punches drifts any part the machine Use welders gloves, hood / goggles, apron and the protective clothing appropriate the welding job being performed. not wear loose fitting torn Remove all rings from loose jewelry , confine long hair and loose ing before working this machinery
Disconnect the battery and hang a Not tag the Operators Remove ignition make all repairs with the machine parked a firm level Block the machine does not roll while working under the Hang a Not tag the Operators not work any machine that supported only jacks a Always use blocks jack capable supporting the machine, before performing any disassembly .
A TTENTION: not operate this machine unless you have read and understand the instructions the
A T OR’S MANUAL. Improper machine operation dangerous and could result injury death.
Relieve all pressure air , oil water systems before any fittings related items are disconnected removed. Always make sure all raised components are blocked correctly and alert for possible pressure when disconnecting any device from a system that utilizes
Lower the dozer , other attachments the ground before performing any work the this cannot make sure the dozer , ripper other attachment blocked correctly prevent from dropping unexpectedly
Use steps and grab handles when mounting dismounting a machine. Clean any mud debris from steps, walkways work platforms before Always face the machine when using ladders and When not possible use the designed access provide scaf work platforms form safe repair
T o avoid back injury , use a hoist when lifting components which weigh 20kg (45lbs) Make sure all hooks, slings, etc., are good condition and are the correct capacity . sure hooks are positioned correctly . Lifting eyes are not side loaded during a lifting
10. T o avoid burns, alert for hot parts machines which have just been stopped and hot fluids lines, tubes and
1 careful when removing cover Gradually back f the last two capscrews nuts located opposite ends the cover device and carefully pry cover loose relieve any spring other before removing the last two capscrews nuts completely
12. careful when removing filler caps, breathers and plugs the machine. Hold a rag over the cap plug prevent being sprayed splashed liquids under The danger even greater the machine has just been stopped because fluids can
Always use the proper tools that are good condition and that are suited for the job sure you understand how use them before performing any service
Reinstall all fasteners with the same part number not use a lesser quality fastener replacements are essary
15. Repairs which require welding should performed only with the benefit the appropriate reference tion and personnel adequately trained and knowledgeable welding Determine type metal
47516729A 05/04/2013
6
being welded and select correct welding procedure and rods wire provide a weld metal strength equivalent least that the parent Make sure disconnect battery before any welding procedures are not damage wiring during removal
Reinstall the wiring not damaged nor will damaged operation the machine contacting sharp corners, rubbing against some object hot surface. not connect wiring a line containing
17. Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair a guard shield must removed perform the repair use extra caution and replace the guard shield after repair
The maintenance and repair work while holding the bucket raised dangerous due the possibility a falling fail lower the attachment and place the bucket the ground before starting the
19. Loose damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. not bend strike high pressure lines install ones which have been bent Inspect tubes and hoses carefully not check for leaks with your V ery small (pinhole) leaks can result a high velocity oil stream that will invisible close the This oil can penetrate the skin and cause personal injury Use card - board paper locate pinhole
20. T ighten connections the correct torque. Make sure that all heat shields, clamps and guards are installed rectly avoid excessive vibration rubbing against other parts during Shields that protect against oil spray onto hot exhaust components event a tube seal failure must installed correctly not operate a machine any rotating part damaged contacts any other part during Any high speed rotating component that has been damaged altered should checked for balance before
Be careful when servicing separating the tracks
