New Holland E485C User manual

CONSTRUCTION
SERVICE MANUAL
E485C
Hino Diesel Engine
Supplement to Service Manual 84557350A
Print no. 84561180A
1st Edition
English 12/11

WARNING
Read this manual before operating the machine
Most accidents occurring during work are due to non-observance of simple safety norms and elementary
precautions.
Many accidents can be avoided if the causes are known and opportune cautions taken beforehand.
There is no device or protection, no matter how advanced, that may prove so effective at avoiding accidents
as a careful and attentive behaviour.
COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A.
Product Support
Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY
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E485C
ENGINE
(HINO DIESEL ENGINE P11C-VC)
CONTENTS
Group 1 General ........................................................................................ W5-1
Group 2 Standard Value ............................................................................. W5-2
Group 3 Parts to be prepared .................................................................... W5-3
Group 4 Engine mounting/dismounting ...................................................... W5-4
Group 5 Fuel System ................................................................................. W5-5
Group 6 Emission Control .......................................................................... W5-6
Group 7 Electrical........................................................................................ W5-7
Group 8 Intake ............................................................................................ W5-8
Group 9 Engine Mechanical ....................................................................... W5-9
Group 10 Exhaust ...................................................................................... W5-10
Group 11 Cooling ........................................................................................W5-11
Group 12 Lubrication .................................................................................. W5-12
Group 13 Starting and Charging ................................................................ W5-13
Group 14 Turbocharger .............................................................................. W5-14
Group 15 Failure Diagnosis for each Engine Status .................................. W5-15
Group 16 Engine Diagnosis Code .............................................................. W5-16
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GENERAL E485C
W5-1-1
ENGINE
1 GENERAL
GeneralGeneral information
Warning................................................................... 1-2
How to read this manual ......................................... 1-3
Precautions for work ............................................... 1-7
Tightening of engine bolts and nuts...................... 1-11
Tightening of flare nuts and hoses........................ 1-13
Taper thread sealant for piping ............................. 1-14
Assembly of joints and gaskets for piping............. 1-15
Handling of liquid gasket....................................... 1-17
Failure diagnosis table for each problem .............. 1-18
Failure diagnosis procedures................................ 1-19
Failure diagnosis using Hino DX........................... 1-21
Connection method of Hino DX ............................ 1-24
Engine number...................................................... 1-25
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GENERALE485C
W5-1-2
Warning
JP30ZDE010102001
Observe the following precautions to work safely and to prevent damage to customers’ vehicles.
This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the machine, but also put service
engineers and surrounding people in danger.
•Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
machine. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
•Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
•If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of machine
may be impaired. Never use a method or tool not recommended.
•This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
during service or repair, or that damage to machine due to improper method may not impair safety and reliability
of machine. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
“Caution” are not absolute for safety.
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GENERAL E485C
W5-1-3
How to read this manual
JP30ZDE010102002
1. Scope of repair work
(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly⋅disassembly and inspection⋅adjustment" and "Final inspection".
(2) This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,
assembly⋅disassembly and inspection⋅adjustment" in the second process. Explanation of "Final inspection"
in the third process is omitted here.
(3) Although the following work is not described in this manual, it should be performed in actual work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual inspection
2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.
3. Items to be prepared
(1) Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually
equipped in general service shop are omitted.
4. How to read sections and titles
(1) Sections are classified according to J2008, SAE standard.
(2) For areas that show system names like "Engine control system", "Inspection", "Adjustment",
"Replacement", "Overhaul", etc. of components are described.
(3) For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.
(4) Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in
the illustration. Major names and tightening torque are listed in the table.)
! CAUTION
•The part layouts in this manual are inserted based on illustrations and part numbers of the
parts catalog CD-ROM issued in November, 2010. (Some areas do not show exploded view.
They will be additionally issued when the parts catalog CD is revised.) Be sure to use the
parts catalog for confirmation of illustrations and part numbers and for ordering parts.
•The parts layout drawings for the cylinder head are based on the illustrations of the parts
catalog issued in March 2011.
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GENERALE485C
W5-1-4
5. How to read troubleshooting
(1) Failure diagnosis in this manual describes Step 2 and Step 3 below:
(2) Pre-inspection
(1) Question "Step 1" Hear from customers for conditions and environments of
