Tier 4B (final)
Compact Hydraulic Excavator
PIN NETN36001(PX17-40001) and above
Part number S5HX0011E01
1st edition English October 2014
SERVICE MANUAL E35B
SER VICE MANUAL
E35B Cab TIER (FINAL)
E35B Canopy TIER (FINAL)
S5HX001 1E01 14/10/2014
Contents
INTRODUCTION
Machine completion and equipment
Machine completion Engine
[10.202] Air cleaners and lines
[10.216] Fuel tanks
[10.254] Intake and exhaust manifolds and muf fler
Engine cooling system
[35.000] Hydraulic systems
Reservoir , cooler , and filters
Combination pump units
Hydraulic swing system
Hydraulic travel system
[35.736]
[35.737]
[35.738] Excavator and backhoe bucket hydraulic system
[48.100]
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
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Hydraulic systems
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Pilot system Main control valve [35.525] Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.8
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Boom hydraulic system
hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10
Dipper
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 1 Swing arm hydraulic system Dozer blade cylinders Frames and ballasting
Upper frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 T racks and track suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
[39.101]
T racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 S5HX001 1E01 14/10/2014
T rack frame and driving wheels
T rack tension units
T rack rollers
Cab climate control
[50.200] Air conditioning
Electrical systems
Electrical system
Fuel tank system
Engine cooling system
Hydraulic system control
Harnesses and connectors
Engine starting system
Alternator
Battery
External lighting
W arning and instruments
Cab controls 1
Cab lighting
Wiper and washer system
Cab engine controls
Electronic modules
Booms, dippers, and buckets
Bucket
14] Boom pivoting support
Boom
Dipper arm
Dozer blade and arm
[86.1 10] Dozer blade
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
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[90.150] Cab . . .
[90.151] Cab interior
bodywork, and decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Platform, cab,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
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S5HX001 1E01 14/10/2014 1
INTRODUCTION
Foreword - Important notice regarding equipment servicing
Safety rules - Ecology and the environment (*)
instructions - Shop and assembly (*)
T orque - Minimum tightening torques for normal assembly (*)
T orque - Standard torque data for hydraulics (*)
Capacities
Hydraulic contamination (*)
General specification
Product identification (*)
(*) See content for specific models
Contents INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Safety
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Safety rules
Safety rules Personal
(*)
Basic
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S5HX001 1E01 14/10/2014 2
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed this manual must carried out only qualified dealership strictly complying with the instructions and whenever the special
Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall responsible for any subsequent
The manufacturer and all the organizations its distribution chain, including - without limitationnational, regional, local reject any responsibility for damages caused parts and / components not approved the facturer , including those used for the servicing repair the product manufactured marketed the manufacturer any case, warranty given attributed the product manufactured marketed the manufacturer case damages caused parts and / components not approved the manufacturer
The manufacturer reserves the right make improvements design and changes specifications any time without notice and without incurring any obligation install them units previously and illustrative material herein are accurate known time publication but are subject change without notice. case refer your NEW HOLLAND CONSTRUCTION Sales and Service
INTRODUCTION
S5HX001 1E01 14/10/2014 3
Safety rules
Personal safety
This the safety alert used alert you potential personal injury Obey all safety messages that follow this symbol avoid possible death injury
Throughout this manual you will find the signal words W and CAUTION followed special These precautions are intended for the personal safety you and those working with
Read and understand all the safety messages this manual before you operate service the
DANGER indicates a hazardous situation not will result death serious injury
W ARNING indicates a hazardous situation not could result death serious injury
CAUTION indicates a hazardous situation not could result minor moderate injury
F AILURE T O FOLLOW
Machine safety
NOTICE: Notice indicates a situation that, not avoided, could result machine property damage.
Throughout this manual you will find the signal word Notice followed special instructions prevent machine property damage. The word Notice used address practices not related personal safety .
Information
NOTE: Note indicates additional information that clarifies other information this
Throughout this manual you will find the word Note followed additional information about a step, other information the The word Note not intended address personal safety property
INTRODUCTION
DANGER,
DEA
W ARNING, AND CAUTION MESSAGES COULD RESUL T
SERIOUS INJUR Y .
