New Holland E305C EVO User manual

SERVICE MANUAL
E305C EVO
Crawler Excavator
Part number 48034225
English
June 2016
© 2016 CNH Industrial Italia S.p.A. All Rights Reserved.
SERVICE
MANUAL
1/2
Part number 48034225
E305C EVO
Crawler Excavator

SERVICEMANUAL
E305CEVOCrawlerexcavatorsLCversion(TIER3)-LATAMMarket
4803422523/06/2016
EN
Find manuals at https://best-manuals.com

Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.102]Panandcovers....................................................................10.2
[10.106]Valvedriveandgears..............................................................10.3
[10.101]Cylinderheads.....................................................................10.4
[10.105]Connectingrodsandpistons.......................................................10.5
[10.103]Crankshaftandywheel............................................................10.6
[10.216]Fueltanks..........................................................................10.7
[10.206]Fuellters..........................................................................10.8
[10.218]Fuelinjectionsystem...............................................................10.9
[10.250]Turbochargerandlines...........................................................10.10
[10.254]Intakeandexhaustmanifoldsandmufer.......................................10.11
[10.501]ExhaustGasRecirculation(EGR)exhausttreatment............................10.12
[10.400]Enginecoolingsystem...........................................................10.13
[10.414]Fananddrive....................................................................10.14
[10.310]Aftercooler........................................................................10.15
[10.304]Enginelubricationsystem........................................................10.16
[10.408]Oilcoolerandlines...............................................................10.17
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.300]Reservoir,cooler,andlters........................................................35.2
[35.104]Fixeddisplacementpump..........................................................35.3
[35.106]Variabledisplacementpump.......................................................35.4
[35.102]Pumpcontrolvalves................................................................35.5
[35.359]Maincontrolvalve..................................................................35.6
[35.357]Pilotsystem........................................................................35.7
4803422523/06/2016
Find manuals at https://best-manuals.com

[35.355]Hydraulichandcontrol.............................................................35.8
[35.356]Hydraulicfootcontrol...............................................................35.9
[35.352]Hydraulicswingsystem..........................................................35.10
[35.353]Hydraulictravelsystem..........................................................35.11
[35.354]Hydrauliccentraljoint............................................................35.12
[35.736]Boomhydraulicsystem..........................................................35.13
[35.737]Dipperhydraulicsystem..........................................................35.14
[35.738]Excavatorandbackhoebuckethydraulicsystem................................35.15
[35.360]Hammerandrotatingbuckethydraulicsystem..................................35.16
Framesandballasting.................................................................39
[39.140]Ballastsandsupports..............................................................39.1
Tracksandtracksuspension........................................................48
[48.130]Trackframeanddrivingwheels....................................................48.1
[48.100]Tracks..............................................................................48.2
[48.134]Tracktensionunits.................................................................48.3
[48.138]Trackrollers........................................................................48.4
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.200]Airconditioning.....................................................................50.2
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.100]Harnessesandconnectors.........................................................55.2
[55.525]Cabenginecontrols................................................................55.3
[55.015]Enginecontrolsystem..............................................................55.4
[55.201]Enginestartingsystem.............................................................55.5
[55.301]Alternator...........................................................................55.6
[55.302]Battery..............................................................................55.7
[55.202]Coldstartaid.......................................................................55.8
4803422523/06/2016
Find manuals at https://best-manuals.com

[55.010]Fuelinjectionsystem...............................................................55.9
[55.014]Engineintakeandexhaustsystem...............................................55.10
[55.989]ExhaustGasRecirculation(EGR)electricalsystem.............................55.11
[55.012]Enginecoolingsystem...........................................................55.12
[55.013]Engineoilsystem................................................................55.13
[55.640]Electronicmodules...............................................................55.14
[55.512]Cabcontrols......................................................................55.15
[55.036]Hydraulicsystemcontrol.........................................................55.16
[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.17
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem...............55.18
[55.416]Swingcontrolsystem............................................................55.19
[55.417]Travelcontrolsystem............................................................55.20
[55.530]Camera...........................................................................55.21
[55.518]Wiperandwashersystem........................................................55.22
[55.404]Externallighting..................................................................55.23
[55.514]Cablighting......................................................................55.24
[55.408]Warningindicators,alarms,andinstruments....................................55.25
[55.992]Anti-theftsystem.................................................................55.26
[55.DTC]FAULTCODES..................................................................55.27
Booms,dippers,andbuckets.......................................................84
[84.910]Boom...............................................................................84.1
[84.912]Dipperarm.........................................................................84.2
[84.100]Bucket..............................................................................84.3
Platform,cab,bodywork,anddecals.............................................90
[90.150]Cab.................................................................................90.1
[90.156]Cabwindshieldandwindows......................................................90.2
[90.120]Mechanically-adjustedoperatorseat...............................................90.3
4803422523/06/2016
Find manuals at https://best-manuals.com

