CNH E805 Tier 3 User manual

Printed in France

CNH Lep 9-42691EN September 2006

E805 Tier 3 Crawler Excavators

Table of Contents

DIVISION/SECTION SECTION NqREFERENCE Nq

1 GENERAL INFORMATION

Safety, general information and standard torque data .....................................1001 7-27691EN

General specifications and special torque setting............................................1002 9-94710EN

2ENGINE

Radiator and engine, removal and installation .................................................2001 9-94910EN

Engine specifications ............................................................................................. *

Disassembly and assembly of the engine.............................................................. *

3 FUEL SYSTEM

Fuel tank ..........................................................................................................3001 9-36821EN

Fuel engine system................................................................................................ *

4 ELECTRICAL SYSTEM

Electrical system, electrical and electronic troubleshooting.............................4001 9-94700EN

Inspection and maintenance of batteries and connecting a booster battery....4002 9-36830EN

Main and engine electronic control boxes........................................................4003 9-94510EN

5 UNDERCARRIAGE

Removal and installation of tracks ...................................................................5001 9-36860EN

Rollers..............................................................................................................5003 9-36881EN

Sprocket ...........................................................................................................5004 9-36890EN

Idler wheel and tension shock absorber ..........................................................5005 9-94350EN

6 DRIVE TRAIN

Drive motor and final drive transmission removal and installation ...................6001 9-36980EN

Drive motor and final drive transmission disassembly and assembly ..............6002 9-40351EN

Swing reduction gear, removal and installation................................................6003 9-36991EN

Swing reduction gear, disassembly and assembly...........................................6004 9-42631EN

7 UNDERCARRIAGE HYDRAULICS

8 UPPERSTRUCTURE HYDRAULICS

Depressurising and decontaminating the hydraulic system, use of the

vacuum pump and bleeding the components ..............................................8000 9-94430EN

Specifications, troubleshooting, checks and hydraulic pressure settings.........8001 9-94740EN

Hydraulic reservoir removal and installation ....................................................8002 9-94490EN

Main and pilot pumps, removal and installation ...............................................8003 9-40771EN

Main hydraulic control valve, removal and installation .....................................8004 9-94501EN

Attachment cylinders, removal and installation ................................................8005 7-27792EN

Hydraulic swivel, removal and installation........................................................8006 9-94600EN

Pilot blocs, removal and installation .................................................................8007 9-94520EN

Swing motor, removal and installation..............................................................8008 9-94420EN

Main hydraulic pump, disassembly and assembly ...........................................8010 9-94590EN

Main hydraulic control valve, disassembly and assembly ................................8011 9-94781EN

Attachment cylinders, disassembly and assembly...........................................8012 9-40941EN

Hand control levers, disassembly and assembly .............................................8013 9-94630EN

Foot control levers, disassembly and assembly...............................................8014 9-40992EN

Six-solenoid valves, disassembly and assembly..............................................8015 9-42521EN

Caution valve, disassembly and assembly.......................................................8016 9-94531EN

Safety valve......................................................................................................8017 9-42770EN

Hydraulic swivel, disassembly and assembly...................................................8018 9-42511EN

Swing motor, disassembly and assembly ........................................................8019 9-42530EN

Hydraulic functions...........................................................................................8020 9-94720EN

Lep 9-42691EN Edition 09-06

DIVISION/SECTION SECTION N° REFERENCE N°

Fan motor, removal and installation .................................................................8022 9-94660EN

Fan motor, disassembly and assembly ............................................................8023 9-94670EN

Fan pump, removal, disassembly, assembly and installation ...........................8024 9-94680EN

Hydraulic component functions........................................................................8030 9-94130EN

9 UPPERSTRUCTURE

Upperstructure, turntable and counterweight...................................................9002 9-42551EN

Boom, dipper and bucket .................................................................................9003 9-42621EN

Seat and seat belt ............................................................................................9004 9-40960EN

Cab and cab equipment...................................................................................9005 9-94650EN

Air conditioning troubleshooting.......................................................................9006 7-xxxxxFR

Air conditioning unit disassembly and assembly..............................................9007 9-94640EN

Air conditioning servicing .................................................................................9008 7-xxxxxFR

Air conditioning components............................................................................9009 7-xxxxxFR

Removal and installation attachment, counterweight and side fram ................9010 9-94730EN

Large format hydraulic schematic .................................................................Pocket 87520431

Large format electrical schematic ................................................................. Pocket 9-93930

* Consult the Engine Service Manual

Sections to be distributed at a later date

NOTE: CNH Company reserves the right to make changes in the specifi-

cation and design of the machine without prior notice and without incur-

ring any obligation to modify units previously sold.

