New Holland CE E55BX Service Manual

E55Bx Tier 4 Compact Hydraulic Excavator PIN NETN55001 - PS04-10001 and above SERVICE MANUAL Part number S5HS0013E01 1 st edition English April 2014

SHOP MANUAL model INDEX HYDRAULIC EXCAVATOR SPECIFICATIONS MAINTENANCE SYSTEM DISASSEMBLING TROUBLESHOOTING E/G OPT. 1 2 3 4 5 6 SPECIFICATIONS SECTION MAINTENANCE SECTION SYSTEM SECTION DISASSEMBLY SECTION TROUBLESHOOTING ENGINE SECTION Book Code No.S5HS0013E01 0-1 E55Bx

0-2 GENERAL SAFETY INFORMATION Do not operate or perform any maintenance on this machine until all instructions found in the OPERA- TOR’S MANUAL and this MANUAL have been thor- oughly read and understood. Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death. Always keep the manual in storage. If it is missing or damaged, place an order with an authorized our Distributor for a replacement. If you have any questions, please consult an authorized our Distributor. (1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the manual and on the machine should be read and understood by all personnel before starting any work with or on the machine. (2) Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in the manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. (3) Messages of safety appear in the manual and on the machine : All messages of safety are identified by either word of "DANGER", "WARNING" and "CAUTION". 1) DANGER- Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows: 2) WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows: 3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in mi- nor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as follows: (4) It is very difficult to forecast every danger that may occur during operation. However, safety can be en- sured by fully understanding proper operating procedures for this machine according to methods recommended by Manufacturer. (5) While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur. (6) Continue studying the manual until all Safety, Oper- ation and Maintenance procedures are completely understood by all persons working with the machine.

0-3 SAFETY PRECAUTIONS The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR’S MANUAL for the machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MAN- UAL before performing any lubrication or maintenance. The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component. Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section ; SPECIFICATIONS. The following is a list of basic precautions that must always be observed. (1) Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine. (2) Always wear protective glasses and protective shoes when working around machines. In particu- lar, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fit- ting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery. (3) Disconnect the battery and hang a "Do Not Oper- ate" tag in the Operators Compartment. Remove ig- nition keys. (4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine so it does not roll while working on or under the machine. Hang a "Do Not Operate" tag in the Opera- tors Compartment. (5) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands, capable of supporting the machine, before performing any disassembly. Do not operate this machine unless you have read and understand the instructions in the OP- ERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death. (6) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are discon- nected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure. (7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly. (8) Use steps and grab handles when mounting or dis- mounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face to the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaf- folds, or work platforms to perform safe repair operations. (9) To avoid back injury, use a hoist when lifting components which weigh 20kg (45lbs) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. (10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments. (11)Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely. (12)Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liq- uids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

0-4 (13)Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work. (14)Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary. (15)Repairs which require welding should be performed only with the benefit of the appropriate ref- erence information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted. (16)Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line contain- ing fluid. (17)Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed. (18)The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t fail to lower the attachment and place the bucket to the ground before starting the work. (19)Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. (20)Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot ex- haust components in event of a line, tube or seal failure must be installed correctly. (21)Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. (22)Be careful when servicing or separating the tracks (crawlers). Chips can fly when removing or installing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets. Block the machine to prevent it from moving.

0-5 33 51 42 43 11 34 21 44 46 31 32 25 1 3 2 13 12 22 23 24 Index No. Title Book Code No. Distribution Year–Month _ _ _ _ NETN55001~ PS04-10001~ STANDARD MAINTENANCE TIME SCHEDULE MAINTENANCE STANDARD AND TEST PROCEDURE MECHATRO CONTROL (OPT.) DISASSEMBLING & ASSEMBLING OUTLINE SPECIFICATIONS ATTACHMENT DIMENSIONS TOOLS HYDRAULIC SYSTEM ELECTRIC SYSTEM COMPONENTS SYSTEM AIR-CONDITIONER SYSTEM ATTACHMENT UPPER STRUCTURE TRAVEL SYSTEM ENGINE ENGINE BY ERROR CODES ELECTRIC SYSTEM HYDRAULIC SYSTEM APPLICABLE MACHINES SPECIFICATIONS MAINTENANCE SYSTEM DISASSEMBLING TROUBLESHOOTING E/G INDEX E55Bx North America 1 2 3 11 12 13 21 22 23 24 25 31 32 33 34 42 43 44 46 51 S5PA0105E01 2013-09 S5PS0213E01 2013-09 S5PS0313E01 2013-09 S5PS1113E01 2013-09 S5PS1213E01 2013-09 S5PS1313E01 2013-09 S5PS2113E01 2013-09 S5PS2213E01 2013-09 S5PS2313E01 2013-09 S5PS2413E01 2013-09 S5PS2513E01 2013-09 S5PA3105E01 2013-09 S5PS3213E01 2013-09 S5PS3313E01 2013-09 S5PS3413E01 2013-09 S5PS4213E01 2013-09 S5PS4313E01 2013-09 S5PS4413E01 2013-09 S5PS4613E01 2013-09 S5PS5113E01 2013-09

