New Holland E485 Instruction manual

Copyright © New Holland

NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support
Print No. 604.13.684
Edition - February 2006
WORKSHOP MANUAL
All the information and data contained in this manual are based upon most recent information available at the
time of its publication.
NEW HOLLAND KOBELCO has the right to implement, at any time, any modification without providing any
communication.
R0077
E485
(Repowering)
Copyright © New Holland

Copyright © New Holland

E485 IN-1
INTRODUCTION
TO THE READER
• This manual is written for an experienced techni-
cian to provide technical information needed to
maintain and repair this machine.
- Besuretothoroughlyreadthismanualforcorrect
information concerning the service procedures.
- If you have any questions or comments, or if you
found any errors regarding the contents of this
manual, please contact:
NEW HOLLAND KOBELCO
CONSTRUCTION MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONALREFERENCES
• Pleaserefertothematerialslistedbelowinaddition
to this service manual:
-Operation and Maintenance Instruction
Manual
-Parts Catalog
WORKSHOP MANUAL COMPOSITION
- The “Operational Performance Test” part includes
the information needed to carry out the machine
operational performance test.
- The “Troubleshooting” part includes the technical
information needed for troubleshooting and mal-
function detection.
- The “Repair Instruction” part includes information
neededformaintenanceandrepairofthemachine,
tools and devices needed for maintenance and
repair, maintenance standards, removal/installa-
tion and assembly/disassembly procedures.
• The Workshop Manual consists of five parts:
-“Safety Precautions”
-“Operational Principle”
-“Operational Performance Test”
-“Troubleshouting”
-“Repair Instructions”
- The “Safety Precaution” part includes the recom-
mendedprocedures that,if followed,can avoidthe
risk of accident for operator and for staff related to
the work and maintenance machine operations.
- The “Operational Principle” part includes the tech-
nical information concerning the operation of main
devices and systems.
Copyright © New Holland

E485
INTRODUCTION
IN-2
To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm210.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW CV-PS 1.360
Volume L US qt 1.057 kW HP 1.341
m3yd31.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
PAGE NUMBER
• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist)
Section number
T: Technical Manual
W: Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for
personal injury or machine damage.
This is the safety alert symbol.
When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
Toavoidinjuryanddamage,besuretouseappropriateliftingtechniquesandequipmentwhenliftingheavy
parts.
UNITS USED
SI Units (International System of Units) are used in this manual.
MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 MPa (250 kgf/cm2)
A table for conversion from SI units to other system units is shown below for reference purposes.
Copyright © New Holland

E485 INDEX
INDEX
Section 3 COMPONENT OPERATION
Group 1 Hydraulic Pump Assy .............................................................. T3-1
Group 2 Pilot Valve ............................................................................... T3-2
Group 3 ControlValve ........................................................................... T3-3
Group 4 SwingDevice........................................................................... T3-4
Group 5 Travel Device........................................................................... T3-5
Group 6 Swivel Joint ............................................................................. T3-6
Group 7 Cylinders ................................................................................. T3-7
Group 8 AirConditioner ......................................................................... T3-8
Group 9 Attachment Automatic Lubrication System .............................. T3-9
MANUAL INDEX
Section 4 OPERATIONAL PERFORMANCETEST
Group 1 Introduction ..............................................................................T4-1
Group 2 StandardPerformances............................................................T4-2
Group 3 Test Procedures .......................................................................T4-3
Group 4 Mechatro Controller Adjustment ...............................................T4-4
OPERATIONAL PERFORMANCE TEST
Pag.
Section 1 GENERALITIES.................................................................... S1
Section 2 SAFETY PRECAUTIONS.................................................. S2
Section 3 SAFETY PLATES ................................................................ S3
SAFETY PRECAUTIONS
TROUBLESHOOTING
Section 5 TROUBLESHOOTING
Group 1 MechatroControl ..................................................................... T5-1
Group 2 Hydraulic System .................................................................... T5-2
Group 3 Electrical System .................................................................... T5-3
Group 4 Engine ..................................................................................... T5-4
Section 1 GENERAL
Group 1 Specifications ........................................................................... T1-1
Group 2 Component Layout ................................................................... T1-2
Section 2 SYSTEM
Group 1 Mechatro Control System........................................................ T2-1
Group 2 Mechatro Controller................................................................. T2-2
Group 3 Hydraulic System .................................................................... T2-3
Group 4 Electrical System .................................................................... T2-4
OPERATIONAL PRINCIPLE
Copyright © New Holland

