New Holland E175C Crawler Excavator Service Repair Manual by kmd9isobnvmk

Hydraulic

Hydraulic systems

. . . . . . . . . .

Pump control valves [35.106] V ariable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

Reservoir , cooler , and filters Hydraulic swing system [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 Hydraulic central joint Hydraulic hand control Hydraulic foot control [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10

Contents

INTRODUCTION

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine and crankcase [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Fuel tanks Intake and exhaust manifolds and muf fler [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hydraulic system 1

hydraulic system

Excavator and backhoe bucket hydraulic system

. . .

. . . . [39.101] Upper frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 Swing ring assembly Ballasts and supports T racks and track suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [48.100] T racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.1 47494131A 1 1/03/2013

Boom

Dipper

[35.738]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.13 Frames and ballasting . .

. . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab climate control

T rack

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48.4

rack frame and driving wheels T rack tension units [48.138]

rollers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine control system [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 55.3 [55.051] Cab Heating, V entilation, and Air-Conditioning

AC) controls

Harnesses and connectors

Battery . . . . . . . . . . . . . .

. . . . . . . 55.6 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

55.7

Booms, dippers, and buckets . . . . . . . . . . . . . . . . . . . . . . . . . .

[84.100] Bucket

Boom Platform, cab, bodywork, and decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine shields and guards [90.1 16] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.124] operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 Cab 47494131A 1 1/03/2013

Air conditioning

systems

Electrical system

. . . . . . . . . . . . . . . . . . . . . . . . . .

(HV

. . . . . . . . . . . . . . . . . . . 55.4

[55.302]

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

F AUL T CODES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.1

47494131A 1 1/03/2013 1

INTRODUCTION

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 DANGER, W ARNING, 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 machine.

DANGER indicates a hazardous situation not will result death serious injury

W ARNING indicates a hazardous situation which, not avoided, could result death serious injury .

used with the safety alert indicates a hazardous situation not could result minor moderate injury .

F AILURE T O FOLLOW DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .

Machine safety

NOTICE: Notice indicates a situation not could result machine property

Throughout this manual you will find the signal word Notice followed special instructions prevent machine property The word Notice used address practices not related personal safety

Information

NOTE: Note indicates additional information which clarifies steps, procedures, other information this manual.

Throughout this manual you will find the word Note followed additional information about a other information the manual. The word Note not intended address personal safety property damage.

INTRODUCTION

47494131A 1 1/03/2013 3

Personal safety

Carefully read this Manual before proceeding with refuelling other machine

Repairs have carried out only authorized and structed staf specific precautions have taken when welding when using mallets heavy mers.

Not authorized persons are not allowed repair carry out maintenance this machine. not carry out any work the equipment without prior

Ask your employer about the safety instructions force and safety

Nobody allowed seat the operator ’ s place during machine maintenance unless a qualified operator helping with the maintenance

necessary move the equipment carry out pairs not lift lower the equipment from any other position than the operator ’ s seat.

Never carry out any operation the machine when the engine except when specifically

Stop the engine and ensure that all pressure relieved from hydraulic circuits before removing caps, covers,

All repair and maintenance operations should carried out with the greatest care and

Service stairs and platforms used a workshop the field should built compliance with the safety rules

Any functional especially those fecting the safety the should therefore rectified mediately .

DANGER

Unexpected movement! Make sure parking brake applied. Secure machine with wheel chocks. Failure comply will result death serious injury .

