New Holland E485C, Service Manual

Page 1: ...CONSTRUCTION SERVICEMANUAL E485C Hino Diesel Engine Supplement to Service Manual 84557350A Print no 84561180A 1st Edition English 12 11 ...

Page 2: ... can be avoided if the causes are known and opportune cautions taken beforehand There is no device or protection no matter how advanced that may prove so effective at avoiding accidents as a careful and attentive behaviour COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S p A Product Support Strada di Settimo 323 S MAURO T SE TO ITALY Find manuals at https best manuals com ...

Page 3: ... System W5 5 Group 6 Emission Control W5 6 Group 7 Electrical W5 7 Group 8 Intake W5 8 Group 9 Engine Mechanical W5 9 Group 10 Exhaust W5 10 Group 11 Cooling W5 11 Group 12 Lubrication W5 12 Group 13 Starting and Charging W5 13 Group 14 Turbocharger W5 14 Group 15 Failure Diagnosis for each Engine Status W5 15 Group 16 Engine Diagnosis Code W5 16 Find manuals at https best manuals com ...

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Page 5: ...1 11 Tightening of flare nuts and hoses 1 13 Taper thread sealant for piping 1 14 Assembly of joints and gaskets for piping 1 15 Handling of liquid gasket 1 17 Failure diagnosis table for each problem 1 18 Failure diagnosis procedures 1 19 Failure diagnosis using Hino DX 1 21 Connection method of Hino DX 1 24 Engine number 1 25 Find manuals at https best manuals com ...

Page 6: ... Hino genuine parts for replacement of parts Do not use deteriorated parts in quality Items described in this manual are the procedures to be observed in service and repair For service and repair according to this procedure be sure to use the special tools designed for each purpose If a method or a tool not recommended is used safety of service engineers and safety and reliability of machine may b...

Page 7: ...d Items such as general tools jack rigid rack etc that are usually equipped in general service shop are omitted 4 How to read sections and titles 1 Sections are classified according to J2008 SAE standard 2 For areas that show system names like Engine control system Inspection Adjustment Replacement Overhaul etc of components are described 3 For areas that show part names like Injection pump Mounti...

Page 8: ... 4 Check if failure occurs again after repair If it is difficult to reproduce a failure perform the confirmation test under the conditions and environment of the failure Pre inspection Pre inspection is performed in the following steps Diagnosis inspection Diagnosis deletion Failure status check Use the reproduction method if not reproduced Diagnosis reconfirmation Estimate the failure system befo...

Page 9: ... E485C W5 1 5 6 How to read explanation details 1 Part layout It is the ID number for parts to prepare electronic data It is not required for repair work SAPH30ZDE0100001 Find manuals at https best manuals com ...

Page 10: ...t is an item that should not be performed including inhibited work or an item that require attention in working procedures 7 Reference It is supplementary explanation in work 8 Unit 1 SI unit is used in this manual SI unit is the international unit to unify the conventional different international units into one unit per quantity and to promote smooth technical communications 2 This manual shows b...

Page 11: ...he vehicle 2 Precautions for service work Pay attention to the following points before service work 1 Preparation before disassembly a Prepare general tools special tools and gauges before work b To disassemble a complicated area put a stamp or match mark on the location not functionally affected to ease assembly To repair the electric system disconnect the cable from the minus terminal of the bat...

Page 12: ...nut by 10N m 102kgf cm 7lbf ft 2 Handling of electronic parts a Do not give impact on electronic parts such as computer and relay b Do not place electronic parts at a high temperature and humidity area c Do not expose electronic parts to water in washing of a vehicle 3 Handling of wire harness a Mark clamps and clips to prevent interference of a wire harness with body edge sharp edge and bolts Be ...

Page 13: ...t out Do not pull the wire harness b Unlock the locking connector before pulling c Insert the locking connector completely until it clicks d To insert a test lead into the connector insert it from the back of the connector e If it is difficult to insert a test lead from the back of the connector prepare a harness for inspection SAPH30ZDE0100005 ...

Page 14: ...grounding of the electric welding machine near the welding area Connect grounding from a bolt plated bolt or a frame near the welding area Remove paint of the frame for connection of grounding from the frame 7 Other precautions a Put a cover on rubber hoses wire harnesses pipes tires etc around the welding area so that they may not be exposed to spatter b Perform welding under appropriate conditio...

Page 15: ...10 160 M14 x 2 Coarse thread 154 1 570 114 199 2 030 147 Remark Bolt with number 7 on the head Bolt with number 9 on the head Screw diameter x Pitch 4T 7T 9T M6 x 1 Coarse thread 6 60 4 10 100 7 13 130 9 M8 x 1 25 Coarse thread 14 140 10 25 250 18 31 320 23 M10 x 1 25 Fine thread 29 300 22 51 520 38 64 650 47 M10 x 1 5 Coarse thread 26 270 20 47 480 35 59 600 43 M12 x 1 25 Fine thread 54 550 40 93...

Page 16: ...le method 1 Precautions Some engines are tightened with the plastic region tightening method Since it is different from the conventional method tighten it according to the instruction in the text 2 Parts tightened Cylinder head bolt crankshaft main bearing cap bolt connecting rod bearing cap bolt etc CAUTION Measure the overall length of the bolt before assembly and replace the bolt if the length ...