INDEX E485
INDEX
Section 1 GENERAL INFORMATION
Group 1 Precautions for Disassembly and Assembly......................... W1-1
Group 2 TighteningTorque.................................................................. W1-2
Section 2 UPPERSTRUCTURE
Group 1 Cab....................................................................................... W2-1
Group 2 AirConditioner ...................................................................... W2-2
Group 3 Counterweight ....................................................................... W2-3
Group 4 MainFrame........................................................................... W2-4
Group 5 Pump Device ........................................................................ W2-5
Group 6 ControlValve ........................................................................ W2-6
Group 7 SwingDevice........................................................................ W2-7
Group 8 Pilot Valve ............................................................................ W2-8
Group 9 SolenoidValveUnit............................................................... W2-9
Section 3 UNDERCARRIAGE
Group 1 SwingBearing....................................................................... W3-1
Group 2 Travel Device ........................................................................ W3-2
Group 3 Swivel Joint .......................................................................... W3-3
Group 4 Track Adjuster....................................................................... W3-4
Group 5 FrontIdler ............................................................................. W3-5
Group 6 Upperand LowerRoller ......................................................... W3-6
Group 7 Tracks................................................................................... W3-7
Section 4 FRONT ATTACHMENT
Group 1 FrontAttachment .................................................................. W4-1
Group 2 Cylinders .............................................................................. W4-2
REPAIR INSTRUCTIONS
Copyright © New Holland

E485 INDEX
INDEX
Section 5 ENGINE AND ACCESSORY
Group 1 GeneralInformation .............................................................. W5-1
Group 2 Maintenance ......................................................................... W5-2
Group 3 EngineI(Disassembly)......................................................... W5-3
Group 4 Engine II(Inspection and Repair) .......................................... W5-4
Group 5 Engine III (Assembly) ........................................................... W5-5
Group 6 LubricationSystem............................................................... W5-6
Group 7 CoolingSystem .................................................................... W5-7
Group 8 Fuel System ......................................................................... W5-8
Group 9 Turbocharger ......................................................................... W5-9
Group 10 EngineElectrical................................................................. W5-10
Group 11 Troubleshooting................................................................... W5-11
Group 12 SpecialTools ...................................................................... W5-12
Group 13 RepairStandard .................................................................. W5-13
Group 14 Electronic Control System .................................................. W5-14
Copyright © New Holland

Copyright © New Holland

SAFETY PRECAUTIONS
R0077
Copyright © New Holland

Copyright © New Holland

E215-E235 W1-1-1
Section 1 GENERALITIES
Section 2 SAFETY PRECAUTIONS
Section 3 SAFETY PLATES
E485
SAFETYPRECAUTIONS
INDEX
Copyright © New Holland

