New Holland E385C EVO User manual

1/1
Printed in Brazil
Copyright © 2016 – CNH Industrial Latin America LTDA.
All Rights Reserved.
Part Number
48024968
1st Edition
English 08/2016
Part Number
48024968
1st Edition
English 08/2016
E385C EVO
E405C EVO
Hydraulic Excavator
E385C EVO
E405C EVO
Hydraulic
Excavator
SERVICE MANUAL
SERVICE
MANUAL

SERVICEMANUAL
E385CEVOCRAWLEREXCAVATOR-TIER3
E405CEVOMASSEXCAVATORMODEL-TIER3
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.106]Valvedriveandgears..............................................................10.1
[10.101]Cylinderheads.....................................................................10.2
[10.105]Connectingrodsandpistons.......................................................10.3
[10.103]Crankshaftandywheel............................................................10.4
[10.218]Fuelinjectionsystem...............................................................10.5
[10.501]ExhaustGasRecirculation(EGR)exhausttreatment..............................10.6
[10.400]Enginecoolingsystem.............................................................10.7
[10.414]Fananddrive......................................................................10.8
[10.310]Aftercooler..........................................................................10.9
[10.001]Engineandcrankcase...........................................................10.10
[10.102]Panandcovers..................................................................10.11
[10.206]Fuellters........................................................................10.12
[10.216]Fueltanks........................................................................10.13
[10.250]Turbochargerandlines...........................................................10.14
[10.254]Intakeandexhaustmanifoldsandmufer.......................................10.15
[10.304]Enginelubricationsystem........................................................10.16
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.300]Reservoir,cooler,andlters........................................................35.2
[35.106]Variabledisplacementpump.......................................................35.3
[35.102]Pumpcontrolvalves................................................................35.4
[35.304]Combinationpumpunits...........................................................35.5
[35.359]Maincontrolvalve..................................................................35.6
[35.352]Hydraulicswingsystem............................................................35.7
[35.353]Hydraulictravelsystem............................................................35.8
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[35.354]Hydrauliccentraljoint..............................................................35.9
[35.355]Hydraulichandcontrol...........................................................35.10
[35.356]Hydraulicfootcontrol.............................................................35.11
[35.357]Pilotsystem......................................................................35.12
[35.360]Hammerandrotatingbuckethydraulicsystem..................................35.13
[35.736]Boomhydraulicsystem..........................................................35.14
[35.737]Dipperhydraulicsystem..........................................................35.15
[35.738]Excavatorandbackhoebuckethydraulicsystem................................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
[55.301]Alternator...........................................................................55.1
[55.302]Battery..............................................................................55.2
[55.010]Fuelinjectionsystem...............................................................55.3
[55.014]Engineintakeandexhaustsystem.................................................55.4
[55.989]ExhaustGasRecirculation(EGR)electricalsystem...............................55.5
[55.012]Enginecoolingsystem.............................................................55.6
[55.013]Engineoilsystem..................................................................55.7
[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls...................55.8
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.9
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[55.518]Wiperandwashersystem........................................................55.10
[55.404]Externallighting..................................................................55.11
[55.000]Electricalsystem.................................................................55.12
[55.015]Enginecontrolsystem............................................................55.13
[55.036]Hydraulicsystemcontrol.........................................................55.14
[55.100]Harnessesandconnectors.......................................................55.15
[55.201]Enginestartingsystem...........................................................55.16
[55.202]Coldstartaid.....................................................................55.17
[55.408]Warningindicators,alarms,andinstruments....................................55.18
[55.416]Swingcontrolsystem............................................................55.19
[55.417]Travelcontrolsystem............................................................55.20
[55.512]Cabcontrols......................................................................55.21
[55.514]Cablighting......................................................................55.22
[55.525]Cabenginecontrols..............................................................55.23
[55.530]Camera...........................................................................55.24
[55.640]Electronicmodules...............................................................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
[90.120]Mechanically-adjustedoperatorseat...............................................90.1
[90.150]Cab.................................................................................90.2
[90.156]Cabwindshieldandwindows......................................................90.3
[90.100]Enginehoodandpanels...........................................................90.4
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INTRODUCTION
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Contents
INTRODUCTION
Foreword-Importantnoticeregardingequipmentservicing....................................3
Safetyrules.....................................................................................4
Safetyrules-Generalinformation..............................................................5
Safetyrules-Personalsafety..................................................................6
Safetyrules-Cabprotectivestructure..........................................................8
Torque-Boltandnut............................................................................9
Torque-Specialtorquesetting...............................................................10
Basicinstructions-Shopandassembly......................................................14
Generalspecication.........................................................................16
Generalspecication.........................................................................20
Generalspecication-Mainequipment......................................................24
Weight........................................................................................31
Weight........................................................................................33
Dimension....................................................................................35
Dimension....................................................................................37
Conversionfactors............................................................................39
Consumables.................................................................................51
Capacities.....................................................................................53
Abbreviation..................................................................................54
Productidentication-Machineorientation..................................................57
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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.
