New Holland E135B Crawler Excavator Service Manual [PDF]

Zitiervorschau

Copyright © New Holland

SERVICE MANUAL

SERVICE MANUAL E135B

E135B

Crawler Excavator

Crawler Excavator

Print No.84136002

Print No.84136002

Copyright © New Holland

E135B 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.

NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support Print No. 84136002 Edition - November 2008

Copyright © New Holland

Copyright © New Holland INTRODUCTION

E135B

TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

- If you have any questions or comments, or if you found any errors regarding the contents of this manual, please contact:

- Be sure to thoroughly read this manual for correct information concerning the service procedures.

NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA PRODUCT SUPPORT Fax. ++39 011 0077357

ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this service manual: - Operation Manual

and

Maintenance

Instruction

- Parts Catalog

WORKSHOP MANUAL COMPOSITION - The “Operational Performance Test” part includes the information needed to carry out the machine operational performance test.

• The Workshop Manual consists of five parts: - “Safety Precautions” - “Operational Principle” - “Operational Performance Test”

- The “Troubleshooting” part includes the technical information needed for troubleshooting and malfunction detection.

- “Troubleshouting” - “Repair Instructions” - The “Safety Precaution” part includes the recommended procedures that, if followed, can avoid the risk of accident for operator and for staff related to the work and maintenance machine operations.

- The “Repair Instruction” part includes information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, removal/installation and assembly/disassembly procedures.

- The “Operational Principle” part includes the technical information concerning the operation of main devices and systems.

IN - 1

Copyright © New Holland E135B

INTRODUCTION

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. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy 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.

Quantity

To convert from (SI)

Into (Others)

Multiply by

Quantity

To convert from (SI)

Into (Others)

Multiply by

Lenght

mm

in

0.03937

Pressure

MPa

kgf/cm2

10.197

mm

ft

0.003281

MPa

psi

145.0

L

US gal

0.2642

kW

CV-PS

1.360

L

US qt

1.057

kW

HP

1.341

m3

yd3

1.308

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

L/min

US gpm

0.2642

N.m

kgf.m

0.10197

mL/rev

cc/rev

1.0

N.m

lbf.ft

0.7375

Volume

Torque

Power

Flow rate

IN - 2

Copyright © New Holland INDEX

E135B

MANUAL INDEX SAFETY PRECAUTIONS

Page

Section 1 GENERALITIES ..................................................................... S1 Section 2 SAFETY PRECAUTIONS ...................................................... S2 Section 3 SAFETY PLATES .................................................................. S3

OPERATIONAL PRINCIPLE Section 1 GENERAL Group 1

Specifications................................................................................. T1-1

Section 2 SYSTEM Group 1 Group 2 Group 3

Mechatro control system................................................................ T2-1 Hydraulic System........................................................................... T2-2 Electrical System ........................................................................... T2-3

Section 3 COMPONENT OPERATION Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 Group 9

Hydraulic Pump Assy..................................................................... T3-1 Pilot Valve ...................................................................................... T3-2 Control Valve ................................................................................. T3-3 Swing Device ................................................................................. T3-4 Travel Device ................................................................................. T3-5 Swivel Joint.................................................................................... T3-6 Cylinders........................................................................................ T3-7 Air Conditioner system................................................................... T3-8 Blade control.................................................................................. T3-9

OPERATIONAL PERFORMANCE TEST Section 4 OPERATIONAL PERFORMANCE TEST Group 1 Group 2 Group 3 Group 4

Introduction ................................................................................... T4-1 Standard Performances ................................................................. T4-2 Test Procedures ............................................................................ T4-3 Mechatro Controller ....................................................................... T4-4

TROUBLESHOOTING Section 5 TROUBLESHOOTING Group 1 Group 2 Group 3

Troubleshooting (by error codes)................................................... T5-1 Troubleshooting (by trouble) .......................................................... T5-2 Troubleshooting (trouble diagnosis mode)..................................... T5-3

Copyright © New Holland E135B

INDEX

REPAIR INSTRUCTIONS Section 1 GENERAL INFORMATION Group 1 Group 2

Precautions for Disassembly and Assembly.................................W1-1 Tightening Torque ........................................................................W1-2

Section 2 UPPERSTRUCTURE Group 1 Group 2 Group 3 Group 4 Group 5

Upperstructure ..............................................................................W2-1 Pump Device.................................................................................W2-2 Control Valve ................................................................................W2-3 Swing Device ...............................................................................W2-4 Pilot Valve .....................................................................................W2-5

Section 3 UNDERCARRIAGE Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7

Swing Bearing ..............................................................................W3-1 Travel Device ...............................................................................W3-2 Swivel Joint ..................................................................................W3-3 Track Adjuster ..............................................................................W3-4 Front Idler .....................................................................................W3-5 Upper and Lower Roller ...............................................................W3-6 Tracks ...........................................................................................W3-7

Section 4 FRONT ATTACHMENT Group 1

Front attachment...........................................................................W4-1

Section 5 ENGINE Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 Group 9 Group 10 Group 11 Group 12 Group 13 Group 14

General ........................................................................................W5-1 Service data .................................................................................W5-2 Service tools ................................................................................W5-3 Determination of overhaul ............................................................W5-4 Disassembly of basic engine .......................................................W5-5 Inspection and repair of basic engine ..........................................W5-6 Reassembly of basic engine .........................................................W5-7 Fuel System ..................................................................................W5-8 Lubrification system .....................................................................W5-9 Cooling system ..........................................................................W5-10 Inlet and exhaust system ........................................................... W5-11 Electrical system ........................................................................W5-12 Adjustment and operation ..........................................................W5-13 Troubleshooting .........................................................................W5-14

Copyright © New Holland

SAFETY PRECAUTIONS

Copyright © New Holland

Copyright © New Holland

SAFETY PRECAUTIONS

E135B

INDEX Section 1

GENERALITIES

Section 2

SAFETY PRECAUTIONS

Section 3

SAFETY PLATES

Copyright © New Holland

Copyright © New Holland GENERALITIES

E135B

SAFETY PRECAUTIONS GENERALITIES Do not leave the machine until it has come to a complete stop.

Read the Operation and Maintenance Instruction Manual carefully before starting, operating, maintaining, fuelling or servicing the machine.

Always check height, width and weight limitations which may be encountered in the working site and ensure the machine does not exceed them.

Carefully read the explanation to each and all safety signs in the special section of this Manual before starting, operating, maintaining, fuelling or servicing the machine.

Assess exact paths of gas ducts, water mains, telephone lines, sewers, overhead and underground electric lines and all other possible obstacles.

Machine-mounted safety plates are colour coded yellow with black borders when they refer to points where special ATTENTION must be paid and failure to observe them may cause a serious DANGER to the integrity of machine operators. They are white with red borders and black lettering when they refer to a FORBIDDEN practice.

Such paths should be opportunely defined by competent Authorities. If necessary, require that the service is interrupted or said installations are moved prior to starting the work. You must know the working capacity of the machine. Define the rear upperstructure swing area and provide for opportune barriers to prevent access into it.

It is fundamental that all machine operators know very well the meaning of each safety plate as this considerably decreases operating hazards and accidents.

Never exceed machine lifting capacity. Remain within the limits shown in the loading capacity chart which located on the machine.

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 or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators every time the job requires it. Ask your employer about safety regulations in force and protective equipment.

STARTING Never start or operate a failed machine. Walk all around the machine before mounting. Before operating the machine, make sure that any possible dangerous condition has been properly removed. Before starting machine, check that steering and attachment controls are in the neutral position and the safety lever is in the LOCK position. Immediately report any malfunction of parts or systems to the maintenance managers for proper action.

Always keep the operator’s compartment, step plates, grab-rails and handles clean and clear of foreign objects, oil, grease, mud or snow to minimise the danger of slipping or stumbling. Remove mud or grease from your shoes before operating the machine.

Prior to starting the engine, check, adjust and lock the driver’s seat for maximum riding comfort and control accessibility. Prior to operating the machine and/or its attachments, check that bystanders are outside the machine operating range. Sound the horn.

Do not jump on or off the machine. Always keep both 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 inadvertently moved and cause unexpected movement of the machine or its attachments.

Obey all hand signals, safety indications and signs.

Never operate the machine or its attachments from any position other than sitting in the driver’s seat. Keep head, body, limbs, hands and feet inside the operator’s compartment at all times to reduce exposure to external hazards.

Ensure that nobody is within the excavator operating area before starting the machine, swinging the upper structure or moving in any direction.

Be careful of possible slippery conditions of the steps and hand rails as well as of the ground around the machine. Wear protective boots or shoes with the soles made of highly no-slip rubber

Ensure that engine speed is appropriate to the job to be carried out.

Due to the presence of flammable fluids, never check fuel level, refuel, charge the batteries in the presence of smoking materials, open flames or sparks.

Adjust all rear-view mirrors for maximum visibility of the area behind the machine.

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Copyright © New Holland E135B

GENERALITIES

If any hydraulic control or system exhibits erratic performance or responds abnormally, have the machine checked for air in the system.

properly 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.

Air in these circuits may cause incorrect movements with consequent accident hazard. Refer to the Operation and Maintenance Instruction Manual about corrective action to be taken.

In darkness, check area of operation carefully before moving in with the machine. Use all lights provided. Do not move into low visibility areas. If the engine tends to slow down and stall for whatever reason under load or at idle, immediately report this problem to the maintenance managers for proper action.

OPERATING Do not run the engine of this machine in closed buildings without proper ventilation capable to remove harmful exhaust gases which concentrate in the air.

Do not operate the machine until this condition is corrected. Regularly check all exhaust system components, as exhaust fumes are toxic for the operator.

Keep the operator’s compartment free of foreign objects, especially if not firmly secured. Never use the machine to transport objects, unless proper securing points are provided.

Operators must know the performance of the machine 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 machine control could result.

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.

If noise level is high and exceeds 90 dB (A) over 8 hours at the operator’s ear, wear approved ear protection in compliance with local regulations.

Make sure that bystanders are clear of the machine operating range before starting the engine and operating the attachment. Sound the horn. Obey all hand signals, safety indications and signs.

Do not operate the machine if you are extremely tired or feel ill. Be especially careful towards the end of the working shift.

When backing, always look to where the machine is to be moved.

Where removable counterweights are provided, do not operate the machine if they have been removed.

Be alert of the position of bystanders. Should someone enter the work area, stop the machine. Maintain a safe distance from other machines or obstacles to ensure required visibility conditions.

When operating the machine, keep in mind height limits of overhead doors, arches, overhead cables and lines as well as width limits of corridors, roads and narrow passages.

Always give way to loaded machines.

Also, get to know load limits of the ground and paving type of the ramps you are to work on.

Maintain a clear vision of the surroundings of the travel or work area at all times. Keep cab windows clean and repaired.

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 extreme care.

When pulling loads or towing through a cable or chain, 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 problems before proceeding. Do not pull through a kinked chain or cable as the high anomalous stresses existing in this condition may induce failures in the kinked portion.

Whenever possible, avoid crossing over obstacles such as very rough terrain, rocks, logs, steps, ditches, railroad tracks.

Always wear heavy gloves when handling chains or cables.

When obstructions must be crossed, do so with extreme care and at a square angle, if possible. Slow down.

Chains and cables should be securely anchored using suitable hooks. Anchor points should be strong enough to withstand the expected load.

Ease up to the break-over point, pass the balance point slowly and ease down the other side also using the attachment, if necessary.

Keep anyone clear of anchor points and cables or chains.

To overcome deep trenches or sinking ground, place the machine perpendicular to the obstacle, drastically reduce ground speed and start crossing using also

Do not pull or tow unless the operator’s compartments of the machines involved are S1 - 2

Copyright © New Holland GENERALITIES

E135B

the attachment if necessary, only after assessing that ground conditions allow the traverse safely and without risks.

The load must always be properly arranged in the bucket; move with extreme care when transporting oversize loads.

The gradient you may attempt to overcome is limited by factors such as ground conditions, load being handled, machine type and speed, and visibility. There is no substitute for good judgement and experience when working on slopes.

Do not lift and move the bucket overhead where persons are standing or working, nor downhill when working on a slope as this would decrease machine stability. Load the bucket from the uphill side. Loads to be raised using the machine should be exclusively hooked to the hitch specially provided.

Avoid operating the attachment too close to an overhang or high wall, either above or below the machine. Beware of caving edges, falling objects and landslides. Remember that such hazards are likely to be concealed by bushes, undergrowth and such.

The excavator is no lifting and transportation means, therefore it should not be used to position loads accurately. Should it be exceptionally used to lift and lay building components, special caution must be taken as follows:

Avoid bushes, logs and rocks. Never drive over them, nor over any other surface irregularities that discontinue adherence or traction with the ground, especially near slopes or drop-offs.

- The machine must be equipped compulsorily with the appropriate variant provided upon request. - Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms.

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 or near drop-offs.

- Nobody should be allowed to remain under the raised load or within the excavator operating range for any reason whatever.

The word “bulldozing” generally refers to work in virgin rough terrain, characterised by the presence of all the perils and risks listed above. We emphasise the danger represented in these conditions by large tree limbs (possibly falling on the machine) and large roots (which may act as a leverage under the machine when up-rooted and cause the unit to overturn).

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.

Position the machine dependent upon the loading and unloading areas in order to swing leftwards to load to obtain best visibility.

All loading capacities are referred to the machine on a level surface and should be disregarded when working on a slope.

Never use the bucket or attachment as a man lift or carry riders. Never use the machine as a work platform or scaffolding. The machine must not be improperly used for works not consistent with its features (such as pushing railway cars, trucks or other machines).

Avoid travelling across slopes. Proceed from uphill downhill and vice-versa. If machine starts slipping sideways when on a slope, lower the bucket and thrust 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.

Always pay attention to people within the machine operating range. Never move or stop the bucket, other loads or the attachment above ground personnel or truck cabs.

Do not move full bucket or a load from uphill downhill as this would reduce machine stability. Do not work with the bucket turned to the uphill side.

Ensure the truck driver is in a safe place before loading the truck.

Do not work with the bucket turned uphill as counterweights protruding downhill would reduce machine stability on the slope and increase risk of overturning.

Load trucks from side or rear. Use only the type of bucket recommended considering machine type, materials to be handled, material piling up and loading characteristics, ground type and other typical conditions of the work to be performed.

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°.

When transporting a loaded bucket, keep it as rolled-back as possible. Keep boom and arm as low as possible.

Position the carriage at a right angle relative to slopes, hanging walls, etc. to exit the working area easily.

Ground speed should be adequate to the load and ground conditions.

Standard use, provides for the travel controls at the front and travel motors at the back. Should travel S1 - 3

Copyright © New Holland E135B

GENERALITIES - Look up the in the telephone directory.

motors be positioned at the front with regard to the actual travel direction. Remind relative to travel direction that controls are reversed.

- Define together with the Company representative which precautions should be taken to guarantee work safety.

Always check travel motor position before moving off.

- All electric lines should be considered as operative live lines even though it might be well known that the line in question is out of work and visibly connected to the ground.

Properly judge ground conditions with particular attention to consistency of the area you are going to work on. Keep the machine sufficiently edge.

far from the ditch

- The Electric Power Company, if previously advised and involved in the work, as well as machine Operator, 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 liable for the adoption of the necessary precautions.

Never dig under the machine. Should it be necessary to dig under the machine, always ensure that digging walls are opportunely propped up against landslide to prevent the machine from falling into the trench. Do not swing the upperstructure, raise the load or brake abruptly if not required. This may cause accidents.

- Decrease work speed. Reaction time could be too slow and distance evaluation wrong. - Warn all ground personnel to keep clear of the machine 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.

Prior to beginning the work near gas distribution mains 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.

- Appoint a person in charge of signalling duties. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the electric lines from a standpoint more favourable than the Operator’s. This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied.

- Define together which precautions should be 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 utilities installations, appoint a person in charge of signalling duties. This person will have the responsibility of observing the machine, any part of it and/or the load approaching the gas mains from a standpoint more favourable than the Operator’s. This signal man (flag-man) must be in direct communication with the Operator and the Operator must pay undivided attention to the signals supplied.

When working in or near pits, in ditches or very high walls, check that the walls are sufficiently propped up to avoid cave-in hazards. Pay the utmost attention when working near overhang walls or where landslides may take place. Make sure that the support surface is strong enough to prevent landslides.

- The gas distributing Company, if previously advised and involved in the work, as well as machine Operator, Owner and/or any natural person or legal entity having rent or leased the machine or being responsible at the time by contract or by law, are liable for the adoption of the necessary precautions.

When digging, there is the risk of cave-ins and landslides. Always check ground conditions and conditions of the material to be removed. Support everywhere it is required to prevent possible cave-ins or landslides when: - Digging near previous trenches filled with material.

Working near electric lines can be very dangerous, therefore some special precautions must be observed.

- Digging in bad ground conditions. - Digging trenches subject to vibration from railroads, working machines or highway traffic.

Within this Manual, “work near electric lines” means when the attachment or load raised by the excavator (in any position) may reach the minimum safety distance established by local or international Safety Regulations.

STOPPING

To work without risks, keep maximum possible distance from electric lines and never trespass minimum safety distance.

When the machine is to be stopped for whatever reason, always check that all controls are in the neutral position and that the safety lever is on the lock position to guarantee risk-free start-up.

- Contact the Company owner of the electric lines or its nearest branch before starting the work. S1 - 4

Copyright © New Holland GENERALITIES

E135B

Read all safety plates mounted on the machine and observe instructions they contain before starting, operating, repairing, fuelling or servicing the machine.

Never leave the machine unattended with the engine running. 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.

Do not allow unauthorised personnel to repair or service the machine. Follow all recommended maintenance and service procedures.

Check that all controls are in the neutral position. Move engine controls to the shut-down position. Switch off the key-start switch. Consult the Operation and Maintenance Instruction Manual.

Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, no-slip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators when required. Ask your employer about safety regulations in force and protective equipment.

Park the machine in a non-operating and no-traffic area. Park on firm level ground. If this is not possible, position the machine at a right angle to the slope, making sure there is no danger of uncontrolled sliding.

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 inadvertently moved and cause unexpected movement of the machine or its attachments.

If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and other signals as required to adequately warn the oncoming drivers. Always switch off the key-start switch before cleaning, repairing, or parking the machine to prevent accidental unauthorised start-up.

Do not jump on or off the machine. Always keep both hands and one foot, or both feet and one hand in contact with steps and/or grab rails.

Never lower the attachment or auxiliary tools other than from sitting in the operator’s seat. Sound the horn. Make sure that nobody is within the machine operating range. Lower the attachment slowly.

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.

Securely block and lock the machine every time you leave it unattended. Return keys to the safe place previously agreed upon. Perform all necessary operations for stopping as detailed in the Operation and Maintenance Instruction Manual.

Keep the operator’s compartment, step plates, grab rails and handles clear of foreign objects, oil, grease, mud orsnow to minimise the danger of slipping or stumbling.

Drive the machine far from pits, trenches, rocky hanging walls, areas with overhead electric lines, and slopes before stopping it at the end of the working day.

Clean mud or grease from your shoes before climbing on the machine or driving it. Never attempt to operate the machine or its attachments from any position other than sitting in the operator’s seat.

Align the upperstructure to the tracks in order to allow to easily get on and off the driver’s compartment.

Keep the driver’s seat free from foreign objects, especially if these are not secured.

Move all controls to the position specified for machine stopping. Refer the Operation and Maintenance Instruction Manual.

Should it be necessary to move the attachment for maintenance purposes, do not raise or lower the attachment from any other position than sitting in the operator’s seat. Before starting the machine or moving its attachment, sound the horn and require that nobody remains near the machine.

Never park on an incline without accurately blocking the machine to prevent unexpected movement. Follow stopping instructions contained in the Operation and Maintenance Instruction Manual.

Raise the attachment slowly. Always lock all moving components or parts of the machine that must be lifted for maintenance purposes using adequate external means as required by local and national regulations. Do not allow anyone to pass or stay near or below a raised attachment. If you are not absolutely sure about your safety, do not stay or walk under a raised attachment.

MAINTENANCE GENERALITIES Carefully read the Operation and Maintenance Instruction Manual before starting, operating, maintaining, fuelling or servicing the machine in any manner.

Do not place head, body, limbs, hands, feet or fingers near articulated cutting edges deprived of the necessary guards, unless they are suitably and safely locked. S1 - 5

Copyright © New Holland E135B

GENERALITIES flammable fluids to clean parts. Use proprietary certified non-flammable, non-toxic solvents only.

Never lubricate, repair or adjust the machine with the engine running, except when this is specifically required by the Operation and Maintenance Instruction Manual.

When using compressed air to clean parts, wear safety glasses with side shields. Limit pressure to max. 2 bars, in accordance with local and national safety regulations in force.

Do not wear loose clothing, jewellery near rotating parts.

Do not run the engine of this machine in closed buildings without proper forced ventilation capable to remove toxic exhaust gases concentrating in the air.

When service or maintenance require access to areas that cannot be reached from the ground, use a ladder or step platform conforming to local or national regulations to reach the working area. If such means are not available, use machine grab rails and steps. Always perform all service or maintenance work with the greatest care and attention.

Do not smoke, nor allow open flames or sparks nearby while refuelling the unit or handling highly flammable materials. Do not use open flames as light sources to look for leaks or inspect anywhere on the machine.

Shop and/or field service platforms or ladders should be manufactured and maintained in accordance with local or national safety regulations in force.

Make sure that all mechanical tools provided are in good condition at all times. Never use tools with mushroomed or damaged heads. Always wear eye protections with side shields.

Disconnect batteries and label all controls to warn that service work is in progress, according to local and national safety regulation requirements.

Move with extreme care when working under, on or near the machine or its attachments.

Block the machine and all attachments to be raised according to local and national safety regulation requirements.

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 at work.

Do not check or fill fuel tanks or install batteries near burning or smoking materials and open flames due to the presence of flammable vapours.

Keep hands and clothes far off moving parts.

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 beginning to the end of the fuelling operation to avoid possible generation of sparks due to static electricity.

Stop the engine and move the safey lever to the lock position before starting adjusting or repairing an assembly. Do not carry out any work on the attachment without prior authorisation. Observe maintenance and repair procedures.

Use a truck or trailer to haul a failed machine. Should it be necessary to tow it, provide for suitable danger signals as required by the local norms and regulations and observe recommendations given in the Operation and Maintenance Instruction Manual. Load/unload the machine on firm level ground providing safe support to the wheels of the truck or trailer. Use strong access ramps, with adequate height and angle. Keep the trailer flatbed free of mud, oil or slippery materials. Tie the machine securely to the trailer and block carriages and upperstructure.

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 attachments. Move the machine to level ground as soon as possible. Do not twist chains and cables. Never use a twisted chain or cable for lifting or pulling. Always wear 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.

Never align holes or slots using your fingers; alwaysuse appropriate aligning tools. Remove all sharp edges and burrs from re-worked parts.

Keep all bystanders clear of the anchor point, cables or chains. Do not pull or tow unless the operator’s compartments of the machines involved are fitted with proper guards against cable or chain backlash.

Use only approved and effectively grounded auxiliary power sources for heaters, battery chargers, pumps and similar equipment to reduce electrical shock hazard.

Keep the maintenance area clean and dry at all times.

Lift and handle heavy components using hoisting devices of appropriate capacity. Ensure the parts are supported by appropriate straps and hooks.

Clean immediately all water and oil spillage. Do not pile up oily or greasy rags as they represent a major fire hazard. Always store them in closed metal containers.

Use lifting eyes provided to this aim. Pay attention to bystanders near the lifting area.

Before starting the machine or its attachment, check, adjust and lock the operator’s seat. Also ensure that nobody is within the machine or attachment

Never pour gasoline or diesel fuel into open containers. Never use gasoline, solvents or other

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E135B

injuries are most likely to occur. Pay attention to prevent possible part movements by means of blocks or by keeping clear of such zones when motion may take place during maintenance or repair.

operating range before starting or operating the machine and/or its attachments. Sound the horn. Rust inhibitors are volatile and flammable.

Move the hydraulic system lock safety lever to the lock position when stopping the machine for whatever reason.

Prepare parts in well ventilated areas. Keep open flames away. Do not smoke.

Always install the safety stays for the hood and other hinged covers before performing any maintenance or repair work in the engine compartment.

Store containers in a cool well ventilated place where they could not be reached by unauthorised people. Do not carry loose objects in your pockets that might fall unnoticed into open compartments. Wear appropriate safety clothing such as hard hat, safety shoes and gloves, safety glasses when splinters or other particles may be ejected.

TRANSFERS AND TRANSPORTATION Before moving or transporting the machine, block upperstructure swing to prevent accidental movement.

Wear the appropriate welder’s equipment such as dark safety glasses or mask, hard hat, protective clothing, safety gloves and footwear always while welding or arc-cutting. Wear dark safety glasses when you are near a welding in progress.

Pay particular attention during transfer on inclines, both uphill and downhill. Keep the bucket in a position to provide a possible anchor point into the ground in case of slipping.

Do not look the welding arc without proper eye protection.

During transfers on inclines, both uphill and downhill, keep the upperstructure aligned with the carriages. Do not travel across the slope.

Become acquainted with all your jacking equipment and their capacity. Ensure that the jacking point on the machine is appropriate for the load applied. Also, be sure the supports under the jack and between the jack and the machine are appropriate and stable.

Never transfer the machine in the working site, in a crowded area, or near people without having at least one person charged with hand-signals who could guide the Operator.

Any equipment supported by a jack represents a possible hazard. Always support the load onto appropriate blocking means as a safety measure before proceeding with service or maintenance work, in compliance with local or national safety regulations.

Sound the horn to inform that you are about to move off. It is necessary to know load limits of bridges and dimensional limits of tunnels. Such limits must never be exceeded. You should also know machine height, width, and weight. Have a signal-man help you when clearances are limited.

Metal cables produce steel splinters. Always wear certified protection clothes such as safety gloves and glasses while handling them.

Check distance between boom/arm and dimensional limits during transfer or transportation.

Do not use makeshift jacks to adjust track sag. Follow instructions given in the Repair Manual.

Rough terrain may cause the machine to sway and roll to such an extent that boom/arm could get to contact electric lines or other obstacles. Cross obstacles at a right angle at low speed. Pay attention to machine shaking when the centre of gravity overcomes the obstacle.

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 and footwear. The attachment is kept constantly in position by an oil column trapped into the high pressure circuit. Lower the attachment to the ground and relieve pressure from all circuits prior to carrying out any type of maintenance or repair work.

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 regulations.

Do not service or repair the machine if it is parked downhill. If this is unavoidable, in case of emergency, block the carriages to prevent unexpected movement, particularly if the work is to be carried out on the final reduction units or travel motors.

Consider boom/arm and upperstructure dimensions while turning. Use a ramp to load the machine on a trailer. If a ramp is not available, fabricate one using blocks. The ramp should be sufficiently strong to support machine weight. Always load and unload on level surface.

Consult the Operation and Maintenance Instruction Manual for correct maintenance procedure. Areas near articulated cutting edges where mechanical parts are in motion are where personal S1 - 7

Copyright © New Holland E135B

GENERALITIES Before any maintenance or repair, make sure that there are no fuel or electrolyte leaks from the batteries. If any, correct prior to proceeding with further work. Do not recharge batteries in confined spaces. Ensure proper ventilation is provided to avoid accidental explosions due to build-up of explosive gas released during charging.

Tow the machine following the instructions contained in the Operation and Maintenance Instruction Manual.

ENGINE

Disconnect batteries before working on the electrical system or carrying out any other type of work.

Do not run the engine in closed buildings without proper ventilation capable to remove harmful exhaust fumes. Do not place head, body, limbs, feet, hands or fingers near rotating fans or belts. Be especially careful near blower fans.

HYDRAULIC SYSTEM

Loosen the radiator cap very slowly to relieve system pressure before removing it. Always top-up coolant level with the engine off or idling if hot. See the Operation and Maintenance Instruction Manual.

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.

Keep the exhaust manifold and tube free from combustible matters. Fit the machine with shields and guards when working in the presence of combustible matter free in the air.

Do not use hands. If injured by escaping fluid, obtain medical attention immediately or serious infection 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 Instruction Manual.

Do not refuel with the engine running, especially if hot, as this increases fire hazard in case of fuel spillage.

Always use gauges of adequate capacity for pressure testing. Refer to the Operation and Maintenance Instruction Manual or Repair Manual.

Never attempt to check or adjust fan belt tensions when the engine is running. Do not adjust the fuel injection pump when the machine is operating. Do not lubricate the machine with the engine running. 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 before servicing the engine.

TOOLS Always keep head, body, limbs, feet, hands, and fingers away from the bucket and attachments, when in the raised position.

ELECTRICAL SYSTEM

Prior to any maintenance or repair work, install all supports necessary to this aim according to local and national safety regulations.

Pay attention to connect connecting cables to correct poles (+ to +) and (- to -) at both ends. Do not shortcircuit terminals. Thoroughly follow instructions given in Operation and Maintenance Instruction Manual.

In case the attachment is to be operated for maintenance or repair purposes, do so exclusively while sitting in the driver’s seat. Sound the horn before starting the machine or moving the attachment. Require that nobody remain near the machine. Raise the attachment slowly.

Always move the key-start switch in the lock position before servicing or repairing the machine. Batteries contain SULPHURIC ACID. Protect the eyes when working near the batteries against possible sprays of the acid solution. Should acid contact skin, eyes, or clothes, RINSE IMMEDIATELY IN WATER FOR AT LEAST 15 MINUTES. Immediately seek medical attention.

Do not use the machine to transport loose objects, unless proper securing devices are provided. Never use gases other than nitrogen to charge the accumulators.

Battery released gas is highly flammable. Leave the battery compartment cover open during recharging 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 explosion hazard. S1 - 8

Copyright © New Holland SAFETY PRECAUTIONS

E135B

RECOGNISE SAFETY INFORMATION • This is your SAFETY ALERT SYMBOL - When you see this symbol on your machine or in this Manual, be alert of the potential for personal injury. - Follow recommended precautions and safe operating practices.

UNDERSTAND SIGNAL WORDS • In this Manual you will find the following words referring to different hazard risks: - DANGER; - WARNING; - CAUTION.

DANGER

These words are always accompanied by the safety alert symbol.

WARNING

DANGER: indicates an imminent hazardous situation which, if not avoided, will result in death or serious injury.

CAUTION

WARNING: indicated a potential hazardous situation which, if not avoided, could result in death or serious injury.

IMPORTANT

CAUTION: indicates a potential hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTE

IMPORTANT: indicates a situation which, if not avoided, may cause damage to the machine. NOTE: indicates an additional explanation for information purposes.

ENVIRONMENTAL PROTECTION • This Manual also contains this symbol accompanying instructions for correct behaviour as regards environmental protection.

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SAFETY PRECAUTIONS

FOLLOW SAFETY PRECAUTIONS • Carefully read and observe all safety signs on the machine and read all safety precautions in this Manual. • Safety signs should be installed, maintained, and replaced when necessary. - If a safety sign or this Manual are damaged or missing, obtain a replacement from your Dealer in the same way you order a spare part (be sure to detail machine model and serial number upon ordering). • Learn how to operate the machine and its controls correctly and safely. • Allow only trained, qualified, authorised personnel to operate the machine. • Keep the machine in proper working conditions. - Unauthorised changes to the machine may impair function and/or safety and affect machine life. • Safety messages in this Chapter “SAFETY PRECAUTIONS”, are intended to illustrate basic safety procedures of the machine. However, it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any doubts, consult your direct supervisor prior to operating or servicing the machine.

PREPARE FOR EMERGENCIES • Be prepared if a fire starts or an accident occurs. - Keep the first-aid kit and fire extinguisher on hand. - Thoroughly read and understand the label attached to the fire extinguisher to use it properly. - Establish emergency priority procedures to cope with fires and accidents. - Keep emergency numbers for doctors, ambulance service, hospitals and fire department posted near the telephone.

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WEAR PROTECTIVE CLOTHING • Wear close-fitting clothing and safety equipment appropriate to the job. You need: - A hard hat; - Safety shoes; - Safety glasses or face shield; - Heavy gloves; - Ear protection; - Reflective clothing; - Waterproof clothing; - Respirator or filter mask; Be sure to correctly wear equipment and clothing for the job. - Do not take any chances. - Avoid wearing loose clothing, jewellery, or other items that can catch on control levers or other parts of the machine. • Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. - Wear a suitable hearing protection such as earmuffs or earplugs to protect objectionable or uncomfortably loud noise.

INSPECT THE MACHINE • Inspect the machine carefully every day or workshift by an attentive visual inspection of machine outside prior to starting it to prevent damages and personal injuries.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

USE HAND HOLDS AND STEPS • Falling is one of the major causes of personal injury. - When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. - Prior to climbing or leaving the machine, check that the fasteners of stepping points and the handrails are tightened and are undamaged. Repair them as required. - Keep the access to the machine clear of foreign objects and clean. Remove grease or mud from stepping points and rails to minimise the danger of slipping or stumbling. - Do not use the controls or the safety lever as hand holds when climbing on or off the machine. - Do not climb or leave the machine running. Do not jump on or off the machine. - Do not climb or leave the machine while holding tools or other objects in your hands. - Do not climb or leave the machine while it is moving.

ADJUST THE OPERATOR'S SEAT • A seat poorly adjusted for operator or work requirements may quickly fatigue the operator leading to improper operations. - The seat should be adjusted whenever machine operator changes. - The operator should be able to fully press the pedals and correctly move the control levers with his back resting against the seat back. - If not, move the seat fore and aft, and check again.

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FASTEN SEAT BELT • Should the machine overturn, the operator may become injured and/or thrown from the cab. Not only, the operator may be crushed by the overturning machine resulting in serious injury or even death. - Prior to operating the machine, thoroughly examine belt webbing, buckle, and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. - Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimise injury hazard in case of accident. - After a significant accident, replace the seat belts even though they do not look damaged.

MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. - Pay the utmost attention not to run over bystanders. - Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Sound horn to inform bystanders that the machine is going to be operated. - When operating, swinging, or moving the machine in a congested area use a signal man.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

OPERATE ONLY FROM THE DRIVER'S SEAT • Inappropriate engine starting procedures may cause the machine unexpected movement, possibly resulting in serious injury and even death. - Start the engine only from the operator’s seat. - NEVER start the engine while standing on the track or on the ground. - Do not start the engine by shorting across starter motor terminals. - Before starting the engine, ensure that all control levers are in the neutral position.

DO NOT CARRY PERSON ON THE MACHINE • Riders on the machine are exposed to serious injuries. - DO NOT carry riders on the machine. Besides precluding a full vision by the operator, there is the possibility of serious bodily harm or death due to accidental falls from the machine.

CONFIRM DIRECTION WHERE THE MACHINE IS TO BE DRIVEN • Incorrect travel controls operation may result in serious injury and even death. - Before driving the machine, be aware of the undercarriage position relative to the operator’s position. If travel motors are located at the front of the cab, the machine will move reverse when travel controls are moved towards cab front.

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AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. • To avoid back-over and swing accidents: - Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. - ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. - USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. - Use hand signals, which conform to your local regulations, when work conditions require a signal person. - No machine motions shall be made unless signals are clearly understood by both signalman and operator. - Learn the meanings of all flags, signs, and markings used on the job and confirm with the person in charge of signalling. - Always make sure that rear mirrors are clean and correctly adjusted. - Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

DRIVE MACHINE SAFELY • Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go. - Pushing down on the front of the travel pedals or pushing the levers forward moves the machine towards the idlers. • Traveling on a grade may cause the machine to slip or to overturn, possibly resulting in serious injury or death. - When traveling up or down a grade, keep the bucket in the direction of travel, approximately 20 to 30 cm (A) above the ground. - If machine starts to skid or becomes unstable, lower the bucket immediately. - Traveling across the face of a slope may cause the machine to skid or to overturn. When travelling (ascending/descending) on a slope, be sure to point the tracks uphill/downhill.

- Turning on an incline may cause the machine to tip over. If turning on an incline is absolutely unavoidable, do so at a place where the slope is gentle and the surface is firm. - Do not travel on slopes with an angle exceeding 30°. Do not travel across hill on slopes exceeding an angle of 15°.

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AVOID OVERTURNING • When working on a slope or on unstable terrain, the danger of tipping over is present with the possibility of subsequent serious damages or fatal injuries. - Pay the utmost attention when working on a slope. If possible, level first the work area. - Avoid swing or steering the machine on a slope. - Decrease the operating speed and actuate the controls carefully, to prevent sudden movements that could result in slipping or tipping over. - In case the engine is cut-off, lower the bucket to the ground, move the controls in neutral and restart the engine. • Pay the utmost attention when operating the machine on frozen ground or in snowy conditions. - Frozen ground, when the ambient temperature increases, tends to be less firm jeopardising the stability of the machine. - Operate carefully when in snowy conditions. The snow could hide invisible dangerous spots. - Actuate the controls slowly and carefully to prevent the machine from making unwanted slippery manoeuvres or movements. - Even on minor slopes, when snow is present and on frozen ground, unwanted slippery manoeuvres or movements of the machine could occur.

PARK MACHINE SAFELY • To avoid accidents: - Park machine on a level surface. - Lower bucket to the ground. - Pull the safety lever (pilot-control shut-off lever) to the LOCK position. - Turn auto-idle switch off. - Run engine at slow idle speed without load for 5 minutes. - Turn key-start switch to OFF to stop engine. - Remove the ignition key from the key switch. - Prior to leaving the machine, close the windows, the cab door and all panels.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

INVESTIGATE JOB SITE BEFORE OPERATING THE MACHINE • Explore the working area to identify potential risks before starting and operating the machine. Make sure that the structure and the conditions of the ground are safe before starting operations. - Make sure that the digging area is sufficiently stable and firm to support the weight of the machine during the work operations. - Working near edges and ditches presents a risk for the stability of the machine. Check first that edges and the walls of the digging are sufficiently strong. If necessary, prop the edges appropriately to prevent caving-ins. - DO NOT dig too near the machine. - Always position the tracks perpendicular to the edge of the digging with the travel motors on the rear side. - When working on a slope or near the edge of the road, have a flagman available.

PROTECTING AGAINST THE FALL OF ROCKS AND LANDSLIDES • When operating in zones where the possibility of falling rocks or landslides exists or when there is the risk for front impacts with objects that could penetrate the cab, make sure that protection structures are installed: F.O.P.S. (Falling Object Protection Structure) and FRONT GUARD. - DO NOT install any cab lifting device to the protection structures. - DO NOT weld, drill or modify protective structures. Any type of modification could weaken the structural integrity of the safety system, with serious consequences for the operator, in case of collision, falling objects or landslides. - After an accident, DO NOT try to straighten or repair protective structures. Contact a Dealer to verify the functionality, to repair or to completely or partially replace the protective structures.

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DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. - Before digging, check the location of cables, gas lines, and water lines. - Keep the minimum distance required by law from cables, gas lines, and water lines. If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury. - Contact local authorities and/or the utility companies directly (electric power, gas, telephone, water, sewers, telecommunications, etc.) to obtain information about underground utility lines.

OPERATE WITH CAUTION • If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may results as well. - Take care to avoid hitting overhead obstacles with the boom or arm.

AVOID ELECTRIC LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. - When operating near an electric line, NEVER MOVE any part of the machine or load closer than 5 m plus twice the line insulator length (L). - Check and comply with any local regulations that may apply. - Wet ground will expand the area that could cause any person on it to be affected by electric shock. - Keep all bystanders or co-workers away from the site.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

KEEP PERSONNEL CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. - Keep all persons clear from the area of operation and machine movement. - Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

NEVER MOVE THE BUCKET OVER ANY ONE • Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

SP0030

DO NOT OPERATE IN TUNNELS • DO NOT operate the machine in enclosed spaces or, in any case, without appropriate ventilation. Operations in tunnels or underground sites where potential explosive conditions exist are not allowed. There is a danger for explosions and potentially deadly injuries. Please comply with the ATEX regulation relative to devices to be used in a potentially explosive environment.

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NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death.

SAFETY LOADS MOVING • The excavator is a machine designed specifically to perform digging/loading works, thus it must not be used to handle suspended loads. In the event, under exceptional conditions, it becomes necessary to handle materials, the following indications must be strictly implemented: - The machine must be equipped compulsorily with the appropriate variant provided upon request. Also, totally comply with the safety precautions for the operation of the excavator as a lifting equipment. - Secure the loads to be raised using cables or chains fastened with appropriate hooking mechanisms. - Never hook cables or chains to the bucket teeth. - Nobody should be allowed to remain under the raised load or within the excavator operating range 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. - In any case, comply with the current national or local regulations on this matter.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

AVOID EXCESSIVE DIGGING EFFORTS • Operate the machine complying with the load limits in accordance with the "table of lifting loads" located inside the cab. - Do not exceed the prescribed load limits. - Do not use the strength of the attachment to travel or move the machine. - Do not try digging exploiting the mass of the machine.

PAY ATTENTION WHEN DIGGING DEEPLY • When digging deeply, pay special attention to prevent contacts of the attachment and the relevant hydraulic hoses with the ground. • DO NOT swing the turret or the undercarriage when the attachment boom is fully lowered. Under these conditions there is the danger that the boom collides with the track chains.

DO NOT USE THE TRACTION FORCE OF THE MACHINE FOR DIGGING • Do not travel the machine to dig. In doing this, an excessive stress on the front attachment could results in damages to the structure. Use the undercarriage for travelling only.

DO NOT USE THE TURRET SWING FOR DIGGING • Do not use the turret swing for digging or moving rocks. An excessive stress on the front attachment could results in damages to the structure reducing the operating life of the swing system. Also, this inappropriate use of the machine could cause serious injuries or fatalities.

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DO NOT USE THE BUCKET AS A HAMMER • The use of the bucket as a hammer or for piling operations could cause serious damages to the bucket itself and the components of the front attachment. Also, this inappropriate use of the machine could cause serious injuries or fatalities.

AVOID OPERATING THE CYLINDERS TO FULL STROKE • Do not extend repeatedly the bucket and the arm cylinders full stroke with the purpose of cleaning the bucket from residual materials. This could cause damages to the cylinders. To remove residues from the bucket, use water under pressure or remove them manually. Tolerance A ≥ 50 mm

PROVIDE SIGNALS FOR JOBS INVOLVING A NUMBER OF MACHINES For jobs involving several machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to co-ordinate the job site. Make sure that all personnel obey the signal person’s directions.

TRANSPORTING THE MACHINE UNDER SAFE CONDITIONS

• During loading or unloading operations of the machine on a truck or trailer the danger for tipping over is always present. - Use a truck or trailer appropriate for transporting the machine. - Secure safely the machine to the trailer with appropriate chains or cables. Please refer to the chapter "TRANSPORTATION" of this Manual for the safe loading and unloading procedures. - Make sure that you comply with National and local regulations when transporting the machine on open roads.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

SAFE MAINTENANCE • To avoid accidents: - Understand maintenance procedure before starting the work. - Keep the working area clean and dry. - Do not spray water or steam inside the cab. - Do not lubricate or service the machine when it is in motion. - Keep hands, feet and clothes far from moving parts. Prior to service in the machine: 1. Park the machine on the level ground. 2. Lower the bucket to the ground. 3. Move the safety lever (pilot-control shut-off lever) to the LOCK position. 4. Switch off the Auto-Idle. 5. Let the engine idle with no load for at least five minutes until it has cooled down. 6. Move the key-start switch position to stop the engine.

to the OFF

7. Remove the ignition key from the start switch. 8. Apply the "Maintenance in progress" tag (see SA FETY PLATE in this C hapter). This tag can be applied o the left-hand control lever, safety lever or cab door. 9. Let the engine cool down. - Do not leave the machine unattended if servicing requires the engine running. - If the machine is to be raised, place boom and arm at an angle 90 to 110°. Lock machine components which should be raised for maintenance or repair using suitable supporting means. - Never work under a machine kept raised by the boom. - Inspect certain component regularly, repair or replace as necessary. Refer to the Chapter MAINTENANCE in this Manual. - Keep all components in good condition and properly install. Immediately repair any fault. - Immediately repair any damage.Replace worn or failed components. Remove grease, oil, debris build-ups. - Disconnect the negative cable (-) from the battery before carry out any work on he electrical sysem or arc-welding on he machine.

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WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. - Before performing any work on the machine, attach a maintenance in progress tag (see also SAFETY PLATES in this Chapter) . This tag can be applied o the left-hand control lever, safety lever or cab door.

SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. - Always lower the attachment or tool to the ground before working on the machine. - If you must work on a lifted machine or attachment, securely support the machine or attachment. - Do not support the machine on cinder blocks, bollow tires, or props that may crumble under continuous load. - Do not work under a machine that is supported solely by a jack.

STOP THE ENGINE PRIOR TO PERFORMING • DO NOT perform any maintenance operation with the engine running. Trapping by moving parts could cause serious injuries. Stop the engine and wait that it cools-off prior to performing maintenance operations. In case it is indispensable to perform maintenance operations with the engine running, have a person co-operating with you sitting in the operator's seat, to cut-off the engine immediately in case of necessity.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

DISPOSE OF WASTE IN THE APPROPRIATE MANNER • Waste improperly disposed of represents a danger for the envinronment. Potentially dangerous waste used on the excavators includes lubricants, fuel, coolant, brake fluid, filters and batteries. - Used sealed containers when discharging fluids. Do not use containers for food or beverages which may induce drinking. - Do not spill waste over the ground, into drains, or water beds. - Obtain information about the correct methods to recycle or dispose of waste from local Authorities, collection centres or your Dealer.

WORK IN A CLEAN AREA - Before starting an operation, clean the working area. Clear the area from all the objects that can be dangerous for mechanics or people in the working area.

PROPERLY LIGHT THE WORKING AREA • Properly and safely light the working area. - Use safe portable lamps in order to work inside and under the machine. - Make sure that the lamp is shielded by a cage; the incandescent filament of a lamp, accidentally broken, can cause fuel or oil fire.

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KEEP CLEAN THE MACHINE • Keep clean the engine compartment, radiator, batteries, hydraulic pipes, fuel tank and operator's position. - The engine compartment temperature can quickly rise, after stopping the engine. IN THESE CASES, BE CAREFUL TO POSSIBLE FIRES. Open the access doors in order to quicken the engine cooling process and clean the compartment. • Remove all the traces of grease, oil and deposits, in order to avoid people accidents or damages to things. - Do not spray water or steam in the cab.

PREVENT ACID SCALDS • The sulphuric acid, contained in the battery, is poisonous. It is strong enough to scald the skin, corrode clothes and cause blindness, if it is sprayed into the eyes. To avoid dangers: - Fill the batteries in airy areas. - Wear eye protections and rubber gloves. - Avoid breathing the electrolyte vapours when topping up. - Avoid spilling or dripping the electrolyte. - Use proper emergency starting techniques. If you are touched with acid sprays: - Rinse your skin well with water. - Put on your skin sodium bicarbonate or clay to help the acid neutralization. - Rinse your eyes with water for 10-15 minutes. - Immediately see a doctor. If you have swallowed the acid: - Immediately see a doctor.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

STARTING THE ENGINE WITH BOOSTER BATTERIES • If the engine is to be started using booster batteries, ensure to comply with all procedures detailed in the chapter OPERATING INSTRUCTIONS. - The operator should be sitting in the driver’s seat to keep the machine under control when the engine starts. Starting the engine with booster batteries is a two man operation. - Do not use batteries that have been stored in the cold for a long time. - Mistakes in following procedures detailed for starting the engine with slave batteries may cause the batteries to explode or machine to move unexpectedly

PREVENT BATTERY EXPLOSIONS • Battery gas can explode. - Keep sparks, lighted matches, and flames away from the top of battery. - Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. - Do not charge a frozen battery; it may explode. Warm battery to 16 °C. • Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. - Be sure to wear eye protection when checking electrolyte specific gravity.

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PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. - To prevent possible injury from hot spraying water. Do not remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. - The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

Hot fluids and surfaces: • Engine oil, reduction gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. - Wait for the oil and components to cool down before starting any maintenance or inspection work.

STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic breakers and blades can fall and cause serious injury or death. - Securely store attachments and implements to prevent falling. - Keep bystanders away from storage areas.

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E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. - Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. - Tighten all pressure.

connections

before

applying

- Search for leaks with a piece of cardboard; take care to protect hands and body from highpressure fluids. Wear a face shield or goggles for eye protection. - In an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

PREVENT PARTS FROM FLYING OFF • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. - NEVER attempt to remove GREASE FITTING or VALVE ASSEMBLY. - As pieces may fly off, be sure to keep body and face away from valve.

• Travel reduction gears are under pressure. - As pieces may fly off, be sure to keep body and face away from air release plug to avoid injury. Reduction gear oil is hot. Wait for gear oil to cool down, then gradually loosen the air release plug to release pressure.

S2 - 22

SP0047

Copyright © New Holland SAFETY PRECAUTIONS

PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. - Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. - Keep bystanderds away from the working area before striking any object.

HANDLE FLUIDS SAFELY - AVOID FIRES • Handle fuel with care: it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injuty or death. - Do not refuel the machine while smoking or when near open flame or sparks. - Always stop the engine before refuelling the machine. - Fill the tank outdoors.

• All fuels, most lubrificants, and some antifreeze fluids are flammable. - Store flammable fluids well away from fire hazards. - Do not burn or puncture pressurized containers. - Do not store oily rags; they can ignite and burn spontaneously.

S2 - 23

E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

PREVENT FIRES • Check for Oil Leaks: - Fuel, hydraulic oil and lubricant leaks can lead to fires. - Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts which may cause oil leaks. - Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oilcooler flange bolts. - Do not bend or strike high-pressure lines. - Never install bent or damaged lines, pipes, or hoses. • Check for Shorts: - Short circuits can cause fires. - Clean and tighten all electrical connections. - Check before each shift or after about ten (10) hour operation for loose, kinked, hardened or frayed electrical cables and wires. - Check before each shift or after about ten (10) hour operation for missing or damaged terminal caps. - DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. • Clean up Flammables: - Spilled fuel and lubricans, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. - Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. • Check Key-start Switch: - If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. - Always check key-start switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key-start switch to the OFF position to confirm that the engine stops. - If any abnormalities are found, be sure to repair them before operating the machine. • Check Heat Shields: - Damaged or missing heat shields may lead to fires. - Damaged or missing heat shields must be repaired or replaced before operating the machine.

S2 - 24

Copyright © New Holland SAFETY PRECAUTIONS

E135B

EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: - Stop the engine by turning the key-start switch to the OFF position if there is time. - Use a fire extinguisher if there is time. - Exit the machine.

BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. - If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

SP0062

USE APPROPRIATE TOOLS • Use tools appropriate for the job to be performed. - Inappropriate tools, parts and procedures might generate dangerous conditions. - Use tools of correct size to tighten or loosening securing elements, in order to avoid injuries caused by a wrench getting out of control. - Do not use U.S. Standard or British Standard tools on metric fasteners and vice versa. • Use only genuine spare parts (please refer to the Spare Parts Catalogue).

S2 - 25

Copyright © New Holland E135B

SAFETY PRECAUTIONS

AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire resistant guards to protect hoses or other materials when welding, soldering, etc.

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS - Do not weld or flame cut pipes or tubes that contain flammable fluids. - Clean them thoroughly with non-flammable solvent before welding or flame cutting them.

REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paints is heated by weiding, soldering, or using a torch. If inhaled, these fumes may cause sickness. - Avoid breathing potentially toxic fumes and dust. - Do all such work outside or in a well-ventilated area. - Dispose of paint and solvents properly. - Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from a re a. Allow fumes to disperse at least 15 minutes before welding or heating.

S2 - 26

Copyright © New Holland SAFETY PRECAUTIONS

WELDING REPAIR INTERVENTIONS • Welding repair interventions must be performed only by a certified welder with sufficient experience. Also, appropriate safety rules must be implemented by all the personnel involved in the operations. The duration through time of the welding depends upon the quality and the accuracy with which the operation is performed. - Identify first all the fracture points and the zones in which welding is required. - Clean accurately the zones involved. - Remove all paint and inspect the parts with penetrating liquid or a magnetic particle tester. - Move the starter switch into position "OFF" and wait for 4 seconds to cut-off electricity from the system. - Disconnect the negative terminal (-) from the battery. - Connect the ground cable of the welder at least 1 m from the component to be welded. - Make sure that the ground cable is NOT connected to a seal or bearing and that there are noo seals or bearings between the ground cable and the part to be welded. - Avoid welding pieces at low temperature i. e. below 16 °C. If necessary, warm-up the part involved prior to welding it. - Remove paints from all surfaces prior to warming-up or welding. Painted surfaces, when warmed-up or when welded, can generate toxic fumes. - Use appropriate masks or protective glasses. - Wear gloves and adequate clothing to protect the skin.

S2 - 27

E135B

Copyright © New Holland E135B

SAFETY PRECAUTIONS

NOTE:

S2 - 28

Copyright © New Holland SAFETY PLATES

E135B

SAFETY PLATES

1

2

1

SP0108

1

1

2

SP0109

1. Attachment operating range safety plate. 2. Track adjuster plate.

S3 - 1

Copyright © New Holland E135B

SAFETY PLATES

4

5

3

6

9

7

11

10

8

SP0110

3. Counterweight operating range safety plate.

8. Engine hood warning plate.

4. Read-your-manual plate.

9. Controls lock/unlock plate (safety lever).

5. Special equipment movement warning plate.

10. Hydraulic oil pressurised tank warning plate.

6. Open windscreen warning plate aperta (inside the cab).

11. No-stepping warning plate.

7. Tag indicating maintenance in progress.

S3 - 2

Copyright © New Holland SAFETY PLATES 1 - Attachment operating range safety plate Ensure that any person near the working site is outside the machine operating range before starting the machine or operating the attachments. Sound the horn. Background: yellow Border and icons: black

2 - Track adjuster plate It shows that obligation is made to consult the Operation and Maintenance Instruction Manual prior to acting on the track adjust valve. Danger of severe injuries. Background: yellow Border and icons: black

3 - Counterweight operating range safety plate Ensure that any person near the working site is outside the machine operating range before starting the machine or operating the attachments. Sound the horn. Background: yellow Border and icons: black

S3 - 3

E135B

Copyright © New Holland E135B

SAFETY PLATES

4 - Read-your-manual plate It is positioned in the cab to recommend to carefully read the Operation and Maintenance Instruction Manual prior to starting, operating, servicing, refuelling or carrying out any other work on the machine. Background: yellow Border and icons: black

5 - Special equipment movement warning plate It shows the danger represented by the special equipment hitting the cab. Pay special attention as no stops are provided to prevent this problem. Background: yellow Border and icons: black

6 - Open windscreen warning plate It indicates the risk of injuries deriving from the windscreen not being locked or being improperly locked in the open position. Background: yellow Border and icons: black

S3 - 4

Copyright © New Holland SAFETY PLATES 7 - Tag indicating maintenance in progress Maintenance staff is obliged to apply the tag that indicates that the machine is not fully efficient and warns about maintenance staff being located in not visible positions. This tag should be applied to the left-hand control lever, safety lever or cab door. Background: yellow Border and icons: black

8 - Engine hood warning plate It highlights the obligation to stop the engine before opening engine hood. Danger of severe injuries following the presence of rotating parts such as fan, pulleys, and belts. Background: yellow Border and icons: black

9 - Controls lock/unlock plate It shows the position that the safety lever can assume when the engine is running. When the operator is about to leave the cab with the engine running, even if for a short time, he must move the safety lever to the LOCK position. Controls are disabled and therefore no accidental machine or attachment movement is possible. Background: white Border and icons: black

S3 - 5

E135B

Copyright © New Holland E135B

SAFETY PLATES

10 - Hydraulic oil pressurised tank warning plate It indicates that the hydraulic oil is pressurised. Consult the Operation and Maintenance Instruction Manual. Prior to intervening on the hydraulic oil tank, bleed the pressure by actuating the appropriate bleeding button located on the cap. The hydraulic oil, at operating temperature, can cause burns in case of contact with the skin. Background: yellow Border and icons: black

11 - No-stepping warning plate It instructs not to step on the zone where this decal is attached. Background: yellow Cross: red Border and icons: black

S3 - 6

Copyright © New Holland

OPERATIONAL PRINCIPLE

Copyright © New Holland

Copyright © New Holland

OPERATIONAL PRINCIPLE

E135B

SECTION AND GROUP CONTENTS Section 1

GENERAL

Group 1

Specifications

Section 2

SYSTEM

Group 1 Group 2 Group 3

Mechatro Control System Hydraulic System Electrical System

Section 3

COMPONENT OPERATION

Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 Group 9

Hydraulic Pump Assy Pilot Valve Control Valve Swing Device Travel Device Swing Joint Cylinders Air Conditioner Blade control

Copyright © New Holland

Copyright © New Holland

SECTION 1

GENERAL

CONTENTS Group 1 - Specifications Main components.................................... T1-1-1 Hydraulic components ........................... T1-1-5 Excavator performance .......................... T1-1-8 Engine data............................................. T1-1-8 Engine characteristic curve..................... T1-1-9 Digging data (Monoblock Version).......... T1-1-10 Digging data (Triple Articulation Version) ............................................. T1-1-11 Digging data (Monoblock Version with undercarriage equipped with blade) .. T1-1-12 Digging data (Triple Articulation Version with undercarriage equipped with blade).......................... T1-1-13 Transporting dimensions (Monoblock Version) .......................... T1-1-14 Transporting dimensions (Triple Articulation Version) ............... T1-1-15 Transporting dimensions (Monoblock Version with undercarriage equipped with blade) .. T1-1-16 Transporting dimensions (Triple Articulation Version with undercarriage equipped with blade) .. T1-1-17 Bucket applications as a function of the arms ........................................ T1-1-18

E135B

Copyright © New Holland

Copyright © New Holland SPECIFICATIONS

E135B

MAIN COMPONENTS

SM2863

12345678910 -

Bucket Bucket link Idler link Bucket cylinder Arm Arm cylinder Boom Boom cylinder Cab Swivel joint

11 12 13 14 15 16 17 18 19 20 -

Swing motor Fuel tank Hydraulic oil tank Control valve Engine muffler Hydraulic pump Engine Counterweight Engine radiator Travel motor

T1-1-1

21 22 23 24 25 26 27 28 29 -

Track link Batteries Upper roller Track guide Lower roller Air cleaner Crawler adjuster Front idler Shoe plate

Copyright © New Holland E135B

SPECIFICATIONS

Main Components – Upper Structure

1

8 H

C

A

E

F

B

G

D B

7

2 6

5

3

4

1-

Control Cab

5-

Hydraulic Pump

2-

Proportional Solenoid Valve Block

6-

Control Valve

3-

Radiators

7-

Swing Motor Unit

4-

Engine

8-

Center Joint

T1-1-2

SM2859

Copyright © New Holland SPECIFICATIONS

E135B

Main Components – Under Carriage

5

4

3

2 H

1

I C D B

A E

E

section A - A SM2860

1-

Right Travel Motor Unit

4-

Swing Gear

2-

Left Travel Motor Unit

5-

Front Idler Assy

3-

Center joint

T1-1-3

Copyright © New Holland E135B

SPECIFICATIONS

Main Components – Front Attachment

2

7

5

1 3

6

4

2

8

7

3

1

SM0014

1-

Boom cylinder

5-

Monoblock Boom

2-

Arm cylinder

6-

Boom (Triple Articulation Version)

3-

Bucket Cylinder

7-

Arm

4-

Positioning Cylinder (Triple Articulation Version)

8-

Positioner (Triple Articulation Version)

T1-1-4

Copyright © New Holland SPECIFICATIONS

E135B

HYDRAULIC COMPONENTS HYDRAULIC PUMP Main pump

Gear pump for pilot

Pump

Item

K7V63DTP175R-0E13-VC

ZX10L7RZ2-07G

Type

Variable displacement plunger pump: regulator attached type

Fixed displacement type gear pump

65.2 (3.98) x 2

10 (0.61)

2000

←

Max. displacement capacity

cm3 (in3)

Revolution

Rated

rpm (Clockwise seen from shaft end)

Pressure

Rated

MPa (psi)

34.3 (4974)

5.0 (725)

Max. flow

L/min (gal/min)

130 (34) x 2 at 7.8 MPa (1130 psi)

20 (5.3)

Max. input Power (at 2000 rpm)

kW (PS)

64.9 (88.3)

3.1 (4.2)

Max. input torque (at 1600 rpm)

N•m (lbf•ft)

310 (229)

14.7 (10.8)

Model Regulator

Mass

KR76-0E13PV - KR76-0E13-V

Control function

Electric flow control, positive flow control

Others

With solenoid proportional reducing valve (KDRDE5K-31/ 30C50-123)

kg (lb)

84 (185)

NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.

CONTROL VALVE Item

STD VALVE

Model

KMX13YD / B44006

Max. flow rate

L/min (gal/min)

Main relief valve set pressure

MPa (psi)

Over load relief valve set pressure

MPa (psi)

Boom R, Bucket R, Arm H Mass

34.3 (4,974) at 30 (7.9 gal/min) x 2 L/min 37.8 (5,482) at 30 (7.9 gal/min) L/min

kg (lb) Item

155 (341) OPT VALVE

Model Over load relief valve set pressure

130 (34) x 2

KADV22Y / 501103A03 MPa (psi)

Positioner R

37.8 (5,482) at 30 (7.9 gal/min) L/min

Positioner H

37.8 (5,482) at 30 (7.9 gal/min) L/min

Mass

kg (lb)

T1-1-5

11 (24.3)

Copyright © New Holland SPECIFICATIONS

E135B

PILOT VALVE Model Primary pressure

ATTACHMENT

TRAVEL

PV48K2004

6TH6NRZ

5.0 MPa (725 psi)

4.9 MPa (710 psi)

0.6 ~ 3.2 MPa (87 ~ 464 psi)

0.54 ~ 2.35 MPa (78.3 ~ 340.7 psi)

Rated flow

20 L/min (5.3 gal/min)

25 L/min (6.6 gal/min)

Mass

Approx. 2 kg (4.4 lbs)

Approx. 8 kg (17.6 lbs)

Secondary pressure

Hydraylic motor

SWING MOTOR UNIT

Antireaction valve block

Model

M2X63CHB-13A-36/28E-60

Type

Swash-plate type, fixed-displacement plunger motor

Displacement

cm3 (in3)

60.0 (3.66)

Working pressure

MPa (psi)

28.0 (4,060)

Max. flow

L/min (gal/min)

132 (34.87)

Braking torque

N•m (lbf•ft)

655 (483)

Release pressure

MPa (psi)

2.3 (333)

Relief set pressure

MPa (psi)

29 (4,206)

Mass

kg (lb)

Type Mass

Hydraulic motor assy mass

2KAR6P72/240-716 kg (lb)

5 (11)

kg (lb)

34 (75)

Model

RG06D19J2

Reduction unit

Speed reduction type

Total mass

Planetary 2-stage

Reduction ratio

19.2

Lubicate oil Lubicate oil volume

29 (64)

Gear oil SAE90 (API class GL–4 grade) L (gal)

Grease

1.65 (0.43) Extreme pressure lithium base # 2 grease

Grease volume

cm3 (in3)

Mass

kg (lb)

79 (174)

kg (lb)

113 (249)

T1-1-6

500 (30.51)

Copyright © New Holland SPECIFICATIONS

E135B

TRAVEL DEVICE Type

GM21VA-A-45/76-2 Gear ratio

Reduction unit

54.0

Rating torque

11,100/19,200 N•m (8,186/14,160 lbf•ft)

Output speed

51.4/31.3 rpm

Lubricant oil

Hydraulic motor

Gear oil SAE#90 GL4

Lubricant oil volume

2.1 L (0.55 gal)

Max. displacement

44.9/75.5 cm3/rev (2.74/4.61 cu.in/rev)

Max working pressure

34.32 MPa (4,976.4 psi)

Max. speed

2,777/1,688 rpm (2nd/1st)

Flow rate

130 L/min (34 gal/min)

2 speed control pressure

1.96~6,86 MPa (284~995 psi)

Auto 2 speed control pressure Parking brake

28.44 MPa (4,124 psi)

Brake torque

206 N•m (152 lbf•ft)

Release pressure

0.76 MPa (110 psi)

Mass

145 kg (320 lbs)

CYLINDERS

Use

Boom Arm Bucket Positioning

Cylinder bore / Rod Dia.

Stroke

mm (in)

mm (in)

Center distance of pins Full extend B / Full retract A mm (in)

Ø 100 / Ø 70 (3.94 / 2.76) Ø 115 / Ø 80 (4.53 / 3.15) Ø 95 / Ø 65 (3.74 / 2.56) Ø 125 / Ø 85 (4.92 / 3.35)

1,028 (40.47) 1,120 (44.09) 903 (35.55) 825 (32.48)

2,516 / 1,488 (99.05 / 58.58) 2,835 / 1,715 (111.61 / 67.52) 2,293 / 1,390 (90.27 / 54.72) 2,190 / 1,365 (86.22 / 53.74)

T1-1-7

Cushion

Mass kg (lb)

With cushion on rod side With cushion on both sides With cushion on rod side Without cushion

100 (220) 138 (304) 82 (180) 177 (390)

Copyright © New Holland E135B

SPECIFICATIONS

EXCAVATOR PERFORMANCE GRADEABILITY ......................................................................................................................................... 70% TRAVEL SPEED Speed First speed

3.4 km/h (2.1 mph)

Second speed

5.5 km/h (3.5 mph)

ENGINE DATA MAIN SPECIFICATIONS -

Manufacturer .........................................................................................MITSUBISHI HEAVY INDUSTRIES

-

Model ...................................................................................................................................... D04FR-74KW

-

Type ..................................................................................... Diesel, 4 stroke, direct injection, turbocharged

-

Number of cylinder ...........................................................................................................................4 in-line

-

Bore ................................................................................................................................... 102 mm (4.02 in)

-

Stroke................................................................................................................................. 130 mm (5.12 in)

-

Total displacement .................................................................................................... 4,249 cm3 (259.28 in3)

-

Compression ratio ............................................................................................................................... 17.8:1

-

Net power at flywheel at 2,000 rpm (ISO 14396) ................................................................. 74 kW (101 PS)

-

Net power at flywheel at 2,000 rpm (ECE R120) ................................................................. 74 kW (101 PS)

-

Torque at 1,600 rpm....................................................................................................... 375 N•m (277 lbf•ft)

-

Engine idle at no-load ............................................................................................. 1,015 min-1 (1,015 rpm)

INJECTION PUMP -

Manufacturer .................................................................................................................................... BOSCH

-

Type ................................................................................................................... Common rail high pressure

-

Injection order ....................................................................................................................................1-3-4-2

BATTERY -

Voltage - Capacity............................................................................................................. 2 x 12 V - 100 Ah

STARTER MOTOR -

Manufacturer ................................................................................................NIKKO ELECTRIC INDUSTRY

-

Voltage - Output......................................................................................................................... 24 V - 5 kW

ALTERNATOR -

Manufacturer ................................................................................................NIKKO ELECTRIC INDUSTRY

-

Type ........................................................................................................................................0-35000-4838

-

Voltage - Output.......................................................................................................................... 24 V - 50 A

T1-1-8

Copyright © New Holland SPECIFICATIONS

E135B

ENGINE CHARACTERISTIC CURVE Condition to be measured: the net value is indicated, measuring without cooling fan.

SM2862

Fuel consumption volume = (Fuel consumption rate / 0.835 x 1000) x kW x Load factor (α) = (233 g/kW h / 0.853 x 1000) x 74 kW x α = 20.65 α L/h α: standard load factor (0.70 ~ 0.80) Fuel consumption in regular operation (load factor 0.70 ~ 0.80) 14.5 L/h ~ 16.5 L/h

T1-1-9

Copyright © New Holland SPECIFICATIONS

E135B

DIGGING DATA (Monoblock Version)

A A‘

E

C D

B

B‘

NH0701

Unit: mm (in) Arm

2100 (82.68)

2450 (96.46)

2950 (116.14)

A

8097 (318.78)

8428 (331.81)

8914 (350.94)

A’

7940 (312.60)

8278 (325.90)

8774 (345.43)

B

5147 (202.63)

5498 (216.46)

5998 (236.14)

B’

4884 (192.28)

5267 (207.36)

5807 (228.62)

C

8411 (331.14)

8633 (339.88)

8977 (353.42)

D

6009 (236.57)

6232 (245.35)

6575 (258.86)

E

2600 (102.36)

2651 (104.37)

2918 (114.88)

T1-1-10

Copyright © New Holland E135B

SPECIFICATIONS

DIGGING DATA (Triple Articulation Version)

A A‘

E

C D

B

B‘

NH0702

Unit: mm (in) Arm

2100 (82.68)

2450 (96.46)

2950 (116.14)

A

8195 (322.64)

8534 (335.98)

9030 (355.51)

A’

8041 (316.57)

8386 (330.16)

8890 (349.99)

B

4919 (193.66)

5267 (207.36)

5769 (227.13)

B’

4789 (188.54)

5142 (202.44)

5655 (222.64)

C

9386 (369.53)

9701 (381.92)

10168 (400.31)

D

6951 (273.66)

7268 (286.14)

7738 (304.64)

E

2600 (102.36)

2198 (86.53)

2628 (103.46)

T1-1-11

Copyright © New Holland SPECIFICATIONS

E135B

DIGGING DATA (Monoblock Version with undercarriage equipped with blade)

A A‘

E

C D

B

B‘

NH0703

Unit: mm (in) Arm

2100 (82.68)

2450 (96.46)

2950 (116.14)

A

8097 (318.78)

8428 (331.81)

8914 (350.94)

A’

7940 (312.60)

8278 (325.90)

8774 (345.43)

B

4853 (191.06)

5201 (204.76)

5701 (224.45)

B’

4613 (181.61)

4994 (196.61)

5522 (217.40)

C

8411 (331.14)

8633 (339.88)

8977 (353.42)

D

6009 (236.57)

6232 (245.35)

6575 (258.86)

E

2600 (102.36)

2651 (104.37)

2918 (114.88)

T1-1-12

Copyright © New Holland SPECIFICATIONS

E135B

DIGGING DATA (Triple Articulation Version with undercarriage equipped with blade)

A A‘

E

C D

B

B‘

NH0704

Unit: mm (in) Arm

2100 (82.68)

2450 (96.46)

2950 (116.14)

A

8195 (322.64)

8534 (335.98)

9030 (355.51)

A’

8041 (316.57)

8386 (330.16)

8890 (349.99)

B

4919 (193.66)

5267 (207.36)

5769 (227.13)

B’

4723 (185.94)

5086 (200.24)

5609 (220.82)

C

9386 (369.53)

9701 (381.92)

10168 (400.31)

D

6951 (273.66)

7268 (286.14)

7738 (304.64)

E

2600 (102.36)

2198 (86.53)

2628 (103.46)

T1-1-13

Copyright © New Holland SPECIFICATIONS

E135B

TRANSPORTING DIMENSIONS (Monoblock Version)

E G

D

H

F

C

I

L

A B

M N

NH0705

Unit: mm (in) A

B

C

D

E (1)

F

7853

(1)

(309.17) 3044 (119.84)

3750 (147.64)

892 (35.12)

2130 (83.86)

(2)

7858 7790

H

I

L

2413 (95.0)

2880 (113.39)

787 (30.99)

456 (17.95)

2693 (106.02)

(2)

(309.37) (3)

G

2803 (110.35)

(3)

3150

(306.69)

(124.02)

With arm: (1) 2100 mm (82.68 in) (2) 2450 mm (96.46 in) (3) 2950 mm (116.14 in)

M Track shoe width

mm (in)

500 (19.68)

600 (23.62)

N Gauge

mm (in)

2490 (98.03)

2590 (101.97) 2690 (105.91) 2790 (109.84)

(*) Working weight Spec. ground pressure

kg (lb) bar (psi)

700 (27.56)

800 (31.50)

13175 (29045) 13400 (29541) 13625 (30037) 13850 (30533) 0.42 (6.09)

0.36 (5.22)

(*) With arm 2450 mm (96.46 in) and bucket 0.61 m3 (0.80 yd3)

T1-1-14

0.31 (4.50)

0.28 (4.05)

Copyright © New Holland E135B

SPECIFICATIONS

TRANSPORTING DIMENSIONS (Triple Articulation Version)

E G

D

H

F

C

I

L

A B

M N

NH0706

Unit: mm (in)

A

B

C

D

E (1)

F

7852

(1)

(309.13) 3044 (119.84)

3750 (147.64)

892 (35.12)

2130 (83.86)

(2)

7823 7733

H

I

L

2413 (95.0)

2880 (113.39)

787 (30.99)

456 (17.95)

2579 (101.54)

(2)

(307.99) (3)

G

2710 (106.69)

(3)

3116

(304.45)

(122.68)

With arm: (1) 2100 mm (82.68 in) (2) 2450 mm (96.46 in) (3) 2950 mm (116.14 in)

M Track shoe width

mm (in)

500 (19.68)

600 (23.62)

N Gauge

mm (in)

2490 (98.03)

2590 (101.97) 2690 (105.91) 2790 (109.84)

(*) Working weight Spec. ground pressure

kg (lb) bar (psi)

700 (27.56)

800 (31.50)

13695 (30192) 13920 (30688) 14145 (31184) 14370 (31680) 0.44 (6.38)

0.37 (5.37)

(*) With arm 2100 mm (82.68 in) and bucket 0.61 m3 (0.80 yd3)

T1-1-15

0.33 (4.79)

0.29 (4.21)

Copyright © New Holland SPECIFICATIONS

E135B

TRANSPORTING DIMENSIONS (Monoblock Version with undercarriage equipped with blade)

E O G

D

H

F

C

I

L

A B

M N

NH0707

Unit: mm (in) A

B

C

D

E (1)

F

7853

(1)

(309.17) 3044 (119.84)

3750 (147.64)

892 (35.12)

2130 (83.86)

(2)

7858 7790

H

I

L

O

2413 (95.0)

2880 (113.39)

787 (30.99)

456 (17.95)

2434 (95.83)

2693 (106.02)

(2)

(309.37) (3)

G

2803 (110.35)

(3)

(306.69)

3150 (124.02)

With arm: (1) 2100 mm (82.68 in) (2) 2450 mm (96.46 in) (3) 2950 mm (116.14 in)

M Track shoe width

mm (in)

500 (19.68)

600 (23.62)

N Gauge

mm (in)

2490 (98.03)

2590 (101.97) 2690 (105.91) 2790 (109.84)

(*) Working weight Spec. ground pressure

kg (lb) bar (psi)

700 (27.56)

800 (31.50)

13905 (30655) 14140 (31173) 14380 (31702) 14615 (32220) 0.45 (6.53)

0.38 (5.51)

(* ) With arm 2450 mm (96.46 in) and bucket 0.61 m3 (0.80 yd3)

T1-1-16

0.33 (4.79)

0.30 (4.35)

Copyright © New Holland SPECIFICATIONS

E135B

TRANSPORTING DIMENSIONS (Triple Articulation Version with undercarriage equipped with blade)

E O G

D

H

C

I

L

F

M

A B

N

NH0708

Unit: mm (in) A

B

C

D

E (1)

F

7852

(1)

(309.13) 3044 (119.84)

3750 (147.64)

892 (35.12)

2130 (83.86)

(2)

7823 7733

H

I

L

O

2413 (95.0)

2880 (113.39)

787 (30.99)

456 (17.95)

2434 (95.83)

2579 (101.54)

(2)

(307.99) (3)

G

2710 (106.69)

(3)

(304.45)

3116 (122.68)

With arm: (1) 2100 mm (82.68 in) and blade positioned toward the equipment (2) 2450 mm (96.46 in) (3) 2950 mm (116.14 in)

M Track shoe width

mm (in)

500 (19.68)

600 (23.62)

N Gauge

mm (in)

2490 (98.03)

2590 (101.97) 2690 (105.91) 2790 (109.84)

(*) Working weight Spec. ground pressure

kg (lb) bar (psi)

700 (27.56)

800 (31.50)

14425 (31801) 14660 (32319) 14900 (32848) 15135 (33366) 0.46 (6.67)

0.39 (5.66)

(*) With arm 2100 mm (82.68 in) and bucket 0.61 m3 (0.80 yd3)

T1-1-17

0.34 (4.93)

0.30 (4.35)

Copyright © New Holland SPECIFICATIONS

E135B

BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS Monoblock BUCKETS Arm mm (in)

Capacity Widthmm (in)

dm3 (yd3) SAE J296 (ISO 7451)

Masskg (lb)

500 (19.68)

280 (0.37)

315 (694.45)

750 (29.53)

424 (0.55)

350 (771.62)

850 (33.46)

498 (0.65)

370 (815.71)

900 (35.43)

536 (0.70)

380 (837.76)

1000 (39.37)

610 (0.80)

415 (914.92)

1100 (43.31)

684 (0.89)

440 (970.03)

1200 (47.24)

758 (0.99)

470 (1036.17)

2100 (82.68)

2450 (96.46)

2950 (116.14)

Triple Articulation

BUCKETS

Widthmm (in)

Capacity dm3 (yd3) SAE J296 (ISO 7451)

Masskg (lb)

500 (19.68)

280 (0.37)

315 (694.45)

750 (29.53)

424 (0.55)

350 (771.62)

850 (33.46)

498 (0.65)

370 (815.71)

900 (35.43)

536 (0.70)

380 (837.76)

1000 (39.37)

610 (0.80)

415 (914.92)

1100 (43.31)

684 (0.89)

440 (970.03)

1200 (47.24)

758 (0.99)

470 (1036.17)

Arm mm (in) 2100 (82.68)

2450 (96.46)

General digging work (specific weight of material < 1.8 t/m3) Slightly heavy digging work (specific weight of material < 1.5 t/m3) Loading work (specific weight of material < 1.2 t/m3) Bucket not applicable

T1-1-18

2950 (116.14)

Copyright © New Holland

Copyright © New Holland

SECTION 2

E135B

SYSTEM

CONTENTS Group 1 - Mechatro Control System 1 Preface .............................................. T2-1-1 2 Summary of Mechatro control system T2-1-2 2.1

Mechatro control system in general ..................................... T2-1-2

2.2

Unload valve control ................. T2-1-4

2.3

Positive control & P-Q control... T2-1-5

2.4

Boom up conflux control ........... T2-1-7

2.5

Arm in recirculation & conflux control....................................... T2-1-8

2.6

Arm-in anti-cavitation control .... T2-1-10

2.7

Arm-out conflux control............. T2-1-11

2.8

Bucket digging (dump) control.. T2-1-12

2.9

Swing priority control ................ T2-1-13

2.10 Travel straight control ............... T2-1-14 2.11 Pressure release control (include extra pressure release) T2-1-16 2.12 N&B switch control (option) ...... T2-1-18 2.13 Option conflux control (option).. T2-1-19 2.14 N&B solenoid relief valve control . T2-1-20 3 Mechatro controller ............................ T2-1-21 3.1

Summary of multi display ......... T2-1-21

3.2

Self diagnosis display ............... T2-1-27

3.3

Service diagnosis display function ..................................... T2-1-33

3.4

Trouble history diagnosis.......... T2-1-43

3.5

Trouble diagnosis mode ........... T2-1-44

3.6

Set procedure of maintenance schedule ................................... T2-1-45

3.7

Adjusting procedure of display . T2-1-46

3.8

Mechatro control equipment ..... T2-1-54

Group 2 - Hydraulic circuits 1 Summary ........................................... T2-2-1 2 Hydraulic circuits and components .... T2-2-2 3 N&B hydraulic circuit (option) ............ T2-2-4 4 Holding valve for boom & arm (option)T2-2-6 5 Dozer hydraulic circuit ....................... T2-2-8

6 Positioning circuit (triple articulation version) .............................................. T2-2-10 7 Color coding standard for hydraulic circuits................................................ T2-2-12 8 Neutral circuit .................................... T2-2-12 9 Travel circuit ...................................... T2-2-14 10 Bucket circuit ..................................... T2-2-16 11 Boom circuit ...................................... T2-2-18 12 Swing circuit ...................................... T2-2-22 13 Arm circuit ......................................... T2-2-24 14 Combined circuit ............................... T2-2-30 15 Pressure draining (releasing) circuit . T2-2-34

Group 3 - Electrical system Electrical system main components........ T2-3-1 Electrical system (Overall system) ..... T2-3-1 Electrical system diagram ...................... T2-3-14 Electrical system diagram (No. 1) ...... T2-3-14 Electrical system diagram (No. 2) ...... T2-3-16 Electrical system diagram (No. 3) ...... T2-3-18 Electrical system diagram (No. 4) ...... T2-3-20 Wiring harness ........................................ T2-3-22 Cluster gauge wiring harness assembly................................... T2-3-23 Platform wiring harness assembly .... T2-3-25 Upper frame wiring harness assembly . T2-3-27 ECU wiring harness assembly ........... T2-3-29

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

1. PREFACE This chapter explains only those related to the electro hydraulic conversion as mechatro control. This chapter summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the conditions before and after each conversion, refer to the hydraulic system and the electric system.