Copyright © New Holland

E485 S1-1
GENERALITIES
GENERALITIES
Read the Operation and Maintenance Instruction
Manualcarefully beforestarting, operating,maintain-
ing, fuelling or servicing the machine.
Carefully read the explanation to each and all safety
signsinthespecial sectionofthisManualbeforestart-
ing, operating, maintaining, fuelling or servicing the
machine.
Machine-mountedsafety platesarecolourcodedyel-
lowwithblackborderswhenthey refertopoints where
special ATTENTION must be paid and failure to ob-
serve them may cause a serious DANGER to the in-
tegrity of machine operators.They are white with red
bordersand blacklettering whenthey refertoaFOR-
BIDDEN practice.
Itisfundamentalthat allmachineoperators knowvery
well the meaning of each safety plate as this consid-
erablydecreases operatinghazardsandaccidents.
Do not allow unauthorised personnel to operate or
service this machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves,unbuttoned orunzipped jacketsthat canget
caught in moving parts.Wear certified safety clothes
suchas:hardhat, no-slipfootwear, heavy gloves, ear
protection, safety glasses , reflector vests, respira-
torseverytime thejob requiresit. Askyour employer
aboutsafety regulationsinforceandprotectiveequip-
ment.
Alwayskeeptheoperator’s compartment, stepplates,
grab-rails and handles clean and clear of foreign ob-
jects, oil, grease, mud or snow to minimise the dan-
ger of slipping or stumbling. Remove mud or grease
fromyourshoesbeforeoperating themachine.
Donot jump onor offthe machine.Alwayskeepboth
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvert-
entlymoved andcause unexpectedmovement ofthe
machine or its attachments.
Never operate the machine or its attachments from
anyposition otherthansittinginthe driver’sseat.Keep
head, body, limbs, hands and feet inside the opera-
tor’s compartment at all times to reduce exposure to
externalhazards.
Becareful ofpossible slipperyconditions ofthe steps
and hand rails as well as of the ground around the
machine.Wearprotectivebootsorshoeswiththesoles
madeof highlyno-slip rubber
Do not leave the machine until it has come to a
complete stop.
Always check height, width and weight limitations
which may be encountered in the working site and
ensure the machine does not exceed them.
Assess exact paths of gas ducts, water mains, tel-
ephonelines,sewers,overheadandundergroundelec-
tric lines and all other possible obstacles.
Suchpaths shouldbeopportunelydefinedbycompe-
tentAuthorities.If necessary, require thatthe service
is interrupted or said installations are moved prior to
starting the work.
You must know the working capacity of the machine.
Definetherear upperstructureswingareaand provide
for opportune barriers to prevent access into it.
Never exceed machine lifting capacity.
Remain within the limits shown in the loading capac-
ity chart which located on the machine.
STARTING
Never start or operate a failed machine.Walk all
aroundthe machinebefore mounting.
Before operating the machine, make sure that any
possible dangerous condition has been properly re-
moved.Before starting machine, check that steering
and attachment controls are in the neutral position
andthesafety leveris inthe LOCKposition. Immedi-
ately report any malfunction of parts or systems to
the maintenancemanagersforproperaction.
Prior to starting the engine, check, adjust and lock
thedriver’s seatformaximum ridingcomfortandcon-
trol accessibility.Prior to operating the machine and/
or its attachments, check that bystanders are out-
sidethe machineoperating range.Sound thehorn.
Obey all hand signals, safety indications and signs.
Dueto thepresenceof flammable fluids,nevercheck
fuellevel, refuel,charge thebatteries inthe presence
of smoking materials, open flames or sparks.
Ensure that nobody is within the excavator operat-
ing area before starting the machine, swinging the
upper structure or moving in any direction.
Adjust all rear-view mirrors for maximum visibility of
thearea behindthemachine.
Ensure that engine speed is appropriate to the job to
becarriedout.
Ifany hydrauliccontrolorsystemexhibitserraticper-
formance orresponds abnormally, havethe machine
checked for air in the system.
Airinthesecircuitsmay causeincorrect movements
withconsequent accidenthazard.Refer totheOpera-
tion and Maintenance Instruction Manual about cor-
rective action to be taken.
OPERATING
Do not run the engine of this machine in closed
buildings without proper ventilation capable to re-
move harmful exhaust gases which concentrate in
the air.
Keep the operator’s compartment free of foreign ob-
jects, especially if not firmly secured. Never use the
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S1-2 E485
GENERALITIES
machineto transport objects,unlesspropersecuring
pointsare provided.
Do not carry riders on the machine.
Study and familiarise with escape routes alternative
to normal exit routes.
For your personal safety, do not climb on or off the
machine while it is in motion.