The description of the models shown in this manual has been made in

accordance with the technical specifications known as of the date of

design of this document.

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CNH

Printed in France

June 2006

Lep 9-94880EN

1001

SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS

Section

1001

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1001-2

Lep 9-94880EN Issued 06-06

TABLE OF CONTENTS

GENERAL INFORMATION .......................................................................................................................................3

SAFETY.....................................................................................................................................................................4

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6

WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see

this symbol, carefully read the message that follows, as there is a risk of serious injury.

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1001-3

Lep 9-94880EN Issued 06-06

GENERAL INFORMATION

Cleanning

Clean all metal parts except bearings, in a suitable

cleaning solvent or by steam cleaning. Do not use

caustic soda for steam cleaning. After cleaning, dry

and put oil on all parts. Clean oil passages with

compressed air. Clean bearings in a suitable cleaning

solvent, dry the bearings completely and put oil on

the bearings.

Inspection

Check all parts when the parts are disassembled.

Replace all parts that have wear or damage. Small

scoring or grooves can be removed with a hone or

crocus cloth. Complete a visual inspection for

indications of wear, pitting and the replacement of

parts necessary to prevent early failures.

Bearings

Check bearings for easy action. If bearings have a

loose fit or rough action replace the bearing. Wash

bearings with a suitable cleaning solvent and permit

to air dry. DO NOT DRY BEARINGS WITH

COMPRESSED AIR.

Needle bearings

Before you press needle bearings in a bore always

remove any metal protrusions in the bore or edge of

the bore. Before you press bearings into position put

petroleum jelly on the inside and outside diameter of

the bearings.

Gears

Check all gears for wear and damage. Replace gears

that have wear or damage.

Oil seals, O-rings and gaskets

Always install new oil seals, O-rings and gaskets. Put

petroleum jelly on seals and O-rings.

Shafts

Check all shafts that have wear or damage. Check

the bearing and oil seal surfaces of the shafts for

damage.

Service parts

Always install genuine NEW HOLLAND service parts.

When ordering refer to the Parts Catalog for the

correct part number of the genuine NEW HOLLAND

replacement items. Failures due to the use of other

than genuine NEW HOLLAND replacement parts are

not covered by warranty.

Lubrication

Only use the oils and lubricants specified in the

Operator’s or Service Manuals. Failures due to the

use of non-specified oils and lubricants are not

covered by warranty.

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1001-4

Lep 9-94880EN Issued 06-06

SAFETY

This symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED. The message that follows the

symbol contains important information about safety. Carefully

read the message. Make sure you fully understand the

causes of possible injury or death.

To prevent injury always follow the Warning, Caution

and Danger notes in this section and throughout the

manual.

Put the warning tag shown below on the key for the

keyswitch when servicing or repairing the machine.

One warning tag is supplied with each machine.

Additional tags Part Number 331-4614 are available

from your service parts supplier

WARNING: Read the operator’s manual to

familiarize yourself with the correct control

functions.

WARNING: Operate the machine and

equipment controls from the seat position

only. Any other method could result in

serious injury.

WARNING: This is a one man machine, no

riders allowed.

WARNING: Before starting engine, study

Operator’s Manual safety messages. Read

all safety signs on machine. Clear the area of

other persons. Learn and practice safe use

of controls before operating.

It is your responsibility to understand and

follow manufacturers instructions on

machine operation, service and to observe

pertinent laws and regulations. Operator’s

and Service Manuals may be obtained from

your NEW HOLLAND dealer.

WARNING: If you wear clothing that is too

loose or do not use the correct safety

equipment for your job, you can be injured.