failures and check the fact.
(2) Pre-inspection
(3) Reproduction method "Step 2"
Perform diagnosis inspection, status inspection,
function inspection and basic inspection. Check the
failure status. If it is difficult to reproduce the problem
with status inspection, use the reproduction method.
(4) Troubleshooting for each
diagnosis code
(5) Troubleshooting for each
failure status
"Step 3"
Summarize inspection results obtained from Step 2.
Perform inspection systematically according to
troubleshooting procedures for each diagnosis code or
failure status.
(6) Confirmation test "Step 4"
Check if failure occurs again after repair. If it is difficult to
reproduce a failure, perform the confirmation test under
the conditions and environment of the failure.
Pre-
inspection
•Pre-inspection is performed in the following steps:
Diagnosis inspection →Diagnosis deletion →Failure status check (Use the reproduction
method if not reproduced.) →Diagnosis reconfirmation
•Estimate the failure system before the reproduction test. Attach a tester and evaluate
estimated failure together with failure status. Refer to the troubleshooting chart for
estimated cause of a failure.
•An error code is displayed if a failure occurs instantaneously. If any specific failure is not
found, perform troubleshooting using the reproduction method.
•Failure status check
If failure is reproduced, perform Step 2 →Step 3 →Step 4.
If failure is not reproduced, use the reproduction method (simulation of external
conditions or check of each wire harness and connector, etc.)
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GENERAL E485C
W5-1-5
6. How to read explanation details
(1) Part layout
It is the ID number for parts to prepare electronic data. It is not required for repair work.
SAPH30ZDE0100001
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GENERALE485C
W5-1-6
7. Definition of terms
Terms in this manual are defined as follows :
(1) Direction
a. Individual unit.
Front/back direction.
The power input side is front and the output side is back.
Rotating direction.
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is
left rotation.
Vertical direction.
With a unit mounted on the vehicle (chassis), the upward direction is upper and the downward direction
is lower.
Left/right direction.
When viewed from the rear, the left direction is left and the right direction is right.
(2) Standard value ⋅⋅⋅⋅⋅⋅⋅Basic dimension excluding tolerance and clearance generated by tolerances when two
parts are joined.
(3) Repair limit⋅⋅⋅It is the value requiring repair. Symbol of + or - with the value means increase or decrease to
the standard value.
(4) Operation limit⋅⋅⋅It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
(5) Warning⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that may result in risk of human life or serious injury by incorrect handling.
(6) Caution⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that should not be performed including inhibited work or an item that require
attention in working procedures.
(7) Reference⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is supplementary explanation in work.
8. Unit
(1) SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
(2) This manual shows both the SI unit and conventional units. The conventional units are shown in { }.
*1 : X means the value when 1 [Conventional unit] is converted to the SI unit. It is used as the
conversion factor from the conventional unit to the SI unit.
*2 : The conversion value of the torque may vary depending on the unit. Observe the standard
values described for each unit.
Item SI unit Conventional
unit
Conversion value*1
(1[Conventional unit] = X [SI unit])
Force N kgf 1kgf=9.80665N
Torque*2 N⋅mkgf⋅cm 1kgf⋅cm=0.0980665N⋅m
Pressure Pa kgf/cm21kgf/cm2=98.0665kPa=0.0980665MPa
mmHg 1mmHg=0.133322kPa
Rotational speed r/min rpm 1rpm=1r/min
min-1 1rpm=1min-1
Spring constant N/mm kgf/mm 1kgf/mm=980665N/mm
Volume L cc 1cc=1mL
Efficiency W PS 1PS=0.735499kW
Calorific value W⇒H cal 1kcal=1.13279W⇒h
Fuel consumption rate g/W⇒hg/PS⇒h1g/PS⇒h=1.3596g/kW⇒h
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GENERAL E485C
W5-1-7
Safety information
Precautions for work
JP30ZDE010101001
1. General precautions
To ensure safety in work and to prevent accidents, observe the following items:
(1) Appearance
a. Wear safety goggles.
b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
c. Bind long hair at the back.
d. Be sure to wear a cap and safety shoes.
(2) Safety work
a. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during
operation of the engine.
c. Remove the starter key when the engine is not started.
d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.
e. Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the
area.
f. Since the battery fluid is poisonous and corrosive, be careful for handling.
g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may occur.
h. If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
i. To tow a failure vehicle, refer to “Towing or being towed” in the "Operation manual" of the vehicle.
2. Precautions for service work
Pay attention to the following points before service work
(1) Preparation before disassembly
a. Prepare general tools, special tools and gauges before work.
b. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected
to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the
battery before work.
c. Perform inspection according to the procedure in the text before disassembly.
(2) Inspection during disassembly
Every time parts are removed, check the area where the parts are assembled and check for deformation,
damage, wear or scratch.
(3) Arrangement of disassembled parts
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.
(4) Washing of disassembled parts
Clean and wash parts to be reused well.
(5) Inspection and measurement
Inspect and measure parts to be reused as required.
(6) Assembly
a. Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct
parts in the correct order.
b. Be sure to use genuine parts for parts to be replaced.
c. Use new packing, gasket, O–ring and cotter pins.
d. Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas
where application of oil is required, and apply specified grease to the oil seal lip before assembly.
(7) Check of adjustment
Make adjustments to the service standard values using a gauge or tester.