Make sure that bystanders are clear of the machine
operatingrangebefore starting theengine andoper-
atingthe attachment.Sound thehorn.
Obey all hand signals, safety indications and signs.
When backing, always look to where the machine is
to be moved. Be alert of the position of bystanders.
Should someone enter the work area, stop the ma-
chine.
Maintain a safe distance from other machines or ob-
stacles to ensure required visibility conditions.
Always give way to loaded machines.
Maintain a clear vision of the surroundings of the
travel or work area at all times.
Keep cabwindowsclean andrepaired.
Whenpullingloadsortowingthrough acableorchain,
do not start suddenly at full throttle. Take-up slack
carefully.
Avoid kinking or twisting chains or cables.
Carefully inspect the towing items for flaws or prob-
lemsbefore proceeding.
Do not pull through a kinked chain or cable as the
highanomalousstressesexistinginthisconditionmay
induce failures in the kinked portion.
Alwayswearheavy gloves when handlingchains or
cables.
Chains and cables should be securely anchored us-
ing suitable hooks. Anchor points should be strong
enoughto withstandtheexpectedload.
Keep anyone clear of anchor points and cables or
chains. Do not pull or tow unless the operator’s
compartments ofthe machines involvedare prop-
erly protected against possible backlash in case
of cable or chain failure or detachment.
Be alert of soft ground conditions close to newly
constructed walls.The fill material and machine
weight may cause the wall to collapse under
the machine.
In darkness, check area of operation carefully
before moving in with the machine. Use all lights
provided. Donot move into low visibility areas.
If the engine tends to slow down and stall for what-
everreason underload orat idle, immediatelyreport
thisproblem tothemaintenancemanagersfor proper
action. Do not operate the machine until this condi-
tion is corrected.
Regularly check all exhaust system components, as
exhaust fumes are toxic for the operator.
Operators must know the performance of the ma-
chine they are driving.
When working on slopes or near sudden level drops
in the terrain, pay attention not to lose adherence
and avoid loose soft ground since overturn or loss of
machinecontrolcould result.
If noise level is high and exceeds 90 dB (A) over 8
hoursat theoperator’s ear,wearapprovedearprotec-
tion in compliance with local regulations.
Donot operatethemachineif you areextremely tired
or feel ill.
Be especially careful towards the end of the working
shift.
Whereremovablecounterweightsare provided,donot
operate the machine if they have been removed.
Whenoperatingthemachine, keepinmind heightlim-
its of overhead doors, arches, overhead cables and
lines as well as width limits of corridors, roads and
narrowpassages.Also,get toknow loadlimits ofthe
groundandpaving typeof theramps youareto work
on.
Beware of fog, smoke or dust that obscure visibility.
Always inspect the working area to identify potential
risks such as: inclines, overhangs, trees, demolition
rubble, fires, ravines, steep slopes, rough terrain,
ditches, crowns, ridge trenches,diggings in traffic
areas, crowded parking lots, crowded service areas,
fenced zones. In such conditions, proceed with ex-
tremecare.
Whenever possible, avoid crossing over obstacles
such as very rough terrain, rocks, logs, steps,
ditches, railroad tracks. When obstructions must
be crossed, do so with extreme care and at a
square angle, if possible. Slow down. Ease up to
the break-over point, pass the balance point slowly
and ease down the other side also using the at-
tachment, if necessary.
To overcome deep trenches or sinking ground,
place the machine perpendicular to the obsta-
cle, drastically reduce ground speed and start
crossing using also the attachment if necessary,
only after assessing that ground conditions al-
low the traverse safely and without risks.
Thegradientyou mayattempt toovercome islimited
byfactors suchasgroundconditions,load beinghan-
dled, machine type and speed, and visibility.
Thereis nosubstitutefor goodjudgementandexperi-
ence when working on slopes.
Avoid operatingthe attachment tooclose toanover-
hangor highwall, eitheraboveorbelow themachine.
Beware of caving edges, falling objects and land-
slides. Remember that such hazards are likely to be
concealed by bushes, undergrowth and such.
Avoid faggots, bushes, logs and rocks. Never drive
over them, nor over any other surface irregularities
thatdiscontinueadherenceortractionwiththeground,
especiallynearslopes ordrop-offs.
Be alert to avoid changes in adherence conditions
that could cause loss of control.Work with extreme
care on ice or frozen ground and on stepped slopes
ornear drop-offs.
The word “bulldozing” generally refers to work in
virgin rough terrain, characterised by the presence
of all the perils and risks listed above.We empha-
sise the danger represented in these conditions by
large tree limbs (possibly falling on the machine)
Copyright © New Holland