S5HX001 1E01 14/10/2014 4
E35B
Safety rules - Ecology and the environment
air , and water quality
important for all industries and life
When legislation does not yet rule the treatment some the substances that advanced technology sound judgment should govern the use and disposal products a chemical and petrochemical
NOTE: The following are recommendations that may assistance:
• Familiarize yourself with the relative legislation applicable your country , and make sure that you understand this
• Where legislation obtain information from suppliers anti - cleaning agents, etc., with regard the fect these substances man and nature and how safely store, use, and dispose these
Helpful hints
• A void the use cans other inappropriate pressurized fuel delivery systems fill Such delivery systems may cause considerable
• avoid skin contact with all Most these products contain substances that may harmful your
• Modern oils contain not burn contaminated fuels and waste oils ordinary heating
• A void spillage when you drain fluids such used engine coolant engine hydraulic brake etc. not mix drained brake fluids fuels with lubricants. Store all drained fluids safely until you can dispose the fluids a proper way that complies with all local legislation and available
• not allow coolant mixtures get into the soil. Collect and dispose coolant mixtures properly .
• The air - conditioning system contains gases that should not released into the Consult airtioning specialist use a special extractor recharge the system properly
• Repair any leaks defects the engine cooling system hydraulic system immediately
• not increase the pressure a pressurized circuit this may lead a component
• Protect hoses during Penetrating weld splatter may burn a hole weaken allowing the loss
Battery recycling
Batteries and electric accumulators contain several substances that can have a harmful fect the environment the batteries are not properly recycled after use. NEW HOLLAND CONSTRUCTION strongly recommends that equipment owners return all used batteries a [Brand] dealer , who will dispose the used batteries recycle the used batteries properly some this a legal
INTRODUCTION
S5HX001 1E01 14/10/2014 5
E35B
Safety rules Personal Safety
Most accidents involving machine operation and maintenance can avoided following basic safety rules and Read and understand all the safety messages this manual and the safety signs the machine before you operate service the See your dealer you have any
READ THIS MANUAL COMPLETEL Y and make sure you understand the All equipment has a Make sure you understand the speed, stability , and load characteristics the machine before you start operate this
NOT remove this manual from the machine.
The safety information given this manual does not replace safety insurance local laws. Make sure that your machine has the correct equipment according these rules laws.
Additional safety messages are used the text the manual show specific safety
NOTICE: The safety messages this chapter point out conditions which can happen during the normal operation and maintenance your machine. These safety messages also give possible ways dealing with these conditions.
INTRODUCTION
S5HX001 1E01 14/10/2014 6
E35B
Basic instructions - Shop and assembly
Shimming
For each adjustment select adjusting shims and measure the adjusting shims individually using a eter , then add the recorded not rely measuring the entire shimming which may the rated value shown each
Rotating shaft seals
For correct rotating shaft seal proceed follows:
Before assembly , allow the seal soak the oil will sealing for least thirty
Thoroughly clean the shaft and check that the working surface the shaft not
Position the sealing lip facing the fluid.
NOTE: W ith hydrodynamic take into consideration the shaft rotation direction and position the grooves that they will move the fluid towards the inner side the
Coat the sealing lip with a thin layer lubricant (use oil rather than grease). Fill the gap between the sealing lip and the dust lip double lip seals with
Insert the seal its seat and press down using a flat punch seal installation not tap the seal with a hammer
While you insert the check that the seal perpendicular the When the seal make sure that the seal makes contact with the thrust
T o prevent damage the seal lip the position a protective guard during installation
O - ring seals
Lubricate the O - ring seals before you insert them the
This will prevent the O - ring seals from overturning and twisting, which would jeopardize sealing ficiency .