D0013A

Before performing any work the machine, attach a maintenance progress This tag can applied the left - hand control lever , safety lever cab door

TULI12WEX2004AA 1

TULI12WEX2005AA 2

TULI12WEX2006AA 3

INTRODUCTION

47494131A 1 1/03/2013 4

Emergency

prepared for emergencies. Always keep disposal the machine a first aid kit and a fire extinguisher Make sure that the fire extinguisher serviced accordance with the manufacturer ’ s

SMIL12WEX0174AA 4

Equipment

W ear close fitting clothing and safety equipment ate for the job:

• Safety helmet

• Safety shoes

• Heavy gloves

• Reflective clothing

• W weather clothing environment condition require following personal safety equipment should hand:

• Respirators (or dust proof masks)

• Ear plugs acoustic ears protections

• Goggles with lateral shield masks for eyes protection not wear unbuttoned flapping clothing such torn open jackets shirts with open zips which could get caught into moving

Engine - Radiator

Never leave the engine run closed spaces without lation and not able evacuate toxic exhaust Keep the exhaust manifold and tube free from combustion terials.

not refuel with the engine especially this increases fire hazard case fuel spillage.

Never attempt check adjust the belts when the engine

Never lubricate the machine with the engine

TULI12WEX2008AA 5

TULI12WEX2009AA 6

INTRODUCTION

47494131A 1 1/03/2013 5

Pay attention rotary pieces and not allow anyone approach avoid becoming

clothes tools get caught the fan blades the transmission belt, this can cause amputations, violent tears and generate condition serious danger; for this reason avoid touching come close all rotary moving

A violent jet the coolant from the radiator can cause damages and

you are check the coolant you have shut - f the engine previously and let cool down the radiator and its Slowly unscrew the cap release the inside

necessary , remove the cap with hot wear safety clothes and equipment, then loosen the cap slowly lieve the pressure gradually

When checking the fuel, oil and coolant levels, use clusively explosion proof classified this kind lamps are not used fires explosions may occur

Hydraulic systems

Splashes fluids under pressure can penetrate the skin causing serious

A void this hazard relieving pressure before ing hydraulic other

Relieve the residual pressure moving the hydraulic control levers several

T ighten all connections before applying

T o protect the eyes wear a facial shield safety

Protect your hands and body from possible splashes fluids under

Swallowing hydraulic oil a severe health

TULI12WEX2010AA 7

TULI12WEX201 1AA 8

TULI12WEX2012AA 9

INTRODUCTION

47494131A 1 1/03/2013 6

When hydraulic oil has been avoid but consult a doctor a

accident see a doctor familiar with this type injury immediately .

Any fluid penetrating the skin must removed within few hours avoid serious infections.

Flammable splashes may originate because the heat near pipes with fluids under pressure, with the result serious scalds for the persons not weld use torches near pipes containing fluids other flammable

Pipes under pressure can accidentally pierced when the heat expands beyond the area immediately heated.

Arrange for fire resistant temporary shields protect hoses other components during welding.

Have any visible leakage repaired immediately

Escaping oil pollutes the

Soak any oil that has escaped with a proper binding Sweep binding agent and dispose separately from other

Never search for leakages with the but use a piece cardboard and always wear

Never repair damaged piping; always replace Replace hydraulic hoses immediately detecting any damage moist

Always store hydraulic oil the original

INTRODUCTION

TULI12WEX2013AA 47494131A 1 1/03/2013 7

SER VICE MANUAL

Engine

E175C

47494131A 1 1/03/2013

Fuel tanks E175C

Intake and exhaust manifolds and muf fler E175C

Engine cooling system E175C

Contents

Engine[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 E175C [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 E175C

47494131A 1 1/03/2013

EngineEngine and crankcase - 001 E175C 47494131A 1 1/03/2013 10.1 [10.001] / 1

Contents Engine -

and crankcase - 001

Engine

General specification 3 SER VICE Engine Prepare 6 Remove 8 Install Measure 1 1 Service instruction 47494131A 1 1/03/2013 10.1 [10.001] / 2