E485 S1-3
GENERALITIES
and large roots (which may act as a leverage un-
der themachine when up-rootedandcausetheunit
to overturn).
Position the machine dependent upon the loading
and unloading areas in order to swing leftwards to
load to obtain best visibility.
Never use the bucket or attachment as a man lift or
carryriders.Neverusethe machineasa workplatform
or scaffolding. The machine must not be improperly
usedforworks notconsistent withitsfeatures(such as
pushing railway cars, trucks or other machines).
Always pay attention to people within the machine
operatingrange.
Never move or stop the bucket, other loads or the
attachment above ground personnel or truck cabs.
Ensurethetruck driveris ina safeplacebefore load-
ing the truck.
Load trucks from side or rear.
Use only the type of bucket recommended consider-
ing machine type, materials to be handled, material
pilingup andloadingcharacteristics,ground typeand
other typical conditions of the work to be performed.
When transportinga loadedbucket,keep it asrolled-
back as possible. Keep boom and arm as low as
possible.
Ground speed should be adequate to the load and
ground conditions.
The load must always be properly arranged in the
bucket; move with extreme care when transporting
oversizeloads.
Donotliftandmove thebucket overhead whereper-
sonsarestandingorworking,nordownhillwhenwork-
ing on a slope as this would decrease machine sta-
bility. Load the bucket from the uphill side.
Loads to be raised using the machine should be ex-
clusively hooked to the hitch specially provided.
Theexcavatoris noliftingand transportationmeans,
therefore it should not be used to position loads ac-
curately. Should it be exceptionally used to lift and
lay building components, special caution must be
taken as follows:
- Themachine mustbe equippedwithout failurewith
the appropriate variant supplied, upon request, by
NEW HOLLAND KOBELCO. Also, totally comply
with the safety precautions for the operation of the
excavator as a lifting equipment.
- Securetheloadstoberaised usingcablesorchains
fastened with appropriate hooking mechanisms.
- Nobody should be allowed to remain under the
raisedload orwithintheexcavatoroperatingrange
for any reason whatever.
Never exceed specified loading capacity. Incorrect
fastening of slings or chains may cause boom/arm
failure or failure of the lifting means with consequent
bodily injuries and even death.
Always ensure that slings and chains used for lifting
are adequate to the load and in good condition.
All loading capacities are referred to the machine
on a level surface and should be disregarded
when working on a slope.
Avoid travelling across slopes. Proceed from uphill
downhill and vice-versa. If machine starts slipping
sidewayswhenonaslope,lowerthebucket andthrust
bucket teeth into the ground.
Working on slopes is dangerous. Grade the working
area if possible. Reduce work cycle time if it is not
possible to grade the working area.
Donotmove fullbucket ora loadfromuphill downhill
as this would reduce machine stability. Do not work
with the bucket turned to the uphill side.
Do not work with the bucket turned uphill as coun-
terweightsprotrudingdownhill wouldreducemachine
stability on the slope and increase risk of overturn-
ing.
We recommend to work on slopes with the bucket
downhill, after checking machine stability with the
bucket empty and attachment retracted, by slowly
swinging the upper structure by 360°.
Positionthecarriageat arightanglerelativeto slopes,
hanging walls, etc. to exit the working area easily.
Standard use, provides for the travel controls at the
front and travel motors at the back. Should travel
motors be positioned at the front with regard to the
actual travel direction. Remind relative to travel di-
rection that controls are reversed.
Alwayscheck travelmotorpositionbeforemoving off.
Properly judge ground conditions with particular at-
tention to consistency of the area you are going to
work on.
Keepthe machinesufficiently farfromthe ditchedge.
Never dig under the machine.
Should it be necessary to dig under the machine, al-
ways ensure that digging walls are opportunely
proppedup against landslideto preventthe machine
from falling into the trench.
Do not swing the upperstructure, raise the load or
brake abruptly if not required. This may cause acci-
dents.
Priortobeginning thework neargas distributionmains
or other public utilities:
- Contact the company owner of the gas mains or
its nearest branch before starting the work. Look
up the number in the telephone directory.
- Definetogether whichprecautions shouldbe taken
to guarantee work safety.
- Decrease work speed. Reaction time could be too
slow and distance evaluation wrong.
- When working near gas mains or other public utili-
tiesinstallations,appoint apersonin chargeof sig-
nalling duties. This person will have the responsi-
bilityof observingthemachine,anypartof itand/or
the load approaching the gas mains from a stand-
pointmore favourablethanthe Operator’s.Thissig-
nal man (flag-man) must be in direct communica-
tion with the Operator and the Operator must pay
undivided attention to the signals supplied.
- Thegas distributingCompany, ifpreviouslyadvised
and involved in the work, as well as machine Opera-
tor, Owner and/or any natural person or legal entity
havingrentorleasedthe machineor beingresponsi-
Copyright © New Holland