Always wear clothing that will not catch on

objects. Extra safety equipment that can be

required includes hard hat, safety shoes, ear

protection, eye or face protection, heavy

gloves and reflector clothing.

WARNING: When working in the area of the

fan belt with the engine running, avoid loose

clothing if possible, and use extreme caution.

WARNING: When doing checks and tests

on the equipment hydraulics, follow the

procedures as they are written. DO NOT

change the procedure.

WARNING: When putting the hydraulic

cylinders on this machine through the

necessary cycles to check operation or to

remove air from a circuit, make sure all

people are out of the way.

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1001-5

Lep 9-94880EN Issued 06-06

WARNING: Use insulated gloves or mittens

when working with hot parts.

WARNING: Lower all attachments to the

ground or use stands to safely support the

attachments before you do any maintenance

or service.

WARNING: Pin sized and smaller streams

of hydraulic oil under pressure can penetrate

the skin and result in serious infection. If

hydraulic oil under pressure does penetrate

the skin, seek medical treatment

immediately. Maintain all hoses and tubes in

good condition. Make sure all connections

are tight. Make a replacement of any tube or

hose that is damaged or thought to be

damaged. DO NOT use your hand to check

for leaks, use a piece of cardboard or wood.

WARNING: When removing hardened pins

such as a pivot pin, or a hardened shaft, use

a soft head (brass or bronze) hammer or use

a driver made from brass or bronze and a

steel head hammer.

WARNING: When using a hammer to

remove and install pivot pins or separate

parts using compressed air or using a

grinder, wear eye protection that completely

encloses the eyes (approved goggles or

other approved eye protectors).

WARNING: Use suitable floor (service)

jacks or chain hoist to raise wheels or tracks

off the floor. Always block machine in place

with suitable safety stands.

WARNING: When servicing or repairing the

machine, keep the shop floor and operator’s

compartment and steps free of oil, water,

grease, tools, etc. Use an oil absorbing

material and/or shop cloths as required. Use

safe practices at all times.

WARNING: Some components of this

machine are very heavy. Use suitable lifting

equipment or additional help as instructed in

this Service Manual.

WARNING: Engine exhaust fumes can

cause death. If it is necessary to start the

engine in a closed place, remove the exhaust

fumes from the area with an exhaust pipe

extension. Open the doors and get outside

air into the area.

WARNING: When the battery electrolyte is

frozen, the battery can explode if (1), you try

to charge the battery, or (2), you try to jump

start and run the engine. To prevent the

battery electrolyte from freezing, try to keep

the battery at full charge. If you do not follow

these instructions, you or others in the area

can be injured.

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1001-6

Lep 9-94880EN Issued 06-06

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Tightening of cap screws, nuts

Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the

order of tightening.

JS00481A

Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or

suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then

tighten.

Torque table

Tighten cap screws and nuts according to the table below if there are no other special instructions.

Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20

Cap Screw

Spanner

[mm] 10 13 17 19 22 24 27 30

[in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18

Tightening

torque

[Nm] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2

[lb-ft] 5.1 14.5 28.9 43.4 72.3 115.7 144.6 217

Socket

Head Cap

Screw

Spanner

[mm] 5 6 8101214 1417

[in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67

Tightening

torque

[Nm] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2

[lb-ft] 6.5 15.9 31.1 57.9 86.9 130.2 181 253.2

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CNH

Printed in France

June 2006

Lep 9-94870EN

1002

SPECIFICATIONS

AND SPECIAL TORQUE SETTINGS

Section

1002

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1002-2

Lep 9-94870EN Issued 06-06

TABLE OF CONTENTS

TYPE, SERIAL NUMBER

AND YEAR OF MANUFACTURE OF THE MACHINE..............................................................................................3

FLUIDS AND LUBRICANTS .....................................................................................................................................4

SPECIFICATIONS.....................................................................................................................................................8

COMPONENT WEIGHT..........................................................................................................................................16

DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY ...........................................................................18

DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..........................................................23

SHIMS FOR ADJUSTING ATTACHMENT GAPS...................................................................................................28

SPECIAL TORQUE SETTINGS ..............................................................................................................................29

MACHINE OVERALL DIMENSIONS.......................................................................................................................32