[90.100]Enginehoodandpanels...........................................................90.4
4803422523/06/2016
Find manuals at https://best-manuals.com

4803422523/06/2016
Find manuals at https://best-manuals.com

INTRODUCTION
4803422523/06/2016
1
Find manuals at https://best-manuals.com

Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing....................................3
Safetyrules.....................................................................................4
Safetyrules-Generalinformation..............................................................5
Safetyrules-Personalsafety..................................................................6
Safetyrules-Cabprotectivestructure..........................................................8
Safetyrules-Ecologyandtheenvironment....................................................9
Torque-Boltandnut..........................................................................10
Torque-Specialtorquesettings..............................................................11
Basicinstructions-Shopandassembly......................................................15
Hydrauliccontamination......................................................................17
Generalspecication.........................................................................18
Generalspecication-Mainequipment......................................................22
Weight........................................................................................28
Dimension....................................................................................30
Conversionfactors............................................................................33
Consumables.................................................................................45
Abbreviation..................................................................................49
Productidentication..........................................................................52
Productidentication-Machineorientation..................................................54
4803422523/06/2016
2
Find manuals at https://best-manuals.com

INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecicationsatanytimewithout
noticeandwithoutincurringanyobligationtoinstallthemonunitspreviouslysold.Specications,descriptions,and
illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
Incaseofquestions,refertoyourNEWHOLLANDCONSTRUCTIONSalesandServiceNetworks.
4803422523/06/2016
3
Find manuals at https://best-manuals.com

INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY.
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
4803422523/06/2016
4

INTRODUCTION
Safetyrules-Generalinformation
Cleaning
Cleanthemetalpartswithcleaningsolutionthatmeetsthestandardandsteamcleaning.(exceptforbearings)
Aftercleaning,drywell,andinjectoilinallparts.
Alsoinjectoilintothebearingsafterdrying.
Inspection
Whendisassemblingparts,checkalltheparts.
Ifthereareanywornordamagedparts,replacethem.
Inspectcarefullytopreventinitialbreakdowns.
Bearing
Replaceanyloosebearings.
Airdrybearingsbeforeinstallingthem.
Needlebearing
Wheninsertingneedlebearings,beverycarefulnottodamagethem.
Applygreasetothesectionwheretheneedlebearingwillbeinserted.
Gear
Checkthatthereisnowearandnodamage.
Oilseal,O-ring,gasket
Alwaysinstallnewoilseals,O-rings,andgaskets.
ApplygreasetosectionswhereoilsealsandO-ringswillbeinserted.
Shaft
Checkthatthereisnowearandnodamage.
Checkthebearingsandcheckfordamagedoilsealsontheshaft.
Serviceparts
InstallNEWHOLLANDCONSTRUCTIONgenuineserviceparts.
Whenplacinganorder,checkthepartscatalog.ItcontainstheNEWHOLLANDCONSTRUCTIONgenuinepart
numbers.
Anybreakdownsarisingfromtheinstallationofnon-genuinepartsarenotcoveredbythewarranty.
Lubricants(fuel,hydraulicoil)
Usetheoilfromthespeciedcompanyorspeciedintheoperator'smanualorserviceManual.
Anybreakdownsarisingfromanyfuelorhydraulicoilotherthanthosespeciedarenotcoveredbythewarranty.
4803422523/06/2016
5

INTRODUCTION
Safetyrules-Personalsafety
WARNING:
Thissymbolindicatesaprecaution.
Itgivesinformationconcerningthesafetyoftheoperatorandthoseinthesurroundings.
Readandunderstandtheseprecautionsthoroughlybeforeperformingthework.
Alwayscomplywithwarningsandprecautionssoastoavoidanyaccidents.
Thissectioncoversinformationrelatedtooverallsafety.
Checkwhetherallwarninglabelsareinplace.
AdditionallabelscanbeorderedfromServiceParts.
WARNING:
Readtheoperator'smanualtogainathoroughunderstandingofmachinecontroloperations.
WARNING:
Performanymachineoperationsfromtheseatingposition.
Anyothermethodmaycausesevereinjuries.
WARNING:
Onlytheoneoperatoristorideonthemachine.Nooneelseistorideonit.
WARNING:
Checkthesafetymessagesintheoperator'smanualbeforestartingtheengine.
Checkallthewarninglabelsonthemachine.
Checkthatnooneiswithinthemachine’soperatingrange.
Checktheoperatingmethodsinasafelocationbeforestartingtheactualwork.
Understandthemachineoperationswell,thenoperateincompliancewithallservice-relatedlawsandregulations.
Theoperator'smanualcanbepurchasedatyourNEWHOLLANDCONSTRUCTIONdealer.
WARNING:
Workingwithsloppyclothesorclotheswithwhichsafetycannotbeensuredleadstodamagetothemachine
andinjurytotheoperator.
Alwayswearclothesthatensuressafety.
Inordertoworkmoresafely,itisrecommendedtowearadditionalsafetyequipment.
Helmet,safetyshoes,earprotection,goggles,workclothes,andgloves
WARNING:
Paycarefulattentionwhenworkingwiththeenginerunning.
WARNING:
Checkhydraulicequipment.
Workaccordingtotheprocedure.
Donotchangetheprocedure.
4803422523/06/2016
6