T2-1-1

Copyright © New Holland E135B

SUMMARY OF MECHATRO CONTROL SYSTEM

2.1

MECHATRO CONTROL SYSTEM IN GENERAL

ELECTRIC CONTROLLER INPUT SIGNAL HYDRAULIC‫ޓޓ‬ PILOT SECONDARY PRESSURE

VOLTAGE OUTPUT L1

SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT

L2 LH

RH

LH

RH

OPTION PILOT VALVE PILOT VALVE FOR TRAVEL

PILOT VALVE FOR ATT

SE-9 SE-10

COOLANT TEMP. GAUGE

SE-16

SERIAL COMMUNICATION

SERIAL COMMUNICATION

LOWER SW. SCREEN CHANGE BUZZER STOP MODE WASHER WIPER TRAVEL DECEL

LOW PRESSURE SENSOR

SE-4

(4)

SE-3 SE-2

(2)

SE-1 SE-8 SE-7

L3 L4 L5

(3)

(1)

(8) (7)

L6

(6) SE-5

(5)

OUTPUT VOLTAGE

LCD DISPLAY FOR SELECTION FUEL GAUGE

ACCEL DIAL

SE-11

MULTI CONTROL VALVE OR SENSOR BLOCK

GAUGE CLUSTER

PROPORTIONAL VOLTAGE

2

MECHATRO CONTROL SYSTEM

SE-23 HIGH PRESSURE SENSOR

C-1

SE-22

MECHATRO CONTROLLER ENGINE

A3

PSV -P1 P1 PUMP PROPORTIONAL VALVE

: HIGH PRESSURE SENSOR (FOR P1,P2 : 2pcs)

PSV -P2 P2 PUMP PROPORTIONAL VALVE

: INJECTOR

: LOW PRESSURE SENSOR (ATT : 7pcs, TRAVEL : 2pcs)

L7 A2

INJECTOR SPEED SENSOR SE-13

KPSS RELEASE SWITCH

: E/G SPEED SENSOR

A1

CAN COMMUNICATION ENGINE SPEED COMMAND CURRENT

L8

C-3 ENGINE CONTROLLER

: ACCEL DIAL POTENTIOMETER

L9 VOLTAGE 24V PROPORTIONAL COMMAND CURRENT

E-27 EMERGENCY MODE ACCEL DIAL SM3167

T2-1-2

Copyright © New Holland MECHATRO CONTROL SYSTEM

L1

E135B

MAIN CONTROL VALVE SE-29

L2

L3 L4 L5

REVERSE

REVERSE

(5)

(7)

PSV-I

PSV-E SV-13 N&B SELECTOR VALVE

P2 UNLOAD

BOOM UP CONFLUX

OPTION

UP

(8)

ARM 1 SPEED

DIGGING

P1 P2

(6)

SWING

(3)

(3)

TRAVEL LEFT

(4)

(1)

LEFT ARM OUT

FORWARD

DOWN FORWARD

BOOM LOW SPEED

BUCKET

ARM 2 SPEED

(2)

TRAVEL P1 UNLOAD STRAIGHT

DUMP

(8)

TRAVEL RIGHT

ARM OUT

SOL

RIGHT ARM IN

SOLENOID VALVE

L6 SWING MOTOR PARKING RELEASE

TRAVEL MOTOR 1,2 SPEED SELECT

PSV -A

PSV PSV PSV -D -C -B

SV -3

SV -1

SAFETY LOCK LEVER

SWING PARKING BRAKE

TRAVEL 1,2 SPEED

P2 UNLOAD

TRAVEL STRAIGHT

P1 UNLOAD

L7

ARM IN 2 SPEED

BOOM CYLINDER BOOM DOWN RECIRCULATION BOOM CONFLUX

SV -4

ARM CYLINDER ARM OUT CONFLUX ARM IN CONFLUX

(7) ARM IN

L8

BUCKET CYLINDER DIGGING / DUMP CONFLUX

L9 PROPORTIONAL VALVE SOLENOID VALVE

) BLOCK SM3168

T2-1-3

Copyright © New Holland E135B

P2

(LEFT)

(RIGHT)

OPTIONAL PILOT VALVE

PILOT VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

UNLOAD VALVE CONTROL

OPTION

2.2

MECHATRO CONTROL SYSTEM

P1

PILOT VALVE

PILOT VALVE FOR TRAVEL

SE-11 SE-10

SE-9

LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4

SE-5,7,8

pi

PILOT SIGNAL PROCESS

PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

MECHATRO PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0118

1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective low pressure sensors. 2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve. 3. Each unload pressure proportional valves output pilot secondary pressure according to the command output by mechatro controller and switches each unload spools. 4. With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating. T2-1-4

Copyright © New Holland MECHATRO CONTROL SYSTEM

P2

SE-23

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

TRAVEL STRAIGHT

OPTIONAL PILOT VALVE

P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

BOOM UP CONFLUX

POSITIVE CONTROL & P-Q CONTROL

OPTION

2.3

E135B

P1

SE-22

SE-11

(LEFT)

(RIGHT)

PILOT VALVE

PILOT VALVE

PILOT VALVE FOR TRAVEL

SE-10

SE-9

LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4

SE-5,7,8

pi PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE COMMAND

P2 PUMP PROPORTIONAL VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi

pi

PILOT SIGNAL PROCESS PILOT SECONDARY PRESSURE

P1 PUMP PROPORTIONAL VALVE COMMAND

P1 PUMP PROPORTIONAL VALVE PSV-P1

MECHATRO CONTROLLER pi : PROPORTIONAL VALVE

SECONDARY PRESSURE SM0119

T2-1-5

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

1. Positive control 1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve. 3) Each pump proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes the tilting angle of each pump and controls the delivery rate. 4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator, and consequently the working speed according to the lever manipulated movement will be obtained. 2. P-Q control 1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller and the mechatro controller processes pilot signal and operates the command according to the input voltage (load pressure). 2) The lower value between command values calculated by positive control and operated value found by P-Q control {operated value found in item 1)} is selected and is output to each pump proportional valve as command value. 3) Each pump proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes tilting angle of each pump and controls the delivery rate. 4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and consequently working speed will be obtained according to lever movement.

P-Q CONTROL

PILOT SIGNAL PROCESS

PUMP PROPORTIONAL SECONDARY PRESSURE

PUMP PROPORTIONAL SECONDARY PRESSURE

POSITIVE CONTROL

PILOT PRESSURE

PILOT SIGNAL PROCESS

PUMP DELIVERY PRESSURE

SM0120

T2-1-6

Copyright © New Holland MECHATRO CONTROL SYSTEM

P2

PILOT VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

BOOM UP CONFLUX CONTROL

OPTION

2.4

E135B

P1

LOW PRESSURE SENSOR SE-3

pi

PILOT SIGNAL PROCESS

BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS MECHATRO CONTROLLER BOOM UP PILOT SECONDARY PRESSURE

P2 PUMP PROPORTIONAL VALVE PSV-P2

P1 PUMP PROPORTIONAL VALVE PSV-P1

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P2 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

SM0121

1. On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux spool and is input to low pressure sensor. 2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and P2 unload proportional valves. 3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valve. 4. With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.

T2-1-7

Copyright © New Holland E135B

P2

LOW PRESSURE SENSOR SE-1~6

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX

PILOT VALVE

P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

ARM IN RECIRCULATION & CONFLUX CONTROL

OPTION

2.5

MECHATRO CONTROL SYSTEM

P1

LOW PRESSURE SENSOR SE-7

CONTROL PROCESS FOR 2 SPEED

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

ARM IN PILOT SECONDARY PRESSURE P1 PUMP PROPORTIONAL VALVE PSV-P1

PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

ARM IN PILOT SECONDARY PRESSURE P1 UNLOAD PROPORTIONAL VALVE PSV-D

pi PILOT SECONDARY PRESSURE

pi REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

ARM PILOT SECONDARY PRESSURE

P2 PUMP PRESSURE

MECHATRO CONTROLLER

pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0122

T2-1-8

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

1. Recirculation and conflux (Low loading) 1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool and low pressure sensor. 2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool. In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal according to the combined operation and outputs command, which is different from the armin independent operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for arm-in 2 spool. 3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls recirculation rate and conflux rate.) The other proportional valves output proportional secondary pressure according to command from mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload valve. 4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload spools and arm 2 spool are switched according to the command output by mechatro controller, and consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil during arm operation. 2. Recirculation cut The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is raised during arm operation the mechatro controller processes pilot signal processing according to the pressure detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for arm-in 2 spool. The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation passage is blocked.

T2-1-9

Copyright © New Holland E135B

P2

LOW PRESSURE SENSOR SE-7

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

TRAVEL STRAIGHT

PILOT VALVE

P2 UNLOAD

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

BOOM UP CONFLUX

ARM-IN ANTI-CAVITATION CONTROL

OPTION

2.6

MECHATRO CONTROL SYSTEM

P1

ACCEL POTENTIO

pi

PILOT SIGNAL PROCESS

ARM IN PILOT SECONDARY PRESSURE pi

PILOT SIGNAL PROCESS

pi P2 PUMP PROPORTIONAL VALVE PSV-P2

REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL PSV-Bpi

ARM IN PILOT SECONDARY PRESSURE

pi REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL COMMAND

ENGINE SPEED (COMMAND VALUE)

MECHATRO CONTROLLER

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

pi

pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM0123

1. On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low pressure sensor. 2. The engine speed command output by accel potentiometer is input to mechatro controller. 3. Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2 unload proportional valve. 4. And also outputs command according to input pressure output by potentiometer to reverse proportional valve for arm 2 spool. 5. Each proportional valve outputs pilot secondary pressure according to each command output by mechatro controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump delivery rate is low due to low engine speed.

T2-1-10

Copyright © New Holland MECHATRO CONTROL SYSTEM

P2

PILOT VALVE

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

ARM-OUT CONFLUX CONTROL

OPTION

2.7

E135B

P1

LOW PRESSURE SENSOR SE-8

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

ARM OUT PILOT SECONDARY PRESSURE pi P1 PUMP PROPORTIONAL VALVE PSV-P1

ARM OUT PILOT SECONDARY PRESSURE

pi P2 UNLOAD PROPORTIONAL VALVE PSV-B

ARM OUT PILOT SECONDARY PRESSURE pi

MECHATRO CONTROLLER ARM OUT PILOT SECONDARY PRESSURE

P1 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

SM0124

1. On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is input to low pressure sensor. 2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and P2 unload proportional valves. 3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valves. 4. With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation. T2-1-11

Copyright © New Holland E135B

PILOT VALVE

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

BUCKET DIGGING (DUMP) CONTROL

OPTION

2.8

MECHATRO CONTROL SYSTEM

P1

LOW PRESSURE SENSOR SE-1(2) pi

PILOT SIGNAL PROCESS

P1 PUMP PROPORTIONAL VALVE PSV-P1

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P1 UNLOAD PROPORTIONAL VALVE PSV-D

MECHATRO BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE

SECONDARY PRESSURE

SM3169

1. On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket spool and is input to low pressure sensor. 2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 pump proportional valve and P1 unload proportional valve. 3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes P1 pump delivery rate and switches P1 unload valve.

T2-1-12

Copyright © New Holland MECHATRO CONTROL SYSTEM

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

BOOM UP CONFLUX

TRAVEL LEFT

SOLENOID

P2 UNLOAD

N&B SELECTOR VALVE

SWING

PILOT VALVE

ARM 1 SPEED

SWING PRIORITY CONTROL

OPTION

2.9

E135B

P1

LOW PRESSURE SENSOR SE-5

SE-7

pi

PILOT SIGNAL PROCESS

ARM IN PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2 P1 PUMP PROPORTIONAL VALVE PSV-P1 P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL VALVE PSV-D

ARM IN PILOT SECONDARY PRESSURE

pi

SWING PILOT SECONDARY PRESSURE

pi

SWING PILOT SECONDARY PRESSURE

TRAVEL STRAIGHT PROPORTIONAL VALVE COMMAND

TRAVEL STRAIGHT COMMAND PROPORTIONAL VALVE PSV-C

REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL

REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A

MECHATRO CONTROLLER

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

SM0127

1. During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot secondary pressure switches swing spool and is input to low pressure sensor. 2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool. 3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight spool, arm 2 spool. 4. With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil on arm cylinder rod side is recirculated into arm cylinder head side. 5. Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum speed drop possible. T2-1-13

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

(RIGHT)

PILOT VALVE

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD

TRAVEL LEFT

BOOM UP CONFLUX

PILOT VALVE

TRAVEL STRAIGHT

(LEFT)

P2 UNLOAD

SOLENOID

SWING

N&B SELECTOR VALVE

ARM 1 SPEED

OPTIONAL PILOT VALVE

OPTION

2.10 TRAVEL STRAIGHT CONTROL

P1

PILOT VALVE FOR TRAVEL

SE-10

SE-9

SE-11

LOW PRESSURE SENSOR

TRAVEL STRAIGHT SIGNAL

pi PILOT SIGNAL PROCESS

TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C

‫ޓޓ‬ PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

‫ޓޓޓ‬ PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P1 PUMP PROPORTIONAL VALVE PSV-P1

PILOT ‫ޓ‬ SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P2 UNLOAD PROPORTIONAL VALVE PSV-B

PILOT SECONDARY PRESSURE pi

PILOT SIGNAL PROCESS

pi : PROPORTIONAL VALVE SECONDARY PRESSURE

P1 UNLOAD PROPORTIONAL VALVE PSV-D

PILOT‫ޓޓޓ‬ SECONDARY PRESSURE SM3170

T2-1-14

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

1. Judgment travel straight 1) During travel operation (right and left), pilot pressure switches each travel spool and is input to low pressure sensor on carrying out attachment system operation. 2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns travel straight signal on. 3) On turning travel straight signal on, the following commands are output to each proportional valve. 2. Operation of each proportional valve (Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in travel straight condition.) 1) Travel straight proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating (Boom, arm, bucket, swing, option) pilot pressure during operation. 2) P1 unload proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation. 3) P2 unload proportional valve outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation. 4) P1 pump proportional valve outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation. 5) P2 pump proportional valve outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation. ATT operation

Boom

Arm

Travel operation (P1) Travel operation (P2)

T2-1-15

Bucket

Swing

Option

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX PILOT VALVE

P2 UNLOAD

GAUGE CLUSTER

SWING

SOLENOID

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

2.11 PRESSURE RELEASE CONTROL (INCLUDE EXTRA PRESSURE RELEASE)

P1

SE-22

SE-23

ENGINE

EXTRA P4 SE-28

UNLOAD VALVE

PRESSURE RELEASE CONTROL

pi

SOLENOID

pi

pi

ENGINE SPEED CONTROL

PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

pi

PILOT SIGNAL PROCESS

pi

pi

PILOT SIGNAL PROCESS

PILOT SIGNAL PROCESS MECHATRO CONTROLLER

P1 PUMP PROPORTIONAL VALVE PSV-P1

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

pi : PROPORTIONAL VALVE SECONDARY PRESSURE SM3171

T2-1-16

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

1. Change mechatro controller to “PRESSURE DRAING MODE” by operating switch on gauge cluster. For detail of changing mode method, refer to “Pressure draining (releasing) circuit” on GROUP 2 HYDRAULIC CIRCUIT. 2. Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot, accel potentiometer, etc.) the mechatro controller; 1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum tilt angle. 2) Outputs command of pressure release to control step-by step motor (M2) and fixes engine speed to pressure release control speed. 3) Outputs maximum command to P1 and P2 unload proportional valves and each pilot secondary pressure fixes P1 and P2 unload valves to the maximum opening. 3. Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster. 4. Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching spool with the unload valve opened. 5. In case of EXTRA pressure release specification, switch mechatro controller to pressure release control mode in a similar way of above mentioned (1.). And in similar way of usual pressure release control, pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching spool.

T2-1-17

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SWING

SOLENOID

OPTION

PRESSURE SENSOR N&B FOR BREAKER SELECTOR SE-29 VALVE

ARM 1 SPEED

2.12 N&B SWITCH CONTROL (OPTION)

P1

A MODE

B MODE

GAUGE CLUSTER

pi

B MODE SWITCH

MECHATRO CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID

SM0131

1. Nibbler circuit 1) Select A mode through gauge cluster. 2) Nibbler display appears on gauge cluster. 3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main control valve. 4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output. It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display is output to gauge cluster. 2. Breaker circuit 1) Select B mode through gauge cluster. 2) Breaker display appears on gauge cluster. 3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank. 4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal. It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display is output to gauge cluster.

T2-1-18

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

P2

LOW PRESSURE SENSOR

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX P2 UNLOAD

SOLENOID

SWING

PILOT VALVE

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

2.13 OPTION CONFLUX CONTROL (OPTION)

P1

SINGLE / CONFLUX SWITCH

SE-11

pi PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

P2 PUMP PROPORTIONAL VALVE PSV-P2

P1 PUMP PROPORTIONAL VALVE PSV-P1

OPTION PILOT SECONDARY PRESSURE

pi

PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS

OPTION PILOT SECONDARY PRESSURE

P2 UNLOAD PROPORTIONAL VALVE PSV-B

P1 UNLOAD PROPORTIONAL VALVE PSV-D

TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C

MECHATRO pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE

SM0132

1. Select the Conflux with the aid of Conflux/Single switch. 2. On starting option operation, option operating pilot pressure switches option spool and is input to low pressure sensor. 3. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload pressure proportional valves and travel straight proportional valve. 4. Each proportional valves output pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve. 5. The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.

T2-1-19

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

PILOT VALVE

P2

ARM 2 SPEED

BUCKET

BOOM

TRAVEL RIGHT

P1 UNLOAD TRAVEL STRAIGHT

TRAVEL LEFT

BOOM UP CONFLUX SWING

P2 UNLOAD

SOLENOID RELIEF VALVE

SOLENOID

PSV-E

ARM 1 SPEED

N&B SELECTOR VALVE

OPTION

SOLENOID RELIEF VALVE

2.14 N&B SOLENOID RELIEF VALVE CONTROL

P1

PSV-I

RELIEF VALVE SOLENOID OUTPUT LOW PRESSURE SENSOR SE-11 OPTION PILOT SECONDARY PRESSURE

SM3172

1. Solenoid relief valve Using solenoid relief valve, relief pressure is able to set in advance. 1) Using gauge cluster, setting pressure of A and B mode is selectable individually. 2) When optional operation is done, command value according to setting pressure which is selected with solenoid relief valve is output from mechatro controller. 3) Each proportional valve outputs pilot proportional secondary pressure according to command value from mechatro controller, and the pressure switches relief pressure.

T2-1-20

Copyright © New Holland MECHATRO CONTROL SYSTEM 3.

E135B

MECHATRO CONTROLLER

3.1

SUMMARY OF MULTI DISPLAY

Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. 1. Controls

GAUGE CLUSTER SAFETY LOCK LEVER RIGHT CONTROL LEVER STARTER SWITCH

KPSS WORK MODE RELEASE SWITCH

ACCEL DIAL

FUSE & RELAY BOX

MECHATRO CONTROLLER EMERGENCY ACCEL DIAL

SWING PARKING BRAKE RELEASE SWITCH

ENGINE ECU

A

DETAIL A SM3173

2. Gauge cluster

11

22:00 H

1

2 3

10 6 4

9

8

5

7

No.

Name

1

Engine coolant temperature gauge

2

Fuel level gauge

3

Screen change switch

4

Buzzer stop switch

5

Work mode select switch

6

Washer switch

7

Wiper switch

8

Travel high speed, low speed select switch

9

Auto accel switch

10

Select switch

11

Multi display (LCD)

SM0134

T2-1-21

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

3. Screen selection by work mode select switch After starting engine, "S" mode is usually set. The work modes "S","H","B" and "A" are selected in order every time ( ) is pressed. Select efficient work mode according to the working condition and the purpose from the following table. The selected mode is displayed on the left lower corner on multi display. • • • •

S mode: For standard digging work H mode: For heavy duty digging work B mode: For works with breaker A mode: For works with crusher (nibbler)

10:25

CAUTION -

-

-

The initial setting (default) of work mode had been set to “S” mode at factory. As for the work mode after engine starts, the mode that was used the last time engine was stopped is automatically set. Check that the selected mode conforms to the work before starting work. Check that the attachment in use conforms to the work mode before starting work. If not conformed, select proper mode with the work mode select switch. The operation under improper work mode may cause damage to machine.

H

SM0135

Work mode

Display

10:25

S mode

Contents "S mode"is suitable for standard digging and loading works and is in fuel saving and is maintained well-balanced relations with workload.

㧿

10:25

H mode

"H mode"is suitable for heavy duty digging work which gives priority to the workload at the high speed.

㧴

10:25

B mode

For the work with breaker, select "B mode" without fail.

㧮

10:25

A mode

For the work with crusher (nibbler), select "A mode".

㧭 CAUTION For the work with breaker, select “B mode” without fail. The work with breaker in any mode other than “B mode” may cause damage to the hydraulic equipment and breaker

T2-1-22

Copyright © New Holland MECHATRO CONTROL SYSTEM 1) Pump flow rate adjustment (A mode /B mode)

1

2

E135B

3

4

No. Switches 1

Screen change switch

2

Buzzer stop switch

3

KPSS work mode select switch

4

Washer switch

5

Wiper switch

6

Travel speed select switch

7

Auto accel switch

8

5 8

Select switch

7

6

SM0140

Depending upon the type of breaker or crusher mounted, it is possible to select one of the nine pre-set flow rate/pressure settings. To select one of the nine settings, follow the procedure mentioned below. Main screen

In Nibbler mode (A mode)

10:25 Flow rate Pressure A

H

L/ 150 min 50 MPa

Flow rate Pressure B

A

L/ 150 min 50 MPa

A

(a)

SET 1

Flow rate Pressure A

SET 2

SET 9

SET 2

SET 9

L/ 200 min 50 MPa

A In Breaker mode (B mode)

Flow rate Pressure B

L/ 150 min 50 MPa

B

SET 1

Flow rate Pressure B

L/ 200 min 50 MPa

B

SM1432

1) Turn the starter key into position “ON”. The display shows the main screen (a). 2) The display on the left lower corner of screen is changed in order of "S"→"H"→"B"→"A" each time the work mode button (3) is pressed under the condition where main screen (a) is displayed. 3) Press work mode button (3) and select mode “A” or mode “B”. The display shows the values of the flow rate and pressure. 4) Press “Select” button (8) to enter the selection menu of the pre-set flow rate/pressure values. 5) Select the setting using windshield washer button (4) or wiper button (5). 6) Confirm the setting by pressing “Select” button (8). 7) By pressing "Screen Change" button you return to the main screen (a).

T2-1-23

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

4. MAINTENANCE SCREEN DISPLAYS This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/oil. For the initial set value of recommenced replacement/change time, see the following table. Replacement interval Item

Default

Engine oil

500 Hr

Fuel filter

500 Hr

Hydraulic oil filter

1,000 Hr

Hydraulic oil

5,000 Hr

This menu is available for confirmation of the following items. The maintenance screen changes each time the screen change switch is pressed.

1) Remaining time display to the engine oil change This display shows the remaining time to the coming engine oil change.

492Hr ENGINE OIL

H

2) Remaining time display to the coming fuel filter replacement This display shows the remaining time to the coming engine fuel filter replacement.

492Hr FUEL FILTER

H

3) Remaining time display to the coming hydraulic oil filter replacement This display shows the remaining time to the coming hydraulic oil filter replacement.

992Hr HYD. FILTER

H

4) Remaining time display to the coming hydraulic oil change This display shows the remaining time to the coming hydraulic oil change.

4992Hr HYD. OIL

H

NOTE: • The display automatically changes to the main screen, if switch is not operated for 30 seconds. • For the setting procedure of maintenance time to be performed to the coming oil change in each type and filter replacement, see the paragraph 3.6 “SET PROCEDURE OF MAINTENANCE SCHEDULE”.

T2-1-24

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

5. Gauge cluster display After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The display functions of multi display are explained below.

CLOCK DISPLAY SELF DIAGNOSIS / WARNING MACHINE CONDITION

H MULTI DISPLAY INDICATIONS

SM0146

1) Display function for operator .........................Screen usually displayed during operation 1.1 Clock display function ............................Current time is displayed. 1.2 Self-diagnosis display ............................When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays error code. 1.3 Warning display .....................................When machine was thrown into dangerous state, or was failed, displays warning symbol. (For warning contents, see items shown on the next page.) 1.4 Machine condition display ......................Displays machine operating condition. 2) Display function for maintenance...................Displays remaining time up to replacement/change of following items. (1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil 3) Failure history display function.......................Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence. 4) Mechatro adjustment display .........................Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment, etc. 5) Service diagnosis display...............................Displays information like pressure sensor sensed value, proportional valve command, etc. output by mechatro controller 6) Failure diagnosis mode display function .......Specifies failed section automatically for failures which are not detected by self diagnosis and displays the results.

T2-1-25

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

• Warning table These descriptions indicate error codes stored as “trouble history code”

W009

CAUTION ATTACHMENT

W005

LOW ENG OIL PRESS.

W011

PREHEAT

W006

HEAVY LIFT ON

HIGH ENG WATER TEMP.

CPU

CHARGE ERROR

W004

DATA COMMUNICATION ERROR

LOW ENG WATER LEVEL

W001

W010

SWING BRAKE DISENGAGED

DRAIN WATER SEPARATOR

LOW FUEL LEVEL

AUTO WARMING UP

W008

ENG LOW PRESSURE (ENGINE STOP)

CLOGGED AIR FILTER

CHANGE ENG OIL

CPU ATTACHMENT OVER LOAD

HYDRAULIC SYSTEM BACK UP MODE

NOTE: Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.

T2-1-26

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B Warning Condition

Level Priority (*) 1 1 1 A 1 2

Screen

Condition

Engine Only Key ON Run

Data from Mechatro controller is not received The swing parking brake SWING BRAKE DISENGAGED switch is turned ON Engine is stopped after engine ENGINE STOP oil pressare low warning HYDRAULIC SYSTEM BACK UP KPSS release switch is switched to “Release” side. MODE Impossible to drain hyd. FAIL DRAIN HYD. PRESSURE Pressure DATA COMMUCATION ERROR

2

DRAINING HYD. PRESS.

1

CAUTION ATTACHMENT

2

FINISH WARM-UP

3

LOW ENG OIL PRESS.

3

x

O

O

O

2

O

O

1

O

x

O

3.2

W001

O

O

2

O

O

O

O

1

x

O

O

4

x

O

O

2

x

O

O

2

O

x

O

2

x

O

W005

O

O

3

x

O

W006

O

O

3

x

O

W010

O

O

3

x

O

W008

O

O

3

x

O

O

O

3

The selector valve (OPT) is malfunction After finishing warming up control

W009

O

The engine water is more than 105 °C Water in water separator filter is increased

3

HIGH ENG. WATER TEMP.

3

DRAIN WATER SEPA

3

CLOGGED AIR FLTR

3

(SELF DIAGNOSIS SCREENS)

3

PREHEAT

4

CHARGE ERROR

No signal from the alternator

4

LOW FUEL LEVEL

The fuel level is less than 10 %

4

LOW ENG WATER LEVEL

5

AUTO WARMING UP

5

CHANGE ENG OIL

The air filter is clogged According to the self diagnosis control The heater relay contact is faulty

The warter engine coolant reservoir is low The auto warming up control is activated The remaining time is reached zero Huors

(*) 1: these extremely influence safety and the machine performance 2: these warn the machine control mode is switched 3: fatal failure 4: normal priority warning 5: low priority message

Auto Stop

O

Low engine oil pressure

B

Type (**)

O

Possible to drain hyd. Pressure

Disconnection

Trouble History Manual Code Stop

Buzzer sounds

O

O

-

O

-

O

O

O

O

-

O

-

W011

W004

(**) 1: Continuation 2: Beep ON 0.2 sec. OFF 0.3 sec. 3: Beep ON 0.5 sec. OFF 0.5 sec. 4: Beep ON 0.5 sec. OFF 1.0 sec.

SELF DIAGNOSIS DISPLAY

CONTROL

1. Outline This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector No. and pin No., refer to the section "Mechatro Control Equipment" explained later. Electric circuit diagram or harness is available to identify wire No. and wire color. 2. I/O configuration Pressure sensor, Engine controller INPUT Proportional valve, Battery relay Selector valve (SOL)

SERIAL COMMUNICATION Gauge cluster (Buzzer sound) SM1433

T2-1-27

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

3. Self diagnosis display items As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with the aid of error code. Alphabet: Decide system failure occurred.

10:25

B 01 3

B013

Last 2nd and 3rd digits: Specifies failed section.

Last 1 digit: Specifies failure type. This failure symbol is displayed simultaneously with error code during failure diagnosis.

ERROR CODE

SM0148

ALPHABET A Controller memory

B

C

Low pressure sensor

High pressure sensor

D Proportional valve for

E

2 01

F

Proportional valve for

nd

Solenoid valve

G Speed sensor

H Potentiometer etc.

I

K

R

Communication

Battery relay

Relay output

Battery relay

Wiper ark prevention

rd

AND 3 DIGIT

Boom up

P1 pump

P1 unload

P1 pump

ATT boost

Throttle

02

Torque adjust data

Boom down

P2 pump

P2 unload

P2 pump

Swing parking brake

Boom angle

Wiper ark forward

03

Unload adjust data

Arm out

Boom head

Travel straight

Relief adjust 1

Travel 1,2 speed

Arm angle

Wiper ark reverse

Relief adjust 2

Option selector

04

Arm in

05

Bucket digging

06

Bucket dump

07

Swing

09

Travel right

10

Travel left

11

Selector position

Washer motor

Arm 2 spool for arm in

Fuel sensor

CAN communication

13 14 15 16

P1 side option

AIS relay 2

17

P2 side option

Engine stop relay Safety lock lever relay

18 21

Adjustment data sector 1

22

Adjustment data sector 2

23

Hourmeter sector 1

24

Hourmeter sector 2

25

Proportional valve adjust

Safety relay

Cluster communication

31

LAST DIGIT Larger than normal range

0 1 2

Larger than normal range Transistor OFF failure/

-

Wrong output

Wrong output

3

-

Disconnection

Disconnection

4

-

Power source short circuit

Power source short circuit

5

Wrong value

Transistor ON failure Disconnection

Transistor ON failure Disconnection

CAN error Over run

Transistor ON failure /

Disconnection

Disconnection Power source short circuit

T2-1-28

Time is over Contact point is melted and adhered

Power source short circuit

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

ECU failure code list

Failure Code

Malfunctioned component

20081 20082 20084

Content of Failure ECU failure

ADC monitoring

[Class]/Limitation of output when failure occurs

[1]

A/D converter is abnormal in ECU.

Engine is shut down

20088 00291 00292 03838

Accelerator sensor 1

Atmospheric pressure sensor fails Atmospheric pressure sensor

01021 01022

Boost pressure sensor

05181 05182 06351

Q tune resistance SRC Cam single operation warning

06361 06362

02281

Q tune resistance failure Input failure of Q tune resistance is detected. Crank sensor failure

Failure of cam sensor (Disconnection, short circuit, and damaged tooth) is detected. Crank sensor failure Failure of crank sensor (Disconnection, short circuit, and damaged tooth) is detected.

Misalignment between cam and crank

Misalignment between cam and crank Misalignment between cam and crank is detected. CAN communication failure

CAN accelerator

16744

APPREQ message timeout

20284

CAN transmission time-out

06771 06772 06774

It is detected that accelerator opening (APPREQ) received with CAN is defective. CAN communication failure Accelerator opening (APPREQ) signal is received by CAN. But it detects that the CAN cannot receive the signal. CAN communication failure The transmission of CAN message is defective. Glow relay failure

Glow relay power stage

[5] [4]

[4] Engine power down [5]

[8] [3]

It is detected that crank sensor fails and engine is operated Engine power down with the cam sensor.

Crank sensor

00914

-

Defective operation of coolant temperature sensor attached to engine (Disconnection, short circuit and characteristic Engine power down defect) is detected.

Cam sensor failure Cam sensor

06371 06372

Defective operation of boost pressure sensor attached to engine (Disconnection, short circuit and characteristic defect) is detected. Coolant temperature sensor failure

Coolant temperature sensor

[5]

Defective operation of atmospheric pressure sensor in ECU (Disconnection, short circuit and characteristic defect) is Engine power down detected. Boost pressure sensor failure

01101 01102

Defective analog input signal from controller is detected.

Accelerator signal mutual comparison is defective. Accelerator sensor mutual When there is deflection of 20% or more between CAN diagnosis signal and analog signal, sensor detects it.

01081 01082

Analog signal input is defective.

Failure of glow relay or wiring harness is detected.

[5] [3] Engine power down [3] Engine power down [7] [7] [7] [5] -

06778 ECU failure 12311

SPI communication error

[1]

SPI (Serial peripheral interface): Serial communication malfunction between CPU and each internal IC occurs.

T2-1-29

Engine is shut down

Copyright © New Holland E135B

Failure Code

MECHATRO CONTROL SYSTEM

Malfunctioned component

12352 12354

Content of Failure ECU failure

EEPROM

12358

[5]

Defective reading and writing to EEPROM are detected. ECU failure

16688

Recovery occurrence

16698

Recovery generation

16708

Recovery generation

15421

CJ940 excessive voltage

15432

CJ940 voltage is too low

Recovery (partial reset) occurred by ECU internal malfunction. Recovery (partial reset) occurred by ECU internal malfunction.

6518 6524

Injector drive bank 1

6531 6532

ECU failure

[1]

The supply voltage is excessive for power stage control IC. Engine is shut down ECU failure

[1]

The supply voltage is too low for power stage control IC.

The injector drive circuit detected short circuit. Injector failure (ECU internal circuit) The injector drive circuit detected disconnection. Injector failure (ECU internal circuit)

Injector drive bank 2

[5]

Recovery (partial reset) occurred by ECU internal malfunction.

Injector failure (ECU internal circuit) Injector drive bank 1

[5]

ECU failure

6511

[5]

ECU failure

6512

[Class]/Limitation of output when failure occurs

The injector drive circuit detected short circuit.

Engine is shut down [1] Engine is shut down [1] Engine is shut down [1] Engine is shut down

6538 6544

Injector drive bank 2

6551 6552 6554

Injector failure (ECU internal circuit) The injector drive circuit detected disconnection. ECU failure

Injector drive IC

[1] Engine is shut down [1]

IC which controls injector is malfunctioned.

Engine is shut down

6558 6561 6562 6564

ECU failure Injector drive IC

[1]

IC which controls injector is malfunctioned.

Engine is shut down

6568 6571 6574

Injector failure Injector #1

6578 6584

Injector #1

6591 6594

Injector #2

Injector #2

6611 6614

Injector failure

Injector #3

Engine is shut down [5]

Disconnection is detected in injector or harness.

[1]

Short circuit is detected in injector or harness. Injector failure

Engine is shut down [5]

Disconnection is detected in injector or harness. Injector failure

Injector #3

6618 6624

Short circuit is detected in injector or harness.

Injector failure

6598 6604

[1]

[1]

Short circuit is detected in injector or harness. Injector failure

Engine is shut down [5]

Disconnection is detected in injector or harness.

T2-1-30

-

Copyright © New Holland MECHATRO CONTROL SYSTEM

Failure Code

Malfunctioned component

6631 6634

Content of Failure Injector failure

Injector #4

6638

Injector failure

Injector #4

20004

MPROP power stage Disconnection and excessive load

MPROP failure

MPROP power stage VB short

MPROP failure

MPROP power stage GND short circuit

MPROP failure

20008 20011 20022 14848 16711 16731 198 1008 20051 20411

Supervision CAN A Pass off CAN C Pass off Oil pressure switch Oil pressure switch Engine speed DBV valve opening

Disconnection is detected in injector or harness. Disconnection or short circuit of MPROP or harness. Battery short circuit of MPROP or harness GND short circuit of MPROP or harness ECU failure Malfunction judgment by self-diagnosis function in ECU. CAN communication failure Disconnection and short circuit of CAN communication line CAN communication failure Disconnection and short circuit of CAN communication line Oil pressure switch failure Engine speed is high but sensor is OFF status. Oil pressure switch failure Engine speed is high but sensor is OFF status. ECU failure Recognized engine speed is defective. DBV valve opening It is recognized that DBV opened.

DBV valve is seized in closed position

282

20112 20121 20122 20131

If you try to open valve forcibly, valve doesn't open. Holding pressure of DBV is abnormal. Holding pressure of DBV 2-step is higher than standard level. Holding pressure of DBV is abnormal.

Disconnection and short circuit of PTO or harness are detected. Rail pressure sensor failure

Rail pressure sensor SRC

[7] [7] [8] LOW IDLE [1] Engine is shut down [2] Engine power down [2] Engine power down [1] Engine is shut down [1] Engine is shut down [1]

Holding pressure of DBV 2-step is lower than standard level. Engine is shut down PTO failure for backup

20111

Engine is shut down

[5]

DBV valve is seized in closed position

PTO accelerator sensor

Engine power down [1]

20434

281

Engine power down [2]

Open valve forcible command is ordered for entering into Limp-home mode.

Holding pressure of DBV 2-step is too low

Engine power down [2]

DBV kick off

20452

[2]

20422

Holding pressure of DBV 2-step is too high

Engine is shut down [5]

DBV valve is opened forcibly.

20441

[Class]/Limitation of output when failure occurs

[1]

Short circuit is detected in injector or harness.

6644

E135B

Disconnection and short circuit of rail pressure sensor or harness are detected.

Rail pressure sensor offset Rail pressure sensor failure monitoring Zero-adjustment failure of rail pressure sensor. Rail pressure governor has Rail pressure control failure deviation (Nonattainment of target Rail pressure doesn't achieve target value. value)

T2-1-31

[2] Engine power down [2] Engine power down [2] Engine power down [4] Engine power down

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

Malfunctioned component

Failure Code

Content of Failure

[Class]/Limitation of output when failure occurs

20141

Rail pressure governor has Rail pressure control failure [1] deviation (Nonattainment of target Despite fully pressurized feed of pump, rail pressure doesn't Engine is shut down value & Fully pressurized achieve target value. feed of pump)

20151

Rail pressure governor has Rail pressure control failure [2] deviation (Pressure exceeds target Despite fully closed pump, rail pressure is higher than target Engine power down value & Pump doesn't value. inject)

20161

Rail pressure governor (Real pressure is too low)

20171

Rail pressure control failure Rail pressure governor (Real pressure is too high) Rail pressure is higher than standard value.

11102 11104

10792 10801 10802 6201 6202

Rail pressure is lower than standard value.

ECU failure Shut-off pass test

11108 10791

Rail pressure control failure

ECU failure

Sensor supply voltage monitor 2

ECU failure

Sensor supply voltage monitor 3

ECU failure

TPU monitoring

20108

SPI

[5]

Failure of 5V power line which supplies power to sensor.

[5]

Failure of 5V power line which supplies power to sensor.

[5]

Failure of 5V power line which supplies power to sensor. ECU failure

20098

[2] Engine power down [5]

Emergency injection stop circuit doesn't operate.

Sensor supply voltage monitor 1

[1] Engine is shut down

[1]

Failure of TPU in ECU Failure of Arithmetic circuit of rotational pulse. ECU failure

Engine is shut down [1]

Judgment of malfunction by self-diagnosis for ECU Error of Engine is shut down watch dog.

NOTE: for detail of engine error code refer to section “ENGINE”

T2-1-32

Copyright © New Holland MECHATRO CONTROL SYSTEM 3.3

E135B

SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This section explains the operating procedure and examples of each screen. The values in display changes according to the conditions like engine speed, attachment position, etc. 1. Service diagnosis display screen operating procedure 1)

Turn starter switch ON keeping buzzer stop switch pressed.

2) After logo mark is displayed, the screen changes in service diagnosis mode. The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first. The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in "Screen No.1". The screen number each mode can display differs. The screen number displayed by each mode is as follows. • Mode No.1: Screen No.1~No.30 • Mode No.2: Screen No.1, Screen No.31~No.40 • Mode No.3: Screen No.1, Screen No.41~No.50 3) The screen changes each time each switch is pressed from now on. Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...) Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...) Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1. (No.1→No.2→No.3→No.1→...) Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to No.3. (No.3→No.2→No.1→No.3→...) 4) Turn key switch OFF and the display of service diagnosis mode is closed.

T2-1-33

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

2. Service diagnosis display screen (Example) The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low speed and lever to neutral position.) 1) Service diagnosis “Mode No.1”

No. 1

Displays

Contents

NO.1 MAIN CONT. P/N YY22E00131F1 PROGRAM VERSION 1-VER 1.00 2-VER 0.00

P/No. indication

Service diagnosis mode

3

NO.2 ENG G-3 SPEED SET 1000 MEAS1 1000 MEAS2 1000 G-5 ENG PRS. LIVE WATER TEMP 20°C --MODE H H-1 ACCEL VOLT. 0.5V POS. 0% ECU OUTPUT 1.0V

NO.3 SOL.VALVE F-1 POWER BOOST COMP. MEAS. SWITCH F-2 SWING-BRAKE COMP. MEAS. RELEASE SW F-3 1/2-TRAVEL COMP. MEAS. SWITCH

5 No load setting rpm Actual rpm 1 Actual rpm 2 (Engine controller) Engine oil pressure Coolant temperaturre sensor Work mode Potentiometer voltage Voltage % indication Accel output voltage to engine controller

6 -------

Set value in computer Measured value Switch

ON ON OFF

Set value in computer Measured value Switch

OFF OFF OFF

Set value in computer Measured value Switch

Displays

Contents

NO.4 RELAY K-1 AIS RELAY 2 K-2 SAFETY RLY K-3 ENG STOP KEY SWITCH START SWITCH CHARGE K-4 LOCK LEVER SWITCH

Program version indication MERIT controller program version

SERVICE DIAG 1

2

No. 4

NO.5 PRESS.SENSOR B-1 BOOM RAISE 0.4 V 0.0 M B-2 BOOM LOWER 0.4 V 0.0 M B-3 ARM OUT 0.4 V 0.0 M B-4 ARM IN 0.4 V 0.0 M B-5 BUCKET DIG 0.4 V 0.0 M B-6 BUCKET DUMP 0.4 V 0.0 M

NO.6 PRESS.SENSOR B-7 SWING 0.4 V 0.0 M B-9 TRAVEL (R) 0.4 V 0.0 M B-10 TRAVEL (L) 0.5 V 0.0 M B-16 P1 OPT. 0.4 V 0.0 M B-17 P2 OPT. 0.4 V 0.0 M B-18 DOZER 1 0.0 V 0.0 M B-19 DOZER 2 0.0 V 0.0 M

ON --OFF ON OFF LIVE ON OFF

Indicated value Indicated value Indicated value Key switch Starter switch Alternator Indicated value Switch

Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value

Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value

SM3174

T2-1-34

Copyright © New Holland MECHATRO CONTROL SYSTEM

No. 7

8

9

10

11

Displays

Contents

NO.7 P.SENSOR PROPO-V C-1 PUMP P1 0.4 V 0.3 M C-2 PUMP P2 0.5 V 0.3 M C-3 BOOM-HEAD 0.7 V 3.4 M C-4 BOOM-ROD 0.0 V 0.0 M E-3 OPT RELIEF 1 COMP. 0 mA 20.0 M MEAS. 0 mA 20.0 M E-4 OPT RELIEF 2 COMP. 0 mA 20.0 M MEAS. 0 mA 20.0 M

NO.8 PROPO-VALVE D-1 P1 UN-LOAD(BP-CUT) COMP. 750 mA 3.0 M MEAS. 750 mA 3.0 M D-2 P2 UN-LOAD(BP-CUT) COMP. 750 mA 3.0 M MEAS. 750 mA 3.0 M D-3 S-TRAVEL COMP. 350 mA 0.6 M MEAS. 350 mA 0.6 M D-6 ARM IN-2-SPEED COMP. 750 mA 0.0 M MEAS. 750 mA 0.0 M

NO.9 PROPO-VALVE E-1 P1 PUMP COMP. 430 mA MEAS. 425 mA POWER SHIFT FLOW RATE E-2 P2 PUMP COMP. 430 mA MEAS. 425 mA POWER SHIFT FLOW RATE

Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value

18 Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure

1.0 M 1.0 M 0 mA 30 L

Set value in computer / Converted value from pressure Measured value / Converted value from pressure

Power shift Flow rate of pump P1

Power shift Flow rate of pump P2

20 Fuel level Hydraulic oil temperature Glow switch Air filter clogging Water separator clogging Engine oil filter clogging Front window open/close switch Conflux/Single flow select switch KPSS switch Command from grid heater Engine oil level Coolant level

21

NO.16 PRESS.SENSOR B-11 0.4 V 0.0 M B-12 0.0 V 0.0 M B-13 0.0 V 0.0 M B-14 0.0 V 0.0 M B-15 0.0 V 0.0 M B-20 0.0 V 0.0 M

Contents

Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value

Set value in computer / Converted value from pressure Measured value / Converted value from pressure

Set value in computer / Converted value from pressure Measured value / Converted value from pressure

OFF OFF

Displays NO.17 PRESS.SENSOR C-5 0.0 V 0.0 M C-6 0.0 V 0.0 M C-7 0.0 V 0.0 M C-8 0.0 V 0.0 M

Set value in computer / Converted value from pressure Measured value / Converted value from pressure

1.0 M 1.0 M 0 mA 30 L

SPOOL POS. NIB SELECT SWITCH --F-5 FAN PUMP COMP. --MEAS. --F-6 COMP. --MEAS. ---

16

Sensor voltage / Pressure converted value

19

NO.10 SENSOR,SWITCH H-9 FUEL LEVEL 2.1 V 38% H-10 HYD.OIL TEMP 0.0 V 0 ͠ GLOW OFF AIR FILTER LIVE WATER SEPA. LIVE ENG OIL FILTER --FRONT WINDOW OFF DOUBLE FLOW OFF KPSS SW OFF HEATER --ENG OIL LEVEL --COOLANT LEVEL OK NO.11 SOL.VALVE F-4 OPT SELECT COMP. MEAS.

No. 17

E135B

Set value in computer Measured value (Feed back value) Spool position Mode of selector valve Set value in computer Measured value Set value in computer Measured value

22 Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value

NO.18 DIGITAL INPUT DI1 --DI2 ON DI3 --DI4 --DI5 OFF DI6 OFF DI7 OFF DI8 OFF DI9 --DI10 OFF DI11 --DI12 OFF DI13 --DI14 ---

ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication

NO.19 DIGITAL INPUT DI15 --DI16 ON DI17 ON DI18 --DI19 OFF DI20 ON DI21 --DI22 --DI23 OFF DI24 OFF DI25 OFF DI26 OFF DI27 OFF DI28 ---

ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication

NO.20 DIGITAL INPUT DI29 OFF DI30 --DI31 --DI32 OFF DI33 ON DI34 --DI35 --DI36 --DI37 --DI38 --DI39 --DI40 --DI41 --DI42 ---

ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication

NO.21 DIGITAL OUTPUT DO1 COMP. OFF MEAS. OFF DO2 COMP. OFF MEAS. OFF DO3 COMP. OFF MEAS. OFF DO4 COMP. OFF MEAS. OFF DO5 COMP. --MEAS. --DO6 COMP. OFF MEAS. OFF DO7 COMP. OFF MEAS. OFF

Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value

NO.22 DIGITAL OUTPUT DO8 COMP. ON MEAS. ON DO9 COMP. --MEAS. --DO10 COMP. --MEAS. --DO11 COMP. OFF MEAS. OFF DO12 COMP. OFF MEAS. ON DO13 COMP. OFF MEAS. ON DO14 COMP. OFF MEAS. ON

Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value

See Mechatro controller connector

SM3175

T2-1-35

Copyright © New Holland E135B

No. 23

24

25

MECHATRO CONTROL SYSTEM

Displays

Contents

NO.23 DIGITAL OUTPUT DO15 COMP. OFF MEAS. OFF DO16 COMP. ON MEAS. ON DO17 COMP. OFF MEAS. OFF DO18 COMP. ON MEAS. ON DO19 COMP. OFF MEAS. ON DO20 COMP. --MEAS. --DO21 COMP. --MEAS. ---

Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value

NO.24 DIGITAL OUTPUT DO22 COMP. --MEAS. --DO23 COMP. OFF MEAS. ON DO24 COMP. OFF MEAS. ON DO25 COMP. --MEAS. --DO26 COMP. --MEAS. --DO27 COMP. --MEAS. --DO28 COMP. --MEAS. ---

Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value

NO.25 WIPER SYSTEM WIPER SW RISEUP SW REVERSE SW PREVENT ARC CW MOTOR RLY CCW MOTOR RLY WASHER SW MOTOR RELAY

OFF ON ON OFF OFF OFF OFF OFF

Wiper switch Wiper rise-up switch Wiper reverse rotation switch Wiper motor ark prevention relay

Wiper normal rotation relay Wiper reverse rotation relay Washer switch Washer motor relay

27 NO.27 MERIT SYSTEM COMMUNICATION

OFF 0

Status of communication in MERIT controller

0000000000

28

NO.28 ENG CONT. TRANS.COUNT. 0 RECEIVE COUNT. 0 DIAG STATUS 0 NUMBER OF DIAG 0 BOOST PRESS. 0 BOOST TEMP. 0°C BAROMETRIC P. 0 FUEL TEMP. 0°C FUEL CONS. 0 INTAKE TEMP. 0°C ENG PRESS. 0 GLOW --ENG STOP --TORQUE 500

Counted number of transmission error Counted number of reception error Diagnosis status Numbers of error Boost pressure Boost temperature Atmospheric pressure Fuel temperature Fuel consumption Intake air temperature Engine oil pressure Glow output from ECU Engine stop command from ECU Calculated torque of ECU

SM3176

T2-1-36

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

2) Service diagnosis “Mode No.2”

No. 1

Displays

Contents

NO.1 MAIN CONT. P/N YY22E00131F1 PROGRAM VERSION 1-VER 1.00 2-VER 0.00

P/No. indication Program version indication MERIT controller program version

SERVICE DIAG 2

31

32

No. 33

Service diagnosis mode 2

34

NO.31 BOOM C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) B-1 BOOM RAISE B-2 BOOM LOWER G-3 ENG SPEED POWER SHIFT

0.2 M 0.3 M 417 mA 417 mA 750 mA 750 mA 0.0 M 0.0M 1000 0 mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Boom up pressure sensor Boom down pressure sensor Engine actual speed Power shift current

NO.32 ARM,SWING C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL D-6 ARM-IN-2 B-3 ARM OUT B-4 ARM IN B-1 BOOM RAISE B-7 SWING G-3 ENG SPEED POWER SHIFT

0.2 M 0.3 M 417 mA 417 mA 750 mA 750 mA 350 mA 750 mA 0.0 M 0.0 M 0.0 M 0.0 M 1000 0 mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current Arm out pressure sensor Arm in pressure sensor Boom up pressure sensor Swing pressure sensor Engine actual speed Power shift current

35

Displays

Contents

NO.33 BUCKET C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL B-5 BUCKET DIG B-6 BUCKET DUMP G-3 ENG SPEED POWER SHIFT

0.2 M 0.3 M 417 mA 417 mA 750 mA 750 mA 350 mA 0.0 M 0.0 M 1000 0 mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Bucket digging pressure sensor Bucket dump pressure sensor Engine actual speed Power shift current

NO.34 TRAVEL C-1 P1 PUMP C-2 P2 PUMP E-1 P1-PSV E-2 P2-PSV D-1 P1-UL(BPC) D-2 P2-UL(BPC) D-3 S-TRAVEL B-9 TRAVEL(R) B-10 TRAVEL(L) Pi-P1 Pi-P2 G-3 ENG SPEED POWER SHIFT

0.2 M 0.3 M 417 mA 417 mA 750 mA 750 mA 350 mA 0.0 M 0.0 M 0.0 M 0.0 M 1000 0 mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Travel right pressure sensor Travel left pressure sensor Pilot pressure at travel straight (P1 side) Pilot pressure at travel straight (P2 side) Engine actual rpm Power shift current

NO.35 OPT C-1 P1 PUMP 0.2 M C-2 P2 PUMP 0.3 M E-1 P1-PSV 417 mA E-2 P2-PSV 417 mA D-1 P1-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA D-3 S-TRAVEL 350 mA E-3 OPT RELIEF 0 mA B-16 P1 OPT 0.0 M B-17 P2 OPT 0.0 M F-4 OPT SELECT --DOUBLE FLOW SW OFF G-3 ENG SPEED 1000 POWER SHIFT 0 mA

Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current P1 side option pressure sensor P2 side option pressure sensor Optional selector SOL (Nibbler line) Conflux/ Single selector switch Engine actual rpm Power shift current SM3177

3) Service diagnosis “Mode No.3” No. 1

Displays NO.1 MAIN CONT. P/N YY22E00131F1 PROGRAM VERSION 1-VER 1.00 2-VER 0.00 SERVICE DIAG 3

41

NO.41 ADJUSTMENT 1 ENG HI-IDLE 2230 PUMP ACT I 515 mA 7 mA PUMP P 35.0 M ESS N 930 UN-LOAD P1 565 mA P2 565 mA BOOM 0 0 ARM 0 0 OFFSET 0 0 INTER-B 0 0

Contents

No. 43

P/No. indication Program version indication MERIT controller program version Service diagnosis mode 3

44 Engine speed high idle Current at pump adjustment Current correction at pump adjustment Pressure at pump adjustment Engine speed sensor rpm P1 unload corrective current P2 unload corrective current Angle adjustment Angle adjustment Angle adjustment Angle adjustment

Displays NO.43 MACHINE-INFORM. HOUR METER 3550 TRIP METER 3500 OPERATION 3300 TRAVEL 300 SWING 3000 HAMMER 100 CRANE 100 STARTER 1200

Contents Hour meter of controller Trip meter of controller All accumulated operating time All accumulated traveling time All accumulated swing time All accumulated breaker operating time All accumulated high-reach crane operating time

All accumulated starter operating time

NO.44 MACHINE-INFORM. PUMP PRESS. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%

Pump pressure distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours

WATER TEMP. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%

Coolant temperature distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours

SM3178

T2-1-37

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

3. Service diagnosis data list Preface and precaution The following is the data decided as normal status after service diagnosis for every operation. Use these data to decide normal/abnormal status. • The values in following display are reference values with standard attachment attached machine. • The value of pressure sensor is calculated taking variation into accounts. When compared to performance check reference criteria, measure it with the aid of calibrated measuring instrument. • The current of proportional valve is not the measured value, but command value. The measured value should be confirmed by the value in the displayed value for each proportional valve. • The current value of pump proportional valve is reference value because it varies according to pump pressure and adjusted torque value. • The value in display during operation shows the value in steady state, rather than, at start of operation. • Check on machine after sufficiently warming up machine. • The value in display may differ according to software version. Contact our dealer/distributor.

Operation No.1 : No operation H mode Hi idle

Operation No.2 : No operation S mode Hi idle

No.32 ARM, SWING

No.32 ARM, SWING

C-1 P1-PRES

0.2~1.5 M

C-1 P1-PRES

0.2~1.5 M

C-2 P2-PRES

0.2~1.5 M

C-2 P2-PRES

0.2~1.5 M

E-1 P1-PSV

350 mA

E-1 P1-PSV

350 mA

E-2 P2-PSV

350 mA

E-2 P2-PSV

350 mA

D-1 P1-UL(BPC)

750 mA

D-1 P1-UL(BPC)

750 mA

D-2 P2-UL(BPC)

750 mA

D-2 P2-UL(BPC)

750 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

D-6 ARM-IN-2

750 mA

D-6 ARM-IN-2

750 mA

B-3 ARM OUT

0.0 M

B-3 ARM OUT

0.0 M

B-4 ARM IN

0.0 M

B-4 ARM IN

0.0 M

B-1 BOOM RAISE

0.0 M

B-1 BOOM RAISE

0.0 M

B-7 SWING

0.0 M

B-7 SWING

0.0 M

G-3 ENG SPEED POWER SHIFT

1970~2030

G-3 ENG SPEED

0 mA

POWER SHIFT

1970~2030 0 mA

Operation No.3 : Boom up in full lever operation & relief H mode Hi idle

Operation No.4 : Boom up in full lever operation & in operation H mode Hi idle

No.31 BOOM

No.31 BOOM

C-1 P1-PRES

32.0~35.8 M

C-1 P1-PRES

11.0~16.0 M

C-2 P2-PRES

32.0~35.8 M

C-2 P2-PRES

11.0~16.0 M

E-1 P1-PSV

385~495 mA

E-1 P1-PSV

560~750 mA

E-2 P2-PSV

385~495 mA

E-2 P2-PSV

450~550 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

B-1 BOOM RAISE

3.0 M

B-1 BOOM RAISE

3.0 M

B-2 BOOM LOWER

0.0 M

B-2 BOOM LOWER

0.0 M

G-3 ENG SPEED POWER SHIFT

1970~2030

G-3 ENG SPEED

0 mA

POWER SHIFT T2-1-38

1970~2030 0 mA

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

Operation No.5 : Boom down in full lever operation & in operation H mode Hi idle

No.31 BOOM C-1 P1-PRES

12.5~16.0 M

C-2 P2-PRES

0.2~1.5 M

E-1 P1-PSV

549 mA

E-2 P2-PSV

350 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

750 mA

B-1 BOOM RAISE

0.0 M

B-2 BOOM LOWER

3.0 M

G-3 ENG SPEED POWER SHIFT

1970~2030 0 mA

Operation No.6 : Arm-in in full lever operation & relief H mode Hi idle

Operation No.7 : Arm-in in full lever operation & in operation

No.32 ARM, SWING

No.32 ARM, SWING

H mode Hi idle

C-1 P1-PRES

32.0~35.8 M

C-1 P1-PRES

12.0~16.5 M

C-2 P2-PRES

32.0~35.8 M

C-2 P2-PRES

12.0~16.5 M

E-1 P1-PSV

385~495 mA

E-1 P1-PSV

550~700 mA

E-2 P2-PSV

385~495 mA

E-2 P2-PSV

550~750 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

D-6 ARM-IN-2

200 mA

D-6 ARM-IN-2

370 mA

B-3 ARM OUT

0.0 M

B-3 ARM OUT

0.0 M

B-4 ARM IN

3.0 M

B-4 ARM IN

3.0 M

B-1 BOOM RAISE

0.0 M

B-1 BOOM RAISE

0.0 M

B-7 SWING

0.0 M

B-7 SWING

0.0 M

G-3 ENG SPEED POWER SHIFT

1970~2030

G-3 ENG SPEED

0 mA

POWER SHIFT

T2-1-39

1970~2030 0 mA

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

Operation No.8 : Arm-out in full lever operation & relief H mode Hi idle

Operation No.9 : Arm-out in full lever operation & in operation H mode Hi idle

No.32 ARM, SWING

No.32 ARM, SWING

C-1 P1-PRES

32.0~35.8 M

C-1 P1-PRES

12.0~18.0 M

C-2 P2-PRES

32.0~35.8 M

C-2 P2-PRES

12.0~18.0 M

E-1 P1-PSV

385~495 mA

E-1 P1-PSV

606~750 mA

E-2 P2-PSV

385~495 mA

E-2 P2-PSV

606~750 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

D-6 ARM-IN-2

750 mA

D-6 ARM-IN-2

750 mA

B-3 ARM OUT

3.0 M

B-3 ARM OUT

3.0 M

B-4 ARM IN

0.0 M

B-4 ARM IN

0.0 M

B-1 BOOM RAISE

0.0 M

B-1 BOOM RAISE

0.0 M

B-7 SWING

0.0 M

B-7 SWING

0.0 M

G-3 ENG SPEED

1970~2030

POWER SHIFT

G-3 ENG SPEED

0 mA

1970~2030

POWER SHIFT

0 mA

* Measure the values after a lapse of 5 minutes or after release of low temperature mode

* Measure the values after a lapse of 5 minutes or after release of low temperature mode

Operation No.10 : Swing in full lever operation & relief H mode Hi idle

Operation No.11 : Swing in full lever operation & in operation H mode Hi idle

No.32 ARM, SWING

No.32 ARM, SWING

C-1 P1-PRES

0.2~1.5 M

C-1 P1-PRES

0.2~1.5 M

C-2 P2-PRES

28.0~35.8 M

C-2 P2-PRES

8.0~13.0 M

E-1 P1-PSV

350 mA

E-1 P1-PSV

350 mA

E-2 P2-PSV

500~610 mA

E-2 P2-PSV

642 mA

D-1 P1-UL(BPC)

750 mA

D-1 P1-UL(BPC)

750 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

D-6 ARM-IN-2

750 mA

D-6 ARM-IN-2

750 mA

B-3 ARM OUT

0.0 M

B-3 ARM OUT

0.0 M

B-4 ARM IN

0.0 M

B-4 ARM IN

0.0 M

B-1 BOOM RAISE

0.0 M

B-1 BOOM RAISE

0.0 M

B-7 SWING

3.0 M

B-7 SWING

3.0 M

G-3 ENG SPEED POWER SHIFT

1970~2030

G-3 ENG SPEED

0 mA

POWER SHIFT

T2-1-40

1970~2030 0 mA

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

Operation No.12 : Bucket digging in full lever operation & relief H mode Hi idle

Operation No.13 : Bucket digging in full lever operation & in operation H mode Hi idle

No.33 BUCKET

No.33 BUCKET

C-1 P1-PRES

32.0~35.8 M

C-1 P1-PRES

4.0~8.0 M

C-2 P2-PRES

32.0~35.8 M

C-2 P2-PRES

0.2~1.5 M

E-1 P1-PSV

500~610 mA

E-1 P1-PSV

750 mA

E-2 P2-PSV

350 mA

E-2 P2-PSV

350 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

B-5 BUCKET DIG

3.0 M

B-5 BUCKET DIG

3.0 M

B-6 BUCKET DUMP

0.0 M

B-6 BUCKET DUMP

0.0 M

G-3 ENG SPEED

1970~2030

POWER SHIFT

G-3 ENG SPEED

0 mA

POWER SHIFT

1970~2030 0 mA

Operation No.14 : Bucket dump in full lever operation & relief H mode Hi idle

Operation No.15 : Bucket dump in full lever operation & in operation H mode Hi idle

No.33 BUCKET

No.33 BUCKET

C-1 P1-PRES C-2 P2-PRES

32.0~35.8 M

C-1 P1-PRES

6.0~15.0 M

0.2~1.5 M

C-2 P2-PRES

0.2~1.5 M

E-1 P1-PSV

500~610 mA

E-1 P1-PSV

650 mA

E-2 P2-PSV

350 mA

E-2 P2-PSV

350 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

B-5 BUCKET DIG

0.0 M

B-5 BUCKET DIG

0.0 M

B-6 BUCKET DUMP

3.0 M

B-6 BUCKET DUMP

3.0 M

G-3 ENG SPEED POWER SHIFT

1970~2030

G-3 ENG SPEED

0 mA

POWER SHIFT

T2-1-41

1970~2030 0 mA

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

Operation No.16 : P2 side option in full lever operation & relief A mode Hi idle

Operation No.17 : P2 side option in full lever operation & relief B mode Hi idle

No.35 OPT

No.35 OPT

C-1 P1-PRES

22.5~26.0 M

C-1 P1-PRES

0.2~1.5 M

C-2 P2-PRES

22.5~26.0 M

C-2 P2-PRES

22.5~26.0 M

E-1 P1-PSV

480~590 mA

E-1 P1-PSV

500 mA

E-2 P2-PSV

480~590 mA

E-2 P2-PSV

665~750 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

750 mA

D-2 P2-UL(BPC)

360 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

720 mA

D-3 S-TRAVEL

350 mA

E-3 OPT RELIEF

0 mA

E-3 OPT RELIEF

0 mA

B-16 P1 OPT

0.0 M

B-16 P1 OPT

0.0 M

B-17 P2 OPT

2.0~2.6 M

B-17 P2 OPT

2.0~2.6 M

F-4 OPT SELECT DOUBLE FLOW SW. G-3 ENG SPEED POWER SHIFT

NIB

F-4 OPT SELECT

ON

DOUBLE FLOW SW.

1970~2030

G-3 ENG SPEED

0 mA

POWER SHIFT

BRK OFF 1970~2030 0 mA

* Conflux switch is ON. Relief set pressure is value of shipping.

* Conflux switch is OFF. Relief set pressure is value of shipping.

Operation No.18 : Travel right in full lever operation & travel idling H mode Hi idle

Operation No.19 : Travel left in full lever operation & travel idling H mode Hi idle

No.34 TRAVEL

No.34 TRAVEL

C-1 P1-PRES

5.0~12.0 M

C-1 P1-PRES

0.2~1.5 M

C-2 P2-PRES

0.2~1.5 M

C-2 P2-PRES

5.0~12.0 M

E-1 P1-PSV

750 mA

E-1 P1-PSV

350 mA

E-2 P2-PSV

350 mA

E-2 P2-PSV

750 mA

D-1 P1-UL(BPC)

360 mA

D-1 P1-UL(BPC)

750 mA

D-2 P2-UL(BPC)

750 mA

D-2 P2-UL(BPC)

360 mA

D-3 S-TRAVEL

350 mA

D-3 S-TRAVEL

350 mA

B-9 TRAVEL (R)

2.0~2.5 M

B-9 TRAVEL (R)

0.0 M

B-10 TRAVEL (L)

0.0 M

B-10 TRAVEL (L)

2.0~2.5 M

Pi-P1

0.0 M

Pi-P1

0.0 M

Pi-P2

0.0 M

Pi-P2

0.0 M

G-3 ENG SPEED POWER SHIFT

1970~2030

G-3 ENG SPEED

0 mA

POWER SHIFT

T2-1-42

1970~2030 0 mA

Copyright © New Holland MECHATRO CONTROL SYSTEM 3.4

E135B

TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one of history. And the errors are able to be indicated on the multi display. • •

A part of warning contents is stored (the stored items are listed in warning table). The error code for self diagnosis is stored.

1. How to display 1) Turn starter switch on. 2) Press buzzer stop switch continuously 5 times and the trouble history screen is displayed.

(Example) No errors

NO ERROR

Error detected in the past

SM0154

3) Transmit trouble history data (One or many) and hour meter to gauge cluster. • Hour meter and 4 failure data are displayed on screen. • In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns. 4) Paging (Up and down) • Press washer switch ( ) A, and the item moves upward. • Press wiper switch ( ), and the item moves downward. 5) Turn starter switch off, and the display is disappeared. 2. How to delete contents of trouble history 1) 2) 3) 4)

Display trouble history screen. Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more. When "NO ERROR" is displayed, the deletion is completed. Turn starter switch off.

NOTE: all the stored items are erased. It is impossible to erase data partially.

T2-1-43

Copyright © New Holland E135B 3.5

MECHATRO CONTROL SYSTEM

TROUBLE DIAGNOSIS MODE

The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be detected through the use of self diagnosis function (the failure can be specified through the use of error code) like disconnection and abnormal output. This is useful to save the time for troubleshooting. 1. Function There are two types of trouble diagnosis mode. 1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine system. 2) Trouble diagnosis mode 2: Used to diagnose pilot system. In any mode, with the attachment not moved, both directional valve and proportional valve are automatically actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition or failed condition of the system. For details of how to use, refer to Chapter: “TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".

T2-1-44

Copyright © New Holland MECHATRO CONTROL SYSTEM 3.6

E135B

SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display which allows confirmation of remaining time to the coming replacement/change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc. and perform the initial setting by the following order. NOTE: interval of replacement of parts is mentioned below. • • • •

Screen change switch

Buzzer stop switch

KPSS work mode select switch Washer switch

Engine oil : 500 Hr Fuel filter : 500 Hr Hydraulic filter : 1,000 Hr Hydraulic oil : 5,000 Hr

Select switch

Auto accel switch

Travel speed select switch

Wiper switch SM0155

Procedure

1

Operating Procedure

Display on Multidisplay NEW HOLLAND

Turn starter key switch on.

KOBELCO

After several seconds, display is changed to clock autmatically.

10:25 H

2

3

Press " " switch press once display change switch on the switch panel once. And the clock display changes to the display of remaining time for coming engine oil change. Press " " switch press once select switch once and the display for the engine oil change reverses.

10:25

Press screen change switch once more.

H

250 Hr ENGINE OIL

H

250 Hr ENGINE OIL

Press select switch once more.

250 Hr ENGINE OIL

H

4

5

When required to adjust the interval to the coming change time by 10 hours, press " " switch and the time to the coming engine oil change is added. Press " " switch and the time to the coming engine oil change is reduced. When desired to return to the initial set time, press " " buzzer stop switch once. Press " " select switch once and the set time is stored.

250 Hr ENGINE OIL

500 Hr ENGINE OIL

Replacing interval is changed with each pressing of switch.

To set the desired interval, press the select switch

500 Hr ENGINE OIL

500 Hr ENGINE OIL

H SM0156

NOTE: 1. After displaying the display for setting by pressing the display change switch, set the respective maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5. 2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not sound.

T2-1-45

Copyright © New Holland E135B 3.7

MECHATRO CONTROL SYSTEM

ADJUSTING PROCEDURE OF DISPLAY

1. For operator 1) Clock Adjustment Switches No.

1

2

3

4

Switches

1

Screen Change Switch

2

Buzzer Stop Switch

3

Work Mode Select Switch

4

Washer Switch

5

Wiper Switch

6

Travel Speed Select Switch

7

Auto Accel Switch

8

Select Switch

5 8

7

6

(a)

Main screen

10:25

SWITCH STATUS CLOCK/CONTRAST

13:15

H (a)

SM0140

H (b)

(c) SWITCH STATUS CLOCK/CONTRAST

(d)

(e)

ADJUST CLOCK ADJ CONTRAST

Y M D H M 06 04 01 13 15

Select Year/Month/Day/Hour/Minute

Enter

Increase/Decrese SM0157

1) Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b). 2) In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed. 3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select switch (8) and the "ADJUST CLOCK" screen (e) is displayed. 4) Select any of "Y•M•D•H•M" in operation of FEED operations of FEED (6) and FEED (7).

(4) and FEED

(5) and vary the values in

5) After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is completed, and then the screen returns to main screen (a).

T2-1-46

Copyright © New Holland MECHATRO CONTROL SYSTEM

2) Contrast Adjustment Switches No.

1

E135B

2

3

4

Switches

1

Screen Change Switch

2

Buzzer Stop Switch

3

Work Mode Select Switch

4

Washer Switch

5

Wiper Switch

6

Travel Speed Select Switch

7

Auto Accel Switch

8

Select Switch

5 8

7

6

SM0140

Main screen

10:25

SWITCH STATUS CLOCK/CONTRAST

H (a)

(b)

(c) SWITCH STATUS CLOCK/CONTRAST

(d)

(a)

ADJUST CLOCK ADJ CONTRAST

10:25 H

(e) ADJUST CLOCK ADJ CONTRAST

(f) Enter

ADJ CONTRAST 55555

Adjustable range 11111~99999 (Default 55555)

Increase/Decrease SM0158

1) Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH STATUS CLOCK CONTRAST" select screen (b). 2) In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST" screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed. 3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed. 4) Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed. 5) Vary the values by pressing the desired figure in operations of FEED (4) and FEED The available setting range is in 9 steps from "11111" to "99999". [Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.

(5).

6) Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is completed, and then the screen returns to main screen (a).

T2-1-47

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

2. Function for service Following items are provided for adjustment of service function. •

LANGUAGE/LOGO Function

Explanation

Range

All language data is stored in 15 one gauge cluster languages

LANGUAGE

To change language

LOGO

To change Company Logo

•

Note

5 Logos

Default ISO NHK

ADJUSTING MODE 1 Function

Explanation

RISE-UP WIPER

Note

To change wiper control, when special CAB is installed on demolition OFF is for special CAB machine

Range ON/OFF

Default ON

P1 OPT SENSOR To activate the self-diagnosis when P1 Switch to ON when 2PB is ON/OFF ACTIVE OPT pressure sensor is failed installed

OFF (*)

P2 OPT SENSOR To activate the self-diagnosis when P2 Switch to ON when N&B ON/OFF ACTIVE OPT pressure sensor is failed option is installed

OFF (*)

LEFT ACTIVE

PEDAL

SELECT SYSTEM

OPT

To use P1 option pedal for P4-rotation circuit, releasing auto accel. And not activating unload valve

ON/OFF

1:No selector valve Switch to ON when N&B 2:Selector Valve + Mechanical relief 1 or 3 option is installed 3:Selector Valve + Electrical relief

OFF

1 or 3 (*)

ADJ OVERLOAD To change the pressure for overload PRESS alarm in EU

10 - 27

18

ENG DISPLAY

ON/OFF

OFF

SPEED To activate the engine information for customer

speed

AUTO ACCEL

To change auto accel control type

START MODE

To change (S,H,B,A)

the

starting

6, 8, 10, 12, 18 14, 16, 18

MODE X: return to default MODE S, H, B, A, X X when key sw is ON

To cancel the low temp. mode to CANCEL LOW OFF = Low Temp. Mode ON/OFF prevent hydraulic hunching at low TEMP MODE ACTIVE temp.

OFF

DRAIN PRESS

OFF

HYD. To activate the pressure function

drain

hydraulic When switch is ON, this ON/OFF function starts.

To adjust Pressure and Flow for ADJ OPT HAMMER Follow setting procedure Hammer (9set)

20 35 20 Mpa (at Pressure 130 L/min) 30 - 130 130 L/min Flow rate

To adjust Pressure and Flow for Follow setting procedure Nibbler (9set)

20 35 20 Mpa (at Pressure 130 L/min) 30 - 130 130 L/min Flow rate

ADJ OPT NIBBLER

(*) Autodetect

T2-1-48

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

2.1 Setting the language To modify the language, proceed as follows: 1. Keep BUZZER CUT-OFF button (1) pressed and, at the same time, move the STARTER SWITCH onto “ON”; the screen shows display (A).

10:25

2. Keep BUZZER CUT-OFF button (1) pressed, then press SELECT button (2) three times; the screen shows display (B). 3. Press SELECT button (2); the screen shows display (C) indicating the symbol of the language previously set, for example: ENG (English). 4. Press WIPER button (3) or WINDSHIELD WASHER button (4), once or more until the symbol of the desired language is displayed, for example FRA (French); the screen shows display (D).

S

1 4 5 3

2

5. Press SELECT button (2) to memorize the language selected, the screen shows display (E). At this stage, the language is selected and after about three seconds returns automatically to display (B). To exit the program, move the STARTER SWITCH onto “OFF”.

SM0069

NO. 1

(A) List of the languages available:

MAIN CONT. P/N YY22E00131F1 PROGRAM VERSION 1-VER 1.00 2-VER 0.00 SERVICE DIAG 1

1

EU (ISO icons only)

2

ITA

(B)

USA

LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY

CHN IDN THA

SELECT LANGUAGE

ESP

(C)

FRA

ENG FEED

DEU VNM MYS

4

MMR

3

TAM

SELECT LANGUAGE

POR

(D)

ENG

FRA FEED

JPN

SELECT LANGUAGE

(E)

FRA FEED SM3179

T2-1-49

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

2.2 Setting Adjusting Mode 1 NO. 1

To enter the displays Adjusting Mode 1 proceed as follows: 1. Keep BUZZER CUT-OFF button (1) pressed and, at the same time, move the STARTER SWITCH onto “ON”; the screen shows display (A) 2. Keep BUZZER CUT-OFF button (1) pressed, then press SELECT button (2) three times; the screen shows display (B). 3. Press WINDSHIELD WASHER button (3) to get ADJUSTING MODE 1, the screen shows display (C).

(A)

MAIN CONT. P/N YY22E00131F1 PROGRAM VERSION 1-VER 1.00 2-VER 0.00 SERVICE DIAG 1

x3

1 (B)

2

LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY

3

(C)

4. By pressing SELECT button (2) you enter the Adjusting Mode 1 functions; the first function is shown on the screen, display (D). To enter the other functions, actuate WIPER button (3), to move forward or WINDSHIELD WASHER button (4), to return back.

LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY

11 RISE-UP WIPER ON

(D)

FEED

2.3Adj. Overload Press (tip-over momentum device)

3

4

SM3180

To modify the value of the pressure at which the pressure sensor goes ON to operate the tip-over momentum device, proceed as follows: 1. In function Adjusting Mode 1, display (C), press SELECT button (2) to enter the functions and use WIPER button (3), to select function 63 ADJ OVERLOAD PRESS on display (E).

(C) 2

3

2. Press SELECT button (2) to choose the number relative to the setting pressure, display (F). 18 = 180 bar

63

3. Press WINDSHIELD WASHER button (4), to increase the pressure, or WIPER button (3), to decrease it. 4. Set the desired pressure value (for example: 11), display (G), press SELECT button (2) to memorise it. By pressing SCREEN CHANGE button (5) you return to display (C). To exit the program, move the STARTER SWITCH onto “OFF”.

LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY

(E)

ADJ OVERLOAD PRESS 18

FEED

63

(F)

ADJ OVERLOAD PRESS 18

FEED

3

4 63

(G)

ADJ OVERLOAD PRESS 11

FEED

63 ADJ OVERLOAD PRESS 11

FEED

5 SM0073

T2-1-50

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

2.4 Drain Hyd. Press To drain the hydraulic pressure from the system, proceed as follows: 1. In function Adjusting Mode 1, display (C), press SELECT button (2) to enter the functions and using WIPER button (3), select on the display function DRAIN HYD. PRESS, display (H).

(C)

3

2

2. Press SELECT button (2) to show the writing OFF, display (I).

(H)

3. Press WINDSHIELD WASHER button (4) to activate function ON, display (L).

DRAIN HYD PRESS OFF

FEED

4. Press SELECT button (2) and start the engine. The screen shows display (M). At this point, with the engine in operation, actuate the pilot valves performing all the movements so that the pressure is drained from all the actuators. The function is automatically deactivated by returning the STARTER SWITCH onto “OFF”. NOTE: if the monitor displays “FAIL DRAIN HYD PRES.” this means that the pressure draining operation has not been performed correctly. In this case, repeat the operation.

LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY

(I)

DRAIN HYD PRESS OFF

FEED

4 (L)

DRAIN HYD PRESS ON

FEED

10:25

(M)

PR

S SM0072

T2-1-51

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

2.5Adj. Opt. Hammer/Nibbler To adjust pressure and flow rate for hammer or nibbler, follow the procedure mentioned below. The initial flow rate and pressure for hammer or nibbler are set by Manufacturer at 130 L/min and 50 MPa. The adjustment (increase or decrease) of flow rate is changeable by 10 L/min step, the adjustment (increase or decrease) of pressure is changeable by 1 MPa. Nibbler (Crusher) LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY

(C)

69 ADJ OPT

(N)

FEED

SET 2

SET 1

SET 3

SET 9

Flow rate Pressure A

L/ 130 min 50 MPa

Flow rate Pressure A

L/ 130 min 50 MPa

Flow rate Pressure A

L/ 130 min 50 MPa

Flow rate Pressure A

L/ 130 min 50 MPa

Flow rate Pressure A

L/ 130 min 50 MPa

Flow rate Pressure A

L/ 130 min 50 MPa

Flow rate Pressure A

L/ 130 min 50 MPa

Flow rate Pressure A

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

SM3181

1. In function Adjusting Mode 1, display (C), press SELECT button to enter the functions and use WIPER button to select function 69 – ADJ OPT, on display (N). 2. Press SELECT button to enter the selection menu of the set flow rate/pressure values for adjusting. 3. Press SELECT button to choose the number relative to the flow rate. Press WINDSHIELD WASHER button to increase the flow rate, or WIPER button to decrease it. 4. Press SELECT button to choose the number relative to the pressure (A). To select the pressure, start the engine and actuate the breaker/crusher pedal, keeping it pressed with the heel of the foot. Press WINDSHIELD WASHER button to increase the pressure, or WIPER button to decrease it. When desired pressure is indicated, press SELECT button to set. (When SELECT button is pressed, be careful that 0MPa is usually displayed at time if you do not depress the heel side of breaker/crusher pedal down.) 5. Then pressure (B) is indicated, and adjust the pressure, keeping the breaker/crusher pedal pressed with the toe of the foot. Press WINDSHIELD WASHER button to increase the pressure, or WIPER button to decrease it. When desired pressure is indicated, press SELECT button to set.(When SELECT button is pressed, be careful that 0MPa is usually displayed at time if you do not depress the toe side of breaker/ crusher pedal down.) 6. Set the desired flow rate and pressure values, press SELECT button to return to display (N). By pressing SCREEN CHANGE button you return to display (C). To exit the program, move the STARTER SWITCH onto “OFF”.