Sealing compounds
Apply a sealing compound the mating surfaces when specified the procedure. Before you apply the sealing prepare the surfaces directed the product container
Spare parts
Only use CNH Original Parts NEW HOLLAND CONSTRUCTION Original
Only genuine spare parts guarantee the same quality , duration, and safety original parts, they are the same parts that are assembled during standard Only CNH Original Parts NEW HOLLAND CONSTRUCTION Original Parts can fer this
When ordering spare always provide the following information:
• Machine model (commercial name) and Product Identification Number (PIN)
• Part number the ordered which can found the parts catalog
INTRODUCTION
S5HX001 1E01 14/10/2014 7
Protecting the electronic and / electrical systems during charging and welding
T o avoid damage the electronic and / electrical systems, always observe the following practices:
Never make break any the charging circuit connections when the engine including the battery
Never short any the charging components
Always disconnect the ground cable from the battery before arc welding the machine any machine
• Position the welder ground clamp close the welding area
• you weld close proximity a computer then you should remove the module from the
• Never allow welding cables lie near , across any electrical wiring electronic component while you weld.
Always disconnect the negative cable from the battery when charging the battery the machine with a battery charger
NOTICE: you must weld the unit, you must disconnect the battery ground cable from the machine battery . The electronic monitoring system and charging system will damaged this not
Remove the battery ground Reconnect the cable when you complete
W ARNING
Battery acid causes Batteries contain sulfuric A void contact with skin, eyes clothing. Antidote (external): Flush with water . Antidote (eyes): flush with water for minutes and seek medical attention immediately . Antidote (internal): Drink large quantities water not induce Seek medical attention immediately
Failure comply could result death serious injury .
Special tools
The special tools that NEW HOLLAND CONSTRUCTION suggests and illustrate this manual have been specifically researched and designed for use with NEW HOLLAND CONSTRUCTION The special tools are essential for reliable repair The special tools are accurately built and rigorously tested fer ficient and longlasting
using these repair personnel will benefit from:
• Operating optimal technical conditions
• Obtaining the best results
• Saving time and fort
• W orking safe conditions
INTRODUCTION
W01
1
S5HX001 1E01 14/10/2014 8
INTRODUCTION T orque - Minimum tightening torques for normal assembly E35B Decimal hardware Grade 5 bolts, nuts and studs Size / 1 / 4 - 108 - 132 5 / - 204 - 252 3 / 8 - 420 - 504 7 / -1 / 2 109 - 1309 / 149 - 179 1 - 132
/ 8 203 - 244 150 - 180
/ 4 366 - 439 270 - 324 7 / 8 542 - 651 400 - 480 1 787 - 944 580 - 696 1 - 1 / 8 1085 - 1 193 800 - 880 1 - 1 / 4 1519 - 1681 1 120 - 1240 1 - 3 / 8 1980 - 2278 1460 - 1680 1 - 1 / 2 2631 - 2983 1940 - 2200 Grade 8 nuts and studs Size / 1 / 4 - 144 - 180 5 / - 288 - 348
/ 8 - 540 - 648
/ - 11 / 2 149 - 179 1 - 132 9 / 217 - 260 160 - 192 5 / 8 298 - 358 220 - 264 3 / 4 515 - 618 380 - 456 7 / 8 814 - 976 600 - 720 1 1220 - 1465 900 - 1080 1 - 1 / 8 1736 - 1953 1280 - 1440 1 - 1 / 4 2468 - 2712 1820 - 2000 1 - 3 / 8 3227 - 3688 2380 - 2720