GENERALE485C
W5-1-8
3. Precautions for electric system
(1) Removal of battery cable
a. In an electric system, remove the cable from the battery
minus (-) terminal to prevent burnout due to short -
circuit.
b. When the battery cable is removed, the battery terminal
may be damaged. Loosen the nut completely and never
pry it for removal.
c. If you remove the nut, always re-tighten the nut by
10N⋅m {102kgf⋅cm, 7lbf⋅ft}.
(2) Handling of electronic parts
a. Do not give impact on electronic parts such as
computer and relay.
b. Do not place electronic parts at a high temperature and
humidity area.
c. Do not expose electronic parts to water in washing of a
vehicle.
(3) Handling of wire harness
a. Mark clamps and clips to prevent interference of a wire
harness with body edge, sharp edge and bolts. Be sure
to reassemble it to the original position.
b. When parts are assembled, be careful not to pinch a
wire harness.
Loosen
SAPH30ZDE0100002
SAPH30ZDE0100003
SAPH30ZDE0100004

GENERAL E485C
W5-1-9
(4) Handling of connector
a. When a connector is removed, hold the connector (as
shown by the arrow in the left figure) and pull it out. Do
not pull the wire harness.
b. Unlock the locking connector before pulling.
c. Insert the locking connector completely until it clicks.
d. To insert a test lead into the connector, insert it from the
back of the connector.
e. If it is difficult to insert a test lead from the back of the
connector, prepare a harness for inspection.
SAPH30ZDE0100005

GENERALE485C
W5-1-10
4. Precautions for electric welding
Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding
circuit, resulting in damage to electric and electronic parts. Observe the following items for electric
welding.
(1) Turn "OFF" the starter switch.
(2) Make sure that switches are "OFF".
(3) Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.
(4) Disconnect connectors of each computer.
(5) Remove all fuses. (For locations of fuses, refer to "Electrical Chapter".)
(6) Be sure to connect grounding of the electric welding machine near the welding area.
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
Remove paint of the frame for connection of grounding from the frame.
(7) Other precautions
a. Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they
may not be exposed to spatter.
b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also
maintain welding quality.
(8) After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same
color.
(9) After reassembly, check the function if it operates correctly.
General information