S1-4 E485
GENERALITIES
bleat thetime by contract orby law, areliableforthe
adoptionofthe necessaryprecautions.
Working near electric lines can be very dangerous,
therefore some special precautions must be ob-
served.
Within this Manual, “work near electric lines” means
when the attachment or load raised by the excava-
tor (in any position) may reach the minimum safety
distance established by local or international Safety
Regulations.
To work without risks, keep maximum possible dis-
tancefrom electriclinesandnever trespassminimum
safety distance.
- ContacttheCompany ownerof theelectric linesor
its nearest branch before starting the work.
Look up the in the telephone directory.
- Define together with the Company representative
whichprecautionsshouldbetakentoguaranteework
safety.
- Allelectriclinesshouldbe consideredas operative
live lines even though it might be well known that
the line in question is out of work and visibly con-
nectedtothe ground.
- TheElectricPowerCompany, ifpreviouslyadvised
and involved in the work, as well as machine Op-
erator, Owner and/or any natural person or legal
entity having rent orleased the machine or being
responsible at the time by contract or by law, are
liablefor theadoptionof thenecessaryprecautions.
- Decrease work speed. Reaction time could be too
slowand distanceevaluation wrong.
- Warn allground personnelto keepclear ofthe ma-
chine and/or load at all times. If the load has to be
guided down for laying, consult the Electric Power
Company to know which precautions should be
taken.
- Appoint a person in charge of signalling duties.
This person will have the responsibility of observ-
ing the machine, any part of it and/or the load ap-
proachingtheelectriclinesfrom astandpoint more
favourablethantheOperator’s.Thissignalman(flag-
man) must be in direct communication with the
Operator and the Operator must pay undivided at-
tention to the signals supplied.
When working in or near pits, in ditches or very high
walls,check thatthe wallsare sufficientlypropped up
to avoid cave-in hazards.
Paythe utmostattentionwhenworkingnear overhang
wallsorwherelandslidesmay takeplace. Makesure
that the support surface is strong enough to prevent
landslides.
When digging, there is the risk of cave-ins and land-
slides.
Alwayscheck groundconditionsand conditionsofthe
material to be removed.Support everywhere it is re-
quiredtopreventpossiblecave-insorlandslideswhen:
- diggingnear previoustrenchesfilledwithmaterial
- diggingin badground conditions
- diggingtrenches subjectto vibrationfromrailroads,
workingmachinesor highwaytraffic.
STOPPING
Whenthemachineistobestoppedforwhateverreason,
always check that all controls are in the neutral position
andthatthesafetyleverisonthelockpositiontoguaran-
teerisk-freestart-up.
Neverleavethemachineunattendedwiththeenginerun-
ning.
Prior to leaving the driver’s seat, and after making
sure that all people are clear of the machine, slowly
lower the attachment until resting it safely to the
ground. Retract possible auxiliary tools to the closed
safety position.
Checkthatallcontrolsareintheneutralposition. Move
engine controls to the shut-down position. Switch off
thekey-start switch.Consult theOperationand Main-
tenanceInstruction Manual.
Parkthemachineinanon-operatingandno-trafficarea.
Park on firm level ground.If this is not possible, posi-
tionthemachineata rightangle tothe slope,making
surethereis nodanger ofuncontrolledsliding.
If parking in traffic lanes cannot be avoided, provide
appropriateflags, barriers,flaresandothersignals as
requiredto adequatelywarn theoncoming drivers.
Always switch off the key-start switch before clean-
ing,repairing, orparking themachinetoprevent acci-
dentalunauthorised start-up.
Never lower the attachment or auxiliary tools other
thanfromsittingintheoperator’sseat.Soundthehorn.
Make sure that nobody is within the machine operat-
ingrange.Lowertheattachment slowly.
Securely block and lock the machine every time you
leave it unattended. Return keys to the safe place
previouslyagreed upon.Performall necessaryopera-
tions for stopping as detailed in the Operation and
MaintenanceInstruction Manual.
Drivethe machinefarfrom pits,trenches,rocky hang-
ingwalls,areaswithoverheadelectriclines,andslopes
before stopping it at the end of the working day.
Alignthe upperstructureto thetracksinorderto allow
to easily get on and off the driver’s compartment.
Moveall controlstothe positionspecified formachine
stopping. Refer the Operation and Maintenance In-
structionManual.
Never park on an incline without accurately blocking
themachineto preventunexpected movement.
Follow stopping instructions contained in the Opera-
tionandMaintenanceInstructionManual.
MAINTENANCE
GENERALITIES
CarefullyreadtheOperationandMaintenanceInstruc-
tion Manual before starting, operating, maintaining,
fuelling or servicing the machine in any manner.
Read all safety plates mounted on the machine and
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E485 S1-5
GENERALITIES
observeinstructions they containbeforestarting,op-
erating,repairing,fuellingorservicing themachine.