TECHNICAL T A Engine

Engine - Engine and crankcase Engine - General specification Performance Maximum climbable gradient : 70% Swing speed : 1 1.5 RPM T ravel speed Slow / h ( mph ) Fast 4.9 / h ( 3.04 mph ) Engine specifications Main specifications Maker FPT Model F4GE9484D*JG T ype W atercooled, 4 cycle direct injection type, diesel engine with intercooler turbo - charger Number cylinders 4 - line Bore 104 ( 4.09 ) Stroke 132 ( 5.20 ) T otal displacement l ( 275 in³ ) Compression ratio Rated output power (at 2200 RPM ) ( ISO 14396 : without fan) ( 131 ) Maximum torque (at 1250 RPM ) ( ISO 14396 ) 525 N·m ( 387.2 ) High idling 2380 RPM - 2480 RPM Low idling 750 RPM - 850 RPM Fuel consumption rate 231 g / kWh Engine oil quantity l ( 3.2 gal ) W eight 392 ( 864 ) Feeding T ype Direct injection from rotary pump Injection sequence 1 - 3 - 4 - 2 Battery V oltage 2 x V Capacity 2 x 100 A·h Starter motor Maker BOSCH V oltage V Output 4 ( 5.4 ) Alternator Maker BOSCH V oltage V Output A Engine characteristic curve Condition measured: The net value measuring without cooling 47494131A 1 1/03/2013 10.1 [10.001] / 3

Engine - Engine and crankcase

47494131A 1 1/03/2013 10.1 [10.001] / 4

SMIL13CEX0173HA 1 Performance between nominal maximum torque and maximum power taken LDA intervention shown the lowest possible engine

LDA intervention area

Fuel consumption volume

= (Fuel consumption rate / x 1000) x x Load factor (α)

= ( 231 g / kWh / 0.835 x 1000) x ( 126.4 ) x α

= α L / h

standard load factor -

Fuel consumption regular operation (load factor19.322.1 l / hour ( 5.15.8 gal / hour )

NOTE: Fuel consumption curve derived from engine prototype

Engine - Engine and crankcase

47494131A 1 1/03/2013 10.1 [10.001] / 5

Engine - Prepare

Remove battery

Remove bonnet and Remove under cover

Remove air cleaner hose. Remove

Remove radiator hose and intercooler hose.

Remove fuel hose and heater and essary disconnect air - con necessary , remove muf fler and tor

Remove harness connector Remove E / G ground

Starter cable - starter B

Remove the connector that connects the upper harness with the engine and ECU harness.

Upper harness Alternator B terminal

- 160 E / G speed sensor

- 141 , CN142 , Pump proportional valve

- 139 , - 140 , pump pressure sensor

M - 1 Starter motor C terminal

NOTE: Prepare a which withstands the weight the engine assy and can place the removed engine firmly

Engine - Engine and crankcase

47494131A 1 1/03/2013 10.1 [10.001] / 6

Engine - Engine and crankcase SMIL13CEX0174GB 1 Alternator Thermostat Oil filter element Fuel filter element Starter 47494131A 1 1/03/2013 10.1 [10.001] / 7

Engine - Engine and crankcase Engine - Remove SMIL13CEX0175HB 1 47494131A 1 1/03/2013 10.1 [10.001] / 8

Remove hose engine oil filter .

Place oil pan under the connection filter (1) and disconnect hoses (2) , (3)

Plug connector filter side and

Remove hose fuel injection

Place fuel pan under the connection fuel injection pump (4) and disconnect the following hoses: hose (A) from fuel injection pump filter; hose (B) from water separator fuel injection; hose (C) from fuel injection pump tank; hose (D) from filter fuel injection pump

Loosen engine mounting bolt frame:

Remove 4 nuts (10) M16 and 4 washers

: Remove 2 capscrews (33) M16 , 2 capscrew (8) M16 and 4 washers

Remove plates (30) and (31) and covers (5) and (6)

Remove upper rubber mounts (32) and (7)

Slinging engine body

Sling engine hooking wire lifting lugs the front and rear W eight: 392 ( ) Wire: 6 ( 0.232 ( 0.01 ) ) x 1 m ( 3.28 ) - 2 pcs.