T2-1-52

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

Breaker

LANGUAGE/LOGO ADJUSTING MODE 1 PRESET BY FACTORY

(C)

69 ADJ OPT

(N)

FEED

SET 2

SET 1

SET 3

SET 9

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

Flow rate Pressure B

L/ 130 min 50 MPa

SM3182

1. In function Adjusting Mode 1, display (C), press SELECT button to enter the functions and use WIPER button to select function 69 – ADJ OPT, on display (N). 2. Press SELECT button to enter the selection menu of the set flow rate/pressure values for adjusting. 3. Press SELECT button to choose the number relative to the flow rate. Press WINDSHIELD WASHER button to increase the flow rate, or WIPER button to decrease it. 4. Press SELECT button to choose the number relative to the pressure (B). To select the pressure, start the engine and actuate the breaker/crusher pedal, keeping it pressed with the toe of the foot. Press WINDSHIELD WASHER button to increase the pressure, or WIPER button to decrease it. When desired pressure is indicated, press SELECT button to set. (When SELECT button is pressed, be careful that 0MPa is usually displayed at time if you do not depress the toe side of breaker/crusher pedal down.) 5. Set the desired flow rate and pressure values, press SELECT button to return to display (N). By pressing SCREEN CHANGE button you return to display (C). To exit the program, move the STARTER SWITCH onto “OFF”.

T2-1-53

Copyright © New Holland E135B 3.8

MECHATRO CONTROL SYSTEM

MECHATRO CONTROL EQUIPMENT

1. C-1 Mechatro controller 1) Outside view 2 1

10

6

2 1

22

18

4 2 1 8

2

1

16 26 34 27 CN101 CN105

CN102

16 12 CN103

28

22

CN104

CN106 CN107 CN108 CN109 21 7 2 16 21 9 21 7 21

9 21

10

31

24

7

12

8

16 22

17

17

28 10 22 13 19 20 15 16

8

SM0159

2) List of connectors Connector No.

Pin No.

Port name

CN101

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

GA A1 +5VA +5VA A2 GA GA A3 +5VA +5VA A4 GA GA A5 +5VA +5VA A6 GA TXD1 RXD1 GP SHG1 TXD3 RXD3 DL GP CANH1 CANL1 DO 20 DO 21 DO 22 DO 23 DO 24 DI 36

Function

Input/putput

Boom up

Input

Boom down

Input

Arm in

Input

Arm out

Input

Bucket digging

Input

Bucket dump

Input

Gauge cluster

Transmission

Reception

Down load

Transmission

Reception

E/G ECU Spare Spare Spare Extra pressure release Spare Heavy lift

Output Output Output Output Output Input

Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V RS232C communication RS232C communication 0V Shield GND RS232C communication RS232C communication EARTH / OPEN(5V） 0V CAN communication CAN communication EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN SM1437

T2-1-54

Copyright © New Holland MECHATRO CONTROL SYSTEM

Connector No. CN102

Connector No. CN103

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Port name GA A8 +5VA +5VA A9 GA GA A10 +5VA +5VA A13 GA GA A14 +5VA +5VA A27 GA GA A28 +5VA D1 37

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Port name GA A +5VA +5VA A11 GA GA A12 +5VA +5VA A15 GA GA A16 +5VA

Function

E135B

Input/putput

Travel right

Input

Travel left

Input

Accelation

Input

P1 option

Input

P2 option

Input

Separate option

Input

Dozer

Input

Spare

Input Function

Input/putput

Swing

Input

P1 pump

Input

P2 pump

Input

Spare

Input

Spare

Input

Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V GND / OPEN Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V

Reserved SM3183

T2-1-55

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

Connector No. CN104

Connector No. CN105

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Port name GA A17 +5VA +5VA A18 GA GA A19 +5VA +5VA A20 GA A21 GA A22 GP A23 GA GA A24 +5VA +5VA A25 GA GA A26 +5VA DI 1

Pin No. 1 2

Port name +24V +24V

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

+24V DO 7 DO 8 DO 9 DO 11 GND GND D10+ D1+ D1D2+ D2D3+ D3D4+ D4D5+ D5GND D10D6+ D6D7+ D7D8+ D8D9+ D9+24V

Function

Input/putput

Boom head

Input

Spare

Input

Spare

Input

Spare

Input

Spare

Input

Fuel level

Input

Spare

Input

Selector detection

Input

Extra pressure source

Input

Spare

Input

Spare

Input Function

Input/putput

Battery relay output side Battery relay output side Travel 1,2 speed select valve

Swing P/B select valve Spare Selector opt. Battery (-) Battery (-) OPT changeable relief 1 P1 unload

Output Output Output Output

Output Output

P2 unload

Output

Travel straight

Output

Arm in

Output

P1 pump

Output

Battery (-) OPT changeable relief 1 P2 pump

Output Output

Spare

Output

Spare

Output

Spare

Output

Battery direct connection

Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5㨪4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0,5~4,5V 0V 0,5~4,5V 0V 0,5~4,5V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V GND / OPEN Signal level 20~32V 20~32V 20~32V 24V/OPEN 24V/OPEN 24V/OPEN 24V/OPEN 0V 0V +0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA -0~800mA +0~800mA 20~32V SM3184

T2-1-56

Copyright © New Holland MECHATRO CONTROL SYSTEM

Connector No. CN106

Connector No. CN107

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Port name +24V SHGF F1+ F1F2+ F2OIL OILG D11+ D11D12+ D12D13+ D13D14+ D14GND D12+ D12E1+ E1SHG3 CANH2 CANL2

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Port name DI 3 DI 8 DI 9 DI 10 DI 11 DI 12 DI 13 DI 14 DI 15 DI 20 DI 28 DI 32 DI 38 DI 39 DI 40 DI 41

Function Battery relay secondary side Spare

E135B

Input/putput

0

Spare

Output Output Output Output 0

OPT changeable relief 2

Output

Spare

Output

Spare

Output

Spare

Output

Battery (-) Spare

Output

Spare

E/G speed sensor

Input

Spare

Function Spare Water separator Spare Air filter Spare KPSS release Spare Spare Spare ECU main relay Spare Spare Quick coupler Extra pressure Spare Spare Reserved

Input/putput

Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input

Signal level 20~32V Shield GND +24V 1.5A +24V 1.5A +24V 1.5A +24V 1.5A

+0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V +0~800mA -0~800mA XX~XXVp-p 0V Shiled GND CAN communication CAN communication Signal level +24V/OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN SM3185

T2-1-57

Copyright © New Holland E135B

Connector No. CN108

MECHATRO CONTROL SYSTEM

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Connector No. CN109

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Port name

DI 2 DI 4 DI 5 DI 6 DI 7 DI 16 DI 17 DI 18 DI 19 DI 21 DI 22 DI 23 DI 24 DI DI DI DI DI

25 26 27 29 30

GP DI 33 DI 34 DI 35 H1+ H2H2+ H2Port name

DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 12 DO 13 DO 14 DO 15 DO 16 DO 17 DO 18 DO 19 GP TXD2 RXD2 RTS CTS SHG2 DO 10

Input Input Input Input Input Input Input Input Input Input Input Input Input

Signal level +24V / OPEN +24V / OPEN GND / OPEN +24V / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN +24V / OPEN +24V / OPEN +24V / OPEN GND / OPEN

Front window open or close Spare Conflux/single select Overload select Drain pressure Reserved

Input Input Input Input Input

GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN

Charge Spare Spare Reserved Accel signal 1

Input Input Input

~12V / 12V~ +24V / OPEN +24V / OPEN

Function Key switch (ON) Spare Swing P/B release E/G start Boom/Dozer Wiper rise up㩩 Wiper reverse Spare Spare Spare Spare Lever lock Hand control rotation

Input/putput

0~5V 0V 0~5V 0V

Spare

Function Wiper arc prevention Wiper normal moving Wiper reserve moving Washer motor Spare Boom/Dozer select Spare Spare Spare Spare Auto idle stop relay Engine stop Lever lock Spare Reserved

Input/putput

Output Output Output Output Output Output Output Output Output Output Output Output Output Output

Signal level GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN 0V

Tranmission RS232C communication

Spare

Spare

Reception RS232C communication RS232C communication RS232C communication Shiled GND 24V/OPEN SV SM3186

T2-1-58

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

2. Gauge cluster (symbol C-2) 1) General view

4. BUZZER 1. MULTI DISPLAY LCD

2. COOLANT TEMPERATURE

GAUGE FUEL LEVEL GAUGE

MATED SIDE AMP 040 HOUSING : 174044-2 TERMINAL : 173681-2

5. SCREEN CHANGE SWITCH ETC. 6. BUZZER STOP SWITCH

7. WORK MODE SWIHCH SM0165

2) Connector CN-600 (Harness side) No.

Item name

Wire color

No.

Item name

Wire color

1

Gauge cluster → Mechatro controller (RS232C communication)

White

5

GND source (+24V Battery direct connection)

Yellow / Black

2

Mechatro controller → Gauge cluster (RS232C communication)

Red

6

GND

Black

3

—

—

7

Source (+24V starter switch ON)

White

4

—

—

8

GND communication)

Black

(RS232C

3) Function a. It processes signals by communication between the gauge cluster and the mechatro controller, displays them in lamps, displays them in LCDs and actuates the buzzer. b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro controller through the communication port. 4) Summary of display and drive item No.

Item

Remarks

1

Monitor display

LCD dot 120×168

2

Gauge display (Coolant temp., Fuel level)

Stepping motor

3

—

4

Buzzer

5

Screen change switch

6

Buzzer stop switch

7

Work mode select switch

Piezo-electricity type

T2-1-59

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

3. Relay & fuse box (symbol E-1) 1) General view

(Overhead view of box)

LABEL

INSIDE

Note) These circles indicate the parts which are used in standard specification 1

14

CN2-1

20

1

14

1

12

CN2-2

20

CN4-1

17

11

22

1

7

1

10

CN5

15

1

3

26

13

26

13

13

1

20

2

2

6

1

3

1

3

2

6

2

6

1

3

1

3

12

8

16

6

12

1

3 CN12 2

1 CN8

2

1 CN9

CN15

CN14

CN4-2

CN3-2 24

12

3

6

9

1 17 CN3-1

9

1 CN17

CN16

2

1 CN2-3 3

CN13 6

2

6

CN1 1

2 2

4

2

CN10

LOCATION OF CONNECTORS (Seen from backside)

LOCATION OF RELAY & FUSE

LABEL OF RELAY & FUSE BOX No. CODE IN CIRCUIT

PARTS NAME

SM3187

T2-1-60

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

2) Circuit diagram

SM0167

T2-1-61

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

SM3188

T2-1-62

Copyright © New Holland MECHATRO CONTROL SYSTEM

E135B

SM0169

T2-1-63

Copyright © New Holland E135B

MECHATRO CONTROL SYSTEM

4) High pressure sensor : YN52S00048P1

SPECIFICATION :

ECONOSEAL SERIES MARK(+)> 3POLES CAP MATING HOUSING174357-2

PRESSURE RANGE : 0

50 MPa

POWER SOURCE VOLTAGE : 5.0+0.5V DC OUTPUT : 1/10Vs-9/10Vs

COMMON

(Vs=5V DC 0.5

OUTPUT (+)

4.5V DC)

INSURANCE RESISTANCE : 100M

POWER SOURCE (+) HOUSING TERMINAL PLASTIC POTTING

OR MORE

(BETWEEN CASING AND ALL IN/OUT TERMINALS AT 50V DC MEGGER)

CONDENSER COVER

ELECTRIC CONNECTING DIAGRAM

DIE CASING

FLEXIBLE BOARD CIRCUIT

DIAPHRAGM

O-RING P14 JIS B2401 CLASS1B PF 3/8 Tightening torgue 73.5N.m (54.2lbf.ft)

(Ex. Construction of internal controller)

PIPE THREAD

STRUCTURE

SM0170

5) Low pressure sensor : LC52S00019P1

Tightening torgue

Vout

29.434.3N.m (21.725.3lbf.ft) PF1/4

Vcc

GND

ELECTRIC CONNECTING DIAGRAM (Ex. Construction of internal controller)

SPECIFICATION : PRESSURE RANGE : 0

3.0 MPa

RATED VOLTAGE : 5.0+0.5V DC OUTPUT CHARACTERISTIC

INSURANCE RESISTANCE : 50M

OR MORE

(BETWEEN BODY AND EACH TERMINAL AT 50V DC MEGGER)

SM0171

T2-1-64

E135B

1. SUMMARY The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety, mass volume handling and low fuel consumption.

• 1-2 travel speed change and low speed / high torque at heavy duty

• Auto parking brake

• Automatic braking when parking

• Motor overrun protection

• Prevents overrunning of travel motor on the down hill slope.

• Travel pilot operation

• Prevents hunting by the built in travel shockless mechanism

• Reverse rotation protective function

• Easy positioning to protect it from swinging back when stops swinging.

• Swing priority circuit (simultaneous operation of arm in and swing motions)

• Easy operation of stable swing speed, arm slanted leveling, swing press digging

• Automatic swing parking brake

• Swing parking brake when operating at on a slope

• Hydraulic pilot control system

• Light action with operating lever

• Pilot safety lock system

• Cut out of pilot circuit by safety lock lever.

• Lock valve (boom / arm)

• Protect boom and arm from unexpected drop (Natural fall).

• Boom/Arm safety valve (Option)

• Prevention of boom and arm falling when boom head side and arm rod side pipings

manual

valve

for

lowering

Pump

• Travel 2-speed change & Auto 1st (low) speed return

Device

Attachment

• Travel straight at combined operation Mass handling capability

Performance

Micro computer

Swing Attachment

Features

• Travel straight

• Emergency attachment

Others

Easy operability and safety

Function

Low fuel consumption

Device

Travel

Performance

Function

Features

• Electric flow controlled variable displacement pump

• Pump delivery rate control by a current command to the solenoid proportional valve of the variable displacement pump

• Positive flow rate control

• Flow control by positive pilot control pressure

• Boom up conflux circuit

• Speed up of boom up operation

• Arm conflux circuit

• Speed up of arm operation

• Optimum operation by work mode select (H,S,A,B)

• Efficient operation in all work modes

• Auto accel

• Reduce fuel consumption and noise by lowering engine speed when control lever is in neutral position.

• For safety, this valve lowers risen attachment to the ground, if the machine stops with engine trouble, and the pressure in the cylinder of attachment can be released.

• Pressurized hydraulic oil tank

• To prevent hydraulic oil from entering dust and to promote self suction ability of pump

• Suction strainer

• Remove dust on suction side.

• Line filter; pilot circuit

• To prevent pilot malfunctioning

• Return circuit oil filter

• To prevent hydraulic oil from contamination

• Cooling hydraulic oil by oil cooler

• To prevent hydraulic oil from being deteriorated.

• Pressure draining circuit

• To release the main circuit pressure for piping repair work.

• Main control valve with optional valve

• Optional piping and additional work are easy

• Switching of return line for N&B machine in the cab (Option)

• Switching of return line for N&B machine is able to change with a switch in the cab

operating

circuit

from

T2-2-1

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

2. HYDRAULIC CIRCUITS AND COMPONENTS HYDRAULIC DIAGRAM READING KEY Item

T2-2-2

Component name

1

Hyd. pump assy

2

Control valve (main)

3

Swing motor unit

4

Travel motor unit

5

Boom cylinder (RH & LH)

6

Arm cylider

7

Bucket cylinder

8

Swivel joint

9

Pilot valve (ATT)

10

Pilot valve (travel)

11

Inline filter

12

Suction strainer

13

Solenoid valve assy

14

Return filter

15

Air breather

16

Restrictor

17

Shuttle valve

18

Low pressure sensor block

Copyright © New Holland

E135B

E135B

HYDRAULIC CIRCUIT (MONOBLOCK VERSION)

4

4 1

8

3

11

2 12

15

14

18

17

9

9

7 6 5

13

10

16

16

SM3189

T2-2-3

Copyright © New Holland

HYDRAULIC SYSTEM

Copyright © New Holland

E135B

HYDRAULIC SYSTEM

3. N&B HYDRAULIC CIRCUIT (OPTION) N&B HYDRAULIC CIRCUIT READING KEY

Item

Component name

50

Selector valve

51

Stop valve

52

Pilot valve

53

Overload relief valve

The hydraulic circuit for N&B is used to add to standard circuit Selection condition and proportional valve command when any of nibbler single & conflux flow or breaker in service. SELECTION

Conflux/single flow changeover switch

Electromagnetic command signal of selector valve (50) (W:O, W/O: -)

Conflux flow of nibbler

Conflux “ON”

Single flow of nibbler Breaker

P1 Pump

P2 Pump

Travel Straight

P1 Unload

P2 Unload

-

O

O

O

O

O

Conflux “OFF”

-

-

O

-

-

O

Conflux “OFF”

O

-

O

-

-

O

When using nibbler, according to specification of nibbler installed, choose confluence or single flow by confluence flow changeover switch. Adjust overload relief valve (53) of optional port to customize specification ordinary set pressure.

T2-2-4

Command signal of solenoid proportional valve (W:O, W/O: -)

E135B

N&B HYDRAULIC CIRCUIT

51

52

53

50

SM3190

T2-2-5

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

4. HOLDING VALVE FOR BOOM & ARM (OPTION) HOLDING VALVE FOR BOOM The holding valve for boom prevents the boom falling in case of head side cylinder piping breaks. HOLDING VALVE FOR ARM The holding valve for arm prevents the arm falling in case of rod side cylinder piping breaks.

HYDRAULIC CIRCUIT READING KEY Item

T2-2-6

Component name

54

Holding valve for boom cylinders

55

Holding valve for arm cylinder

Copyright © New Holland

E135B

E135B

HOLDING VALVE FOR BOOM & ARM HYDRAULIC CIRCUIT

55

54

54

SM3191

T2-2-7

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

5. DOZER HYDRAULIC CIRCUIT READING KEY Item

Name of component

56

Hydraulic pump

57

Gear pump

58

Solenoid valve

59

Control valve

60

Right dozer cylinder

61

Left dozer cylinder

62

Boom/dozer pilot valve

The dozer hydraulic circuit is added to the standard hydraulic circuit. OPERATION When the relevant button is pressed either on the right pilot valve or the switch panel, solenoid valve (58) is actuated thus the spool of solenoid valve (58) is moved. When the blade lifting operation is performed, the piloting secondary proportional pressure exits port 4 of the right pilot valve (62), it is monitored by low pressure sensor (SE-3) and is sent to port P1 of solenoid valve (58). The piloting secondary proportional pressure exits port B1 of solenoid valve (58), enters port Pa1 of control valve (59) and moves the spool of control valve (59). The oil delivered by gear pump (57) enters port P and exists port A1 of control valve (59) and flows to the blade cylinder rod sides (60, 61). From the opposite side, the oil returning from the blade cylinder head side (60, 61) flows to port B1 of control valve (59) and through the spools returns to the tank. When the blade lowering operation is performed, the piloting secondary proportional pressure exits port 2 of the right pilot valve (62), it is monitored by low pressure sensor (SE-4) and is sent to port P2 of solenoid valve (58). The piloting secondary proportional pressure exits port B2 of solenoid valve (58), enters port Pb1 of control valve (59) and moves the spool of control valve (59). The oil delivered by gear pump (57) enters port P and exists port B1 of control valve (59) and flows to the blade cylinder head side (60, 61). From the opposite side, the oil returning from the blade cylinder rod side (60, 61) flows to port A1 of control valve (59) and through the spools returns to the tank.

T2-2-8

Copyright © New Holland

E135B

E135B

DOZER HYDRAULIC CIRCUIT

60

56

61

57

62

58

59

SM3192

T2-2-9

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

6. POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION) HYDRAULIC POSITIONING CIRCUIT READING KEY Item

Component name

63

P1 OPT valve

64

Holding valve for positioner cylinder

65

Positioner cylinder

66

Positioning pilot valve

OPERATION When the operation for positioning is performed, the pilot proportional secondary pressure is delivered through port A of the positioning pilot valve (66) and flows to PAo1 port of the P1 OPT valve (63) then, the spool of P1 OPT valve (63) is switched. The pressure oil by P1 pump is supplied to (R) side of positioner cylinder (65) through Ao1 port of P1 OPT valve (63). On the other hand, the return oil from (H) side of positioner cylinder (65) returns to the tank circuit thorough Bo1 port of P1 OPT valve (63). The holding valve (64) prevents the positioning falling in case of rod side cylinder piping breaks.

T2-2-10

Copyright © New Holland

E135B

E135B

POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION)

64

R

F

65

66

63

SM3193

T2-2-11

Copyright © New Holland

HYDRAULIC SYSTEM

7. COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS Blue Feed, drain circuit less than 0.44 MPa (64 psi) Green Return, make up circuit, 0.44~0.59 MPa (64~86 psi) Purple Secondary pilot pressure, (including proportional vlave) 0.59~5 MPa (86~725 psi) Red Primary pilot pressure, (including proportional vlave) 5 MPa (725 psi) Orange Main pump drive pressure, 5~34.3 MPa (725~4970 psi) Blue tone At valve operation Red valve When solenoid proportional valve (reducing) is operating Red solenoid In active and exciting Displaying the flow circuit and standby circuit when operating. Regarding the electrical symbols in this manual, refer to the electric circuit diagram.

HYDRAULIC SYSTEM

8. NEUTRAL CIRCUIT

8.3 PUMP POSITIVE FLOW CONTROL

This section describes the following. 8.1 Bypass cut valve and unload valve control 8.2 Safety lock lever and pilot circuit 8.3 Pump positive flow control 8.4 Pump P-Q (Pressure-Quantity) curve control

(1) Type: Electric flow controlled variable displacement pump.

(3) Operation: 8.1 OPERATION OF BY-PASS CUT VALVE AND UNLOADING VALVE HOUSED IN CONTROL VALVE (1) By-pass cut valve On starting engine, P1 and P2 unloading proportional valves (PSV-D, PSV-B) output secondary pressure according to the command output by mechatro controller, and this pressure exerts on PBp1 and PBp2 ports, and consequently the by-pass cut spool is switched to CLOSE side. The by-pass cut spool is usually held on CLOSE side after the engine started. And it is switched to OPEN side only when failure occurred on pump proportional valve and mechatro controller. (2) Unloading valve On starting engine, like by-pass cut valve, the secondary pressures output by P1 and P2 unloading proportional valves (PSV-D, PSV-B) exert on PCb and PCa ports, consequently the P1 and P2 unloading valves are switched to OPEN side. 8.2 SAFETY LOCK LEVER AND PILOT CIRCUIT (1) Purpose: To protect attachment movement for safety.

from

unexpected

(2) Principle: Cut pressure source of pilot valve for operation. (3) Operation: If the safety lock lever (red) is pushed forward after the engine starts, the limit switch (SW-11) is turned on. The timer relay is actuated one second later which causes the solenoid (SV-4) of the solenoid valve block (13) to be energized and makes the pilot operating circuit to stand by.

T2-2-12

(2) Principle: The current command I to the pump’s solenoid proportional valve controls the delivery rate of the pump. 1) Flow rate rise operation (Eg. P1 pump) By operating any of control levers, the operating secondary pressure of pilot valve rises, and the rising pressure is transformed to the rise of output voltage corresponding to the pressure input by the low pressure sensor. Mechatro controller signalprocesses this change of voltage, resulting in rise of command current value I to the pump proportional solenoid valve and consequently the pump flow rate rises. This is called "Positive Control System". As the pump command current value rises, the secondary pressure of proportional solenoid valve also rises. On the regulator attached on the pump, the spool (652) through piston (643) is pushed leftward, and stops at the position where being in proportion to the force of pilot spring (646). The tank port connected to the large bore of servo piston (532) opens, and the piston moves leftward by delivery pressure P1 of the small bore resulting in the increase of tilt angle ( ). The servo piston (532) and spool (652) are connected to feedback lever (611). Therefore when servo piston moves leftward, the spool (652) also moves rightward by means of feedback lever. With this movement, the opening of spool sleeve closes gradually, and the servo piston stops at the position the opening closed completely. 2) Flow rate reduction operation As the current value I of mechtro controller reduces, the secondary pressure of solenoid proportional valve reduces, and spool (652) is moved rightward by the force of pilot spring (646). With the movement of spool, the delivery pressure P1 usually flows into the large bore of piston through the spool. The delivery pressure P1 flows in the small bore of servo piston, but the servo piston moves rightward due to the difference of area, resulting in the reduction of tilt angle. Similarly, when the servo piston moves rightward, the spool (652) is moved leftward by the feedback lever.

The operation is maintained until the opening of spool sleeve is closed.

8.4 PUMP P-Q CURVE CONTROL OPERATION (1) Type: Electrical flow control type variable pump (2) Principle: Perform an operation of the value from pump high pressure sensor to P-Q curve control value, and send a command to the pump solenoid proportional valve. (3) Operation: The pump high pressure sensor converts the pressure to the output voltage corresponding to the pump delivery pressure. The mechatro controller converts the voltage output by the high pressure sensor to the P-Q curve control value. On the other hand, select the pump positive control command current value from the low pressure sensor in lower order, and the values are output to respective pump proportional valve as a command current. With this operation, the pump power is controlled so as not to be exceed the engine power, therefore engine dose not stall.

Copyright © New Holland

E135B

E135B

NEUTRAL CIRCUIT: Positive control function at safety lock lever down (unloked position)

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SM3207

T2-2-13

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

9. TRAVEL CIRCUIT This section describes the following. 9.1 Travel forward pilot simultaneous operation circuit 9.2 2 speed travel solenoid command circuit and auto 1-speed return function 9.3 Travel main circuit 9.4 Travel motor function 9.1 TRAVEL FORWARD PILOT SIMULTANEOUS OPERATION CIRCUIT (1) Purpose: Light operating force and shockless operation (2) Mechatronics : 1) If the travel lever with damping mechanism is operated for travel right, left and forward motions, the secondary pilot proportional pressure comes out of the 3, 1 ports of P/V (10). The higher of the pressures is selected, comes out of the 6, 5 ports and acts upon the low pressure sensors (SE-9) (SE-10). 2) The pilot secondary pressure flows to PBr and PBL ports of the control valve (2), moves the travel spool, and switches the main circuit. 3) The low pressure sensor output voltage is input into mechatro controller. The mechatro controller performs signal processing and outputs current corresponding to the increase of flow rate to P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2), and at the same time the command current is output to P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B). 4) The secondary pressures output by P1 pump proportional valve (PSV-P1) and P2 pump proportional valve (PSV-P2) exert on pump regulator, actuating the pump on the delivery flow rate increase side. 5) The secondary pressure delivered in P1 unloading valve (PSV-D) and P2 unloading valve (PSV-B) is fed to PBp1, PCb, PBp2 and PCa ports provided in control valve (2). The secondary pressure from proportional valve which has exerted on PBp1 and PBp2 ports holds the by-pass cut spool on CLOSE side, like the operation in the lever neutral position. The secondary pressure from proportional valve which has exerted on PCb and PCa ports switches the unloading spool in CLOSE side.

T2-2-14

9.2 2-SPEED TRAVEL SOLENOID COMMAND CIRCUIT AND AUTO 1st SPEED RETURN FUNCTION 1) Purpose: Change travel motor speed with switch. (2) Principle: If the switch is turned, an electric signal is issued. It excites the 2-speed travel solenoid which in turn converts the primary pilot pressure and the self pressure to a tilting angle of the variable displacement motor. (3) Operation: If the rabbit marked switch on the gauge cluster is pressed, the solenoid (SV-3) of the proportional valve block (13) is excited and changes the proportional valve. Then the solenoid command pressure is issued from port A3, enters the P port of the travel motor (4), opens the oil passage to the 2nd speed select piston, and causes the motor to run in the 2nd speed tilting mode by its self pressure. However, when the main circuit pressure rises above 27.3 MPa (3960 psi), the motor’s self pressure pushes the 2nd speed select piston back to the 1st speed. 9.3 TRAVEL MAIN CIRCUIT (1) Operation: The delivery oil from Pump A1 and A2 ports by changing the travel spool with the operation of travel pilot flows into A port on the left side motor (4) and B port on the right side motor (4) through C,D ports of swivel joint (8) from Br, BL ports of C/V, and rotates the travel motor. 9.4 TRAVEL MOTOR FUNCTION (1) Function: 1) Prevents the motor from over running on a slope. 2) Check valve that prevents cavitation of the hydraulic motor. 3) Shockless relief valve and anti cavitation valve when inertia force stops. 4) High/Low 2 step speed change mechanism and auto 1st speed return at high load. 5) Travel parking brake.

Copyright © New Holland

E135B

E135B

TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation.

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SM3208

T2-2-15

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

10. BUCKET CIRCUIT This section describes the following. 10.1 Bucket digging pilot circuit 10.2 Auto accel operation 10.3 Flow control in the work mode

When the pressure 0.6MPa (87psi) is input to low pressure sensor in STD specification (travel, bucket, swing, arm), proportional voltage from low pressure sensor inputs in mechatro controller, and then the engine speed returns to the dial set position corresponding to the lever operation.

10.1 PILOT CIRCUIT FOR BUCKET DIGGING (1) Mechatronics : 1) When the operation for bucket digging is performed, the pilot proportional secondary pressure is delivered through port 1 of the right pilot V (9), flows to PAc port, and acts on the low pressure sensor (SE-1), and at the same time the bucket spool is switched. 2) The voltage output by low pressure sensor (SE-1) inputs in mechatro controller. The Mechatro controller performs signal processing and outputs current corresponding to the increase of pump flow rate to pump proportional valve (PSV-P1) on the P1 pump side, and at the same time the command current is output to P1 unloading valve (PSV-D). In the following pages, the relation of operation of low pressure sensor to both the increase of pump flow rate and unloading proportional valve is the same. Therefore the explanation is omitted. 3) The secondary pressure output by P1 pump proportional valve (PSV-P1) exerts on pump regulator, actuating the pump onto the delivery flow increase side. 4) The secondary pressure delivered in P1 unloading valve (PSV-D) is led to PBp1 and PCb ports provided in control valve (2). The secondary pressure from proportional valve which has exerted on PBp1 port holds the by-pass cut spool on CLOSE side, like the operation in the lever neutral position. The secondary pressure from proportional valve which has exerted on PCb port switches the unloading spool in CLOSE side.

10.2 AUTO ACCELERATION OPERATION (1) Principle: Auto acceleration actuates according to signals from low pressure sensor. (2) Operation:

In the event where the sensor does not receive signal for 4 seconds or more even though the acceleration dial is set to MAX position, the engine speed should be raised to 1000 rpm. T2-2-16

10.3 FLOW CONTROL IN THE WORK MODE (1) Principle: When the engine speed is intermediate speed or lower, command current value to have the pump delivery rate constant is output. (2) Operation: Even if the engine speed specified by acceleration potentiometer is low speed, as the delivery rate corresponds to the intermediate speed, the actuator moves earlier than the movement equivalent to the control lever angle rate in light load operation.

Copyright © New Holland

E135B

E135B

BUCKET CIRCUIT: Bucket digging, Auto-accelation and Standby flow rate constant control

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SM3209

T2-2-17

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

11. BOOM CIRCUIT This section describes the boom raise conflux operation. 11.1 Boom up pilot circuit 11.2 Boom up 2 pumps conflux main circuit in C/V 11.1 BOOM RAISE PILOT CIRCUIT (1) Operation: 1) If boom up operation is performed, the secondary pilot proportional pressure from the right pilot valve (9) gets out of port 4 and acts upon the low pressure sensor (SE3). At the same time, the pressure acts upon the PAb and PB1 ports. 2) The secondary pressure which enters the PAb port of C/V (2) shifts the boom spool. The secondary pressure which enters the PB1 port shifts the boom conflux spool. 11.2 BOOM UP 2 PUMPS CONFLUX MAIN CIRCUIT IN C/V (1) Purpose: Boom up speed up (2) Principle: Confluxing oil from 2 pumps (3) Operation: 1) The oil delivered through A1 port of P1 pump flows into C/V (2) P1 port, and branches into bypass circuit and parallel circuit. Since P1 unloading valve is closed, the boom spool is moved and bypass circuit is closed, the oil opens load check valve LCb through parallel circuit and flows into boom spool. 2) Then the oil passes through boom spool, opens lock valve of boom lock valve CRb, and is led into (H) side of boom cylinder through C/V (2) Ab port. 3) Meanwhile, the oil delivered from the A2 port of the P2 pump enters the P2 port of C/ V (2) and due to shut off the P2 unloading valve, the oil then passes through the parallel circuit and via the restrictor on the circumference of the boom conflux spool, pushes the load check valve CCb open from the boom conflux circuit, and combines the oil delivered by the P1 pump internally. 4) The return oil from boom cylinder (R) side flows into tank circuit through boom spool from C/V (2) Bb port.

T2-2-18

Copyright © New Holland

E135B

E135B

BOOM CIRCUIT : Boom up operation, Confluence function.

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SM3194

T2-2-19

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM This section describes boom lower operation. 11.3 Boom down pilot circuit 11.4 Prevention of natural fall by lock valve and actuation at lowering 11.5 Constant recirculation function of boom down main circuit 11.3 BOOM DOWN PILOT CIRCUIT (1) Operation: 1) If the boom down operation is performed, the secondary pilot proportional pressure comes out of port 2 of the right pilot valve (9) and acts upon the low pressure sensor (SE4). At the same time, the pressure acts upon the PBb port of C/V (2). 2) The voltage output of the low pressure sensor (SE-4) enters the mechatro controller and processed in it. 3) Then, the proportionl secondary pressure fed into C/V (2) PBb port and branches off in two lines and switches boom spool and releases boom lock valve. 11.4 PREVENTION OF NATURAL FALL BY LOCK VALVE AND ACTUATION AT LOWERING (1) Purpose: Prevention of natural fall when the lever is neutral (2) Principle: The oil is prevented from returning to the boom spool by the poppet seat of the boom lock valve. (3) Operation: In the boom down action, the selector valve is changed over by the secondary proportional pressure of PBb port. Then the poppet spring chamber of the lock valve CRb gets through the drain line (Dr) and makes the lock valve poppet open. When the boom lever is at neutral, the drain line on the lock valve CRb poppet spring chamber is closed which causes the poppet closed. The result is that the oil returning from the boom cylinder head (H) to the boom spool is held and makes the leak from the boom spool zero. Thus the boom cylinder is prevented from making a natural fall.

T2-2-20

11.5 CONSTANT RECIRCULATION FUNCTION OF BOOM DOWN MAIN CIRCUIT (1) Purpose: Prevention of cavitation during boom lowering motion. (2) Principle: The oil returning from the boom cylinder head (H) is recirculated to the rod (R). (3) Operation: When the oil is supplied to the boom cylinder rod (R) side during boom down operation, the boom moves faster than it should do in some cases by the self weight of the attachment. On that occasion, the circuit pressure on the rod (R) side is on the negative side. The oil supplied to the boom cylinder rod (R) flows into the A1 port of the P1 pump and the P1 port of C/V. The oil then passes through the boom spool and goes out of the Bb port. On that occasion, the oil returning from the head (H) goes through the recirculation path in the boom spool, pushes the check valve in the spool open, is recirculated to the Bb port and is supplied to the rod (R). When the (R) pressure is larger than the head (H) pressure, the check valve in spool closes. Thereupon, the recirculation is stopped.

Copyright © New Holland

E135B

E135B

BOOM CIRCUIT: Boom down operation & Prevention of natural boom falling.

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SM3195

T2-2-21

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

12. SWING CIRCUIT This section describes the following operations. 12.1 Swing left pilot circuit 12.2 Swing auto parking brake 12.3 Swing main circuit 12.4 Swing motor circuit 12.1 PILOT CIRCUIT FOR LEFT SWING (1) Operation: 1) When the left swing operation is performed, the pilot proportional secondary pressure is delivered through port (1) of left pilot V (9), and the secondary pressure acts on PAs port of C/V (2), and simultaneously flows out from Pss port of C/V and acts on low pressure sensor (SE-5). 2) The voltage output by the low pressure sensor is input in the mechatro controller, and is signal-processed. 3) Then, the secondary pressure led into PAs port of C/V (2) switches the swing spool. 12.2 SWING AUTO PARKING BRAKE (1) Purpose: Swing lock in neutral position and parking (2) Principle: Release mechanical brake only when required to operate swing and arm in. (3) Operation: 1) The swing parking system excites the swing parking SOL (SV-1) usually if the key switch is turned on and works by the action of the mechanical brake. 2) The mechanical brake is released if the swing parking solenoid is de-excited only when the secondary operating pressure in the swing and arm in actions acts upon any of the low pressure sensors (SE-5, 7). 3) The swing parking solenoid (SV-1) is excited five seconds after the pressure of the swing low pressure sensors (SE-5) is reduced to zero. In the case of arm in operation, the swing parking solenoid (SV-1) is excited the moment the pressure of the arm in low pressure sensor (SE-7) is reduced to zero. This causes the mechanical brake to operate. 12.3 SWING MAIN CIRCUIT (1) Operation: The oil delivered from the A2 port of the P2 pump enters the P2 port of C/V (2) and is branched off into the bypass line and the parallel circuit. However, since the bypass line is closed T2-2-22

as the swing spool is shifted, the oil pushes the load check valve LCs open through the parallel circuit, enters the B port of the swing motor via the As port of C/V (2), and rotates the swing motor counterclockwise. 12.4 SWING MOTOR CIRCUIT (1) Anti cavitation circuit at swing deceleration (2) Shockless relief valve that prevents the swing motor from being reversed.

Copyright © New Holland

E135B

E135B

SWING CIRCUIT: Swing operation (LH)

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SM3196

T2-2-23

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

13. ARM CIRCUIT This section describes the following operations. 13.1 Arm in, light-load operating pilot circuit 13.2 Arm in, light-load variable normal recirculation main circuit / internal conflux main circuit 13.1 ARM IN, LIGHT-LOAD OPERATING PILOT CIRCUIT (1) Purpose: Speed-up and Anticavitation when the arm is at light loaded. (2) Principle: The oil returning from the arm cylinder rod (R) is recirculated variably to the head (H) at arm 2 spool in C/V. (3) Operation: 1) When the arm in operation is performed, the secondary pilot proportional pressure gets out of port 4 of the left pilot valve (9) and acts upon the low pressure sensor (SE-7). At the same time, the pressure is branched off in two flows, acts upon the PAa1 port and the PLc2 port, changes over the arm spool and the arm lock valve CRa releases. 2) The output voltage by the low pressure sensor is input into mechatro controller, and is pilot signal-processed, and is output to P1, P2 pump proportional valve (PSV-P1), (PSV-P2) and arm 2 inverse proportional valve (PSV-A). 3) The secondary pressure from pilot proportional valve, which is reduced by arm 2 inverse proportional valve (PSV-A) switches arm 2 spool.

flowed into arm cylinder head (H) side through Aa port of C/V (2). 3) The return oil from arm cylinder (R) side flows in Ba port of C/V (2) and passes through the Ba port because the arm lock valve CRa is open, and is flowed into arm 2 spool through arm 1 spool. 4) Because arm 2 spool is switched to normal recirculation position, causing restriction of passage to tank, the return oil from arm cylinder (R) side flows into arm cylinder (H) side. • Because, at light load, the pressure in cylinder rod (R) side is higher than that in the head (H) side, it opens the check valve housed-in arm 2 spool and is recirculated in the head (H) side, resulting in the speed up of arm-in operation at light load. 5) Cavitations prevention control in arm-in operation. Command current is output to arm 2 solenoid proportional valve by signal processing of E/G speed and arm-in pilot pressure, accordingly the arm 2 spool is switched to neutral (cavitations prevention) position, resulting in cavitations prevention. Position of arm 2 spool

Normal recirculation position

Neutral position (Anticavitation position)

Recirculation

From arm out P/V From arm 2 inverse proportional valve

13.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL RECIRCULATION, INTERNAL CONFLUX MAIN CIRCUIT (1) Operation: 1) The P2 pump delivery oil flows in travel left section through P2 port of C/V (2) and is branched off in by-pass circuit and parallel circuit, but because arm 1 spool is switched, the delivery oil which goes through parallel circuit opens load check valve LCa and is flowed into arm 1 spool. 2) On the other hand, P1 pump delivery oil flows in P1 port of C/V (2), and the flows in travel straight section and travel right tandem path. Then because arm 2 spool was switched, the delivery oil opens load check valve LCAT2, goes through arm 2 spool, and confluences with P2 pump delivery oil in the valve section, and then is

T2-2-24

SM3197

Reference: In light-load arm-in operation (normal recirculation, conflux), when the attachment to which the circuit in P1 pump side is applied is operated, the meter-in path of arm 2 spool is closed, resulting in single flow operation. Spool position at arm in, light load and combined operation (This position is not shown in hydraulic diagram) Meter-in passage (Close) Neutral position

Normal recirculation position

Arm 2 spool SM3198

Copyright © New Holland

E135B

E135B

ARM CIRCUIT: Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function

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SM3199

T2-2-25

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM This section describes the following operations. 13.3 Arm in, heavy load operating pilot circuit (recirculation cut) 13.4 Arm in, heavy load operating sequence confluxed main circuit

4) The return oil returns directly into tank circuit because arm 2 spool is switched to recirculation cut position. Position of arm 2 spool

Recirculation cut position

Neutral position

13.3 ARM IN, HEAVY LOAD OPERATING PILOT CIRCUIT From arm out P/V

(1) Operation: 1) 1)In arm-in operation, when the heavy loading is applied to arm and the P2 pump pressure increases to the set pressure, the voltage output by P2 pump pressure sensor (SE-23) is converted to signal (signal processing) by mechatro controller, consequently the current of arm 2 solenoid proportional valve is controlled according to the load pressure and the arm variable recirculation is cut. When the recirculation is cut, internal confluence is held similarly to that in light load operation. 2) Left pilot valve actuation due to arm-in operation is equivalent to that at light load operation.

13.4 ARM IN, HEAVY LOAD OPERATING RECIRCULATION CUT MAIN CIRCUIT (1) Purpose: Speed up for arm in operation (2) Principle: Cut the recirculation and reduce rod pressure. (3) Operation: 1) P2 pump delivery oil flows in the travel left section through P2 port of C/V (2) and branched off in by-pass circuit and parallel circuit. Consequently the arm spool is switched and pushes and opens load check valve LCa through parallel circuit, and flows in the arm spool. 2) On the other hand, P1 pump delivery oil flows in P1 port of C/V (2), and flow in travel right tandem passage through travel straight section. Then because arm 2 spool was switched, the delivery oil opens load check valve LCAT2, and confluences with P2 pump delivery oil in the valve section, and is flowed into arm cylinder head (H) side through Aa port of C/V(2). 3) The return oil from arm cylinder (R) side flows in Ba port of C/V(2) and is flowed to arm lock valve CRa, but because the arm lock valve CRa is open, the return oil goes through arm lock valve CRa and flows in arm 2 spool. T2-2-26

From arm 2 inverse proportional valve

SM3200

Copyright © New Holland

E135B

E135B

ARM CIRCUIT: Arm in (Heavy load) operation, Arm confluence & recirculation cut function

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SM3211

T2-2-27

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM This section describes the following operations. 13.5 Arm out pilot circuit 13.6 Arm out 2 pumps conflux main circuit 13.7 Natural fall protection with arm lock valve 13.5 ARM OUT PILOT CIRCUIT (1) Operation: 1) When the arm out operation is performed, the secondary pilot proportional pressure gets out of port 2 of the left pilot valve (9), and acts upon the low pressure sensor (SE8). At the same time, the oil is branched off in two flows and act upon the PBa1 and PBa2 ports of C/V (2). 2) The operating proportional secondary pressure flowed in PBa1 port of C/V (2) switches the arm 1 spool. 3) Then, the operating secondary pressure flowed in PBa2 port of C/V (2) switches the arm 2 spool valve. 13.6 ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT (1) Purpose: Arm out operation speed up. (2) Principle: The oil delivered by the P1 pump is confluxed with that delivered by the P2 pump in C/V (2). (3) Operation: 1) P1 pump delivery oil opens load check valve (LCAT2) by switching arm 2 spool and confluxes with P2 pump delivery oil just short of the arm lock valve. 2) And, P2 pump delivery oil flows through arm 1 spool and confluences with P1 delivery oil, opens lock valve of arm lock valve CRa with free flow and is flowed into arm cylinder rod (R) side through Ba port of C/V(2). 3) On the other hand, the return oil from arm cylinder (H) side flows in Aa port, and returns into tank circuit through arm 1 spool and arm 2 spool. The return line which does not pass through boost check valve is used for this return circuit to reduce the pressure loss.

T2-2-28

13.7 NATURAL FALL PROTECTION WITH ARM LOCK VALVE (1) Purpose: To prevent the arm from falling naturally by the weight of the arm and bucket. (2) Principle: Complete seat of the return circuit against the arm spool of the arm cylinder (R) side circuit. (3) Operation: 1) When the secondary pressure for arm operation disappears and the arm cylinder stops, the pressure on the rod (R) side passes through the selector of the lock valve from the Ba port of C/V, acts the back pressure on the lock valve CRa and seats the lock valve. 2) Since the oil flow into the arm spool from the lock valve is shut off completely, natural fall of the arm due to oil leaks through the arm spool is prevented.

Copyright © New Holland

E135B

E135B

ARM CIRCUIT: Arm out operation, Confluence function

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SM3212

T2-2-29

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

14. COMBINED CIRCUIT This section describes only the difference in combined operation. 14.1 Boom up / travel, pilot circuit 14.2 Boom up / travel, main circit 14.1 BOOM UP / TRAVEL, PILOT CIRCUIT (1) Operation:

1) The mechatro controller outputs command current to travel straight solenoid valve (PSV-C) after signal processing, and the solenoid proportional valve outputs secondary pressure and acts on PTb port of C/V (2). 2) Then the pressure of PTb port switches the travel straight valve one step. 14.2 BOOM UP / TRAVEL, MAIN CIRCUIT (1) Purpose: To insure straight travel movement during travel operation even if the attachment is operated. (2) Principle: The travel action and the attachment action are actuated by separate pumps. (3) Operation: 1) P1 pump delivery oil flows through P1 port of C/ V(2) and branches off in P1 parallel circuit and travel straight spool. P2 pump delivery oil flows through P2 port of C/ V(2) and branches off in P2 tandem circuit and travel straight spool. 2) The delivery oil flowed into P1 parallel circuit of P1 pump opens check valve CT1 and LCb and flows in boom spool, which exerts on boom up operation. The delivery oil flowed into travel straight spool of P1 pump opens check valve CT2 because the travel straight spool is shifted, and flows in boom conflux spool and exerts on boom up operation with the internal oil conflux. (In travel independent operation, P1 pump delivery oil exerts on swing and attachment operations.) 3) The delivery oil flowed into P2 tandem circuit of P2 pump flows in left travel spool to travel leftward. The delivery oil flowed into travel straight spool of P2 pump flows in right travel spool because the travel straight spool is shifted and exerts on the right travel operation. (In travel independent operation, P2 pump delivery oil exerts on travel operations.)

T2-2-30

4) However, a portion of the flow is led to the travel straight spool notch restriction. The speed of attachments like, boom, travel, etc. is adjusted by the circuit of restriction.

Copyright © New Holland

E135B

E135B

COMBINED CIRCUIT: Boom up & Travel forward 1st speed operation, Travel straight function.

4

4 1

8

3

11

2 12

15

14

18

17

9

9

7 6 5

13

10

16

16

SM3210

T2-2-31

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM In this section, the independent operation is omitted and describes difference in combined operation. 14.3 Swing / Arm in light load, pilot circuit 14.4 Swing / Arm in, swing priority main circuit

Position of arm 2 spool

14.3 SWING / ARM IN LIGHT LOAD, PILOT CIRCUIT

From arm 2 inverse proportional valve

(1) Operation: 1) On operating swing (left) and arm in motions simultaneously, mechatro controller outputs command current to travel straight solenoid proportional valve (PSV-C) and arm 2 solenoid inverse proportional valve (PSV-A) according to signal processing, and this proportional valve outputs secondary pressure, which acts on PTb port and PAa2 port of C/V(2). 2) PTb port pressure switches the travel straight spool, and the PAa2 port pressure switches the arm 2 spool to the forced recirculation position. 14.4 SWING / ARM IN, SWING PRIORITY MAIN CIRCUIT (1) Purpose: Stable swing speed. (2) Principle: Raise the oil pressure flowing to arm cylinder, and give a priority of the delivery of P2 pump to swing operation. (3) Operation: 1) The swing main circuit operates with P2 pump flow. But on P2 pump circuit side, the flow goes to the swing circuit and arm circuit simultaneously because the swing circuit and arm circuit are parallel. Then since the return oil from arm cylinder rod (R) side is restricted in the arm 2 spool because the arm 2 spool is switched to forced recirculation position, the pressure of return oil is raised, causing the rise of circuit pressure on the arm cylinder head (H) side. 2) At the same time meter-in of arm 2 spool closes and arm in conflux is therefore cancelled, and delivery oil from P2 pump and P1 pump are combined in the parallel circuit on P2 pump side because the travel straight spool was switched. The conflux oil of P1 and P2 delivery oil in high pressure flows in swing side taking priority over all others. This operation is called "Swing Priority Circuit".

T2-2-32

Position of forced recirculation Meter-in passage (Close) Neutral position

Normal recirculation position

From arm out P/V Arm 2 spool SM3214

Copyright © New Holland

E135B

E135B

COMBINED CIRCUIT: Swing / Arm in operation, swing priority function

4

4 1

8

3

11

2 12

15

14

18

17

9

9

7 6 5

13

10

16

16

SM3215

T2-2-33

Copyright © New Holland

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM

15. PRESSURE DRAINING (RELEASING) CIRCUIT This section describes the following operations. 15.1 Pressure releasing pilot circuit 15.2 Pressure releasing main circuit 15.1 PRESSURE RELEASING PILOT CIRCUIT (1) Purpose: To release the pressure in main circuit for piping repair works. (2) Principle: After the mode is switched to "Pressure Relief Mode" with switch on gauge cluster, mechatro controller outputs the following commands. 1) Minimum tilting command value to pump proportional valve (PSV-P1, PSV-P2). 2) Output “pressure relief control speed command value” at ECU. (Electric system). 3) Stand-by command value to P1, P2 unloading proportional valves. How to switch to "Pressure release mode" 1) Select the service diagnosis mode 1. (Keeping pressing of the "BUZZER STOP SWITCH" [ ] on gauge cluster, turn the starter key ON.) 2) Select the service Adjustment Mode 1. (Under the condition that "Screen No.1" of "Service diagnosis mode 1" is indicated, keeping pressing of the "BUZZER STOP SWITCH", press the SELECT switch [ ] 3 times. When "LANGUAGE/LOGO", "ADJUSTING MODE 1" and "PRESET BY FACTORY" are displayed, press [ ] or [ ] switch, and highlight "ADJUSTING MODE 1", and then press "SELECT Switch" again.) 3) When "ADJUSTING MODE 1" screen is displayed, press [ ] or [ ] switch, several times and "DRAIN HYD. PRESS. OFF " screen appears. 4) Press "SELECT Switch" and highlight "OFF", and press [ ] switch to change to "DRAIN HYD. PRESS. ON", and then press " SELECT Switch" again. (3) Operation: 1) Pump proportional valve reduces the pump flow rate to the minimum. 2) Unloading proportional valves (PSV-D, PSV-B) output secondary pressure and the secondary pressure flows in PCb, PCa ports of C/V(2) and switches the P1, P2 unloading valves to OPEN position.

T2-2-34

15.2 PRESSURE RELEASING MAIN CIRCUIT (1) Operation: CAUTION: before to perform the hydraulic pressure releasing, make sure to place bucket on the ground. When the operating lever is shifted to neutral during engine running, "DRAINING HYD. PRESS." is displayed on the gauge cluster while the mode switch is changed to pressure relieving mode. In this time the intermittent buzzer sounds continuously. When right and left operating levers are operated 4 or 5 times to their full stroke, pressure is relieved. After draining pressure is completed, turn off the starter key and buzzer sound stops. If the pump pressure is determined to be more than 1 MPa (145 psi) by the output value of the high pressure sensor (SE 22, SE 23) (or the high pressure sensors are broken) "FAIL DRAIN HYD. PRESS" is displayed and the buzzer sounds continuously. In that case, also the buzzer is not stopped unless the engine key is turned to OFF. Repeat the pressure releasing procedure once again. (2) Hydraulics: If the Unloading valves are turned to the pressure release position, the oil delivered by each pump is unloaded to the tank passage. If the spools are switched by pilot operation, the remaining pressure from the actuators may be relieved to the tank circuit, i.e. the main circuit pressure may be released.

Copyright © New Holland

E135B

E135B

PRESSURE DRAINING (RELEASING) CIRCUIT: at pressure release mode

4

4 1

8

3

11

2 12

15

14

18

17

9

9

7 6 5

13

10

16

16

SM3213

T2-2-35

Copyright © New Holland

HYDRAULIC SYSTEM

T2-2-36

HYDRAULIC SYSTEM

Copyright © New Holland

E135B

Copyright © New Holland ELECTRICAL SYSTEM

E135B

ELECTRICAL SYSTEM MAIN COMPONENTS ELECTRICAL SYSTEM (Overall system)

$

)

%

' '

&

(

A - Cab Control B - Mechatro Controller and Fuse&Relay box C - Batteries, Batteries Relay, Fuse link

60

D - Hydraulic System Electrical Components E - Engine Electrical Components F - Light, Horn, ect

T2-3-1

Copyright © New Holland E135B

ELECTRICAL SYSTEM

A - CAB CONTROL Electrical components

















   



  









60

1 - Cluster gauge (C2) 2 - Blade selection button (SW-81) 3 - Starter switch (SW-1) 4 - Engine speed throttle (SE-16) 5 - Work lights switch (SW-55) 6 - Single/Double flow switch (SW-15) 7 - “Heavy Lift” switch (opt.) (SW-35) 8 - Load momentum switch (opt.) (SW-12) 9 - Cigarette lighter (E-14) 10 - Hour meter (E-3)

11 - Climate controls panel (C-4) 12 - Quick coupling switch (opt.) (SW-59) 13 - Tuner (E-7) 14 - Cab work lights switch (opt.) (SW-26) 15 - Parking brake release switch (SW-4) 16 - Horn switch (SW-10) 17 - "KPSS" switch (SW-5) 18 - Drain pressure switch (SW-96) 19 - Blade selection switch (SW-80) 20 - "Emergency Mode" Potentiometer (E-27)

T2-3-2

Copyright © New Holland ELECTRICAL SYSTEM

E135B

Cluster Gauge

SM0003

1 - Coolant temperature indicator 2 - Fuel level indicator 3 - Screen change button 4 - Select button 5 - Auto-Idle button 6 - Work Mode button

7 - Windshield washer button 8 - Wiper button 9 - Buzzer cut-off button 10 - Travel speed button 11 - Display

T2-3-3

Copyright © New Holland E135B

ELECTRICAL SYSTEM

Cluster gauge wiring harness

 





9,(:,

 







 







  







,











 (



 :



%U

 9,(:( 60

1 - Starter switch (SW-1) 2 - Engine speed throttle (SE-16) 3 - Work light switch (SW-55) 4 - Single/Double flow switch (SW-15) 5 - “Heavy Lift” switch (SW-35) (opt.) 6 - Over load alarm select switch (SW-12) (opt.) 7 - (opt.) 8 - Cigarette lighter (E-14) 9 - Cluster gauge (C-2) 10 - Starter switch (GND) (SW-1)

11 - Wiper motor (M-3) 12 - 12 V socket (E-23) 13 - Speaker right (E-9) 14 - Connector for cab work light (SW-26) 15 - Connector for room light (L-5) 16 - Connector for wiper interlock switch (SW-19) 17 - Speaker left (E-8) 18 - Hour meter (E-3) 19 - Connector with “A” label (CN-5F) 20 - Connector with “B” label (CN-6F)

T2-3-4

Copyright © New Holland ELECTRICAL SYSTEM

E135B

Control levers, safety lever

    

   







 

60

1 - Horn switch (SW-10) 2 - Horn switch (Equipment rotation - opt.) (SW-5) 3 - Equipment rotation left switch (Equipment rotation - opt.) (SW-34) 4 - Blade selection button (SW-81) 5 - Equipment rotation right switch (Equipment rotation - opt.) (SW-33) 6 - Safety lever switch (SW-11)

7 - Cab work lights switch (opt.) (SW-26) 8 - Quick coupling switch (opt.) (SW-59) 9 - Tuner (E-7) 10 - Platform wiring harness 11 - Blade selection switch (SW-80) 12 - Drain pressure switch (SW-96) 13 - Opt.

T2-3-5

Copyright © New Holland E135B

ELECTRICAL SYSTEM

B - MECHATRO CONTROLLER, ENGINE CONTROLLER UNIT, FUSES & RELAY BOX, DC – DC CONVERTER









  



60

1 - Mechatro Controller Unit (C-1) 2 - Fuse & Relay box (E-1) 3 - DC-DC Converter (E-22) 4 - Engine Controller Unit ECU (C-6) 5 - ECU wiring harness 6 - Platform wiring harness 7 - "KPSS" switch (SW-5)

T2-3-6

Copyright © New Holland ELECTRICAL SYSTEM

E135B

Fuse & Relay box FUSES

60

FUSES BOX

FUSES BOX

FUSE No.

PROTECTED CIRCUIT

Rating (A)

FUSE No.

PROTECTED CIRCUIT

Rating (A)

FUSE 1

Cab Work Light

20

FUSE 19

Air Conditioner

5

FUSE 2

Cab Work Light

20

FUSE 20

Work Light

20

FUSE 3

Monitor

5

FUSE 21

DC-DC Converter

10

FUSE 4

Wiper , Washer

20

FUSE 22

Option 8

5

FUSE 5

Option 1

20

FUSE 23

Option 7

15

FUSE 6

Option 3

20

FUSE 24

Option

20

FUSE 7

Air Conditioner

15

FUSE 25

Safety Look Lever

10

FUSE 8

Air Conditioner

5

FUSE 26

Mechatro Controller

5

FUSE 9

Opt. (Bucket rotation)

5

FUSE 27

Mechatro Controller

20

FUSE 10

Relay, Hour Meter

5

FUSE 28

Engine Controller (ECU)

15

FUSE 11

Cigarette Lighter

10

FUSE 29

Engine Controller (ECU)

15

FUSE 12

Horn, Horn Relay

10

FUSE 30

Monitor (Back Up)

5

FUSE 13

Radio

10

FUSE 31

Fuel Supply Pump

15

FUSE 14

Starter Key Switch

20

FUSE 32

Mechatro Contr. (Back Up)

5

FUSE 15

Room Lamp, Tuner

5

FUSE 33

Spare

5

FUSE 16

Option 2

10

FUSE 34

Spare

10

FUSE 17

Option 4

10

FUSE 35

Spare

15

FUSE 18

Solenoid Valve

10

FUSE 36

Spare

20

T2-3-7

Copyright © New Holland E135B

ELECTRICAL SYSTEM

RELAYS

60

1 - Window washer motor relay (R-32) 2 - Wiper motor reversing relay (R-30) 3 - Cab working light relay (R-9) 4 - Cab working light relay (R-11) 5 - Working light relay (R-6) 6 - Alternator relay (R-28) 7 - Auto-Idle stop relay 2 (R-24) 8 - Lever look relay (R-26) 9 - Auto-Idle stop relay 1 (R-23)

10 - Engine emergency stop relay (R-25) 11 - Horn relay (R-5) 12 - Glow relay (R-53) 13 - Blade selector relay (R-40) 14 - Wiper motor relay (R-31) 15 - Wiper motor relay (R-29) 16 - Extra dis-press sensor relay (R-17) 17 - Revolution right relay (R-12) 21 - Revolution left relay (R-13)

T2-3-8

Copyright © New Holland ELECTRICAL SYSTEM

E135B

C - BATTERIES, BATTERIES RELAY, FUSES LINK





 



60

4 - Pre-Heater relay (R-3) 5 - Fuse Link 5 (E-27)

1 - Batterie relay (R-1) 2 - Fuse Link 1, 2, 3, 4 (E-25) 3 - Batteries (E-12)

Fuses located into radiators compartment Fuse No.

Protected circuit

Value (A)

FUSE 1

Fuses powering (1 – 6)

60

FUSE 2

Fuses powering (17 - 32)

60

FUSE 3

Alternator

80

FUSE 4

Glow plug relay (R-3)

60

FUSE 5

Fuses powering (10 - 15)

60

T2-3-9

Copyright © New Holland E135B

ELECTRICAL SYSTEM

D – HYDRAULIC SYSTEM ELECTRICAL COMPONENTS (1)

 

  

 















1 - Pomp P2 proportional solenoid valve (PSV-P2) 2 - Pump P1 proportional solenoid valve (PSV-P1) 3 - Lever lock solenoid valve (SV-4) 4 - Swing pressure sensor (SE-5) 5 - P2 Unload proportional solenoid valve (PSV-B) 6 - Travel priority prop. solenoid valve (PSV-C) 7 - P1 Unload proportional solenoid valve (PSV-D) 8 - Arm 2 inverse prop. solenoid valve (PSV-A) 9 - Two speed select solenoid valve (SV-3)









60

10 - Swing parking brake solenoid valve (SV-1) 11 - Pump P2 sensor (SE-23) 12 - Bucket digging sensor (SE-1) 13 - Bucket dump sensor (SE-2) 14 - Boom raising sensor (SE-3) 15 - Boom lowering sensor (SE-4) 16 - Arm in sensor (SE-7) 17 - Arm out sensor (SE-8) 18 - Pump P1 sensor (SE-22)

T2-3-10

Copyright © New Holland ELECTRICAL SYSTEM

E135B

D – HYDRAULIC SYSTEM ELECTRICAL COMPONENTS (2) 

 



 4

'

 " 0

!

! 0

4













60

21 - Extra valve selector press sensor (SE-29) (opt.) 22 - Extra dis-press solenoid valve (opt.) (SV-11) 23 - Extra dis-press sensor (opt.) (SE-28) 24 - P1 opt. sensor valve (SE-20) 25 - Travel right sensor (SE-9) 26 - Travel left sensor (SE-10)

27 - P2 Opt. sensor valve (SE-11) 28 - Selector B&N solenoid valve (SV-13) 29 - Quick coupler solenoid valve (SV-14) (opt.) 30 - Blade selection solenoid valve (SV-17) 31 - Bucket rotation solenoid valve (opt.) (SV-6) 32 - Bucket rotation solenoid valve (opt.) (SV-7)

T2-3-11

Copyright © New Holland E135B

ELECTRICAL SYSTEM

E – ENGINE ELECTRICAL COMPONENTS

 



 







60

1 - Air filter restriction switch (SW-8) 2 - Water separator switch (SW-36) 3 - Receiver dryer (E-10) 4 - Starter motor assembly (M-1)

5 - Alternator assembly (E-2) 6 - Engine revolution sensor (SE-13) 7 - Air compressor (E-11) 8 - Fuel sensor (SE-15)

T2-3-12

Copyright © New Holland ELECTRICAL SYSTEM

E135B

F – ELECTRICAL COMPONENTS (Lights, Horns)













 60

1 - Frame Working light (L-2) 2 - Boom Working light left (L-1) 3 - Boom Working light right (L-6) 4 - Horn high (E5)

5 - Horn low (E6) 6 - Engine room light (L-11) 7 - Engine room light switch (SW-16)

T2-3-13

Copyright © New Holland E135B

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 1) Item

Description

Code

Fuse box

E-1

2

Key starter switch

SW - 1

3

Fuse link box

E - 25

4

Auto-Idle stop relay 1

R - 23

5

Starter motor

M-1

6

Starter relay

R-2

7

Safety relay

R-4

8

Alternator relay

R - 28

9

Battery relay

R-1

10

Fuse link (60 A)

E - 27

11

Auto-Idle stop relay 2

R - 24

12

Alternator

E-2

13

Engine controller check connector

14

Battery

E - 12

15

Engine emergency stop relay

R - 25

1

-

16

Resistor

17

Glow relay (ECU)

-

18

Glow plug relay

R-3

20

Emergency Mode Potentiometer

E - 27

21

Glow plug

-

23

Engine harness

-

R - 53

25

Diode

D-4

26

Diode

D - 13

27

Diode

D - 14

28

Diode

D-9

29

Diode

D - 12

31

Hour meter

E-3

32

Engine controller unit (ECU)

C-6

33

Mechatro Controller

C-1

T2-3-14

E135B

ELECTRICAL SYSTEM DIAGRAM (No. 1)

  







 

























  







  

60

T2-3-15

Copyright © New Holland

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 2)

Item

T2-3-16

Description

Code

33

Mechatro Controller

C-1

34

Cluster gauge

C-2

35

"KPSS" switch

SW - 5

36

Accel potentio pressure sensor

SE -16

37

Bucket digging sensor

SE - 1

38

Bucket dump sensor

SE - 2

39

Boom raising sensor

SE - 3

40

Boom lowering sensor

SE - 4

41

Arm in sensor

SE - 7

42

Arm out sensor

SE - 8

43

Swing sensor

SE - 5

44

Travel right sensor

SE - 9

45

Travel left sensor

SE - 10

46

Pump P1 sensor

SE - 22

47

Pump P2 sensor

SE - 23

48

P1 option sensor (2PB)

SE - 20

49

P2 option sensor (Hammer)

SE - 11

50

Fuel level sensor

SE - 15

51

Engine speed sensor

SE - 13

52

Resistor

E - 15

53

Blade selection relay

R - 40

54

Swing parking release switch

SW - 4

55

Swing parking brake solenoid valve

SV - 1

56

Two-speed select solenoid valve

SV - 3

57

Blade selection solenoid valve

SV - 17

58

P2 Unload proportional solenoid valve

PSV - B

59

Travel priority proportional solenoid valve

PSV - C

60

P1 Unload proportional solenoid valve

PSV - D

61

Arm two-speed inverse proportional solenoid valve

PSV - A

62

Pump P1 proportional solenoid valve

PSV - P1

63

Pump P2 proportional solenoid valve

PSV - P2

64

OPT. Relief adjustment proportional solenoid valve 1

PSV - E

65

OPT. Relief adjustment proportional solenoid valve 2

PSV - I

66

Boom/blade selection switch

SW - 80

67

Blade selection button

SW - 81

Copyright © New Holland

E135B

E135B

ELECTRICAL SYSTEM DIAGRAM (No. 2)



  

 











     



 



 



 





 







 

60

T2-3-17

Copyright © New Holland

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 3) Item

T2-3-18

Description

Code

33

Mechatro Controller

C-1

68

Air filter restriction switch

SW - 8

69

Water separator switch

SW - 36

70

Conflux/single select switch

SW - 15

71

Lever lock switch

SW - 11

72

Lever lock relay

R- 26

73

Operating lever lock solenoid valve

SV - 4

74

Heavy lift switch

SW - 35

76

Extra dis-press solenoid valve (opt.)

SV - 11

77

Extra dis-press sensor relay (opt.)

R - 17

78

Prevent spark relay

R - 31

79

Wiper motor relay

R - 29

80

Wiper motor reversing relay

R - 30

81

Window washer motor relay

R - 32

82

Wiper motor

M-3

83

Washer motor

M-4

84

Wiper interlock switch

SW - 19

85

Selector detect sensor (opt.)

SE - 29

86

Selector solenoid (opt.)

SV - 13

87

Air conditioner ampl.

C-4

88

Receiver drier

E - 10

89

Air compressor clutch

E - 11

90

Cigarette lighter

E - 14

91

Room light

L-5

92

Horn relay

R-5

93

Horn high

E-5

94

Horn low

E-6

95

Horn switch right (opt.)

SW - 5

96

Horn switch left

SW - 10

97

Extra pressure switch (opt.)

SW - 44

98

Extra dis-press sensor (opt.)

SE - 28

Copyright © New Holland

E135B

E135B

ELECTRICAL SYSTEM DIAGRAM (No. 3)

 







 

 

 



 

   









 







  



60

T2-3-19

Copyright © New Holland

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 4) Item

T2-3-20

Description

Code

33

Mechatro Controller

C-1

99

Revolution left nibbler relay - Extra (A) relay

R - 13 / R - 43

100

Revolution right nibbler relay - Extra (B) relay

R - 12 / R - 42

101

Diode

D - 16

102

Diode

D - 17

103

Diode

D - 10

104

Revolution right nibbler switch - Extra (B) switch

SW - 33

105

Revolution left nibbler switch - Extra (A) switch

SW - 34

106

Revolution right nibbler solenoid valve - Extra (B) solenoid

SV - 6

107

Revolution left nibbler solenoid valve - Extra (A) solenoid

SV - 7

108

Engine room light switch

SW - 16

109

Engine room light

L - 11

110

Fuel supply pump (automatic fuel stop)

M - 11

111

Auto grease motor opt.

M-8

112

Fleet link opt.

-

113

Antenna GPS

-

114

Antenna GSM

-

115

6P Connector

-

116

Cab working light relay 1 (opt.)

R-9

117

Cab working light relay 2 (opt.)

R - 11

118

Cab working light switch (opt.)

SW - 26

119

Cab working light front 1 (opt.)

L-7

120

Cab working light front 2 (opt.)

L-8

121

Cab working light front 3 (opt.)

L - 15

122

Cab working light front 4 (opt.)

L - 16

123

Cab working light back 1 (opt.)

L - 18

124

Cab working light back 2 (opt.)

L - 17

125

12 V Socket

E - 23

126

DC – DC Converter

E - 22

127

Radio

E-7

128

Antenna

-

129

Speaker left

E-8

130

Speaker right

E-9

131

Seat heater (opt.)

SW - 36

132

Over load alarm select switch (opt.)

SW - 12

133

Pressure sensor: boom head cylinder (for over load alarm) (opt.)

SE - 26

134

Drain pressure switch

SW - 96

135

Work light relay

R-6

136

Work light switch

SW - 55

137

Boom working light right

L-6

138

Boom working light left

L-1

139

Frame working light

L-2

140

Qiuck Coupler solenoid valve (opt.)

SV - 14

141

Qiuck Coupler switch (opt.)

SW - 64

142

Diode

D - 22

143

Diode

D - 23

Copyright © New Holland

E135B

E135B

ELECTRICAL SYSTEM DIAGRAM (No. 4)

















 

 

















 



 









  

 



 





 

  

60

T2-3-21

Copyright © New Holland

ELECTRICAL SYSTEM

Copyright © New Holland

E135B

ELECTRICAL SYSTEM

WIRING HARNESS CLUSTER GAUGE WIRING HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable are from “X” side SM0199 SM0251

T2-3-22

E135B

CLUSTER GAUGE WIRING HARNESS ASSEMBLY

SM0099

T2-3-23

Copyright © New Holland

ELECTRICAL SYSTEM

Copyright © New Holland

E135B

ELECTRICAL SYSTEM

PLATFORM WIRING HARNESS ASSEMBLY READING KEY

60

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable are from “X” side SM0199

T2-3-24

E135B

PLATFORM WIRING HARNESS ASSEMBLY

60

T2-3-25

Copyright © New Holland

ELECTRICAL SYSTEM

Copyright © New Holland

E135B

ELECTRICAL SYSTEM

UPPER FRAME WIRING HARNESS ASSEMBLY READING KEY

60

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable are from “X” side SM0199

T2-3-26

E135B

UPPER FRAME WIRING HARNESS ASSEMBLY

60

T2-3-27

Copyright © New Holland

ELECTRICAL SYSTEM

Copyright © New Holland

E135B

ELECTRICAL SYSTEM

ECU WIRING HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

60

- The connector view on the cable are from “X” side SM0199

T2-3-28

E135B

ECU WIRING HARNESS ASSEMBLY

60

T2-3-29

Copyright © New Holland

ELECTRICAL SYSTEM

NOTES:

T2-3-30

ELECTRICAL SYSTEM

Copyright © New Holland

E135B

Copyright © New Holland

COMPONENT OPERATION

Copyright © New Holland

Copyright © New Holland

COMPONENT OPERATION

E135B

SECTION AND GROUP CONTENTS Section 3

COMPONENT OPERATION

Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 Group 9

Hydraulic Pump Assy Pilot Valve Control Valve Swing Device Travel Device Swivel Joint Cylinders Air Conditioner system Blade control

Copyright © New Holland

Copyright © New Holland

SECTION 3

E135B

COMPONENT OPERATION

CONTENTS Group 1 - Hydraylic pump assy Outline .................................................... T3-1-1 General view and hydraulic ports ...... T3-1-1 Hydraulic circuit diagram .................. T3-1-2 Specifications .................................... T3-1-3 Hydraulic pump ...................................... T3-1-4 Operation .......................................... T3-1-7 Regulator ............................................... T3-1-9 Construction....................................... T3-1-9 Operation .......................................... T3-1-11 Adjusting the regulator ....................... T3-1-14 Causes of fault resulting from regulator ........................................ T3-1-15 Control curve of pump............................. T3-1-16

Group 2 - Pilot valve

Cartridge type solenoid proportional relief valve for N&B ..................................... T3-3-41 Installation.......................................... T3-3-41 Air breathing....................................... T3-3-42 Outside view ...................................... T3-3-43 Specifications..................................... T3-3-43 Construction....................................... T3-3-44

Group 4 - Swing device Outline .................................................... T3-4-1 General view ...................................... T3-4-1 Specifications..................................... T3-4-3 Construction ........................................... T3-4-4 Swing motor ....................................... T3-4-4 Anti-reaction valve ............................. T3-4-6 Swing reduction unit........................... T3-4-7

Pilot valve (ATT) ..................................... T3-2-1

Hydraulic motor ....................................... T3-4-8

Outline ............................................... T3-2-1

Valve casing section ............................... T3-4-9

Construction....................................... T3-2-2

Operation of anti-cavitation check plunger ........................................... T3-4-9

Operation ........................................... T3-2-3 Pilot valve (travel) ................................... T3-2-5 Outline ............................................... T3-2-5 Construction and operation................ T3-2-6

Group 3 - Control valve Control valve ........................................... T3-3-1 Control valve ports ............................. T3-3-3 Specifications .................................... T3-3-4 Construction and operation................ T3-3-5 Main relief valve (601) ....................... T3-3-12 Over load relief valve (602, 606)........ T3-3-13 Arm 2 spool (308) .............................. T3-3-14 Boom spool (301) .............................. T3-3-14 Lock valve selector (211) ................... T3-3-15 Bypass cut valve (605) ...................... T3-3-16 Swing shuttle valve cover (204) ......... T3-3-17 Hydraulic circuit diagram......................... T3-3-18 Operation ................................................ T3-3-19

Operation of relief valve ..................... T3-4-9 Brake section .......................................... T3-4-12 Swing reduction unit................................ T3-4-13

Group 5 - Travel device Outline .................................................... T3-5-1 Characteristics ................................... T3-5-1 General view ...................................... T3-5-2 Rotation direction ............................... T3-5-2 Hydraulic circuit.................................. T3-5-3 Construction ............................................ T3-5-4 Travel motor....................................... T3-5-4 Reduction unit .................................... T3-5-6 Operating description .............................. T3-5-7 Reduction gear................................... T3-5-7 Hydraulic drives....................................... T3-5-8 Function ............................................. T3-5-8

Copyright © New Holland

Group 6 - Swivel joint Outline..................................................... T3-6-1 Construction (Standard Version .............. T3-6-2 Construction (Version with blade) ........... T3-6-4 Operation ................................................ T3-6-5

Group 7 - Cylinders Outline..................................................... T3-7-1 Construction ............................................ T3-7-2 Boom cylinder ................................... T3-7-2 Arm cylinder ...................................... T3-7-3 Bucket cylinder .................................. T3-7-4 Positioning ........................................ T3-7-5 Blade cylinder .................................... T3-7-6 Operation ................................................ T3-7-7

Group 8 - Air conditioner system Basic system of air conditioner (HVAC air conditioner) ....................... T3-8-1 Air cycle ............................................. T3-8-1 Auto air conditioner system outline .... T3-8-2 Component and construction .................. T3-8-3 Function ............................................. T3-8-11 Disassembly and assembly..................... T3-8-17 Precautions to be exercised in operation ........................................ T3-8-17 Disassembly and assembly of unit..... T3-8-18 Charging refrigerant ................................ T3-8-22 Precautions to be exercised in operation ........................................ T3-8-22 Operating procedure .......................... T3-8-23 Electric circuit .......................................... T3-8-27 Wiring diagram and connectors ......... T3-8-27 Structure and operation of each functional parts and the inspection .... T3-8-29 Troubleshooting ...................................... T3-8-32 Self diagnosis function on display of panel .................................................. T3-8-39 Explanation of indication for failure .... T3-8-39 Explanation of monitor mode ............. T3-8-41

Group 9 - Blade control Outline..................................................... T3-9-1 Blade.................................................. T3-9-3 Blade control cylinders....................... T3-9-4 Swivel joint ......................................... T3-9-4 Blade control valve............................. T3-9-5 Blade switching hydraulic valve ......... T3-9-6 Gear pump for blade .......................... T3-9-7

Boom/Blade selection button ............. T3-9-9 Boom/Blade selection switch ............. T3-9-9 Boom/Blade selection relay................ T3-9-10

Copyright © New Holland HYDRAULIC PUMP ASSY

E135B

OUTLINE General view and hydraulic ports

PSV1 a5 Dr1 A3

A2

A1 B3 B1

PSV2

a4

3

4

4

a5

2

a4 PSV1 PSV2 a5

PSV1

PSV2

5

Dr1 B3

Dr1

6

B3

B1 a1

Dr3

Dr1

a2

A3 a3 B3

B1

Dr2

a3 (Dr1)

(PH1)

(PH2)

Dr3

Dr1

PH2

1 SM2801

1Main pump assy 2Regulator assy 3Regulator assy 4Solenoid proportional reducing valve (Q.ty 2) 5Gear pump assy (for pilot) 6PTO gear case A1 - Delivery port SAE 6000 psi 3/4'' A2 - Delivery port SAE 6000 psi 3/4'' B1 - Suction port SAE 2500 psi 2 1/2'' Dr1 - Drain port G 1/2-19 Dr2 - Drain port G 3/4-20 PSV1 - Servo assist port G 1/4-13

PSV2 - Servo assist port G 1/4-13 PH1 - Pressure sensor port G 3/8-17 PH2 - Pressure sensor port G 3/8-17 a1 - Gauge port G 1/4-15 a2 - Gauge port G 1/4-15 a3 - Gauge port G 1/4-14 a4 - Gauge port G 1/4-13 a5 - Gauge port G 1/4-13 A3 - Delivery port of gear pump G 1/2-19 B3 - Suction port of gear pump G 3/4-20.5 Dr3 - Drain port of gear pump G 3/8-15

T3-1-1

Copyright © New Holland E135B

HYDRAULIC PUMP ASSY

Hydraulic circuit diagram

4

PSV1

PH1 A1

a1

a2 A2 PH2

4

PSV2

a4

a5

3

2

B1 Dr1

A3

5

1 B3 Dr3

a3

Dr2

6

SM2802

123456-

Main pump assy Regulator assy Regulator assy Solenoid proportional reducing valve (Q.ty 2) Gear pump assy (for pilot) PTO gear case

T3-1-2

Copyright © New Holland HYDRAULIC PUMP ASSY

E135B

Specifications

Main pump

Gear pump for pilot

Pump

Item

K7V63DTP175R-OE13-VC

ZX10L7RZ2-07G

Type

Variable displacement plunger pump: regulator attached type

Fixed displacement type gear pump

65.2 x 2

10

2000

←

Max. displacement capacity

cm3

Revolution

rpm (Clockwise seen from shaft end)

Pressure

Rated Rated ATT boost

MPa (psi)

34.3 (4974)

5.0 (725)

-

Max. flow

L/min (gal/min)

130 (34) x 2 at 7.8 MPa (1131 psi)

20 (5.3)

Max. input Power (at 2000 rpm)

kW (PS)

64.9 (88.3)

3.1 (4.2)

Max. input torque (at 1600 rpm)

Nm (lbf•ft)

310 (229)

14.7 (10.8)

Model Regulator

Mass

KR76-OE13PV - KR76-OE13-V

Control function

Electric flow control, positive flow control

Others

With solenoid proportional reducing valve (KDRDE5K-31/30C50-123)

kg (lbs)

84 (185)

NOTE: the max. input power and the max. input torque of the main pump include those of the gear pump.