- 1 / 2 4285 - 4827 3160 - 3560
nuts with Grade 8 Metric hardware Grade nuts and studs Size / 4 3 - 45 7 - 86 1 1 - - 108 8 - 228 - 276 - 456 - 540 - 107144 - 172 106 - 127 217 - 271 160 - 200 434 - 515 320 - 380 675 - 815 500 - 600 1250 - 1500 920 - 1 100 2175 - 2600 1600 - 1950 S5HX001
9
5
3
3
7
1
NOTE: Use thick
1E01 14/10/2014
Split flange mounting bolts
INTRODUCTION Grade nuts and studs Size / 4 4 - 55 9 - 1 16 - 132 - 156 8 - 324 - 384 -125 - 150 - 1 200 - 245 149 - 179 310 - 380 230 - 280 610 - 730 450 - 540 1050 - 1275 780 - 940 2000 - 2400 1470 - 1770 3500 - 4200 2580 - 3090
Size / T ypically the torque values specified for grade hardware can used satisfactorily grade
37° flare fitting T ube outside diameter / Hose inside diameter inch Thread size / 6.4 1 / 4 7 / - 8 - - 144 5 / 1 / 2 - 1 1 - - 192 9.5 3 / 8 9 / - - 120 - 300 1 / 2 3 / 4 - - 180 - 504 15.9 5 / 6 7 / 8 - - 300 - 696 3 / 4 1 - 1 / - - 10822.2 7 / 8 1 - 3 / - - 135 - 100 25.4 1 1 - 5 / - 102 - 158 - 1 31.8 1 - 1 / 4 1 - 5 / 8 - 169 - 223 125 - 165 38.1 1 - 1 / 2 1 - 7 / 8 - 285 - 338 210 - 250
T ube outside diameter / Hose inside diameter inch Thread size / 1 / 4 7 / - - 144 - 228 7.9 5 / 1 / 2 - - 192 - 300 3 / 8 9 / - - 300 - 480 12.7 1 / 2 3 / 4 - - 540 - 804 5 / 6 7 / 8 - - 12419.0 3 / 4 1 - 1 / - 108 - 174 - 128 22.2 7 / 8 1 - 3 / - 136 - 216 100 - 160 25.4 1 1 - 5 / - 159 - 253 1 - 187 31.8 1 - 1 / 4 1 - 5 / 8 - 224 - 357 165 - 264 1 - 1 / 2 1 - 7 / 8 - 339 - 542 250 - 400
Size / 5 / - - 180 - 240
/ 8 - - 240 - 300
/ - - 420 - 540 1 / 2 - -S5HX001 1E01 14/10/2014
Grade nuts and studs
Steel hydraulic fittings
Straight threads with O - ring
3
7
INTRODUCTION Size / 5 / 8 - 1 1 190 - 203 140 - 150 O - ring face seal end O - ring boss end fitting lock nut T ube outside diameter Nominal SAE dash size Thread size / Thread size / - 4 1 / 4 9 / - - 120 - 144 7 / - - 204 - 240 - 6 3 / 8 1 1 / - - 216 - 240 9 / - - 300 - 360 - 8 1 / 2 / - - 384 - 480 3 / 4 - - 540 - 600 - 5 / 8 1 - - 552 - 672 7 / 8 - -- 3 / 4 1 - 3 /1 - 1 - 1 /112222.2 7 / 8 1 - 3 /1 - 1 - /129136 - 10025.41 1.0 1 - 7 /125140 - 105 1 - 5 /156169 1 - 12531.8 1 - 1 / 4 1 - 1 1 /170190 125 - 140 - 5 / 6201217 150 - 160 - 1 - 1 / 2 2 - 200254 150 - 180 1 - 7 / 8 - 258271 190 - 200 S5HX001 1E01 14/10/2014 1 1
T orque - Standard torque data for hydraulics E35B
Installation adjustable fittings straight thread O - ring bosses
Lubricate the O - ring coating with a light oil
Install the O - ring the groove adjacent the metal backup washer which assembled the extreme end the groove (4)
Install the fitting into the SAE straight thread boss until the metal backup washer contacts the face the boss (5)
NOTE: not over tighten and distort the metal backup washer
Position the fitting turning out (counterclockwise) a maximum one Holding the pad the fitting with a tighten the locknut and washer against the face the boss (6)
Standard torque data for hydraulic tubes and fittings T ube nuts for 37° flared fittings O - ring boss plugs adjustable fitting
These torques are not recommended for tubes ( 1 / 2 ) and larger with wall thickness ( 0.035 ) The torque specified for 0.889 ( 0.035 ) wall tubes each application individually
Before installing and torquing ° flared clean the face the flare and threads with a clean solvent Loctite cleaner and apply hydraulic sealant L OCTITE ® 569™ the ° flare and the