GENERAL E485C
W5-1-11
Tightening of engine bolts and nuts
JP30ZDE010102003
1. Tightening torque of general standard bolts
(1) For bolts with seatings
Unit : N⋅m{kgf⋅cm, lbf⋅ft}
! CAUTION
•8T bolt is in accordance with 7T bolt.
(2) For bolts with washers
Unit : N⋅m{kgf⋅cm, lbf⋅ft}
! CAUTION
•8T bolt is in accordance with 7T bolt.
Screw diameter x Pitch 7T 9T
M8 x 1.25 (Coarse thread) 28.5 {290, 21} 36 {370, 27}
M10 x 1.25 (Fine thread) 60 {610, 44} 74.5 {760, 55}
M10 x 1.5 (Coarse thread) 55 {560, 41} 68.5 {700, 51}
M12 x 1.25 (Fine thread) 108 {1, 100, 80} 136 {1, 390, 101}
M12 x 1.75 (Coarse thread) 97 {990, 72} 125 {1, 280, 93}
M14 x 1.5 (Fine thread) 171.5 {1, 750, 127} 216 {2, 210, 160}
M14 x 2 (Coarse thread) 154 {1, 570, 114} 199 {2, 030, 147}
Remark Bolt with number “7” on the head Bolt with number “9” on the head
Screw diameter x Pitch 4T 7T 9T
M6 x 1 (Coarse thread) 6 {60, 4} 10 {100, 7} 13 {130, 9}
M8 x 1.25 (Coarse thread) 14 {140, 10} 25 {250, 18} 31 {320, 23}
M10 x 1.25 (Fine thread) 29 {300, 22} 51 {520, 38} 64 {650, 47}
M10 x 1.5 (Coarse thread) 26 {270, 20} 47 {480, 35} 59 {600, 43}
M12 x 1.25 (Fine thread) 54 {550, 40} 93 {950, 69} 118 {1,200, 88}
M12 x 1.75 (Coarse thread) 49 {500, 36} 83 {850, 61} 108 {1,100, 80}
M14 x 1.5 (Fine thread) 83 {850, 61} 147 {1,500, 108} 186 {1,900, 137}
M14 x 2 (Coarse thread) 74 {750, 54} 132 {1,350, 98} 172 {1,750, 127}
Remark
Bolt with number “4”
on the head
Projection bolt Stud
with R surface at free
end
Bolt with number ”7”
on the head Stud with C
surface at free end
Bolt with number “9”
on the head
R surface (4T) C surface (7T)
SAPH30ZDE0100006

GENERALE485C
W5-1-12
2. Precoated bolt
Precoated bolt is the bolt with application of seal lock
agent at the thread.
(1) When re-application of lock agent is required
a. When precoated bolts are removed
b. When precoated bolts are moved due to tightening
check (for loosening or tightening)
N
OTICE
•Check torque with the lower limit of the
tightening torque allowable value. If
movement is found, tighten the bolt
according to the procedure below.
(2) Re-use method of precoated bolt lock
a. Clean bolt and screw holes. (Clean screw holes for
replacement.)
b. Dry completely by blowing air.
c. Apply the specified seal lock agent to the thread of the
bolt.
3. Plastic region tightening method (angle method)
(1) Precautions
Some engines are tightened with the plastic region
tightening method.
Since it is different from the conventional method, tighten
it according to the instruction in the text.
(2) Parts tightened
Cylinder head bolt, crankshaft main bearing cap bolt,
connecting rod bearing cap bolt, etc.
!CAUTION
•Measure the overall length of the bolt before
assembly and replace the bolt if the length
exceeds the operation limit.
Apply engine oil to bolt seating and bolt
thread in assembly.
(3) Tightening method after tightening to seating torque
Tightening of 90°, 135° (90° once and 45° once) and 180°
(90° twice) is available.
Seal Lock Agent
SAPH30ZDE0100007
One turn by 90°
Tighten it 90°
SAPH30ZDE0100008
One turn by 90°
One turn by 45°
Tighten it 90°
(First time)
Tighten it 45°
(Second time)
SAPH30ZDE0100009
Two turns by 90°
Tighten it 90°
(First time)
Tighten it 90°
(Second time)
SAPH30ZDE0100010

GENERAL E485C
W5-1-13
Tightening of flare nuts and hoses
JP30ZDE010102004
1. Tightening torque of pipe flare nut
Unit : N⋅m{kgf⋅cm, lbf⋅ft}
2. Tightening torque of hoses
Unit : N⋅m{kgf⋅cm, lbf⋅ft}
3. Lock nut tightening torque of brass joint
Unit : N⋅m{kgf⋅cm , lbf⋅ft}
Pipe outer
diameter φ4.76 φ6.35 φ8φ10 φ12 φ15
Tightening
torque
15±5
{153±50,
11±3.6}
21±1
{214±10,
15±0.7}
32±3
{326±31,
24±2.2}
44±5
{449±51,
32±3.6}
64±5
{653±51,
47±3.6}
66±2.5
{673±25,
47±1.8}
Type Hose outer diameter
φ10.5 fitting
Hose outer diameter
φ13, φ20, φ22, fitting at
packing
Hose outer diameter
PF3/8 fitting
Air hose
21.5±1.5 {215±15, 15±1}
46±2.5 {469±25, 33±1.8} —
Only meter gauge
10 {100, 7}
Brake hose Packing
51.5±7.5 {525±75, 15±1} 46±2.5 {469±25, 33±1.8} —
Screw nominal
size M14M16M20M22M24
Tightening
torque
48±10
{489±102,
35±7}
66±13
{673±204,
47±14}
120±36
{1,224±367,
89±26}
130±30
{1,326±306,
96±22}
150±30
{1,530±306,
110±22}