Page 17: ... 11 3 6 21 1 214 10 15 0 7 32 3 326 31 24 2 2 44 5 449 51 32 3 6 64 5 653 51 47 3 6 66 2 5 673 25 47 1 8 Type Hose outer diameter φ10 5 fitting Hose outer diameter φ13 φ20 φ22 fitting at packing Hose outer diameter PF3 8 fitting Air hose 21 5 1 5 215 15 15 1 46 2 5 469 25 33 1 8 Only meter gauge 10 100 7 Brake hose Packing 51 5 7 5 525 75 15 1 46 2 5 469 25 33 1 8 Screw nominal size M14 M16 M20 M2...

Page 18: ...ning torque in the table below Remove dirt completely from the mating part female before tightening CAUTION If your eye or skin comes in contact with sealant wash it off immediately with water Tightening torque of taper joint Unit N m kgf cm lbf ft 2 When a sealing tape is replaced with sealant remove the tape completely first as in 1 CAUTION Be careful to prevent entry of dirt or foreign matter i...

Page 19: ...ghtening apply the specified pressure to each pipe joint to ensure that there is no leak 4 Observe the values above for each tightening torque When assembled soft washer 4840FR N aluminum and rubber carbon pressure bonding is loosened or removed be sure to replace it with a new part This is not necessary for normal retightening Screw size Sealing method Gasket sealing method Aluminum Rubber or Cop...

Page 20: ... Gasket Sealing surface 5 places Sealing surface 3 places Nut Connector nipple Flare connector Gasket Sealing surface 5 places Joint bolt Sealing surface 8 places Lock washer Nut Bracket Sealing surface 1 place Nut Connector nipple Sealing surface 1 place Flare connector Box nut Sealing surface 8 places Joint pipe Nut Lock washer 3 way joint Bracket Sealing surface 3 places One piece eye joint wit...

Page 21: ...remove the liquid gasket and apply it again 4 Start the engine at least 15 minutes or more after assembly of parts 2 Removal of parts 1 When parts are removed do not pry one place only Remove parts by prying each other using collar or clearance on the flange When gasket is removed be careful to prevent entry of gasket offal into the engine 3 Others 1 When the liquid gasket is contained in a tube u...

Page 22: ...GENERAL E485C W5 1 18 Failure diagnosis table for each problem JP30ZDE010301001 SAPH30ZDE0100026 ...

Page 23: ... Refer to HinoDX operation manual 3 Deletion of cluster gauge past failure 1 Turn ON the starter switch during pushing the buzzer stop switch 2 When pushing the enter key 3 times during pushing the buzzer stop switch the failure history mode is displayed 3 Press work mode selecting switch and the buzzer stop switch at the same time for 10 seconds or more 4 When the display shows No error deletion ...

Page 24: ... 1 Connect the ECU side connector of the signal check harness After deleting the past failure output the diagnosis code again Standard Normal NG OK 1 Remove the connector of the main engine speed sensor and measure the resistance between No 1 and No 2 terminals at the sensor Standard value Approx 125 5 NG OK 1 Measurement of resistance between terminals B B6 B7 SAPH03Z010300010 3 Go to measurement...

Page 25: ...unction PC DOS V standard Operating system OS Windows95 Windows98 IE5 0 or later Windows2000 SP3 IE5 0 or later WindowsXP SP1a IE6 0 or later CPU and memory Conditions that assure operation of the above operating system Display 800 x 600 256 colors or more Hino Diagnostic eXplorer Hino DX Software and CD ROM NOTICE Install the software of the Hino Diagnostic eXplorer Hino DX in the PC For the inst...

Page 26: ...ak the locking tab of the connector b Connect the signal check harness to the machine harness and the ECU Cable between machine and Hino Bowie S0904 21220 09042 1220 Cable for machine side diagnosis connector Signal check harness 09843 E9020 Interrupting installation between vehicle harness and ECU allows inspection with a tester rod while the power is supplied Part name Part No External shape Gen...

Page 27: ...GENERAL E485C W5 1 23 2 Terminal No For the signal check harness connector the ECU terminal number in the text is treated as follows ECU unit Signal check harness ECU side Vehicle side SAPH30ZDE0100040 ...

Page 28: ...r 16 P is on the inside 2 Connection of HinoDX 1 Connect the engine failure diagnosis connector to the PC which installed Hino DX through the interface box Special tool 09993 E9070 Hino Bowie Interface box S0904 21220 09042 1220 Connecting cable CD ROM HinoDX 2 Set the starter key to ON and start HinoDX SAPH30ZDE0100041 SAPH30ZDE0100042 Failure diagnosis connector Connect to the failure diagnosis ...

Page 29: ...P30ZDE010401001 1 Engine type and engine number 1 Engine type and engine number are stamped at the left cylinder block For order of parts information of this number will facilitate procedures smoothly Example P11C TB10001 SAPH30ZDE0100044 ...

Page 30: ...GENERAL E485C W5 1 26 NOTES ...

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