T3-1-3

Copyright © New Holland E135B

HYDRAULIC PUMP ASSY

HYDRAULIC PUMP MAIN PUMP (Three Bond No.1305N)

533 789 733 732 532 214 548 531 702 792 901 534 535 808 806 953

954 724 717 723 402 151 981

152 211 899 255 04

490 261 111

983

774 A

A

127 710 406 123 824 251 212 271 153 468 156 466 157 313 124 711 727 723

401, 402 406 466 467 468 490 531, 532 533 806 808

M16 M6 PF 1/4 PF 3/8 PF 1/2 NPTF1/16 M20X1.5 M30 M12 M16

116 312 886 314 401 467 141 732 05

Nm (lbf ft) 240 (177) 12 (8.9) 36 (27) 74 (55) 110 (81) 11 (6.5) 240 (177) 220 (162) 60 (44) 130 (96)

section A-A

111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 255 261 271 272

Drive shaft (F) Drive shaft (G) Gear #1 Roller bearing (Q.ty 2) Needle bearing (Q.ty 2) Bearing spacer (Q.ty 2) Cylinder block (Q.ty 2) Piston (Q.ty 18) Shoe (Q.ty 18) Retainer plate (Q.ty 2) Spherical bushing (Q.ty 2) Cylinder spring (Q.ty 12) Shoe plate (Q.ty 2) Swash plate (Q.ty 2) Tilting bushing (Q.ty 2) Swash plate support (Q.ty 2) Lock pin (Q.ty 2) Seal cover (F) Pump casing (F) Pump casing (R)

272 113

312 313 314 401 402 406 466 467 468 490 531 532 533 534 535 548 702 710 711 717

Valve block Valve plate (R) Valve plate (L) Socket bolt; M16X150 (Q.ty 2) Socket bolt; M16x190 (Q.ty 2) Socket bolt; M6X16 (Q.ty 4) VP plug; PF1/4 (Q.ty 2) VP plug; PF3/8 (Q.ty 2) VP plug; PF1/2 (Q.ty 4) VP plug; NPTF1/16 (Q.ty 9) Tilting pin; M20X1.5 (Q.ty 2) Servo piston M20×1.5 (Q.ty 2) Plug; M30 (Q.ty 2) Stopper (L) (Q.ty 2) Stopper (S) (Q.ty 2) Feed back pin (Q.ty 2) O-ring; 1B G30 (Q.ty 2) O-ring; 1B G95 O-ring; 1B G80 O-ring; 1B G125 (Q.ty 2)

SM2803

723 724 727 732 733 774 789 792 806 808 824 886 899 901 953 954 04 05

O-ring; 1B P11 (Q.ty 6) O-ring; 1B P8 (Q.ty 12) O-ring; 1B P18 (Q.ty 4) O-ring; 1B P14 (Q.ty 4) O-ring; 1B P28 (Q.ty 2) Oil seal Back up ring; P14 (Q.ty 2) Back up ring; G30 (Q.ty 2) Nut; M12 (Q.ty 2) Nut; M16 (Q.ty 2) Snap ring (Q.ty 2) Spring pin (Q.ty 4) C-ring (Q.ty 2) Eye bolt M10 (Q.ty 2) Socket screw; M12X23 (Q.ty 2) Set screw; M16 (Q.ty 2) Gear pump PTO unit

The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

T3-1-4

Copyright © New Holland HYDRAULIC PUMP ASSY

E135B

GEAR PUMP (FOR PILOT)

887 Section X-X

710

700

354

351

887

433

Z X

B3

X

434 X

311

A3

312

X

732

Dr3

435

361

353

850

a3

Dr3

Z

307

308

310

309

355 434

466 725

Section Z-Z

312 433, 434 435 466

M14x1,5

Nm (lbf ft) 29 (21)

M8

17 (13)

G 1/4

16 (11) SM2804

307 308 309 310 311 312 351 353 354 355 361 433 434 -

Poppet Seat Ring Spring Adjust screw Lock nut; M14×1.5 Gear case Drive gear Driven gear Filter Front case Flange socket; M8×40 (Q.ty 2) Flange socket; M8×55 (Q.ty 2)

435 466 700 710 725 732 850 887 a3 A3 B3 Dr3 -

T3-1-5

Flange socket; M8×20 (Q.ty 4) Vp plug; G1/4 Ring O-Ring O-Ring O-Ring Locking ring Pin; (Q.ty 2) Gauge port; G1/2 53 Nm (39.1 lbf•ft) Delivery port; G1/2 53 Nm (39.1 lbf•ft) Suction port; G3/4 74 Nm (54.6 lbf•ft) Drain port; G3/8 34 Nm (25.1 lbf•ft)

Copyright © New Holland E135B

HYDRAULIC PUMP ASSY

PTO GEAR CASE

468

125 711 118 11

262 728

117 414 126

825

128

710 435

10 12

886

826

SM0749

10 11 12 117 118 125 126 128 262 -

Idle shaft Gear case Pin 2nd gear 3rd gear Ball bearing (Q.ty 2) Roller bearing Bearing spacer (Q.ty 2) Cover

414 435 468 710 711 728 825 826 886 -

T3-1-6

Socket bolt; M10x20 (Q.ty 4) Flange socket; M10×20 (Q.ty 4) Vp plug: G3/4 O-Ring; 1B G80 O-Ring; 1B G85 O-Ring; 1B P24 Snap ring Snap ring Pin (Q.ty 2)

Copyright © New Holland HYDRAULIC PUMP ASSY

E135B

Operation The pump assy is equipped with two pumps arranged on the same axis that are connected with gear (116) and distribute the rotating power to the gear trains on a different axis. Thus the engine rotation is transmitted to front shaft (111) that drives the two pumps and, at the same time, drives the pilot gear pump arranged on another shaft. The pump assy consists largely of: - the rotary group, the main part of the pump that makes rotary on;

111

116

- the swash plate group that changes the delivery rate; - the valve block group that selects between oil suction and delivery; - the PTO group that transmits the drive power to the gear pump. SM0750

ROTARY GROUP The rotary group consists of shaft (111) (113), cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156), bearing space (127) and cylinder spring (157). The shaft is supported by bearings (123) and (124) at its both ends. The shoe, which is caulked to the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure. Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic balance.

The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder blocks (141) are also pressed against valve plates (314) by the action of cylinder spring (157).

111

312

313 124

116 141

314

124

157 153

156

151 211

152 SM0245

T3-1-7

Copyright © New Holland E135B

HYDRAULIC PUMP ASSY

SWASH PLATE GROUP The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), lock pin (256), C-ring (899), tilting bushing (214), tilting pin (531) and servo piston (532). The swash plate is the cylindrical part that is formed on the opposite side of the shoe sliding surface and is supported by the swash plate support. The hydraulic force controlled by the regulator flows into the hydraulic chamber that is provided on both sides of the servo piston. This moves the servo piston to the right and left. The result is that the swash plate swings on the swash plate support via the spherical part of the tilting pin and changes the tilting angle (a).

532 531 214

211 212

251 SM0246

VALVE BLOCK GROUP The valve block group consists of valve block (312), valve plates (313) (314) and spring pin (886). The valve plates having two crescent-shaped ports are installed to valve block (312) to feed oil and recycle it from cylinder block (141). The oil switched over by the valve plate is connected with the external pipe by way of the valve block.

313 312

111 886

116 141

314

PTO GROUP The PTO group is composed of 1st gear (116), 2nd gear (117) and 3rd gear (118). The 2nd and the 3rd gear are supported by bearings (125) and (126) respectively and installed to the valve block. Now, if the shaft is driven by the engine, the cylinder block rotates together by the spline linkage. If the swash plate is inclined, the pistons arranged in the cylinder block make reciprocating motion with respect to the cylinder while rotating with the cylinder block. If we keep an eye on a single piston, it makes a motion away from the valve plate (oil suction process) in the first 180° and a motion toward the valve plate (oil delivery process) in the remaining 180°. If the swash plate is not inclined (zero tilting angle), the piston does not stroke i.e. delivers no oil. The shaft rotation is taken up by the 1st gear (116) and transmitted to the 2nd gear (117) and the 3rd gear (118), in that order, to drive the gear pump that is linked to the 3rd gear. T3-1-8

SM2805

117

126

125

118

125

SM0248

Copyright © New Holland HYDRAULIC PUMP ASSY

E135B

REGULATOR Construction

496

O-RING

325

079 624

631

627

A

643 B

B

731 924 407 801

724

402 656 A

733

651

646

652

754

658

887

754

466 755 897

496

418

755

496

726

543

616

545

614

755 541

724

708

611 A-A

543

601

415

875

541

545 B-B

Nm (lbf ft)

12 (8.9)

402,407

M6

415

M8

29 (21)

418

M5

6.9 (5.1)

466

PF 1/4

16 (12)

496

NPTF1/16

8.8 (6.5)

614

M14˜1.5

27 (20)

801

M10

29 (21) SM2806

T3-1-9

Copyright © New Holland E135B

325 402 407 415 418 466 496 541 543 545 601 611 614 616 624 627 631 643 646 -

Valve casing Socket bolt; M6x16 (Q.ty 4) Socket bolt; M6x30 (Q.ty 4) Socket bolt; M8x40 (Q.ty 4) Socket bolt; M5x12 (Q.ty 2) Vp plug; PF1/4 Plug; NPTF1/16 (Q.ty 9) Seat (Q.ty 2) Stopper (Q.ty 2) Ball (Q.ty 2) Casing Feedback lever Fulcrum plug Prevention plug Spring seat Adjusting stem Sleeve Pilot piston Pilot spring

HYDRAULIC PUMP ASSY

651 652 656 658 708 724 726 731 733 754 755 801 875 887 897 924 079 -

Sleeve Spool Block cover Plug O-Ring O-Ring (Q.ty 5) O-Ring O-Ring O-Ring O-Ring (Q.tà 2) O-Ring (Q.tà 3) Nut; M10 Pin Pin Pin Set screw; M10x20 Solenoid proportional reducing valve

The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

T3-1-10

Copyright © New Holland HYDRAULIC PUMP ASSY

E135B

Operation CONTROL FUNCTION Electric flow control • Positive flow control SUMMARY The regulator KR76-OE13-V for the in-line type axial piston pump K7V series is composed of the control mechanism as mentioned below: Electric flow control and positive flow control The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control (positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to attain optimum power according to the operating condition. Also, since the pump delivers only the necessary oil flow, the machine does not consume excessive power.

POSITIVE FLOW CONTROL As shown in the figure on the right, the regulator regulates the delivery rate of the pump by command current I.

Q

I

T3-1-11

SM0250

Copyright © New Holland E135B

HYDRAULIC PUMP ASSY

FLOW RATE INCREASE As the command current I rises, the secondary pressure of solenoid proportional reducing valve (079) increases. This causes spool (652) to move via pilot piston (643) and stops where the hydraulic pressure pushing the spool rightwards balances with the action of pilot spring (646). If the spool (652) moves, port CL opens to the tank port. This causes the pressure of the large diameter part of servo piston (532) to go away. This causes the servo piston (532) to the left by delivery pressure P1 of the small diameter part, resulting in an increase in the tilting angle. Feedback lever (611) is linked with the servo piston and sleeve (651). As the servo piston moves to the left, the feedback lever rotates on point A which causes the sleeve to the right. As the servo piston moves to the right, the feedback lever rotates on point A to move the sleeve to the left. The result is that the opening of the spool sleeve begins to close gradually and the servo piston settles down when the opening of the spool sleeve closes completely.

FLOW RATE DECREASE As the command current I decreases, the secondary pressure of the solenoid proportional valve decreases. This causes the spool to move to the left. When the spool (652) has moved, delivery pressure P1 reaches port CL via spool and is admitted to the large diameter chamber of the servo piston. Delivery pressure P1 is admitted to the small diameter part of the servo piston at all times. The servo piston moves rightward by areal difference to decrease tilting angle. As the servo piston moves to the right, the feedback lever rotates on point A to move the sleeve to the left. The sleeve keeps moving till the opening of the spool sleeve closes and settles down when the spool sleeve closes completely.

T3-1-12

Copyright © New Holland HYDRAULIC PUMP ASSY

E135B

079

651 652 627 643

DELIVERY PRESSURE P1

801 924

808

646

954

611 953 P1 DELIVERY PRESSURE

806 532

TILTING MAX.

TILTING MIN. PSV

a

CL PORT

SM2807

T3-1-13

Copyright © New Holland E135B

HYDRAULIC PUMP ASSY

Adjusting the regulator The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at back-up control) control characteristics, flow control characteristics using the adjust screw.

Q

ADJUSTING THE MAXIMUM FLOW (See HYDRAULIC PUMP-construction) Adjust the maximum flow by loosening nut (808) and by tightening set screw (954) (or loosening it). Tightening set screw (954) decreases the delivery rate, as indicated. Only the maximum flow varies, but other control characteristics remain unchanged. Adjust screw No No. of turns for tightening Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min

I (Pi)

954

Q

1/4 No change 3.4

ADJUSTING THE MINIMUM FLOW (See HYDRAULIC PUMP-construction) Adjust the minimum flow by loosening nut (806) and by tightening socket screw (953) (or loosening it). Tightening socket screw increases the delivery rate, as indicated. Other control characteristics remain unchanged in the same way as maximum flow adjustment, care should be used of the fact that overtightening may increase a required power at the maximum delivery pressure (at relieving action). Adjust screw No

953

No. of turns for tightening

1/4

Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min

ADJUSTING THE FLOW CHARACTERISTICS (See REGULATOR-Construction)

SM0996

Q

No change 2.9

CONTROL

Adjust them by loosening nut (801) and socket bolt (924) (or loosening it). Socket bolt causes the control chart to move to the right as shown. Adjust screw No

I (Pi)

924

No. of turns for tightening

1/4

Increase Pilot pressure Pi MPa

0.16

Decrease in delivery flow L/min

10.1

T3-1-14

I (Pi)

SM0998

Copyright © New Holland HYDRAULIC PUMP ASSY

Causes of fault resulting from regulator When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter W2-2". WHEN THE ENGINE IS OVERLOADED Load every unit of pump, and check on pumps on the right and left sides for possible damages. When pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the one side is failed, start checking from para. 3). 1.

Check that the power shift command current I is normal.

2.

The power shift pressure is low. • Check the dither of amp. • Replace solenoid proportional valve.

reducing

3.

Spool (652) and sleeve (651) are stuck • Disassemble and clean it.

4.

Pilot piston (643) are stuck • Disassemble and clean it.

THE MAX. FLOW RATE IS NOT DELIVERED 1.

Check that secondary pressure of solenoid proportional reducing valve is normal.

2.

Pilot piston (643) are stuck • Disassemble and clean it.

3.

Spool (652) and sleeve (651) are stuck • Disassemble and clean it.

NOTE: when the damage of part is severe, replace the part with new one.

T3-1-15

E135B

Copyright © New Holland E135B

HYDRAULIC PUMP ASSY

CONTROL CURVE OF PUMP

250

200

150 Q [ L/min ]

Q 2000min-1 (H mode)

1800min-1 (S mode)

100 [3]

[2]

[1]

50 Q min. (2000min-1)

0

5

10

15

20

25

30

35

40 Pd [MPa] SM2808

Two pumps loaded: [1] 49 kW H mode at operating attachment [2] 64 kW H mode at traveling or optional working [3] 44 kW S mode at operating attachment

T3-1-16

Copyright © New Holland PILOT VALVE

E135B

PILOT VALVE (ATT) OUTLINE

5-PF3/8 T=49.0 (36.1)

Single operating angle Single operating angle (Port 2, 4) (Port 1, 3) The adjust nut (opposing flats : 22) : Fix adjust nut (opposing flats : 22) when the lever is installed by means of spanner or the like. Then tighten the mating lock nut to 41 + 3 N.m (302.2 lbf.ft).

PF1/4 T=29.4 (21.7)

VIEW A

T=Tightening torque : N.m (lbf.ft)

PV48K2004

Model

Refer to the curve below

Operating torque

6.9 MPa (1000 psi)

Max. primary pressure

5.0 MPa (725 psi)

Primary pressure

20 L/min (5.3gal/min)

Rated flow Weight

Approx. 1.9 kg (4.2 lbs)

A

PORT 1, 3

PORT 2, 4

3.0(2.2) SINGLE OPERATING TORQUE

2.21(1.63)

(290)2.0

2.0(1.5) SECONDARY PRESSURE

(145)1.0

1.0(0.74) 0.94(0.69)

(87)0.6

0

1.17 (0.86) 0.98 (0.72)

0 1.1 2 4 6 7 PUSH ROD STROKE (mm) 0

0

(464)3.2

(435)3.0

2.29(1.69)

2.0(1.5) SECONDARY PRESSURE

(145)1.0

1.0(0.74) 0.94(0.69)

(87)0.6

0

1.17 (0.86) 0.98 (0.72)

0

0 P

3.0(2.2)

SINGLE OPERATING TORQUE

(290)2.0

5 10 15 19 Operating angle (deg.)

1

4.0(3.0) Operation torque [N.m (lbf.ft)]

(464)3.2

(435)3.0

(580)4.0 Secondary pressure [MPa (psi)]

4.0(3.0) Operation torque [N.m (lbf.ft)]

Secondary pressure [MPa (psi)]

(580)4.0

1.1

2 4 6 8 PUSH ROD STROKE (mm) 5 10 15 20 Operating angle (deg.)

9.4

0

25

T

3 2

4

HYDRAULIC SYMBOL SM0591

T3-2-1

Copyright © New Holland E135B

PILOT VALVE

CONSTRUCTION

****312 302 501 ***301

*212 213 151

211

214

216- 2

216- 1

241- 2

241- 1

201- 2 201- 1

**217 101

221

PORT 2,4

PORT 1,3 SM0592

No.

Parts

101

Casing

151

Q.ty

Tightening torque Nm (lbf•ft)

No.

Parts

Q.ty

1

216-2

Spring seat

2

Plate

1

**217

Washer 2 (Shim)

4

201-1 Spool

2

221

Spring

4

201-2 Spool

2

241-1

Spring

2

211

Plug

4

241-2

Spring

2

*212

Push rod

4

***301 Joint: M14

213

Seal

4

214

O-ring: 1B P20

216-1 Spring seat

4 2

302

Circular plate

****312 Adjust nut: M14 501

Boots

Note: * apply grease on top section; ** secondary pressure adjusting shim *** apply grease on rotating and sliding sections. Be careful the assembling drirection **** apply Loctite #277

T3-2-2

1

Tightening torque Nm (lbf•ft)

47.1 (34.7)

1 1 1

68.6 (50.6)

Copyright © New Holland PILOT VALVE

E135B

OPERATION 1.

Lever in neutral (See Fig.SM0593) The action of spring (509) (for secondary pressure setting) that determines the output pressure of the pilot valve does not act upon spool (201). Therefore, spool (201) (for return) is pushed up by spring (221) [spring seat (216)]. The output ports (2, 4) connect with the T port. The result is that the output pressure is equal to the tank pressure.

216 509 221 201 PORT (2,4)

2.

When the pilot lever is tilted (See Fig.SM0594) When the lever is tilted and the push rod (511) strokes, the spool (201) [spring seat (216)] moves downward to make the port P to connect with the port 2, 4, with the result that the oil of the pilot pump flows to the port 2 ,4 to produce a pressure.

PORT (1,3)

SM0593

511

216

201 PORT (2,4)

PORT (1,3) SM0594

3.

Lever held (See Fig.SM0595) When the pressure at ports (2, 4) rises to a level equivalent to the action of spring (509) that is set by tilting the lever, the hydraulic pressure balances the spring action. When the pressure of ports (2, 4) rises above a set value, ports (2, 4) and the P port close while ports (2, 4) and the T port open. When the pressure at ports (2, 4) falls below a set value, ports (2, 4) and the P port open while ports (2, 4) and the T port close. Thus the secondary pressure is kept constant.

509

T PORT P PORT

PORT (2,4)

T3-2-3

PORT (1,3)

SM0595

Copyright © New Holland E135B

4.

PILOT VALVE

Operation in the area where the tilting angle of the lever is large. (varies with the model) If the lever is inclined beyond a certain angle on certain models, the top end of the spool contacts the bottom of the bore of the push rod. This keeps the output pressure connected with the P port pressure. Furthermore, on a model in which a spring seat and a spring are built in the push rod, the bottom of the bore of the push rod contacts the spring if the lever is turned beyond a certain angle. This causes the secondary pressure gradient to change by the spring action. Thereafter, the bottom of the bore of the push rod contacts the top end of the spring seat, keeping the output pressure connected with the P port.

T3-2-4

Copyright © New Holland PILOT VALVE

E135B

PILOT VALVE (TRAVEL) OUTLINE Outside view

Port size

Tightening torque Port name N.m (lbf.ft)

PF3/8

PF1/4

30 (22)

Function

1

LH travel forward port

2

LH travel reverse port

3

RH travel forward port

4

RH travel reverse port

T

Tank port

5

LH travel pressure sensor port

6

RH travel pressure sensor port

P

Pilot primary pressure port

16.7 (12.3)

SM0596

Specifications P

Type

6TH6NRZ

Primary pressure

4.9MPa (711psi)

Secondary pressure

0.54~2.35MPa (78~341 psi)

Rated flow

25 L/min (6.6 gal/min)

Weight

Approx. 8kg (18 lbs) 1

5

2 3 Hydraulic symbol

Performance characteristics Secondary pressure [MPa (psi)]

Secondary pressure

2.35 + 0.15 (340 + 22) 0.54 + 0.1 (78 + 15) 0 (4.7 + 0.5) 6.4 + 0.64 7.7 + 0.77 (5.7 + 0.6) 12.7 + 1.27 (9.4 + 0.9)

Operating torque

[N.m (lbf.ft)]

1 30' 2 30'

11 30' 12 30'

Pedal angle (degree)

Operating torque Control diagram

SM0598

T3-2-5

T

6

4 SM0597

Copyright © New Holland E135B

PILOT VALVE

CONSTRUCTION AND OPERATION The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve. The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is equipped with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6). Every pressure-reducing valve is made up of control spool (2), control spring (3), return spring (4) and plunger (5). The damper system is made up of plunger (8), orifice (9) and return spring (10). In stationary condition, the pedal is held in neutral position by return spring (10). In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for dumper system. The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the hydraulic oil trapped in the damper chamber is forced out. Consequently the return speed is controlled by the flow rate of hydraulic oil led through orifice (9).] Simultaneously, the plunger (5) is pushed against return spring (4) and control spring (3). The control spring (3) first moves the control spool (2) downwards, and then closes the passage between control port and the return pipe to tank port (T). At the same time, the control port is connected to passage (7). When the control spool reaches to the position the force of control spring (3) balances the pressure of control port (1 or 2), it starts retaining the condition. The pressure of control port is proportional to the stroke of plunger (5) and the position of pedal (1) according to the mutual relations between the control spool (2) and control spring (3). The closed circuit pressure control makes proportional control of selector valve and high responsibility of hydraulic pump and motor possible in relation with the characteristics of foot pedal (1) position and control spring (3)

1

5 3 8

3 11

10 12

4 10

2 9 9 7

6

2 control ports 1-3

control ports 2-4

P line T line

SM0599

T3-2-6

Copyright © New Holland CONTROL VALVE

E135B

CONTROL VALVE CONTROL VALVE OUTSIDE VIEW (1/2)

PAo PAa2

PBo

PBa2

Option

Arm 2 PLC2 PAc PBa1

Arm 1

Bucket (P3)

(P4)

PAb

PAs

Boom PBr

Swing

PCa

Travel right

P2 unload T3

PTb

PBL Travel left

Travel straight

PBo

PBa2

A

VIEW A

T2 CT1 PAL

PCb

PTb Travel straight PAr

PBL

CMR1

CMR2

P1 unload

Br

CP1

Ar

Travel right

PBr XAb

PBb PBs PAb PBc

Ab LCb (HEAD) CRb

XAb Boom

PAr

PBb

LCc

PAo PBa2

PBp1

Bb (ROD)

PAa1 PAc

(MU1) PAa2

PCb

PL

Ac (HEAD) LCAT2

Bc (ROD) LCAP2

PBc Bucket Arm 2

PAa2

PBp2

SM2809

T3-3-1

Copyright © New Holland E135B

CONTROL VALVE

CONTROL VALVE OUTSIDE VIEW (2/2)

PTb

PCa

PBL

(MU2)

P2 (P6)

(P5)

P1

PCb

T2

CT2

T1

PAL

PCb

PAL

PB1

PBs

Travel left

CP2 AL

Boom confluence Swing

DR

PAa1

PAo

PBL

BL

CCb

P2 unload

Bs

As

Option

LCa LCo

Ao

PBL

PBb PBs

PAs CRa

Aa (HEAD)

PAr

PCa

XAb

LCs

Pss Arm 1

PAL

PBc

PAa1

PBa1

Ba (ROD)

(MU1) PAa2

PAo

PBo

Bo

PBp1

PBp2

SM2810

T3-3-2

Copyright © New Holland CONTROL VALVE

E135B

CONTROL VALVE PORTS Port size

Tightening torque

Ports

PF3/4

150~180 N•m (111~133 lbf•ft)

(MU1), (MU2)

Pluged

(T3)

Pluged

PF1/2

PF3/8

98~120 N•m (72~89 lbf•ft)

69~78 N•m (51~58 lbf•ft)

Description

Ar

Right travel motor port (reverse)

Br

Right travel motor port (forward)

AL

Left travel motor port (reverse)

BL

Left travel motor port (forward)

As

Swing motor port (right)

Bs

Swing motor port (left)

Ab

Boom cylinder head side port (up)

Bb

Boom cylinder rod side port (down)

Aa

Arm cylinder head side port (in)

Ba

Arm cylinder rod side port (out)

Ac

Bucket cylinder head side port (digging)

Bc

Bucket cylinder rod side port (dump)

Ao

Optional pilot port

Bo

Optional pilot port

(P3)

Pluged

(P4)

Pluged

(P5)

Pluged

(P6)

Pluged

PAa1

Arm 1 (in) pilot port

PBa1

Arm 1 (out) pilot port

PAb

Boom (up) pilot port

PBb

Boom (down) pilot port

PAc

Bucket (digging) pilot port

PBc

Bucket (dump) pilot port

PAL

Travel left (reverse) pilot port

PBL

Travel left (forward) pilot port

PAr

Travel right (reverse) pilot port

PBr

Travel right (forward) pilot port

PAs

Swing (left) pilot port

PBs

Swing (right) pilot port

PAa2

Arm 2 (in) pilot port

PBa2

Arm 2 (out) pilot port

PAo

Option pilot port

PBo

Option pilot port

DR

Drain port

T3-3-3

Copyright © New Holland E135B

CONTROL VALVE

Port size

Tightening torque

Ports

PF1/4

34~39 N•m (25~29 lbf•ft)

Pss

M10

49~65 N•m (36~48 lbf•ft)

M12

83~110N•m (61~81 lbf•ft)

Description Swing pilot high pressure select port

PLc2

Lock valve select pilot port

PBp1

Bypass cut valve (P1 side) pilot port

PBp2

Bypass cut valve (P2 side) pilot port

(PL)

Attachment boost port

PB1

Boom (up) conflux pilot port

PTb

Travel straight pilot port

PCa

Unload valve (P2 side) pilot port

PCb

Unload valve (P1 side) pilot port

XAb

Lowering boom for emergency

P1

Pump port (P1 side)

P2

Pump port (P2 side)

T1

Tank port 1

T2

Tank port 2

SPECIFICATIONS Item Model

Specifications KMX13YD/B44006

Maximum flow rate [L/min (gal/min)]

130 (34)×2

Maximum set pressure [MPa (psi)]

37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)

Main relief valve set pressure [MPa (psi)]

Std 34.3 (4970) [at 30 ×2L/min (8×2gal/min)]

Overload relief valve set pressure (Boom head, Bucket head, Arm rod) [MPa (psi)]

37.8 (5760) [at 30L/min (8gal/min)]

T3-3-4

Copyright © New Holland CONTROL VALVE

E135B

CONSTRUCTION AND OPERATION Construction Control valve (1/6)

PAa2

PAo

PAo

PBp1 PBp2

275x4 213 274x4

(P4) (P3)

212

PBo

PBa2

273x10 273x10 A B 273x10 T2

J

J P1 unload (Travel straight)

PAL

PCb

273x10

Travel left

C

C PAr

PB1

PBb

PBs

PBc

PAa1

Travel right D

Boom conflux (P2 unload) D

XAb XAb

Boom E

Swing E

Pss

Bucket

Arm 1

F

F Arm 2

PAa2

PAo

MU1

G

PBp1

Option G

PBp2

H

H

B

A

T3-3-5

SM2811

Copyright © New Holland E135B

CONTROL VALVE

Control valve (2/6) K

155

(P5)

163

101 P2

T1 T2

CT2

K PAL

PBL

PB1

PCa

PBs

PAs

Pss PAa1

PBa1

PAo

PBc

PAp2

166

SECTION A-A

(P4)

161 161155 154

163164

567 155 163

(MU2)

(P6)

102

P1

973

973

CT1

PTb

POb

973

973 PBr

PAr

PAb

PBb

973

973 PAc

PBc

973

973 PBa2

PAa2

PBp1

973

SECTION B-B

(P3)

161

164 163 155 161

161 SM2812

T3-3-6

Copyright © New Holland CONTROL VALVE

E135B

Control valve (3/6) 202 333 331 336 328 325 331 601 261 309 159 166 157 161 161

P1 unload

201 333 331 339 327 325

Travel left

PCb

PAL

331 261 306

MR (PL)

AL

511 521

512 522

CP2

551 561

CMR2

556 561 561 556 522 512

BL

CMR1

307 261 331 325 326 336 331 333 202

264 PBL

205

SECTION C-C PTb

Travel straight

201 333 331 339 327 325 602 331 261 166 164 162

201 333 331 336 322 321

Travel right Boom conflux PB1

PAr

AbR

331 261 305 DR Ar

CCb

306 511 521

551 561 CP1

551 561 166 164 166 161

551 561

Br

310

T3

166 264 205

PBr

SECTION D-D

SM2813

511 521

PCa

P2 unload

T3-3-7

261 331 325 328 336 331 333 202

Copyright © New Holland E135B

CONTROL VALVE

Control valve (4/6)

203 333 331 339 320 319 379X3 211 331 216 L M

Swing PBs PBb

Pss

L M

261 266 160 301 561

204 333 331 336 322 321 266 331 261 166

Boom

XAb

303 CRb Ab

As

161

(HEAD)

556 524 514 551 561 521 511

511 524

LCb

LCs

556 561 Bb (ROD)

Bs

161

264 264

602 205

PAb

206

PAs

BbR

160 266 SECTION E-E 201 333 331 339 320 319 602 331 261

Bucket PBc

201 333 331 336 322 321

Arm 1 PAa1

BcR

602

AaR

331 261

161

304

Aa(HEAD)

Bc (ROD)

511 521 LCc

LCa

551 561

161 561 556

Ac (HEAD)

CRa Ba(ROD)

PLc2

264 602 205 SM2814

511 521 551 561

L PAc

PBa1

AcR

SECTION F-F

T3-3-8

L

524 514 156 167 160x2 302 264 211 205

Copyright © New Holland CONTROL VALVE

E135B

Control valve (5/6)

201 333 331 339 326 325 331 261 154 567

201 333 331 337

Option

Arm 2 PAa2

PAo

AoR MU1

161 308 162 515 521 551 561 561

330 329 604 331 261 311

Ao

511 521

LCAP2 LCo

551 LCAT2

561

551 521 511

Bo Ba(ROD)

162 162 162 PBa2

264

264 606

PBo

205

SECTION G-G

205 605

PaR

605 PBp1

PBp2

Bo

BoR

166

604

153

SECTION H-H

T3-3-9

SM2815

Copyright © New Holland E135B

CONTROL VALVE

Control valve (6/6)

T2

511 521

P1

T1

CT1

551 561 C

P2

(MU2)

CT2

511 521 551 561

E

SECTION M-M

162 SECTION J-J 278x5 160 266 207 267

267

528

527 T1

518

517

SECTION L-L

SECTION K-K SM2816

T3-3-10

Copyright © New Holland CONTROL VALVE

Tightening torque N•m (lbf•ft)

25~29 (18~21)

No.

Parts Name

Q.ty

Tightening torque N•m (lbf•ft)

E135B

No.

Parts Name

Q.ty

101 Casing A

1

320 Spring

2

102 Casing B

1

321 Spring

3 3

153 Plug

1

322 Spring

220~250 (162~184)

154 Plug PF3/4

2

325 Spring

6

110~130 (81~96)

155 Plug PF1/2

4

326 Spring

1

13~17 (9.6~13)

156 Plug PF1/8

1

20~24 (15~18)

157 Plug PF1/4

1

34~39 (25~29)

159 Plug PT1/4

1

7.8~9.8 (5.8~7.2)

160 Plug PT1/16

5

327 Spring

2

161 O-ring

13

328 Spring

3

162 O-ring

6

329 Spring

1

163 O-ring

4

330 Spring

1

164 O-ring

4

331 Spring seat

24

166 O-ring

7

333 Spacer bolt

12

167 O-ring

1

336 Stopper

6

168 O-ring

1

337 Stopper

1

201 Cover

6

339 Stopper

5

202 Cover

4

511 Poppet

11

203 Cover

1

9.8~14 (7.2~13)

16~18 (11.8~13.3) Loctite #262

204 Cover

1

205 Cover

7

512 Poppet

2

206 Cover

1

514 Poppet

2

207 Back pressure check valve cover

1

515 Poppet

1

211 Lock valve selector sub

2

517 Boost check valve

1

518 Poppet

1

212 Plate

1

521 Spring

11

213 Plate

1

522 Spring

2

215 Boom lowering valve

1

524 Spring

3

216 Piston

1

527 Spring

1

261 O-ring

12

264 O-ring

8

266 O-ring

4

528 Spring

1

267 O-ring

2

130~150 (96~111)

551 Plug

12

130~150 (96~111)

25~34 (18~25)

273 Socket bolt

40

556 Plug

5

98~120 (72~89)

274 Socket bolt

4

561 O-ring

17

98~120 (72~89

275 Socket bolt

4

567 O-ring

2

25~34 (18~25)

278 Socket bolt

5

9.8~14 (7.2~13)

279 Socket bolt

3

301 Boom spool sub

1

69~78 (51~58)

601 Main relief valve

1

302 Arm 1 spool

1

69~78 (51~58)

602 Over load relief valve

5

1

69~78 (51~58)

Plug assy for relief valve 604 hole

2

304 Bucket spool

1

98~120 (72~89)

605 By-pass cut valve

2

305 Boom conflux spool

1

306 Travel spool

2

69~78 (51~58)

606 Over load relief valve

1

307 Travel straight spool

1

140~180 (103~133)

973 Socket bolt

9

308 Arm 2 spool sub

1

309 P1 unload spool

1

303 Swing spool

310 P2 unload spool

1

311 Option spool

1

319 Spring

2

T3-3-11

Copyright © New Holland E135B

CONTROL VALVE

Main relief valve (601)

Main relief valve (Two step relief) Tightening torque N•m (lbf•ft)

No.

69~78 (51~58)

103

Plug; M27

1

562

Back up ring

1

121

C-ring

1

611

Poppet

1

122

Spacer

1

612

Spring seat

1

123

C-ring

1

621

Spring

1

124

Filter stopper

1

651

Adjust screw

1

125

Filter

1

661

O-ring

1

163

O-ring

1

671

Lock nut; M14

1

512

Plunger

1

521

Spring

1

541

Seat

1

561

O-ring

1

Parts

Q’ty

Tightening torque N•m (lbf•ft)

28~31 (21~23)

T3-3-12

No.

Parts

Q’ty

Copyright © New Holland CONTROL VALVE

E135B

Over load relief valve (602, 606)

521

564 563

301

511

124 123

522 161

611

561 562

125

101

621

671

102

541

162

661 612

651 SM0828

Over load relief valve Tightening torque N•m (lbf•ft)

No.

69~78 (51~58)

101

Body; M27

1

541

Seat

1

69~78 (51~58)

102

Plug; M27

1

561

O-ring

1

161

O-ring

1

562

Backup ring

1

162

O-ring

1

563

O-ring

1

123

C-ring

1

564

Backup ring

1

124

Filter stopper

1

611

Poppet

1

125

Filter

1

612

Spring seat

1

301

Piston

1

621

Spring

1

511

Plunger

1

651

Adjust screw

1

521

Spring

1

661

O-ring

1

522

Spring

1

671

Lock nut; M14

1

Parts

Q’ty

Tightening torque N•m (lbf•ft)

28~31 (21~23)

T3-3-13

No.

Parts

Q’ty

Copyright © New Holland E135B

CONTROL VALVE

Arm 2 spool (308)

350

371 361 340 317

317 340 361 371

308

351 SM2818

Arm 2 spool Tightening torque N•m (lbf•ft)

No.

Parts

Q’ty

Tightening torque N•m (lbf•ft)

No.

Parts

Q’ty

308

Spool

1

18~20 (13~15) Loctite #638

350

Plug

1

317

Plunger

1

18~20 (13~15) Loctite #638

351

Plug

1

340

Spring

2

361

O-ring

2

371

Backup ring

2

Boom spool (301)

301

317

340

361 371 350 SM2819

Boom spool Tightening torque N•m (lbf•ft)

No.

Parts

Q’ty

Tightening torque N•m (lbf•ft)

No.

18~20 (13~15) Loctite #638

350

Plug

1

Parts

Q’ty

301

Spool

1

317

Plunger

1

361

O-ring

1

340

Spring

1

371

Backup ring

1

T3-3-14

Copyright © New Holland CONTROL VALVE

E135B

Lock valve selector (211)

101 164

171

201

321

PLc

166

A

541

B

Dr

167

511

161 SM0831

Lock valve selector Tightening torque N•m (lbf•ft)

No.

Parts

Q’ty

Tightening torque N•m (lbf•ft)

No.

Parts

Q’ty

101

Casing

1

10~14 (7.4~10.3)

171

Socket bolt

3

161

O-ring

4

49~59 (36~44)

201

Plug

1

164

O-ring

1

321

Spring

1

166

O-ring

1

511

Spool

1

167

O-ring

1

541

Sleeve

1

T3-3-15

Copyright © New Holland E135B

CONTROL VALVE

Bypass cut valve (605)

302

301

402

401

Pi

P

T

Dr

201

202

101

102

SM0832

Bypass cut valve Tightening torque N•m (lbf•ft)

No.

98~120 (72~89)

101

Plug

1

301

Plunger

1

102

O-ring

1

302

Spring

1

201

Poppet

1

401

Plug

1

202

Spring

1

402

O-ring

1

Parts

Q’ty

Tightening torque N•m (lbf•ft)

69~78 (51~58)

T3-3-16

No.

Parts

Q’ty

Copyright © New Holland CONTROL VALVE

E135B

Swing shuttle valve cover (204)

PBs

555 A Pss

SECTION B-B

A 166

542

541

PBs

G1/4

G3/8

B

B Pss

554

202

PAs

SECTION A-A

SM0833

Swing shuttle valve cover Tightening torque N•m (lbf•ft)

No.

Parts

Q’ty

Tightening torque N•m (lbf•ft)

No.

Parts

Q’ty

166

O-ring

1

542

Seat

1

202

Cover

1

25~29 (18~21)

554

Plug

1

541

Steel ball

1

7.9~9.8 (5.9~7.2)

555

Plug

1

T3-3-17

Copyright © New Holland E135B

CONTROL VALVE

HYDRAULIC CIRCUIT DIAGRAM

1 2

12

3

10 11

9

4

8

5

6

7

SM2820

123456-

Travel straight P1 Unload Travel right Boom Bucket Arm 2

789101112-

T3-3-18

Option Arm 1 Swing P2 Unload Boom conflux Travel left

Copyright © New Holland CONTROL VALVE

E135B

OPERATION 1.

In neutral position The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system, because the by-pass cut valve (605) located on the downstream of center by-pass passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel straight spool (307), and then flows though the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut valve (605) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut valve (605) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass cut valve (605) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

52 (D)

605

517

307

T1 T1

P2

P1

605 55

309 (*) (D)

310

SM2821

In neutral position (*) Connected to low pressure circuit of P2 side casing

T3-3-19

Copyright © New Holland E135B

2.

CONTROL VALVE

Actuation in travel operation a) In travel independent operation On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot pressure enters ports PBr and PBL, and the right and left travel spools (306) moves leftward or rightward the force of springs (325) (327) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports PCb and PCa and switches unloading spools (309) (310). The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into main circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into B side of right travel motor through port Br. The hydraulic oil delivered by hydraulic pump P2 flows through between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through port BL similarly to the stream of hydraulic oil delivered by hydraulic pump P1. But in the meantime, the return oil from the A and B sides of left and right travel operations passes through between the perimeter of right and left travel spools (306) and casing through ports Ar and AL and flows into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PAr and PAL of control valve), the actuation is similar to that in forward travel operation. Left travel motor

B

A BL

AL CP2 327

306

325

PBL

PAL (D)

SM2822

In left forward travel (at PBL is pressurized)

T3-3-20

Copyright © New Holland CONTROL VALVE

E135B

b) In travel straight operation When actuator other than travel operation and the travel operation are operated simultaneously in the said item a) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel straight spool (307) moves upward. With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel simultaneous operation. (Travel straight function). At circuit (I) position, a part of hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel straight spool (307) and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch on travel straight spool (307) closes and the pump line on the travel sides is independent from pump line on actuator.

P2 CMR2

CMR2

P2

B

B

P1

CMR1

P1

CMR1

A

A

307

307

325

325

328

328

PTb

P2 P1

P2 P1

PTb Dr

Dr B

PTb Dr

Dr

A B

Circuit (I)

PTb

A

Circuit (II) A - to each actuator B - to travel right Movement of travel priority spool

T3-3-21

SM2823

Copyright © New Holland E135B

3.

CONTROL VALVE

Actuation in bucket operation a) In bucket digging operation On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward the force of springs (319) (320), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac). In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.

53

PBc

PAc

320 319 304

(D) Bc

511

LCc

(R) In bucket digging operation

T3-3-22

Ac

(H)

SM2824

Copyright © New Holland CONTROL VALVE

E135B

b) In bucket dumping operation On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves rightward the force of springs (319) (320), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder rod side (R) through port (Bc). In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of bucket spool (304) and casing and flows through low pressure circuit (D'), boost check valve (517) and returns to the hydraulic tank through tank port T1.

(D)

53

PAc

PBc

320 319 304 Ac

Bc 511 LCc

(R)

(H)

In bucket dumping operation

T3-3-23

SM2825

Copyright © New Holland E135B

4.

CONTROL VALVE

Boom a) In boom up operation On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward against the force of springs (319) (320), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port Pcb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and supplied to the both boom cylinders head side (H) through port (Ab). In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.

(R)

(R)

(H)

(H)

53 (D)

Bb

511 LCb

Ab CRb

514

A

301

319 320 PAb

PBb

SM2826

(A): BH chamber In boom up operation (Boom spool)

T3-3-24

Copyright © New Holland CONTROL VALVE

E135B

b) In boom up conflux operation When boom up operation is performed, the pilot pressure also enters port PB1, and boom conflux spool (305) is switched by pressure which counters against the force of springs (321) (322). Simultaneously, secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unload spool (310). The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic oil from the hydraulic pump P1 side.

PB1

322 321

305 511

CCb (B)

56 SM2827

(B): Conflux passage to Ab port of P1 casing

In boom up conflux operation (Boom conflux spool)

T3-3-25

Copyright © New Holland E135B

CONTROL VALVE

c) In boom down operation On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward against the force of springs (319) (320) and the secondary pressure of solenoid proportional valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is connected to the drain circuit. The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb). In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and passes through between the perimeter of boom spool (301) and casing, and flows through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)

(R)

(R)

(H)

(H) (A)

511 317

Bb 53

LCb

Ab CRb

514

301 319 320 PAb PBb

(D) (A): BH Chamber

In boom down operation

T3-3-26

SM2828

Copyright © New Holland CONTROL VALVE

5.

E135B

Arm operation a) In arm out operation On starting arm out operation, the pilot pressure enters port PBa1 and arm 1 spool (302) moves rightward against the force of springs (321) (322). Simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). And the pilot pressure also enters PBa2 and arm 2 spool (308) is switched against the force of springs (325) (326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unload spool (309). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R). In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm 1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage (HH) and then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308) and casing. The return oil in low pressure circuit (D') returns to hydraulic tank through tank port T1 passing through boost check valve (517).

(H)

Aa

(R)

511 LCa

CRa Ba

514

302

321 (AR)

322

211

P1

56

PAa1

PBa1

Arm 1 (D) (D)

Arm 2

HH

RH 52

RR

(D') (D)

PAa2 Dr PBa2 [XR]

PAa2 53

326

(F) Aa (HEAD) Ba (ROD)

53

(MU1)

LCAT2 LCAP2 P1 PBa2 Dr

(G)

325 308

515 LCAP2 LCAT2 511 (F): To arm 1 spool (G): To pilot cut valve In arm out operation

T3-3-27

SM2829

Copyright © New Holland E135B

CONTROL VALVE

b) In arm in operation (At light load: arm recirculation function) On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves rightward against the force of springs (321) (322). Simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, since the spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRa (514) is connected to the drain circuit and the retention of poppet (514) is released. And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves rightward against the force of springs (325) (326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAP2 (515) provided with orifice and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa). In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRa (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRa (514) and enters AR chamber. The return oil in AR chamber flows through between perimeter of arm 1 spool (302) and casing, and flows through low pressure circuit (D) and boost check valve (517). And finally, the oil returns to hydraulic oil tank through tank port T1. The return oil in AR chamber is led to arm 2 spool (308) through casing inside passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302). The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head side (H) again. (Arm recirculation function) And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and flows through boost check valve (517) through low pressure circuit (D) and returns to the hydraulic tank through tank port T1.

T3-3-28

Copyright © New Holland CONTROL VALVE

E135B

(H)

(R)

511

Aa

CRa LCa

514 Ba 302

321 322

(AR)

211

56

PAa1

PBa1 Arm 1 HH

(a)

RH

Arm 2

RR

(D)

52

PAa2 [XR]

PBa2 53 (MU1) 326

(D)

325

308 317

515 LCAP2 LCAT2

511

319

P1 (D')

LCAT2 LCAP2

(D)

Circuit (I)

P1 PBa2 Dr

Ba (ROD)

(F) Aa (HEAD)

(G) (F): To arm 1 spool (G): To pilot cut valve

In arm in operation (At light load: arm recirculation function)

T3-3-29

SM2830

Copyright © New Holland E135B

CONTROL VALVE

c) In arm in operation (In heavy load operation) The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in heavy load operation (work required large power); the function causes the power loss. This control valve selects the presence of recirculation function in light and heavy load operation with solenoid proportional valve [XR]. (Variable recirculation function) The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRa (514) and enters AR chamber. The return oil in AR chamber flows through between perimeter of arm 1 spool (302) and casing, and flows through low pressure circuit (D) and boost check valve (517). And finally, the oil returns to hydraulic oil tank through tank port T1. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure passage (D) at circuit (II), the return oil passes through between the perimeter of arm 2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through tank port T1. The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH), but flows through check valve (319) and passes through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through port T1.

(R)

(H)

Aa 511 LCa

CRa Ba 514

321 322

(AR)

Circuit (II) 302 211

P1

PAa1

PBa1 Arm 1

HH

Arm 2 PAa2

(a)

RH RR (D) 52 53

(MU1)

LCAP2

(D)

P1

PAa2 Dr

PBa2

[XR]

LCAT2

(D')

56

PBa2 Dr

Ba (ROD)

(D)

(F) Aa (HEAD)

(G)

326 325 308 317 515 LCAP2 LCAT2 511 319 (F): To arm 1 spool (G): To pilot cut valve

In arm in operation (In heavy load operation)

T3-3-30

SM2831

Copyright © New Holland CONTROL VALVE

6.

E135B

Swing operation On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss. The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs). In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

204

PAs

PBs

Pss

(D) 303 Bs

As

56

511

A

321

322

(D)

B

Swing motor SM2832

Swing operation

T3-3-31

Copyright © New Holland E135B

7.

CONTROL VALVE

Spool actuation for operation in option This spool is used to control the attachment in option like Nibbler (Crusher), etc. When the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports PAo, and option spool (311) moves against the force of springs (329) (330), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens load check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through U-shaped passage and is supplied to actuator for attachment through port (Ao). In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The operation where the pilot pressure acts on PBo port is the same as the above. * The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this oil passage is used as passage to connect to N&B selector valve.

(O) Ao

511

311

Bo

LCo

604 56 330

329

PAo PBo

(D) Spool actuation for operation in option

T3-3-32

SM2833

Copyright © New Holland CONTROL VALVE

8.

E135B

Lock valve operation The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure caused by each cylinder. a) At boom spool neutral position (Arm spool makes the same operation.) When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left side as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet, the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541) spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed the lower side as shown in the figure and restricts the leaking to the minimum.

2 (a) (b) 541 511

1 Ab

CRb

Sb PLc

Dr 321 PLc Sa Sb

RH A

514

Dr

SECTION A-A

A Sa

BH

319 320

PBb

(D) Dr 301

SM2834

1. Return oil from boom cylinder head 2. Lock valve selector

Lock valve operation (At boom spool neutral position)

T3-3-33

Copyright © New Holland E135B

CONTROL VALVE

b) In boom down operation (In arm in operation) Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511) moves rightward as shown in the figure. After the spool (511) was moved, orifice (a) of bushing (541) first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514). And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR through spring chamber (319). With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down as shown in the figure is released. And since lock valve poppet (514) receives holding pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed upward and is open. The said operation, in boom down operation, is performed before making the opening (meter out opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open, the operation has no effect on the operability of boom down operation. In case of arm in operation, the same operation is performed because pilot pressure PAa1 of arm in acts on lock valve selector port PLc2.

2 (a) (b)

541

1

Ab

511 CRb

Sb

PLc

Dr 321 PLc Sa Sb Dr

RH A

514

SECTION A-A

A Sa

BH

319 320

PBb

(D)

Dr

301

SM2835

1. Return oil from boom cylinder head 2. Lock valve selector

Lock valve selector operation (At boom down operation)

T3-3-34

Copyright © New Holland CONTROL VALVE

9.

E135B

By-pass cut valve This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and center by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil from each center by-pass passage to low pressure passage (D). a) In normal operation On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot ports PBp1 and PBp2 of by-pass cut valve (605). This secondary pressure is the same as that actting on pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310). The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2 side is the same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301) moves downward against the force of spring (302). The taper section at the top end of plunger (301) is seated on the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber (b) of plug (101). The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure as center by-pass passage (52) and poppet (201) is pushed the seat section of casing shutting off center by-pass passage (52) and low pressure passage (D). Consequently, in normal operation, center by-pass passage (52) is always disconnected from low pressure passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center by-pass passage (52), but returns to the hydraulic tank through P1 unloading spool (309).

[X1] PBp1

301

302

(C)

(b)

Dr

101

201

(a)

(D) 52

SM0969

By-pass cut valve (In normal operation)

T3-3-35

Copyright © New Holland E135B

CONTROL VALVE

b) At the time when failure occurred When the electric system is failed and consequently the secondary pressure of solenoid proportional valves [X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since the taper section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other. The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet (201) passes through from seat section of plug (101) to spring chamber (b) and flows into passage (Dr) through passage (c). Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet (201) receives the pressure of center by-pass passage (52) and is lifted up against the force of spring (202), and the hydraulic oil from center by-pass passage (52) flows into low pressure passage (D) through poppet (201) of by-pass cut valve (605). Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position and the passage to low pressure passage (D) is cut off, but because center by-pass passage (52) is connected to low pressure passage (D) through by-pass cut valve (605), the abnormal rise of the pump pressure is prevented.

PBp1

301

302

(C)

(b)

Dr

101

201

(a)

(D)

202

52

SM0970

By-pass cut valve (In condition of failure)

T3-3-36

Copyright © New Holland CONTROL VALVE

E135B

10. Boost check valve, By-pass check valve a) Boost check valve The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost pressure necessary for the low pressure passage. a. In normal operation The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure generated by spring (527) is used as the boost pressure for the low pressure passage.

528 527 T1 518 517 T2

(D) Boost check valve operation

T3-3-37

SM2836

Copyright © New Holland E135B

CONTROL VALVE

b) By-pass check valve Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected from possible damage. When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns to the hydraulic tank through tank port T2.

528 527 T1 518

517 T2

(D) By-pass check valve operation

T3-3-38

SM2837

Copyright © New Holland CONTROL VALVE

E135B

11. Emergency manual valve for leaving attachment Needle valve (Emergency manual valve for lowering attachment) is equipped internally between Ab port of boom cylinder head side and boom lock valve. For safety, this valve lowers risen attachment to the ground, if the machine stops with engine trouble. Only in case that the boom is lowering, the pressure in the cylinder of attachment can be released by operating arm or bucket control lever. a) Functional explanation In normal cases, the needle valve was blocked completely to prevent pressure leak of boom circuit. a. Lowering of boom Loosen lock nut at first and loosen the needle valve to the end of contact. IMPORTANT: needle valve is provided the mechanism of stopper against falling out. But the mechanism might cause break by undue force. The oil of boom cylinder (1) head side (H) flows into drain passage (4) through orifice, and boom lowers slowly. The time of boom lowering to the ground takes about 4 to 8 minutes in accordance with machine position and holding pressure b. Function of actuator Oil pressure of XAb port is reduced by releasing holding pressure of boom cylinder head side to drain passage (4) through orifice. Operation of actuator with pilot control valve is possible by leading medium pressure via orifice from XAb port to shuttle valve (7). In this function, this leading of medium pressure ensures primary pressure of remote control (source of pressure). This function ensures that the cylinder movement of boom, arm, bucket and others can be actuated only downward by self weight. Consequently the releasing of pressure becomes possible. But after attachment is lowered to the ground by lowering boom, holding pressure disappears, and remote control, via pilot valve, becomes impossible. c. Boom cylinder with holding valve If the boom cylinder has holding valve, loosen above-mentioned needle valve together with port relief valve of holding valve, and boom cylinder starts boom lowering. Spool of holding valve moves to open side by back pressure of port relief valve, and holding pressure of boom cylinder is led to “Emergency manual valve for lowering attachment”, operation of actuator by pilot valve is possibile.

T3-3-39

Copyright © New Holland E135B

CONTROL VALVE

Emergency manual valve for lowering attachment

(R)

1 (H)

2

Ab

3 4 6 5

XAb

7

8 9 SM0993

12345-

Boom cylinder head side Control valve Hydraulic oil tank Drain passage Needle valve

6789-

T3-3-40

Lock nut Shuttle valve To lever lock solenoid valve To control pilot valve

Copyright © New Holland CONTROL VALVE

E135B

CARTRIDGE TYPE SOLENOID PROPORTIONAL RELIEF VALVE FOR N&B INSTALLATION TOOLS

No.

PARTS

TOOLS

TIGHTENING TORQUE Nm (lbf•ft)

101

Body

36 mm Spanner and torque wrench

73.5±5 (54.2±3.7)

801

Proportional solenoid (coil fixing nut)

32 mm Spanner and torque wrench

15.7 (11.8)

PROCEDURE 1.

When attaching cartridge to control valve, if the cartridge can not be screwed in because connector of solenoid valve interferes with the surrounding parts, perform the procedure in the following items 2) ~ 4). If no interference and so on is found, only procedure in item 3) should be performed.

2.

Hold the hexagonal section (Opposing flats: 36mm) of body (101) and loosen coil fixing nut on the solenoid (801) upper part for the coil section to be rotated freely. CAUTION

Do not remove nut, but only loosen. 3.

Hold the hexagonal section (Opposing flats: 36mm) of body (101) and tighten it on the control valve. Tightening torque: 73.5 ± 5 Nm (54.2 ± 3.7 lbf•ft) CAUTION

Do not hold the parts other than body (101) for tightening. 4.

Fit connector of solenoid valve to the proper position and tighten coil fixing nut. Tightening torque: 15.7 Nm (11.8 lbf•ft)

COIL FIXING NUT

BODY (101)

T3-3-41

SM2838

Copyright © New Holland E135B

CONTROL VALVE

AIR BREATHING TOOLS

No.

PARTS

TOOLS

TIGHTENING TORQUE Nm (lbf•ft)

801

Proportional solenoid (air breathing plug)

17 mm Spanner and torque wrench

23 (17)

PROCEDURE 1.

Perform the operation in items 2) and 3) under the condition where oil is flowing into control valve and consequently back pressure (R port pressure) is produced.

2.

Loosen air breathing plug of solenoid valve until the hydraulic oil starts flowing out. Air is flown out with hydraulic oil. CAUTION

Be careful not to mistake it for pressure adjusting screw fixing nut. 3.

After hydraulic oil left flowing out for a while, tighten air breathing plug. Tightening torque: 23 Nm (17 lbf•ft)

PRESSURE ADJUSTING SCREW FIXING NUT AIR BREATHING PLUG O-RING OIL FLOWS OUT

SOLENOID TUBE

SM2839

T3-3-42

Copyright © New Holland CONTROL VALVE

E135B

OUTSIDE VIEW

M27x1.5

Air breathing plug Width across flats 17 (1/2-20UNF-2B) Tightening torque: 23 Nm (17.6 lbf.ft)

Manual screw seal nut Width across flats 12 (M6x1.0) Tightening torque: 7.35 0.5 Nm (5.42 0.37 lbf.ft) Nut Width across flats 32 (M22x1.5) Tightening torque: 15.7 Nm (11.6 lbf.ft)

Width across flats 36 (M27x1.5) Tightening torque: 73.5 5 Nm (54.2 3.7 lbf.ft)

Width across flats 36

Use this across flats for attaching this valve to the casing

TYPE OF CONNECTOR EQUIVALENT TO AMP ECONOSEAL J SERIES CONNECTORS MARK (+) CAP HOUSING CAP HOUSING 174354-2 TERMINAL 173706-1

HYDRAULIC SYMBOL

SM2840

SPECIFICATIONS Working pressure range (Pressure in port P)

MPa (psi)

15~40 (2180~5800)

Max. working pressure (Pressure in port T)

MPa (psi)

1.0 (145)

L/min (gal/min)

300 (79.3)

Max. flow Electrical specifications

Rated current

mA e

Coil resistance

T3-3-43

700 19.5 (at 20° C)

Copyright © New Holland E135B

CONTROL VALVE

CONSTRUCTION

Across flats for tightening solenoid tube assy

801

402 701 403 202 401 204

304 305 102

303

301

M22 X 1.5 1/2-20

M6 X 1.0

201

208 101 203 205 206 207 501 302 601 SM2841

No.

801

Tightening torque Nm (lbf•ft)

TIGHTENING TORQUE Nm (lbf•ft)

REMARKS

M16X1

44 (32.5)

SOLENOID TUBE ASSY

M22X1.5

15.7 (11.6)

COIL LOCK NUT

SIZE

1/2-20

23 (17)

AIR VENT PLUG

M6X1

7.35±0.5 (5.42±0.37)

MANUAL SCREW SEAL NUT

No.

Name

Q.ty

73.5±5 (54.2±3.7)

101

Body; M27x1.5

1

102

O-ring

110 (81.1)

201

Plug; M30x1.5

Tightening torque Nm (lbf•ft)

No.

Name

Q.ty

302

O-ring

1

1

303

Backup ring

1

1

304

Spring

1

202

O-ring

1

305

Spring

1

203

O-ring

1

401

Poppet

1

204

Backup ring

1

402

Spring

1

205

Filter

1

403

Spring

1

206

Filter stopper

1

501

Sheet

1

207

C-ring

1

601

Sheet

1

208

Sheet

1

701

O-ring

1

301

Plunger

1

801

Solenoid

1

T3-3-44

Copyright © New Holland SWING DEVICE

E135B

OUTLINE General view

L, IP

THREAD FOR EYE BOLT 2-M10 DEPTH 18

PB

DP

B

GN RELIEF VALVE (B PORT SIDE)

AN

DB RELIEF VALVE (A PORT SIDE)

A

PG PA

C SM2841

Symbol

Port name

Port size

Tightening torque Nm (lbf•ft)

A, B

Main port

PF 3/4

108 (123)

DB

Drain port

PF 3/8

74 (55)

Make-up port

PF 3/4

167 (123)

Pressure measuring port

PF 1/4

36 (27)

Parking brake release port

PF 1/4

36 (27)

L

Gear oil level gauge

PT 3/4

98 (72)

IP

Gear oil filling port

PT 3/4

98 (72)

DP

Outlet port of gear oil

PT 1/2

65 (48)

DP2

Outlet port of gear oil

PF 1/2

108 (80)

AN

Air vent port

PT 1/4

-

GN

Inlet port of grease

PT 1/4

-

C PA, PB PG

T3-4-1

Copyright © New Holland E135B

SWING DEVICE

A,(B)

C

DB

PG ANTI-REACTION VALVE BLOCK

DP2

IP

DP AN

GN

SM2842

PG DB

C

PA

PB

A

B

Hydraulic diagram

T3-4-2

SM2843

Copyright © New Holland SWING DEVICE

E135B

Hydraulic motor

Specification

Antireaction valve block

Model

M2X63CHB–13A–36/285–60

Type

Swash-plate type, fixed-displacement plunger motor

Displacement

cm3 (in3)

60 (3.66)

Working pressure

MPa (psi)

28.0 (4060)

Max. flow

L/min (gal/min)

132 (35)

Braking torque

Nm (lbf•ft)

314 (232)

Release pressure

MPa (psi)

2.3~4.9 (334~711)

Relief set pressure

MPa (psi)

28.0 (4060) at 110 L/min (29 gal/min)

Mass

kg (lbs)

Type Mass

Hydraulic motor assy mass

2KAR6P72/240-716 kg (lbs)

5 (11)

kg (lbs)

34 (75)

Model

RG06D19J2

Reduction unit

Speed reduction type

Total mass

Planetary 2-stage

Reduction ratio

19.2

Lubicate oil Lubicate oil volume

29 (64)

Gear oil SAE90 (API class GL–4 grade) L (gal)

Grease

1.65 (0.44) Extreme pressure lithium base # 2 grease

Grease volume

cm3 (in3)

Mass

kg (lbs)

79 (174)

kg (lbs)

113 (249)

T3-4-3

500 (30.5)

Copyright © New Holland E135B

SWING DEVICE

CONSTRUCTION Swing motor

992

303 451 131

444

351 355

A-A 051

401 488 469

051-1 468 106 487 444 433 981 390 391 438 980

303

472

451

707

712 131

706 A

A

982

702

114

111

117

743

121

742

113 123

116 117 432 471 443 106 101

491 304 437 124 122

301 SM2844

T3-4-4

Copyright © New Holland SWING DEVICE

Tightening

torque Nm (lbf•ft) 177 (131)

E135B

Tightening

No.

051

Parts

Relief valve; M33-P1.5

051-1 O-ring; 1B G30

Q.ty

2

torque Nm (lbf•ft) 240 (177)

No.

Parts

Q.ty

401

Socket bolt; M16×75

4

2

432

Snap ring

2

101

Drive shaft

1

433

Ring

1

106

Spacer

3

437

Snap ring

1

438

Snap ring

1

1

443

Roller bearing

1

111

Cylinder

1

444

Roller bearing

1

113

Retainer (spherical bushings)

1

451

Pin

2

114

Cylinder spring

1

36 (27)

468

Plug; PF1/4

2

116

Push rod

12

108 (80)

469

ROMH plug; M22-P1.5

2

117

Spacer

2

471

O-ring; 1B G80

1

121

Piston

9

472

O-ring; W1516,WG34

1

122

Shoe

9

487

O-ring; 1B P11

2

123

Set plate

1

488

O-ring; 1B P28

2

124

Shoe plate

1

491

Oil seal

1

131

Valve plate

1

702

Brake piston

1

706

O-ring; W1516,WG31

1

707

O-ring; W1516,WG36

1

712

Brake spring

20

301

Casing

1

742

Friction plate

3

303

Valve casing

1

743

Separator plate

4

304

Front cover

1

1.7 (1.2)

980

Plug; PF3/8

1

351

Plunger

2

4.4 (3.3)

981

Plug; PF3/4

1

0.9 (0.6)

982

Plug; PF1/4

1

98 (72)

992

Plug; PT3/4

1

355

Spring

2

390

Name plate

1

391

Rivet

2

T3-4-5

Copyright © New Holland E135B

SWING DEVICE

Anti-reaction valve

901 902

171

B1

B

A1

A

B

A

C

C

101

A,B

A1,B1 401

403

404

151

904

903

C-C

Tightening torque Nm (lbf•ft)

No.

Parts

Q.ty

101

Body

9 (6.6)

151

29 (21) 69 (51)

SM2845

Tightening torque Nm (lbf•ft)

No.

Parts

Q.ty

1

404

Backup ring

2

Plug

4

901

Name plate

1

171

Socket bolt; M8x60

6

902

Pin

2

401

Swing reactionless valve; M22

2

903

Plug; PF1/2

2

403

O-ring; 1B P20

2

904

O-ring

2

T3-4-6

2.7 (2)

Copyright © New Holland SWING DEVICE

E135B

Swing reduction unit 602

230 231 204 286 211 912 285 287 911 283 403

922

603 210

921 202

282

*

203

913 285

* 402 910 801 925 920 926 102 401 915 201 SM2846

Tightening

torque Nm (lbf•ft)

Tightening

No.

Parts

Q.ty

torque Nm (lbf•ft)

No.

Parts

Q.ty

102

Casing

1

402

Roller bearing

1

201

Drive shaft

1

403

Needle bearing

3

202

Ring gear

1

98 (72)

602

Capscrew; M12x100

8

203

No.2 planetary gear

4

98 (72)

603

Capscrew; M12x135

2

204

No.2 sun gear

1

801

Oil seal

1

210

No.1 planetary gear

3

910

Spring pin

4

211

No.1 sun gear

1

911

Snap ring

3

230

No.2 spider

1

912

Snap ring

1

231

No.1 spider

1

913

Snap ring

1

282

No.2 pin

4

915

Seal

1

283

No.1 pin

3

65 (48)

920

Adapter; PT1/2

1

285

Side plate t=1

7

108 (80)

921

Hose; PF1/2

1

286

Thrust washer t=2

1

108 (80)

922

Plug; PF1/2

1

287

Side plate t=2

3

22 (16)

925

Relief fitting; PT1/4

1

401

Roller bearing

1

22 (16)

926

Grease nipple; PT1/4

1

Coat the part marked * with Three Bond #1217.

T3-4-7

Copyright © New Holland E135B

SWING DEVICE

HYDRAULIC MOTOR Operation If the high pressure oil flows into the cylinder through the inlet port (a) of valve plate (131), as shown on the figure on the right, the hydraulic pressure acts upon piston (121) and creates force F in the axial direction. The force F may be divided into force F1 vertical to shoe plate (124) via shoe (122) and force F2 at right angles with the shaft. The force F2 is transmitted to cylinder block (111) via pistons (121) and causes drive shaft to turn so as to produce a rotating moment. The cylinder block (111) has nine pistons equally arranged. Rotating torque is transmitted to drive shaft by turns by pistons connected to inlet port of high pressure oil. If the oil supply and discharge directions are reversed, the drive shaft rotates in the opposite direction. Theoretical output torque T can be given by the following equation.

T=

Cylinder block (111)

F2 F1 F

Drive shaft (101)

Shoe plate (124)

Shoe (122)

Valve plate (131)

Piston (121)

SM0575

PXq 2X

Low pressure oil

p: Effective differential pressure MPa q: Displacement per revolution cc/rev

OUTLET

High pressure oil

INLET

(a)

SM0576

T3-4-8

Copyright © New Holland SWING DEVICE

E135B

VALVE CASING SECTION Operation of anti-cavitation check plunger Since the system using this type of motor is not equipped with a valve having a counterbalance function, the motor is rotated beyond the oil feed rate in some cases. The system has check plunger (351) and sucks in deficient oil, in order to prevent cavitation from occurring due to oil deficiency.

351

M port

Operation of relief valve 1.

(Make-up port)

Consider where the relief valve is pressurized. The pressure at the P, R ports is equal to the tank pressure at the beginning, as shown in Fig. SM0578. The relief valve begins to operates when the hydraulic pressure that is determined by the product of the pressure-receiving area A1 of plunger (301) and the pressure P balances the hydraulic pressure that is determined by the product of the pressure-receiving area A2 of the plunger (301) and the pressure Pg of chamber g. Thereafter, the pressure of chamber g rises and the piston 1 (302) begins to stroke. The load to spring (321) increases by this movement of the piston. As the result, the relief pressure P is raised and controlled in the pressure boost time t1 from P1 till Ps. This process is explained in the following in the relationships between the movements of the components and the relief pressure: a) Condition shown in Fig.SM0579. If the P port of the relief valve is pressurized, pressure is built up in chamber g via the restrictor m of plunger (301). The hydraulic pressure acting on plunger (301) increases and when it balances the load Fsp of spring (321), the relief valve performs relieving action by the pressure P1. This relationship is expressed as: P1×A1=Fsp1+Pg1×A2 where Fsp1: primary set load value of spring (321).

T3-4-9

DIRECTIONAL VALVE SM0577

Chamber h Orifice m

Spring (321)

Piston 1 (302)

P

Pressure receiving area A1

R Plunger (301)

Chamber g A3 A2 A4 Orifice n SM0578

Orifice m

Spring (321)

Chamber h Pin (303) Piston 1 (302)

P R Plunger (301)

Orifice n

Chamber g SM0579

Copyright © New Holland E135B

SWING DEVICE

b) Condition shown in Fig.SM0580. The pressure of chamber g acts upon the pressure-receiving area A3-A4 of piston 1 (302). When the hydraulic pressure rises above the load of spring (321), the piston 1 begins to move to the left. On that occasion, since the machine turns to the left while discharging the oil of chamber h arranged between piston 1 and adjust plug (401) into chamber g via orifice n provided in piston 1 (302), chamber h serves as a dumping chamber. The load of the spring increases slowly till piston 1 reaches the end of the adjust plug. The relief pressure P rises smoothly.

Orifice m

Chamber h Pin (303) Piston 1 (302)

P R Plunger (301)

Orifice n

Chamber g SM0580

Orifice m

c) Condition shown in Fig.SM0581 The machine does not travel to the left further when piston 1 (302) arrives at the end of adjust plug (401). Therefore, the relief valve keeps its normal relieving action whereby the relief pressure is held at P2. In the processes a. to c. above, the relief pressure changes as shown in Fig.SM0582.

Spring (321)

Spring (321)

Pin (303)

Piston 1 (302)

P R Plunger (301)

Orifice n

Chamber g SM0581

2.

Function when the relief valve pressure is reduced. Let us consider the pressure of the P port is reduced. When the pressure at port P is reduced to zero, the pressure of chamber g falls to the tank pressure level. The result is that the plunger (301) which is now open moves to the left and is seated on seat (341). At the same time, the piston 1 (302) moves to the right by the action of spring (321) and returns to the condition of Fig.SM0580. SM0582

T3-4-10

Copyright © New Holland SWING DEVICE

3.

E135B

Operation of anti-reaction valve a) Neutral condition Fig.SM0583 illustrates the relationship between the neutral condition of the antireaction valve and the hydraulic circuits. Now, let us consider a braking condition in which brake pressure generates on the AM port side. b) When brake pressure occurs: If pressure (P) generates at the AM port, it passes through the passage L, the hole on the shaft of seat (313) and the passage m of plunger (311) and is led to the n chamber. When the pressure P rises above a value (Ps) set by spring (321), plunger (311) compresses spring (321) and shifts it to the left. Seat (313) compresses weak spring (322) as pushed by plunger (311) and moves to the left. c) At anti-reaction action When inertia load stops moving (point Y Fig. SM0587), brake pressure (P) tries to fall. When P The evaporator sensor is in disconnection condition. SM0066

3. Example 3

SM0067

4.

When the segment exclusively used for monitor indicates 2 (displays the solar radiation sensor condition), since the segment indicates FF,the sensor is in short-circuiting condition according to the list of 3 segments. -->The solar radiation sensor is in short-circuiting condition.

List of 3 segments SECOND SEGMENT INNER AIR SENSOR DISCONNECTION EVAPORATOR SENSOR DISCONNECTION

THIRD SEGMENT

SOLAR RADIATION SENSOR SHORT-CIRCUITING

EACH SENSOR IS NORMAL

SOLAR RADIATION SENSOR 5V SIDE SHORT-CIRCUITING

INNER AIR SENSOR SHORT-CIRCUITING EVAPORATOR SENSOR SHORT-CIRCUITING SM0068

T3-8-42

Copyright © New Holland BLADE CONTROL

E135B

OUTLINE General view of the blade control components

4 6

3 1

5

2

SM3154

1 - Blade 2 - Blade control cylinders 3 - Swivel joint

4 - Blade control valve 5 - Blade switching hydraulic valve 6 - Gear pump

T3-9-1

Copyright © New Holland E135B

BLADE CONTROL

7

8 9

SM3155

7 - Boom/blade selection button 8 - Boom/blade selection switch 9 - Boom/blade selection relay

T3-9-2

Copyright © New Holland BLADE CONTROL

E135B

BLADE The blade is composed of a welded frame on which a plate is attached and on this a cutting edge is welded. The frame is pivoting on the lower frame of the undercarriage through two pins. The blade is controlled by the action of two cylinders hinged to the blade frame and the lower frame through four pins. The cylinders control the blade moving upward 500 mm (19.7 in) and downward 587 mm (23.1 in) with respect to the ground. Two guards are installed on the cylinders.

110 (4.3)

Unit: mm (in)

L 2490 (98.0)

690 (27.2)

2590 (101.9)

Ø60 (2.3)

3

2790 (109.8)

110 (4.3)

L

2690 (105.9)

1

4

56

.4

°

480 (18.9)

572 (22.5) 500 (19.7)

29.8 9.1°

769 (30.3)

R8 (34 81 .7)

587 (23.1)

°

2

6 71 R1 7.5) 6 (

1664 (65.5) 2433 (95.8)

SM3156

1 - Blade frame 2 - Blade

3 - Cutting edge 4 - Pivot pins

T3-9-3

Copyright © New Holland E135B

BLADE CONTROL

BLADE CONTROL CYLINDERS The blade control cylinders are installed between the lower frame and the blade. For the features of the blade control cylinders, please refer to Group 7 "Cylinders”.

SM3157

SWIVEL JOINT The swivel joint in blade version differs from the swivel joint of standard version only because it has two additional connections (F, G) for the blade control. For the features of swivel joint in blade version, please refer to group 6 "Swivel joint”.

D C

B G

A

F

SM3158

T3-9-4

Copyright © New Holland BLADE CONTROL

E135B

BLADE CONTROL VALVE The blade control valve is installed on the main control valve and it is made of a spool with a pressure relief valve and two safety valves. Pressure relief valve (V1) is set at 20.6 MPa (at 50 L/min) (2987 psi at 13.2 gal/min) whereas the safety valves (overload) (V2) are set at 27.5 MPa (at 30 L/min) (3987.5 psi at 8 gal/min). Pa1

Pa1

V2

(G) (G) A

A

P

P

B

B

V2

V1 Pb1

Pb1

SM3159

Hydraulic diagram

B1 A1

V2

Pa1 Pb1

V1

(G) P

V1 - Pressure relief valve V2 - Safety valve (overload)

T3-9-5

SM3160

Copyright © New Holland E135B

BLADE CONTROL

BLADE SWITCHING HYDRAULIC VALVE The blade switching valve is installed on the upper frame near the solenoid valve block and the sensor block. It is composed of blade selection solenoid valve (SV-17) directly installed on a one-spool two-way switching hydraulic valve. The boom/blade selection solenoid valve switches the secondary piloting pressure flowing from the right pilot valve to the main control valve controlling the boom lifting spool (under rest conditions; i.e. with solenoid valve SV-17 not energised) or the blade control valve (under work conditions; i.e. with solenoid valve SV-17 energised).

A2

Ev

A1

A

Z

B2

B1

VIEW A

PP

T P2

P1

Z

B2

B1

T PP

SECTION Z-Z

T A2 B2 A1 B1

Ev

PP P2

P1

Vc SM3161

VC - Blade switching hydraulic valve EV - Blade selection solenoid valve (SV-17)

T3-9-6

Copyright © New Holland BLADE CONTROL

E135B

GEAR PUMP FOR BLADE The gear pump for the blade control circuit is installed on the PTO group. General view and hydraulic ports 2

B4, A4

1

SM3162

1 - Main pump assy 2 - Gear pump assy for blade A4 - Delivery port G35 B4 - Suction port G40

Specifications Pump

SGP2A27F1H1-R533

Type

Fixed displacement type gear pump

Max. displacement capacity

cm3

27.4

rpm Rated revolution

Working pressure Max. flow Mass

(clockwise seen from shaft end)

2000

MPa (psi)

20.6 (2987)

L/min (gal/min)

55 (14.5)

kg (lb)

5.4 (11.9)

T3-9-7

Copyright © New Holland E135B

BLADE CONTROL

Construction

65

70

1

2

5

6

3

57

52

50-51

4

56

55 SM3163

1 - Front cover 2 - Body 3 - Drive gear 4 - Driven gear 5 - Side plate (Q.ty 2) 6 - Rear cover 50 - Back-up strip (Q.ty 2)

52 - Gasket (Q.ty 2) 51 - Gasket (Q.ty 2) 55 - Socket bolt M12 (Q.ty 4) 56 - Washer (Q.ty 4) 57 - Bushing (Q.ty 4) 65 - Oil seal 70 - Retainer ring

T3-9-8

Copyright © New Holland BLADE CONTROL

E135B

BOOM/BLADE SELECTION BUTTON The boom/blade selection button (1) located on the back of the right level, selects momentarily, as long as it is kept pressed, the blade controls. When the button is pressed (position ON) the Mechatro Controller energises relay R-40 activating solenoid valve SV-17. 1

SM3164

BOOM/BLADE SELECTION SWITCH The boom/blade selection switch located on the right side switch panel, selects the blade controls, when switched into position ON (side with symbol pressed). When the switch is pressed (position ON) the Mechatro Controller energises relay R-40 activating solenoid valve SV-17.

SM3165

T3-9-9

Copyright © New Holland E135B

BLADE CONTROL

BOOM/BLADE SELECTION RELAY Boom/blade selection relay R-40 (2) is located on the fuse-relay box in the cab behind the operator's seat and has the purpose of activating boom/blade selection solenoid valve SV-17. When the Mechatro Controller receives the activation signal from the boom/blade selection switch or the button, it provides a ground signal to the relay that is energised, thus, boom/blade selection solenoid valve SV-17 is energised.

2

SM3166

T3-9-10

Copyright © New Holland

OPERATIONAL PERFORMANCE TEST

Copyright © New Holland

Copyright © New Holland

OPERATIONAL PERFORMANCE TEST SECTION AND GROUP CONTENTS Section 4

OPERATIONAL PERFORMANCE TEST

Group 1 Group 2 Group 3 Group 4

Introduction Standard Performances Test Procedures Mechatro Controller

E135B

Copyright © New Holland

Copyright © New Holland

SECTION 4

OPERATIONAL PERFORMANCE TEST

CONTENTS Group 1 - Introduction How to Use the Maintenance Standard and Cautions to Be Exercised ........... T4-1-1 Preparation for Performance Tests......... T4-1-2

Group 2 - Standard Performances Performance Inspection Standard Table.................................................. T4-2-1

Group 3 - Test Procedures Measurement of engine speed ............... T4-3-1 Measurement of hydraulic pressure........ T4-3-2 Measuring travel performances .............. T4-3-7 Measuring swing performances .............. T4-3-11 Measuring attachment operating performances ..................................... T4-3-15 Measuring performances of swing bearing............................................... T4-3-17

Group 4 - Mechatro Controller Engine control input/output ..................... T4-4-1 Adjustment of Mechatro controller output (A-B-C adjustment) ............................ T4-4-2

E135B

Copyright © New Holland

Copyright © New Holland INTRODUCTION

E135B

HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED Application

Cautions to be Exercised at Judgment

WHEN THE MACHINE IS NEW

EVALUATION OF MEASURED DATA

Confirm that the performances are in accordance with standard specifications as compared to the performance standards. AT SPECIFIC SELF INSPECTION (RULE BY COUNTRY)

Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are to be evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values.

Use the data for the criterion, for the purpose of correction, adjustment and replacement.

DETERMINING CORRECTION, ADJUSTMENT OR REPLACEMENT

WHEN PERFORMANCES ARE DETERIORATED

Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the operating hours, kind of work and circumstances in which the machine is placed, and condition the machine performances to its most desirable levels.

Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for safety and economical considerations. WHEN MAIN COMPONENTS ARE REPLACED For example, use data to restore performances of pumps and others.

Other Cautions to be Exercised

Terminology

PARTS LIABLE TO DEGRADE

STANDARD VALUES Values to be used to condition or assemble a new machine. Where special notes are not given, these values represent standard specifications (machine with standard attachments and standard shoes). REFERENCE VALUES FOR REMEDY Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited to use the machine over the specified values. SERVICE LIMIT This is the limit value at which reconditioning is impossible without replacement of parts. If the value is expected to exceed the service limit before next inspection and correction are performed, replace the parts immediately. The operation over the specified values causes increase of damage and requires the down time of machine, and also causes safety problems.

Rubber products, such as, hydraulic hoses, ORings, and oil seals deteriorate with time; replace them at regular intervals or at overhauls. PARTS REQUIRING REGULAR REPLACEMENT Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and recommend that they should be replaced regularly. INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well.

T4-1-1

Copyright © New Holland E135B

INTRODUCTION

PREPARATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. The machine 1.

Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.

Test area 1.

Select a hard and flat surface.

2.