NOTICE: Prepare a which withstands the weight the engine assy and can place the removed engine firmly

Position engine the stand stably

Remove lower rubber mounts (32) and (7)

Engine - Engine and crankcase

47494131A 1 1/03/2013 10.1 [10.001] / 9

Engine - Engine and crankcase

- Install Installing done the reverse order T ightening torques for hose Thread size T ightening torque PF 3 / 4 106 - 130 N·m ( - ) 1 1 / - 121 N·m ( - ) 47494131A 1 1/03/2013 10.1 [10.001] /

Engine

Engine - Measure

W arming engine

Start engine raise the coolant temperature engine - ( 140 - 194 ) surface radiator upper

The E / G coolant temperature gauge used

The range white color shows the temperature - 105 ( 149 - 221 ) , confirm that the pointer indicates the temperature within the white range.

Engine - Engine and crankcase

TULI12ECX0098AA 1 47494131A 1 1/03/2013 10.1 [10.001] / 1 1

Engine speed measured value through service diagnosis T urn the starter switch with the buzzer stop switch

A program and actual engine revolution are displayed the

The screen advances like time the arrow the gauge cluster

The screen returns like time the arrow

The display does not disappear unless the starter switch turned

Engine - Engine and crankcase

TULI12ECX0099BA 2 TULI12ECX0100AA 3 47494131A 1 1/03/2013 10.1 [10.001] /

Engine - Engine and crankcase Engine - Service instruction Engine Factors Checking Filters Liquid Leak, clogging T rouble 10* 1 12* 13* 14* 15*

Poor starting ability (takes a long time) Ο Ο Ο Ο Faulty engine starting / engine does not rotate Ο Faulty engine starting / engine rotates but exhaust gas (no fuel injection) Ο Ο Ο Ο Faulty engine starting / exhaust gas emitted but engine does not start (with fuel injection) Ο Ο Ο Ο Ο

Faulty starting

Engine poor run - (low followability) Ο Ο Ο Rotation bad condition (hunting) Ο Ο Ο Poor output Engine stalled during operation Ο Ο Ο Output lowered Ο Ο Ο Ο Ο Overheating Ο Ο Other failures Exhaust smoke black Ο Ο Ο Ο Exhaust smoke white Ο Ο Larger oil consumption (or blue exhaust gas) Ο Ο Early contamination oil Ο Ο Ο Ο Ο Larger fuel consumption Ο Ο Ο Ο Intruding oil back flow , reduction coolant quantity Hydraulic pressure down (monitor lights up) Ο Ο Oil quantity increased (intruding water and fuel) Ο V ibration Shortage fuel level Oil level oil pan Air cleaner clogged 10* Contamination water and fuel with oil Fuel filter clogged 1 Poor deteriorated battery Oil filter clogged 12* clogging fuel system and intruding air Fan belt slipped, fan pulley worn 13* Engine oil leak Breather hose crushed clogged 14* Air leak between turbocharger and intake manifold Improper fuel use 15* Muf fler clogged Coolant level 47494131A 1 1/03/2013 10.1 [10.001] /

Insufficient rotation

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Faulty starting

Poor starting ability (takes a long time)

Faulty engine starting / engine does not rotate

Faulty engine starting / engine rotates but exhaust gas (no fuel injection)

Faulty engine starting / exhaust gas emitted but engine does not start (with fuel injection)

Insufficient

Engine - Engine and crankcase Electric equipment Factors Checking shovel side Shovel side Engine side T rouble 10* 1 12* 13* 14* 15* 16*

Ο Ο Ο Ο

Ο Ο Ο Ο Ο Ο Ο Ο

Ο Ο

rotation Engine poor run - (low followability) Rotation bad condition (hunting)

Engine stalled during operation Ο Output lowered Ο Overheating Ο Ο Ο

Poor output

smoke black Exhaust smoke white

oil consumption

exhaust

oil Larger fuel consumption Intruding oil

flow

Hydraulic

Ο Oil quantity increased

V ibration Ο Loose mounting damage mounting rubber Loose connection battery cable terminal Failure radiator pressure cap 10* Battery relay Radiator core clogged / fin clogged and crushed 1 Alternator Peeling space insulation around radiator 12* Glow plug Failure hydraulic system 13* Glow relay Malfunction unload valve and low pressure sensor 14* Starter motor Startup circuit wiring 15* Safety relay Starter key switch 16* Hydraulic switch 47494131A 1 1/03/2013 10.1 [10.001] /