INTRODUCTION
WARNING:
Checkthatthereisnooneinthesurroundingsbeforedrainingthepressurefromhydrauliccircuitsduring
machinehydrauliccylinderinspection.
WARNING:
Usegloveswhenhandlinghigh-temperatureparts.
WARNING:
Bringthelowerpartsorattachmentsincontactwiththegroundbeforeinspectingorrepairingthem.
WARNING:
Checkthathosesandtubesaresecurelyconnected.
Ifthereisanydamagetoahoseortube,replaceit.
Donotcheckforoilleaksbyhand.Usecardboardorwood.
WARNING:
Whenremovinganattachmentpinorotherhardenedpin,useahammerthathasasofthead.
WARNING:
Weareyeprotectionwhenusingahammertoinstallapinorwhenworkingwithagrinder.
Atthistime,usegogglesoreyeprotectorsthatmeetstandards.
WARNING:
Parkthemachineinasafelocationwhenrepairingorinspectingit.
WARNING:
Useworksiteprotectionwhenrepairingthemachine.
Checktheoil,coolant,grease,andtools.
Recovermaterialsandpartsasnecessary.
Payenoughattentiontosafety.
WARNING:
Someofthemachine'spartsareextremelyheavy.
Useanappropriateliftingequipmentforsuchparts.
Forweightsandprocedures,seetheServiceManual.
WARNING:
Exhaustgasesaretoxic.
Alwaysprovidegoodventilationwhenworkingindoorsorinanyotherenclosedspace.
WARNING:
Iftheelectrolyticbatterysolutionfreezes,itmayexplode.
4803422523/06/2016
7

INTRODUCTION
Safetyrules-Cabprotectivestructure
Cabprotectivestructure
Modifyingthecabmaincomponentsisprohibitedinordertoprotecttheoperator.
Prohibiteditems
•Modicationsthatreducethestrengthofaplatformthathasacabwithaprotectivestructuremountedonit.(Actions
ormodicationsthatreducethefunctionalityoftheanchoringpartattheleft-rearofthecab)
•Modicationsthateffectthestrengthofthecabwithaprotectivestructure.
Modicationsprohibited(redpart)Allmodications(grinding,welding,drillingholes,removing,etc.)
areprohibited.
Modicationspermittedunderconditions(gray
part)
Removalofpartsisprohibited.Barweldingandmakingholes(up
todiameter20mm(0.787in))bydrillingarepossible.
SMPH15CEX6544FA1
4803422523/06/2016
8

INTRODUCTION
Safetyrules-Ecologyandtheenvironment
Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe
treatmentofsomeofthesubstancesthatadvancedtechnologyrequires,soundjudgmentshouldgoverntheuseand
disposalofproductsofachemicalandpetrochemicalnature.
Familiarizeyourselfwiththerelativelegislationapplicabletoyourcountry,andmakesurethatyouunderstandthis
legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,anti-freeze,
cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use,
anddisposeofthesesubstances.
Helpfulhints
•Avoidtheuseofcansorotherinappropriatepressurizedfueldeliverysystemstolltanks.Suchdeliverysystems
maycauseconsiderablespillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostoftheseproductscontainsubstances
thatmaybeharmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhenyoudrainuidssuchasusedenginecoolantmixtures,engineoil,hydraulicuid,brakeuid,
etc.Donotmixdrainedbrakeuidsorfuelswithlubricants.Storealldraineduidssafelyuntilyoucandisposeof
theuidsinaproperwaythatcomplieswithalllocallegislationandavailableresources.
•Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly.
•Theair-conditioningsystemcontainsgasesthatshouldnotbereleasedintotheatmosphere.Consultanair-condi-
tioningspecialistoruseaspecialextractortorechargethesystemproperly.
•Repairanyleaksordefectsintheenginecoolingsystemorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringwelding.Penetratingweldsplattermayburnaholeorweakenhoses,allowingthelossofoils,
coolant,etc.
Batteryrecycling
Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful
effectontheenvironmentifthebatteriesarenotproperlyrecycledafteruse.Improper
disposalofbatteriescancontaminatethesoil,groundwater,andwaterways.NEW
HOLLANDCONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoa
NEWHOLLANDCONSTRUCTIONdealer,whowilldisposeoftheusedbatteriesorrecycle
theusedbatteriesproperly.Insomecountries,thisisalegalrequirement.
Mandatorybatteryrecycling
NOTE:ThefollowingrequirementsaremandatoryinBrazil.
Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead,
CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany
batteries.Donotdisposeofbatteriesinyourhouseholdgarbage.
Pointsofsaleareobligedto:
•Acceptthereturnofyourusedbatteries
•Storethereturnedbatteriesinasuitablelocation
•Sendthereturnedbatteriestothebatterymanufacturerforrecycling
4803422523/06/2016
9