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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.
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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.
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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.
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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.
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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
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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)
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INTRODUCTION
Torque-Specialtorquesetting
CodeRetighteninglocationNominalbolt
diameterWrenchTighteningtorque
1*TravelmotorM2436mm900-1051N·m(664-775lbft)
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*LowerrollerM2036mm902-1049N·m(665.28-773.70lbft)
6*TrackguardM2036mm650-750N·m(479.42-553.17lbft)
7ShoeM2032mm1236-1510N·m(911.63-1113.72lbft)
8CounterweightM3350mm1862-2058N·m(1373.34-1517.90lbft)
9*TurntablebearingM2436mm784-914N·m(578.35-674.25lbft)
10*SwingunitM2436mm784-914N·m(578.35-674.25lbft)
11*MountM2030mm289-337N·m(213-249lbft)
12*FrontbracketM1017mm63.8-73.6N·m(47-54lbft)
13*
Engine
RearbracketM1219mm109-127N·m(80-94lbft)
14*RadiatorM1624mm147.2-176.6N·m(109-130lbft)
15*FlangeM1017mm63.8-73.6N·m(47-54lbft)
16*
Hydraulic
pumpPumpM20
17mm
hexagon
socket
head
367-496N·m(270.69-365.83lbft)
17*HydraulictankM1624mm233-276N·m(172-204lbft)
18*FueltankM1624mm233-276N·m(172-204lbft)
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(14.459-21.688lbft)
CAUTION:
•Foritemsmarkedwith*,alwaysapplyLOCTITE®262™ortheequivalentandtightentothespeciedtorque.
•Thetighteningtorqueinkgf·misdeterminedwithN·m÷9.8(lbf·ft.÷7.2).
Tightentheboltsandnutsforwhichthevaluesarenotspeciedinthetableaboveasfollows.
Nominalboltdiameter(Size)M6M8M10M12M14M16M18M20
Wrench10mm13mm17mm19mm22mm24mm27mm30mm
HexagonboltTightening
torque6.9N·m19.6N·
m
39.2N·
m
58.8N·
m
98.1N·
m
156.9N·
m
196.1
N·m
294.2N·
m
Wrench5mm6mm8mm10mm12mm14mm14mm17mm
Hexagonsocket
headboltTightening
torque8.8N·m21.6N·
m
42.1N·
m
78.5N·
m
117.7N·
m
176.5N·
m
245.2
N·m
343.2N·
m
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INTRODUCTION
SMIL14CEX2929HB1
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INTRODUCTION
SMIL15CEX3370HB2
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INTRODUCTION
SMIL15CEX3371GB3
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INTRODUCTION
Basicinstructions-Shopandassembly
Shimming
Foreachadjustmentoperation,selectadjustingshimsandmeasuretheadjustingshimsindividuallyusingamicrom-
eter,thenadduptherecordedvalues.Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,or
theratedvalueshownoneachshim.