0-6 NOTE: This Manual is prepared as a technical material in which the information necessary for the maintenance and repairing services of our hydraulic excavators are collected, and is categorized into 7 Chapters, Specifica- tion, Maintenance, System, Disassembly, Trouble- shooting, Engine, and Installation Procedures for Optional Attachment. • The Chapter "Specification" describes the specifications for entire machine and material, which are instructive for replacement and repairing of attachments. • The Chapter "Maintenance" describes the material, which is helpful for maintenance service and adjust- ments for entire machine. • The Chapter "System" describes the operating system like hydraulic system, electric system, components, and so on. • The Chapter "Disassembly" describes the removal and installing of assembly mounted on the upper structure and undercarriage, and the assembling and disassembling of the associated hydraulic equipment. • The Chapter "Troubleshooting" describes how to find the fault equipment. • The Chapter "Engine" describes the engines mak- ing use of the "Maintenance Manual" provided by the suppliers. • The Chapter "Installation Procedures for Optional Attachment" describes the supplements added on request as required. This Manual may be properly revised due to the im- provement of products, modification of specifications, etc. And there are cases where the system on actual machine and a part of the contents of this manual may differ due to the variations of specification by countries. For the section in which the description is hardly understood, contact our distributor. The number is assigned to every part handled in this Manual on account of the description, but the parts, which cannot be supplied as service parts are contained. Therefore, the order must be placed with re- spective formal number with due confirmation on the Parts Manual for applicable machine.

1. OUTLINE 1-1 1 Book Code No. S5PA0105E01 1. OUTLINE TABLE OF CONTENTS 1.1 GENERAL PRECAUTIONS FOR REPAIRS ........................................................ 1-3 1.1.1 PREPARATION BEFORE DISASSEMBLING .............................................. 1-3 1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING ................................... 1-3 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......... 1-4 1.1.4 ELECTRICAL EQUIPMENT ........................................................................ 1-6 1.1.5 HYDRAULIC PARTS .................................................................................... 1-7 1.1.6 WELDING REPAIR ...................................................................................... 1-7 1.1.7 ENVIRONMENTAL MEASURE ................................................................... 1-7 1.2 INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS' STANDARD HANDBOOK FOR MECHANICAL ENGINEERS) ................................................ 1-8

1. OUTLINE 1-2 This page is intentionally left blank.

1. OUTLINE 1-3 1 1.1 GENERAL PRECAUTIONS FOR REPAIRS 1.1.1 PREPARATION BEFORE DISASSEMBLING (1) Understanding operating procedure Read OPERATOR'S MANUAL carefully to understand the operating procedure. (2) Cleaning machines Remove soil, mud, and dust from the machine before carrying it into the service shop to prevent loss of work efficiency, damage of parts, and difficulty in rust prevention and dust protection while reassembling. (3) Inspecting machines Identify the parts to be disassembled before starting work, determine the disassembling procedure by yourself considering the workshop situations etc., and request procurement of necessary parts in advance. (4) Recording Record the following items for communication and prevention of recurring malfunction. 1. Inspection date and place. 2. Model name, applicable machine number, and hour meter read. 3. Trouble condition, place and cause. 4. Visible oil leakage, water leakage and damage. 5. Clogging of filters, oil level, oil quality, oil contamination and loosening of connections. 6. Result of consideration if any problem exists based on the operation rate per month calculated from hour meter indication after the last inspection date. (5) Arrangement and cleaning in service shop 1. Tools required for repair work. 2. Prepare space to place the disassembled parts. 3. Prepare oil containers for draining oil etc. 1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING (1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses. (2) Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary meeting before starting work. (3) Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine. (4) Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency. (5) Choose a hard, level and safe place, and place the attachment on the ground securely. (6) Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine. (7) Use proper tools, and replace or repair defective tools. (8) Support the machine and attachment with supports or blocks if the work is performed in the lifted condition. Read Operator's Manual before disassembling WARNING

New Holland CE E55BX Service Manual

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