INTRODUCTION
Torque-Boltandnut
•Tightenalternatingbetweenleftandrightandtopandbottomsothatuniformtighteningforceisapplied.
LPIL12CX00005EA1
•IfLOCTITE®wasusedonaremovedbolt(thereissomethingwhitestickingtotheboltwhenitisremoved),cleanthe
oldLOCTITE®offwithcleaninguid,drythebolt,thenapply2-3dropsofLOCTITE®tothethreadsectionofthebolt.
Torquetable
Boltnominal
diameter(size)M6M8M10M12M14M16M18M20
Wrench10mm13mm17mm19mm22mm24mm27mm30mm
Hexagon
boltTighten-
ingtorque
6.9N·m
(5.089lb
ft)
19.6N·m
(14.456lb
ft)
39.2N·m
(28.912lb
ft)
58.8N·m
(43.369lb
ft)
98.1N·m
(72.355lb
ft)
156.9N·
m(115.72
3lbft)
196.1N·
m(144.63
6lbft)
294.2N·
m(216.99
1lbft)
Wrench5mm6mm8mm10mm12mm14mm14mm17mm
Hexagon
socket
headbolt
Tighten-
ingtorque
8.8N·m
(6.491lb
ft)
21.6N·m
(15.931lb
ft)
42.1N·m
(31.051lb
ft)
78.5N·m
(57.899lb
ft)
117.7N·m
(86.811lb
ft)
176.5N·
m(130.18
0lbft)
245.2N·
m(180.85
0lbft)
343.2N·
m(253.13
1lbft)
4803422523/06/2016
10

INTRODUCTION
Torque-Specialtorquesettings
CodeRetighteninglocationBoltnominal
diameterWrenchTighteningtorque
1*TravelmotorM2436mm900-1051N·m(663.81-775.18lbft)
2*DrivesprocketM2030mm521-608N·m(384.27-448.44lbft)
3*Take-uprollerM1624mm267-312N·m(196.93-230.12lbft)
4*UpperrollerM2030mm521-608N·m(384.27-448.44lbft)
5*LowerrollerM2030mm521-608N·m(384.27-448.44lbft)
6*TrackguardM2436mm902-1049N·m(665.28-773.70lbft)
7ShoeM2030mm814-912N·m(600.38-672.66lbft)
8CounterweightM3350mm1862-2058N·m(1373.34-1517.90lbft)
9*TurntablebearingM2436mm784-914N·m(578.25-674.13lbft)
10*SwingunitM2436mm784-914N·m(578.25-674.13lbft)
11*MountM2030mm289-337N·m(213.16-248.56lbft)
12*FrontbracketM1017mm63.8-73.6N·m(47.06-54.28lbft)
13*
Engine
RearbracketM1219mm109-127N·m(80.39-93.67lbft)
14*RadiatorM1624mm147.2-176.6N·m(108.57-130.25lbft)
15*FlangeM1017mm63.8-73.6N·m(47.056-54.285lbft)
16*
Hydraulic
pumpPumpM20
17mm
hexagon
socket
head
367-496N·m(270.69-365.83lbft)
17*HydraulicoiltankM1624mm232.4-276N·m(171.41-203.57lbft)
18*FueltankM1624mm232.4-276N·m(171.41-203.57lbft)
19*ControlvalveM1624mm267-312N·m(196.93-230.12lbft)
20*LockbarM1624mm267-312N·m(196.93-230.12lbft)
21*CenterjointJointM1219mm109-127N·m(80.39-93.67lbft)
22CabM1624mm149-173N·m(109.90-127.60lbft)
23BatteryM1017mm19.6-29.4N·m(14.46-21.68lbft)
CAUTION:
•Foritemsmarkedwith*,alwaysapplyLOCTITE®262™ortheequivalentandtightentothespeciedtorque.
Thetighteningtorqueinkgf•misdeterminedwithN・m÷9.8(lbf・ft÷7.2).
4803422523/06/2016
11

INTRODUCTION
7DB5DEA41
4803422523/06/2016
12

INTRODUCTION
YYSJMI-0022
4803422523/06/2016
13