Rotatingshaftseals
Forcorrectrotatingshaftsealinstallation,proceedasfollows:
1.Beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes.
2.Thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged.
3.Positionthesealinglipfacingtheuid.
NOTE:Withhydrodynamiclips,takeintoconsiderationtheshaftrotationdirectionandpositionthegroovessothat
theywillmovetheuidtowardstheinnersideoftheseal.
4.Coatthesealinglipwithathinlayeroflubricant(useoilratherthangrease).Fillthegapbetweenthesealinglip
andthedustlipondoublelipsealswithgrease.
5.Insertthesealinitsseatandpressdownusingaatpunchorsealinstallationtool.Donottapthesealwitha
hammerormallet.
6.Whileyouinserttheseal,checkthatthesealisperpendiculartotheseat.Whenthesealsettles,makesurethat
thesealmakescontactwiththethrustelement,ifrequired.
7.Topreventdamagetotheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.
O-ringseals
LubricatetheO-ringsealsbeforeyouinsertthemintheseats.ThiswillpreventtheO-ringsealsfromoverturningand
twisting,whichwouldjeopardizesealingefciency.
Sealingcompounds
Applyasealingcompoundonthematingsurfaceswhenspeciedbytheprocedure.Beforeyouapplythesealing
compound,preparethesurfacesasdirectedbytheproductcontainer.
Spareparts
OnlyuseCNHOriginalPartsorNEWHOLLANDCONSTRUCTIONOriginalParts.
Onlygenuinesparepartsguaranteethesamequality,duration,andsafetyasoriginalparts,astheyarethesame
partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorNEWHOLLANDCONSTRUCTION
OriginalPartscanofferthisguarantee.
Whenorderingspareparts,alwaysprovidethefollowinginformation:
•Machinemodel(commercialname)andProductIdenticationNumber(PIN)
•Partnumberoftheorderedpart,whichcanbefoundinthepartscatalog
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INTRODUCTION
Protectingtheelectronicand/orelectricalsystemsduringchargingandwelding
Toavoiddamagetotheelectronicand/orelectricalsystems,alwaysobservethefollowingpractices:
1.Nevermakeorbreakanyofthechargingcircuitconnectionswhentheengineisrunning,includingthebattery
connections.
2.Nevershortanyofthechargingcomponentstoground.
3.Alwaysdisconnectthegroundcablefromthebatterybeforearcweldingonthemachineoronanymachine
attachment.
•Positiontheweldergroundclampasclosetotheweldingareaaspossible.
•Ifyouweldincloseproximitytoacomputermodule,thenyoushouldremovethemodulefromthemachine.
•Neverallowweldingcablestolieon,near,oracrossanyelectricalwiringorelectroniccomponentwhileyou
weld.
4.Alwaysdisconnectthenegativecablefromthebatterywhenchargingthebatteryinthemachinewithabattery
charger.
NOTICE:Ifyoumustweldontheunit,youmustdisconnectthebatterygroundcablefromthemachinebattery.
Theelectronicmonitoringsystemandchargingsystemwillbedamagedifthisisnotdone.
5.Removethebatterygroundcable.Reconnectthecablewhenyoucompletewelding.
WARNING
Batteryacidcausesburns.Batteriescontainsulfuricacid.
Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):ush
withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge
quantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately.
Failuretocomplycouldresultindeathorseriousinjury.W0111A
Specialtools
ThespecialtoolsthatNEWHOLLANDCONSTRUCTIONsuggestsandillustrateinthismanualhavebeenspecically
researchedanddesignedforusewithNEWHOLLANDCONSTRUCTIONmachines.Thespecialtoolsareessential
forreliablerepairoperations.Thespecialtoolsareaccuratelybuiltandrigorouslytestedtoofferefcientandlong-
lastingoperation.
Byusingthesetools,repairpersonnelwillbenetfrom:
•Operatinginoptimaltechnicalconditions
•Obtainingthebestresults
•Savingtimeandeffort
•Workinginsafeconditions
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