Other failures Exhaust

Larger

(or blue

gas) Early contamination

back

, reduction coolant quantity

pressure down (monitor lights up)

(intruding water and fuel)

Faulty

Engine - Engine and crankcase Factors Fuel system Intake and exhaust system Lubrication system Cooling system T rouble 10* 1 12* 13* 14*

starting ability

Ο Ο

engine starting

engine

rotate

engine

exhaust gas

fuel

engine

exhaust gas emitted

engine

Ο Ο

starting Poor

(takes a long time)

Faulty

does not

Faulty

starting / engine rotates but

(no

injection) Faulty

starting /

but

does not start (with fuel injection)

Engine poor run - (low follow - ability) Ο Ο Ο Rotation bad condition (hunting) Poor output Engine stalled during operation Ο Output lowered Ο Ο Ο Ο Overheating Ο Ο Ο

failures Exhaust smoke black Ο Ο Ο Exhaust smoke white Ο Ο Ο Ο Ο Larger oil consumption (or blue exhaust gas) Ο Ο Ο Early contamination oil Ο Ο Ο Ο Larger fuel consumption Ο Ο Ο Intruding oil coolant, back flow , reduction coolant quantity Ο Ο Hydraulic pressure down

Ο Ο Ο Ο Oil quantity increased

and fuel) Ο Ο Ο V ibration Ο Failure injector Damage EGR cooler Failure supply pump Failure oil pump Improper fuel injection time 10* Failure relief valve Fuel leak into the head cover 1 Failure regulation valve T urbocharger oil drain tube clogged 12* Leak and crush hydraulic piping Seal turbocharger damaged 13* Damage water pump Seizing and interference turbocharger 14* Failure thermostat (not open) 47494131A 1 1/03/2013 10.1 [10.001] /

Insufficient rotation

Other

(monitor lights up)

(intruding water

Faulty starting

Factors Engine body

rouble

Poor starting ability (takes a long time) Ο Ο

10* 1

Faulty engine starting / engine does not rotate Ο

Faulty engine starting / engine rotates but exhaust gas (no fuel injection)

Faulty engine starting / exhaust gas emitted but engine does not start (with fuel injection) Ο Ο

Insufficient rotation

Engine poor run - (low follow - ability) Ο Ο

Rotation bad condition (hunting)

Poor output

Engine stalled during operation Ο

Output lowered Ο Ο Overheating Ο Ο

Other failures

Exhaust smoke black Ο Ο

Exhaust smoke white Ο Ο Ο Ο

Larger oil consumption (or blue exhaust gas) Ο Ο Ο Ο Ο

Early contamination oil Ο Ο

Larger fuel consumption Ο

Intruding oil coolant, back flow , reduction coolant quantity Ο Ο Ο Ο

Hydraulic pressure down (monitor lights up) Ο

Oil quantity increased (intruding water and fuel) Ο Ο Ο Ο

V ibration Ο Ο

Damage engine oil cooler core and O - ring

W ear piston ring and liner , ring stick

Strainer damage oil pipe Hole due cavitation

Damage cylinder head and head gasket

W ear and damage rear oil seal and seal surface

Failure injection holder sleeve 10* Damage dumper W ear and failure valve and valve guide 1

Damage and seizing piston and connecting rod

Damage flywheel gear

Engine - Engine and crankcase

47494131A 1 1/03/2013 10.1 [10.001] /

Index Engine -

Engine and crankcase - 001

Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine - Install

Engine - Measure 1 1

Engine - Prepare 6

Engine - Remove 8

Engine - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47494131A 1 1/03/2013 10.1 [10.001] /