Secure enough space to allow the machine to run straight more than 20 m, and to make a full swing with the front attachment extended.

3.

SM1231

If required, rope off the test area and provide signboards to keep unauthorized personnel away.

Precautions 1.

Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail.

2.

Operate the machine carefully and always give first priority to safety.

3.

While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings.

4.

Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.

Make precise measurement 1.

Accurately calibrate test instruments advance to obtain correct data.

in

2.

Carry out tests under the exact test conditions prescribed for each test item.

3.

Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

T4-1-2

SM1232

Copyright © New Holland STANDARD PERFORMANCES

E135B

PERFORMANCE INSPECTION STANDARD TABLE

NOTE: unless otherwise specified, measure it on "H" mode.

Measuring Position

Standard Value

Unit

Adjusting Point

Hydraulic oil in tank

NAS 9 or less

Class

-

Sampling

Tank surface

50 ± 5

-

Atmospheric temp 50 °C ~ -10 °C

Inspection Item Position

Cleanliness of hydraulic oil

Port

°C Water temperature

Radiator surface

75 ± 15

H mode Lo idle Engine speed

Std. Measuring condition

Hydraulic oil temperature

Size

H mode Hi idle Measure the engine speed at multi display on the gauge cluster, or measure with diesel speed meter

Auto-Idle B mode Hi idle

Main relief valve pressure

2000 ± 50

Full throttle (Hi Idle)

1050 ± 50 min-1 2000 ± 50

S mode Hi idle

1900 ± 50 G pump

a3

P1

a1

P2

a2

-

-

-

-

ATT Travel

Power boost

H a1 R H

PR1

HI idle

34.3 +0.7

MR1

Boom up

-

-

-0

-0,5

R

Main pump

H Arm

OR3

Boom up

37.8 +0

OR4

Boom down

37.8 +0

OR1

Bucket digging

37.8 +0

OR2

Bucket dump

OR7

Arm in

OR8

Arm out

OR5

Swing LH

OR6

Swing RH

-4.0

-4.5

PF 1/4

37.8 a2

+0 -4.0

37.8 +0

-4.0

LH Swing

a2 RH

+3.4 28.0 +0.5

a1

34.3 +1,7 -0,5

Travel

Reverse Forward LH

MPa

-

Forward RH

-

37.8 +0 -4.0

a1 R

Adjustment not required Perform all measurement with the air-conditioner “OFF”

5.0 +0.5

-4.0

Bucket Over load relief valve pressure

Low throttle

2000 ± 50

Boom

High pressure circuit

1000 ± 50

A mode Hi idle

Pilot primary pressure circuit

-

Measuring Condition

-

a2

34.3 +1,7

Simultaneous Operation of travel RH and LH

Reverse

-0,5

-

H

+0.5 -0

-

-

24.5 +0.5 -0

-

-

Blade

24.5 G

R

T4-2-1

Copyright © New Holland E135B

Track link (RH, LH)

STANDARD PERFORMANCES

Inspection Item

Standard value

st revolution 1 speed

23.3~25.7

Measuring condition

Unit s/3 rev

2nd speed

13.8~15.2 In

2.8~3.4

Out

2.4~3.0

Digging

2.8~3.4

Operating time

Dumping

2.1~2.7

of cylinder

In

2.8~3.4

Out

4.8~5.4

Up

1.5~2.1

Down

1.9~2.5

Operating speeds

Arm

Bucket s

(At no load)

Positioner

Performance

Blade Swing speed

RH - LH

Amount of travel deviation

2nd speed

Parking brake drift

15° Gradient

Performance of Swing brake

Neutral position after 180° full speed swing

Swing parking brake drift

15° Gradient

13.8~17.4

s/3 rev

0~240

mm / 20 m

0

mm / 5 min

55~75

degree

0

mm

Tip of the bucket tooth

90

Boom cylinder

3

Arm cylinder

4

-

-

ATT amount of drift

mm / 5 min

Amount of horizontal play at the bucket tooth

30~50

mm

NOTE: over load relief valves OR1~OR8 described in advance correspond to the following operations. 1.

Bucket digging

5.

Swing left

2.

Bucket dump

6.

Swing right

3.

Boom up

7.

Arm in

4.

Boom down

8.

Arm out

T4-2-2

(At no load)

(8) (5)

(4) (6) (1)

(7)

(2) (3)

Copyright © New Holland TEST PROCEDURES

E135B

MEASUREMENT OF ENGINE SPEED Warming up of engine Start engine to raise the coolant temperature of engine to 60 to 90°C (140 to 194°F) at surface of radiator upper tank. The E/G coolant tem-perature gauge is used to measure. The range in white color shows the temperature of approx. 65 to 105°C (149 to 221°F), so confirm that the pointer indicates the temperature within the white range.

RED

WHITE

BLUE SM3143

Engine speed measured value through service diagnosis 1.

Turn "ON" the starter switch with the buzzer stop switch pressed.

2.

A program No. and an actual engine revolution are displayed as the No.2 Item.

3.

The screen advances like No.2, No.3....each time the "Wiper switch" on the gauge cluster is pushed.

4.

The screen returns like No.45, No.44....each time the "Washer switch" is pushed.

5.

The display does not disappear unless the starter switch is turned to"OFF".

GAUGE CLUSTER

BUZZER STOP SWITCH WASHER SWITCH

WIPER SWITCH SCREEN CHANGE SWITCH

NO.2 ENG G-3 SPEED SET MEAS 1 MEAS 2 G-5 ENG OIL PRS. WATER TEMP. F MODE H-1 ACCEL. VOLT. POS ECU OUTPUT

T4-3-1

SM0851

2205 2201 2201 LIVE 100 OF HM 4.2V 100% 0.5V

SM1555

Copyright © New Holland E135B

TEST PROCEDURES

MEASUREMENT OF HYDRAULIC PRESSURE Preparing to measure hydraulic pressure HYDRAULIC EQUIPMENT 6.9 MPa (1000psi) pressure gauge: 1unit 49 MPa (7100psi) pressure gauge: 2 units Pressure measuring equipment and instrument for analysis: 1 set

a4 PSV1 PSV2 a5

MEASURING CLEANLINESS OF HYDRAULIC OIL

IMPORTANT : after releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value is higher than the standard value, replace the return filter or change the hydraulic oil.

Dr1

(Dr1)

B3

(Dr1)

Dr1

a1

a3

a2

SM3144

Place to install pressure gauge MAIN CIRCUIT After releasing the pressure in hydraulic oil tank and system, replace plugs PF1/4 of main pump gauge ports (a1) (a2) with fittings for pressure measurement, and attach pressure gauge 49 MPa (7100 psi). PILOT CIRCUIT Replace pilot gauge plug (a3) with fitting PF1/4 for pressure measurement, and attach pressure gauge 6.9 MPa (1000 psi). BLADE CIRCUIT Replace plug (G) of blade command valve with fitting PF3/8 for pressure measurement, and attach pressure gauge 49 MPa (7100 psi).

G

EXTRA CIRCUIT Replace plug (G) of command valve with fitting PF3/ 8 for pressure measurement, and attach pressure gauge 49 MPa (7100 psi).

SM3153

T4-3-2

Copyright © New Holland TEST PROCEDURES

E135B

Pressure adjustment position MAIN CONTROL VALVE Relief valve position on main control valve.

PLUG FOR OPTIONAL RELIEF

OR7 : ARM (H)

MACHINE TOP

MR1 : MAIN RELIEF (ATT & TRAVEL)

OR3 : BOOM (H)

OR2 : BUCKET (R)

View from right front of machine

OR4 : BOOM (R)

SM3145

OR1 : BUCKET (H)

MACHINE TOP

OR8 : ARM (R) View from left bottom of machine

T4-3-3

PLUG FOR OPTIONAL RELIEF

SM3146

Copyright © New Holland E135B

TEST PROCEDURES

PILOT RELIEF VALVE The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.

A3

a3

Dr3 PR1

B3

SM3147

SWING OVER LOAD RELIEF The swing motor is equipped with plugs PA, PB for pressure measurement, but the measurement is carried out using gauge ports (a1) and (a2).

PA PB

SWING RIGHT OVERLOAD RELIEF OR6

SWING LEFT OVERLOAD RELIEF OR5 SM3148

a4 PSV1 PSV2 a5

Dr1

(Dr1)

(Dr1)

B3

Dr1

a1

a2

a3

SM3144

T4-3-4

Copyright © New Holland TEST PROCEDURES

E135B

Procedure for adjusting relief valve PILOT RELIEF VALVE Adjust it with adjust screw (311). : 24 mm : 29.4 N•m (22 lbf•ft) : 6 mm No. of turns of adjust screw

Pressure change MPa (psi)

1 turn

Approx. 2.1 (305)

LOCK NUT HEX24

MAIN RELIEF VALVE 311

(Commom for travel and ATT sections)

SM1287

Loosen lock nut (7) and adjust the pressure with the adjust screw (6). : 27~31 N•m (20~23 lbf•ft)

7

: 19 mm Adjust screw

6

: 4 mm

No. of turns of adjust screw

Pressure change MPa (psi)

1 turn

Approx. 17.7 (2560)

SM3149

OVER LOAD RELIEF VALVE (Boom, bucket, arm sections) Loosen lock nut (1) and adjust it with adjust screw (2). : 22 mm : 27.4~31.4 N•m (20~23 lbf•ft) : 6 mm No. of turns of adjust screw

Pressure change MPa (psi)

1 turn

Approx. 17.7 (2560)

2

1 SM0860

T4-3-5

Copyright © New Holland E135B

TEST PROCEDURES

OVER LOAD RELIEF VALVE (SWING) When the adjustment of pressure is required, loosen lock nut (1) and adjust the pressure with cap (2).

1

2

: 30, 38 mm : 118 N•m (87 lbf•ft) : 12 mm R

No. of turns of adjust screw

Pressure change MPa (psi)

1 turn

Approx. 10 (1450)

3

SM0861

OVER LOAD RELIEF VALVE (TRAVEL) This valve was adjusted by manufacturer and shipped. Do not replace the parts except O-ring. Loosen cap (205) and adjust the pressure with shim (213).

205

: 10 mm

213 SM3150

T4-3-6

Copyright © New Holland TEST PROCEDURES

E135B

MEASURING TRAVEL PERFORMANCES Travel speed PURPOSES Measure the track link revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system. CONDITIONS Hydraulic oil temperature ;45~55°C (113~131°F) Crawler on the right and left sides are tensioned evenly. PREPARATION Attach the reflection panel with a magnet to the travel motor cover. Swing the swing frame through 90° as shown in Figure and make the crawler on one side take off the ground, using the attachment. MEASUREMENT Engine revolution: 2-speed travel switch:

SM0863

REFLECTION PANEL

Hi idle 1st speed and 2 nd speed Right and left

Measuring points: Method, example: Measure the revolutions visually.

Track link revolution Measurement item

RH& LH

H mode 1st speed H mode 2nd speed

Unit: s/3 rev Standard value

Reference value for remedy

Service limit

23.3~25.7

29.8~32.8

37.0~

13.8~15.2

17.6~19.4

21.9~

SM0864

T4-3-7

Copyright © New Holland E135B

TEST PROCEDURES

Deviation of travel PURPOSE Measure the amount of deviation at 20m (66ft) travel and confirm the horizontal balance between the hydraulic pump and the travel motor of the travel drive system. CONDITION Hydraulic oil temperature:

45~55 °C (113~131°F) RH and LH crawler are tensioned evenly. Firm, level ground Engine revolution: Hi idle.

Approx. 30~40 cm (1~1.3 ft)

PREPARATION

SM0865

1.

Straight course more than 30m (108ft).

2.

Travel position in which the bottom of the bucket is lifted by about 30cm (1ft).

MEASUREMENT 1.

2.

Measure the max. deviation distance of the circular arc in the 20m (66ft) length, excluding the preliminary run of 3~5m (10~16ft).

A 20m

Operate the travel lever at the same time.

Travel deviation

Unit: mm (in)/20m (66ft)

Measuring position

Standard value

Reference value for remedy

Service limit

A

240 (9.45) or less

480 (18.9)

720 (28.4)

SM0866

T4-3-8

Copyright © New Holland TEST PROCEDURES

E135B

Performances of parking brake PURPOSE Confirm that the parking brake holds a stopped condition of the machine in a no-load travel position and on a 15 degree slope. CONDITION BOOM FOOT PIN

A slope with (Approx. 15 deg) gradient and a stopped condition in a no-load travel position. ARM TOP PIN

PREPARATION Place an angle meter on the shoe plate and confirm that it makes an angle more than 15 degree. Hang a perpendicular in parallel with the guide frame rib on the track frame and put a mark (matching mark) on the shoe plate.

15 degree slope

SM0867

MEASUREMENT Five minutes after the engine stops, measure the movement distance of the matching mark. Parking brake

Units: mm (in)/5 min

Measuring position

Standard value

Reference value for remedy

Service limit

C

0

1 (0.04)

2 (0.08)

GUIDE FRAME

C

ANGLE METER

SM0868

T4-3-9

Copyright © New Holland E135B

TEST PROCEDURES

Drain rate of travel motor PURPOSE To measure the drain rate of the travel motor and to confirm the performances of the travel motor. CONDITIONS Hydraulic oil temperature: Engine revolution:

45~55°C (113~131°F) Hi idle

PREPARATION 1.

Place a stopper under the RH and LH travel sprockets.

2.

Stop the engine and release pressure from the hydraulic circuit.

3.

Connect a hose with the drain port of the travel motor and take drain in a container.

MEASUREMENT AT TRAVEL LOCK

90 o 10 (3.54") (0.394")

FORWARD o 22 PIPE (0.866") RIB "A"

40 (1.57") 150 (5.91")

STOPPER "B"

ROTARY DIRECTION

o 80 (3.15") SM0869

WARNING Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in some cases. 1.

Start the engine and relieve pressure at the full stroke of the travel lever.

2.

Measure the drain rate for 30 seconds of relieving.

Drain rate of travel motor

Drain rate of travel motor

Unit: L (gal)/30 s

Measuring position

Standard value

Reference value for remedy

Service limit

Drain rate

5 (1.3)

13 (3.4)

15 (4.0)

SM0870

T4-3-10

Copyright © New Holland TEST PROCEDURES

E135B

MEASURING SWING PERFORMANCES Swing speed PURPOSE Measure the swing time and confirm the performances between the hydraulic pump and the swing motor of the swing drive system. CONDITIONS Hydraulic oil temperature: Firm, level ground Engine revolution:

45~55°C (113~131°F) Hi idle

PREPARATION Put the bucket empty and extend the boom, arm and bucket cylinder fully. And the machine becomes a position of minimum reach. MEASUREMENT Swing the machine by bringing the swing level to its full stroke. After a preliminary run of one turn, measure the time required to make three complete turns.

Swing speed

Unit : s/3 rev

Measuring position

Standard value

Reference value for remedy

Service limit

Swing speed at min. reach

13.8~17.4

17.7~22.3

25.2~

T4-3-11

SM0871

Copyright © New Holland E135B

TEST PROCEDURES

Performance of swing brake PURPOSE Confirm the braking torque performances by the swing relief valve. BOOM FOOT PIN

ARM TOP PIN

CONDITIONS Hydraulic oil temperature: Firm, level ground Engine revolution:

45~55°C (113~131°F) Hi idle SM0872

PREPARATION 1.

Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinders fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin.

2.

Put a matching mark on the outer circumference of the swing bearing of the upper frame side and of the track frame side. Place two poles (flags) on the front and back of the extended line of the matching mark.

MEASUREMENT 1.

2.

When operating in regular swing speed, by shifting lever to neutral position at pole position the swing operation stops. Calculate the swing drift angle by the following equation, after the upper swing body stops, using the amount of deflection (m) of the matching marks on the swing race and the length (m) of the circumference of the swing race:

Swing angle (°)

drift

Amount of deflection of matching marks [m (ft-in)]

MEASURING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE

MATCHING MARKS ON INNER RACE

x 360°

=

Circumferenzial lenght of swing race [m (ft-in)]

Swing brake performance

SM0873

Unit : degree

Measuring position

Standard value

Reference value for remedy

Service limit

Swing 180°

75°

83°

90°

T4-3-12

Copyright © New Holland TEST PROCEDURES

E135B

Performance of swing parking brake PURPOSE To confirm the mechanical performances of the swing parking brake that is fitted to the inside of the swing motor. CONDITIONS On a slope of 15 degree incline. Stop the machine at right angles with the slope. Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. PREPARATION

SM0874

Put the angle meter on the shoe plate and make sure that the angle is more than 15 degree. Put a matching mark on the outer race side and on the inner race side.

MEASUREING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE

MEASUREMENT When five minutes has passed after the engine stops, measure the length of the movement of the matching marks.

Performance of swing parking brake

Unit : mm(in)/5min

Measuring position

Standard value

Reference value for remedy

Service limit

C

0

1 (0.04)

2 (0.08)

T4-3-13

MATCHING MARKS ON INNER RACE

SM0875

Copyright © New Holland E135B

TEST PROCEDURES

Drain rate of swing motor PURPOSE Measure the drain rate of the swing motor and confirm the performances of the swing motor. CONDITIONS Hydraulic oil temperature:

45~55°C (113~131°F)

Firm, level ground Engine revolution:

Hi idle

PREPARATION 1.

Stop the engine.

2.

Release pressure from inside the hydraulic circuit.

3.

Disconnect the swing motor drain hose from its end returning to the hydraulic oil tank and take oil in a container.

4.

Put a plug to the tank side.

MEASUREMENT AT SWING LOCK 1.

Start the engine and put the side faces of bucket against the inside of the right or left shoe plates.

2.

Relieve the swing motor at full stroke of the swing motion.

3.

Collect the amount of drained oil in a container for 30 seconds.

Drain rate of swing motor

Unit : L(gal)/30sec

Measuring position

Standard value

Reference value for remedy

Service limit

Drain rate

5.0 (1.3)

8.0 (2.1)

11.0 (2.9)

T4-3-14

SM0876

Copyright © New Holland TEST PROCEDURES

E135B

MEASURING ATTACHMENT OPERATING PERFORMANCES Operating time of cylinders PURPOSE Measure the operating time of the arm, positioning and bucket and confirm the performances between the hydraulic pump and the cylinder of the attachment drive system. CONDITIONS Hydraulic oil temperature:

45~55°C (113~131°F) Engine revolution: Hi idle Operating time excluding the cushion stroke. PREPARATION Firm level ground with the bucket empty.

30 cm (1 ft)

MEASUREMENT Arm in and out, positioning in and out, bucket digging and dump In a position in which the tooth of the bucket rises to a level of about 30cm (1ft) above ground, measure the full stroke operating time required with the arm, the positioning and bucket operating levers at full stroke.

Cylinder Operating time

Unit : sec

Measuring position

Standard value

Reference value for remedy

Service limit

1

2.8~3.4

3.6~4.4

4.7~

2

2.1~2.7

2.7~3.5

3.6~

7

2.8~3.4

3.6~4.4

4.7~

8

2.4~3.0

3.1~3.8

4.1~

9

2.8~3.4

3.6~4.4

4.7~

10

4.8~5.4

6.1~6.9

7.5~

30 cm (1 ft)

9

10

30 cm (1 ft) SM0877

T4-3-15

Copyright © New Holland E135B

TEST PROCEDURES

Oil tightness of cylinders PURPOSE Confirm that the cylinder oil tight by checking the moving length of the cylinder rods.

B BOOM FOOT PIN

C

CONDITIONS Hydraulic oil temperature:

A

45~55°C (113~131°F)

Firm, level ground After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness. Retract the arm cylinder rod 50mm (2in) from stroke end so that the piston does not match a same range of the cushioning mechanism. PREPARATION Put the bucket empty. Extend the arm cylinder rod 50mm (2in) from the most retracted position. And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at same height with boom foot pin. MEASUREMENT Measure the items five minutes after the engine is turned off. Oil tightness of cylinder

Unit: mm(in)/5min

Measuring position

Standard value

Reference value for remedy

A

3 (0.12)

6 (0.24)

9 (0.35)

B

4 (0.16)

8 (0.32)

12 (0.47)

Service limit

C

-

-

-

D

90 (3.54)

115 (4.53)

150 (5.91)

T4-3-16

D ARM TOP PIN

SM0878

Copyright © New Holland TEST PROCEDURES

E135B

MEASURING PERFORMANCES OF SWING BEARING PURPOSE Measure the gap between the lower frame and the bottom face of the swing bearing and estimate the degree of wear of the swing bearing. CONDITIONS Firm, level ground The swing bearing mounting bolts are not loosened. The swing bearing is lubricated well, not making abnormal sound during turning. PREPARATION 1.

Install a dial indicator to the magnetic base and fix it to the lower frame.

2.

Direct the upper swing body and the lower frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the swing body side and set the reading at zero.

LOCATION OF BEARING MOUNTING BOLTS

SWING BEARING A

DIAL INDICATOR LOWER FLAME

MEASUREMENT Measuring position 1 and 2 Measure the displacement of the outer race in the axial direction in position 1 [The arm at 90°~110° and the crawler front is lifted by attachment about 30cm (1ft)] and in position 2, using a dial indicator. Axial play of swing bearing

SM0879

Unit: mm (in)

Measuring position

Standard value

Reference value for remedy

Service limit

A

0.5~1.5 (0.02~0.06)

1.9~2.9 (0.08~0.11)

3.0~ (0.12~)

90 ~100

30cm

SM0880

Position 1

BOOM FOOT PIN

ARM TOP PIN

SM0872

Position 2

T4-3-17

Copyright © New Holland E135B

TEST PROCEDURES

Measuring position 3 Retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. Then swing the bucket right and left by man power. But in this case, the gap of the attachment is included. Right and left movement of the tip of bucket

BOOM FOOT PIN

ARM TOP PIN

Unit: mm (in)

Measuring position

Standard value

Reference value for remedy

Service limit

Benna

30~50 (1.18~1.97)

80 (3.15)

120 (4.72)

T4-3-18

SM0872

Position 3

Copyright © New Holland MECHATRO CONTROLLER

E135B

ENGINE CONTROL INPUT/OUTPUT

C-3: ENGINE CONTROLLER

C-2: GAUGE CLUSTER

INJECTOR

E-1: FUSE&RELAY BOX

ENGINE ENGINE SPEED SENSOR

PUMP PROPORTIONAL VALVE STARTER SWITCH

ACCEL POTENTIO METER

C-1: MECHATRO CONTROLLER SM1560

ENGINE CONTROL EQUIPMENT Speed sensor Installing place: engine flywheel housing. Sensor attaching procedure: screw the speed sensor into engine flywheel housing.

CN-136F

: 19 mm SM3151

Work mode select switch If the work mode select switch is pressed, a signal istransmitted to the C–1 controller and changes the work modes in the order of H→B→A→S and back to H again.

WORK MODE SELECT SWITCH

SM0885

T4-4-1

Copyright © New Holland E135B

MECHATRO CONTROLLER

ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT) Purpose of the adjustment There are 2 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function to ensure performance of machine. 1.

Adjustment of pump ("B" adjustment) This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with engine rated output.

2.

Adjustment of unloading valve ("C" adjustment) This adjustment is performed to correct the open variation of unloading valve to improve the operability further.

In cases where the adjustment of mechatro controller is required When the following parts are replaced or repaired, carry out the adjustment without fail: 1.

Mechatro controller

2.

Engine or engine controller

3.

Hydraulic pump or hydraulic pump proportional valve

4.

Unloading proportional unloading valve.

valve,

spool

of

Preparation 1.

Raise the oil temperature to about 50°C (122°F) to warm up the engine.

2.

Turn the air-con OFF.

3.

Turn the starter key switch OFF to stop the engine. When the mechatro controller was replaced, the following error code is displayed because the adjustment data is not entered. A215, A225, A025, A035

As the error codes other than those shown above may suggest failures of machine, repair the machine into the ordinary operating condition according to Error Code List.

T4-4-2

Copyright © New Holland MECHATRO CONTROLLER

E135B

Adjusting procedure

MULTI DISPLAY

WORK MODE SELECT SWITCH

BUZZER STOP SWITCH

WASHER SWITCH

WIPER SWITCH

SELECT SWITCH

SM0886

ADJUSTMENT OF PUMP ("B" ADJUSTMENT) PROCEDURE 1.

Turn starter key switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)

2.

Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selecting adjustment is displayed. When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated.And the lever lock solenoid is automatically released, disabling all operations.

3.

Press selector switch on gauge cluster to display "START ENG"."Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.

T4-4-3

SM0887

Copyright © New Holland E135B

4.

5.

MECHATRO CONTROLLER

The adjustment automatically shifts from engine to pump, the speed shifts from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the unloading proportional valve and pump proportional valve actuate, accordingly the loading of pump is increased.The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump "PROPO-VALVE" current (command value) are indicated. After detection of the engine rated speed, the adjustment of pump is automatically completed. And "FINISH PUMP" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.).

T4-4-4

FINISH PUMP ENGINE SPEED 2000rpm PUMP PRESSURE C-1 35.0M C-2 PROPO-VALVE E-1 300mA E-2

35.0M 300mA

SM0889

Copyright © New Holland MECHATRO CONTROLLER

E135B

ADJUSTMENT OF UNLOADING VALVE (“C” ADJUSTMENT) PROCEDURE 1.

2.

The adjustment shifts from pump to unloading, and the unloading valve actuates, accordingly the pump pressure is detected. And "MEMORY UNLOAD" is displayed.The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PROPO-VALVE" voltage (command value) are indicated". When the unloading valve operates to the specified value, the adjustment of unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed. The speed is shifted to the speed corresponding to acceleration potentiometer.The adjusting current value is indicated on the display of current of P1, P2 unloading proportional valves. The adjusting range is usually 520~635mA.

MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA

SM3152

Stop the engine. (The adjusted data is automatically stored.). CORRECTIVE ACTION TAKEN WHEN THE ADJUSTMENT CAN BE NOT PERFORMED 1.

In cases where the adjustment of pump can not be performed; And "ERROR PUMP" is displayed. Judging condition 1: P1 and P2 average pump pressure at the time when the adjustment is completed is 25MPa or less. Judging condition 2: the adjustment does not complete although the pump proportional valve current reaches to the specified value. The P1 and P2 pump pressures usually increase to 33~38MPa. When the pressure does not increase: a. Identify the reason why the pressure does not increase, • Check that the relief valve operates normally. • Check that the hydraulic circuit is free from leak of pressure. • Check that the pressure sensor functions normally. And so on. b. Identify the reason why the actual flow rate does not increase, • Check that the pump proportional valve operates normally. • Check that the pump regulator operates normally. And so on.

T4-4-5

SM0891

Copyright © New Holland E135B

2.

MECHATRO CONTROLLER

In cases where unloading valve can not be performed; And "ERROR UNLOAD" is displayed. Judging condition 1: the pump pressure does not increase up to the pressure in the range of the specified adjustment. Or the increased pressure is held as it is. Judging condition 2: pressure sensor of either P1 pump or P2 pump is failed. Normally the pump pressures of P1 and p2 pumps gradually increase to 10~25MPa. (It may be affected by operating oil temperature.) When the pump pressure does not increase: a. Identify the reason why the pressure does not increase, • Check that the relief valve operates normally. • Check that the hydraulic circuit is free from leak of pressure. • Check that the pressure sensor functions normally. And so on.

T4-4-6

SM0892

Copyright © New Holland MECHATRO CONTROLLER

E135B

OTHER PRECAUTIONS 1.

In the event of a failure, there is case where the adjustment may not be performed normally. First serve the machine, and perform the adjustment work.

2.

In the condition where large load is constantly applied to engine, the adjustment could not be performed normally.

WHEN THE ADJUSTMENT OF UNLOADING VALVE ONLY IS PERFORMED (“C” ADJUSTMENT) In the event where only unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading valve only. PROCEDURE 1.

Turn starter switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)

2.

Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selection of adjustment type is displayed. And "ADJUST" is displayed. When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated.And the lever lock solenoid is automatically released, disabling all operations.

3.

Change the adjusting items with washer switch ( ) and wiper switch ( ), and select "ADJUST UNLOAD". Like the output adjustment, when adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated.

4.

Press selector switch on gauge cluster to display "START ENG". "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.

T4-4-7

MULTI DISPLAY (EXAMPLE)

SM0893

Copyright © New Holland E135B

5.

6.

MECHATRO CONTROLLER

After starting engine, press selector switch on gauge cluster and "MEMORY UNLOAD" is indicated, the engine speed is automatically increased and the adjustment of unloading valve is performed. "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" are indicated. When the unloading proportional valve operates to the specified value, the adjustment of unloading proportional valve automatically completes. "FINISH UNLOAD" is indicated. The speed is shifted to the speed corresponding to acceleration potentiometer. The value of adjusting current is indicated on the display of current of P1 and P2 unloading proportional valves. The adjusting range is usually 520~635mA.

Stop the engine. (The adjusted data is automatically stored.)

T4-4-8

MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA

SM0894

Copyright © New Holland

TROUBLESHOOTING

Copyright © New Holland

Copyright © New Holland

TROUBLESHOOTING

E135B

SECTION AND GROUP CONTENTS Section 5

TROUBLESHOOTING

Group 1 Group 2 Group 3

Troubleshooting (by Error Codes) Troubleshooting (by trouble) Troubleshooting (Trouble diagnosis mode)

Copyright © New Holland

Copyright © New Holland

SECTION 5

TROUBLESHOOTING

CONTENTS Group 1 - Troubleshooting (by Error Codes) 1. Judgment of actual thing at site ......... T5-1-1 2. Classification on failure and troubleshooting .................................. T5-1-2 3. The blown fuse of Mechatro Controller ........................................... T5-1-2 4. Troubleshooting by Error Codes ........ T5-1-2

Group 2 - Troubleshooting (by trouble) 1. Hydraulic system ............................... T5-2-1 2. Electric systems ................................. T5-2-28 2.1 Wiring checking procedure ......... T5-2-28 2.2 Trouble ....................................... T5-2-31 3. Engine................................................ T5-2-35

Group 3 - Troubleshooting (Trouble diagnosis mode) 1. Trouble diagnosis mode .................... T5-3-1

E135B

Copyright © New Holland

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

OUTLINE Troubleshooting provides process locating for the cause of trouble in the order that trouble occurred. This manual describes how to solve the specific phenomenon systematically as early as possible. For troubleshooting concerning the inside of equipment, refer to troubleshooting for each manual of equipment.

1. JUDGMENT OF ACTUAL THING AT SITE

SM0100

GET TO THE SITE AS QUICKLY AS POSSIBLE

Attending the field to verify actual thing

Verify model, serial number, situation of trouble and field, and notify person of arrival time. VERIFY BACKGROUND OF TROUBLE OCCURRED 1. Model name and serial number 2. Kind of attachment Check that the combination of attachment is proper or that the operating method is not unreasonable. 3. Operating time by hour-meter 4. History of trouble occurred and additional works. 5. Recurrence of past trouble, or problems on the additional works.

SM0101

Verifying background of trouble occurred

HOW TO DIAGNOSE TROUBLE 1. Verify defective part 2. Make the condition of trouble again 3. Where defective parts can not be verified, surmise causes systematically. 4. Verify reasons for surmise 5. Report methods, procedure, and period for repairing to user. SM0102

EXPLANATION OF THE CAUSE OF TROUBLE 1. Explain the cause of trouble to clients. For example, oil leak through piston is caused by flaws on the piston rod. And the method of using the machines should be explained so that the same kind of trouble does not reoccur.

Confirm the symptoms of the trouble

2. Treatment of damaged parts The damaged parts to be claimed and returned are evidence so they should be handled with care. Protect them from entry of water, soils, etc. into port of hydraulic unit, etc. and return them. And also use care not to flaw and damage those surfaces.

SM0103

Diagnosing fail by means troubleshooting

T5-1-1

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

2. CLASSIFICATION OF FAILURE AND TROUBLESHOOTING Classify failures into the following 3 types and carry out the troubleshooting. No.

Classes of failure

Troubleshooting

A

When error code after self-diagnosis is displayed Carry out troubleshooting according to the error on gauge cluster code.

B

When no failure is detected currently but error When it is hard to recreate the failure situation, code after self diagnosis is remained in trouble cancel the data in the history and reproduce the history failed situation or suppose the cause according to the troubleshooting by error code, and then repair it.

C

When error code after self diagnosis is not • Carry out troubleshooting according to displayed or is not remained in the history instructions in Chapter T5-2 "TROUBLESHOOTING BY TROUBLE". • Carry out troubleshooting according to instructions in Chapter T5-3 "TROUBLE DIAGNOSIS MODE".

3. THE BLOWN FUSE OF MECHATRO CONTROLLER If the fuse of mechatro controller has blown, the following display appears on the gauge cluster. (1)

The blown fuse of mechatro controller a. Blown fuse 5A of mechatro controller : "DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller program is not executed. b. Blown fuse 20A of mechatro controller The controller functions normally but the power supply applied when the controller drives the solenoid, etc. stops. Many error codes are displayed on the gauge cluster. D013, D023, D033, D063, E013, E023, F021

4. TROUBLESHOOTING BY ERROR CODE When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the troubleshooting referring to applicable page in the contents of error codes.

Error Code

Trouble

Described page

A025

Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.

T5-1-5

A035

Unload valve adjustment (C adjustment) is not adjusted yet or is failed.

T5-1-6

A215

Written data of ROM adjustment data is incorrect.

T5-1-6

A225

Writing of ROM adjustment data is incorrect.

T5-1-7

A235

Written data of ROM hour meter data is incorrect.

T5-1-7

A245

Writing of ROM hour meter data is incorrect.

T5-1-8

A255

Writing of proportional valve adjustment data is incorrect.

T5-1-8

B012

Incorrect output of boom up pressure sensor

T5-1-9

B013

Disconnection of boom up pressure sensor

T5-1-9

B014

Short-circuit of boom up pressure sensor

T5-1-10

B022

Incorrect output of boom down pressure sensor

T5-1-10

B023

Disconnection of boom down pressure sensor

T5-1-11

T5-1-2

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

Error Code

Trouble

E135B

Described page

B024

Short-circuit of boom down pressure sensor

T5-1-11

B032

Incorrect output of arm out pressure sensor

T5-1-12

B033

Disconnection of arm out pressure sensor

T5-1-12

B034

Short-circuit of arm out pressure sensor

T5-1-13

B042

Incorrect output of arm in pressure sensor

T5-1-13

B043

Disconnection of arm in pressure sensor

T5-1-14

B044

Short-circuit of arm in pressure sensor

T5-1-15

B052

Incorrect output of bucket digging pressure sensor

T5-1-16

B053

Disconnection of bucket digging pressure sensor

T5-1-16

B054

Short-circuit of bucket digging pressure sensor

T5-1-17

B062

Incorrect output of bucket dump pressure sensor

T5-1-17

B063

Disconnection of bucket dump pressure sensor

T5-1-18

B064

Short-circuit of bucket dump pressure sensor

T5-1-18

B072

Incorrect output of swing pressure sensor

T5-1-19

B073

Disconnection of swing pressure sensor

T5-1-19

B074

Short-circuit of swing pressure sensor

T5-1-20

B092

Incorrect output of travel right pressure sensor

T5-1-20

B093

Disconnection of travel right pressure sensor

T5-1-21

B094

Short-circuit of travel right pressure sensor

T5-1-22

B102

Incorrect output of travel left pressure sensor

T5-1-23

B103

Disconnection of travel left pressure sensor

T5-1-23

B104

Short-circuit of travel left pressure sensor

T5-1-24

B113

Disconnection of pressure sensor of optional selector positioning

T5-1-25

B114

Short-circuit of pressure sensor of optional selector positioning

T5-1-26

B162

Incorrect output of P1 optional side pressure sensor

T5-1-26

B163

Disconnection of P1 side optional pressure sensor

T5-1-27

B164

Short-circuit of P1 side optional pressure sensor

T5-1-28

B172

Incorrect output of P2 optional side pressure sensor

T5-1-28

B173

Disconnection of P2 side optional pressure sensor

T5-1-29

B174

Short-circuit of P2 side optional pressure sensor

T5-1-29

C012

Incorrect output of P1 pump pressure sensor

T5-1-30

C013

Disconnection of P1 pump pressure sensor

T5-1-30

C014

Short-circuit of P1 pump pressure sensor

T5-1-31

C022

Incorrect output of P2 pump pressure sensor

T5-1-31

C023

Disconnection of P2 pump pressure sensor

T5-1-32

C024

Short-circuit of P2 pump pressure sensor

T5-1-32

C033

Disconnection of boom head pressure sensor

T5-1-33

C034

Short-circuit of boom head pressure sensor

T5-1-33

D012

Failure of output transistor ON at P1 unload proportional valve

T5-1-34

D013

Disconnection of P1 unload proportional valve

T5-1-34

D022

Failure of output transistor ON at P2 unload proportional valve

T5-1-35

D023

Disconnection of P2 unload proportional valve

T5-1-36

D032

Failure of output transistor ON at travel straight proportional valve

T5-1-36

D033

Disconnection of travel straight proportional valve

T5-1-37

D062

Failure of output transistor ON at arm in high speed proportional valve

T5-1-38

D063

Disconnection of arm in high speed proportional valve

T5-1-39

T5-1-3

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Error Code

Trouble

Described page

E012

Failure of output transistor ON at P1 pump proportional valve

T5-1-39

E013

Disconnection of P1pump proportional valve

T5-1-40

E022

Failure of output transistor ON at P2 pump proportional valve

T5-1-41

E023

Disconnection of P2 pump proportional valve

T5-1-41

E032

Failure of output transistor ON at OPT relief 1 proportional valve

T5-1-42

E033

Disconnection of OPT relief 1 proportional valve

T5-1-42

E042

Failure of output transistor ON at OPT relief 2 proportional valve

T5-1-43

E043

Disconnection of OPT relief 2 proportional valve

T5-1-43

F021

Failure of output transistor OFF and GND short of swing parking SOL valve

T5-1-44

F023

Failure of output transistor ON and disconnection of swing parking SOL valve

T5-1-44

F031

Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve

T5-1-45

F033

Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve

T5-1-46

F041

Failure of output transistor OFF and GND short of optional selector SOL valve

T5-1-46

F043

Failure of output transistor ON and disconnection of optional selector SOL valve

T5-1-47

G032

Overrun of speed sensor of direct input Mechatro-controller

T5-1-48

G033

Disconnection of speed sensor of direct input Mechatro-controller

T5-1-48

G042

Mechatro controller direct input speed sensor and received data from engine controller are overrun

T5-1-49

G043

Mechatro controller direct input speed sensor and received data from engine controller are disconnected

T5-1-49

H013

Disconnection of acceleration potentio

T5-1-50

H014

Power short-circuit of acceleration potentio

T5-1-50

H091

Failure of GND short-circuit of fuel sensor

T5-1-51

H093

Disconnection of fuel sensor

T5-1-51

I111

Received error of CAN1 communication (passive error)

T5-1-52

I113

Received error of CAN1 communication (time-out)

T5-1-52

I313

Received error of cluster communication (time-out error)

T5-1-53

K014

Adhesion of battery relay terminal

T5-1-54

R014

Failure of arc prevention relay of wiper motor

T5-1-55

R024

Failure of normal rotation relay of wiper motor

T5-1-56

R034

Failure of reverse rotation relay of wiper motor

T5-1-57

R044

Failure of washer motor relay

T5-1-58

R134

Failure of swing flasher relay

T5-1-59

R144

Failure of swing flasher relay

T5-1-60

R154

Failure of travel alarm relay

T5-1-61

R164

Failure of auto idling stop relay 2

T5-1-62

R174

Failure of engine forcible stop relay

T5-1-63

R184

Failure of lever lock relay

T5-1-64

T5-1-4

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 1 Error code Trouble Judging condition Symptom Control in the event of failure Returned in normal condition Screen No.

Service diagnosis Screen No. checking screen Screen No.

Checking object 1

•

2

•

Checking contents and remedy

3

Table 2 Error code

A025

Trouble

Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)

Judging condition

Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.

Symptom

Deviated from the rated output, but no problem in normal operation.

Control in the Workable with the default proportional valve output. event of failure Returned in The pump proportional valve adjustment is completed normally. normal condition Screen No.

9

E-1 P1 PUMP

Service diagnosis Screen No. checking screen

9

E-2 P2 PUMP

Screen No.

Checking object

Checking contents and remedy

1

• Checking

Carry out pump adjustment (B adjustment). When"ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed"

2

• Mechatro controller

Check that the error is corrected after replacement of controller.

3

T5-1-5

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 3 Error code

A035

Trouble

Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)

Judging condition

The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting range.

Symptom

It is not normal output, but no problem in normal operation.

Control in the Work with the aid of output by default proportional valve. event of failure Returned in The adjustment of unload valve is completed normally. normal condition Screen No.

8

D-1 P1 UN-LOAD (BP-CUT)

Service diagnosis Screen No. checking screen

8

D-2 P2 UN-LOAD (BP-CUT)

Screen No. Checking object

Checking contents and remedy

1

• Checking

Carry out adjustment of unload valve (C adjustment). When"ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed"

2

• Mechatro controller

Check that the error is corrected after replacement of controller.

3

Table 4 Error code

A215

Trouble

The data of ROM adjustment is written incorrectly.

Judging condition

Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)

Symptom

No affect.

Control in the Control at side of correct memory data. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen No. checking screen Screen No. Checking object 1

Mechatro controller

Checking contents and remedy Check that the error is corrected after replacement of controller.

2 3

T5-1-6

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

Table 5 Error code

A225

Trouble

The data of ROM adjustment is written incorrectly.

Judging condition

Check adjustment data, and judge the data is correct or not.

Symptom

It is not normal output, but no problem in normal operation.

Control in the Control can be done by default value. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1

Mechatro controller

Checking contents and remedy Check that the error is corrected after replacement of controller.

2 3

Table 6 Error code

A235

Trouble

The data of ROM houmeter is written incorrectly.

Judging condition

Check hourmeter memory, and judge the data is correct or not. (Trouble history only)

Symptom

No affect.

Control in the Control at side of correct memory data. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1

Mechatro controller

Checking contents and remedy Check that the error is corrected after replacement of controller.

2 3

T5-1-7

E135B

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 7 Error code

A245

Trouble

The data of ROM hourmeter is written incorrectly.

Judging condition

Check hourmeter memory, and judge the data is incorrect.

Symptom

The hourmeter data which was judged as error is taken as 0 Hr. No problem in normal operation.

Control in the Normal control is available. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1

Mechatro controller

Checking contents and remedy Check that the error is corrected after replacement of controller.

2 3

Table 8 Error code

A255

Trouble

The data of proportional valve adjustment is written incorrectly.

Judging condition

Check proportional valve adjustment data, and judge the data is incorrect.

Symptom

It is not normal output, but no problem in normal operation.

Control in the Using fixed value of proportional valve correction data, usual control is done. event of failure Returned in It does not regain. Replace controller. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1

Mechatro controller

Checking contents and remedy Check that the error is corrected after replacement of controller.

2 3

T5-1-8

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 9 Error code

B012

Trouble

Boom up pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The boom up operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

5

B-1 BOOM RAISE

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Boom up pressure sensor SE-3 When B012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between boom up pressure sensor and controller CN-126F CN-101F

When B012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 10 Error code

B013

Trouble

Boom up pressure sensor’s wiring disconnects.

Judging condition

The input voltage from boom up pressure sensor is less than 0.1 V.

Symptom

All operation speed slows down.

Control in the Set proportional valve output rate of P1 and P2 pumps to constant current. (Current value in all event of failure operation is neutral). Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-1 BOOM RAISE

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Boom up pressure sensor SE-3 When B013 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-126F and repair it if necessary. CN-101F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-9

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 11 Error code

B014

Trouble

Boom up pressure sensor’s power source is shortcut.

Judging condition

The input voltage from boom up pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-1 BOOM RAISE

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Boom up pressure sensor SE-3 When B014 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-126F and repair it if necessary. CN-101F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 12 Error code

B022

Trouble

Boom down pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The boom down operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

5

B-2 BOOM LOWER

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-4 Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between boom down pressure sensor and controller CN-127F CN-101F

When B022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-10

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 13 Error code

B023

Trouble

Boom down pressure sensor’s wiring is disconnecting.

Judging condition

The input voltage from boom down pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-2 BOOM LOWER

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the connector with other sensor. SE-4 Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-127F and repair it if necessary. CN-101F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 14 Error code

B024

Trouble

Boom down pressure sensor’s power source is shortcut.

Judging condition

The input voltage from boom down pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-2 BOOM LOWER

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-4 Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between boom down pressure sensor and controller CN-127F CN-101F

When B024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-11

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 15 Error code

B032

Trouble

Arm-in pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

All operation speed slows down.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

5

B-3 ARM OUT

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Arm-out pressure sensor SE-8

When B032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between arm-out pressure sensor and controller CN-131F CN-101F

When B032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 16 Error code

B033

Trouble

Arm-out pressure sensor’s wiring is disconnecting.

Judging condition

The input voltage from arm-out pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-3 ARM OUT

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Arm-out pressure sensor SE-8

When B033 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between arm-out pressure When B033 is displayed after the connector is exchanged with other sensor. sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-131F and repair it if necessary. CN-101F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-12

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 17 Error code

B034

Trouble

Arm-out pressure sensor’s power source is shortcut.

Judging condition

The input voltage from arm-out pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-3 ARM OUT

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Arm-out pressure sensor SE-8

When B034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between arm-out pressure sensor and controller CN-131F CN-101F

When B034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 18 Error code

B042

Trouble

Arm-in pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.

Symptom

The arm-in operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

5

B-4 ARM IN

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Arm-in pressure sensor SE-7

Checking contents and remedy When B042 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between arm-in pressure sensor and controller CN-130F CN-101F

When B042 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-13

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 19 Error code

B043

Trouble

Arm-in pressure sensor’s wiring is disconnecting.

Judging condition

The input voltage from arm-in pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-4 ARM IN

Service diagnosis Screen No. checking screen Screen No. Checking object

Checking contents and remedy

1

• Arm-in pressure sensor SE-7

When B043 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between arm-in pressure When B043 is displayed after the connector is exchanged with other sensor. sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-130F and repair it if necessary.. CN-101F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-14

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 20 Error code

B044

Trouble

Arm-in pressure sensor’s power source is shortcut.

Judging condition

The input voltage from arm-in pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No. Service diagnosis Screen No. checking screen Screen No.

5

B-4 ARM IN

Checking object

Checking contents and remedy

1

• Arm-in pressure sensor SE-7

When B044 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector is exchanged with other sensor. sensor and controller Check wiring for possible failure according to the wiring checking procedure CN-130F and repair it if necessary.. CN-101F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-15

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 21 Error code

B052

Trouble

Bucket digging pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the bucket digging pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The bucket digging operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

5

B-5 BUCKET DIG

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-1 Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F

When B052 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 22 Error code

B053

Trouble

Bucket digging pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from bucket digging pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-5 BUCKET DIG

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-1 Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F

When B053 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-16

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 23 Error code

B054

Trouble

Bucket digging pressure sensor’s power source is shortcut.

Judging condition

The input voltage from bucket digging pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-5 BUCKET DIG

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-1 Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F

When B054 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 24 Error code

B062

Trouble

Bucket dump pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the bucket dump pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The bucket dump operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

5

B-6 BUCKET DUMP

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F

When B062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-17

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 25 Error code

B063

Trouble

Bucket dump pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from bucket dump pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-6 BUCKET DUMP

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F

When B063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 26 Error code

B064

Trouble

Bucket dump pressure sensor’s power source is shortcut.

Judging condition

The input voltage from bucket dump pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.

5

B-6 BUCKET DUMP

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. SE-2 Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F

When B064 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-18

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 27 Error code

B072

Trouble

Swing pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the swing pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The swing operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

6

B-7 SWING

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• Swing pressure sensor

When B072 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-5 2

• Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. CN-103F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 28 Error code

B073

Trouble

Swing pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from swing pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-7 SWING

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Swing pressure sensor SE-5

Checking contents and remedy When B073 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between swing pressure When B073 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. CN-103F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-19

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 29 Error code

B074

Trouble

Swing pressure sensor’s power source is shortcut.

Judging condition

The input voltage from swing pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-7 SWING

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• Swing pressure sensor

When B074 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-5 2

• Wiring between swing pressure When B074 is displayed after turning the starter switch on after the connector sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-169F and repair it if necessary. CN-103F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 30 Error code

B092

Trouble

Travel right pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the travel right pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The travel right operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

6

B-9 TRAVEL (R)

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Travel right pressure sensor SE-9

Checking contents and remedy When B092 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between travel right pressure sensor and controller CN-301F CN-102F

When B092 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-20

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 31 Error code

B093

Trouble

Travel right pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from Travel right pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-9 TRAVEL (R)

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Travel right pressure sensor SE-9

Checking contents and remedy When B093 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between travel right pressure sensor and controller CN-301F CN-102F

When B093 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-21

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 32 Error code

B094

Trouble

Travel right pressure sensor’s power source is shortcut.

Judging condition

The input voltage from Travel right pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-9 TRAVEL (R)

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Travel right pressure sensor SE-9

Checking contents and remedy When B094 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between travel right pressure sensor and controller CN-301F CN-102F

When B094 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-22

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 33 Error code

B102

Trouble

Travel left pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the travel left pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The travel left operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

6

B-10 TRAVEL (L)

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• Travel left pressure sensor

When B102 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-10 2

• Wiring between travel left pressure sensor and controller CN-302F CN-102F

When B102 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 34 Error code

B103

Trouble

Travel left pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from Travel left pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-10 TRAVEL (L)

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• Travel left pressure sensor

When B103 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-10 2

• Wiring between travel left pressure sensor and controller CN-302F CN-102F

When B103 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-23

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 35 Error code

B104

Trouble

Travel left pressure sensor’s power source is shortcut.

Judging condition

The input voltage from Travel left pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-10 TRAVEL (L)

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• Travel left pressure sensor

When B104 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-10 2

• Wiring between travel left pressure sensor and controller CN-302F CN-102F

When B104 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-24

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 36 Error code

B113

Trouble

Option selector position detect pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from option selector position detect pressure sensor is 0.1 V or less.

Symptom

When B mode is selected, option selector valve error is indicated.

Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

16

B-11

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on after pressure sensor exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. SE-29

2

• Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F

When B113 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-25

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 37 Error code

B114

Trouble

Option selector position detect pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from selector position detect pressure sensor is 4.7 V or more.

Symptom

When B mode is selected, option selector valve error is indicated.

Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

16

B-11

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on after pressure sensor exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. SE-29

2

• Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F

When B114 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 38 Error code

B162

Trouble

P1 side option pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P1 side option pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The P1 side option operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

6

B-16 P1 OPT.

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• P1 side option pressure sensor SE-20

Checking contents and remedy When B162 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P1 side option pressure sensor and controller CN-304F CN-102F

When B162 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-26

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 39 Error code

B163

Trouble

P1 side option pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from P1 side option pressure sensor is 0.1 V or less.

Symptom

The P1 side option does not work. All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) event of failure But normal control is done when the left control pedal selection is ON. Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-16 P1 OPT.

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• P1 side option pressure sensor SE-20

Checking contents and remedy When B163 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P1 side option pressure sensor and controller CN-304F CN-102F

When B163 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-27

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 40 Error code

B164

Trouble

P1 side option pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from P1 side option pressure sensor is 4.7 or more.

Symptom

The P1 side option does not work. All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to 0 mA. Control in the (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode) event of failure But normal control is done when the left control pedal selection is ON. Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-16 P1 OPT.

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• P1 side option pressure sensor SE-20

When B164 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P1 side option pressure sensor and controller CN-304F CN-102F

When B164 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 41 Error code

B172

Trouble

P2 side option pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P2 side option pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The P2 side option operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

6

B-17 P2 OPT.

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• P2 side option pressure sensor SE-11

Checking contents and remedy When B172 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F

When B172 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-28

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 42 Error code

B173

Trouble

P2 side option pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from P2 side option pressure sensor is 0.1 V or less.

Symptom

The selection of conflux does not work. All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-17 P2 OPT.

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• P2 side option pressure sensor SE-11

When B173 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F

When B173 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 43 Error code

B174

Trouble

P2 side option pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from P2 side option pressure sensor is 4.7 V or more.

Symptom

The selection of conflux does not work. All operation speed slows down.

Set proportional valve output rate of P1 and P2 pumps to constant current. Control in the (Current value in all operation is neutral). event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). Returned in It returns automatically in normal condition. normal condition Screen No.

6

B-17 P2 OPT.

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• P2 side option pressure sensor SE-11

Checking contents and remedy When B174 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F

When B174 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-29

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 44 Error code

C012

Trouble

P1 pump pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P1 pump pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The P1 pump operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

7

C-1 PUMP P1

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P1 pump pressure sensor

When C012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-22 2

• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F

When C012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 45 Error code

C013

Trouble

P1 pump pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from P1 pump pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Control in the P1 pump pressure is controlled to 25 MPa. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

7

C-1 PUMP P1

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P1 pump pressure sensor

When C013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-22 2

• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F

When C013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-30

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 46 Error code

C014

Trouble

P1 pump pressure sensor’s power source is shortcut.

Judging condition

The input voltage from P1 pump pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Control in the P1 pump pressure is controlled to 25 MPa. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

7

C-1 PUMP P1

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P1 pump pressure sensor

When C014 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-22 2

• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F

When C014 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 47 Error code

C022

Trouble

P2 pump pressure sensor outputs error.

Judging condition

After starter switch ON and engine does not start yet. And the input voltage from the P2 pump pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.

Symptom

The P2 pump operability becomes poor.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

7

C-2 PUMP P2

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P2 pump pressure sensor

When C022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-23 2

• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F

When C022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-31

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 48 Error code

C023

Trouble

P2 pump pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from P2 pump pressure sensor is 0.1 V or less.

Symptom

All operation speed slows down.

Control in the P2 pump pressure is controlled to 25 MPa. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

7

C-2 PUMP P2

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P2 pump pressure sensor

When C023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-23 2

• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F

When C023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 49 Error code

C024

Trouble

P2 pump pressure sensor’s power source is shortcut.

Judging condition

The input voltage from P2 pump pressure sensor is 4.7 V or more.

Symptom

All operation speed slows down.

Control in the P2 pump pressure is controlled to 25 MPa. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

7

C-2 PUMP P2

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P2 pump pressure sensor

When C024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

SE-23 2

• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F

When C024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-32

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 50 Error code

C033

Trouble

Boom head pressure sensor’s wiring is disconnected.

Judging condition

The input voltage from boom head pressure sensor is 0.1 V or less.

Symptom

Overload alarm is not actuated.

Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

7

C-3 BOOM-HEAD

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• Boom head pressure sensor SE-24

When C033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between boom head pressure sensor and controller CN-706F CN-104F

When C033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 51 Error code

C034

Trouble

Boom head pressure sensor’s power source is shortcut.

Judging condition

The input voltage from boom head pressure sensor is 4.7 V or more.

Symptom

Overload alarm is not actuated.

Control in the Normal control. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

7

C-3 BOOM-HEAD

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Boom head pressure sensor SE-24

Checking contents and remedy When C034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between boom head pressure sensor and controller CN-706F CN-104F

When C034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-33

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 52 Error code

D012

Trouble

P1 unload proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

Option conflux can not be done.

Control in the Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode). event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

8

D-1 P1 UN-LOAD (BP-CUT)

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• P1 unload proportional valve PSV-D

When D012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P1 unload proportional valve and controller CN-120F CN-105F

When D012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 53 Error code

D013

Trouble

P1 unload proportional valve’s wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less. (If output is 150 mA or less, judging is not done.)

Symptom

Option conflux can not be done.

Control in the Set output of P1 unload proportional valve to 0mA. (Valve emergency mode). event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

8

D-1 P1 UN-LOAD (BP-CUT)

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• P1 unload proportional valve PSV-D

Checking contents and remedy When D013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P1 unload proportional valve and controller CN-120F CN-105F

When D013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-34

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 54 Error code

D022

Trouble

P2 unload proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

Independent operations of boom up and of bucket digging/dump become slow.

Control in the Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode) event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

8

D-2 P2 UN-LOAD (BP-CUT)

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• P2 unload proportional valve PSV-B

Checking contents and remedy When D022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P2 unload proportional valve and controller CN-118F CN-105F

When D022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-35

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 55 Error code

D023

Trouble

P2 unload proportional valve’s wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less. (If output is 150 mA or less, judging is not done.)

Symptom

Independent operations of boom up and of bucket digging/dump become slow.

Control in the Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode) event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

8

D-2 P2 UN-LOAD (BP-CUT)

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• P2 unload proportional valve PSV-B

When D023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between P2 unload proportional valve and controller CN-118F CN-105F

When D023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 56 Error code

D032

Trouble

Travel straight proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more

Symptom

Travel deviation occurs by combined operation of travel and attachment.

Control in the Set Travel straight proportional valve output to 0 mA event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

8

D-3 S-TRAVEL

Service diagnosis Screen checking screen No. Screen No. Checking object straight

Checking contents and remedy

1

• Travel valve

2

• Wiring between Travel straight proportional valve and controller CN-119F CN-105F

When D032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

PSV-C

proportional When D032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

T5-1-36

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 57 Error code

D033

Trouble

Travel straight proportional valve’s wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less. (If output is 150 mA or less, judging is not done.)

Symptom

Travel deviation occurs by combined operation of travel and attachment.

Control in the Set Travel straight proportional valve output to 0 mA. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

8

D-3 S-TRAVEL

Service diagnosis Screen checking screen No. Screen No. Checking object straight

Checking contents and remedy

1

• Travel valve

2

• Wiring between Travel straight proportional valve and controller CN-119F CN-105F

When D033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

PSV-C

proportional When D033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

T5-1-37

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 58 Error code

D062

Trouble

Arm-in spool 2 proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more

Symptom

Operability of combined operation with arm-in becomes poor.

Control in the Set Arm-in spool 2 proportional valve output to 0 mA. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

8

D-6 ARM IN-2-SPEED

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Arm-in valve

spool

2

PSV-A

Checking contents and remedy

proportional When D062 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F

When D062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-38

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 59 Error code

D063

Trouble

Arm-in spool 2 proportional valve’s wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less. (If output is 150 mA or less, judging is not done.)

Symptom

Operability of combined operation with arm-in becomes poor.

Control in the Set Arm-in spool 2 proportional valve output to 0 mA. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

8

D-6 ARM IN-2-SPEED

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Arm-in valve

spool

2

PSV-A

Checking contents and remedy proportional When D063 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.

2

• Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F

When D063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 60 Error code

E012

Trouble

P1 pump proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

All operation speed slows down.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

9

E-1 PUMP P1

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P1 pump proportional valve

When E012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

PSV-P1

2

• Wiring between P1 pump proportional valve and controller CN-141F CN-105F

When E012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-39

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 61 Error code

E013

Trouble

P1 pump proportional valve’s wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less. (If output is 150 mA or less, judging is not done.)

Symptom

All operation speed slows down.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

9

E-1 PUMP P1

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P1 pump proportional valve

When E013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

PSV-P1

2

• Wiring between P1 pump proportional valve and controller CN-141F CN-105F

When E013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-40

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 62 Error code

E022

Trouble

P2 pump proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

All operation speed slows down.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

9

E-2 PUMP P2

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P2 pump proportional valve

When E022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

PSV-P2

2

• Wiring between P2 pump proportional valve and controller CN-142F CN-105F

When E022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 63 Error code

E023

Trouble

P2 pump proportional valve’s wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less. (If output is 150 mA or less, judging is not done.)

Symptom

All operation speed slows down.

Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

9

E-2 PUMP P2

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• P2 pump proportional valve

When E023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

PSV-P2

2

• Wiring between P2 pump proportional valve and controller CN-142F CN-105F

When E023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-41

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 64 Error code

E032

Trouble

OPT relief 1 proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

Electromagnetic relief valve is disabled.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

7

E-3 OPT RELIEF 1

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• OPT relief 1 proportional valve PSV-P2

When E032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

2

• Wiring between OPT relief 1 proportional valve and controller CN-148F CN-105F

When E032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 65 Error code

E033

Trouble

OPT relief 1 proportional valve's wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less. (If output is 150 mA or less, judging is not done.)

Symptom

Electromagnetic relief valve is disabled.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

7

E-3 OPT RELIEF 1

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• OPT relief 1 proportional valve PSV-P2

Checking contents and remedy When E033 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

2

• Wiring between OPT relief 1 proportional valve and controller CN-148F CN-105F

When E033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-42

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 66 Error code

E042

Trouble

OPT relief 2 proportional valve and output transistor ON are failure.

Judging condition

The feed-back value from proportional valve is 1000 mA or more.

Symptom

Electromagnetic relief valve is disabled.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

7

E-4 OPT RELIEF 2

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• OPT relief 2 proportional valve PSV-P2

When E042 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

2

• Wiring between OPT relief 2 proportional valve and controller CN-132F CN-106F

When E042 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 67 Error code

E043

Trouble

OPT relief 2 proportional valve's wiring is disconnected.

Judging condition

The feed-back value from proportional valve is 100 mA or less. (If output is 150 mA or less, judging is not done.)

Symptom

Electromagnetic relief valve is disabled.

Control in the Normal control. event of failure Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it again. normal condition Screen No.

7

E-4 OPT RELIEF 2

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• OPT relief 2 proportional valve PSV-P2

Checking contents and remedy When E043 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.

2

• Wiring between OPT relief 2 proportional valve and controller CN-132F CN-106F

When E043 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-43

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 68 Error code

F021

Trouble

Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

Swing parking is not available.

Control in the Normal control. event of failure Returned in The feed-back signal is 24 V level while exciting command is output. normal condition Screen No.

3

F-2 SWING-BRAKE

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• Swing parking solenoid valve SV-1

When F021 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it. Check solenoid valve unit for possible failure. If failure found, replace it.

2

• Wiring between swing parking solenoid valve and controller CN-123F CN-105F

When F021 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 69 Error code

F023

Trouble

Swing parking solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24 V level while exciting command is not output.

Symptom

Swing parking is not available or is leaving available.

Control in the Normal control. event of failure Returned in The feed-back signal is grounding level while exciting command is output. normal condition Screen No.

3

F-1 POWER BOOST

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Swing parking solenoid valve SV-1

Checking contents and remedy When F023 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

• Wiring between swing parking solenoid valve and controller CN-123F CN-105F

When F023 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-44

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 70 Error code

F031

Trouble

Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-circuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

Travel 2 speed is not obtainable.

Control in the Normal control. event of failure Returned in The feed-back signal is 24 V level while exciting command is output. normal condition Screen No.

3

F-3 1/2-TRAVEL

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Travel 1, 2 speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector for other solenoid valve. SV-3 Check solenoid valve unit for possible failure. If failure found, replace it.

2

• Wiring between travel 1, 2 speed solenoid valve and controller CN-122F CN-105F

When F031 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-45

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 71 Error code

F033

Trouble

Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24 V level while exciting command is not output.

Symptom

Travel 2 speed is not obtainable or is keeping 1 speed.

Control in the Normal control. event of failure Returned in The feed-back signal is grounding level while exciting command is not output. normal condition Screen No.

3

F-3 1/2-TRAVEL

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Travel 1, 2 speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector for other solenoid valve. SV-3 Check solenoid valve unit for possible failure. If failure found, replace it.

2

• Wiring between travel 1, 2 speed solenoid valve and controller CN-122F CN-105F

When F033 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary..

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 72 Error code

F041

Trouble

Option selector solenoid valve and output transistor OFF are failure, and grounding is short-circuit.

Judging condition

The feed-back signal is grounding level while exciting command is output.

Symptom

Option selector valve does not change to breaker side.

Control in the Normal control. event of failure Returned in The feed-back signal is ground level while exciting command is output. normal condition Screen No.

11

F-4 OPT SELECT

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Option selector solenoid valve SV-13

Checking contents and remedy When F041 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

• Wiring between option selector solenoid valve and controller CN-251F CN-105F

When F041 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-46

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 73 Error code

F043

Trouble

Option selector solenoid valve and output transistor ON are failure, and disconnection.

Judging condition

The feed-back signal is 24 V level while exciting command is not output.

Symptom

Option selector valve does not change to breaker side or it does not change from breaker to nibbler.

Control in the Normal control. event of failure Returned in The feed-back signal is ground level while exciting command is not output. normal condition Screen No.

11

F-4 OPT SELECT

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Option selector solenoid valve SV-13

Checking contents and remedy When F043 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.

2

• Wiring between option selector solenoid valve and controller CN-251F CN-105F

When F043 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-47

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 74 Error code

G032

Trouble

Mechatro controller direct input speed sensor is overrun.

Judging condition

Engine rpm input is 3000 rpm or more. (Only trouble history).

Symptom

Operate without problem.

Control in the Receive rpm from engine controller and control the rpm. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

2

G-3 MEAS 1 (for mechatro controller)

Service diagnosis Screen checking screen No.

2

G-3 MEAS 2 (receive from engine controller)

Screen No. Checking object

Checking contents and remedy

1

• Engine speed sensor

Measure the resistance between terminals of speed sensor.

2

• Wiring between option selector Check wiring for possible failure according to the wiring checking solenoid valve and controller procedure and repair it if necessary. CN-136F Especially check wiring for false disconnection and noise included. CN-106F

3

• Mechatro controller

SV-13

Normal value: 1.6~2.0k

.

Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal).

Table 75 Error code

G033

Trouble

Mechatro controller direct input speed sensor, Disconnection.

Judging condition

Voltage of alternator is 12 V or more, and speed sensor indicates excess low engine rpm.

Symptom

Operate without problem.

Control in the Receive rpm from engine controller and control the rpm. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

2

G-3 MEAS 1 (for mechatro controller)

Service diagnosis Screen checking screen No.

2

G-3 MEAS 2 (receive from engine controller)

Screen No. Checking object 1

• Engine speed sensor SE-13

Checking contents and remedy Measure the resistance between terminals of speed sensor. Normal value: 1.6~2.0k

.

2

• Wiring between engine speed sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-136F CN-106F

3

• Mechatro controller

Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.).

T5-1-48

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 76 Error code

G042

Trouble

Mechatro controller direct input speed sensor and received data from engine controller are overrun.

Judging condition

Engine rpm input is 3000 rpm or more. (Only trouble history).

Symptom

Operate without problem.

Control in the Normal control event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

2

G-3 MEAS 1 (for mechatro controller)

Service diagnosis Screen No. checking screen

2

G-3 MEAS 2 (receive from engine controller)

Screen No.

Checking object 1

Checking contents and remedy

• Engine speed sensor

Measure the resistance between terminals of speed sensor.

SE-13

Normal value: 1.6~2.0k

.

2

• Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure sensor and controller and repair it if necessary. CN-136F Especially check wiring for false disconnection and noise included. CN-106F

3

• Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure speed sensor and controller and repair it if necessary. pressure sensor and controller Especially check wiring for false disconnection and noise included.

4

• Mechatro controller

Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal).

5

• Engine controller

Check that the error is corrected after replacement of controller.

Table 77 Error code

G043

Trouble

Mechatro controller direct input speed sensor and received data from engine controller are disconnected.

Judging condition

Voltage of alternator is 24V or more, and speed sensor and receipt data from engine controller indicate excess low engine rpm.

Symptom

Engine speed down may cause extension by abrupt loading.

Control in the Enter 0 rpm for engine speed. Enter 0 for ESS power shift command event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

2

G-3 MEAS 1 (for mechatro controller)

Service diagnosis Screen No. checking screen

2

G-3 MEAS 2 (receive from engine controller)

Screen No.

Checking object 1

• Engine speed sensor SE-13

Checking contents and remedy Measure the resistance between terminals of speed sensor. Normal value: 1.6~2.0k

.

2

• Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure sensor and controller and repair it if necessary. CN-136F CN-106F

3

• Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure speed sensor and controller and repair it if necessary. pressure sensor and controller

4

• Mechatro controller

Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal).

5

• Engine controller

Check that the error is corrected after replacement of controller.

T5-1-49

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 78 Error code

H013

Trouble

Accel potentiometer is disconnected.

Judging condition

The input voltage from accel potentiometer is 0.1 V or less.

Symptom

LOW idling is fixed.

Control in the LOW idling is fixed. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

2

H-1 ACCEL VOLT.

Service diagnosis Screen checking screen No. Screen No. Checking object 1

Checking contents and remedy

• Accel potentiometer

Measure the resistance between terminals of speed sensor. 1.6~2.4k Turn the potentiometer and measure resistance between signal and GND.

SE-16 2

• Wiring between accel potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-402F CN-102F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 79 Error code

H014

Trouble

Accel potentiometer’s power source is shortcut.

Judging condition

The input voltage from accel potentiometer is 4.7 V or more.

Symptom

LOW idling is fixed.

Control in the LOW idling is fixed. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

2

H-1 ACCEL VOLT.

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Accel potentiometer SE-16

Checking contents and remedy Measure the resistance between terminals of accel potentiometer. 1.6~2.0k . Turn the potentiometer and measure resistance between signal and GND.

2

• Wiring between accel potentiometer and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-402F CN-102F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-50

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 80 Error code

H091

Trouble

Fuel sensor grounding is short-circuited.

Judging condition

The input voltage from fuel sensor is 0.1 V or less.

Symptom

Warning for low fuel level is indicated.

Control in the Fuel level becomes 0%. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

10

H-9 FUEL LEVEL

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• Fuel sensor potentiometer

Move fuel sensor and measure the resistance between terminals of fuel sensor.

SE-15

EMPTY 95

.~ FULL 5

2

• Wiring between fuel sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-152F CN-104F

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

Table 81 Error code

H093

Trouble

Fuel sensor’s wiring is disconnection.

Judging condition

The input voltage from fuel sensor is 4.7 V or more.

Symptom

Warning for low fuel level is indicated.

Control in the Fuel level becomes 0%. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

10

H-9 FUEL LEVEL

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Fuel sensor potentiometer

Move fuel sensor and measure the resistance between terminals of fuel sensor.

2

• Wiring between fuel sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-152F CN-104F

3

• Mechatro controller

SE-15

EMPTY 95

.~ FULL 5

Check that the error is corrected after replacement of controller.

T5-1-51

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 82 Error code

I111

Trouble

Reception of CAN1 communication is abnormal. (Passive error)

Judging condition

Reception from engine controller can not receive correctly.

Symptom

It has been affected little.

Control in the Keep the last receiving condition. event of failure Returned in It returns automatically in normal condition. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Wiring between controller CN-3F CN-101F

2

• Mechatro controller

Checking contents and remedy ECU

and

Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. (There is a possibility of false disconnection). Check that the error is corrected after replacement of controller.

Table 83 Error code

I113

Trouble

Reception of cluster communication is abnormal. (time-out error)

Judging condition

Reception from gauge cluster can not receive correctly. It has been affected little.

Symptom

It has been affected little.

Control in the It can be operated in condition that coolant temperature is 20 °C. event of failure Returned in It returns automatically in normal condition. normal condition Screen No.

2

G-5 WATER TEMP

Service diagnosis Screen checking screen No. Screen No. Checking object 1

2

• Wiring between controller CN-3F CN-101F • Mechatro controller

Checking contents and remedy ECU

and Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check that the error is corrected after replacement of controller.

T5-1-52

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 84 Error code

I313

Trouble

Reception of cluster communication is abnormal. (Time-out error)

Judging condition

Reception from gauge cluster can not receive correctly.

Symptom

Switch operation of gauge cluster can not be done.

Control in the Keep the condition after immediately key-on is operated. event of failure Returned in It returns automatically in normal condition. normal condition Screen No. Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Wiring between gauge cluster and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-600F CN-101F

2

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-53

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 85 Error code

K014

Trouble

Battery relay contact welded.

Judging condition

The power 24 V is continuously supplied to controller for 40 seconds or more while the key switch ON signal turned OFF.

Symptom

The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.

Control in the Normal control with key switch OFF. event of failure Returned in Turn key switch ON. normal condition Or when the power supply 24 V to mechatro controller is stopped. Screen No.

4

K-1 AIS RELAY 2

Service diagnosis Screen checking screen No.

4

K-3 KEY SWITCH OFF

Screen No. Checking object

Checking contents and remedy

1

• Battery relay R-1 CN-256F

Turn key switch off and disconnect the connector (CN-256F) on the battery relay coil. If 24 V power lives on battery relay secondary side, check on battery relay for failure and replace it if failed.

2

• Auto idle stop relay 2 R-24 • Alternator relay

Turn off the key switch, and remove the connector (CN-256F) on the battery relay coil side. If power of battery relay on secondary side falls, remove either auto idling stop relay 2 or alternator relay. The failure may be occurred in case where the power falls after the relay was removed, and therefore check on the relay unit and replace it with new one if failed.

R-28

3

• Wiring between auto idle stop relay/alternator relay and When K014 is left displayed with the relay removed. Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed • Fuse& relay box Replace fuse/relay box. E-1

4

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-54

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 86 Error code

R014

Trouble

Wiper motor arc prevention relay error.

Judging condition

The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power source.

Symptom

Wiper does not move.

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

25

PREVENT ARC

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Wiper motor arc relay R-31

Checking contents and remedy prevention When error is cancelled after removing wiper motor arc prevention relay, check relay unit for failure, replace it with new one if failed.

2

• Wiring between wiper motor arc prevention relay and controller CN-109F, CN2-1 • Fuse& relay box

3

• Mechatro controller

E-1

When resistance between relays (1) and (2) is 0

, it is in abnormal condition.

When R014 is left displayed with the relay removed. Check that no power 24 V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R014 is left displayed. Replace fuse/relay box. Check that the error is corrected after replacement of controller.

T5-1-55

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 87 Error code

R024

Trouble

Wiper motor forward rotation relay error.

Judging condition

The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the power source.

Symptom

Wiper does not move.

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

25

CW MOTOR RLY

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay, check relay unit for failure, replace it with new one if failed. relay R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between wiper motor forward rotation relay and When R024 is left displayed with the relay removed. Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed. • Fuse& relay box Replace fuse/relay box. E-1

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-56

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 88 Error code

R034

Trouble

Wiper motor reverse rotation relay error.

Judging condition

The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power source.

Symptom

Wiper does not move after forward rotation.

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

25

CCW MOTOR RLY

Service diagnosis Screen checking screen No. Screen No. Checking object

Checking contents and remedy

1

• Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay, check relay unit for failure, replace it with new one if failed. relay R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2

• Wiring between wiper motor forward rotation relay and When R034 is left displayed with the relay removed Check that no power 24 V is produced on relay (-) line according to the wiring controller checking procedure and replace it if necessary. CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed • Fuse& relay box Replace fuse/relay box. E-1

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-57

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 89 Error code

R044

Trouble

Washer motor relay error.

Judging condition

The mechatro controller output line to washer motor relay is short-circuited with the power source.

Symptom

Washer motor does not move.

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

25

MOTOR RELAY

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Washer motor relay R-32

Checking contents and remedy When error is cancelled after removing washer motor relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0

, it is in abnormal condition.

2

• Wiring between washer motor When R044 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-112F, CN2-1 checking procedure and replace it if necessary. When no failure found after checking on wiring and R044 is left displayed • Fuse& relay box Replace fuse/relay box. E-1

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-58

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 90 Error code

R134

Trouble

Swing flasher relay error.

Judging condition

The mechatro controller output line to swing flasher relay is short-circuited with the power source.

Symptom

Right swing flasher does not light.

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

22

D13

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Swing flasher relay R-19

Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0 condition.

, it is in abnormal

2

• Wiring between swing flasher When R134 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line (as shown right upper CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-59

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 91 Error code

R144

Trouble

Swing flasher relay error.

Judging condition

The mechatro controller output line to swing flasher relay is short-circuited with the power source.

Symptom

Left swing flasher does not light.

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

22

D14

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Swing flasher relay R-19

Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0 condition.

, it is in abnormal

2

• Wiring between swing flasher When R144 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line (as shown right upper CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if necessary.

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-60

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 92 Error code

R154

Trouble

Travel alarm relay error.

Judging condition

The mechatro controller output line to travel alarm relay is short-circuited with the power source.

Symptom

Travel alarm does not actuate.

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

23

D15

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Travel alarm relay R-8

Checking contents and remedy When error is cancelled after removing of travel alarm relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0

, it is in abnormal condition.

2

• Wiring between travel alarm When R154 is left displayed with the relay removed relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-109F, CN2-2 checking procedure and replace it if necessary. When no failure found after checking on wiring and R154 is left displayed. • Fuse & relay box Replace fuse/relay box. E-1

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-61

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 93 Error code

R164

Trouble

Auto idle stop relay 2 relay error.

Judging condition

The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.

Symptom

Power source for mechatro controller often turns off. Auto idle stop relay 2 does not actuate.

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

4

K-1 AIS RELAY 2

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• Auto idle stop relay 2 relay R-24

When error is cancelled after removing of auto idle stop relay 2, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0

, it is in abnormal condition.

2

• Wiring between auto idle stop When R164 is left displayed with the relay removed relay 2 and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-109F, CN2-2 checking procedure and replace it if necessary. When no failure found after checking on wiring and R164 is left displayed. • Fuse & relay box Replace fuse/relay box. E-1

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-62

Copyright © New Holland TROUBLESHOOTING (BY ERROR CODES)

E135B

Table 94 Error code

R174

Trouble

Engine forcibly stop relay error.

Judging condition

The mechatro controller output line to engine forcibly stop is short-circuited with the power source.

Symptom

When key switch is turned off but engine does not stop. Engine auto idle stop function does not actuate..

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

4

K-3 ENG STOP

Service diagnosis Screen checking screen No. Screen No. 1

Checking object

Checking contents and remedy

• Engine forcibly stop relay R-25

When error is cancelled after removing of engine forcibly stop relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0

, it is in abnormal condition.

2

• Wiring between engine forcibly When R174 is left displayed with the relay removed stop relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring CN-109F, CN2-2 checking procedure and replace it if necessary. When no failure found after checking on wiring and R174 is left displayed. • Fuse & relay box Replace fuse/relay box. E-1

3

• Mechatro controller

Check that the error is corrected after replacement of controller.

T5-1-63

Copyright © New Holland E135B

TROUBLESHOOTING (BY ERROR CODES)

Table 95 Error code

R184

Trouble

Safety lock lever relay error.

Judging condition

The mechatro controller output line to safety lock lever relay is short-circuited with the power source.

Symptom

Safety lock lever timer does not actuate.

Control in the Relay output is stopped. event of failure Returned in When the power is OFF. normal condition Screen No.

4

K-4 LOCK LEVER

Service diagnosis Screen checking screen No. Screen No. Checking object 1

• Safety lock lever relay R-26

Checking contents and remedy When error R184 is cancelled after removing of safety lock lever relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is

2

• Wiring between safety lock lever relay and controller CN-109F, CN2-2 • Fuse & relay box E-1

3

• Mechatro controller

, it is in abnormal condition.

When R184 is left displayed with the relay removed Check that no power 24 V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R184 is left displayed. Replace fuse/relay box. Check that the error is corrected after replacement of controller.

T5-1-64

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

E135B

TROUBLESHOOTING BY TROUBLE 1. HYDRAULIC SYSTEM Preface: The troubleshooting for the failures shown below is explained here. Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number. 1.

All controls do not function/slow

2.

Engine down/stalled

3.

Move at lever neutral position

4.

Poor fine operability

5.

Slow boom up, insufficient power

6.

Slow boom down, insufficient power for lifting up body

7.

Slow arm in, insufficient power

8.

Slow independent arm out (in the air)

9.

Slow bucket digging

10. Slow bucket dumping 11. Swing operation not functioned/slow 12. Noise during swing operation 13. Swing on a slope drifts when control lever is in neutral position 14. Swing drifts at stopping 15. Travel speed is slow/poor 16. Travel deviation 17. Travel 1st/2nd speed cannot be switched 18. Machine does not stay on slope in travelling 19. Machine does not travel straight in simultaneous operation of travelling and attachment. 20. Breaker works slowly and power is poor 21. Option selector valve malfunction: not switched to breaker circuit 22. Option selector valve malfunction: not switched to nibbler circuit

T5-2-1

Copyright © New Holland E135B 1.

TROUBLESHOOTING (BY TROUBLE)

All controls do not function/slow

No.

Sections

Contents/normal value

Corrective action, others

1

Fuse

Check fuse No.4 (10 A)

If the fuse is blown out, check on the short-circuited section.

2

Safety lever lock switch

Carry out service diagnosis

Check action of switch by No.4 K-4 switch: Push down the lever and it turns on, push tester, or check that the power voltage is lowered by pushing up and it turns off. the lever down.

3

Safety lever lock switching

Measure both terminals of solenoid Check that the solenoid is switched connector. 24 V by pushing the lever down, 0 V by pushing it up correctly

4

Safety lever lock relay

Carry out service diagnosis

5

Pilot pressure sensor

6

Solenoid valve for safety lock lever

7

Check solenoid unit for possible failure. Check harness for possible failure.