GENERALE485C
W5-1-14
Taper thread sealant for piping
JP30ZDE010102005
The taper thread of the air pipe joint has application of sealant
[Loctite # 575 (by Japan Loctite)]. Follow the procedures below for
connection or disconnection of pipes.
1. For disconnection
(1) The sealant (# Loctite 575) has strong sealing feature.
The return torque of the taper joint is increased about 1.5
times the initial tightening torque. When the joint is
disconnected, use a long wrench for disconnection.
(2) When a joint at a poorly accessible area is replaced,
remove accessories first and disconnect the joint.
2. For connection
(1) For application of sealant (# Loctite 575), wipe the sealing
area completely with a rag or thinner. Apply sealant
directly to about three ridges for quarter round with offset
of one ridge from the end. Tighten it according to the
tightening torque in the table below.
Remove dirt completely from the mating part (female)
before tightening.
!CAUTION
•If your eye or skin comes in contact with
sealant, wash it off immediately with water.
Tightening torque of taper joint Unit : N⋅m{kgf⋅cm, lbf⋅ft}
(2) When a sealing tape is replaced with sealant, remove the
tape completely first as in (1).
!CAUTION
•Be careful to prevent entry of dirt or foreign
matter in the pipe.
(3) If air leak is found after assembly with application of
sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and
(2).
Removal of joint (Example: Use of magnetic valve)
Magnetic valve
Frame
Air pipe (Flare joint)
(No application of sealant)
Since sealant is
applied to this
area, remove
accessories with
the joint attached
Air hose
SAPH30ZDE0100011
1/4 turn Amount of application: 0.1 g/piece
3 threads
1 thread
SAPH30ZDE0100012
Material Screw diameter
1/4 3/8 1/2
Steel
49±10
{500±100,
36±7}
64±15
{650±150,
47±10}
Aluminum
or brass
25±5
{250±50,
18±3}
34±5
{350±50,
25±3}
44±5
{450±50,
32±3}

GENERAL E485C
W5-1-15
Assembly of joints and gaskets for piping
JP30ZDE010102006
1. Tightening torque of joints
Unit : N⋅m{kgf⋅cm, lbf⋅ft}
2. Joint assembly procedure and subsequent inspection
(1) Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,
gasket, etc.).
(2) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten
pipes finally after temporary tightening to prevent leak.
(3) After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
(4) Observe the values above for each tightening torque.
*When assembled soft washer #4840FR-N (aluminum and rubber carbon pressure bonding) is loosened
or removed, be sure to replace it with a new part. This is not necessary for normal retightening.
Screw size
Sealing method
Gasket sealing method
(Aluminum + Rubber or Copper)
Metal sealing method
(Flare pipe type, nipple connector type)
Type A Type B
M8 13 {130, 9}
M10 20 {200, 14} 11 {110, 8}
M12 25 {250, 18} 20 {200, 14}
M14 25 {250, 18} 31 {320, 23}
M16 29 {300, 22} 39 {400, 29}
M18 39 {400, 29} 59 {600, 43}
M20 *39 {400, 29} 64 {650, 47} 20 {200, 14}
M24 69 {700, 51}
M28 *127 {1,300, 94}

GENERALE485C
W5-1-16
3. Examples of joint methods in various pipes
Gasket sealing method
Metal sealing method
Type A
(Flare pipe type)
Type B
(Nipple connector type)
Joint bolt
Gasket
Sealing surface
: 4 places
One piece eye joint
with sleeve
Gasket
Flare pipe
Connector
Flare nut
Joint bolt
Gasket
Gasket Sealing surface
: 5 places
Sealing surface: 3 places
Nut
Connector nipple
Flare connector
Gasket
Sealing surface: 5 places
Joint bolt
Sealing surface
: 8 places
Lock washer
Nut
Bracket
Sealing surface: 1 place
Nut
Connector nipple
Sealing surface: 1 place
Flare connector
Box nut
Sealing surface
: 8 places
Joint pipe
Nut Lock washer
3-way joint
Bracket
Sealing surface
: 3 places
One piece eye joint without sleeve
Joint bolt
Sealing surface: 4 places
Joint bolt
Joint pipe
Sealing surface: 6 places