Donot allowunauthorisedpersonnel torepairor serv-
ice the machine.
Follow all recommended maintenance and service
procedures.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves,unbuttoned orunzipped jacketsthat canget
caught in moving parts.Wear certified safety clothes
suchas:hardhat, no-slipfootwear, heavy gloves, ear
protection,safety glasses,reflector vests,respirators
whenrequired. Askyour employeraboutsafetyregu-
lations in force and protective equipment.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvert-
entlymoved andcause unexpectedmovement ofthe
machine or its attachments.
Donotjumponor offthe machine.Always keepboth
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Never service the machine with someone sitting in
the driver’s seat, unless this person is an authorised
operator assisting in the maintenance being carried
out.
Keep the operator’s compartment, step plates, grab
railsandhandlesclearof foreignobjects, oil,grease,
mudorsnowtominimisethedangerofslippingorstum-
bling.
Cleanmudorgrease fromyourshoes beforeclimbing
on the machine or driving it.
Never attempt to operate the machine or its attach-
ments from any position other than sitting in the op-
erator’sseat.
Keep thedriver’s seatfree fromforeignobjects,espe-
cially if these are not secured.
Should it be necessary to move the attachment for
maintenance purposes, do not raise or lower the at-
tachment from any other position than sitting in the
operator’s seat.Before starting the machine or mov-
ing its attachment, sound the horn and require that
nobodyremains nearthe machine.
Raise the attachment slowly.
Always lock all moving components or parts of the
machinethatmustbe liftedformaintenance purposes
using adequate external means as required by local
andnationalregulations.Do notallow anyonetopass
or stay near or below a raised attachment. If you are
not absolutely sure about your safety, do not stay or
walkundera raisedattachment.
Donot placehead, body, limbs, hands,feetor fingers
neararticulatedcutting edgesdeprivedof theneces-
sary guards, unless they are suitably and safely
locked.
Neverlubricate, repairoradjustthemachinewiththe
engine running, except when this is specifically re-
quiredby theOperation andMaintenance Instruction
Manual.
Donotwearlooseclothing,jewellerynearrotatingparts.
When service or maintenance require access to ar-
eas that cannot be reached from the ground, use a
ladderor stepplatform conformingtolocalor national
regulationstoreach theworking area.If suchmeans
are not available, use machine grab rails and steps.
Alwaysperformallserviceor maintenancework with
thegreatestcare andattention.
Shopand/or fieldservice platformsor laddersshould
bemanufacturedandmaintainedin accordancewith
local or national safety regulations in force.
Disconnectbatteriesandlabel allcontrolstowarnthat
service work is in progress, according to local and
nationalsafety regulationrequirements
Block the machine and all attachments to be raised
according to local and national safety regulation re-
quirements.
Do not check or fill fuel tanks or install batteries near
burningor smokingmaterials andopenflamesdueto
thepresence offlammablevapours.
The fuel filler pipe nozzle must be constantly kept in
contact with the filler neck and this even before fuel
starts flowing in. Keep this contact from the begin-
ning to the end of the fuelling operation to avoid pos-
sible generation of sparks due to static electricity.
Usea truckortrailertohaul afailed machine.Should
it be necessary to tow it, provide for suitable danger
signals as required by the local norms and regula-
tionsand observerecommendations givenin theOp-
eration and Maintenance Instruction Manual. Load/
unloadthemachineonfirmlevelgroundprovidingsafe
supportto thewheelsofthe truckortrailer.Usestrong
accessramps,withadequateheightandangle.Keep
the trailer flatbed free of mud, oil or slippery materi-
als.Tie the machine securely to the trailer and block
carriagesand upperstructure.
Never align holes or slots using your fingers;
alwaysuseappropriate aligningtools.
Remove all sharp edges and burrs from re-worked
parts.
Useonly approvedand effectivelygroundedauxiliary
power sources for heaters, battery chargers, pumps
andsimilar equipmenttoreduceelectricalshock haz-
ard.
Liftand handleheavy componentsusing hoistingde-
vices of appropriate capacity. Ensure the parts are
supported by appropriate strapsandhooks.
Use lifting eyes provided to this aim.
Pay attention to bystanders near the lifting area.
Never pour gasoline or diesel fuel into open contain-
ers.Never usegasoline, solventsor otherflammable
fluids to clean parts. Use proprietary certified non-
flammable, non-toxic solvents only.
Whenusingcompressedairtocleanparts,wearsafety
glasses with side shields. Limit pressure to max. 2
bars,inaccordancewithlocalandnationalsafetyregu-
lations in force.
Donot runthe engineof thismachine inclosed build-
ings without proper forced ventilation capable to re-
move toxic exhaust gases concentrating in the air.
Donotsmoke,norallowopenflamesorsparksnearby
Copyright © New Holland