Chips can fly when removing installing a track (crawlers) W ear safety glasses and long sleeve protective T racks (crawlers) can unroll very quickly when separated. Keep away from front and rear machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the Block the machine prevent from
INTRODUCTION
47516729A 05/04/2013 7
SER VICE MANUAL Engine E85CMSR 47516729A 05/04/2013
Engine - Engine and crankcase
Engine - General specification
Engine model ISUZU 4LE2X - S W ater - 4 - direct injection type diesel engine with inter T ype cooler turbo - charger Number cylinder - bore X stroke 4 - ( 3.35 ) X ( 3.78 ) T otal displacement 2179 cm³ ( 133 in³ ) Compression ratio Rated out put net ( ) / 2000 RPM Maximum torque 1 ( 156 ) / 1800 RPM High idling 2000 RPM Low idling 1000 RPM Thermostat action Start ( 180 ) / Full open ( 203 ) Firing order 1 - 3 - 4 - 2 Compression pressure 3.04 MPa ( 441 psi ) 200 RPM Fuel injection timing Electronic control type V alve clearance Open Close Intake valve ( ) cold condition ° before top dead point ° after bottom dead point V alve clearance Exhaust valve ( ) cold condition ° before top dead point ° after top dead point Starter capacity 3.2 X V Generator capacity (alternator) A X V Cooling fan drive method 475 ( ) suction type seven fans V - belt pulley ratio Crank / Fan=1.12 Full level Max: 1 1.0 l ( 2.9 gal ) , Min: 8.0 l ( 2.1 gal ) Engine oil quantity Oil pan only Max: 10.4 l ( 2.7 gal ) , Min: 7.3 l ( 1.9 gal ) Dry weight 217 ( 478 ) Fuel consumption ratio 225 g / kWh ( 225 g / kWh ) Allowable inclination Front / Rear and Right / Left: ° Dimension X W X 739 ( ) X 601 ( ) X 771 ( ) Rotating direction Counterclockwise seeing from flywheel side 47516729A 05/04/2013 10.1 [10.001] / 3
Engine characteristic curve (ISUZU 4LE2X -
Condition measured : Without fan
SMIL13CEX1871HA
Engine - Engine and crankcase
1
05/04/2013 10.1 [10.001] / 4
47516729A
Engine - Engine and crankcase
Engine - Special tools
Engine mounting pedestal
05/04/2013 10.1 [10.001] / 5
SMIL13CEX1880GA 1
47516729A
Engine - Engine and crankcase
Rear housing pedestal (17. PVC plate proved)
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SMIL13CEX1881GA 2
Engine - Engine and crankcase
Front oil pan pedestal (140X180X540)
SMIL13CEX1882F A 3
Detail front sandwich bar (70X70X400)
05/04/2013 10.1 [10.001] / 7
SMIL13CEX1883EA 4
47516729A
Engine - Engine and crankcase
SMIL13CEX1884EA 5 W oody materials Parts Qty Remarks 1 Crossbar 2 x x 925 ( ) 2 Base 2 x x 540 ( 0.0053 ) 3 Front oil pan pedestal (With notch) 1 140 x 180 x 540 ( 0.0136 ) (with notch) 4 Right prevention interference bar 1 x x 650 ( 0.0016 ) 5 Front sandwich bar 1 x x 400 ( 0.0020 ) (with notch) 6 Rear housing pedestal 1 x 140 x 540 ( 0.0060 ) (with notch) 7 Rear sandwich bar 1 x x 400 ( 0.0020 ) 8 Left prevention interference bar 1 x x 585 ( 0.0029 ) 9 Bar for stopper 1 30t x 140 x 540 Bolts, Nails, W ood screws Parts Qty Remarks 1 1 Bolt 4 dia x 255 and bottom counterbore) Bolt 2 dia x 185 and bottom counterbore) W ood screw 3.1 dia x (12 Counter sinking) Coach screw 9 dia x counterbore) Screw nail 2.2 dia x - (Drive nail connection points appropriately) Coach screw 2 9 dia x PVG plates Parts Qty Remarks PVG plate 1 x x 564 ood screw cramp) PVG plate 3 x x 130 ood screw cramp) 47516729A 05/04/2013 10.1 [10.001] / 8
Detail rear sandwich bar (70X70X400)
Engine - Engine and crankcase
Engine - Prepare
Remove battery (See Battery - Remove (55.302) )
Remove bonnet and guard. (See Machine shields and guards - Remove ) remove under cover (See Lower guards - Remove (90.1 16) )
Remove air cleaner (See Air cleaners and lines - Remove (10.202) )
Remove counterweight. (See Counterweightmove )
Remove radiator hose and inter - cooler (See Engine cooling system - Remove (10.400) )
Remove fuel hose and heater and necessary disconnect air - con
necessary , remove muf fler and radiator
Remove harness connector (Refer Electrical system - Overview (55.000) )
Remove E / G ground cable
Starter cable - starter B terminal
Upper harness
-E / G control harness
Alternator B terminal
- 136 E / G speed sensor
CN–212 Glow
Starter motor S terminal
NOTE: prepare a which withstands the weight the engine assy and can place the removed engine firmly
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Engine - Engine and crankcase Outside view engine SMIL13CEX2047F A 1 47516729A 05/04/2013 10.1 [10.001] /
Engine - Engine and crankcase
Engine - Remove
SMIL13CEX2048F A 1
Remove hose engine oil filter
Place oil pan under the connection filter (1) , and disconnect 2 hoses (4) .