Check action of relay by tester No.4 K-4 lock lever: Push down the lever and it turns off, push up and it turns on. • Stop engine stop and key is on position. All pilot low pressure sensors are 0 MPa to 0.1 MPa.

Check 5 V power for controller

Measure pressure of solenoid A1 port

About 0 MPa by pushing the lever up, and 4 MPa or more by push it down.

Replace solenoid valve

Pilot line filter

Disassemble and check it visually

Check filter for clogging

Clean filter

8

Pilot gear pump

Check that it is 4 MPa or more in high Measure pilot primary pressure at idling gear pump

9

Multi control valve (in Change position case that travel is operable)

10

Actual measuring current value of P1/ P2 unload proportional valve

11

Secondary pressure Measure the proportional valve of P1, P2 unload secondary pressure proportional valve directly at the ports A7 and A5 of 8 sections solenoid block

12

Actual measuring current value of P1/ P2 pump proportional valve

Carry out service diagnosis

Carry out service diagnosis.

Check gear pump and the relief valve for possible failure

Since all are blocked due to poor switching performance, check that the lever select pattern is set to the proper position. • No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.3 Boom up full lever & relief

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Replace proportional valve Check that P1/P2 unload secondary pressures are within the range of 0.5 to 1.2 MPa in boom up full lever and high idling operation

• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling

T5-2-2

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

E135B

Corrective action, others

13

Secondary pressure Measure the pump of pump proportional proportional valve valve secondary pressure directly in idling operation. (Ports a3, a4)

Replace proportional valve Check that pump proportional valve secondary pressure is 2.7 MPa or more in right (left) travel full lever and high idling operation Right travel: P1 pump proportional valve Left travel: P2 pump proportional valve

14

Main relief pressure

• See Service Diagnosis Data List Measure the relief pressure Operation No.3 Boom up full lever & relief actually

15

Carry out service diagnosis

Check set pressure Check that P1 and P2 pump pressures are 32 MPa in boom up full lever, high idling and H mode operation.

Reset or replace

16

Pump regulator

Visual check

Replace When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.

17

Pump

Visual check

Replace When removing, inside parts (cylinder block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.

2.

Engine down/stalled

No.

Sections

Contents/normal value

Corrective action, others

• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. 1 Operation is nil

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Secondary pressure Measure the pump proportional valve of P1, P2 pump secondary pressure proportional valve directly (Ports a3, a4)

Check that P1/P2 pump proportional valve pressures are within the range of 0.5 to 1.0 MPa in control lever neutral and high idling operation.

Replace proportional valve

3

Pressure sensor of P1, P2 pump

Check pressure

• See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.3 Boom up full lever & relief

Check pressure sensor and replace it if necessary

4

Pump regulator

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.

Replace

5

Pump

Visual check

Replace When removing, inside parts (cylinder block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.

1

Actual measuring current value of P1/ P2 pump proportional valve

2

Carry out service diagnosis

T5-2-3

Copyright © New Holland E135B 3.

TROUBLESHOOTING (BY TROUBLE)

Move at lever neutral position

No. Sections

Contents/normal value

Corrective action, others

1

Pilot pressure sensor

Carry out service diagnosis

Check that targeted pilot pressure of sensor is 0MPa in high idling

Check remote control valve

2

Remote control valve

Check targeted remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

3

Main spool

Check targeted spool visually

Check that spool is free from abnormal damage and spring is free from breakage

Replace

4

Over load relief valve

Check targeted spool visually

Free from dust entered in port relief valve. Seat is free from abnormality

Replace

5

Check targeted Lock valve poppet (in case of boom and poppet visually arm)

Seat is free from abnormality

Replace

6

Lock valve selector Exchange lock (in case of boom and valve selector of boom/arm and arm) boom/arm

Check that the trouble is reversed

Replace

7

Holding valve spool for boom (in case of boom)

Check that smooth sliding of spool in sleeve

Free from abnormal resistance against sliding

Replace Do not pull spool out of sleeve forcibly.

8

Holding valve relief valve for boom (in case of boom)

Check targeted spool visually

Filter free from abnormal contamination Replace

9

Cylinder

Check targeted cylinder visually

Make sure of no problem of seals by disassembling and investigation

4.

Replace cylinder or seals

Poor fine operability

No. Sections

Contents/normal value

Corrective action, others

1

Pressure sensor

Carry out service diagnosis

• See Service Diagnosis Data List Replace pressure sensor Operation No. 1 Operation is nil • All low pressure sensors are 0MPa to 0.1 MPa

2

Actual measuring current value of P1/ P2 unload proportional valve

Carry out service diagnosis

• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No. 1 Operation is nil

3

Secondary pressure Measure the proportional valve of unload secondary pressure proportional valve directly at the ports A7 and A8 of 8 sections solenoid block

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Replace proportional valve Check that P1/P2 unloads secondary pressures is within the range of 2.7 MPa or more in control lever neutral and high idling operation

T5-2-4

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

No. Sections

Contents/normal value

Corrective action, others

Carry out service diagnosis

• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No. 1 Operation is nil

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Check that P1/P2 pump proportional valve pressures are within the range of 0.5 to 1.0 MPa in control lever neutral and high idling operation

Replace proportional valve Check regulator

Check that slow return check valve installed on pilot line is free from dust entered

Clean and replace

4

Actual measuring current value of P1/ P2 pump proportional valve

5

Secondary pressure Measure the pump proportional valve of P1, P2 pump secondary pressure proportional valve directly. (Ports a3, a4)

6

Slow return check valve of pilot line (in case of boom up or arm out)

5.

E135B

Visual check

Slow boom up, insufficient power

No. Sections

Contents/normal value

1

Boom up pressure sensor

Carry out service diagnosis

Check and replace pressure • See Service Diagnosis Data List Operation No.3 boom up full lever and sensor Check remote control valve relief

2

Remote control valve

Measure directly remote control pressure of boom up

Check that pressure is 3.0 MPa or more Check remote control valve When equipped with multi in boom up full lever and high idling control valve, check it while operation changing lever pattern

3

Pump pressure sensor

• See Service Diagnosis Data List Carry out service Operation No.4 boom up full lever and diagnosis for P1, P2 in operation pump pressures in operation.

When there is difference between P1 and P2 pump pressures, check high pressure sensor.

4

Actual measuring current value of P1/ P2 unload proportional valve

Carry out service diagnosis

• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.3 Boom up full lever & relief

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

5

Secondary pressure Measure the proportional valve of P1, P2 unload secondary pressure proportional valve directly at the ports A7 and A5 of 8 sections solenoid block

Check that P1/P2 unload secondary pressures are within the range of 0.5~1.2 MPa in boom up full lever and high idling operation

Replace proportional valve

6

Actual measuring current value of P1/ P2 pump proportional valve

• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.4 boom up full lever & in operation

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

7

Secondary pressure Measure the pump proportional valve of P1, P2 pump secondary pressure proportional valve directly (Ports a3, a4)

Carry out service diagnosis

Corrective action, others

Replace proportional valve Check that P1/P2 pump proportional valve pressures are within the range of 1.8 to 3.0 MPa in boom up full lever and high idling operation

T5-2-5

Copyright © New Holland E135B

No. Sections

TROUBLESHOOTING (BY TROUBLE)

Contents/normal value

Corrective action, others

8

P2 by-pass cut valve Visual check

Only P2 pressure is low.

No problem for sliding ability of main poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)

Clean and replace

9

Remote control valve

Check targeted remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

10

Lock valve poppet

Both P1 and P2 pressures are low.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

11

Conflux check valve Visual check

Only P2 pressure is high.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

12

Holding valve for boom (poppet)

Both P1 and P2 pressures are high.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

13

Boom spool

Only P1 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding Spring is free from breakage.

Replace (Check on the casing side for damage)

14

Check boom spool and recirculation

Only P1 pressure is low.

Disassembly and investigation

Free from abnormal resistance against sliding Spring is free from breakage.

Replace spool assembly

15

Conflux spool

Only P2 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding Spring is free from breakage. Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

16

Main relief valve

Relief pressure is low.

Reset or replace Check set pressure • See Service Diagnosis Data List Operation No.3 boom up full lever and relief

17

Over load relief valve

Relief pressure is low.

Visual check (Head Pressure is 32 MPa or more in boom up When only relief pressure of side) full lever and high idling. Free from dust boom up is low, replace valve entered in over load relief valve. Seat is free from abnormality

6.

Slow boom down, insufficient power for lifting up body

No. Sections

Contents/normal value

Corrective action, others

1

Carry out service diagnosis

Check and replace pressure sensor. Check remote control valve.

Boom down pressure sensor

• See Service Diagnosis Data List Operation No.5 boom down full lever & in operation

T5-2-6

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

E135B

No. Sections

Contents/normal value

2

Remote control valve

Check that pressure is 3.0 MPa or more Check remote control valve Measure remote control pressure of in boom down full lever and high idling When equipped with multi control valve, check it while boom down directly operation changing lever pattern.

3

Actual measuring current value of P1 unload proportional valve

Carry out service diagnosis

4

Secondary pressure Measure the proportional valve of P1 unload secondary pressure proportional valve directly at the ports A7 of 8 sections solenoid block.

5

Actual measuring current value of P1 pump proportional valve

6

Secondary pressure Measure the pump proportional valve of P1 pump secondary pressure proportional valve directly (Ports a3, a4)

7

Actual measuring current value of travel straight proportional valve

Carry out service diagnosis

• Check pressure sensor of Check that the value is not change travel regardless of operation • See Service Diagnosis Data List • In case where the reading is Operation No. 1 Operation is nil largely differed from the Operation No.18 Travel right full lever actually measured value, & idling check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.

8

Travel straight proportional valve secondary pressure

Measure directly the travel straight proportional valve secondary pressure.

High idling pressure is 0.8 MPa or less regardless neutral/operation

Replace proportional valve

9

Remote control valve

Check targeted remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

10

Lock valve poppet

Boom down is low.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

Carry out service diagnosis

Corrective action, others

P1 unload valve (cut valve) • See Service Diagnosis Data List Operation No.5 boom down full lever & in operation

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Replace proportional valve Check that P1 unload secondary pressures are within the range of 0.8 to 1.2 MPa in boom down full lever and high idling operation

• No.9 E-1 P1 pump • See Service Diagnosis Data List Operation No.5 boom down full lever & in operation

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Check that P1 pump proportional valve Replace proportional valve pressures are within the range of 2.0 to 2.5 MPa in boom down full lever and high idling operation

T5-2-7

Copyright © New Holland E135B

TROUBLESHOOTING (BY TROUBLE)

No. Sections

Contents/normal value

Corrective action, others

11

Visual check Holding valve (poppet)

Boom down is slow.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

12

Visual check Boom spool

Boom down is slow.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

13

Check boom spool and recirculation

Machine can not be lifted by supporting with boom.

Disassembly and investigation

Free from abnormal resistance against sliding Spring is free from breakage.

Replace spool assembly

14

Main relief valve

Relief pressure is low.

Reset or replace Check set pressure • See Service Diagnosis Data List Operation No.3 boom up full lever and relief

15

Over load relief valve

Machine can not be lifted by supporting with boom.

Visual check

7. No.

Free from dust entered in port relief valve. Seat is free from abnormality

Replace

Slow arm in, insufficient power Sections

Contents/normal value

Corrective action, others Check and replace pressure sensor Check remote control valve

1

Arm in pressure sensor

Carry out service diagnosis

• See Service Diagnosis Data List Operation No.6 arm in full lever and relief

2

Remote control valve pressure

Measure directly remote control pressure of arm in

Check that pressure is 3.0 MPa or more Check remote control valve When equipped with multi in arm in full lever and high idling control valve, check it while operation changing lever pattern

3

Pump pressure sensor

• See Service Diagnosis Data List Carry out service Operation No.7 arm in full lever and in diagnosis for P1, P2 operation pump pressures in operation.

When there is difference between P1 and P2 pump pressures, check high pressure sensor

4

Actual measuring current value of P1/ P2 unload proportional valve

Carry out service diagnosis

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.6 Arm in full lever & relief

T5-2-8

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

E135B

Corrective action, others

Replace proportional valve Check that P1/P2 unload secondary pressures are within the range of 0.5 to 1.2 MPa in arm in full lever and high idling operation.

5

Secondary pressure Measure the proportional valve of P1, P2 unload secondary pressure proportional valve directly at the ports A7 and A5 of 8 sections solenoid block.

6

Actual measuring current value of P1/ P2 pump proportional valve

7

Secondary pressure Measure the pump proportional valve of P1, P2 pump secondary pressure proportional valve directly. (Ports a3, a4)

Replace proportional valve Check that P1/P2 pump proportional valve pressures are 2.0 MPa or more in arm in full lever and high idling operation. (Secondary pressure is affected by oil temperature and attachment weight)

8

Carry out service Actual measuring current value of arm diagnosis in spool 2 proportional valve

• See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.6 Arm in full lever & relief Operation No.7 Arm in full lever & in operation

9

Secondary pressure Measure directly the proportional of arm in spool 2 valve secondary proportional valve pressure at the ports A8 (arm 2 spool) of 8 sections solenoid block.

Replace proportional valve Check that secondary pressure of proportional valve secondary pressures are within the range of following Lever neutral: 0 MPa Motion in the air: 1.7 to 2.2 MPa Arm in relief: 2.5 MPa or more

10

Actual measuring current value of travel straight proportional valve

11

Secondary pressure Measure directly the proportional of travel straight valve secondary proportional valve pressure at the ports A6 (travel straight) of 8 sections solenoid block

0.8 MPa or less in high idling operation regardless of neutral/operation

Replace proportional valve

12

Remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

Carry out service diagnosis

Carry out service diagnosis

Check targeted remote control valve

• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.7 Arm in full lever & in operation

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

• Check pressure sensor of Check that the value is not change travel regardless of operation • See Service Diagnosis Data List • In case where the reading is Operation No. 1 Operation is nil largely differed from the Operation No.18 Travel right full lever actually measured value, & idling check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.

T5-2-9

Copyright © New Holland E135B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

13

Main relief valve

Relief pressure is low.

Reset or replace Check set pressure • See Service Diagnosis Data List Operation No.3 boom up full lever and relief

14

Over load relief valve

P1, P2 pressure is low.

When only relief pressure of Visual check (Head Pressure is 32 MPa or more in arm in arm in is low, replace valve side) and relief. Free from dust entered in over load relief valve. Seat is free from abnormality

15

Over load relief valve

P1, P2 pressure is low.

Visual check (Rod side)

Pressure is 32 MPa or more in arm out When only relief pressure of arm out is low, replace valve and relief. Free from dust entered in over load relief valve. Seat is free from abnormality.

16

Arm 1 spool

P1, P2 pressure is high.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

17

Arm 2 spool

P1, P2 pressure is high or low.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

18

Check arm 2 spool and recirculation

Arm in power is poor.

Disassembly and investigation

Free from abnormal resistance against sliding Spring is free from breakage.

Replace spool assembly

19

Check lock valve poppet

Both P1, P2 pressures are high.

Visual check

Free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

8. No.

Slow independent arm out (in the air) Sections

Contents/normal value

Corrective action, others

Check and replace pressure • See Service Diagnosis Data List Operation No.8 arm out full lever and sensor Check remote control valve relief

1

Arm out pressure sensor

Carry out service diagnosis

2

Remote control valve

Check that pressure is 3.0 MPa or more Check remote control valve Measure directly When equipped with multi in arm out full lever and high idling remote control control valve, check it while pressure of arm out operation changing lever pattern

T5-2-10

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

E135B

Corrective action, others

3

Pump pressure sensor

• See Service Diagnosis Data List Carry out service Operation No.9 arm out full lever and diagnosis for P1, P2 in operation pump pressures in operation.

When there is difference between P1 and P2 pump pressures, check high pressure sensor

4

Actual measuring current value of P1/ P2 unload proportional valve

Carry out service diagnosis

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

5

Secondary pressure Measure the proportional valve of P1, P2 unload secondary pressure proportional valve directly at the ports A7 and A5 of 8 sections solenoid block

6

Actual measuring current value of P1/ P2 pump proportional valve

7

Secondary pressure Measure the pump proportional valve of P1, P2 pump secondary pressure proportional valve directly (Ports a3, a4)

8

Actual measuring current value of travel straight proportional valve

9

Secondary pressure Measure directly the proportional of travel straight valve secondary proportional valve pressure at the ports A6 (travel straight) of 8 sections solenoid block

0.8 MPa or less in high idling operation regardless of neutral/operation

Replace proportional valve

10

Remote control valve

Check targeted remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

11

Main relief valve

Relief pressure is low.

Reset or replace Check set pressure • See Service Diagnosis Data List Operation No.3 boom up full lever and relief

Carry out service diagnosis

Carry out service diagnosis

• No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.8 Arm out full lever & relief

Replace proportional valve Check that P1/P2 unload secondary pressures are within the range of 0.5 to 1.2 MPa in arm out full lever and high idling operation

• No.9 E-1 P1 pump E-2 P2 pump • See Service Diagnosis Data List Operation No.9 Arm out full lever & in operation

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Check that P1/P2 pump proportional valve pressures are within the range of 1.5 to 2.7 MPa in arm out full lever and high idling operation (Secondary pressure is affected by oil temperature and attachment weight)

Replace proportional valve

• Check pressure sensor of Check that the value is not change travel regardless of operation • See Service Diagnosis Data List • In case where the reading is Operation No. 1 Operation is nil largely differed from the Operation No.18 Travel right full lever actually measured value, & idling check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.

T5-2-11

Copyright © New Holland E135B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value Visual check (Rod side)

Corrective action, others

Pressure is 32 MPa or more in arm out When only relief pressure of arm out is low, replace valve and relief. Free from dust entered in over load relief valve. Seat is free from abnormality

12

Over load relief valve

P1, P2 pressure is low.

13

Visual check Arm 1 spool

P2 pressure is high.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

14

Visual check Arm 2 spool

P1 pressure is high.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

15

Check arm 2 spool and recirculation

Both P1, P2 pressures are low.

Disassembly and investigation (spring side)

Free from abnormal resistance against sliding Spring is free from breakage.

Replace spool assembly

16

Check lock valve poppet

Both P1, P2 pressures are high.

Visual check

Free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

9.

Slow bucket digging

No. Sections

Contents/normal value

Corrective action, others

1

Bucket digging pressure sensor

Carry out service diagnosis

• See Service Diagnosis Data List Operation No.12 bucket digging full lever and relief

Check and replace pressure sensor Check remote control valve

2

Remote control valve

Measure directly remote control pressure of bucket digging

Check that pressure is 3.0M Pa or more Check remote control valve When equipped with multi in bucket digging full lever and high control valve, check it while idling operation changing lever pattern

3

Pump pressure sensor

• See Service Diagnosis Data List Carry out service Operation No.13 Bucket digging full diagnosis for P1, P2 lever and in operation pump pressures in operation.

When there is difference between P1 and P2 pump pressures, check high pressure sensor

4

Actual measuring current value of P1 unload proportional valve

Carry out service diagnosis

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

5

Secondary pressure Measure the proportional valve of P1 unload secondary pressure proportional valve directly at the ports A7 and A5 of 8 sections solenoid block

• No.8 D-1 P1 unload valve (cut valve) • See Service Diagnosis Data List Operation No.12 Bucket digging full lever & relief

Replace proportional valve Check that P1 unload secondary pressures are within the range of 0.5 to 1.2 MPa in bucket digging full lever and high idling operation

T5-2-12

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

E135B

No. Sections

Contents/normal value

Corrective action, others

6

Actual measuring current value of P1 pump proportional valve

Carry out service diagnosis

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

7

Secondary pressure Measure the pump proportional valve of P1 pump secondary pressure proportional valve directly (Ports a3)

8

Actual measuring current value of travel straight proportional valve

9

• No.9 E-1 P1 pump • See Service Diagnosis Data List Operation No.13 Bucket digging full lever & in operation

Check that P1 pump proportional valve Replace proportional valve pressures is 2.7 MPa or more in bucket digging full lever and high idling operation. • See Service Diagnosis Data List Operation No.12 Bucket digging full lever & relief

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

P2 by-pass cut valve Visual check

Only P2 pressure is low.

No problem for sliding ability of main poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)

Clean or replace

10

Remote control valve

Check targeted remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

11

Main relief valve

Reset or replace Check set pressure • See Service Diagnosis Data List Operation No.3 Boom up full lever and relief

12

Travel straight spool Visual check

P2 pressure is high.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

13

Bucket spool

Both P1, P2 pressures are high.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

14

Over load relief valve

Check targeted spool visually

Free from dust entered in over load relief Replace valve. Seat is free from abnormality.

Carry out service diagnosis

10. Slow bucket dumping No.

Sections

Contents/normal value

Corrective action, others Check and replace pressure sensor Check remote control valve

1

Bucket dump pressure sensor

Carry out service diagnosis

• See Service Diagnosis Data List Operation No.14 Bucket dump full lever and relief

2

Remote control valve

Measure directly remote control pressure of bucket dump

Check that pressure is 3.0 MPa or more Check remote control valve in bucket dump full lever and high idling When equipped with multi control valve, check it while operation changing lever pattern

T5-2-13

Copyright © New Holland E135B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

3

Pump pressure sensor

• See Service Diagnosis Data List Carry out service Operation No.15 Bucket dump full diagnosis for P1, P2 lever and in operation pump pressures in operation.

When there is difference between P1 and P2 pump pressures, check high pressure sensor

4

Actual measuring current value of P1 unload proportional valve

Carry out service diagnosis

• No.8 D-1 P1 unload valve (cut valve) • See Service Diagnosis Data List Operation No.14 Bucket dump full lever & relief

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

5

Secondary pressure Measure the of P1 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block

Check that P1 unload secondary pressures are within the range of 0.5~1.2 MPa in bucket dump full lever and high idling operation.

Replace proportional valve

6

Actual measuring current value of P1 pump proportional valve.

• No.9 E-1 P1 pump • See Service Diagnosis Data List Operation No.15 Bucket dump full lever & in operation

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

7

Secondary pressure Measure the pump Check that P1 pump proportional valve Replace proportional valve pressures is 2.7 MPa or more in bucket of P1 pump proportional valve proportional valve secondary pressure dump full lever and high idling operation. directly (Ports a3)

8

Actual measuring current value of travel straight proportional valve

9

Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block

Check that travel straight secondary Replace proportional valve pressure is 2.7 MPa or more in bucket dump full lever and high idling operation

10

P2 by-pass cut valve Visual check

Only P2 pressure is low.

No problem for sliding ability of main poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBP2 port.)

Clean and replace

11

Remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

Carry out service diagnosis

Carry out service diagnosis

Check targeted remote control valve

• See Service Diagnosis Data List Operation No.14 Bucket dump full lever & relief

T5-2-14

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

E135B

Corrective action, others

Reset or replace Check set pressure • See Service Diagnosis Data List Operation No.3 Boom up full lever and relief

12

Main relief valve

Relief pressure is low.

13

Travel straight spool Visual check

P2 pressure is high.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface

Replace (Check on the casing side for damage)

14

Bucket spool

Both P1, P2 pressures are high.

Visual check

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

15

Over load relief valve

Check targeted spool visually

Free from dust entered in over load relief Replace valve. Seat is free from abnormality.

11. Swing operation not functioned/slow No. Sections

Contents/normal value

Corrective action, others

1

Swing pressure sensor

Carry out service diagnosis

• See Service Diagnosis Data List Operation No.11 Swing full lever and in operation

Check and replace pressure sensor Check remote control valve

2

Remote control valve

Measure directly remote control pressure of swing

Check that pressure is 3.0 MPa or more Check remote control valve When equipped with multi in boom up full lever and high idling control valve, check it while operation changing lever pattern

3

Swing parking brake Carry out service solenoid diagnosis

No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF

Check swing pressure sensor Check harness

4

Swing parking brake Measurement of solenoid solenoid valve A2 port

Lever neutral: 0 MPa In operation: 4 MPa or more

Replace solenoid valve

5

Visual check Shuttle valve

Pilot pressure is low.

No contamination on spool cover (short Clean or replace side) and orifice No damage on spool cover (long side) and shuttle

6

Pump pressure sensor

• See Service Diagnosis Data List Operation No.11 Swing full lever and in operation

Carry out service diagnosis for P2 pump pressures in operation

T5-2-15

Check high pressure sensor

Copyright © New Holland E135B

TROUBLESHOOTING (BY TROUBLE)

No. Sections

Contents/normal value

Corrective action, others

7

Actual measuring current value of P2 unload proportional valve

Carry out service diagnosis

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

8

Secondary pressure Measure the proportional valve of P2 unload secondary pressure proportional valve directly at the ports A5 of 8 sections solenoid block

9

Actual measuring current value of P2 pump proportional valve

10

Secondary pressure Measure the pump Check that P2 pump proportional valve Replace proportional valve pressure is 2.7 MPa or more in swing full proportional valve of P2 pump secondary pressure lever and high idling operation proportional valve directly (Ports a3, a4)

11

Actual measuring current value of travel straight proportional valve (Check this trouble by only swing operation)

Carry out service diagnosis

• Check pressure sensor of Check that the value is not change travel regardless of operation • See Service Diagnosis Data List • In case where the reading is Operation No. 1 Operation is nil largely differed from the Operation No.18 Travel right full lever actually measured value, & idling check proportional valve Operation No.19 Travel left full lever & and controller for possible idling failure.

12

Secondary pressure of travel straight proportional valve (Check this trouble by only swing operation)

Measure directly the proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block

0.8 MPa or less in high idling operation regardless of neutral/operation

Replace proportional valve

13

Remote control valve

Check targeted remote control valve

Check that spool is free from abnormal damage and spring is free from breakage

Replace

14

Travel straight spool Visual check

P2 pressure is low.

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

Carry out service diagnosis

• No.8 D-2 P2 unload valve (cut valve) • See Service Diagnosis Data List Operation No.11 Swing full lever & in operation

Replace proportional valve Check that P2 unload secondary pressures are within the range of 0.5 to 1.2 MPa in swing full lever and high idling operation

• No.9 E-2 P2 pump • See Service Diagnosis Data List Operation No.11 Swing full lever & in operation

T5-2-16

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

No. Sections

Contents/normal value

E135B

Corrective action, others

When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.

Replace (Check on the casing side for damage)

15

Visual check Swing spool

P2 pressure is high.

16

Swing relief valve

Relief pressure is low.

Check set pressure • See Service Diagnosis Data List Operation No.10 Swing full lever and relief

17

Swing motor

Visual check

18

Swing reduction gear oil

Sampling oil does not include a lot of Take sample oil metal powder. from swing reduction gear drain

Disassemble and inspect reduction gear

19

Swing reduction

Visual check

Replace

Reset or replace

Inner parts (cylinder block, piston, valve Replace brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)

Tooth surface is not worn abnormally and is not chipped.

12. Noise during swing operation No. Sections

Contents/normal value

Corrective action, others

1

Carry out service No.3 F-2 SWING-BRAKE diagnosis Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF

Check swing pressure sensor Check harness

Measurement of Lever neutral: 0 MPa solenoid valve A2 In operation: 4 MPa or more port

Replace solenoid valve

Swing parking brake solenoid

2

3

Boost check valve Visual check (Sound of cavitation at stopping)

When removing, free from abnormal Replace resistance against sliding Spring is free from breakage.

4

By-pass check valve (Sound of cavitation at stopping)

Visual check

When removing, free from abnormal Replace resistance against sliding Spring is free from breakage.

5

Swing motor (Brake valve/ friction plate)

Visual check

Disassemble and inspect abnormal Replace wear and scuffing

6

Swing motor piston

Visual check

When removing, free from abnormal Replace resistance against sliding Spring is free from breakage.

T5-2-17

Copyright © New Holland E135B

TROUBLESHOOTING (BY TROUBLE)

No. Sections

Contents/normal value

Corrective action, others

7

Swing reduction gear oil

Take sample oil from swing reduction gear drain.

Sampling oil does not include a lot of Disassemble and inspect metal powder. reduction gear

8

Swing reduction

Visual check

Tooth surface has no abnormally worn and chipped.

Replace

13. Swing on a slope drifts when control lever is in neutral position No.

Sections

Contents/normal value

1

Swing sensor

2

Remote valve

3

Swing parking brake Carry out service No.3 F-2 SWING-BRAKE solenoid diagnosis Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF

Corrective action, others

pressure Carry out service • •Engine stop & starter key ON Check and replace pressure diagnosis All pilot low pressure sensors are sensor within range of 0 to 0.1 MPa. control Check remote valve

targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage

Measurement of Lever neutral: 0 MPa solenoid valve A2 In operation: 4 MPa or more port

4

Check swing pressure sensor Check harness Check parking brake release switch Replace solenoid valve

5

Visual check Swing motor (Brake valve/friction plate)

Disassemble and inspect abnormal Replace wear and scuffing

6

Parking brake

Piston and friction plate do not have Replace abnormal resistance against sliding Free from spring damage

Visual check

14. Swing drifts at stopping No.

Sections

1

Shuttle valve Visual check

Pilot pressure is low

2

Swing sensor

3

Swing relief valve Check

pressure Relief pressure is low.

Contents/normal value

Corrective action, others

No contamination on spool cover Clean or replace (short side) and orifice. No damage on spool cover (long side) and shuttle.

pressure Carry out service • Engine stop & starter key ON Replace pressure sensor diagnosis All pilot low pressure sensors are within range of 0 to 0.1 MPa. set • See Service Diagnosis Data List Reset or replace Operation No.10 Swing full lever and relief

T5-2-18

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

No.

Sections

Contents/normal value

4

Anti-reaction valve Visual check

5

Remote valve

6

Swing motor

control Check remote valve

E135B

Corrective action, others

Free from dirt entering Clean or replace Sliding part should be free from foreign matter entering, abnormal damage and wear.

targeted Check that spool is free from Replace control abnormal damage and spring is free from breakage Inner parts (cylinder block, piston, Replace valve brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)

Visual check

15. Travel speed is slow/poor No.

Sections

Contents/normal value

Corrective action, others

1

Check and replace pressure Travel right and left Carry out service • See Service Diagnosis Data List pressure sensor diagnosis Operation No.18 Travel right full lever sensor Check remote control valve and idling Operation No.19 Travel left full lever and idling

2

Remote valve

3

Actual measuring Carry out service • No.9 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) current value of P1/ diagnosis P2 unload • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling

4

the Secondary pressure Measure of P1, P2 unload proportional valve secondary pressure proportional valve directly at the ports A7 and A5 of 8 sections solenoid block

5

Actual measuring Carry out service • No.9 E-1 P1 pump E-2 P2 pump current value of P1/ diagnosis P2 pump • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling

control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve remote control in travel right (left), forward (reverse) full pressure of travel lever and high idling operation right and left In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0 MPa Travel left (P2 unload): 0.5 to 1.0 MPa

T5-2-19

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Copyright © New Holland E135B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7 MPa or more Travel left (P2 pump): 2.7 MPa or more

6

Secondary pressure Measure the pump of P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)

7

Actual measuring Carry out service Check that the value is not change • Check voltage of low regardless of operation current value of diagnosis pressure sensor other than • See Service Diagnosis Data List travel straight sensor for travel Operation No. 1 Operation is nil proportional valve • In case where the reading is Operation No.18 Travel right full lever largely differed from the & idling actually measured value, Operation No.19 Travel left full lever & check proportional valve and idling controller for possible failure

8

Secondary pressure Measure directly the 0.8 MPa or less in high idling operation Replace proportional valve of travel straight proportional valve regardless of neutral/operation proportional valve secondary pressure

9

Remote valve

control Check remote valve

targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice

10 Travel straight spool Visual check

P1 pressure is high.

Visual check 11 Travel spool targeted spool

Pump pressure is high.

When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage. of When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.

12 Travel motor relief Check set pressure Check P1 and P2 pump pressures are valve 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling 13 Travel motor

14 Parking brake travel motor

15 Travel gear oil

If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed.

Visual check

Inner parts (piston, cylinder block, valve Replace plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)

in Visual check

When removing, free from abnormal Replace resistance against sliding No sticking on friction plate and separator plate

reduction Take sample oil Sampling oil does not include a lot of Disassemble and reduction gear from travel metal powder. reduction gear drain

16 Travel reduction

Visual check

Tooth surface is not worn abnormally Replace and is not chipped.

T5-2-20

inspect

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

E135B

16. Travel deviation No.

Sections

Contents/normal value

Corrective action, others

1

Check and replace pressure Travel right and left Carry out service • See Service Diagnosis Data List pressure sensor diagnosis Operation No.18 Travel right full lever sensor Check remote control valve and idling Operation No.19 Travel left full lever and idling

2

Remote valve

3

Actual measuring Carry out service Check that the value is not change • Check voltage of low pressure sensor other than regardless of operation current value of diagnosis sensor for travel • See Service Diagnosis Data List travel straight Operation No. 1 Operation is nil proportional valve • In case where the reading is Operation No.18 Travel right full lever largely differed from the & idling actually measured value, Operation No.19 Travel left full lever & check proportional valve idling and controller for possible failure.

4

directly 0.8 MPa or less in high idling operation Replace proportional valve Secondary pressure Measure proportional regardless of neutral/operation of travel straight the valve secondary proportional valve pressure

5

Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve) current value of P1/ diagnosis P2 unload • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling

6

the Secondary pressure Measure of P1, P2 unload proportional valve secondary pressure proportional valve directly at the ports A7 and A5 of 8 sections solenoid block

7

Actual measuring Carry out service • No.9 E-1 P1 pump E-2 P2 pump current value of P1/ diagnosis P2 pump • See Service Diagnosis Data List proportional valve Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling

8

Secondary pressure Measure the pump of P1, P2 pump proportional valve secondary pressure proportional valve directly (Ports a3, a4)

control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve remote control in travel right (left), forward (reverse) full pressure of travel lever and high idling operation right and left

In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0 MPa Travel left (P2 unload): 0.5 to 1.0 MPa In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7 MPa or more Travel left (P2 pump): 2.7 MPa or more

T5-2-21

Copyright © New Holland E135B

No. 9

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Exchange P1 for P2 Exchange delivery Check the direction of deviation pipe of P1 for P2

10 Remote valve

control Check remote valve

Visual check 12 Travel spool targeted spool

Pump pressure is high.

When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage of When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage

13 Travel motor relief Check set pressure Check P1 and P2 pump pressures are valve 32 MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling

15 Travel gear oil

If the direction is changed, inspect a pump. If the direction is not changed, inspect a valve and travel unit.

targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice

11 Travel straight spool Visual check

P1 pressure is high.

14 Travel motor

Corrective action, others

Visual check

If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed. Replace as necessary

Inner parts (piston, cylinder block, valve Replace plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)

reduction Take sample oil Sampling oil does not include a lot of Disassemble and reduction gear from travel metal powder. reduction gear drain

16 Travel reduction

Visual check

Tooth surface is not worn abnormally Replace and is not chipped.

17 Pump regulator

Visual check

When removing, free from abnormal Replace resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.

18 Pump

Visual check

When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.

T5-2-22

inspect

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

E135B

17. Travel 1st/2nd speed cannot be switched (In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic speed change.) No.

Sections

Contents/normal value

Corrective action, others

1

Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Lever neutral COMP OFF, MEAS OFF Travel operation COMP ON, MEAS ON

Check pressure sensor Check harness Check travel 1/2 speed switch on gauge cluster

2

Travel 1/2 speed Measure A3 port Lever neutral: 0 MPa switching solenoid pressure on In operation: 4 MPa or more solenoid valve

Replace solenoid valve

3

1/2 speed switching Visual check spool in travel motor

Check that spool is free from abnormal Replace damage and spring is free from (Check on the casing side for damage) breakage

4

1/2 speed switching Visual check orifice in travel motor

Free from entry of dust

5

Tilting piston travel motor

Free from abnormal wear on piston and Replace seal (Check on the casing side for damage)

in Visual check

Remove dust or replace

18. Machine does not stay on slope in travelling No.

Sections

Contents/normal value

Corrective action, others

pressure Carry out service • Engine stop & starter key switch is ON Check pressure sensor and diagnosis Targeted pilot low pressure sensor is replace as necessary Check remote control valve in range of 0 to 0.1 MPa

1

Pilot sensor

2

Remote valve

3

Parking brake travel motor

4

Orifice of passage Visual check for parking brake in travel motor

control Check remote valve

targeted Check that spool is free from abnormal Replace control damage and spring is free from breakage

in Visual check

When removing, free from abnormal Replace resistance against sliding Spring free from breakage, damage, etc. Free from entry of dust

Remove dust or replace

19. Machine does not travel straight in simultaneous operation of travelling and attachment. No. 1

Sections

Contents/normal value

Corrective action, others

Actual measuring Carry out service No. 8 D-3 S-TRAVEL is should be • Check voltage of low pressure sensor other than COMP 590 mA and MEAS 560~620 mA current value of diagnosis travel sensor in both travel full lever and in boom-up travel straight full lever at high idling. proportional valve • In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

T5-2-23

Copyright © New Holland E135B

No.

TROUBLESHOOTING (BY TROUBLE)

Sections

Contents/normal value

Corrective action, others

2

Secondary pressure Measure directly of travel straight the proportional proportional valve valve secondary pressure

Check secondary pressure is within Replace proportional valve range of 1.8 to 2.2 MPa in both travel full lever and in boom-up full lever at high idling.

3

Travel straight spool Visual check

When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.

20. Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight) No.

Sections

Contents/normal value

Corrective action, others

1

Check and replace pressure Pressure sensor for Carry out service • See Service Diagnosis Data List optional attachment diagnosis Operation No.16 P2 side OPT full sensor Check remote control valve lever and relief

2

Remote valve

3

•In case where the reading is Actual measuring Carry out service • See Service Diagnosis Data List Operation No.16 P2 side OPT full largely differed from the current value of P1/ diagnosis actually measured value, lever and relief P2 unload check proportional valve and proportional valve controller for possible failure.

4

the Check that P1/P2 unload secondary Replace proportional valve Secondary pressure Measure of P1, P2 unload proportional valve pressures are within the range of 0.5 to secondary pressure 1.2 MPa proportional valve directly at the ports A7 and A5 of 8 sections solenoid block

5

• Check voltage of low Actual measuring Carry out service • See Service Diagnosis Data List pressure sensor other than Operation No.16 P2 side OPT full current value of diagnosis sensor for optional lever & relief travel straight attachment proportional valve • In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.

6

directly Secondary pressure Measure proportional of travel straight the valve secondary proportional valve pressure at the ports A6 (travel straight) of 8 sections solenoid block

Check that travel straight secondary Replace proportional valve pressure is 2.7 MPa or more in optional attachment full lever and high idling operation

7

P1 by-pass cut valve Visual check

Only P1 pressure is low.

No problem for sliding ability of main Clean or replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)

control Measure directly Check that pressure is 2.1 MPa or more Check remote control valve remote control in optional attachment full lever and high pressure of travel idling operation right and left

T5-2-24

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

No.

Sections

8

Relief pressure

9

Remote valve

Contents/normal value

E135B

Corrective action, others

Reset or replace Check set pressure • See Service Diagnosis Data List Operation No.16 P2 side OPT full lever and relief (Set value of factory shipment is 24.5 MPa.)

control Check remote valve

targeted Check sealing ability of shuttle valve and Replace control entry of dust in orifice.

10 Travel straight spool Visual check

P1 pressure is high.

When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.

11 Spool for optional Visual check attachment

P1, P2 pressures are high.

When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.

12 Over valve

relief Check targeted Free from dust entered in over load relief Replace spool visually valve Seat is free from abnormality.

load

21. Option selector valve malfunction: not switched to breaker circuit. (Indication of failure is displayed. For reference, see "Table 1 - Action of optional selector solenoid valve") No.

Sections

Contents/normal value Visual check

Corrective action, others

When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage

1

N&B selector spool

2

N&B solenoid

selector Screw emergency

3

N&B solenoid

selector Carry out service • No.11 F-4 Option selector is B mode diagnosis COMP ON, MEAS ON Spool position BRK Selector switch BRK

4

Check pressure sensor N&B selector Carry out service • No.16 B-11 Check harness pressure sensor diagnosis Data List 3.0 MPa at B mode and 0.0 MPa at A mode

for Check that the error indication is Replace solenoid valve disappeared by turning emergency screw

T5-2-25

Check solenoid valve Check harness

Copyright © New Holland E135B

TROUBLESHOOTING (BY TROUBLE)

22. Option selector valve malfunction: not switched to nibbler circuit. (Indication of failure is displayed. For reference, see "Table 1 - Action of optional selector solenoid valve") No.

Sections

1

N&B selector spool

2

N&B solenoid

Contents/normal value Visual check

Corrective action, others

When removing, free from abnormal Replace (Check on the casing side for resistance against sliding Free from abnormal damage, etc on damage) outside surface Spring is free from breakage.

selector Carry out service • No.11 F-4 Option selector is A mode diagnosis COMP OFF, MEAS OFF Spool position NIB Selector switch NIB

T5-2-26

Check solenoid valve Check harness

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

E135B

Table 1 - Action of optional selector solenoid valve Safety Engine lock lever No. SW's condition input

1

Running

ON

Safety lock lever relay's output

OFF

Work mode

Optional selector valve COMP. MEAS.

A

OFF

Spool position

Selector valve detecting pressure sensor

Warning display

Failure diagnosis display

Nibbler

Normal

—

—

2

Running

ON

OFF

A

ON

Breaker

"SELECTOR Normal FAILURE"

3

Running

ON

OFF

A

OFF

Breaker

Normal

4

Running

ON

OFF

A

ON

Nibbler

Normal

—

[F042] displayed

5

Running

ON

OFF

B

ON

Breaker

Normal

—

—

6

Running

ON

OFF

B

OFF

Nibbler

Normal

"SELECTOR FAILURE"

VALVE [F043] displayed simultaneously

7

Running

ON

OFF

B

ON

N&B

Normal

"SELECTOR FAILURE"

VALVE

8

Running

ON

OFF

B

OFF

Breaker

Normal

—

[F043] displayed

9

Running

ON

OFF

—

—

—

Failure

"SELECTOR FAILURE"

VALVE [B113] displayed

10 Stopping

"SELECTOR FAILURE"

VALVE [F042] displayed simultaneously VALVE

—

—

—

—

—

—

—

—

—

—

11

—

OFF

—

—

—

—

—

—

—

12

—

—

ON

—

—

—

—

—

—

T5-2-27

Copyright © New Holland E135B

TROUBLESHOOTING (BY TROUBLE)

2. ELECTRIC SYSTEMS 2.1 WIRING CHECKING PROCEDURE Check for continuity between connector terminals, presence or absences of short-circuit with other wires, and presence or absences of short-circuit with machine body grounding. 1.

CONNECTOR

Checking for disconnection between connectors. (When both ends measurement is easy because of short distance between connectors) Measure the resistance using tester. Pull out opposite connector first. When the resistance is zero (0), it is in normal condition.

WIRE

TESTER SM0104

(When both ends measurement is difficult because of long distance between connectors) Measure the resistance using tester. Pull out opposite connector first. Where the resistance is zero (0), if the terminal on one side is connected to frame body grounding with jumper wire, it is in normal condition. The resistance is 1 M or more when the terminal on one side is not connected to frame body grounding with jumper wire, it is in normal condition.

2.

JUMPER WIRE

TESTER FRAME BODY GROUNDING SM0105

Checking for presence or absence of shortcircuit with machine body Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M or more, it is in normal condition.

TESTER

FRAME BODY GROUNDING SM0106

3.

Checking for presence or absence of shortcircuit between wirings. Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1 M or more, it is in normal condition.

TESTER SM0107

T5-2-28

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE) 4.

Checking connector terminal for contact Insert male terminal into female terminal unit, and then check that the inserting force is equivalent to other female terminals. If looseness is there, replace the female terminal with new one. Clean the dirt terminal.

E135B

INSERT

MALE TERMINAL

FEMALE TERMINAL SM0108

ATTENTION Do not insert the male terminal the thickness differs. It may cause loose connection. 5.

Caution which should be paid in measuring voltage When measuring the power supply to electric equipment at connector position with the grounding terminal contained inside of connector, measure the voltage between grounding inside of connector and power terminal. When measuring the voltage between frame body grounding and power source, the disconnection of wiring to grounding inside of connector cannot be identified. Since the voltage may vary between with connector connected and with connector not connected. Measure the voltage with each connector connected whenever possible.

6.

Checking the general view of connector CRIMPED PART

a. Check the terminal crimped condition. Pull one electric cable with the about 3kg force, and make sure that the cable does not come out of the terminal. When came out, replace the terminal and crimp it again. b. Check connector for imperfect insertion Check that all top ends form a line on the same position as seen from the connector engaged side. When moved along, push it in further through wire inserting hole. c. Check connector for intruding of water. Pull out the connector and check that the inside is free from intruding of water. When water intruding is found, check rubber plug for damage and also that the sealing is fitted properly.

T5-2-29

RUBBER PLUG RECEPTACLE. CONTACT PLUG SEALING (is housed in plug) DOUBLE LOCK PLATE FOR PLUG DOUBLE LOCK PLATE FOR CAP CAP TAB.CONTACT RUBBER PLUG

SM0109

Copyright © New Holland E135B 7.

TROUBLESHOOTING (BY TROUBLE)

When abnormality occurs at intervals When the abnormality situation can not be reoccurred during checking operation, try the following operations. a. Check that variable of display exists or not on the service diagnosis screen while shaking the harness or giving shock by operating the machine. b. Check that variables of resistance and voltage exist or not using tester while shaking the harness. c. Turn starter switch on and apply electricity continuously, and check it again after the temperature of wiring and equipment was raised.

8.

Checking on body grounding Check attaching bolts of grounding terminal for loosening. And also check that there is no loose connection due to corrosion. There are multiple groundings like centralized grounding box shown in the figure and battery grounding, engine grounding, horn grounding fixed together with horn, body grounding placed on attaching section of boom working light. Block of grounding is located under floor plate of cab.

T5-2-30

SM0110

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE) 2.2 TROUBLE 1.

Engine does not stop.

2.

"CPU DATA COMMUNICATION ERROR" is displayed on multi display.

3.

Auto accel does not actuate. (The engine speed does not automatically slow down.)

4.

Auto accel does not actuate. (The engine speed does not automatically speed up.)

5.

Wiper does not function.

T5-2-31

E135B

Copyright © New Holland E135B 1.

TROUBLESHOOTING (BY TROUBLE)

Engine does not stop.

No .

Sections

Contents/normal value

Corrective action, others

1

Starter key switch Check signal of starter key switch ON by carrying out service diagnosis.

No.4 K-3 Key switch Check continuity between OFF at starter key switch OFF terminals of starter switch position using tester ON at starter key switch ON position

2

Engine forcible When ON is stop relay displayed with the starter switch OFF, then pull out R-25 engine forcible stop relay and carry out the service diagnosis.

No.4 K-3 Key switch Check on engine forcible OFF at starter key switch OFF stop relay position ON at starter key switch ON position

3

Wiring

2.

Voltage between 0 V when starter switch is OFF line No.62 among starter switch, engine forcible stop relay, enginestop solenoid and the body grounding

Check harness Check diode D-9 between starter switch and auto idling stop relay 1

"CPU DATA COMMUNICATION ERROR" is displayed on multi display.

No .

Sections

Contents/normal value

Corrective action, others

1

Fuse

No.1 fuse (5 A)

Not blown fuse

Check harness Replace fuse

2

Mechatro controller

Accel control

Engine speed varies according to Check mechatro controller accel potentiometer operation. and replace as necessary (Use remote control because the auto accel function is working.)

3

Wiring

Transmission See “WIRING circuit line No.770 PROCEDURE" from mechatro controller to gauge cluster

4

Gauge cluster

Gauge cluster

CHECKING Repair wiring

Replace gauge cluster

T5-2-32

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE) 3. No .

Auto accel does not actuate. (The engine speed does not automatically slow down.) Sections

Contents/normal value

1

Engine coolant Check engine temperature coolant temperature by carrying out service diagnosis.

2

Gauge cluster

3

Low sensor

4. No .

1

E135B

Corrective action, others

Replace No.2 G-5 WATER TEMP Auto accel does not work in the sensor temperature -15 °C or less. Warm up and raise the coolant temperature to – 15 °C or more

engine

coolant

Indication of auto Mark "Display/not display" for auto Replace gauge cluster accel accel switches by auto accel switch operation on gauge cluster.

pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor No.6 is in the range of 0~0.1 MPa at control lever neutral position.

Auto accel does not actuate. (The engine speed does not automatically speed up.) Sections

Low sensor

Contents/normal value

Corrective action, others

pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor No.6 is raised with control lever operated.

T5-2-33

Copyright © New Holland E135B 5.

TROUBLESHOOTING (BY TROUBLE)

Wiper does not function.

Wiping range of forward and reverse movements

Wiper motor Rise up limit switch's ON range Reverse limit switch's ON range

Rise up (storing) position Upper reversing position Lower reversing position

SM0111

No.

Sections

Contents/normal value

Corrective action, others

1

Fuse

Check fuse No.20

Replace fuse

2

SW-19: Wiper interlock switch

Check wiper interlock switch Service diagnosis No.19 D125 Wiper switch display (D125) is OFF with front window closed. and repair it if necessary Check according to "WIRING CHECKING PROCEDURE" and repair it if necessary

3

Rise up limit switch Service diagnosis No.25 Wiper system built-in wiper motor Reverse limit switch Switch action in operation

Check according to "WIRING CHECKING PROCEDURE"

Normal condition

4

Rise up limit switch

ON

OFF

OFF

Reverse limit switch

ON

ON

OFF

R-31: Service diagnosis No.25 Wiper system Arc prevention relay When started by forward rotation: STOP START R-29: Arc prevention relay OFF ON ON ON ON Forward rotation Forward rotation relay OFF ON ON ON ON Reverse rotation relay OFF OFF OFF OFF OFF relay Check that the relay is worked as shown in the table. R-30: * When the limit switch does not change in OFF after 4 seconds Reverse rotation from the wiper startup, turn OFF all relay's outputs. relay

T5-2-34

(STOP)

(STOP)

(REVERSE)

(FORWARD)

OFF

ON

ON

ON

OFF

OFF

OFF

OFF

OFF

OFF

ON

OFF

ON

ON

ON

OFF

OFF

Check that the relay is excited. Check relay & fuse box and replace it if necessary.

ON

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

E135B

3. ENGINE

Checking

Poor output

Insufficient rotation

Faulty starting

Poor starting ability (Takes a long time) Faulty engine starting/engine does not rotate Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not rotate (With fuel injection) Engine poor run-up (Low follow-up ability) Rotation in bad condition (hunting) Engine stalled during operation Output is lowered Overheating Exhaust smoke is black Exhaust smoke is white

Other failures

Lager oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased (Intruding of water and fuel) Vibration

T5-2-35

Muffler clogged

Leak, clogging of fuel system and intruding of air

Poor or deteriorated battery

Contamination of water and fuel with oil

Oil level of oil pan

Coolant level

Improper fuel in use

Breather hose crushed or clogged

Air leak between turbocharger and intake manifold

Leak, clogging

Liquid

Fan belt slipped, fan pulley worn

Oil filter clogged

Fuel filter clogged

Trouble

Air cleaner clogged

Shortage of fuel level

Filters

Engine oil leak

Factors

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

Electric equipment

Poor output

Insufficient rotation

Faulty starting

Poor starting ability (Takes a long time) Faulty engine starting/engine does not rotate Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not rotate (With fuel injection) Engine poor run-up (Low follow-up ability) Rotation in bad condition (hunting) Engine stalled during operation Output is lowered Overheating Exhaust smoke is black Exhaust smoke is white

Other failures

Lager oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased (Intruding of water and fuel) Vibration

T5-2-36

Hydraulic switch

Safety relay

Starter motor

Glow relay

Engine side

Alternator

Battery relay

Loose connection of battery cable terminal

Shovel side

Failure of hydraulic system

Peeling of space insulation around radiator

Radiator core clogged/fin clogged and crushed

Trouble

Failure of radiator pressure cap

Loose mounting bolts, damage of mounting rubber

Shovel side

Glow plug

Checking

Starter key switch

Factors

Startup circuit wiring

E135B

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

Poor output

Insufficient rotation

Faulty starting

Poor starting ability (Takes a long time) Faulty engine starting/engine does not rotate Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not rotate (With fuel injection) Engine poor run-up (Low follow-up ability) Rotation in bad condition (hunting) Engine stalled during operation Output is lowered Overheating Exhaust smoke is black Exhaust smoke is white

Other failures

Lager oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased (Intruding of water and fuel) Vibration

T5-2-37

Failure of thermostat (Do not open)

Damage of water pump

Cooling system

Leak and crush of hydraulic piping

Failure of regulation valve

Failure of relief valve

Lubrication system

Failure oil pump

Seizing and interference of turbocharger

Seal of turbocharger worn, damaged

Intake and exhaust system

Turbocharger oil drain tube clogged

Fuel leak into the head cover

Improper fuel injection time

Trouble

Failure of supply pump

Fuel system

Failure of injector

Factors

E135B

Copyright © New Holland TROUBLESHOOTING (BY TROUBLE)

Poor output

Insufficient rotation

Faulty starting

Poor starting ability (Takes a long time) Faulty engine starting/engine does not rotate Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not rotate (With fuel injection) Engine poor run-up (Low follow-up ability) Rotation in bad condition (hunting) Engine stalled during operation Output is lowered Overheating Exhaust smoke is black Exhaust smoke is white Lager oil consumption (or blue exhaust gas) Early contamination of oil Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) Oil quantity increased (Intruding of water and fuel) Vibration

T5-2-38

Damage of flywheel gear

Damage of dumper

Wear and damage of rear oil seal and seal surface

Hole due to cavitation

Wear of piston ring and liner, ring stick

Damage and seizing of piston and connecting rod

Failure of injection holder sleeve

Damage of cylinder head and head gasket

Strainer clogged, damage of oil pipe

Trouble

Other failures

Engine body

Damage of engine oil cooler core and O-ring

Factors

Wear and failure of valve and valve guide

E135B

Copyright © New Holland TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

E135B

1. TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output. 1.

Function There are two types of trouble diagnosis mode. 1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine system. 2) Trouble diagnosis mode 2: Used to diagnose pilot system. In any mode, with the attachment not operated, both selector valve and proportional valve are automatically actuated, the sensor detects the machine condition and the mechatro controller identifies the normal condition or failed condition of the system.

2.

How to use and flow chart The operation is performed through gauge cluster. No.1 Select service adjustment select screen. (Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing buzzer stop switch on the service diagnosis screen No.1.) No.2 Select Trouble diagnosis mode (Move the cursor to the desired position with screen change switch "

", and press the select switch.)

No.3 Select either "DIAG MODE 1" or "DIAG MODE 2" (Move the cursor to the desired position with screen change switch "

", and press the select switch.)

No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.

T5-3-1

Copyright © New Holland E135B

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

No.1

No.2

LANGUAGE/LOGO

No.3

8 FAULT DIAG MODE

ADJUSTING MODE 1 PRESET BY FACTORY

SELECT SWITCH

DIAG MODE 1 DIAG MODE 2

BUZZER STOP SWITCH

FEED

SCREEN CHANGE SWITCH

CASE OF DIAG MODE 1 SENSOR CHECK

CHECK

START ENG ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA

DIAG MODE 1

LOWER BOOM RELEASE LOCK LEVER

TO GROUND C-2 00.0M

About 15 minutes

E-2 005mA D-2 300mA

Turn engine on manually.

BACK TO No.3

RESULT OF DIAGNOSIS

When not failed,

DIAG MODE 1

END

In diagnosis operation

START

ENGINE STOP

RESULT OF DETAIL

DIAG MODE 1

1 P1 UNLOAD

OK

O K DATA END

Engine stops automatically.

FEED

DIAG MODE 1 RESULT 1 P1 UN-LOAD PSV NG P1 UN-LOAD SPOOL NG

DATA END

BACK TO No.3

FEED

The data at the time of judgment can be confirmed with the select switch.

ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA

C-2 00.0M E-2 005mA D-2 300mA

The other judgments can be confirmed with the feed button.

RESULT OF DIAGNOSIS

When failed,

For tthediagnosing Forthe diagnosingitems, items,see seeTable Table 48-1. 1. When Whenrequired requiredto tostop stopin indiagnosis diagnosis operation, operation,press pressthe thebuzzer buzzerstop stopswitch switch and andthe theoperation operationisisforcedly forcedlystopped. stopped.

1 P1 UNLOAD

NG DATA END

FEED

ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA

C-2 00.0M E-2 005mA D-2 300mA

The suspected trouble sections are displayed in order of possibility. The suspected three sections in maximum are displayed. When desired to see other suspected trouble sections, press feed " " button. For diagnosis results and corrective actions to be taken, see Table 2.

SM0114

Notes: 1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. 2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality. Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis. The preliminary investigation of electric system makes the time saving and high precision diagnosis possible. 3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a case no accordance of diagnosis obtained. In this case, contact our dealer/distributor. 4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.

T5-3-2

Copyright © New Holland TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

E135B

No.4 CASE OF DIAG MODE 2 SENSOR CHECK

CHECK

START ENG ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA

C-2 00.0M

DIAG MODE 2

LOWER BOOM

START

TO GROUND

E-2 005mA D-2 300mA

Turn engine on manually.

AT CONTROL LEVER IS NEUTRAL

Example: Case of boom up WHEN FINISHING OF DIAGNOSIS IS REQUIRED. BOOM UP

BOOM UP

OK PRESSURE 0.0

MPa

PRESSURE 1.5

MPa

PRESSURE 3.0

BACK TO No.3 MPa

In the normal condition, OK is displayed when the control lever is moved to stroke end.

SM0115

SEARCHABLE OPERATION Boom up Boom down Bucket digging Bucket dump Arm in Arm out Swing Travel right Travel left P1 side option P2 side option

Notes: 1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers. 2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment. When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UNLOAD PSV NG" is displayed. Check the troubled section according to indication. 3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.

T5-3-3

Copyright © New Holland E135B

TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

Table 1 - Failure diagnosis Mode-1/Diagnosis item No.

Display

Contents of diagnosis

1

1 P1 UNLOAD

Is normal pressure generated in the condition that the flow rate at P1 side is minimum and the unloading valve is in the emergency position?

2

2 P1 UNLOAD

Is normal pressure generated in the condition that the minimum flow rate is relieved at P1 side?

3

3 P1 UNLOAD

Is normal pressure generated in the condition that the unload valve is fully opened, and P1 side flow rate is minimum?

4

1 P2 UNLOAD

Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is minimum?

5

2 P2 UNLOAD

Is normal pressure generated in the condition that the minimum flow rate is relieved at P2 side?

6

3 P2 UNLOAD

Is normal pressure generated in the condition that the unload valve is fully opened, and P2 side flow rate is minimum?

7

1 P1 PUMP

Is normal pressure generated in the condition that the flow rate at P1 side is emergency and the unloading valve is in the emergency position?

8

2 P1 PUMP

Is normal pressure generated in the condition that the unload valve is emergency, and P1 side flow rate is minimum?

9

3 P1 PUMP

Is normal pressure generated in the condition that the unload valve is in emergency position, and P1 side flow rate is maximum?

10 1 P2 PUMP

Is normal pressure generated in the condition that the flow rate at P2 side is emergency and the unloading valve is in the emergency position?

11 2 P2 PUMP

Is normal pressure generated in the condition that the unload valve is emergency, and P2 side flow rate is minimum?

12 3 P2 PUMP

Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is maximum?

13 1 TRAVEL-S

Is normal pressure generated in the condition that P1 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?

14 2 TRAVEL-S

Is normal pressure generated in the condition that P2 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?

15 1 P1 ENGINE

Is rated engine speed obtained in the condition that P1 side flow rate increases little by little when P1 side flow rate is relieved?

16 2 P2 ENGINE

Is rated engine speed obtained in the condition that P2 side flow rate increases little by little when P2 side flow rate is relieved?

Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display) SENSOR CHECK NG

Possible cause

Remedy

Check each pressure sensor by Disconnection of pressure sensor, Short service diagnosis and replace it if circuit, Abnormal output necessary

Secondary pressure is excessive high against the command Check P1 unload proportional valve P1 UN-LOAD PSV NG Secondary pressure is excessive low and replace it if necessary against the command P1 UN-LOAD SPOOL NG

Stuck at full-stroke side

Check P1 unload spool and replace it if necessary

Stuck at neutral side

T5-3-4

Copyright © New Holland TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

E135B

Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display)

Possible cause

Remedy

Secondary pressure is excessive high against the command Check P2 unload proportional valve P2 UN-LOAD PSV NG Secondary pressure is excessive low and replace it if necessary against the command P2 UN-LOAD SPOOL NG P1 B-P CUT NG P2 B-P CUT NG

Stuck at full-stroke side

Check P2 unload spool and replace it if necessary

Stuck at neutral side Stuck at closing side

Check P1 by-pass cut valve and replace it if necessary

Stuck at neutral side Stuck at closing side

Check P2 by-pass cut valve and replace it if necessary

Stuck at neutral side

P1 PUMP PSV NG

Secondary pressure is excessive high against the command Check P1 pump proportional valve Secondary pressure is excessive low and replace it if necessary against the command

P1 PUMP NG

Delivery rate is excessive large against the Check P1 pump regulator and command replace it if necessary. Delivery rate is excessive small against the Check P1 pump and replace it if necessary. command

P2 PUMP PSV NG

Secondary pressure is excessive high against the command Check P2 pump proportional valve Secondary pressure is excessive low and replace it if necessary against the command

P2 PUMP NG

Delivery rate is excessive large against the Check P2 pump regulator and command replace it if necessary. Delivery rate is excessive small against the Check P2 pump and replace it if necessary. command

S-TRAVEL PSV NG

Secondary pressure is excessive high against the command Check travel straight proportional Secondary pressure is excessive low valve and replace it if necessary against the command

S-TRAVEL SPOOL NG

Stuck at full-stroke side

Check travel straight spool and replace it if necessary

Stuck at neutral side

PUMP 1 PRESS. SENPressure is recognized lower than it is SOR NG

Check P1 high pressure sensor and replace it if necessary

PUMP 2 PRESS. SENPressure is recognized lower than it is SOR NG

Check P2 high pressure sensor and replace it if necessary

MAIN RELIEF NG ENGINE NG E/G R SENSOR NG

Set pressure decreases

Check main relief valve and replace it if necessary

Set pressure increases Output is lowered

Check engine and replace it if necessary

Characteristics is misaligned

Check engine speed sensor and replace it if necessary

T5-3-5

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TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

[MEMO:]

T5-3-6

Copyright © New Holland

REPAIR INSTRUCTIONS

Copyright © New Holland

Copyright © New Holland

REPAIR INSTRUCTIONS

E135B

SECTION AND GROUP CONTENTS Section 1

GENERAL INFORMATION

Group 1 Group 2

Precautions for Disassembly and Assembly Tightening Tourque

Section 2

UPPERSTRUCTURE

Group 1 Group 2 Group 3 Group 4 Group 5

Upperstructure Pump device Control device Swing device Pilot valve

Section 3

UNDERCARRIAGE

Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7

Swing bearing Travel Device Swivel joint Track adjuster Front idier Upper and lower roller Tracks

Section 4

FRONT ATTACHMENT

Group 1

Front attachment

Section 5

ENGINE

Group 1 Group 2 Group 3 Group 4 Group 5 Group 6 Group 7 Group 8 Group 9 Group 10 Group 11 Group 12 Group 13 Group 14

General Service data Service tools Determination of overhaul Disassembly of basic engine Inspection and repair of basic engine Reassembly of basic engine Fuel system Lubrification system Cooling system Inlet and exhaust system Electrical system Adjustment and operatio Trobleshooting

Copyright © New Holland

1-

Copyright © New Holland

SECTION 1

E135B

GENERAL INFORMATION

CONTENTS Group 1 - Precautions for Disassembly and Assembly Precautions for Disassembly and Assembly .......................................... W1-1-1

Group 2 - Tightening Torque Torque Chart .......................................... W1-2-1 Piping Joint............................................. W1-2-4

Copyright © New Holland

Copyright © New Holland PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

E135B

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY PREPARATIONS FOR DISASSEMBLY - Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work. - Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. - Check and record the items listed below to prevent problems from occurring in the future. 1. The machine model, machine serial number, and hour meter reading. 2. Reason for disassembly (symptoms, failed parts, and causes). 3. Clogging of filters and oil, water or air leaks, if any. 4. Capacities and condition of lubricants. 5. Loose or damaged parts. - Prepare the necessary tools to be used and the area for disassembling work. - Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves. - Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure and ambulance to prepare for accidents and fire. - Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work.

- If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. - Make match mark on parts for reassembling. - Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not. - For parts which are required to use jig and tools, don’t fail to use the specified jig and tools. - For parts which can not be removed in the specified procedure, never force removal. First check for the cause. - Inspecting parts. Measure the wear of parts and clearance, and record the measured values. - If an abnormality is detected, repair or replace the parts. - The removed parts should be put in order and tagged so as to install on proper places without confusion. - For common parts, pay attention to the quantity and places. REASSEMBLING HYDRAULIC EQUIPMENT - During the parts cleaning, ventilate the room. - Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. - Replace the removed O-ring, back-up rings and oil seal with new ones, and apply gear oil on them before assembling. - Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them.

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT - Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and take out the filter. - Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground. - Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.

- Before assembling, remove rust preventives on new parts. - Use special tools to fit bearings, bushing and oil seal. - Assemble parts matching to the marks. - After completion, check that there is no omission of parts.

- Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on working. DISASSEMBLING HYDRAULIC EQUIPMENT - Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture’s side, disassembly, assembly and modification without permission are strictly prohibited. W1-1-1

Copyright © New Holland E135B

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

INSTALLING HYDRAULIC EQUIPMENT - Confirm hydraulic oil and lubrication oil. - Bleeding Air from Hydraulic System Air release is required in the following cases: 1. Change of hydraulic oil 2. Replacement of parts on suction pipe side 3. Removing and attaching hydraulic pump 4. Removing and attaching swing motor 5. Removing and attaching travel motor 6. Removing and attaching hydraulic cylinder IMPORTANT: if hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged. - For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely. - For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed. IMPORTANT: for cylinder, don’t move it to the stroke end at beginning. - Air in pilot circuit can be bleed out by only operating digging, swing and travelling motions thoroughly. - Check hydraulic oil level. Move attachments to hydraulic oil check position, as indicated in the figure. - Open the hydraulic pump compartment door, then check the oil level on visual indicator (1) located on the hydraulic oil reservoir. If the indicator is within level marks, the oil quantity is acceptable.

W1-1-2

Copyright © New Holland PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

E135B

Floating Seal Precautions 1.

In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures:

A

1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. 2) Check the seal ring face (A) for scuffing, scoring, corrosion, deformation or uneven wear. 3) Check O-Ring (B) for deformation or hardening.

tears, breaks,

B 2.

If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.

SM0172

1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air. 2) Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it. 3) Check that the O-Ring is not twisted, and that it is installed correctly on the seal ring. 4) After installing the floating seal, check that seal ring surface (C) is parallel with mating face (A) by measuring the distances (a) and (b), as illustrated. If these distances differ, correct the O-Ring (B) seating.

RIGHT

WRONG

SM0173

RIGHT

WRONG a

A

a

C B

b

b a=b

a≠b SM0174

W1-1-3

Copyright © New Holland E135B

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY

ELECTRICAL EQUIPMENT - The disassembly of electrical equipment is not allowed. - Handle equipment with care so as not to drop it or bump it. - Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire. - Check that connector is connected and locked completely. - Engine key off before removing and connecting connector. - Engine key off before touching terminals of starter and alternator. - Wash machine with care so as not to splash water on electrical equipment and connector. - When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting. - Remove battery grounding terminal before beginning work close to battery and battery relay with tools.

WARNING Battery fluid is dangerous. The battery fluid is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes, skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical advice. - When it has adhered on skin: wash with soap and water. - When it has got in eyes: wash in water for 10 minutes or more immediately. - When it was swallowed: drink milk or water.

W1-1-4

Copyright © New Holland TIGHTENING TORQUE

TORQUE CHART

WARNING Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use the correct tools. Avoid bodily injury caused by slipping wrenches. Bolt Types Tighten nuts or bolts correctly to torque specifications. Two kinds of bolts, hexagon bolts T and socket bolt, each made of different material, are used. Make sure to employ the correct bolts and tighten them to specification when assembling the machine or components. Hexagon T Bolt

Socket Bolt

SM0175

Specified Tightening Torque Chart

Bolt Dia.

Wrench Size

Hexagon Wrench Size

T Bolt, Socket bolt (Nm)

M18

13

6

29.5

M10

17

8

64

M12

19

10

108

M14

22

12

175

M16

24

14

265

M18

27

14

390

M20

30

17

540

M22

32

17

740

M24

36

19

930

M27

41

19

1370

M30

46

22

1910

M33

50

24

2550

M36

55

27

3140

W1-2-1

E135B

Copyright © New Holland E135B

TIGHTENING TORQUE

IMPORTANT 1.

Apply lubricant (i. e. white zinc B dissolved into spindle oil) to nuts and bolts to stabilize their friction coefficients.

2.

Torque tolerance is ± 10%.

3.

Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force.

4.

The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application.

5.

Make sure that the nut and bolt threads are clean before installing. Remove dirt or corrosion, if any.

Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.

Equally tighten upper and lower alternately

Tighten diagonally 1

1.4

12

9

4

1

6

7

14

13

8

5

2

3

10

11

3

6

5

4 2.3

Tighten from center and diagonally

2

SM0176

W1-2-2

Copyright © New Holland TIGHTENING TORQUE

E135B

Service Recommendations for Split Flange IMPORTANT 1.

Be sure to clean and inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.

2.

Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file Oring surfaces. When installing an O-ring into a groove, use grease to hold it in place.

3.

Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Take care not to pinch the O-ring.

4.

Tighten bolts alternately and diagonally, as shown, to ensure even tightening.

5.

Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to Orings or uneven tightening of bolts.

SM0177

WRONG

SM0178

Nut and Bolt Lockings •

SM0179

Lock Plate

IMPORTANT: do not reuse lock plates. Do not try to bend the same point twice. •

Cotter Pin

IMPORTANT: do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. •

WRONG

RIGHT

Do not bend it round

Bend along edge sharply

RIGHT

RIGHT

WRONG

Lock Wire

IMPORTANT: apply wire to bolts in the bolttightening direction, not in the bolt-loosening direction. Bend along edge sharply

RIGHT

RIGHT

SM0180

WRONG

RIGHT

WRONG Loosen

Tighten

SM0181

W1-2-3

Copyright © New Holland E135B

TIGHTENING TORQUE

PIPING JOINT Pipe Thread Connection / Union Tightening Torque Specifications

Joint

4

1

5

3

2

Union Joint Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. Joint Body

SM0182

IMPORTANT 1.

2.

Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten union nut (3) to specifications.

37° 37°

Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting /disconnecting.

Male Union Joint

Female Union Joint SM0183

Wrench Size

Tightening Torque

Type 37° Union Joint

Union Nut

Joint Body

(Nm)

19

17

29

22

19

39

27

22

78.5

36

30, 32

157

41

36

205

50

46

323.6

NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.

W1-2-4

Copyright © New Holland TIGHTENING TORQUE

E135B

O-Ring Seal Joint O-Ring (6) seats against the end face of adaptor (7) to seal pressure oil.

7

9

6

IMPORTANT 1.

Be sure to replace O-Ring (6) with a new one when reconnecting.

2.

Before tightening union nut (9), confirm that ORing (6) is seated correctly in O-Ring groove (8). Tightening union nut (9) with O-Ring (6) displaced will damage O-Ring, resulting in oil leakage.

3.

Take care not to damage O-Ring groove (8) or sealing face (10). Damage to O-Ring (6) will cause oil leakage.

4.

If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-Ring (6) with a new one, then tighten union nut (9) after confirming that O-Ring (6) is securely seated in place.

Wrench Size

Tightening Torque

Union Nut

Joint Body

(Nm)

19

17

29.4

22

19

68.6

27

22

93

30

27

137.3

36

30

175

41

36

205

50

46

320

W1-2-5

8

10

Joint body SM0184

Copyright © New Holland E135B

TIGHTENING TORQUE

Screwed-In Connection IMPORTANT: many types of screwed-in connections are used for hose connections. Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection. Male Tapered Thread

PT

PF 30°

Male Tapered Thread

Wrench Joint Body

Tightening Torque (Nm)

17, 19

34

22

49

27

93

36, 32

157

41

205

50

320

60

410

Male Straight Thread SM0185

Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leakage between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. •

Internal Thread

Clearance External Thread

SM0186

Application Procedure Leave one to two pitch threads uncovered

Confirm that the thread surface is clean, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. See below for correct tightening torque of each type of low-pressure-hose clamp.

SM0187

T-Bolt Type

Worm Gear Type

T-Bolt Type Band Clamp: 4.4 Nm (0.45 kgf m) Worm Gear Type Band Clamp: 5.9 a 6.9 Nm (0.6 a 0.7 kgf m)

SM0188

W1-2-6

SM0189

Copyright © New Holland TIGHTENING TORQUE

E135B

Connecting Hose WARNING 1.

When replacing hoses, be sure to use only genuine parts. Using hoses other than genuine hoses may cause oil leakage, hose rupture or separation of fitting, possibly resulting in a fire on the machine.

2.

Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leakage, hose rupture or separation of fitting. Utilize print marks on hoses when installing hoses to prevent hose from being installed kinked.

3.

RIGHT

WRONG

SM0190

WRONG

RIGHT

Rubbing Against Each Other

If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care that hoses do not come into contact with moving parts or sharp objects.

SM0191

RIGHT

WRONG Clamp

Clamp

Rubbing SM0192

WRONG

RIGHT

Rubbing Clamp SM0193

W1-2-7

Copyright © New Holland E135B

TIGHTENING TORQUE

NOTE:

W1-2-8

Copyright © New Holland

SECTION 2

E135B

UPPERSTRUCTURE

CONTENTS Group 1 - Upperstructure

Group 3 - Control valve

Removal and installation of upperstructure....................................... W2-1-1 Preparation ....................................... W2-1-1 Removal of upperstructure ............... W2-1-1

Removal and installation of control valveW2-3-1 Preparation ....................................... W2-3-1 Removal of control valve................... W2-3-1 Installation of control valve................ W2-3-2

Removal and installation of the cab ....... W2-1-2 Removal of the cab ........................... W2-1-2 Installation of the cab ........................ W2-1-3

Control valve ports ................................. W2-3-3

Removal and installation of counterweight........................................ W2-1-4 Removal of counterweight ............... W2-1-4 Installation of counterweight ............ W2-1-5 Disconnecting hoses of swivel joint lower side.............................................. W2-1-6 Removal and installation of main frame. W2-1-7 Removal of main frame..................... W2-1-7 Installation of main frame.................. W2-1-8

Group 2 - Pump device Removal and installation of hydraulic pump device.......................................... W2-2-1 Preparation ...................................... W2-2-1 Removing of the hydraulic pump device .............................................. W2-2-2 Installing of the hydraulic pump device ............................................. W2-2-5 Main pump ............................................. W2-2-9 Gear pump ............................................. W2-2-10 Power take off (PTO) ............................. W2-2-11 Disassembly hydraulic pump device...... W2-2-12 Assembly .......................................... W2-2-16 Maintenance standard .......................... W2-2-20 Troubleshooting ..................................... W2-2-21 Disassembly and assembly of regulator... W2-2-23 Regulator disassembly ..................... W2-2-24 Regulator assembly .......................... W2-2-27 Disassembly and assembling PTO unit.... W2-2-30 Maintenance standard ...................... W2-2-32 Tool table .......................................... W2-2-33

Assembly and disassembly of control valve...................................................... W2-3-12 Preparation for disassembly ............. W2-3-12 Inspection after disassembly............. W2-3-25 Reassembly ...................................... W2-3-25 Maintenance standards.......................... W2-3-31 Trobleshooting ....................................... W2-3-32

Group 4 - Swing device Removal and installation of swing device.................................................... W2-4-1 Preparation ....................................... W2-4-1 Removal ........................................... W2-4-2 Installation ........................................ W2-4-3 Disassembly and assembly of swing device ................................................... W2-4-4 Disassembly and assembly of swing motor .................................................... W2-4-6 Preliminary operations ...................... W2-4-8 Disassembly...................................... W2-4-8 Assembly .......................................... W2-4-14 Disassembly and assembly of swing reduction unit ........................................ W2-4-21 Disassembly...................................... W2-4-22 Assembly .......................................... W2-4-27 Maintenance standards ......................... W2-4-33 Swing motor ...................................... W2-4-33 Reduction unit ................................... W2-4-35 Special tools .......................................... W2-4-37 Swing motor ...................................... W2-4-37 Swing reduction unit.......................... W2-4-35

Copyright © New Holland

Group 5 - Pilot valve Removal and installation of right and left pilot valve ........................................ W2-5-1 Preparation ....................................... W2-5-1 Removal............................................ W2-5-1 Installation......................................... W2-5-2 Removal and installation of travel pilot valve...................................................... W2-5-3 Preparation ....................................... W2-5-3 Removal............................................ W2-5-3 Installation......................................... W2-5-4 Disassembly right and left pilot valve ..... W2-5-5 Disassembly right and left pilot valve W2-5-6 Assembly right and left pilot valve.......... W2-5-9 Assembly right and left pilot valve..... W2-5-10 Pilot valve (for travel) ............................. W2-5-13 Construction...................................... W2-5-13 Disassembly and assembly .............. W2-5-14 Drain of hydraulic pilot control unit.... W2-5-21

Copyright © New Holland UPPERSTRUCTURE

E135B

REMOVAL AND INSTALLATION OF UPPERSTRUCTURE WARNING Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and appropriate to hold the weight of load.

Preparation

Removal of upperstructure

1.

Park the machine on a firm, level surface.

1.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at page T21-47.

Remove the front equipment and the boom cylinders, performing the operations described in the procedure at pages W4-1-1 (Refer to: Section 4 - “Front Attachment”).

2.

Remove the cab, performing the operations described in the procedure at page W2-1-2

3.

Remove the counterweight, performing the operations described at page W2-1-4.

4.

Disconnect the hoses of swivel joint lower side, performing the operations described in the procedure at page W2-1-6.

5.

Remove the main frame performing the operations described in the procedure at page W2-1-7.

3.

Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself.

W2-1-1

Copyright © New Holland E135B

UPPERSTRUCTURE

REMOVAL AND INSTALLATION OF THE CAB Removal of the cab 1.

Remove floor mat.

2.

Remove cover (1). Lift cover (1) upwards and remove it. (Fixed with 2 clips).

3.

Remove cover assy (2). 1) Loosen 4 sems bolts (3) M6x16 and lift cover assy (2) up. 2) Disconnect each connector for both speakers. Then remove cover assy (2).

4.

Remove the harness connector (See section T2, group 3) 1) Disconnect connectors of cluster gauge harness: (CN-5F), (CN-6F), (CN-61F), (CN62F) and earth wire (P-1) at rear right of cab. 2) Disconnect antenna cable coming from backside of tuner at rear left of cab.

5.

Remove the plastic tube for the window washer from the rear left of cab.

6.

Remove the right panel of cab. 1) Remove 2 caps (4), loosen 2 sems bolts (5) M6x25 and 1 sems bolt (6) M6x16, and right panels (7) and (8) are freed. : TORX driver T30 2) Lift cover (9) upwards and remove it. (Fixed with 3 clows and 2 clips). 3) Unfix 3 harness clips (10) of inside on right panel (8). And free the harnesses connected to key switch. 4) With harnesses are connected condition, install key switch cover (9) to bracket (11) of rear cab temporally. (See Fig. SM0261). 5) Disconnect harness connectors of work light switch on right panel (7), air conditioner panel and cigarette lighter, and remove right panel (7) and (8). 6) Loosen sems bolts (12) M6x16 and (13) M6x40, one each, and remove front panel (14) with air conditioner duct. : Plus driver

1

3 2

SM0259

Disassembly and assembly of cover (1) and cover assy (2)

9

3 5

10 7

4

10

6

5 10 4

8

12

14

13

SM0260

Disassembly and assembly of right panels (8), (9) and (14)

W2-1-2

Copyright © New Holland UPPERSTRUCTURE

7.

E135B

Remove cab attaching bolt.

9

1) 5 capscrews (15) M12x65 and 1 capscrew (16) M12x30 2) 2 nuts (17) M16 8.

Slinging cab. 1) Remove two plastic plugs at the front of the ceiling of the cab. Then place a wire sling with eye bolts (18) and a hook around the cab, as shown in Fig. SM0263. 2) Then lift up slowly avoiding interference with surroundings. Eye bolts M10 (q.ty 2). Wire with hook: Length 1.5 m (4ft 11in), Dia. 8 mm (0.315in) – (3 pcs).