Install fitting and torque specified loosen fitting and retorque
INTRODUCTION
23085659 1
locknuts, swivel JIC37° seats Size T ubing Thread size T orque T orque 4 6.4 ( 1 / 4 ) 7 / - - N·m ( 9 - ) 8 - N·m ( 6 - ) 5 ( 5 / ) 1 / 2 - - N·m ( - ) - N·m ( - ) 6 9.5 ( 3 / 8 ) 9 / - - ( - ) - ( - ) 8 12.7 ( 1 / 2 ) 3 / 4 - - N·m ( - ) - N·m ( - ) ( 5 / 8 ) 7 / 8 - - N·m ( - ) - N·m ( - ) ( 3 / 4 ) 1 - 1 / - 104 - 1 1 1 N·m ( - ) - N·m ( - ) 22.2 ( 7 / 8 ) 1 - 3 / - 122 - 136 ( - 100 ) - 109 ( - ) 25.4 ( 1 ) 1 - 5 / - 149 - 163 N·m ( 1 - 120 ) 108 - 122 N·m ( - ) ( 1 - 1 / 4 ) 1 - 5 / 8 - 190 - 204 N·m ( 140 - 150 ) 129 - 158 N·m ( - 1 ) 38.1 ( 1 - 1 / 2 ) 1 - 7 / 8 - 217 - 237 ( 160 - 175 ) 163 - 190 ( 120 - 140 ) 50.8 ( 2 ) 2 - 1 / 2 - 305 - 325 ( 225 - 240 ) 339 - 407 ( 250 - 300 )
S5HX001 1E01 14/10/2014
Pipe thread fitting torque
Before installing and tightening pipe clean the threads with a clean solvent Loctite cleaner and apply sealant L OCTITE ® 567™ PST P IPE S EALANT for all fittings including stainless steel L OCTITE ® 565™ PST for most metal fittings. For high filtration / zero contamination systems use L OCTITE ® 545™
Installation ORFS - Ring Flat Seal fittings)
When installing ORFS fittings thoroughly clean both flat surfaces the fittings (1) and lubricate the O - ring (2) with light Make sure both surfaces are aligned properly T orque the fitting specified torque listed throughout the repair
NOTICE: the fitting surfaces are not properly cleaned, the O - ring will not seal properly the fitting surfaces are not properly the fittings may damaged and will not seal properly
NOTICE: Always use genuine factory replacement oils and filters ensure proper lubrication and filtration gine and hydraulic system oils.
The use proper and keeping the hydraulic system clean will extend machine and component life.
INTRODUCTION
Thread size T orque (maximum) 1 / 8 - ( ) 1 / 4 - N·m ( ) 3 / 8 - N·m ( ) 1 / 2 - ( ) 3 / 4 - N·m ( )
5001 1 183 2 S5HX001 1E01 14/10/2014
INTRODUCTION
Component filled Quantity Consumable Manufacturer specifications International specifications NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 10WT3507 Engine oil pan 3.96.7 L (1.8 gal ) NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 15WT3507 API 4 / - 4 ACEA / T ravel motor 0.6 L ( gal ) x 2 Upper rollers cm³ ( 3.4 in³ ) x 2 Idler wheels cm³ ( 4.9 in³ ) x 2 NEW HOLLAND AMBRA HYPOIDE T351 1 API 5 Lower rollers 65.0 cm³ ( 4.0 in³ ) x NEW HOLLAND AMBRA SUPER GOLD 10WT3521 API 4 / - 4 ACEA / Radiator (1) 1.8 L ( gal ) 3.8 L ( 1.0 gal ) (total system) NEW HOLLAND AMBRA AGRIFLU900 C ASTM D 3306 Fuel tank 42.0 L ( 1 1.1 gal ) 590 Hydraulic oil tank (2) L ( 5.4 gal ) 44.8 L ( 1 1.8 gal ) (hydraulic system) NEW HOLLAND AMBRA HYDROSYSTEM T3509 and attachment places Dozer blade cylinder 4 places Slewing bearing 1 place Boom swing cylinder pin 2 place Operating lever and pedal bly required NEW HOLLAND AMBRA T3550 NLGI 2 Swing pinion 1 place NEW HOLLAND AMBRA T3550 NLGI 2 Air conditioning 0.60 ( ) R134 A Compressor 120 cm³ ( in³ ) S ANDENL UBRICANT NOTE:
Coolant mixed with water % Cooling system total volume: ~ 6 l ( 1.59 gal )
Hydraulic system total volume: ~ 44.8 L ( 1 1.8 gal ) the machine was filled with biodegradable hydraulic oil P ANOLIN HLP SYNTH take note that this oil cannot mixed with mineral hydraulic S5HX001 1E01 14/10/2014
Capacities
(1)
NOTICE: (2)
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