T ools: Spanner
Plug connector filter side and hose
Loosen engine mounting bolt frame
Loosen 2 nuts (6) M12
T ool: Socket
Loosen 4 capscrews (12) M12 x 1
Remove 4 plates (6)
Remove upper rubber mounts (5) 4
Slinging engine body
A TTENTION: prepare a which withstands the weight the engine assy and can place the removed engine firmly
Sling engine hooking wire lifting lugs the front and rear
W eight approx 232 ( 1 )
Wire: 6 dia ( 0.236 ) x 1 m ( 3.3 ) 2 pcs
Position engine the stand stably .
10.1 [10.001] / 1 1
47516729A 05/04/2013
Engine - Engine and crankcase
Faulty starting
Poor start ability (take a long time)
Faulty engine starting / engine does not rotate
Faulty engine starting / engine rotates but exhaust gas (no fuel injection)
Faulty engine starting / exhaust gas emitted but engine does not start (with fuel injection)
Insufficient rotation
poor run - (low follow - ability)
bad condition (hunting)
Factors Fuel system Intake and exhaust system Lubrication system Cooling system T rouble 10* 1 12* 13*
Ο
Ο
Ο Ο Rotation
Poor
Engine stalled during operation. Output Ο Ο Ο Overheating O Ο Ο Other failures Exhaust smoke black Ο Ο Exhaust smoke white Ο O Ο Ο Ο Lager oil consumption (or blue exhaust gas) Ο Ο Ο Early contamination oil O Ο Ο Ο Larger fuel consumption Ο O Ο Intruding oil back flow , reduction coolant quantity Ο Ο Hydraulic pressure down (monitor lights up) Ο Ο Ο Ο Oil quantity increased (intruding water and fuel) Ο O V ibration Ο Failure injector pump) Failure oil pump Improper fuel injection time Failure relief valve Fuel leak into the head cover 10* Failure regulator valve T urbocharger oil drain tube clogged 1 Leak and crush hydraulic piping Seal turbocharger damaged 12* Damage water pump Seizing and interference turbocharger 13* Failure thermostat (Not open) Damage EGR cooler 47516729A 05/04/2013 10.1 [10.001] /
Engine
output
Faulty starting
Poor start ability (take a long time)
Faulty engine starting / engine does not rotate
Faulty engine starting / engine rotates but exhaust gas (no fuel injection)
Faulty engine starting / exhaust gas emitted but engine does not start (with fuel injection) Ο Ο
Insufficient rotation
Engine poor run - (low follow - ability) Ο Ο
Rotation bad condition (hunting)
Poor output
Lager oil consumption (or blue exhaust gas)
Engine body T rouble 10* 1
Engine - Engine and crankcase Factors
Ο
Ο
Ο
Overheating
Ο
Engine stalled during operation Ο Output lowered Ο Ο
Ο
Ο Ο
Ο Ο Ο
Other failures Exhaust smoke black
Exhaust smoke white Ο
Ο Ο Ο Ο Ο
Ο Ο
Ο
coolant,
quantity Ο Ο Ο Ο
Early contamination oil
Larger fuel consumption
Intruding oil
back flow , reduction coolant
Ο Oil quantity increased (intruding water
Ο Ο Ο Ο V ibration Ο Ο Damage engine oil cooler core
O
ring W ear piston
,
stick Strainer damage oil pipe Hole due cavitation Damage cylinder head and head gasket W ear and damage rear oil seal and seal surface Failure injection holder sleeve 10* Damage dumper W ear and failure valve and valve guide 1 Damage flywheel gear Damage and seizing piston and connecting rod 47516729A 05/04/2013 10.1 [10.001] /
Hydraulic pressure down (monitor lights up)
and fuel)
and
-
ring and liner
ring
Fuel tank - Prepare
Draining
Unlock cap (B1) with a starter key and open Loosen valve (A14) under the Draining fuel Capacity tank: 120 l ( gal )
Remove panel assy
Remove the connector for fuel level sensor (A5)
Remove fuel
Loosen clip (21) and draw out hoses (14) and (9)
Put plugs that match the hose
Remove drain hose (A8)
Loosen clip (A10) and draw out hose (A8)
- Fuel tanks
Engine
SMIL13CEX2471BA 1 SMIL13CEX2472BA 2 47516729A 05/04/2013 10.2 [10.216] / 3
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