11

NOTE: weight of cab: Approx. 265 kg (584 lbs)

SM0261

17

15

installation of the cab Install it in reverse order of removing according to the Tightening Torque Table. Allen wrench HEX

Tightening torque Nm (lbf•ft)

Nut M16 - (17)

24

191 (140)

Capscrew - (2), (9)

19

79.4 (60)

Sems bolt M6 (5), (6)

Torxdriver T30

8.5 (6.3)

Sems bolt M6 (12), (13)

Plus driver

5.0 (3.7)

Tightening position

15

16 15 15 Smontaggio e rimontaggio dei bulloni di fissaggio 15 SM0262 cabina

18 18

SM0263

W2-1-3

Copyright © New Holland E135B

UPPERSTRUCTURE

REMOVAL AND INSTALLATION OF COUNTERWEIGHT Removal of counterweight 1.

Remove plugs (1) from the counterweight and attach two M36 eye bolts to the counterweight.

1

NOTE: approximate mass of counterweight: 2000 kg (4410 lbs) 2.

3.

Attach wire rope (2) to eye-bolts (3) using shackles. Take out slack of wire rope by applying tension slowly with a crane or hoist. Wire with hook: Length 1.5 m, dia. more than 16 mm – (2 pcs.).

Remove 4 bolts (4) M27. Lift counterweight using a crane or hoist.

2

: 41 mm

4.

SM0264

3

Remove shim (5), (6), (7) from the frame.

5 6 7

4

5.

SM0265

Lower the counterweight on proper stand.

SM0266

W2-1-4

Copyright © New Holland UPPERSTRUCTURE

E135B

Installation of counterweight

NOTE: approx. weight of counterweight: 2000 kg (4410 lbs)

2

1.

Attach lifting tools (2) to eye-bolts (3) of counterweight.

2.

Install shim (5), (6), (7) onto the frame as it was.

3

3.

Lift counterweight and install it onto the frame.

5 6 7

4.

Install bolts M27 (4) and washers counterweight and tighten temporarily.

to

: 41 mm

5.

4

Remove wire rope. Tighten the bolts (4) with a power wrench and torque wrench.

SM0265

1

: 41 mm : 1150 ± 150 Nm (848 ± 110 lbf•ft)

6.

Remove eye-bolts (3) and install plugs (1) onto the counterweight.

4

W2-1-5

SM0267

Copyright © New Holland E135B

UPPERSTRUCTURE

DISCONNECTING HOSES OF SWIVEL JOINT LOWER SIDE Disconnect the hoses on the lower side of swivel joint. NOTE: close all openings with plugs to keep clean. 1.

Disconnect the two hoses (1). (E Port: PF1/2) : 27 mm Tightening torque: 78.5 ± 5 Nm (57.9 ± 3.7 lbf•ft)

2.

Disconnect the hoses (2) and (3). (A and B Port: 1 3/16-12 UN) : 36 mm Tightening torque: 177 ± 18 Nm (130.5 ± 13.2 lbf•ft)

3.

Disconnect the hoses (4) and (5). (C and D Port: 1 3/16-12 UN) : 36 mm Tightening torque: 177 ± 18 Nm (130.5 ± 13.2 lbf•ft)

4.

Disconnect the two hoses (6). (H and I Port: PF1/4) : 19 mm Tightening torque: 29.4 ± 5 Nm (21.7 ± 3.7 lbf•ft)

1

H

I

4 2

C A E

D B

1

5 3

E 6 6

SM2642

W2-1-6

Copyright © New Holland UPPERSTRUCTURE

E135B

REMOVAL AND INSTALLATION OF MAIN FRAME Removal of main frame

NOTE: approximate mass of main frame: 3300 kg (7277 lbs). 1.

Attach a chain block (1) to the boom foot side and the rear of the upper frame.

2.

Adjust chains lengths to level the frame.

IMPORTANT: make sure rear chains do not touch engine.

SM2663

W2-1-7

Copyright © New Holland E135B

UPPERSTRUCTURE

3.

Put matching marks (M) on swing bearing and main frame.

4.

Remove the 36 bolts (5) M16, the reamer bolt (6) M24, from the swing bearing.

M

: 24 mm

5 5.

6.

Lift main frame slightly from undercarriage. Level main frame by adjusting the chain blocks.

SM0271

Remove main frame.

A

Installation of main frame

NOTE: approximate mass of main frame: 3300 kg (7277 lbs).

Installing is done in the riverse order of removing.

6 1.

Clean mating surfaces of upper frame and swing bearing.

2.

Apply Loctite # 515 to the inside of the capscrews on the contact surface (A) (fig. SM0272).

3.

Slinging upper frame. Match marks and install it with a reamer bolt (6) and a washer temporarily.

SM0272

SM0273

W2-1-8

Copyright © New Holland UPPERSTRUCTURE

IMPORTANT: confirm the reamer bolt position (X) referring to Fig SM2178. (S) points to the soft zone of the outer ring.

E135B

S

X 4.

Apply Loctite # 262 onto thread of bolts (5) then, install bolts. : 24 mm : 270 ± 27 Nm (199 ± 19.9 lbf•ft)

5.

Apply Loctite # 262 onto thread of reamer bolts (6) then, install reamer bolt. : 24 mm : 270 ± 27 Nm (199 ± 19.9 lbf•ft)

SM2178

Apply Loctite # 515 to the shaded area

W2-1-9

Copyright © New Holland E135B

UPPERSTRUCTURE

NOTE:

W2-1-10

Copyright © New Holland PUMP DEVICE

E135B

REMOVAL AND INSTALLATION OF HYDRAULIC PUMP DEVICE WARNING Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and appropriate to hold the weight of load.

Preparation 1.

Park the machine on a firm, level surface.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at page T21-5.

3.

Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself.

4.

Remove six capscrews M10x25 (C4).

C4 C1 Q C

: 17 mm 5.

Remove cover (C1).

6.

Take out suction strainer (C).

7.

Install suction stopper (Q) (xxxxxxxx).

8.

Remove all protection panels and doors to give access to the Hydraulic Pump Device.

W2-2-1

SM2181

Copyright © New Holland E135B

PUMP DEVICE

REMOVING OF THE HYDRAULIC PUMP DEVICE 1.

17

Loosen screws (17) M10x35 and remove half clamp (12), then disconnect 2 hoses (1), (2) from the delivery side.

12

17 12

1

: 8 mm

2 2.

Remove pilot pump suction hose (A4).

A15

: 36 mm

A2 3.

3

Remove 4 capscrews (A15) M12x30.

A6

: 10 mm

A5

4.

5.

Disconnect elbow (A6) of suction hose (3) from pump.

SM2922

A2

Remove drain hose (A5).

A1

: 36 mm

6.

Disconnect drain hose (A2) of port Dr3.

A3

: 22 mm

7.

Only if necessary, disconnect pilot primary pressure P1 side hose (A1) of port Psv1. : 22 mm

8.

Disconnect pilot pump delivery hose (A3) of port Psv1.

A4

: 22 mm SM2923

W2-2-2

Copyright © New Holland PUMP DEVICE

9.

E135B

Remove clips (22).

SE-22

SE-23

22

10. Remove the connector of P1 pump pressure sensor (SE-22) and the connector of P2 pump pressure sensor (SE-23).

11. Remove the screw (25) and the clip (26).

23

25

26

12. Remove the connector of P1 pump proportional valve (23) and the connector of P2 pump proportional valve (24).

25 26 24 13. Put a wire sling on the hydraulic pump andtension the wire sling a little. Loosen 8 capscrews (4) M10x30. : 17 mm

W2-2-3

SM2924

Copyright © New Holland E135B

PUMP DEVICE

14. Draw out the power take-off assy from the flywheel housing slowly, adjusting the tension of the wire rope. On that occasion, the assembly is drawn out with the insert NA (2-3) remaining on the flywheel side.

0

3

15. Remove element (2-1) from the tip of the spline shaft.

4 3 2-4

16. Remove 4 capscrews (2-6) M16x45 that fasten insert R (2-4) and remove insert R (2-4).

2-6

2-7

: 14 mm

2-2

17. If you loosen 2 set screws (2-7) M16x18, hub (2-2) comes off from the spline shaft of the pump. : 8 mm

18. Remove 4 capscrews (2-5) M16x55 that fasten the insert NA (2-3) with the engine side flywheel, as necessary. Then remove and spring pin (2-8) from insert NA (2-3). : 14 mm

19. Loosen 2 capscrews (3) M16×50, and remove bracket (4) from pump (0).

W2-2-4

2-8

2-1

2-3

2-5

1 SM2945

Copyright © New Holland PUMP DEVICE

E135B

INSTALLING OF THE HYDRAULIC PUMP DEVICE 2-6

Installing is done in the reverse order of removing. 1.

Installing bracket (1) Tighten bracket (1) with capscrew (3) and install bracket temporarily. Apply Loctite #262

2-4

2-1

: 14 mm

2-2

: 191 ± 19 Nm (141 ± 14 lbf•ft)

aa 2.

Put hub (2-2) into the pump spline till it enters 5 mm (0.12 in) from the end face of the spline. Then, install two set screws (2-7) and fix them together.

2-7

2-8

: 8 mm

I

: 110 ± 10 Nm (81± 7 lbf•ft)

2-3

3.

Installing insert R (2-4) into hub (2-2) by means of capscrews (2-6). : 14 mm

3

1 2-5

5 (0.197")

: 220 ± 10 Nm (162 ± 7 lbf•ft)

4.

Put element (2-1) into hub (2-2) and insert R (24).

50 (1.97")

DETAIL aa

5.

Put spring pin (2-8) into insert NA (2-3) and install it to the engine flywheel by means of capscrews (2-5). : 14 mm : 220 ± 10 Nm (162 ± 7 lbf•ft)

W2-2-5

VIEW I SM2946

Copyright © New Holland E135B

6.

PUMP DEVICE

Lift the pump with bracket (1). Place coupling in the groove of element (2-1) so as to receive insert NA (2-3).

2-1

7.

Coat 8 capscrews (4) M10x30 with Loctite #262 and put them in place. : 17 mm : 64.7 ± 6.4 Nm (48 ± 4.8 lbf•ft)

1 2-3

4 SM3018

8.

Fasten hoses (1), (2) on the delivery side with half clamp (12) and sems bolt (17) M10x35. : 8 mm

17

12

17 12

: 57 ± 5.7 Nm (42 ± 4.2 lbf•ft)

1

9.

2

Install suction hose (3) fixing elbow (A6) to the hydraulic pump with 4 capscrews (A15) M12x30.

A15

: 10 mm

A2

: 67 ± 6.7 Nm (49 ± 4.9 lbf•ft)

3

A6

A5

SM2922

W2-2-6

Copyright © New Holland PUMP DEVICE

10. Install pilot pump delivery hose (A3) of port Psv1.

E135B

A2

A1

: 22 mm : 49 ± 4.9 Nm (36 ± 3.6 lbf•ft)

A3 11. If removed, install hose (A1) of port Psv1. : 22 mm : 49 ± 4.9 Nm (36 ± 3.6 lbf•ft)

12. Install drain hose (A2) of port Dr3. : 22 mm : 49 ± 4.9 Nm (36 ± 3.6 lbf•ft)

A4

SM2923

SE-22

13. Install drain hose (A5).

SE-23

22

: 36 mm : 118 ± 11 Nm (87 ± 8.7 lbf•ft)

14. Install the connectors of the pressure sensor (SE-22) and (SE-23) and fasten them with clips (22).

15. Install the connectors of the proportional valve (23) and (24) and fasten them with clips (26) and screws (25).

23

25

26

25 26 24

W2-2-7

SM2924

Copyright © New Holland E135B

PUMP DEVICE

16. Remove suction stopper (Q) (xxxxxxxx).

C4 17. Install suction strainer (C).

C1 18. Install cover (C1).

Q 19. Tighten six capscrews M10x25 (C4).

C

: 17 mm : 50 ± 5 Nm (37 ± 3.7 lbf•ft)

IMPORTANT: when the pump is replaced, replenish more than 1l (0.26 gal) of hydraulic oil from the drain port (D1).

SM2181

20. Bleed air by loosening the drain port (Dr).

Dr

21. Check the hydraulic oil level.

22. Start engine and check it for oil leak and noise.

23. Attach drain down pipe under engine muffler. SM2947

24. Install all protection panels in reverse order of removing.

W2-2-8

Copyright © New Holland PUMP DEVICE

E135B

MAIN PUMP

(Three Bond No.1305N)

533 789 733 732 532 214 548 531 702 792 901 534 535 808 806 953

954 724 717 723 402 151 981

152 211 899 255 04

490 261 111

983

774 A

A

127 710 406 123 824 251 212 271 153 468 156 466 157 313 124 711 727 723

401, 402 406 466 467 468 490 531, 532 533 806 808

M16 M6 PF 1/4 PF 3/8 PF 1/2 NPTF1/16 M20X1.5 M30 M12 M16

116 312 886 314 401 467 141 732 05

Nm (lbf ft) 240 (177) 12 (8.9) 36 (27) 74 (55) 110 (81) 11 (6.5) 240 (177) 220 (162) 60 (44) 130 (96)

section A-A

04 05 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 255 261

-

Gear pump PTO gear case Shaft (F) Shaft (R) 1st gear Roller bearing (Q.ty 2) Needle bearing (Q.ty 2) Bearing spacer (Q.ty 2) Cylinder block (Q.ty 2) Piston (Q.ty 18) Shoe (Q.ty 18) Retainer (Q.ty 2) Spherical bushing (Q.ty 2) Cylinder spring (Q.ty 12) Shoe plate (Q.ty 2) Swash plate (Q.ty 2) Tilting bushing (Q.ty 2) Swash plate support (Q.ty 2) Lock pin (Q.ty 2) Seal cover (F)

272 113

271 272 312 313 314 401 402 406 466 467 468 490 531 532 533 534 535 548 702 710

-

Pump casing (F) Pump casing (R) Valve block Valve plate (R) Valve plate (F) Socket bolt M16x150 (Q.ty 2) Socket bolt M16x190 (Q.ty 2) Socket bolt M6x16 (Q.ty 4) VP plug PF1/4 (Q.ty 2) VP plug PF3/8 (Q.ty 2) VP plug PF1/2 (Q.ty 4) Plug NPTF1/16 (Q.ty 9) Tilt pin M20x1,5 (Q.ty 2) Servo piston M20x1,5 (Q.ty 2) Plug M30 (Q.ty 2) Stopper (long) (Q.ty 2) Stopper (short) (Q.ty 2) Feed back pin (Q.ty 2) O-ring 1B G30 (Q.ty 2) O-ring 1B G95

SM2803

711 717 723 724 727 732 733 774 789 792 806 808 824 886 899 901 953 954

-

O-ring 1B G80 O-ring 1B G125 (Q.ty 2) O-ring 1B P11 (Q.ty 6) O-ring 1B P8 (Q.ty 12) O-ring 1B P18 (Q.ty 4) O-ring 1B P14 (Q.ty 4) O-ring 1B P28 (Q.ty 2) Oil seal Backup ring P14 (Q.ty 2) Backup ring G30 (Q.ty 2) Nut M12 (Q.ty 2) Nut M16 (Q.ty 2) Stop ring (Q.ty 2) Spring pin (Q.ty 4) C-ring (Q.ty 2) Eye bolt M10 (Q.ty 2) Set screw M12x23 (Q.ty 2) Set screw M16 (Q.ty 2)

The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

W2-2-9

Copyright © New Holland E135B

PUMP DEVICE

GEAR PUMP

887 Section X-X

710

700

354

351

887

433

Z X

B3

X

434 X

311

A3

312

X

732

Dr3

435

361

353

850

a3

Dr3

Z

307

308

310

309

355 434

466 725

Section Z-Z

312 433, 434 435 466

M14x1,5

Nm (lbf ft) 29 (21)

M8

17 (13)

G 1/4

16 (11) SM2804

307 308 309 310 311 312 351 353 354 355 361 433

-

Poppet Seat Ring Spring Adjust screw Lock nut M14x1.5 Gear case Drive gear Driven gear Filter Front case Flange socket; M8x40 (Q.ty 2)

434 435 466 700 710 725 732 850 887 A3 B3 Dr3

W2-2-10

-

Flange socket; M8x55 (Q.ty 2) Flange socket; M8x20 (Q.ty 4) Vp plug PF1/4 Ring O-ring O-ring; 1B O-ring; 1B P16 Locking ring Pin (Q.ty 2) Delivery port G1/2 53 Nm (39.1 lbf•ft) Suction port; G3/4 74 Nm (54.5 lbf•ft) Drain port G3/8 34 Nm (25.1 lbf•ft)

Copyright © New Holland PUMP DEVICE

E135B

POWER TAKE OFF (PTO)

711

468

125

118 11

262 728

117 414 126 128

825 710

435

10 12

886

826

SM0749

10 11 12 117 118 125 126 128 262

-

Idle shaft Gear case Pin 2nd gear 3rd gear Ball bearing (Q.ty 2) Roller bearing Bearing spacer (Q.ty 2) Cover

414 435 468 710 711 728 825 826 886

W2-2-11

-

Socket bolt; M10x20 (Q.ty 4) Socket bolt; M10x20 (Q.ty 4) Vp plug G3/4 O-Ring 1B G85 O-Ring 1B P24 O-Ring 1B G80 Snap ring Snap ring Pin (Q.ty 2)

Copyright © New Holland E135B

PUMP DEVICE

DISASSEMBLY HYDRAULIC PUMP DEVICE •

Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from damaging.

•

Clean the parts removing dust and rust, etc. on pump surface with wash oil.

•

Drain out the oil in the pump casing by removing drain port plug (468). :10 mm

NOTE: drain out oil from the plug of the front pump and the rear pump.

1.

Removing piloto pump. Remove the socket bolts (433), (434) then remove pilot pump (04). : 6 mm

05

435 2.

Removing PTO unit. Remove the socket bolts (435), then remove PTO unit (05). : 8 mm

3.

SM0278

Removing regulator. Remove the socket bolts (415), then remove regulators (2).

415

2

: 6 mm

SM2948

W2-2-12

Copyright © New Holland PUMP DEVICE

4.

Loosen socket bolt (401), (402) that fasten pump casing (271), (272) and valve block (312).

E135B

271

402

272

: 14 mm

401 SM2949

5.

Place the pump level on a work bench with its mounting surface of the regulator facing down. Then separate pump casing (271) and valve block (312).

312

271

NOTE: when facing the mounting surface of the regulator down, place a rubber board on a work bench so as not to score the mounting surface. When the pump casing has been separated from the valve block, draw out the 1st gear (116) at the same time. SM0280

6.

Draw out cylinder (141) out of pump casing (271), (272) in parallel to shaft (111), (113). At the same time draw out piston (151), (152) plate (153), spherical bushing (156) and cylinder spring (157).

271 141(151)(157) 153 156

NOTE: use care so as not to score the sliding surface of the cylinder, spherical bushing, shoe and the swash plate.

SM0281

W2-2-13

Copyright © New Holland E135B

7.

PUMP DEVICE

Remove socket bolt (406) and seal cover (261).

406

: 5 mm

261 NOTE: the seal cover may be drawn out with ease if it is taken out by tightening bolts in the tapped holes of the seal cover. An oil seal is fitted to seal cover. Therefore, use care so as not to score the oil seal.

SM0282

8.

Tap lightly the shaft end (111), (113) by means of a plastic hammer and draw out the shaft from the pump casings (271), (272).

271 272 111 113

SM2925

9.

Draw out shoe plate (211) and swash plate (212) from pump casings (271), (272).

271 272 211 212

SM2926

10. Draw out C-ring (899) and lock pin (255) which locks swash plate support (251). And free the swash plate support from locking, and rotate it counterclockwise. Then remove swash plate support (251) from pump casing.

251

SM2927

W2-2-14

Copyright © New Holland PUMP DEVICE

E135B

11. Remove valve plate (313 and 314) from valve block (312).

NOTE: the valve plate may come off during the separation of pump casing from valve block.

312 314 (313)

SM0286

12. If necessary, remove Q min-plug (533), stopper (L) (534), stopper (S) (535), servo piston (532) and tilting pin (531) from pump casing (271), (272), and remove needle bearing (124) from valve block (312). • •

• •

When removing the tilting pin, use care so as not to score the head of the tilting pin, using a jig. It is hard to separate the tilting pin from the servo piston in some cases as Loctite is coated on the mating part between them. Use care so as not to score the servo piston by applying undue force. Do not draw out needle bearings except when their service life has ended. Do not loosen Q min-plug (533) of valve block (312). A set flow rate changes.

272

533

534

531 532

808

535

806 124

312 SM2928

W2-2-15

Copyright © New Holland E135B

PUMP DEVICE

Assembly 1.

Assembly is a reverse order of disassembly, but notice the following: - Repair scored parts at disassembly. Get replacements ready beforehand. - Wash parts sufficiently in cleaning oil and dry them with jet air. - Do not forget to coat the sliding areas and bearings with clean hydraulic oil. - In principle, replace sealing parts such as ORings and oil seals. - Tighten socket bolts and plugs to specified torques in this manual, using a torque wrench. - Do not mix up front pump parts with rear pump parts.

IMPORTANT: • When the servo piston, the tilting pin, the stopper (L), the stopper (S) and the Q min-plug have been removed, install them to the pump casing. • When tightening servo piston and tilting pin, use a jig so as not to damage the head of the tilting pin and feedback pin. Coat the screwed part with Loctite #262. 2.

Install lock pin (255) and C-ring (889) in pump casing (271). Then align swash plate support (251) with spigot of pump casing, and rotate it in clockwise. And fix swash plate support (251) with lock pin.

3.

Install shoe plate (211) on swash plate (212). Then insert tilting bushing of swash plate into tilting pin (531), and fix swash plate (212) and shoe plate (211) to swash plate support (251) properly.

IMPORTANT: • Confirm by the fingers of your both hands that swash plate moves smoothly. • The shaft be installed easily if grease is applied to the sliding parts of swash plate and swash plate support. • Do not damage the sliding surface of shoe plate.

251 SM2929

SM2930

271 (531)

251

212

SM0289

W2-2-16

Copyright © New Holland PUMP DEVICE

4.

E135B

Install shaft (111), (113) fitted with bearing (123), bearing spacer (127) and snap ring (824), to pump casing (271), (272).

271,272 251

NOTE: Do not knock on the shaft with a hammer or somethings. Fix the bearing by lightly tapping the outer race of it by means of a plastic hammer and set it exactly to the end by using a steel rod and others.

123 127,824

111

5.

Install seal cover (261) to pump casing (271) and fix it with socket bolts (406).

SM2931

271

: 5 mm : 12 Nm (8.8 lbf•ft)

261 406

NOTE: Coat the oil seal in seal cover with a thin film of grease. Handle the oil seal with sufficient care so it is not scored.

SM0291

6.

Assemble the piston cylinder sub compound to the cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156) and cylinder spring (157). Align the spherical bushing with the cylinder spline and insert them into the pump casing.

141(151,152,157) 156 153

SM0292

W2-2-17

Copyright © New Holland E135B

7.

PUMP DEVICE

Install valve plate (313 and 314) to valve block (312) by aligning pin.

312

NOTE: do not mistake the suction and delivery sides of the valve plate.

314 (313)

SM0293

8.

Install valve block (312) to pump casing (271) and fasten them together with socket bolts (401).

312

271 401

: 14 mm : 240 Nm (177 lbf•ft) NOTE: Work will be promoted if assembly is started from the rear pump. Exercise care so as not to mistake the direction of the valve block (312). Install it so the regulator comes up as seen from the front side and the suction flange comes on the right. Insert the 1st gear into the valve block beforehand and connect it with the spline of the shaft.

9.

Install regulator (2) pinching feedback pin of tilting pin in feedback lever of the regulator, then install the regulator and fasten socket bolt (412) e (413).

SM0294

2

: 6 mm : 17 Nm (12.5 lbf•ft) IMPORTANT: do not mistake the front regulator for the rear regulator.

SM2932

W2-2-18

Copyright © New Holland PUMP DEVICE

E135B

10. Install PTO cover (05) and fasten socket bolts (435) and pin (889). : 8 mm : 33 Nm (24.3 lbf•ft)

05

435

SM0278

11. Install gear pump (04) and fasten socket bolts (435). : 6 mm : 17 Nm (12.5 lbf•ft)

435 435

311 312 466

W2-2-19

SM0276

Copyright © New Holland E135B

PUMP DEVICE

MAINTENANCE STANDARD:

Part name and inspection item

Standard dimension mm (in)

Recommended value for replacement mm (in)

Clearance between piston and cylinder bore (D-d)

0.032 (0.00126)

0.056 (0.00220)

Replace piston or cylinder.

0 ~ 0.1 (0 to 0.0039)

0.3 (0.0118)

Replace piston shoe assy.

3.9 (0.154)

3.7 (0.146)

Replace piston shoe assy.

41.1 (1.618)

40.3 (1.587)

Replace cylinder spring.

17.0 (0.669)

15.8 (0.662)

Replace a set of spherical bushing or retainer plate.

Remedy

SM0520

Gap between piston and caulked part of shoe (d)

SM0521

Thickness of shoe (t)

t SM0522

Free height of cylinder spring (L)

L SM0523

Combined height of retainer plate and spherical bushing (H-h)

SM0524

Repair standards for cylinder, valve plate and swash plate (shoe plate face) Valve plate (sliding section). Swash plate (shoe plate face). Cylinder (sliding section). Roughness of each surface.

Surface correction.

roughness

Standard surface (correction value)

W2-2-20

requiring roughness

3-Z Less than 0.4 Z (lapping)

Copyright © New Holland PUMP DEVICE

E135B

TROUBLESHOOTING Locating causes of troubles The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location extremely difficult. However, faults would be found out easily if the following check items were attended to. 1.

Inspecting the filter and drain oil

Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements may be damaged. In that case check the drain oil in the pump casing as well. 2.

Checking for abnormal vibration and sound

Check that the pump does not vibrate and make an abnormal sound. Check that the hunting of the regulator and the attached valve's relief valve's are of regular frequency. In case vibration and sound are abnormal, the pump may be making a cavitation or internally broken. 3.

When two pumps are used

In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This will make clear that the pumps are faulty or the circuit after the pumps is faulty. 4.

Pressure measurements

If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes by measuring pressures.

Troubleshooting 1) Overloading to engine Remedy

Cause

Remarks

1.

Revolution and pressure are 1) higher than set values.

Set pressure value.

2.

Regulator torque is set higher 2) than normal.

Readjust regulator.

2)

Refer to Regulator Manual.

3.

Pump's internal seized or broken.

Replace damaged parts.

3)

Check filter and drain oil to see if abnormal wear particles are present.

4.

Regulator is piped incorrectly.

parts

are 3)

4)

to

specified

Pipe regulator correctly.

W2-2-21

Copyright © New Holland E135B

PUMP DEVICE

2) Pump's oil flow rate is extremely low and delivery pressure is not available. Cause

Remedy

Remarks

1.

Regulator is out of order.

1)

Repair regulator.

1)

Refer to Regulator Manual.

2.

Pump's internal seized or broken.

are 2)

Replace damaged parts.

2)

Check filter and drain oil.

3.

Attached pump is out of order. 3)

Replace damaged parts.

3)

Remove attached pump and check shaft joint.

4.

Attached valve is out of order. 4)

Replace attached valve.

4)

Refer to Manual for Attached Valve.

5.

Regulator is piped incorrectly.

Pipe correctly.

parts

5)

3) Abnormal Sound and Vibration Cause

Remedy

1.

Cavitation.

1)

2.

Caulked part of shoe is broken. 2)

Replace piston shoe and shoe plate.

3.

Cylinder is cracked.

Replace cylinder.

3)

Remarks

Prevent cavitation. 1-1) The boost pressure is low. Check that hydraulic oil is not 1-2) The attached pump is in clouded. trouble. 1-3) The suction pipe is inhaling air. 1-4) The suction resistance is high.

4.

Pump is installed improperly.

4)

Correct installation.

5.

Regulator is hunting.

5)

Repair regulator.

6.

Relief valve in attached valve 6) ishunting.

Repair attached valve.

W2-2-22

5)

See Regulator Manual.

Copyright © New Holland PUMP DEVICE

E135B

DISASSEMBLY AND ASSEMBLY OF REGULATOR

041 601 496 646 724 543 624 545 541 415 755 079

418

402

924

801

496

875 726 614 616

652 496 466 755

656 733 627

651

041 755

496

407 631

658 754 724

887 754

643 731 897

708

611

325 SM2933

041 079 325 402 407 415 418 466 496 541 543 545 601 611 614 616 624 627 631

-

Check valve sub Solenoid proportional reducing valve Valve casing Socket bolt; M6x16 (Q.ty 4) Socket bolt; M6x30 (Q.ty 4) Socket bolt; M8x40 (Q.ty 4) Socket bolt; M5x12 (Q.ty 2) Vp plug; PF1/4 Plug; NPTF1/16 (Q.ty 9) Seat (Q.ty 2) Stopper (Q.ty 2) Ball (Q.ty 2) Casing Feedback lever Fulcrum plug Prevention plug Spring seat Adjusting stem Sleeve

643 646 651 652 656 658 708 724 726 731 733 754 755 801 875 887 897 924

-

Pilot piston Pilot spring Sleeve Spool Block cover Plug O-Ring O-Ring (Q.ty 5) O-Ring O-Ring O-Ring O-Ring (Q.ty 2) O-Ring (Q.ty 3) Nut; M10 Pin Pin Pin Set screw; M10x20

NOTE: the number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

W2-2-23

Copyright © New Holland E135B

PUMP DEVICE

Tightening torque of bolt, plug, nut and servo piston N.

Thread size

Tightening torque Nm (lbf.ft)

401, 402

M16

240 (177)

406

M6

12 (8.8)

414

M10

57 (42)

466

PF1/4

36 (27)

467

PF3/8

74 (55)

468

PF1/2

110 (81)

490

NTPF1/16

8.8 (6.5)

531, 532

M20x1.5

240 (177)

533

M30

220 (162)

806

M12

60 (44)

808

M16

130 (95)

Regulator disassembly 1.

Selecting a place for disassembly.

• •

Choose a clean place. Spread rubber sheet or cloth on work bench to protect parts from damaging.

2.

Remove dust and rust, etc. on regulator surface with wash oil.

3.

Remove socket bolts (415) and separate the regulator from the pump body.

466

SM2934

: 6 mm

4.

Remove ROH-plug (466) for a port of valve casing (601). And remove ROH-plug (466) for psv port too.

5.

Remove socket bolts (407) and remove valve casing (325) with solenoid proportional reducing valve (079).

407

: 5 mm

325 079 SM2935

W2-2-24

Copyright © New Holland PUMP DEVICE

6.

E135B

Remove socket bolt (402) and cover (656). : 5 mm

IMPORTANT: the cover is assembled with set screw (924) and hex nut (801), but do not loosen them. If they are loosened, the pressure settings change.

402

656 SM2936

7.

Draw out sleeve (631) and pilot piston (643) from the regulator body.

631 643

SM2937

8.

Removing looseness prevention plug (616).

IMPORTANT: removing of looseness prevention plug may cause damage of plug. (But in this case, there is no functional problem.)

616 SM2938

W2-2-25

Copyright © New Holland E135B

9.

PUMP DEVICE

Remove fulcrum plug (614) and feedback lever (611).

614 611 SM2939

10. Draw out spool (652) and sleeve (651) from the sleeve hole of the regulator casing.

11. Draw out plunger (627). Then take out pilot spring (646) and spring (624).

652 651 NOTE: the plunger comes off easily if an M4 bolt is used.

SM2940

627 646 624

12. The disassembly is complete when the check valve (041) [seat (541), ball (545), and stopper (543)] have been drawn out.

NOTE: the check valves are placed on two places; the mating surface of the pump casing and on the matching surface of the valve casing.

IMPORTANT: take care not to lose the parts because they are small.

W2-2-26

SM2941

Copyright © New Holland PUMP DEVICE

E135B

Regulator assembly Assembly is a reverse order of disassembly, but notice the following. • Do not fail to correct parts damaged during disassembly and get replacement parts ready beforehand. • Entry of foreign matter causes faulty functions; clean parts thoroughly, dry them with jet air and work in a clean place. • Do not fail to coat the sliding parts with clean hydraulic oil, before proceeding to assembly. • Seals and O-rings must be replaced with new ones. • Using torque wrench, the bolts and plugs should be tightened to the specified torques, with a 10% maximum tolerance.

1.

Install the check valve (041) [Seat (541), ball (545) and stopper (543)] to casing (601).

601

NOTE: assemble the check valve into the matching surface of the pump casing and the matching surface of the valve casing.

2.

Place sleeve (651) and spool (652) into the sleeve hole of casing (601).

651 652 SM2942

IMPORTANT: • Make sure the spool and the sleeve slide smoothly in the casing without catching. • Make sure the direction of the spool is correct.

3.

Insert pin (897) of feedback lever (611) into the pin hole of the sleeve and fix the feedback lever with fulcrum plug (614).

IMPORTANT: operate the feedback lever and make sure that it does not have much looseness and that it operates without catching.

611 SM2943

W2-2-27

Copyright © New Holland E135B

4.

PUMP DEVICE

Place the prevention plug (616).

616 SM2938

5.

Place spring seat (624), pilot spring (646) and plunger (627) into the hole in the sleeve.

624 646 627

SM2944

6.

Attach cover (656) to casing (601) and fasten them together with socket bolts (402).

NOTE: the cover is fitted with adjusting screw (924) and hex nut (801).

402

656 SM2936

7.

Assemble sleeve (631) and pilot piston (643) into casing (601).

631 643

SM2937

W2-2-28

Copyright © New Holland PUMP DEVICE

8.

Attach valve casing (325) fitted with solenoid proportional reducing valve (079) to casing (601) and fasten them together with socket bolts (407).

E135B

407

325 079 SM2935

9.

Install ROH-plug (466) to A port of valve casing (601). And install ROH-plug (466) to Psv port too.

466

SM2934

W2-2-29

Copyright © New Holland E135B

PUMP DEVICE

DISASSEMBLING AND ASSEMBLING PTO UNIT

711

468

125

118 11

262 728

117 414 126 128

825 710

435

10 12

886

826

SM0749

10 11 12 117 118 125 126 128 262

-

Shaft Case Pin 2nd gear 3rd gear Ball bearing (Q.ty 2) Roller bearing Bearing spacer (Q.ty 2) Cover

414 435 468 710 711 718 825 826 886

W2-2-30

-

Socket ROH M10x20 (Q.ty 4) Capscrew ROH M10x20 (Q.ty 4) Vp plug G3/4 O-ring; 1B G80 O-ring; 1B G85 O-ring; 1B P24 Ring Ring Pin (Q.ty 2)

Copyright © New Holland PUMP DEVICE

E135B

Disassembly 1.

2.

Proceed with disassembly operations in a clean place. Spread rubber sheet or cloth on work bench to protect parts from damaging. Remove dust, rust, etc, on pump surface with wash oil (468). : 27 mm

414 262 468

: 74 Nm (54.6 lbf•ft)

SM0525

3.

Remove the socket bolts (414). Then remove the cover (262). : 8 mm : 33.3 Nm (24.6 lbf•ft)

115 4.

Remove snap ring (885) and idle shaft (115). Then draw out 2nd gear (117), roller bearing (126) and bearing spacer (128).

117 (126, 128)

NOTE: roller bearing can not be separated from 2nd gear (117). SM0526

5.

Remove snap ring (825) and draw out 3rd gear (118) and ball bearing (125).

NOTE: ball bearing (125) can not be separated from 3rd gear (118).

125

Assembly Assembly is a reverse order of disassembly, but notice the following: - Repair scored parts at disassembly. replacements ready beforehand.

118

Get

- Wash parts sufficiently in cleaning oil and dry them with jet air. - Do not forget to coat the sliding areas and bearings with clean hydraulic oil. - In principle, replace sealing parts such as O-Rings and oil seals. - Tighten socket bolts and plugs to specified torques in this Manual.

W2-2-31

SM0527

Copyright © New Holland E135B

PUMP DEVICE

MAINTENANCE STANDARD In case a pitching (1 pit is more than 1mm, while the area ratio is more than 5%) is seen on the gear tooth surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the gears also in case they show excessive damage. Air pulling out point 1.

After the relief valve installation, start the engine.

2.

Loosen the air pulling out plug (1), until O-ring (2) comes off, to allow the air flows out.

3.

Air pulling out operation is completed when, for two seconds, only hydraulic oil flows out from plug (1).

4.

Tighten the plug (1) to specified torque.

1

2

: 17 mm : 23 Nm (17 lbf.ft)

SM1251

W2-2-32

Copyright © New Holland PUMP DEVICE

E135B

TOOL TABLE

CODE

DESCRIPTION

Q

XXXXXXXX

Suction stopper assy

1

-

Rod

2

-

Nut M8

3

-

Cover

4

-

O-ring

1

2 3

4

50 (1.97")

113 (4.45")

.3

15

")

O8 (1.315")

M8 NUT

2

(0.08”)

(0.295") 7.5

(1

600 (23.6")

R8

(0.787") 20

REF.

+0.0197 +0.5 ) 100 0 (3.94" 0

M8

108 (4.25" )

1

3

SM2950

W2-2-33

Copyright © New Holland E135B

PUMP DEVICE

NOTE:

W2-2-34

Copyright © New Holland CONTROL VALVE

E135B

REMOVAL AND INSTALLATION OF CONTROL VALVE WARNING Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and appropriate to hold the weight of load.

Preparation

“Releasing the hydraulic pressure” at page. T21-45.

1.

Park the machine on a firm, level surface.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure

3.

Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself.

Removal of control valve 1.

Remove the panel protecting the control valve, removing the securing screws.

1

: 19 mm 2.

Disconnect all hoses, pipes and connectors from the control valve (1).

NOTE: attach caps to hoses and pipes. Attach labels or tags to hoses and pipes, to aid in assembly.

3.

Remove the control valve securing screws (2). : 24 mm

NOTE: control valve assembly mass: 158 kg (348 lbs).

4.

Remove the control valve.

W2-3-1

2

SM2673

Copyright © New Holland E135B

CONTROL VALVE

Installation of control valve 1.

Install control valve (1) to frame and tighten the bolts (2).

1

: 24 mm : 235 ± 24 N•m (173 ± 17.5 lbf•ft)

2.

Connect all hoses, pipes and connectors to the control valve.

2 Thread

Ports

Connector/Bolt

PF1/4

PB1, PBp1, PBp2, PCa, PCb, PL, PLc2, Pss, PTb, XAb

PF3/8

DR, PAa1, PAa2, PAb, PAc, PAL, PAo, PAr, PAs, PBa1, PBa2, PBb, PBc, PBL, PBo, PBr, PBs

PF1/2

(P3), (P4), (P5), (P6)

PF3/4

Aa, Ab, Ac, AL, Ao, Ar, As, Ba, Bb, Bc, BL, Bo, Br, Bs, (MU1), (MU2), T3

M10

P1, P2

M12

T1, T2

3.

SM2673

Hose nut

Type

Opposing flats

Tightening torque N•m (lbf•ft)

Opposing flats

Tightening torque N•m (lbf•ft)

ORS Joint

19

36.5 ± 2.5 (27 ± 2)

19

29 ± 2 (21 ± 3.6)

22

73.5 ± 4.5 (54.5 ± 3.5)

22

49 ± 5 (36 ± 3.6)

27

109 ± 11 (80.5 ± 8.5)

36

165 ± 15 (122 ± 11)

36

118 ± 10 (87 ± 7.2)

8

57 ± 8 (42 ± 6)

10

96.5 ± 13.5 (71 ± 10)

Sems bolt

Install the panel protecting the control valve using the relevant securing screws. : 19 mm : 110 ± 11 N•m (81.1 ± 8.1 lbf•ft)

W2-3-2

Copyright © New Holland CONTROL VALVE

E135B

CONTROL VALVE PORTS (1/2)

Functions

Ports

Ports on right front sides (on machine)

Ports

Functions

PBp1 P1 bypass cut P2 bypass cut PBp2 Option Arm (H) relief valve

PAa2 Arm 2 in

PAo 㧙

Mu

Make-up line

㧙

Bucket (R) relief valve

PBC Bucket out Arm 1 out PBa1

XAb

Emergency manual valve drain

Swing right

PBs

PBb

Boom down

Boom conflux

PB1

㧙

Boom (H) relief valve

PAr

Travel right reverse

Travel left reverse

PAL

㧙

Main relief valve

Tank return

T2

Mounting surface PCb

P1 unload

Ports on rear left sides (on machine) Arm 2 out PBa2 Bucket digging

LEFT

RIGHT

PAc

PBo 㧙

Option Arm (R) relief valve

Bucket (H)relief valve

㧙

PLc2 Arm in lock valve

Boom(R)relief valve

㧙

PBa1 Arm out

Boom up

PAb

PAs

Swing left

Travel right forward

PBr

PCa

P2 unload

Travel straight

PTb

PBL

Travel left forward

Mounting surface

Ports on bottom sides (on machine) LEFT

P2 pump

P2

P1 pump

P1

RIGHT

SM2654

W2-3-3

Copyright © New Holland E135B

CONTROL VALVE

CONTROL VALVE PORTS (2/2)

Function

Ports

Bucket dump

BC

Boom up

Ab

Emergency manual valve drain

XAb

Travel right reverse

AR

Ports on left side (on machine) FRONT SIDE

Ports

Function

REAR SIDE

AC

Bucket digging

Bb

Boom down

BR

Travel right forward

Ao

Option

Aa

Arm 1 out

Mounting surface

Ports on right side (on machine) Option

Bo

REAR SIDE

FRONT SIDE

Arm 1 in

Ba

Pss

Swing low pressure sensor

Swing right

Bs

As

Swing left

Travel left forward

BL

Dr

Drain

AL

Travel left reverse

T1

Tank return

Mounting surface

SM2665

W2-3-4

Copyright © New Holland CONTROL VALVE

E135B

Control valve (1/6)

A B 273x10

T2

J

J 273x10

P1 unload (Travel straight)

PAL

PCb

Travel left

C

C Travel right

PAr

Boom conflux (P2 unload)

PB1

D

977 XAb XAb

Boom

978x2

PBb

PBs

D

Swing

E

E Pss PBc

Bucket

PAa1

Arm 1

F

F Arm 2

PAa2

PAo

MU1

G

Option G

PBp1

PBp2

H

H B

A

PAa2

PAo

PAo

PBp1 PBp2

275x4

213 274x4 (P4)

(P4)

(P3) (P3)

212

PBo

PBa2

273x10

W2-3-5

SM2666

Copyright © New Holland E135B

CONTROL VALVE

Control valve (2/6)

K

155

163

(P5)

101 P2

T1

T2

CT2

K PAL

PBL

PB1

PCa

PBs

PAs Pss PAa1

PBa1

PAo

PBc

PAp2

(P4)

166

161 161 155 163 164 SECTION A-A 154

567 155

(MU2)

(P6)

163

102

P1

973

973

CT1

PTb

POb

973

973 PBr

PAr

PAb

PBb

973

973 PAc

PBc

973

973

PBa2

PAa2

PBp1

973

(P3)

161

164 163 155 161 SECTION B-B

161

SM2667

W2-3-6

Copyright © New Holland CONTROL VALVE

E135B

Control valve (3/6)

202 333 331 336 328 325 331 601 261 309 159 166 157 161 161

P1 unload

201 333 331 339 327 325

Travel left

PCb

PAL

331 261 306

MR (PL)

AL

511 521

512 522

CP2

551 561

CMR2

556 561 561 556 522 512

BL

CMR1

307 261 331 325 326 336 331 333 202

264 PBL

205

SECTION C-C PTb

Travel straight

201 333 331 339 327 325 602 331 261 166 164 162

201 333 331 336 322 321

Travel right Boom conflux PB1

PAr

AbR

331 261 305 DR Ar

CCb

306 511 521

551 561 CP1

551 561 166 164 166 161

551 561

Br

310

T3

166 264 205

511 521

PBr

SECTION D-D

PCa

P2 unload

W2-3-7

261 331 325 328 336 331 333 202

SM2668

Copyright © New Holland E135B

CONTROL VALVE

Control valve (4/6)

203 333 331 339 320 319 379X3 211 331 216 L M

261 266 160 301 561

Swing PBs

204 333 331 336 322 321 266 331 261 166

Boom PBb

Pss

AbR

L M XAb

303 CRb Ab

As

161

(HEAD)

556 524 514 551 561 521 511

511 524

LCb

LCs

556 561 Bb (ROD)

Bs

161

264 264

602 205

PAb

206

PAs

BbR

160 266 SECTION E-E 201 333 331 339 320 319 602 331 261

Bucket PBc

201 333 331 336 322 321

Arm 1 PAa1

BcR

602

AaR

331 261

161

304

Aa(HEAD)

Bc (ROD)

511 521 LCc

LCa

551 561

161 561 556

Ac (HEAD)

CRa Ba(ROD)

PLc2

264 602 205

511 521 551 561

L PAc

PBa1

AcR

L

524 514 156 167 160x2 302 264 211 205

SECTION F-F SM2669

W2-3-8

Copyright © New Holland CONTROL VALVE

E135B

Control valve (5/6)

201 333 331 339 326 325 331 261 154 567

Arm 2

201 333 331 337 330 329 604 331 261 311

Option

PAa2

PAo

AoR MU1

161 308 162 515 521 551 561 561

Ao

511 521

LCAP2 LCo

551 561

LCAT2

551 521 511

Bo Ba(ROD)

162 162 162 PBa2

264

264 606 205

PBo

SECTION G-G

205

605

PaR

605 PBp1

PBp2

Bo

BoR

166 153

604

SECTION H-H

SM2670

W2-3-9

Copyright © New Holland E135B

CONTROL VALVE

Control valve (6/6)

T2

P1

511 521

T1

CT1

551 561 C

511 521

P2

(MU2)

CT2

551 561

E

SECTION M-M

162 SECTION J-J

278x5 160 266 207 267

267

528

527 T1

518

517

SECTION L-L

SECTION K-K SM2671

W2-3-10

Copyright © New Holland CONTROL VALVE

Tightening torque N•m (lbf•ft)

27 ± 2 (18.5 ± 1.5) 235 ± 15 (173 ± 11) 120 ± 10 (88.5 ± 7.5) 15 ± 2 (11.3 ± 1.5) 22 ± 2 (16.5 ± 1.5) 36.5 ± 2.5 (27 ± 2) 8.8 ± 1 (6.5 ± 0.7)

11.9 ± 2.1 (8.75 ± 1.55)

29.5 ± 4.5 (21.5 ± 3.5) 109 ± 11 (80.5 ± 8.5) 109 ± 11 (80.5 ± 8.5) 11.9 ± 2.1 (8.75 ± 1.55) 11.9 ± 2.1 (8.75 ± 1.55)

No. 101 102 153 154 155 156 157 159 160 161 162 163 164 166 167 168 201 202 203 204 205 206 207 211 212 213 216 261 264 266 267 273 274 275 278 279 301 302 303 304 305 306 307

Name Casing A Casing B Plug Plug PF3/4 Plug PF1/2 Plug PF1/8 Plug PF1/4 MEC Plug PF1/4 Plug PF1/16 MEC O-ring 1B G30 O-ring 1B G25 O-ring 1B P18 O-ring 1B P15 O-ring 1B P10 O-ring 1B P8 O-ring 1B P11 Cover Cover Cover Cover Cover Cover Cover Valve selector Plate Plate Boom lowering valve O-ring O-ring 1B G35 O-ring 1B P7 O-ring 1B P32 Socket bolt Socket bolt Socket bolt Socket bolt Socket bolt Boom spool Arm 1 spool Swing spool Bucket spool Boom conflux spool Travel spool Travel straight spool

Tightening torque N•m (lbf•ft)

Q.ty 1 1 1 2 4 1 1 1 5 13 6 4 4 7 1 1 6 4 1 1 7 1 1 2 1 1 1 12 8 4 2 40 4 4 5 3 1 1 1 1 1 2 1

17 ± 1 (12.55 ± 0.75)

140 ± 10 (103.5 ± 7.5) 140 ± 10 (103.5 ± 7.5)

73.5 ± 4.5 (54.5 ± 3.5) 73.5 ± 4.5 (54.5 ± 3.5) 73.5 ± 4.5 (54.5 ± 3.5) 109 ± 11 (80.5 ± 8.5) 73.5 ± 4.5 (54.5 ± 3.5) 160 ± 20 (118 ± 15)

W2-3-11

E135B

No. 308 309 310 311 319 320 321 322 325 326 327 328 329 330 331 333 336 337 339 511 512 514 515 517 518 521 522 524 527 528 551 556 561 567 601 602 604 605 606 973 977 978

Name Arm 2 spool P1 unload spool P2 unload spool Optino spool Spring Spring Spring Spring Spring Spring Spring Spring Spring Spring Spring seat Spacer bolt Stopper Stopper Stopper Poppet Poppet Poppet Poppet Poppet Poppet Spring Spring Spring Spring Spring Plug Plug O-ring 1B P20 O-ring 1B P24 Main relief valve

Port relief valve Relief valve plug Bypass cut valve Port relief valve Socket bolt Name plate Rivet

Q.ty 1 1 1 1 2 2 3 3 6 1 2 3 1 1 24 12 6 1 5 11 2 2 1 1 1 11 2 3 1 1 12 5 17 2 1 5 2 2 1 9 1 2

Copyright © New Holland E135B

CONTROL VALVE

ASSEMBLY AND DISASSEMBLY OF CONTROL VALVE PREPARATION FOR DISASSEMBLY •

General cautions •

Since hydraulic components are finished for precision with small clearance, it is necessary to disassemble them in a clean and not dusty place. Use clean tools and cleaning oil and handle components with sufficient care.

•

If the control valve is removed from the machine, clean ports thoroughly and put a plug in each port so as to prevent entry of dust and water. When installing the control valve back to the machine, do not remove plugs until the valve is properly piped.

•

Study the structural drawing before beginning work and prepare necessary parts according to the purpose and the scope of the operation. Some parts are not available loosely but in assemblies. Therefore, prepare parts beforehand according to the Parts Manual

•

Cautions in disassemly •

Do not strike or twist components by force even if they are tight, or the components develop burrs or are broken. This makes the components impossible to be assembled and results in oil leakage and deterioration in performances. Therefore, handle components with full care. • Attach a tag to each component so it is reassembled in a correct position. • Once disassembled, do not reuse O-rings and backup rings. Remove them with the tip of a steel wire shaped in a spatula. Take care so the groove is not scored. • If parts are left, as they are halfway during disassembly or after disassembly, they may rust due to moisture and dust. When interrupting work for unavoidable reason, use care so as to prevent parts from rusting, or being exposed to dust. Replacing the main plungers

Since components are finished to high precision, handle them with sufficient care. Use care so as not to bump components against each other or drop them.

Since the main plunger is selectively fitted to the housing, it is designated as “not service part”. Therefore, note that in principle the main plunger cannot be replaced in the field. In case the plunger must be replaced fore some reason, inform us with the model and the manufacturing number that are stamped on the nameplate.

Tools Prepare the following tools before disassembling the control valve. No.

Tools

Q.ty

Remarks

a

Vise

1

b

Box and wrench

1 of each size

19 mm, 24 mm, 27 mm, 32 mm

c

Allen wrench

1 of each size

5 mm, 6 mm, 10 mm, 12 mm, 14 mm, 22 mm

d

Spanner

e

Loctite #262

-

f

Spatula

1

g

Pincers

1

h

Adjustable wrench

1

1

32 mm

W2-3-12

Copyright © New Holland CONTROL VALVE

E135B

The figures in parentheses after part names in this manual represent those item numbers in the structural sectional drawing under Fig. SM2666 to Fig. SM2671. 1.

Place the control valve on a work bench so as to locate back pressure check valve upwards.

CAUTION: Disassemble the valve in a clean place, and be careful not to damage flange surfaces or plate mounting surfaces.

SM2678

Disassembling P1 unload spool 1.

Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for P1 unload spool.

202

273

SM2679

2.

Draw out, from casing B (102), as a assy of P1 unload spool (309), spring seat (331), springs (325), (328), stopper (336) and bolt (333).

309 331 325 328 336 333

102

SM2680

3.

Fix the P1 unload spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (325), (328) and stopper (336) from P1 unload spool (309).

309 331 325 328 336 333

SM2681

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Copyright © New Holland E135B

CONTROL VALVE

Disassembling the travel spool (left travel and right travel) 1.

201 273

Loosen the socket bolts (273) and remove the spring cover (201) and the O-ring (261) for travel.

SM2682

2.

Draw out the assy of travel spool (306), spring seat (331), springs (325), (327), stopper (339) and bolt (333) from casing A (101).

306 331 325 327 339 333

101

CAUTION: When drawing out the spool assy, take care so as not to score the casing A (101) or the casing B (102).

SM2683

3.

Loosen the socket bolts (273), remove the spring cover (201) and the O-ring (261) for travel.

273

201

SM2684

4.

Draw out the assy of travel spool (306), spring seat (331), springs (325), (327), stopper (339) and bolt (333) from casing B (102).

306 331 325 327 339 333 102

CAUTION: When drawing out the spool assy, take care so as not to score the casing A (101) or the casing B (102).

SM2685

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Copyright © New Holland CONTROL VALVE

5.

Fix the travel spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (325), (327) and stopper (339) from travel spool (306).

E135B

306 331 325 327 339 333

SM2686

Disassembling the boom conflux spool 1.

202 273

Loosen socket bolts (273) and remove spring cover (201) for boom conflux and O-ring (261).

SM2687

2.

Draw out the assy of boom conflux spool (305), spring seat (331), springs (321), (322), stopper (339) and bolt (333) from casing A (101).

305 331 321 322 339 333

101

CAUTION: When drawing out the spool assy, use care so as not to score casing A (101).

SM2688

3.

Fix the boom conflux spool with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (339) from boom conflux spool (305).

305 331 321 322 339 333

SM2689

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Copyright © New Holland E135B

CONTROL VALVE

Disassembling the boom spool 1.

Loosen socket bolts (273) and remove spring cover (203) for boom spool and O-ring (261), (266).

203

273

SM2690

2.

Draw out the assy of boom spool (301), spring seat (331), springs (319), (320), stopper (339) and bolt (333) from casing B (102).

301 331 319 320 339 333 102

CAUTION: When drawing out the spool assy, take care so as not to score casing B (102).

SM2691

3.

Fix the boom spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (319), (320) and stopper (336) from boom spool (301). Do not disassemble boom spool (301) further unless there is special reason.

301 331 319 320 339 333

SM2692

Disassembling the swing spool 1.

Loosen the socket bolts (273) and remove the spring cover sub (204) and the O-ring (261), (266) for swing. Do not disassemble spring cover sub (204) further unless there is special reason.

204 273

SM2693

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Copyright © New Holland CONTROL VALVE

2.

Draw out the assy of swing spool (303), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing A (101).

E135B

303 331 321 322 339 333

101

CAUTION: When drawing out the spool assy, use care so as not to score casing A (101).

SM2694

3.

Fix the swing spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from swing spool (303).

303 331 321 322 339 333

SM2695

Disassembling bucket spool 1.

Loosen socket bolts (273) and remove bucket spring cover (201) and O-ring (261).

201

273

SM2696

2.

Draw out the assy of bucket spool (304), spring seat (331), springs (319), (320), stopper (339) and bolt (333) from casing B (102).

CAUTION: When drawing out the spool assy, use care so as not to score casing B (102).

304 331 319 320 339 333 102

SM2697

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Copyright © New Holland E135B

3.

CONTROL VALVE

Fix the swing spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from swing spool (303).

304 331 319 320 339 333

SM2698

Disassembling arm 1 spool 1.

Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 1 spool.

201 2.

Draw out the assembly which is consist of arm 1 spool (302), spring seat (331), spring (321, 322), stopper (336) and bolt (333) from casing A (101).

302 331 321 322 339 333

273

SM2699

101

CAUTION: When drawing out the spool assy, use care so as not to score casing A (101).

SM2700

3.

Fix the arm 1 spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (321, 322) and stopper (336) from arm 1 spool (302).

302 331 321 322 339 333

SM2901

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Copyright © New Holland CONTROL VALVE

E135B

Disassembling arm 2 spool 1.

201

Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 2 spool.

273

SM2902

2.

Draw out the assembly which is consist of arm 2 spool (308), spring seat (331), spring (325, 326), stopper (339) and bolt (333) from casing B (102).

308 331 325 326 339 333 102

CAUTION: When drawing out the spool assy, use care so as not to score casing B (102).

SM2903

3.

Fix the arm 2 spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (325, 326) and stopper (339) from arm 2 spool (308). Do not disassemble arm 2 spool (308) further unless there is special reason.

308 331 325 326 339 333

SM2904

Disassembling option spool 1.

Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of option spool.

273

201

SM2905

W2-3-19

Copyright © New Holland E135B

2.

CONTROL VALVE

Draw out the assembly which is consist of option spool (311), spring seat (331), spring (329, 330), stopper (337) and bolt (333) from casing A (101).

311 331 329 330 337 333

101

CAUTION: When drawing out the spool assy, use care so as not to score casing A (101).

SM2906

3.

Fix the option spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (329, 330) and stopper (337) from option spool (311).

311 331 329 330 337 333

SM2907

Disassembling travel straight spool 1.

Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for travel straight.

2.

Draw out the assy of travel straight spool (307), spring seat (331), springs (325), (328), stopper (336) and bolt (333) from casing B (102).

307 331 325 328 336 333

102

CAUTION: When drawing out the spool assy, take care so as not to score the casing B (102). SM2908

3.

Fix the travel straight spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (325), (328) and stopper (336) from travel straight spool (307).

307 331 325 328 336 333

SM2909

W2-3-20

Copyright © New Holland CONTROL VALVE

E135B

Disassembling P2 unload spool 1.

202

Loosen socket bolts (273), and remove spring cover (202) of P2 unload spool and O-ring (261).

273

SM2910

2.

Draw out the assembly which is consist of P2 unload spool (310), spring seat (331), spring (325), (328), stopper (336) and bolt (333) from casing A (101).

310 331 325 328 336 333 101

CAUTION: When drawing out the spool assy, use care so as not to score casing A (101).

SM2911

3.

Fix the P2 unload spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (325), (326) and stopper (336) from P2 unload spool (310).

310 331 325 328 336 333

SM2912

Removing spool covers 1.

Travel, boom, bucket, arm 1, arm 2 and option. Loosen socket bolts (273) and remove spool cover (205) and O-ring (264).

2.

Swing. Loosen socket bolts (273) and remove spool cover (206) and O-ring (264), (266). Do not disassemble spool cover (206) further unless there is special reason.

273

205 206 205 SM2913

W2-3-21

Copyright © New Holland E135B

CONTROL VALVE

Removing relief valve and plug assy for relief valve hole 1.

Remove the main relief valve (601) and overload relief valve (602), (606) and relief hole plug (604) from the casing.

NOTE: • Distinguish overload relief valve between (602) and (606) with a tag to prevent them from being confused during reassembly, as they are the same in appearance and shape but differ in pressure setting. • Regarding the disassembly of the relief valves themselves, do not disassemble it.

601

602 602 604 SM2914

Removing by-pass cut valve 1.

Remove by-pass cut valve (605) from the casing. Remove the by-pass cut valve, giving particular attention to the poppet and spring which may be remained on the inside of casing

605

SM2915

W2-3-22

Copyright © New Holland CONTROL VALVE

E135B

Removing lock valve selector valve sub 1.

Loosen socket bolt and remove lock valve selector valve sub (211) from the casing. Further disassembly of the lock valve selector sub is not allowed. When the removal of lock valve selector sub on boom spool side is required, remove the boom lowering emergency manual valve (216) simultaneously. Further disassembly of the boom lowering emergency manual valve (216) is not allowed.

211 SM2916

Removing back pressure check valve 1.

207

Loosen socket bolt (278) and remove back pressure check valve (207) from the casing.

278

SM2917

2.

Remove springs (527), (528), boost check valve poppet sub (517) and by-pass check valve poppet (518) from the casing. The further disassembly of boost check valve poppet sub (517) is not allowed. Replace control valve so that the spool cover face directs downward.

517 527

518 528

CAUTION: When replacing, take care so as not to score the spool cover.

SM2918

W2-3-23

Copyright © New Holland E135B

CONTROL VALVE

Removing plate 1.

Loosen socket bolts (274), (275) and remove plates (212), (213).

2.

After removing plates, remove all O-rings (161), (164) remained on the casing side.

213

275

212 274

SM2919

Removing check valve 1.

Remove plugs of load check valve, conflux check valve, etc. and then remove poppet (511) and spring (521).

2.

Load check valve on the swing section. Remove plug (556) and then remove poppet (511) and spring (524).

551

556

CAUTION: The plug and spring in use differ from the above. Do not mix the parts when assembling parts again. 3.

Load check valve on arm 2 section. Remove plug (551) and then remove poppet (515) and spring (521).

SM2920

CAUTION: The poppet in use differs from the above. Do not mix the parts when assembling parts again. 4.

Lock valve. Remove plug (556) and then remove poppet (514) and spring (524).

CAUTION: The plug, poppet and spring in use differ from the above. Do not mix the parts when assembling parts again.

511 SM2921

5.

Main relief valve. Remove plug (556) and then remove poppet (512) and spring (522).

CAUTION: The plug, poppet and spring in use differ from the above. Do not mix the parts when assembling parts again. The plugs in which the procedure for disassembly is not included in the above procedure are usually used to block auxiliary holes and holes caused by casting. Do not disassemble further if unnecessary.

W2-3-24

Copyright © New Holland CONTROL VALVE

E135B

INSPECTION AFTER DISASSEMBLY Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean sheet of paper or cloth for inspection. Control valve 1.

Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.

2.

Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.

3.

If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.

IMPORTANT: take care not leave lapping compound behind in the casing or block. 4.

Confirm that the outer circumference of the sliding part of a manual spool is free from scratches, dents, and the like. Remove any small defects with an oil stone or lapping compound.

5.

Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are free from foreign matter.

6.

Replace any broken or deformed spring with new one.

7.

Replace all O-ring with new ones.

Relief valve 1.

Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact surface is even all over.

2.

Manually confirm that the main poppet slides smoothly onto and off the seat.

3.

Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free from defects such as scratches.

4.

Confirm that each spring is free from breakage, deformation, and excessive wear.

5.

Confirm that the orifices of the main poppet and its seat are not clogged.

6.

Replace all O-rings with new ones. (Between casing and seal)

REASSEMBLY Assembly is performed in reverse order of disassembly. For the tightening torque of socket bolts and plugs refer to page W2-3-11. Precautions on reassembling O-ring 1.

Confirm that O-rings are free from defects caused by poor handling.

2.

Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.

3.

Do not stretch O-rings to the extent that they become permanently set.

4.

When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after installation, and can cause oil leaks.

5.

Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance Standards.".

W2-3-25

Copyright © New Holland E135B

CONTROL VALVE

Installing check valve 1.

Load check valve, conflux check valve, and so on. Attach poppet (511) and spring (521) in place, place O-ring (561) in plug (551) and tighten them to the specified torque. (8 places) : 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)

2.

Load check valve of swing section. Attach poppet (511) and spring (524) in place, place O-ring (561) in plug (556) and tighten them to the specified torque. (1 place) : 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)

3.

Load check valve of arm 2 section. Attach poppet (515) and spring (521) in place, place O-ring (561) in plug (551) and tighten them to the specified torque. (1 place) : 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)

4.

Lock valve section. Attach poppet (514) and spring (524) in place, place O-ring (561) in plug (556) and tighten them to the specified torque. (2 places) : 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)

5.

Main relief valve section. Attach poppet (512) and spring (522) in place, place O-ring (561) in plug (556) and tighten them to the specified torque. (2 places) : 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)

CAUTION: take care to prevent misassembling of parts and assembling position error because the parts are similar in shape. Assembling plate 1.

Place O-rings (161), (164) in casing.

2.

Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque. : 109 ± 11 N•m (80.5 ± 8.5 lbf•ft)

NOTE: Replace control valve so that this plate face directs downward.

W2-3-26

Copyright © New Holland CONTROL VALVE

E135B

Assembling back pressure check valve 1.

Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527), (528).

2.

Attach O-rings (267) in back pressure check valve cover, attach it to casing A (101) and tighten socket bolt (278) to the specified torque. : 11.9 ± 2.1 N•m (8.75 ± 1.55 lbf•ft)

Assembling lock valve selector sub 1.

Attach lock valve selector sub (211) to the casing and tighten socket bolt to the specified torque. : 11.9 ± 2.1 N•m (8.75 ± 1.55 lbf•ft)

Assembling by-pass cut valve 1.

Attach by-pass cut valve (605) to casing and tighten it to the specified torque. : 109 ± 11 N•m (80.5 ± 8.5 lbf·ft)

CAUTION: Take care to prevent drop of poppet and spring when attaching by-pass cut valve. Assembling relief valve and relief valve hole plug assembly 1.

Tighten main relief valve (601), port relief valves (602), (606) and relief valve hole plug assembly (604) in respective place to the specified torque. : 73.5 ± 4.5 N•m (54.5 ± 3.5 lbf•ft)

CAUTION: Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief valves (602), (606) are similar in shape. Assembling P2 unload spool 1.

Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to the specified torque. : 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)

CAUTION: • Apply Loctite #262 when tightening bolt (333). • Take care not to deform P2 unload spool (310) because of careless over clamping. 2.

Place P2 unload spool assembly in casing A (101).

CAUTION: Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place. 3.

Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten socket bolt (273) to the specified torque. : 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)

W2-3-27

Copyright © New Holland E135B

CONTROL VALVE

Assembling spool in option 1.

Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (329), (330) and stopper (337) and tighten bolt (333) to the specified torque. : 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)

CAUTION: • Apply Loctite #262 when tightening bolt (333). • Take care not to deform option spool (311) because of careless over clamping. 2.

Place spool assembly in option in casing A (101).

CAUTION: Place option spool assembly in casing A (101) carefully. Do not squeeze it into place. 3.

Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten socket bolt (273) to the specified torque. : 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)

Assembling arm 2 spool 1.

Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (325), (326) and stopper (339) and tighten bolt (333) to the specified torque. : 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)

CAUTION: • Apply Loctite #262 when tightening bolt (333). • Take care not to deform arm 2 spool (308) because of careless over clamping. 2.

Place arm 2 spool assembly in option in casing B (102).

CAUTION: Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place. 3.

Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten socket bolt (273) to the specified torque. : 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)

W2-3-28

Copyright © New Holland CONTROL VALVE

E135B

Assembling arm 1 spool 1.

Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.) and fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque. : 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)

CAUTION: • Apply Loctite #262 when tightening bolt (333). • Take care not to deform arm 1 spool (302) because of careless over clamping. 2.

Place arm 1 spool assembly in casing A (101).

CAUTION: Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place. 3.

Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten socket bolt (273) to the specified torque. : 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)

Assembling bucket spool 1.

Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (319), (320) and stopper (339) and tighten bolt (333) to the specified torque. : 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)

CAUTION: • Apply Loctite #262 when tightening bolt (333). • Take care not to deform bucket spool (304) because of careless over clamping. 2.

Place bucket spool assembly in casing B (102).

CAUTION: Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place. 3.

Attach spring cover (201) with O-ring (261) attached to the spring side of bucket spool assembly and tighten socket bolt (273) to the specified torque. : 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)

W2-3-29

Copyright © New Holland E135B

CONTROL VALVE

Assembling swing spool 1.

Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque. : 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)

CAUTION: • Apply Loctite #262 when tightening bolt (333). • Take care not to deform swing spool (303) because of careless over clamping. 2.

Place swing spool assembly in casing A (101).

CAUTION: Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place. 3.

Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and tighten socket bolt (273) to the specified torque. : 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)

W2-3-30

Copyright © New Holland CONTROL VALVE

E135B

MAINTENANCE STANDARDS Inspection of components Part name

Casing

Spool

Inspection item

1. Look for corrosion.

scratches,

Criterion and remedy

rusting

1. If any of the following parts are damaged, replace the casing. • Sliding part of casing hole and spool, particularly the land, to which holding pressure is applied. • Area of sealing part that is in contact with O-ring. and • Sealing and seating part of main or overload relief valve. • Area of seating part or sliding part of poppet. • Sealing part of plug. • Defects of other parts that seem to prevent normal function.

1. Look for scratches, galling, rusting and corrosion.

1. If a detectable defect with your fingernail is found on the sliding part of the outer circumference, replace the spool.

2. Insert the spool in the casing bore, and 2. If the spool damages the O-ring or does not move it while turning it. move smoothly, repair or replace the spool.

Poppet

1. Look for damage on the poppet and If spring is damaged, replace it. 1. If the seat of poppet or spring are damaged, the spring. correct or replace it. 2. Insert the poppet in the casing, and 2. If the poppet moves lightly without catching, it is normal. move it.

Spring and related parts

1. Look for rust, corrosion, deformation, and breakage of the spring, spring 1. If damaged heavily, replace. seat, stopper, spacer bolt and cover. 1. Look for rust and damage on outer 1. Replace. surface.

Main relief valve, Port relief valve, By-pass cut valve

2. Inspect the contact face of the valve 2. If damaged, replace. seat. 3. Inspect the O-ring, backup ring, and 3. As a general rule, replace all parts with new seal. ones. (Between casing and seal)

W2-3-31

Copyright © New Holland E135B

CONTROL VALVE

TROUBLESHOOTING 1.

If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure, load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and reassembly procedures in this manual.

2.

Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system is to be disassembled, take dust protection measures beforehand.

3.

Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.

4.

Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.

Control valve Trouble 1. Travel does not occur. Slow to start up (or poor power). Slow response.

Cause

Remedy

1. Check travel relief valve pressure. 1. Malfunctioning main relief valve. • Disassemble and clean. If • Foreign matter between main damaged heavily, replace the poppet and seat. assy as a unit. • Foreign matter between poppet • Same as above. and seat. • Correct sticking part with oil • Sticking main poppet. stone. • Broken or deformed spring. • Replace spring. • Clogged main poppet throttle. • Remove foreign matter. • Loosened adjusting screw. • Readjust, and tighten lock nut to specified torque.

2. Machine does not move straight 1. Malfunctioning travel straight valve. 1. Check pilot pressure. • Correct sticking part with oil • Sticking spool. during simultaneous operation of stone. • Broken or deformed spring. travel and attachment. • Replace spring. • Clogged small hole in spool. • Remove foreign matter. 2. Malfunctioning main relief valve.

W2-3-32

2. Remove main relief valve.

Copyright © New Holland CONTROL VALVE

Trouble

Cause

E135B

Remedy

3. Excessive natural falls of 1. Excessive clearance between 1. Replace spool. casing and spool. attachment under its own weight when spool is in neutral. 2. Spool is not completely in neutral 2. Check secondary pilot pressure. • Disassemble, clean and smooth position. sticking part with oil stone. • Foreign matter between casing • Replace spring. and spool, or sticking spool. • Remove foreign matter. • Broken or deformed spring. • Clogged pilot circuit. overload relief valve 3. Malfunctioning overload relief 3. Check pressure. (See page W2-3-25) valve. Refer to item 1. 1) above. • Clean and check damage on seat (See page W2-3-25) surface. • Foreign matter between valve seat and casing. 4. Replace 4. Lock valve function is faulty. • Disassemble, clean. (Arm, boom) • Correct stuck part with oil stone or • Foreign matter between poppet replace. seat and casing. • Replace spring. • Poppet is stuck. • Replace lock valve selector assy. • Broken or deformed spring. • Selector spool is stuck. 1. 4. When raising attachment, at first it 1. Malfunctioning load check valve. • Disassemble and clean. If heavily drops. • Foreign matter between poppet damaged, replace control valve. and casing. • Correct sticking part with oil • Sticking poppet. stone. • Broken or deformed spring. • Replace spring. 1. Check secondary pilot pressure. 5. Bucket, boom, arm or swing does 1. Malfunctioning main spool. • Replace spool. • Excessive clearance between not operate. • Disassemble and clean. casing and spool. Slow to start up (or poor power). • Correct stuck part with oil stone. Foreign matter between casing Slow response. • Replace spring. and spool. • Remove foreign matter. • Sticking spool. • Broken or deformed return spring. • Clogged pilot circuit. 2. Malfunctioning main relief valve. 2. Check main relief valve pressure. Refer to item 1. 1) above. Refer to item 1. 1) above. (See page W2-3-25) (See page W2-3-25) 3. Malfunctioning overload relief 3. Check overload relief valve. Refer to item 1. 1) above. pressure. (See page W2-3-25) (See page W2-3-25)

W2-3-33

valve

Copyright © New Holland E135B

CONTROL VALVE

Trouble 6. Boom conflux does not operate.

Cause

Remedy

1. Measure pilot pressure. 1. Malfunctioning conflux valve. • Replace spool. • Excessive clearance between • Disassemble and clean. casing and spool. • Correct stuck part with oil stone. • Foreign matter between casing • Replace spring. and spool. • Remove foreign matter. • Sticking spool. • Broken or deformed return spring. • Clogged pilot circuit.

Relief valve Trouble

Cause

Remedy

1. No pressure rise.

Main or pilot poppet of relief valve is Check for foreign matter on each sticking and valve is open, or there is poppet. Confirm that each component slides foreign matter on valve seat. smoothly. If failure is found, replace it as an assembly.

2. Unstable relief pressure.

Main or pilot poppet of relief valve seat If failure is found, replace it as an is damaged. assembly.

3. Incorrect relief pressure setting.

1. Wear due to foreign matter.

1. Replace damaged assembly.

2. Loosened locknut or adjusting 2. Adjust pressure. screw. 4. Oil leak.

1. Damaged seat. Damaged O-ring.

Confirm that each component operates smoothly. Replace damaged or worn component. 1. If failure is found, replace it as an assembly.

2. Sticking component due to foreign 2. Confirm that there are no scratches, matter. scores, or foreign matter present before reassembling. If failure is found, replace it as an assembly.

W2-3-34

Copyright © New Holland SWING DEVICE

REMOVAL AND INSTALLATION OF SWING DEVICE

WARNING Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank. Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and appropriate to hold the weight of load.

Preparation 1.

Park the machine on a firm, level surface.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure “Releasing the hydraulic pressure” at page. T21-45.

3.

Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself.

4.

Remove the bracket assy and the top cover.

W2-4-1

E135B

Copyright © New Holland E135B

SWING DEVICE

Removal 1.

Remove hose (1) from the Tee in the makeup port C.

1

: 36 mm 2.

6

Remove the hoses (2 and 3) from the Tee in the drain port DB.

C

2

B

5

: 27 mm

3

A DB

3.

Remove the hose (4) from the elbow of the PG port. PG

: 19 mm

4 SM3141

4.

Remove the hoses (5 and 6) from the connectors of the A, B port. : 30.32 mm 10

5.

Put in plugs into the opened ports on the swing motor unit.

6.

Remove the clip (7) from the frame by loosing the screws (8). : 17 mm

9 8

7.

Remove the swing motor unit by loosing the screws (9) (Q.ty 9). : 30 mm

7 7 8

8.

Remove the plastic cap (10) M10 at the top of the swing motor and install the lifting eye bolt.

9.

Sling and remove the swing unit.

NOTE: swing unit weight: 113 kg (249.2 lbs)

W2-4-2

SM3142

Copyright © New Holland SWING DEVICE

E135B

Installation 1.

Clean mating surfaces of swing motor unit and upper frame.

2.

Apply Loctite #515 on entire mounting surface of swing motor unit.

3.

Place the swing unit on the upper frame.

10

IMPORTANT: use care so no dirt falls into the swing grease bath.

9 8

NOTE: swing unit weight: 113 kg (249.2 lbs) 4.

5.

7 7

Remove the lifting eye bolts and inserts on the holes, the plastic caps (10) M10, previsiously removed.

8

Fix the swing unit to the frame by tightening the screws (9) (Q.ty 9). : 30 mm

1

: 539 ± 54 Nm (397.5 ± 40 lbf.ft) 6.

SM3142

6

Fix the clip (7) to the frame by tightening the screws (8).

C

: 17 mm

5

: 46.1 ± 4.9 Nm (34 ± 3.6 lbf.ft) 7. 8.

Before piping for draining, fill casing with hydraulic oil from drain port of motor. Install the hoses (5 and 6) on the elbows of port A and B.

2

B

3

A DB

PG

4

: 30,32 mm SM3141

: 137 ± 14 Nm (101 ± 10 lbf.ft) 9.

Install the hose (4) on the elbow of port PG. : 19 mm : 29 ± 4.9 Nm (21.4 ± 3.6 lbf.ft)

10. Install the hoses (2 and 3) on the tee in the drain port DB. : 27 mm : 78 ± 4.9 Nm (57.5 ± 3.6 lbf.ft) 11. Install the hose (1) on the make up port C. : 36 mm : 118 ± 9.8 Nm (87 ± 7.2 lbf.ft) 12. Before starting operation, check the gear oil level of swing reduction unit. Amount of oil: 1.65 L (0.436 US gal)

IMPORTANT: when starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leak and noise.

W2-4-3

Copyright © New Holland E135B

SWING DEVICE

DISASSEMBLY AND ASSEMBLY OF SWING DEVICE Before disassembly, clean the outside of the reduction unit thoroughly and check for no damage or scratches. Disassembly swing motor from reduction unit 1.

3

Place the swing device on a stable work bench as shown in figure, remove plug (1) and drain out oil. Amount of oil: 1.65 L (0.436 US gal)

4

X

: 27 mm

2.

Remove the drain hose (2) from reduction unit. 2

: 27 mm

1 SM3140

3.

Remove oil filling tube (3) from reduction unit. : 24 mm

4.

Put a matching mark (X) on the matching surface of the figure on the right side.

5.

Loosen all socket bolt (4) M12. Attach eye bolts (M10) in the lifting bolt holes in the top surface of the swing motor and lift the assy by crane. If it is hard to remove the swing motor assy from the reduction unit, float it by inserting a flatblade screwdriver in the groove of the flange. : 10 mm

W2-4-4

Copyright © New Holland SWING DEVICE

E135B

Assembly swing motor on reduction unit 1.

Place the reduction unit on a stable work bench. Attach eye bolts (M10) in the tapped holes of the swing motor and put a wire sling in them.

2.

Apply sealant Loctite #515 on the matching surface of reduction unit, insert the spline joint of the swing motor and match the matching marks (X).

3

3.

4

X

Apply sealant Three-Bond #1217 on the socket bolts (4) M12 and fasten them at the prescribed tightening torque. : 10 mm

2

: 98 Nm (72.2 lbf•ft)

1 SM3140

4.

Fit drain hose (2) and plug (1). : 27 mm : 108 ± 11 Nm (80 ± 8 lbf•ft)

5.

Coil sealing tape on the thread portion of oil filling tube (3) and fit it to the reduction unit. : 24 mm : 108 ± 11 Nm (80 ± 8 lbf•ft)

NOTE: temporarily fit the level bar to the pipe and check the level. 6.

Fill reduction unit with gear oil SAE90 (API Service Grade GL-4). Amount of oil: 1.65 L (0.436 US gal)

W2-4-5

Copyright © New Holland E135B

SWING DEVICE

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

992

303 451 131

444

351 355

A-A 051

401 488 469

051-1 468 106 487 444 433 981 390 391 438 980

303

472

451

707

712 131

706 A

A

982

702

114

111

117

743

121

742

113 123

116 117 432 471 443 106 101

491 304 437 124 122

301 SM2844

W2-4-6

Copyright © New Holland SWING DEVICE

Tightening

torque Nm (lbf•ft) 177 (131)

E135B

Tightening

No.

051

Parts

Relief valve; M33-P1.5

051-1 O-ring; 1B G30

Q.ty

2

torque Nm (lbf•ft) 240 (177)

No.

Parts

Q.ty

401

Socket bolt; M16×75

4

2

432

Snap ring

2

101

Drive shaft

1

433

Ring

1

106

Spacer

3

437

Snap ring

1

438

Snap ring

1

1

443

Roller bearing

1

111

Cylinder

1

444

Roller bearing

1

113

Retainer (spherical bushings)

1

451

Pin

2

114

Cylinder spring

1

36 (27)

468

Plug; PF1/4

2

116

Push rod

12

108 (80)

469

ROMH plug; M22-P1.5

2

117

Spacer

2

471

O-ring; 1B G80

1

121

Piston

9

472

O-ring; W1516,WG34

1

122

Shoe

9

487

O-ring; 1B P11

2

123

Set plate

1

488

O-ring; 1B P28

2

124

Shoe plate

1

491

Oil seal

1

131

Valve plate

1

702

Brake piston

1

706

O-ring; W1516,WG31

1

707

O-ring; W1516,WG36

1

712

Brake spring

20

301

Casing

1

742

Friction plate

3

303

Valve casing

1

743

Separator plate

4

304

Front cover

1

1.7 (1.2)

980

Plug; PF3/8

1

351

Plunger

2

4.4 (3.3)

981

Plug; PF3/4

1

0.9 (0.6)

982

Plug; PF1/4

1

98 (72)

992

Plug; PT3/4

1

355

Spring

2

390

Name plate

1

391

Rivet

2

W2-4-7

Copyright © New Holland E135B

SWING DEVICE

Preliminary operations 1.