S1-6 E485
GENERALITIES
whilerefuellingthe unitor handling highlyflammable
materials.
Do not use open flames as light sources to look for
leaks or inspect anywhere on the machine.
Make sure that all mechanical tools provided are in
goodconditionat alltimes. Neveruse toolswithmush-
roomedor damagedheads. Alwayswear eyeprotec-
tions with side shields.
Move with extreme care when working under, on or
near the machine or its attachments.
In case of attachment tests during which the engine
should be kept running, a qualified operator must sit
in the driver’s seat at all times while the mechanic is
atwork.
Keep hands and clothes far OFF moving parts.
Stop the engine and move the safey lever to the lock
position before starting adjusting or repairing an as-
sembly.
Do not carry out any work on the attachment without
priorauthorisation.Observemaintenanceand repair
procedures.
In case of field service, move the machine to level
ground and block it. If work on an incline cannot be
avoided, securely block the machine and its attach-
ments.Movethemachineto levelground assoon as
possible.Do nottwist chainsandcables.Never usea
twistedchainor cableforliftingor pulling.Alwayswear
safety gloves to handle chains or cables.
Be sure chains and cables are firmly fastened and
that the anchor point is strong enough to withstand
the expected load. Keep all bystanders clear of the
anchor point, cables or chains. Do not pull or tow
unless the operator’s compartments of the ma-
chines involved are fitted with proper guards
against cable or chain backlash.
Keep themaintenancearea cleananddryatall times.
Cleanimmediatelyall waterandoil spillage.
Donotpile upoily orgreasy ragsasthey representa
major fire hazard. Always store them in closed metal
containers.
Before startingthemachineoritsattachment,check,
adjust and lock the operator’s seat.Also ensure that
nobodyis withinthemachine orattachmentoperating
rangebeforestartingoroperating themachineand/or
its attachments.
Soundthe horn.
Rustinhibitorsarevolatileand flammable.
Preparepartsinwellventilatedareas.Keepopenflames
away.
Do not smoke. Store containers in a cool well venti-
latedplace wheretheycould notbereachedbyunau-
thorisedpeople.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
safetyshoes andgloves, safety glasses whensplin-
ters or other particles may be ejected.
Weartheappropriatewelder’sequipmentsuchasdark
safetyglasses ormask,hardhat,protective clothing,
safety gloves and footwear always while welding or
arc-cutting.Wear dark safety glasses when you are
neara weldingin progress.Do not look the welding
arc without proper eye protection.
Become acquainted with all your jacking equipment
andtheircapacity.
Ensure that the jacking point on the machine is ap-
propriate for the load applied.Also, be sure the sup-
ports under the jack and between the jack and the
machineare appropriateandstable.
Anyequipmentsupported by ajackrepresentsapos-
sible hazard.Always support the load onto appropri-
ate blocking means as a safety measure before pro-
ceedingwith serviceor maintenancework, incompli-
ance with local or national safety regulations.
Metal cables produce steel splinters. Always wear
certified protectionclothes suchas safetyglovesand
glasseswhilehandlingthem.
Do not use makeshift jacks to adjust track sag. Fol-
low instructions given in the Repair Manual.
Handle all parts carefully. Keep hands and fingers
away from gaps, gears, and similar. Always use and
wear certified safety clothes such as safety glasses,
gloves andfootwear.
The attachment is kept constantly in position by an
oilcolumntrappedintothehigh pressurecircuit.Lower
theattachmenttothegroundandrelievepressurefrom
all circuits prior to carrying out any type of mainte-
nanceor repairwork.
Do not service or repair the machine if it is parked
downhill.Ifthisis unavoidable,in caseof emergency,
blockthecarriagesto preventunexpected movement,
particularly ifthe work isto be carriedouton thefinal
reductionunitsor travelmotors.
Consult the Operation and Maintenance Instruction
Manualfor correctmaintenance procedure.
Areasnear articulated cuttingedges wheremechani-
calparts areinmotion arewherepersonalinjuriesare
mostlikely tooccur.Payattentiontopreventpossible
part movements by means of blocks or by keeping
clearof suchzones whenmotion maytakeplacedur-
ingmaintenance orrepair.
Move the hydraulic system lock safety lever to the
lock position when stopping the machine for what-
everreason.
Alwaysinstallthe safetystays forthe hoodand other
hingedcovers beforeperforming anymaintenanceor
repairworkintheenginecompartment.
TRANSFERSANDTRANSPORTATION
Before moving or transporting the machine, block
upperstructure swing to prevent accidental move-
ment.
Pay particular attention during transfer on inclines,
both uphill and downhill.Keep the bucket in a posi-
tion to provide a possible anchor point into the
ground in case of slipping.
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E485 S1-7
GENERALITIES
Duringtransfers oninclines, bothuphillanddownhill,
keep the upperstructure aligned with the carriages.
Do not travel across the slope.
Never transfer the machine in the working site, in a
crowdedarea,or nearpeople withouthavingat least
onepersonchargedwithhand-signalswhocouldguide
theOperator.
Soundthe hornto informthat youareabouttomoveoff.
It is necessary to know load limits of bridges and di-
mensional limits of tunnels. Such limits must never
be exceeded.You should also know machine height,
width,and weight.Haveasignal-manhelp youwhen
clearancesarelimited.
Checkdistance betweenboom/arm anddimensional
limitsduring transferortransportation.
Rough terrain may cause the machine to sway and
rollto suchan extentthat boom/armcould getto con-
tactelectric linesorotherobstacles.Cross obstacles
at a right angle at low speed. Pay attention to ma-
chine shaking when the centre of gravity overcomes
the obstacle.
Keep the bucket down at all times during transfers.
Drive with the lights on and use appropriate signals
and flags.
Get to know and respect local and national regula-
tions.
Consider boom/arm and upperstructure dimensions
whileturning.
Usearampto loadthemachine ona trailer.If aramp
isnotavailable, fabricate oneusing blocks.The ramp
should be sufficiently strong to support machine
weight.Alwaysload andunload on levelsurface.
Tow themachine followingthe instructions contained
intheOperationand MaintenanceInstructionManual.
ENGINE
Donotruntheengineinclosedbuildingswithoutproper
ventilationcapable toremoveharmful exhaustfumes.
Donot placehead, body,limbs, feet, handsorfingers
nearrotatingfansorbelts. Beespecially carefulnear
blowerfans.
Loosenthe radiatorcap veryslowly torelieve system
pressure before removing it. Always top-up coolant
level with the engine off or idling if hot. See the Op-
erationand MaintenanceInstruction Manual.
Keep the exhaust manifold and tube free from com-
bustible matters. Fit the machine with shields and
guardswhen workinginthepresenceof combustible
matter free in the air.
Do not refuel with the engine running, especially if
hot, as this increases fire hazard in case of fuel spill-
age.
Never attempt to check or adjust fan belt tensions
whenthe engineis running.
Do not adjust the fuel injection pump when the ma-
chineisoperating.
Donot lubricatethe machinewiththe enginerunning.
Do not run the engine with the air intakes open and
not protected. If this cannot be avoided for service
reasons, place protection meshes on all intakes be-
foreservicingthe engine.
ELECTRICAL SYSTEM
Pay attention to connect connecting cables to cor-
rect poles (+ to +) and (- to -) at both ends. Do not
short-circuit terminals. Thoroughly follow instruc-
tions given in Operation and Maintenance Instruc-
tion Manual.
Always move the key-start switch in the lock posi-
tion before servicing or repairing the machine.
Batteries contain SULPHURIC ACID. Protect the
eyes when working near the batteries against pos-
sible sprays of the acid solution. Should acid con-
tact skin, eyes, or clothes, RINSE IMMEDIATELY
INWATER FOR AT LEAST 15 MINUTES.Immedi-
ately seek medical attention.
Battery released gas is highly flammable. Leave
thebattery compartmentcoveropen during recharg-
ing to improve ventilation. Never check battery
charge by placing metal objects across the posts.
Keep sparks or open flames away from batteries.
Do not smoke near the battery to prevent explo-
sion hazard.
Before any maintenance or repair, make sure that
there are no fuel or electrolyte leaks from the bat-
teries. If any, correct prior to proceeding with fur-
ther work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to
avoid accidental explosions due to build-up of ex-
plosive gas released during charging.
Disconnect batteries before working on the electri-
cal system or carrying out any other type of work.
HYDRAULIC SYSTEM
Pressure fluid escaping from a very small hole can
be almost invisible and still have sufficient force to
penetrate the skin. Always check any suspected
pressure leaks using a piece of cardboard or wood.
Do not use hands. If injured by escaping fluid, ob-
tain medical attention immediately or serious in-
fection or reaction may develop.Stop the engine
and ensure pressure is relieved from all systems
before removing side panels, housings, guards and
covers. See the Operation and Maintenance In-
struction Manual.
Always use gauges of adequate capacity for pres-
sure testing. Refer to the Operation and Mainte-
nance Instruction Manual or Repair Manual.
Copyright © New Holland