Hydraulic components are precision products and have small clearance. Therefore, assemble and disassemble in a less dusty clean place. Use clean tools and cleaning oil and handle components with full care.

2.

If a component is removed from the main body, clean the area around the ports thoroughly and plug them up so no dust and water do not enter. When fitting them back to the body, do not remove the plugs till piping is completed.

3.

Study the structural drawing before the work begins and prepare necessary parts according to your purpose and the scope of work. Seals and O-Rings once removed can not be used again.

4.

The piston and the cylinder block are shop fitted when new. If you intend to reuse them, put a matching mark on the piston and the cylinder block.

Disassembly

NOTE: choose a clean place, and lay with a rubber sheet or a cloth on a work bench. Handle the valve casing with care so parts do not have dents. 1.

Fixing the motor to the work bench. Direct the shaft end of the drive shaft (101) downand fix it on a bench convenient for disassembly. On that occasion, leave a matching mark on themating part between casing (301) and valve casing (303).

303

301 SM3061

W2-4-8

Copyright © New Holland SWING DEVICE

2.

E135B

Remove relief valve. Loosen relief valve (051) and separate it from valve cover (303).

303 051

: 41 mm

SM3062

3.

Remove swing shockless valve block. Loosen socket bolt (V171) and separate swing shockless valve block (052) from valve casing (303).

V171

052

303

: 6 mm

SM3063

4.

Removing the anti-cavitation check plunger. Separate RO plug (469) from valve casing (303) and draw out spring (355) and plunger (351). : 10 mm

NOTE: exercise care so as not to score the plunger seat.

W2-4-9

Copyright © New Holland E135B

5.

SWING DEVICE

Remove valve casing and valve plate. Loosen socket bolt (401) and separate valve casing (303) from casing (301). [If the socket bolt (401) are loosened, the valve casing floats off casing (301) by the force of brake spring (712)].Then separate valve plate (131) from valve casing (303). : 14 mm

401

303 301

NOTE: work with care so the valve seat does not come off from the valve casing. (In some cases, the valve plate is adhered on the cylinder side.) When inserting a screwdriver or something between the matching surfaces, use care so as not to score the matching surfaces.

6.

Remove brake spring. Draw out brake spring (712) from brake piston (702).

SM3064

303

712

301

SM3065

7.

Remove brake piston. Draw out brake piston (702) from casing (301), using the special tool (A) (380001938).

NOTE: hold it upright, utilizing the bolt holes in the brake piston.

(A) 702

301

SM3066

W2-4-10

Copyright © New Holland SWING DEVICE

8.

E135B

Remove cylinder. Place the motor level and draw out the cylinder (111) from the drive shaft (101). Then draw out piston (121), retainer plate (123), spacer (117) and shoe plate (124).

301

WARNING use care when drawing out the cylinder as push rod (116) tends to come off. Exercise care so as not to score the sliding surfaces of the cylinder, retainer and shoe. In case the shoe plate does not come off, remove it after the work sequence (12).

9.

111 SM3067

Remove separator plate. Draw out friction plate (742) and separator plate (743) from casing (301).

437

304

301 SM3068

10. Remove front cover. Take off snap ring (437) with pliers and separate front cover (304) from casing (301). 304

WARNING when drawing out the front cover, take care so as not to score the sliding surface of the oil seal. You may remove the front cover with the drive shaft.

301 SM3069

W2-4-11

Copyright © New Holland E135B

SWING DEVICE

11. Remove drive shaft. Separate drive shaft (101) from casing (301) by lightly tapping the end face of the valve casing side (303) of drive shaft (101), using a plastic mallet.

NOTE: use care so as not to score the sliding surface of the oil seal. 12. Remove shoe plate. Draw out shoe plate (124) from the housing side of roller bearing (443) of casing (301) by lightly tapping it with a steel rod.

13. Remove inner race of roller bearing. Remove snap ring (432) and spacer (106) from drive shaft (101) and draw out the inner race of roller bearing (443) by means of a press.

NOTE: you may knock on the inner race of the roller bearing with a steel bar, but knock on it evenly all around so the bearing is not damaged. Do not use the removed bearing again.

101

301 SM3070

PRESS 101

443

Put the press bench on the inner race. SM3071

14. Remove oil seal. Draw out oil seal (491) from front cover (304), utilizing a round plate.

304 (491)

NOTE: do not reuse the removed oil seal.

ROUND PLATE

PRESS 491

SM3072

304 SM3073

W2-4-12

Copyright © New Holland SWING DEVICE

E135B

15. Remove roller bearing. Separate roller bearing (444) from valve casing (303), using a slide hammer bearing puller. 101

NOTE: do not reuse the removed bearing.

444

303

SM3074

W2-4-13

Copyright © New Holland E135B

SWING DEVICE

Assembly 1.

Holding casing. Place the casing (301) facing its valve casing (303) downward.

301

SM3075

2.

Installing inner race of roller bearing. Fit snap ring (432) and spacer (106) to drive shaft (101), insert the inner race of roller bearing (443), and shrinkage fit the inner race. Put spacer (106) in and fix snap ring (432).

444 101

WARNING 106

beware of the orientation of the inner race of the roller bearing.

SM3076

OUT PUT SHAFT SIDE Set the spacer to the R (round) side of the bearing inner race.

432

106

SM3077

SM3078

W2-4-14

Copyright © New Holland SWING DEVICE

3.

4.

E135B

Shrinkage fitting inner race of roller bearing. Shrinkage-fit the inner race of roller bearing (444) to drive shaft (101). Then fit snap ring (433).

444

Installing outer race of roller bearing. Place drive shaft (101) with roller bearing (443) on its output shaft, and insert the drive shaft into casing (301). Then lightly knock on the outer race of roller bearing (443) via a steel bar, using a hammer.

101

NOTE: knock on the outer circumference of the outer race evenly all round till it stops at the step of the casing. 5.

SM3079

Insert oil seal. Put oil seal (491) into front cover (304), using a jig.

WARNING: be careful about the direction of the oil seal. Fix the oil seal till it stops at the step of the casing. 304 (491)

6.

SM3080

Fit O-ring. Fit O-ring (471) to casing (301).

NOTE: coat the lip of the oil seal with a thin film of grease and put it in with care so as not to score the lip of it. (Wind tape on the spline of the drive shaft so the lip of it is not scored by the spline.) Tap the outer circumference evenly round to prevent it from being scored.

471 301

SM3081

Wind protective tape

101

SM3082

W2-4-15

Copyright © New Holland E135B

7.

8.

SWING DEVICE

Installing front cover. Fit front cover (304) to casing (301) by lightly tapping the cover with a plastic mallet.

304

Fitting the snap ring. Fit snap ring (437) to casing (301), using pliers.

SM3083

9.

Put shoe plate (124) into casing (301). 124

NOTE: put the larger chamfer side of the shoe plate into the casing side. Coat the matching surface with a thin film of grease to prevent the shoe plate from falling off. 301

SM3084

10. Insert push rod. Put push rod (116) in cylinder (111).

NOTE: use care so as not to score the sliding surface of the cylinder. (Put two push rods into one hole.)

111

116 SM3085

11. Installing retainer. Then mount retainer (113) fitted with spacer (117) on the cylinder.

113

117

SM3086

W2-4-16

Copyright © New Holland SWING DEVICE

E135B

12. Installing the piston sub assy to the plate. Set piston sub assy (121,122) to plate (123).

123

121,122

SM3087

13. Assembling the piston sub assy into the cylinder. Assemble piston sub assy (121,122) with plate (123) into cylinder (111) and insert it in place, aligning it with the spline of drive shaft (101).

121,122,123 111

NOTE: the drive shaft can be set easily if the phase of the retainer (113) and the cylinder spline is matched. 14. Installing separator plate and friction plate. Replace casing (301) so front cover (304) side faces down. Then Assemble separator plate (743) and friction plate (742) into casing (301), in that order. Fit four separate plates and three friction plates.

101 SM3088

743

NOTE: assemble four notches in the gear teeth of friction plate so the same phases are aligned up and down. Fix notches in the four claws of separator plate. 301

SM3089

742 Selector valve mount SM3090

301

SM3091

W2-4-17

Copyright © New Holland E135B

SWING DEVICE

15. Fit O-ring. Fit O-rings (706)(707) to casing (301).

707 (706)

NOTE: in that case, coat the O-rings with grease beforehand. This will prevent the O-rings from breaking when inserting brake piston.

301

SM3092

16. Installing brake piston. Fit brake piston (702) to casing (301).

702

NOTE: install the brake piston so four slits of it are positioned as shown in the below figure. (Match the M8 screws to the below figure.) If brake piston is hard to enter because of the resistance of the O-rings, screw in socket bolt M8 into the brake piston and knock on it evenly by means of a plastic mallet.

301

SM3093

2-M8

702

SLIT Selector valve mount SM3094

702

17. Installing brake spring. Fit brake spring (712) to brake piston (702).

712

NOTE: at that time, make sure that the spring is set snugly in the spotface of the brake piston.

SM3095

W2-4-18

Copyright © New Holland SWING DEVICE

E135B

18. Insert outer race of roller bearing. Insert the outer race of roller bearing (444) into valve casing (303), knocking it lightly by means of a steel bar. NOTE: knock on the outer circumference of the outer race evenly around and fix it so it stops at the step of the valve casing.

444 303

SM3096

19. Installing valve plate. Assemble valve plate (131) into valve casing (303) and then fit O-ring (472) in place.

131

NOTE: coat the contact surface of the valve plate with a thin film of grease. (To prevent it from falling off.)

Apply grease

SM3097

20. Installing valve casing. Attach valve casing (303) to casing (301) and fasten it with socket bolt (401). : 14 mm : 240 Nm (177 lbf•ft) 303

WARNING

301

beware of the direction of the valve casing. Be careful so the valve plate does not come off. Use care so the brake spring does not fall down. Fasten the socket bolts evenly all around.

SM3098

W2-4-19

Copyright © New Holland E135B

SWING DEVICE

21. Fitting plunger. Place plunger (351) and spring (355) into valve casing. Fasten RO plug (469) with O-ring (488) into valve casing.

401

351

: 10 mm : 108 Nm (80 lbf•ft)

NOTE: make sure that the plunger moves smoothly.

355 (488,469) SM3099

22. Installing relief valve. Fit backup ring (051-2) and O-ring (051-1) to relief valve (051) and fasten the relief valve against valve casing (303).

051 (051-1, 051-2)

303

: 41 mm : 177 Nm (130 lbf•ft) 23. Installing plugs. Fit O-ring (487) to plug (468) and attach it to valve casing (303). : 19 mm : 36 Nm (27 lbf•ft) 24. Installing swing shockless valve block. Fit O-ring (V161) to the swing shockless valve block. Then fasten the valve block against valve casing (303) with socket bolts (V171). : 6 mm

SM3100

052 (V161)

303

V171

: 29 Nm (22 lbf•ft)

SM3101

W2-4-20

Copyright © New Holland E135B

SWING DEVICE

DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT 602

230 231 204 286 211 912 285 287 911 283 403

922

603 210

202

282

*

203

921

913 285

* 402 910 801 925 920 926 102 401 915 201 SM2846

Tightening torque Nm (lbf•ft)

No.

Parts

Q.ty

Tightening torque Nm (lbf•ft)

No.

Parts

Q.ty

102

Casing

1

402

Roller bearing

1

201

Drive shaft

1

403

Needle bearing

3

202

Ring gear

1

98

602

Capscrew; M12x100

8

203

No.2 planetary gear

4

98

603

Capscrew; M12x135

2

204

No.2 sun gear

1

801

Oil seal

1

210

No.1 planetary gear

3

910

Spring pin

4

211

No.1 sun gear

1

911

Snap ring

3

230

No.2 spider

1

912

Snap ring

1

231

No.1 spider

1

913

Snap ring

1

282

No.2 pin

4

915

Seal

1

283

No.1 pin

3

65

920

Adapter; PT1/2

1

285

Side plate t=1

7

108

921

Hose; PF1/2

1

286

Thrust washer t=2

1

108

922

Plug; PF1/2

1

287

Side plate t=2

3

22

925

Relief fitting; PT1/4

1

401

Roller bearing

1

22

926

Grease nipple; PT1/4

1

Coat the part marked * with Three Bond #1217.

W2-4-21

Copyright © New Holland SWING DEVICE

E135B

Disassembly 1.

Remove snap ring (912).

2.

Remove No.1 sun gear (211).

211

SM3102

3.

Remove No.1 carrier assy. Remove the No.1 carrier assy (231) with the No.1 planetary gear (210) and others.

210

SM3103

W2-4-22

Copyright © New Holland E135B

4.

SWING DEVICE

Disassembly No.1 carrier assy.

NOTE: put a matching mark on each of the planetary gears and pins so combination and pairing do not change. a. Remove snap ring (911). Then remove side plate (287) at the top.

911 287 SM3104

b. Remove No.1 planetary gear (210) and needle bearing (403).

403

210 SM3105

c. Remove side planetary gear.

plate

(285)

under

the 285

SM3106

d. After removing three No.1 planetary gears (210), remove thrust washer (286) in the center. NOTE: do not remove No.1 pin (283) from No.1 carrier (231) unless there is anything wrong. If the No.1 pin is removed, you need a special caulking tool at reassembly. However, make sure that the ø2 mm (0.079 in) oil hole of No.1 pin (283) is directed outwards with respect to the center of No.1 carrier (231).

286

2 (0.079") (OIL HOLE)

SM3107

W2-4-23

Copyright © New Holland SWING DEVICE

5.

E135B

Remove No.2 sun gear (204).

204

SM3108

6.

Remove No.2 carrier assy (230).

230

SM3109

7.

Disassembly No.2 carrier assy. 282,910

NOTE: do not disassemble the No.2 carrier assy further unless there is anything wrong. Check all parts for possible failure. It is recommended that the No.2 carrier assy be replaced as a pair, but in case part of it must be replaced for an unavoidable reason, follow the procedure below.

203,285

a. Push spring pin (910) in further and draw out No.2 pin (282). SM3110

NOTE: do not reuse the removed No.2 pin.

b. Draw out No.2 planetary gear (203) and side plate (285) sideways.

W2-4-24

Copyright © New Holland E135B

8.

SWING DEVICE

Remove ring gear. The bottom of the two holes is provided with M12 screw threads to draw out the ring gear (202). Utilise motor mounting socket bolts (602) to draw it out.

202

: 10 mm

SM3111

9.

Separate snap ring (913) from drive shaft (201).

10. Remove drive shaft. Support the flanged part of the drive shaft (201) so the shaft end faces down and place the drive shaft on a work bench. Draw out the shaft downwards, while tapping the center of it with a plastic mallet. NOTE: do not disassemble it further unless there is anything wrong. Check all parts for possible failure. It is recommend that the drive shaft assy be replaced as a set. In case part of it must be replaced for an unavoidable reason, follow the procedure below. If nothing faulty is discovered on inspection at this stage, no further disassembly is needed.

W2-4-25

913

201

SM3112

Copyright © New Holland E135B

SWING DEVICE

11. Remove roller bearing. As shown on the figure on the right, support the drive shaft assy and draw out bearing seal (915) and roller bearing (401), using a press and a special tool (C) (380001942).

PRESS (C)

WARNING roller bearing (402) is left in the casing. Since the shaft falls down, use care so as not to damage it. The removed oil seal and the bearing seal can not be used again. 915

401

SM3113

12. Remove oil seal (801) from casing (102). 102

801

SM3114

W2-4-26

Copyright © New Holland SWING DEVICE

E135B

Assembly 1.

Assembly drive shaft assy. a. Insert bearing seal. Insert bearing seal (915) into drive shaft (201).

102

402 801 GRASSO 401

915 201 SM3115

b. Press-fitting roller bearing. Coat the inside of roller bearing (401) with sufficient grease and press it into the drive shaft, using a press. Set the inner race firm into the shaft by knocking on the steel bar, till the hammer springs back. Then apply grease so it reaps as shown in Figure. Grease: EP type (Shell Alvania grease EP2). NOTE: roller bearing (401) has a bank in the middle. Push grease in to both sides before assembling the bearing into the shaft.

2.

Place casing (102) on a level bench.

3.

Installing drive shaft assy. Lift the drive shaft assy upright, using the screw in the end of the shaft and put it into the casing. Thread size: M10, Depth 20 mm (0.787 in).

GRASSO

201

SM3116

201

NOTE: lightly tap the outer race of the bearing so it is completely level. If the outer race is tilted, it does not enter by light tapping in some cases. On such occasion, pull it out once, place it level and do the job once again.

102

SM3117

W2-4-27

Copyright © New Holland E135B

SWING DEVICE

4.

Place the casing by supporting the flanged part so the shaft end faces down.

5.

Installing oil seal. Insert oil seal (801) into casing (102).

NOTE: use the special tool (B) (380001941). Place the oil seal level and fix it so the lip is not scored.

6.

Press-fitting roller bearing. Insert roller bearing (402) by using the special tool (D) (380001943) that holds down both the inner race and the outer race and also using a press. Always use the special tool (D) (380001943) and set it properly..

(D)

402

SM3118

7.

Fit snap ring (913).

913

SM3119

W2-4-28

Copyright © New Holland SWING DEVICE

8.

E135B

Assembly No. 2 carrier assy. a. Place side plate (285) by matching it to the pinholes. b. Put No.2 planetary gear (203) in. c. Check the hole location, peeping through it from above. Match the No.2 pin (282) with the hole for spring pin (910) and the hole in the No.2 carrier and set the pin, while tapping it lightly.

230

285

282

203

910 SM3120

9.

Apply liquid packing to the matching surface between casing (102) and ring gear (202). Three-Bond #1104B

10. Installing ring gear. Install ring gear (202) to casing (102), checking the location of the matching marks and temporarily fasten them together by means of four capscrews or socket bolts M12×100. Always place plain washers on the bolts so the matching surface of the motor is not scored. : 19 mm o

202 102

: 10 mm

: 78 Nm ( 58 lbf•ft) or over SM3121

11. Installing No.2 carrier assy. Install the No.2 carrier assy (230) into the ring gear. 12. Installing No.2 sun gear. Put in No.2 sun gear (204).

230

SM3122

W2-4-29

Copyright © New Holland E135B

SWING DEVICE

13. Assembly No.1 carrier assy. a. Place No.1 carrier (231) on a level bench. b. Make sure that all three ø2 mm (0.079 in) oil holes of No.1 pin (283) are directed outwards with respect to the center of No.1 carrier (231), as shown in the figure.

204 286 211

285 287 283 403 210

231

2 (0.079") (OIL HOLE)

231 SM3123

SM3125

c. Installing thrust washer. Put in thrust washer (286) in the center.

286

SM3124

W2-4-30

Copyright © New Holland SWING DEVICE

E135B

d. Installing side plate. Put in side plates (285). 286

WARNING the upper and lower side plates differ in thickness; take care so as not to mistake one for another.

403 285 SM3126

e. Installing needle bearing and No.1 planetary gear. Fit needle bearing (403) and No.1 planetary gear (210) into position as shown in Figure.

210

SM3127

f. Installing side plate. Put side plate (287) in and fit snap ring (911).

911

287 SM3128

14. Installing No.1 carrier assy. Assemble the No.1 carrier assy (231). Make sure that thrust washer (286) in the center sits in the convex part of No.2 sun gear (204).

231

286 204

SM3129

W2-4-31

Copyright © New Holland E135B

SWING DEVICE

15. Installing No.1 sun gear. Assemble No.1 sun gear (211). 211

16. Apply liquid packing. Remove the temporarily fastened bolts and coat the mounting surface of the hydraulic motor of ring gear (202) with liquid packing (Three-Bond #1104B).

202

17. Fit snap ring (912).

SM3130

W2-4-32

Copyright © New Holland SWING DEVICE

E135B

MAINTENANCE STANDARD Swing motor 1.

Replacement standards for parts. If parts are worn out beyond the below standards, replace or recondition them. However if they show excessive damage on their surface, replace them.

Item

Standard Dimension mm (in)

Recommended Value for Replacement mm (in)

0.016 (0.00063)

0.046 (0.00181)

0

0.3 (0.01181)

Replace piston and shoe assy

4.0 (0.1575)

3.8 (0.1496)

Replace piston and shoe assy

5.5 (0.2165)

5.0 (0.1968)

Replace a spherical bushing and a retainer plate as a pair.

3.5 (0.1378)

3.1 (0.1220)

Replace

Remedy

Clearance between piston and cylinder bore (D-d)

d

D

Replace piston or cylinder

SM3131

Gap between piston and caulked part of shoe (σ)

SM3132

Thickness of shoe (t)

t

SM3133

Assembled height of retainer plate and retainer (H-h)

H h

SM3134

Thickness of friction plate

t

SM3135

W2-4-33

Copyright © New Holland E135B

2.

SWING DEVICE

Standard for correcting sliding surfaces If the surface roughness of the sliding surface of a part exceeds the following standard, correct it or replace the part.

Standard for correcting sliding surfaces Name of part

Standard surface roughness

Surface roughness requiring correction

Shoe

Ra = 0.2 (lapping)

Ra = 0.8

Shoe plate

Ra = 0.1 (lapping)

Ra = 0.8

Cylinder

Ra = 0.4 (lapping)

Ra = 3.2

Valve plate

Ra = 0.2 (lapping)

Ra = 1

•

Lap each sliding surface roughness level or finer.

to

a

standard

•

If the sliding surface of the cylinder block, valve plate, retaining plate or spherical bushing is roughened, replace parts in pairs.

W2-4-34

Copyright © New Holland SWING DEVICE

E135B

Reduction Unit 1.

PARTS INSPECTION AND REPLACEMENT STANDARDS. a. If pitching is seen on the tooth surface of the sun gear, the planetary gear and the ring gear; (Single pit is more than ø1 mm (0.039 in) and the area occupancy of all pits is more than 5%.) b. Oil seal. Replace the oil seal if the lip face of it is scored and worn. Always replace when the reduction gear is disassembled for inspection or some reason. c. Drive shaft roller bearing (Front side). Inspect as below without drawing it out from the drive shaft: Œ Inspect the race surface and the rollers as far as you can see and make sure that there is no pitching and flaking.  Inspect the following as well: a.The gear oil does not contain large worn particles. b.Large worn particles are not deposited between the roller and the retainer. c.The bearing turns smoothly by hand. Replace it if there is any fault on the above inspection. Do not reuse the bearings drawn out of the shaft.

W2-4-35

d. Drive shaft roller bearing (Rear side). Replace the bearing if the race surface and the rollers show pitching and flaking. e. No. 2 planetary gear Check for the circumferential gap between the No. 2 planetary gear and the No. 2 pin without disassembling the No. 2 carrier assy. Replace the planetary gear if the gap is more than 0.5 mm (0.01969 in). f. Thrust plate and thrust washers. Replace the gear if the sliding surface in contact with the No. 2 sun gear is extremely scored. g. If pitching and flaking are seen on the rolling surfaces of the needle cage and the No. 1 pin that support the No. 1 planetary gear; Replace such faulty parts.

Copyright © New Holland E135B

2.

SWING DEVICE

TABLE OF PARTS TO BE REPLACED TOGETHER

m marks represent such parts that must be replaced together. ∆ marks represent such parts that should preferably be replaced together.

NOTE: Replace the inner race and the outer race of the roller bearing together.

Parts to be replace together

Needle cage

Spring pin

No. 1 pin

Side plate

No. 1 carrier

No. 2 pin

No. 1 planetary gear

No. 2 carrrier

m

∆

m

-

m

∆

m

282 No. 2 pin

∆

∆

-

∆

m

285 Side plate

∆

∆

m

-

m

910 Spring pin 210 No. 1 planetary gear

∆

∆

m

∆

-

∆

∆

∆

231 No. 1 carrier

∆

-

m

∆

283 No. 1 pin

∆

m

-

∆

403 Needle cage

∆

∆

∆

-

Roller bearing

∆

∆

Roller bearing

-

230 No. 2 carrier

Drive shaft

203 No. 2 planetary gear

210 Drive shaft

-

m

m

401 Roller bearing

∆

-

∆

402 Roller bearing

∆

∆

-

NAME

Parts for replacement

201 401 402 203 230 282 285 910 210 231 283 403 No. 2 planetary gear

N.

W2-4-36

Copyright © New Holland SWING DEVICE

E135B

SPECIAL TOOLS Swing motor

Figure 2 X 7 (0.276")

40 (1.57")

Brake piston drawing tool

M10 SCREW ON BOTH ENDS (EFFECTIVE THREAD 40 (1.57") LENGTH 20 (0.787")

BORE DIA. 11 (0.433")

2 X NUT M10

250 (10") 10 (0.4")

(A) 380001938

Purpose

100 (4")

Tool Part Number

M10

123 (4.84") 200 (7.87") SM3136

W2-4-37

Copyright © New Holland E135B

SWING DEVICE

Swing reduction unit

Tool Part Number

Figure

Oil seal fitting

Ø93

(B) 380001941

Purpose

9

SM3137

Roller bearing (401) removing

125

(C) 380001942

118 138

0

Ø1

28 Ø1

SM3138

W2-4-38

Copyright © New Holland SWING DEVICE

Figure

Roller bearing (402) fitting

Ø74

(D) 380001943

Purpose

Ø140

Tool Part Number

E135B

45 SM3139

W2-4-39

Copyright © New Holland E135B

SWING DEVICE

NOTE:

W2-4-40

Copyright © New Holland PILOT VALVE

E135B

REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE WARNING Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and appropriate to hold the weight of load. Preparation 1.

Park the machine on a firm, level surface.

“Releasing the hydraulic pressure” at page. T21-47.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure

3.

Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself.

Removal 1.

Free and lift rubber cap (5) complete with plate (4) unlocking its hooks using a screwdriver.

2.

Remove side panels (2) and (3) removing securing screws.  

3.

Remove the handgrip (1) removing lock-nut (6) disconnecting the relevant electric connection.

 

: 22 mm IMPORTANT: attach an identification tag on each hose to aid in reassembly.

 

4.

Disconnect hoses from port connector PF 3/8 (7) and PF 1/4 (8) of pilot valve body (9).

60

: 19.22 mm 

NOTE: attach a cap on each of disconnectd hose ends. 5.

Remove pilot valve (9) removing securing screws (10) M6x25 complete with washers.



: 5 mm





60

W2-5-1

Copyright © New Holland E135B

PILOT VALVE

Installation 1.

Install pilot valve (9) on the frame tightening securing screws (20) M6x25 complete with washers.

7

 

: 5 mm



: 11.8 Nm (8.7 lbf•ft) 2.

7



 

Connect hoses to pilot valve body (9).



: 19 mm (Port: P)

3

3 

60

: 29.4 Nm (22 lbf•ft) : 22 mm (Port: 1 to 8, T)

LEFT SIDE

: 49 Nm (36 lbf•ft) 3.

Tighten the handgrip on the pilot valve (9), tighten lock-nut (6) and reconnect the electric connector. : 22 mm

4.

Install side panels (2) and (3) tightening securing screws.

5.

Arrange rubber cap (5) complete with plate (4) locking the hooks on side panel (2).

RIGHT SIDE BUCKET 1 (H)

RED

BUCKET (R)

BLUE

5 SWING (L)

GRAY

6 SWING (R)

RED

2

7 ARM (H)

BLUE

3 BOOM (H)

GREEN

8 ARM (R)

GREEN

4 BOOM (R)

GRAY

   

  60

W2-5-2

Copyright © New Holland PILOT VALVE

E135B

REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE WARNING Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and appropriate to hold the weight of load. Preparation 1.

Park the machine on a firm, level surface.

“Releasing the hydraulic pressure” at page. T21-47.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure

3.

Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself.

Removal 1.

Remove the cover under the cab

2.

Remove the floor mats in the cab.

3.

Remove the pedal removing securing screws (1) (Q.ty 4) then remove the levers, removing securing screws (2) (Q.ty 4). : 13, 17 mm

4.

Disconnect pressure sensors (7) from body (8). : 24 mm

 

IMPORTANT: attach an identification tag on each hose to aid in reassembly.

 5.

Disconnect pipes (from 3 through 6) of body (8).





: 19, 22 mm



 NOTE: attach a cap on each of disconnected hose ends.

6.

Remove body (8) removing securing screws (9) complete with washers. : 17 mm

W2-5-3

 

60

Copyright © New Holland E135B

PILOT VALVE

Installation 1.

Install body (8) on the frame tightening securing screws (9) complete with washers. : 17 mm : 37 Nm (27.4 lbf•ft)

2.

Connect pipes (from 3 through 6) to body (8). : 19 mm : 16.7 Nm (12.3 lbf•ft) : 22 mm : 30 Nm (22.0 lbf•ft)

3.

Connect pressure sensors (7) to body (8).



: 24 mm



: 16.7 Nm (12.3 lbf•ft) 4.

Install the levers tightening securing screws (2) and the pedals tightening securing screws (1).



: 17 mm : 46.1 Nm (34.1 lbf•ft)





: 13 mm





: 23.5 Nm (17.4 lbf•ft)

 5.



Install the cover under the cab : 19 mm : 108 Nm (80.0 lbf•ft)

W2-5-4

60

Copyright © New Holland PILOT VALVE

E135B

DISASSEMBLY RIGHT AND LEFT PILOT VALVE

60

123456-

Adjusting nut M14 Boots Circular plate Joint M14 Plate Seal (Q.ty 4)

789121415-

Plug (Q.ty 4) O-Ring (Q.ty 4) Push rod (Q.ty 4) Spring seat 1 (Q.ty 2) Spring seat 1 (Q.ty 2) Spring (Q.ty 4)

W2-5-5

171819202122-

Spring (Q.ty 2) Spring (Q.ty 2) Washer 2 (shim) (Q.ty 4) Spool (Q.ty 2) Spool (Q.ty 2) Casing

Copyright © New Holland E135B

PILOT VALVE

Disassembly right and left pilot valve Be sure to thoroughly read "Precautions for Disassembly and Assembly" on page W1-1-1 before starting the disassembly work. NOTE: replace O-Ring operations, as a rule.

every



disassembly

1.

Plug each port of pilot valve, and clean it. P Port : PF 1/4” 1÷4 Port and T: PF 3/8”

2.

Fix pilot valve with vise, via a protective plate (Alminum plate etc.), and remove boot (2).

3.

Remove adjusting nut (1) applying spanners to circular plate (3).

60

: 22, 32 mm 4.



Remove circular plate (3). : 32 mm

 5.

Turn joint (4) in counterclockwise with jig (E) (380001055) to remove it. : 24 mm

60

WARNING When the force of return springs (15) is high, never loosen joint (4). If loosened, it might result in jumping out of plate (5) plug (7) and push rod (9). Remove joint (4) pressing plate (5) downward with two fingers.

( 

60

W2-5-6

Copyright © New Holland PILOT VALVE

6.

E135B

Remove plate (5).



NOTE: When the force of return spring (15) è is high, press plate to let it come up slowly. When the force of return spring (15) is low, plug (7) is left in casing (22) due to sliding resistance of ORing (8).

60

 

60

7.

Pull plug (7) out with a driver. WARNING

To prevent personal injury, plug (7) must be removed slowly and evenly until the return spring (15) force is completely released

 8.

Remove push rod (9), plug (7), pressure reducing valve assy (spool) and the return springs (15) from casing (22).

NOTE: record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.

60

  



60

W2-5-7

Copyright © New Holland E135B

9.

PILOT VALVE

Press springs seats (12 and 14) so that the movement is 7 mm (max), then remove spools (20 and 21) through the larger hole of the seat.

 IMPORTANT: Never push down spring seat (12) in 7 mm or more. (For port 1 and 3). Never push down spring seat (14) in 9.4 mm or more. (For port 2 and 4).



60

10. Remove spool (20 and 21), spring seats (12 and 14), springs (17 and 18) and washer (19).

 





60

11. Pull out push rod (9) from plug (7).



12. Remove O-Ring (8) from plug (7).





60

13. Remove inside seal (6) from plug (7) with small driver

Cleaning parts 1.

Clean parts with wash oil roughly and the parts of pilot valve completely.

2.

Dry parts by swabbing clean waste cloth.

3.

Apply rust preventives on parts.

 W2-5-8

60

Copyright © New Holland PILOT VALVE

E135B

ASSEMBLY RIGHT AND LEFT PILOT VALVE

     















 











60

12345678-

Adjusting nut M14 Boots Circular plate Joint M14 Plate Seal (Q.ty 4) Plug (Q.ty 4) O-Ring (Q.ty 4)

910111213141517-

Push rod (Q.ty 4) Spring (Q.ty 4) Spring seat 2 (Q.ty 2) Spring seat 1 (Q.ty 2) Spring seat 2 (Q.ty 2) Spring seat 1 (Q.ty 2) Spring (Q.ty 2) Spring (Q.ty 2)

W2-5-9

18192021222324-

Spring (Q.ty 2) Washer 2 (shim) (Q.ty 4) Spool (Q.ty 2) Spool (Q.ty 2) Casing 2E4 Port 1E3 Port

Copyright © New Holland E135B

PILOT VALVE

Assembly right and left pilot valve 1.

Fit washer 2 (19), springs (17) and (18), spring seats (12) and (14) to spools (20) and 21).

 



 60

2.

Push spring seat 1 (12) so that the movement is 7 mm or less, and install spool (20) through the large hole of spring seat 1. For spring seat 1 (14), push spring seat (14) in 9.4 mm or less and install spool (21).



IMPORTANT: never push down spring seat (12) in 7 mm or more. (For port 1 and 3). Never push down spring seat (14) in 9,4 mm or more. (For port 2 and 4).



60

3.

Place springs (15) into ports 1 of casing (22), and then install pressure reducing valve assy in it. Place spring (16) into ports 2,4 and then install pressure reducing valve assy in it.

 

NOTE: install the removed respective assy into respective holes.



60

W2-5-10

Copyright © New Holland PILOT VALVE

4.

E135B

Fit O-Ring (8) and seal (6) into plug (7). Apply hydraulic oil on surface of push rod (9).









 



60 60

5.

Insert push rod (9) in plug (7).



6.



60

Fit plug (7) assy to casing (22).



NOTA: When the force of spring (15) is low, it stops at the position where it is pushed in by the sliding resistance of O-Ring (8). When the force of spring (15) is high, attach plate (5) and press 4 push rods by hand at the same time, and tighten joint (4) temporarily. Install spools (20) ande (21) straight and evenly into the hole of casing (22). Take care so that plugs (7) and plate (5) do not jump out of casing (22)



60



 60

W2-5-11

Copyright © New Holland E135B

7.

PILOT VALVE

nstall joint (4) on casing (22) with special tool (E) (380001055) securely. : 22 mm : 47.1±2.9 Nm (34.8±2.1 lbf•ft)

 (

60

8.

Install circular plate (3) to joint (4).

IMPORTANT: screw it in until it comes in contact with 4 push rods (9) equally. The exceeding of screw in may cause malfunction of machine.





9.

Screw adjusting nut (1), applying Loctite #277 to the thread of joint, until it touches circular plate (3), and tighten it applying spanner to stop circular plate returning. 60

: 22 mm : 68.6±4.9 Nm (50±3.6 lbf•ft) : 32 mm *

10. Apply heat-resisting grease (G) to joint (4) rotating section and the top of push rod (9).

  60



11. Cover it with boots (2). 12. Spray rust preventives through each port and attach plug respectively.

60

W2-5-12

Copyright © New Holland PILOT VALVE

E135B

PILOT VALVE (FOR TRAVEL) CONSTRUCTION

R R

K

R \ 

\ [

[

 



I G /RFWLWH J 7  J

O



T

7 

 U

X W 7  



L 7  N 7  K





X W 7  



M

X 

W

U

T 7 



/RFWLWH U

]





Z

 7 aa 60

NOTE: T=tightening torque Nm (lbf•ft) No.

Parts

5

Rubber boots

6

Foot pedal (Switch plate)

Q.ty 2 (2)

No.

Parts

Q.ty

12-x Seal ø14×20×3

6

12-y Wiper ring

6

6-d

Switch plate

2

13

Damper spring

4

6-f

Regulation screw M8×28

4

14

Check valve kit

(2)

6-g

Set screw M5x8

4

14-q Plug M8

2

6-l

Damping screw

4

14-r Ball M6, 35

2

7

Retaining plate kit

7-h

Plate

(1)

15-t Orifice M6, ø0.6

Capscrew M10×20

2

7-j

Shaft

2

Set screw M4×10 Flange kit

8

Orifice

15-u Plug M6

7-i 7-k

15

1

17

(4) 4 4

Shuttle valve kit

(2)

2

17-w’ Shuttle valve & orifice

2

4

17-r Ball M6, 35

2

17-z Orifice M5, ø0.8

10

Control spool

4

11

Return spring

4

21

Plug

4

12

Damper flange kit

(4)

22

Valve body

1

12-o Damper plunger ø14

4

W2-5-13

2

Copyright © New Holland E135B

PILOT VALVE

DISASSEMBLY AND ASSEMBLY 1.

Boot replacement

 NOTE: the pilot control unit does not need to be removed from the machine to perform this operation.



1) Remove both faulty boots. (using a flat screw driver if necessary) 2) Replace both boots with a new one. * Reassembly: • First fit the lower part of the rubber boot (5) on the retaining plate (7-h) between the 2 switch plate (6) • Then put the lower part in the external groove of the retaining plate. • Finish by fitting the upper part of the rubber boot on the switch plate.

K



60

2.

Switch plate removal 1) Remove: • The pilot control unit from the machine • Both rubber boots 2) Remove the screw (7-k) locking the axis using a 2 mm socket wrench. (See Fig. SM0757 A) * Reassembly: • Apply a droplet of Loctite #262 on the locking screw thread. • Torque: 1.2 Nm (0.89 lbf•ft) 3) Fit a M3 screw on the switch plate axis (7-j) in order to remove it (Using pliers if necessary). (See Fig. SM0757 B) * Reassembly: • Position the axis so that the hole (f) is aligned with the locking screw (7-k) as shown on the picture (See Fig. SM0757 C) 4) Mark out the position of the switch plate before removing it. 5) Repeat the operation for the second switch plate. 6) Reassemble parts in reverse order.

W2-5-14

%

$

N &

I

M

'

(

60

Copyright © New Holland PILOT VALVE

3.

E135B

Switch plate adjustment

I NOTE: if the switch plate (6) is replaced, it is necessary to adjust the regulation screws (6-f). 1) Unscrew the 2 locking screws (6-g) using a 2.5 mm socket wrench * Reassembly : • Apply a droplet of Loctite #262 on the locking screw thread. • Torque: 3 Nm 2.2 (lbf•ft) 2) Set the switch plate (6) horizontally 3) Screw on simultaneously both regulation screws (6-g) using a flat screw driver (5.5x150) until feeling some resistance. NOTE: do not misadjust the two damping screws (6-l).

J

 60

4) Tighten the locking screws (6-g) to hold the regulation screws (6-f) in position. 5) Repeat the operation for the second switch plate making sure both switch plates are parallel.

O

I 4.

Retaining plate removal (7-h) 1) Remove • The pilot control unit from the machine • Both rubber boots • Both switch plates (6) 2) Unscrew simultaneously both screws (7-i) holding the retaining plate using a 8 mm socket wrench. * Reassembly : • Apply a droplet of Loctite #262 on the screw thread. • Torque: 30 Nm (22 lbf•ft)

 60

 L K

60

W2-5-15

Copyright © New Holland E135B

PILOT VALVE

3) Lift the retaining plate (7-h) to remove it. * Reassembly: • Use the retaining plate (7-h) to insert the 4 guides into the body simultaneously and perpendicularly (22). 4) Reassemble parts in reverse order. 5) Drain the pilot control unit.

5.



K

Damping plunger seals replacement

60

1) Remove: • The pilot control unit from the machine. • Both rubber boots. • Both switch plates. • The retaining plate. 2) Remove the wiper ring (12-y) Remove the wiper ring (12-o). * Reassembly: • Replace with a new wiper ring (12-y).

R

\ %

$

60

CAUTION Always place the damping plunger (12-o) prior to the wiper ring (12-y), and make sure the wiper ring (12-y) is correctly positioned.

K \

3) Remove the damping plunger (12-o). 4) Using a needle, remove the seal (12-x) placed inside the body (22) * Reassembly: • Replace with a new seal and grease it.

[ R   60

[

$

W2-5-16

%



60

Copyright © New Holland PILOT VALVE

• A: Squeeze the seal (12-x) between your fingers to obtain a 8-shape. • B, C: Insert the seal (12-x) ithin the groove with your fingers (lip in bottom position). • D: Push the seal (12-x) against the side using the round head of a small socket wrench.

[

$ IMPORTANT: during the reassembly, make sure the seal (12-x) is correctly positionned, and pay attention not to damage nor twist it. 5) Repeat the operation for the other 3 assemblies. 6) Extract the damping springs (13) from the body (22) (using flat nose pliers). 7) Inspect the damping springs (13). If defects are detected, replace the 4 springs. 8) Reassemble parts in reverse order. 6.

E135B

[

%

[

&

'

60



Guide/plunger and regulation unit replacement. 1) Remove • The pilot control unit from the machine. • Both rubber boots • Both switch plates • The retaining plate 2) Guide/plunger replacement: • Insert the end of a thin screwdriver between the guide and the body (22), carefully lift the guide to remove it from the body.

NOTE: hold the guides with the other hand during the extraction operation to limit the effect of the return spring. 3) Remove the guide / plunger assembly. 4) Repeat the operation for the other 3 subassemblies. 5) Visually check that the guides / plungers are in good condition. If defects are present, replace the 4 sub-assemblies.





60

W2-5-17

Copyright © New Holland E135B

PILOT VALVE

6) Guide/plunger and relulation unit replacement. • Extract the regulation units from the body (22) (using flat nose pliers). • Inspect the regulation units. If defects are detected on the parts, replace the 4 units. 7) Return spring replacement (11): • Extract the return springs (11) from the body (22) (using flat nose pliers).





60

• Inspect the return springs (11). If defects are detected, replace the 4 springs.



8) Reassemble parts in reverse order.



60

7.

Throttle kit replacement 1) Remove • The pilot control unit from the machine • Both rubber boots • Both switch plates • The retaining plate • The damping plungers and springs 2) Unscrew the screw (15-u) using a 3 mm socket wrench * Reassembly: • Apply a droplet of Loctite #262 on the screw thread • Screw on until it sets just above the body (22).

W2-5-18

X



60

Copyright © New Holland PILOT VALVE

E135B

3) Unscrew the throttle (15-t) using a 3 mm socket wrench. * Reassembly: • Torque: 4 Nm (3 lbf•ft) 4) Repeat the operation for the other 3 assemblies. 5) Replace with new screws (15-u) and new throttles (15-t). 6) Reassemble parts in reverse order.



X

W 60

8.

Shuttle valve kit removal (17) 1) Remove the pilot control unit from the machine

NOTE: the pilot control unit does not need to be disassembled to perform this operation. 2) Unscrew the shuttle valve (17-w) using a 4 mm socket wrench * Reassembly: • Thoroughly clean the body to remove any trace of loctite. • Apply a droplet of Loctite #242 on the shuttle valve thread (17-w). • Torque: 4 Nm (3 lbf•ft) 60

IMPORTANT: wait for 8 hours before using the machine to let the Loctite #242 dry completely.

Z

60

W2-5-19

Copyright © New Holland E135B

PILOT VALVE

3) Put the body up-side-down to remove the shuttle valve (17-w) and the ball (17-r). 4) Unscrew the throttle (17-z) using a 2.5 mm socket wrench. * Reassembly: • Hand tighten 5) Repeat the operation for the other subassemblies. 6) Inspect the shuttle valves (17-w), balls (17-r) and throttles (17-z). If defects are detected, replace all the assemblies. 7) Reassemble parts in reverse order.

60

W ]

Z

60

9.

Check valve kit removal (14) 1) Remove the pilot control unit from the machine

T

NOTE: the pilot control unit does not need to be disassembled to perform this operation. 2) Unscrew the check valve plug (14-q) using a 4 mm socket wrench. * Reassembly: • Drain the pilot control unit • Torque: 5 Nm (3.7 lbf•ft) 3) Put the body (22) up-side-down to remove the ball (14-r). 4) Repeat the operation for the second check valve kit. 5) Inspect the check valve plugs (14-q), Orings and balls (14-r). If defects are detected, replace all the assemblies. 6) Reassemble parts in reverse order.

60

 T

U

W2-5-20

60

Copyright © New Holland PILOT VALVE

E135B

DRAIN OF HYDRAULIC PILOT CONTROL UNIT 1.

When removing the retaining plate, the throttle kit or the shuttle valve kit, it is necessary to drain the pilot unit.

2.

Reassemble the pilot unit control completely.

3.

Install the pilot unit control in the machine.

4.

Slightly unscrew the check valve plug (14-q) using a 4 mm socket wrench

5.

Switch on the machine.

6.

Operate gently the pedal until the bubbles disappear.

7.

Tighten the check valve plug (14-q). Torque: 5 Nm (3.7 lbf•ft)

8.

Repeat the operation for the other check valve plug.

T

60

W2-5-21

Copyright © New Holland E135B

PILOT VALVE

NOTE:

W2-5-22

Copyright © New Holland

SECTION 3

E135B

UNDERCARRIAGE

CONTENTS Group 1 - Swing bearing Removal and installation of swing bearing .................................................. W3-1-1 Tool table ............................................... W3-1-2

Group 2 - Travel device Removal and installation of travel device ................................................... W3-2-1 Removing ......................................... W3-2-2 Installing............................................ W3-2-4 Disassembly and assembly of travel motor unit ........................................................ W3-2-5 Construction of travel motor unit ....... W3-2-5 Exploded view of reduction unit ........ W3-2-7 Exploded view of hydraulic motor ..... W3-2-7 Disassembling procedure ................. W3-2-11 Assembly .......................................... W3-2-25 Maintenance standard ........................... W3-2-41 Sprocket............................................ W3-2-43 Tool table ............................................... W3-2-44

Group 3 - Swivel joint Removal and installation of swivel joint . W3-3-1 Swivel joint disassembly and assembly . W3-3-4 Version equipped with blade.................. W3-3-5 Disassembly ..................................... W3-3-6 Assembly .......................................... W3-3-8 Maintenance standard ........................... W3-3-10

Group 4 - Track adjuster Removal and installation of track adjuster (with front idler) ..................................... W3-4-1 Disassembly and assembly track adjuster ................................................. W3-4-2 Maintenance standard ........................... W3-4-7 Tool table ............................................... W3-4-8

Group 5 - Front idler Disassembly and assembly front idler assy....................................................... W3-5-1 Disassembly...................................... W3-5-1 Assembly .......................................... W3-5-3 Maintenance standard............................ W3-5-4 Tool table ............................................... W3-5-5

Group 6 - Upper and lower roller Removal and installation of upper roller ...................................................... W3-6-1 Removal............................................ W3-6-1 Installation......................................... W3-6-2 Removal and installation of lower roller ...................................................... W3-6-4 Removal............................................ W3-6-4 Installation......................................... W3-6-5 Disassembly & assembly of the upper roller . W3-6-7 Disassembly ........................................ W3-6-8 Assembly ............................................ W3-6-10

Upper roller maintenance standard........ W3-6-13 Tool table for upper roller ...................... W3-6-14 Disassembly & assembly of the lower roller ............................................ W3-6-15 Disassembly ........................................ W3-6-16 Assembly ............................................ W3-6-18 Lower roller maintenance standard........ W3-6-20 Tool table for lower roller........................ W3-6-21

Group 7 - Tracks Removal and installation of tracks ......... W3-7-1 Removal............................................ W3-7-1 Installation......................................... W3-7-3 Maintenance standard............................ W3-7-5

Copyright © New Holland

Copyright © New Holland SWING BEARING

E135B

REMOVAL AND INSTALLATION OF SWING BEARING WARNING Wear close-fitting clothing and safety equipment appropriate to the job. Use tools appropriate for the job to be performed. Always ensure that slings and chains used for lifting are adequate to the load and in good condition. Before removing the swing bearing, the upperstructure must be removed first. For removal and installation of the upperstructure, refer to “Remove and Install Main Frame” section. In this section, the procedure starts on the premise that the upperstructure has already been removed. Removal 1.

$

Put alignment marks on (A) swing bearing (1) and track frame (2).



 60

2.

Remove screws M16 (3) (Q.ty 36) and the relevant washers (Q.ty 36). : 24 mm

 60

IMPORTANT: swing bearing weight: 150 kg (331 lbs). 3.

Attach lifting tools (380001026), hoist swing bearing (4) and remove it.

 60

W3-1-1

Copyright © New Holland E135B

SWING BEARING

Installation Clean the matching surfaces of swing bearing and the frame. 1.

Apply THREEBOND 1102 to the matching surfaces of swing bearing and track frame.

IMPORTANT: swing bearing weight: 150 kg (331 lbs).

60

IMPORTANT: the soft zone (S) of the inner race (left side of the lower frame) and the inserting hole for steel balls of the outer race (B) (right side of the lower frame) should be opposed by 180°. 2.

$ 6

Hoist the swing bearing. Align the swing bearing with the alignment mark on the track frame and install the swing bearing.

% NOTE: apply Loctite #262 on the thread of the screws (3) before assembling.

60

A: Front Side B: Position of Plug

3.

Install screws M16 (3) (Q.ty 36) with the relevant washers (Q.ty 36) and tighten them to the prescribed torque. :24 mm : 270 ± 27 Nm (199 ± 20 lbf•ft)

NOTE: fill in greasebath with 8 ± 0.82 kg (17.6 ± 1.8 lbs) AMBRA MG2 or IP BIMOL 481 or equivalent grease.

 60

TOOL TABLE TOOL NO.

DESCRIPTION

380001026

Lifting tools slewing ring

W3-1-2

Copyright © New Holland TRAVEL DEVICE

E135B

REMOVAL AND INSTALLATION OF TRAVEL DEVICE WARNING Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and appropriate to hold the weight of load. Preparation 1.

Park the machine on a firm, level surface.

2.

To drain the hydraulic pressure from the Hydraulic System, refer to procedure "Releasing the hydraulic pressure" at page T2-1-47.

3.

Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure present in the tank itself. INSTALL ASSY

No.

YY53D00012F1

NAME

Q'TY

REMARKS

3

CAPSCREW

40

M16x45

4

TRAVEL MOTOR ASSY

2

YY53D00013F1



4

60

W3-2-1

Copyright © New Holland E135B

TRAVEL DEVICE

REMOVING Preparation for removal 1.

Remove crawler, lift up crawler frame using attachment, and put it on square timbers to float and stabilize.

Removing cover 2.

Remove sems bolt (6) M12x25 and also remove covers (1). 6

: 19 mm 1

SM0616

3.

Preparation of oil pan.

Removing hydraulic pipe 4.

Release pressure from travel circuit, and bleed air in hydraulic oil tank, then remove all pipes connecting to travel motor. Then plug up all pipes and joint section to protect them from entry of dust. : 19 mm : 27 mm : 36 mm

SM0617

W3-2-2

Copyright © New Holland TRAVEL DEVICE

E135B

Removing sprocket 5.

Removing (one side) capscrews (5) M16x45 (q.ty 18). : 24 mm

NOTE: sprocket mass: 43 kg

5 SM2019

Loosening travel motor attaching bolts 6.

Apply match marks on travel motor and crawler frame, and remove (one side) capscrews (3) M16x45 (q.ty 20). : 24 mm 3

SM1812

Slinging travel motor assy 7.

Sling travel motor with nylon sling applied on the side close to sprocket installing section and remove the motor.

NOTE: motor mass: about 144 kg (317.5 lbs)

60

W3-2-3

Copyright © New Holland E135B

TRAVEL DEVICE

INSTALLING Installing of the travel motor piping is performed in the reverse order of removal. 1.

Cleaning Check that contact surface of travel motor and crawler frame is free from burr and stain.

2.

Tightening torque Tighten capscrew and hydraulic pipes to the torque specified in "Tightening Torque").

3.

Fill inside from motor drain port to casing with hydraulic oil before piping for drain. When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and noise.

NAME Bolts

SIZE

TOOLS

No.

TIGHTENING TORQUE Nm (lbf•ft)

M12

19

6

110 ± 11 Nm (81.1 ± 8.1 lbf•ft)

M16

24

3

270 ± 27 Nm (199 ± 20 lbf•ft)

M16

24

5

279 ± 28 Nm (206 ± 20 lbf•ft)

Flareless nut for pipes, sleeve

PF1/4 PF1/2

17 22; 27

-

29.4 ± 5 Nm (21.7 ± 3.7 lbf•ft) 78.5 ± 5 Nm (57.9 ± 3.7 lbf•ft)

Connector

PF1/4 PF1/2 PF3/4

19 27 36

-

36.3 ± 2 Nm (26.7 ± 1.5 lbf•ft) 108 ± 10 Nm (79.7 ± 7.3 lbf•ft) 162 Nm (119 lbf•ft)

W3-2-4

REMARKS Apply Loctite #262

Copyright © New Holland TRAVEL DEVICE

E135B

DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR UNIT CONSTRUCTION OF TRAVEL MOTOR UNIT Cross-sectional view of travel motor unit assembly (1/2)

324 328 336 326 325 331 330 327 323 301 396 343 34

208

207 209 210 212 205 213 211 203 206 204 202 201 SECTION A-A

354

352

358

353

381

384

383

380

358 352 380 383

SECTION D-D

381 378 379 396 398 343

SECTION E-E SM2644

W3-2-5

Copyright © New Holland E135B

TRAVEL DEVICE

Cross-sectional view of travel motor unit assembly (2/2)

377 104 115 116 108 103 167 171

17

12

9

28

10

16

5

35 27

110

11

113

6

341 114

15

145

36

102

8

301

14

150

4

109

13

399

132

357

149

359

3

366

7

363

30 31

112

185 354

161 32

376 33 139 135

2

29

1

23 24

105 151 107 22 106 162

329

384

398

398

354 SECTION F-F

SECTION G-G

SM2645

W3-2-6

Copyright © New Holland TRAVEL DEVICE

E135B

EXPLODED VIEW OF REDUCTION UNIT

24 22

1

29 24 29 23 2 32 34

33 35 14 13

6 3

15

36

4

16

8 10 17 7 30 31

27

11

5 11

28

12

9 12

SM2646

W3-2-7

Copyright © New Holland E135B

TRAVEL DEVICE

EXPLODED VIEW OF HYDRAULIC MOTOR

115

116

135 112

324

139

336 328

109

325

341

326 331

377 327

354 301

330

380 383358 352 353 329 398

113 150 376

396 358 352 343

323 327

366 363 359 357

353 358 352 381 383 380

379 330 378 331 398 326 208 201 325 210 208 207 328 210

398 399 384

336

209 212

324

203

103

204 202

106 105

213 206 211 205

107 108 151 104

110 114 145

110

132 149 102

171 167

162

185 161

SM2647

W3-2-8

Copyright © New Holland TRAVEL DEVICE

E135B

TRAVEL MOTOR UNIT READING KEY No.

NAME

Q'ty

No.

NAME

Q'ty

No.

NAME

1

HUB

1

105 •••CYLINDER BLOCK

1

2

SPINDLE

1

106 •••PISTON

1

CARRIER 1 ASSY

1

104 •SHOE 1

1

REAR FLANGE ASSY

1

3

•CARRIER 1

1

107 RETAINER PLATE

1

•REAR FLANGE KIT

1

5

•PLANETARY GEAR 1

3

108 THRUST BALL

1

•••SPOOL ASSY

1

6

•CARRIER PIN 1

3

109 TIMING PLATE

1

323 •••SPOOL

1

11 •THRUST WASHER 1

6

110 WASHER

2

326 •••PLUG

2

16 •PARALLEL PIN 1

3

112 PISTON

1

327 •••VALVE

2

ROLLE 27 •NEEDLE BEARING

3

113 SPRING

10

330 •••SPRING

2

CARRIER 2 ASSY

1

114 SPRING

1

331 •••O-RING

2

7

•CARRIER 2

1

115 FRICTION PLATE

3

301 ••REAR FLANGE

1

9

•PLANETARY GEAR 2

3

116 MAITING PLATE

4

324 •PLUG

2

10 •CARRIER PIN 2

3

132 OIL SEAL

1

325 •WASHER

2

12 •THRUST WASHER 2

6

135 O-RING

1

328 •SPRING

2

17 •PARALLEL PIN2

3

139 O-RING

1

329 •ORIFICE

2

ROLLE BEAR28 •NEEDLE ING

3

145 SNAP RING

1

336 •O-RING

2

4

SUN GEAR 1

1

149 BALL BEARING

1

352 •PLUG

3

8

SUN GEAR 2

1

150 BALL BEARING

1

353 •BALL

2

13 THRUST PLATE

1

151 NEEDLE ROLLER

3

SOCKET 354 •HEXAGON PLUG

5

14 COVER

1

1

357 •PLUG 1

1

15 COUPLING

1

161 •PISTON

1

358 •O-RING

3

22 LOCK WASHER

2

162 •SHOE

1

359 •O-RING

1

23 SHIM

1

167 PIVOT

2

363 •SPOOL

1

BALL 24 ANGULAR BEARING

2

171 PARALLEL PIN

2

366 •SPRING

1

1

185 SPRING

1

376 •ORIFICE

1

FLOATING SEAL KIT

PISTON ASSY

W3-2-9

213 •SHIM

Q'ty 1

Copyright © New Holland E135B

No.

TRAVEL DEVICE

NAME

Q'ty

29 •FLOATING SEAL

2

30 PLUG

3

31 O-RING

3

32 O-RING

No.

NAME

Q'ty

No.

NAME

Q'ty

377 •FILTER

1

2

378 •BALL

1

201 •VALVE SEAT

1

379 •PLUG

1

1

202 •VALVE

1

380 •PLUG

2

33 O-RING

2

203 •SLEEVE

1

381 •PISTON

1

34 PARALLEL PIN

2

204 •COLLAR

1

383 •O-RING

2

35 HEXAGON SOCKET BOLT

12

205 •PLUG

1

384 •ORIFICE

2

36 SNAP RING FOR HOLE

1

206 •SPRING

1

SOCKET 396 •HEXAGON PLUG

2

207 •O-RING

1

SOCKET 398 •HEXAGON PLUG

8

RELIEF ASSY

102 SHAFT

1

208 •BACK-UP RING

2

399 •NAME PLATE

1

103 SWASH PLATE

1

209 •O-RING

1

341 PARALLEL PIN

1

CYLINDER & PISTON KIT

1

210 •BACK-UP RING

2

SOCKET 343 HEXAGON BOLT

10

•PISTON KIT

1

211 •O-RING

1

••PISTON ASSY

9

212 •O-RING

1

W3-2-10

Copyright © New Holland TRAVEL DEVICE

E135B

DISASSEMBLING PROCEDURE 1.

Cleaning travel motor.

A

1) Tighten the eye bolts (A) into the tapped holes of the spindle (2). Eye bolt: M16

2

NOTE: fasten two eye bolts into the tapped holes for the spindle so they are located diagonally opposite to one another.

2) Place a wire sling in the eye bolts, lift the travel motor by hoist, and carry in to the cleaning bath.

NOTE: travel motor assy mass: Approx. 144kg (320 lbs)

SM2198

2

3) Clean the travel motor with a car brush.

NOTE: since soil and sand are entered in the clearance (where the floating seal is fixed) between hub (1) and spindle (2), clean it with particular care.

2.

1

SM2199

Installing travel motor. 1) Placing travel motor on working bench.

NOTE: align threaded holes of hub (1) and working bench, and place travel motor in fixing hole of working bench slowly. 1

2) Fix travel motor with two socket bolts (B) on working bench. SM2200

: 14 mm

CAUTION Tighten 2 socket bolts (B) securely. If not tightened securely, when the travel motor is reversed, it falls and causes injury.

B

SM2501

W3-2-11

Copyright © New Holland E135B

3.

TRAVEL DEVICE

Draining lubricating oil.

NOTE: if you want to disassemble only the rear flange, go to 6. 1).

35, 31 1) Turn over the travel motor.

30 CAUTION Loosen plug (30) slowly to avoid spurt of lubricating oil. SM2502

2) Loosen and remove two socket plugs (30) to release inner pressure. : 10 mm

NOTE: when draining out the lubricating oil, place container under the work bench. 3) Draw out the lube oil by reversely turning the travel motor slowly. 4) Remove O-rings (31) from removed plugs. NOTE: do not reuse removed O-ring (31). 4.

Removing cover. 1) Turn over the travel motor. 2) Remove ten socket bolts (35).

A 14

: 10 mm 3) Because sealant is applied between cover (14) and hub (1), hit upward the corner of cover with a hammer using soft metal to protect the cover.

CAUTION

SM2503

The cover (14) may jump and remove suddenly by hitting. Be careful not to drop the cover to avoid injury. 4) Place a hook and a wire sling to eye bolts (A), lift it up and remove cover (14). 13

5.

Removing thrust plate. 1) Removing thrust plate (1)

SM2504

W3-2-12

Copyright © New Holland TRAVEL DEVICE

6.

E135B

Removing 1st stage reduction gear. 1) Remove sun gear 1 (4) by hand.

4

IMPORTANT: be careful not to drop sun gear 1 (4) it could be slippery by lubricant.

2) Fasten 3 eyebolts to the tapped holes of carrier 1 (3). And attach wire slings and hook in the eye bolts. Lift the carrier (3) assembly with hoist. SM2505

NOTE: when carrier assembly (3) is lifted with hoist, the edge of planetary gear 1 (5) may damage the internal teeth of hub (1). Align center line of hub (1) with that of carrier 1 assembly, lift carrier 1 slowly and straightly.

3

7.

1

Removing coupling. 1) Remove coupling (15) from shaft (102).

SM2506

8.

2nd stage reduction gear removal.

15

1) Fasten three eyebolts to the tapped holes of carrier 2 (7). Place a wire sling and hook in the eyebolts, lift carrier 2 assembly by crane. NOTE: when carrier 2 assy is lifted by crane, the edge of planetary gear 2 (9) could damage the internal teeth of hub (1). Lift up it slowly, and carefully.

SM2507

2) Remove sun gear 2 (8) by hand.

NOTE: be careful not to drop sun gear 2 (8). If could be slippery by lubricant.

8 7 9 1

SM2508

W3-2-13

Copyright © New Holland E135B

9.

TRAVEL DEVICE

Removing lock washer. 1) Fix hub (1) and workbench with using three holes (ø14) of hub (1).

1

SM2509

2) Put a flathead screwdriver into the clearance between two lock washers (22), and widen the clearance. Place the tip of the screwdriver to the one end of the lock washers (22), tap it by hammer, and remove two lock washers (22).

22

SM2510

10. Removing hub.

1

1) Remove the hexagon socket bolts, which fixed hub (1) and workbench. 2) Fasten two eyebolts on the tapped holes of spindle (101). Place a wire sling and hook in the eyebolts. Lift hub (1) by crane.

WARNING Lift up hub (1) slowly and carefully. If hub (1) is inclined against spindle (2), for the interference, wire sling or eyebolts could be destroyed and hit the worker. If hub (1) does not come out smoothly, do not pull forcefully. Instead, use other tools such as press machine.

SM2511

11. Removing floating seal. 1) Grasp inner side of floating seal (29) and lift it up by hand.

CAUTION Use work gloves to prevent from cutting hands at the edge of floating seal (29). If lifting up by hand is difficult by mudpack or such reason, use flat head screwdriver as a lever.

W3-2-14

29 SM2512

Copyright © New Holland TRAVEL DEVICE

E135B

12. Removing angular ball bearing. 1) Put a steel rod on the inner race of angular bearing (24), tap 3 or 4 points evenly. Take care not to damage the bearing.

24

NOTE: - do not remove the angular ball bearing (24), except for replacing the bearing. When the outer race of angular ball bearing (24) separates from fitness hub (1), angular ball bearing (24) falls from hub (1 ). - Please place a container under the workbench and cover with the rubber mat on it so that angular ball bearing (24) does not get damage.

SM2513

13. Removing rear flange.

324

1) Turn over travel motor. (Rear flange (301) is on top.) NOTE: this work is carrying out to remove easily the plugs (324) at the following work. Do not loosen the plugs (324) if the inside of rear flange assembly is not disassembled. 2) Temporarily loosen plugs (324) (2 plugs). 3) Temporarily loosen plugs (380) (2 plugs). SM2514

NOTE: this work is carrying out to remove easily the plugs (380) at the following work. Do not loosen the plugs (380) if the inside of rear flange assembly is not disassembled.

380

4) Temporarily loosen plugs (352) (2 plugs).

352 357 NOTE: this work is carrying out to remove easily the plugs (352) at the following work. Do not loosen the plugs (352) if the inside of rear flange assembly is not disassembled. 5) Temporarily loosen plugs (357). SM2515

NOTE: this work is carrying out to remove easily the plug (357) at the following work. Do not loosen the plug (357) if the inside of rear flange assembly is not disassembled.

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Copyright © New Holland E135B

TRAVEL DEVICE

6) Temporarily loosen relief valve assy (203 others) (2pcs). 7) Loosen the relief valve assemblies (203 others) (2 pcs).

203 SM2516

8) Remove the relief valve assemblies (203 others) (2 pcs). NOTE: do not reuse O-ring (207), (209), (212) and backup ring (208), (210) which have been removed.

203 SM2517

9) Loosen and remove hexagon socket bolts (343) (10 pcs) from rear flange (301). : 8 mm

10) Remove rear flange (301) from spindle (2).

343 SM2518

NOTE: hold rear flange (301) with both hands, hold up rightly and gently, and remove it. Timing plate (109) could fall off and get damaged during this operation.

301

11) Removing ten springs (113). 12) Removing parallel pins (341) from spindle (2). 13) Removing O-ring (27), (30) from spindle (2). NOTE: do not reuse O-ring (27), (30) which have been removed.

109(341)

113 2

SM2519

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E135B

14) Pull out parallel pins (34) (2 pcs) from spindle (2).

34

SM2520

15) Remove O-ring (32), (33) (2 pcs) from spindle (2).

32 33

NOTE: do not reuse O-ring (32), (33) which have been removed.

SM2521

14. Removing the rear flange fittings. 1) Place rear flange (301) on a work bench, with the mating surface for spindle (2) facing up. 2) Remove timing plate (109) from rear flange (301). NOTE: if it is hard to remove the rear flange in some cases as its mating surface is stuck with oil, insert a spatula into the draft groove of the mating surface on the rear flange side and hold the timing plate up. Then the rear flange comes off. If a sharp tool like a screwdriver is put into the mating surface, the mating surface is scored, causing oil leakage ; do not use sharp tools. 3) Remove parallel pins (341) from rear flange (301). 4) Remove ball bearing (150) from rear flange (301).

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301(341)

150

SM2522

Copyright © New Holland E135B

TRAVEL DEVICE

15. Removing the brake valve from the rear flange. 1) Remove two plugs (324) from rear flange (301). : 36 mm

301

2) Remove O-ring (336) from plug (324). NOTE: do not reuse removed O-ring (336).

324(336) SM2523

3) Remove two spring retainer (325) and two springs (328) from rear flange (301). 4) Remove spool (323) from rear flange (301).

301 NOTE: to remove spool (323), place your hand on one part of the plug port of rear flange (301) and tilt it down. Then spool (323) falls down. Hold the tip and remove it.

328

323

328

325 SM2524

16. Disassemble the 2-speed selector valve. 1) Remove plug (357) from rear flange (301). : 10 mm

357(359) 301

SM2525

2) Remove spool (363) and spring (366) from rear flange (301). 3) Remove O-ring (359) from plug (357). NOTE: do not reuse removed O-ring (359).

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E135B

17. Removing piston. 1) Remove plugs (380) (2 pcs) from rear flange (301).

380(383)

2) Remove O-ring (383) from plug (380). NOTE: do not reuse removed O-ring (383)

301

SM2527

3) Remove piston (381) from rear flange (301).

381 SM2528

18. Disassembling ball check part. 1) Remove plugs (352) (2 pcs) from rear flange (301). 2) Remove O-ring (358) from plug (352). NOTE: do not reuse O-ring (358) which have been removed.

352 SM2529

3) Remove steel balls (353) from rear flange (301). NOTE: when it is hard to remove steel balls (353), remove them using the magnet etc.

353 SM2530

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19. Disassembling parking brake.

CAUTION

C

The sudden blowing of compressed air may cause parts to fly out incurring the danger of injury. Cover piston (112) for protection with a rag (C). 1) Blow jet air into the passage hole for the parking brake of the spindle (2) and remove the piston (112) from the spindle (2). 2) Remove O-ring (135), (139) from piston (112).

2

112

SM2531

112 (135,139)

NOTE: do not reuse removed O-ring (135), (139). 20. Disassembling the hydraulic motor section. NOTE: when placing the travel motor on its side, oil spills ; place a container under the travel motor. 1) Lay down the travel motor through 90 degrees. 2) Drain out the oil of the travel motor. 3) Hold cylinder block (104) by hand, turn it both ways a few times alternately and separate shoe (106) from swash plate (103).

SM2532

104(103,106,115,116) NOTE: if cylinder block (104) is drawn out in that condition, shoe (106) stays with swash plate (103). Then parts (pistons, shoes, etc.) attached to cylinder block (104) come off from cylinder block (104) and fall into spindle (2). Care should be used about it.

4) Hold the cylinder block (104) and remove the shaft (102). SM2533

NOTE: also, friction plate (115) and separator plate (116) are also removed with cylinder block (104).

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Copyright © New Holland TRAVEL DEVICE

E135B

5) Remove friction plate (115) and separator plate (116), attached on the removed cylinder block (104).

105

6) Remove piston assy [piston (105) and shoe (106)] and retainer plate (107) from cylinder block (104). NOTE: - when removing the cylinder block, hold the retainer plate (107) by both hands and remove it with the piston assy. - Cylinder block (104) and piston assy [piston (105) and shoe (106)] are the minimum parts unit as cylinder & piston kits. When they have to be replaced, replace the cylinder & piston kit as a set. (Refer to the parts manual.)

106

107 110 104

108

7) Remove the piston assy (105),(106) from retainer plate (107). [Nine pistons]

116

8) Remove thrust ball (108) from cylinder block (104).

115 SM2534

9) Draw out washer (111) from cylinder block (104).

10) Remove three needle rollers (151) from cylinder block (104).

151

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104

SM2535

Copyright © New Holland E135B

TRAVEL DEVICE

21. Remove spring from inside of cylinder block. 1) Place cylinder block (104) on the press bench.

104

NOTE: - do not remove the spring except when spring is replaced. - When removing the spring, align the jig (M) with the washer in order to prevent the cylinder block from being damaged by contact. - Put a plastic sheet over the sliding surface of the cylinder block so as not to damage it.

145(110)

SM2536

2) Place the retainer metal jig (M) on washer (110) and remove snap ring (145) from the snap ring groove of cylinder block (104) by means of snap ring pliers, while holding down the jig (M).

114(110) 104

CAUTION If the press is loosened too suddenly, the spring jumps out and causes injuries. Always loosen the press slowly. 3) Loosen the press slowly till the spring action is released.

SM2537

4) Remove the snap ring (145), washer (110), spring (114), and washer (110) from inside the cylinder block (104). 22. Removing out shaft (102). 1) Removing swash plate (103) from spindle (2). NOTE: when removing it, check that pivot (167) does not adhere to swash plate. 2) Draw out shaft (102) from spindle (2). On that occasion, the inner race of ball bearing (149) comes off with the shaft. 3) Draw out two pivots (167), two parallel pins (171) and the outer race of ball bearing (149) from spindle (2). 4) Draw out the 2-speed switch piston assy [piston 162 (161) and shoe (162)] and spring (185) from spindle (2).

2(103,167) 149

102 SM2538

162 161 185 2

SM2539

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Copyright © New Holland TRAVEL DEVICE

E135B

23. Removing ball bearing (149). NOTE: ball bearing (149) is removed only when replacing.

E

1) Place holder (D) on the press bench and put shaft (102) into the holder (D).

D

2) Remove ball bearing (149) from shaft (102) by pressing on the shaft end with press (E). NOTE: do not reuse the removed ball bearing (149). SM2540

24. Removing spindle fittings. 1) Remove shim (23) from spindle (2).

23 SM2541

2) Remove floating seal (29) from spindle (2). NOTE: do not reuse floating seal (29) which have been removed.

29

SM2542

3) Remove oil seal (132) from spindle (2). NOTE: do not reuse oil seal (132) which have been removed.

2

132

SM2543

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TRAVEL DEVICE

25. Rough washing of parts. 2

1) Distinguish the four parts; hub (1), spindle (2), cover (14), and rear flange (301) from other parts (hereafter called built-in parts).

3,7 301

2) Put the hub, spindle, cover and rear flange in a cleaning bath and clean them. NOTE: - soil and sand adhere to the outer surface of parts in some cases; clean them and remove soil and sand from the parts. - Wash oil is combustible. Be careful not to cause fire and get burns. - Before cleaning stained parts, immerse them in wash oil until dust and stain become soft and are floated to protect them from damaging when cleaning.

1(14) SM2544

3) Put the built-in parts in a rough cleaning container containing wash oil and clean the parts.

26. Finish cleaning. 1) Put parts in a finish cleaning container containing wash oil and clean them well, turning them slowly.

3,7

2) Blow parts with dry air to remove cleaning oil. NOTE: - blow compressed air in the inner surface of hub (1), spindle (2) and rear flange (301) to dry in the dust free and dry conditions. After drying, apply hydraulic oil to every part. - Inner surface of rear flange (301), hydraulic motor components, and RV gear assy are to be dried naturally in the dust free and dry conditions. After drying every part, apply hydraulic oil to every part. - Use care not to damage the surface of twenty four pins (17) nor to lose them while handling.

SM2545

2

SM2546

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E135B

ASSEMBLY General precaution for assembly 1.

Assembly it by reversing the procedure of disassembly.

2.

Assemble it in clean air condition.

3.

Do not use cloth gloves during assembly.

4.

Replace or repair the damaged parts during disassembly according to the instructions in the "Maintenance standard". Replace O-ring, oil seal, etc. with new one.

5.

Clean every part sufficiently, and blow them with compressed air do not use waste cloth.

6.

Prior to assembling, apply clean hydraulic oil to moving and sliding portions of hydraulic motor valve.

7.

Tighten bolt and plug to the specified torque using torque wrench.

8.

Replace reamer bolt with new ones. If it is unavoidably reused, remove completely the adhesive agent on reamer bolt, repair flaws on bolt seat surface with oilstone, and degrease it.

9.

Prior to assembling, apply grease to lip portions of O-ring, oil seal, and floating seal to protect it from being damaged, and to moving section and sliding section.

10. After assembly, plug every port to protect the entry of dust, etc.

Preparatory arrangement for assembly 1.

After replacing parts with new ones, adjust the pre-load of bearing and thickness of snap ring without fail. 1) When the following parts are replaced, the pre-load adjustment of bearing is required. Hub (1) Spindle (2) Bearing (24)

NOTE: where replacing the above parts, the previously adjusted parts should be used. If unadjusted parts are used, the travel motor moves abnormally, causing early breakage.

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TRAVEL DEVICE

ASSEMBLING PROCEDURE E 1.

Assembling hub. 1) Place hub (1) on the press bench (F).

1

2) Place angular ball bearing (24) on hub (1), and press in by using the main plate and a press machine (E) using tool (G) and a fitting press stand (H).

G

3) Turn over hub (1).

24

4) Insert angular ball bearing (24) into hub (1) in the same way 2).

H F

NOTE: make sure that the installing direction of angular ball bearing (24) is correct.

SM2547

5) Apply grease on the O-ring of floating seal (29), and fit the O-ring into the floating seal groove on hub (1).

J

NOTE: - when applying grease to the O-ring, remove the O-ring from floating seal (29), and then, apply grease thinly to entire surface. - Use floating seal installation tool (I) and (J). Make sure to keep the parallel tolerance 1mm (0.039") to end surface of the groove. If not, it could cause seizure on floating seals (29) or oil leak.

I

29 1

2.

Assembling spindle. 1) Apply grease on the O-ring of floating seal (29), and fit the O-ring into the floating seal groove on spindle (2) SM2548

NOTE: when applying grease to the O-ring, remove the O-ring from floating seal (29), and then, apply grease thinly to entire surface. Use floating seal installation tool (J) and (K).Make sure to keep the parallel tolerance 1mm (0.039") to end surface of the groove. If not, it could cause seizure on floating seals (29) or oil leak.

J

2) Install eyebolts to spindle (2) so they are symmetrically positioned.

T

K

2

29 SM2549

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E135B

3) Fix spindle (2) on workbench with two hexagon socket bolts, which should locate symmetrically.

CAUTION Tighten the hexagon bolts securely. Failure to do so could result in injury if GM motor is inverted and falls. 3.

2

Clearance adjustment procedure for angular ball bearing. SM2550

NOTE: if any of hub (1), angular ball bearing (24) or spindle (2) is replaced, clearance adjustment should be conducted. If not, angular ball bearings (24) could break in short period.

c

1) Insert lock washers (22) for measuring the dimensions, and measure the distance (c). 2) Measure the distance (d). NOTE: rotate hub assembly for stabilizing the distance (d). 3) Select one of the classified shim (23) which makes the distance "(c) -(d)" from -0.17 to 0.13mm (-0.0051"~0.0067"). Shim (23) thickness shall be refer to the following table. T : mm (in)

ITEM

T : mm (in)

A

0.9 (0.035")

G

1.5 (0.059")

B

1.0 (0.040")

H

1.6 (0.063")

C

1.1 (0.043")

I

1.7 (0.067")

D

1.2 (0.047")

J

1.8 (0.071")

E

1.3 (0.051")

K

1.9 (0.075")

F

1.4 (0.055")

L

2.0 (0.079")

d

ITEM

SM2551

4) Attach shim (23) to spindle (2).

SM2552

23 SM2553

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4.

TRAVEL DEVICE

Assembling hub. 1) Insert hub (1) into angular ball bearing (24) assembled in spindle (2) with keeping both center axes parallel.

1

2

SM2554

2) Fix hub (1) to the workbench with three long hexagon socket bolts. 3) Put steel rod on the inner race of angular ball bearing (24) located on reduction gear, and tap softly by hammer to stabilize angular ball bearing (24).

1

SM2555

4) Place lock washers (22) to the groove of spindle (2).

5) Fit lock washers (22) into the groove of spindle (2) by using installation tool (N).

22 SM2556

NOTE: insert lock washers (22) fully into the groove so as not to interfere with carrier 2 (7). 6) Remove the long hexagon socket bolts, which fix hub (1) and the workbench. 7) Rotate hub (1) two or three times.

N

NOTE: contacting state between both sliding surface of floating seal (29) will be improved by rotating spindle (2), and prevent initial oil leak. 8) Turn over spindle (2).

22 SM2557

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Copyright © New Holland TRAVEL DEVICE

5.

E135B

Assembling spindle fittings. 1) Drive oil seal (132) into spindle (2) by using the tool (L) to prevent it from being inclined. L

NOTE: apply lithium grease around the lip portion of oil seal (132) when mounting. Be careful in the inclusion direction of oil seal (132).

132 2

2) Install two parallel pins (171) into the pin holes of spindle (2). 3) Apply lithium grease to hemispherical surface of two pivots (167), and fit it into parallel pins (171) of spindle (2).

SM2558

4) Apply lithium grease to spring (185), and install spring (185) into the piston kit [piston (161) and shoe (162)]. 5) Apply hydraulic fluid to the sliding surface of the piston kit, install it into the piston hole of spindle (2). 6) Install two parallel pins (34) into the pin holes of spindle (2).

162 161 SM2559

6.

Assembling shaft.

E

102

CAUTION 149

CAUTION: Wear thick leather gloves in handling the heated ball bearing (149).

D

1) Put ball bearing (149) in a heating tank to heat it at 90 to 110°C [194 to 230°F] for ten minutes and then insert it onto shaft (102), using holder (D) and a press (E).

SM2560

2) Turn the workbench by 90 degrees. 3) Insert shaft (102) to spindle (2). IMPORTANT: take care not to scratch or cut the lip portion of oil seal (132) in place with the splined foremost end of shaft (102).

102

SM2561

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Copyright © New Holland E135B

7.

TRAVEL DEVICE

Install oil seal (132). 1) Turn over travel motor. 2) Coat the lip of the oil seal with lithium grease and fix oil seal (132) into the oil seal hole in spindle (2), using retainer metal and a hammer.

132 149

3) Assemble the outer race (with roller) of bearing (149) into spindle (2).

2

SM2562

4) Insert swash plate (103) into spindle (2). NOTE: apply lithium grease on swash plate (103) where mating surface of spindle (2).Make sure that the locating pivots (167) of spindle (2) enter pivots' holes of swash plate (103). 8.

103

Assembling cylinder block interior

NOTE: - the sharp edge of snap ring (145) is turned and put into the entrance side of cylinder block (104). - Washer (110) which touches snap ring (145) turns and puts its sharp edge side into snap ring side.

SM2563

110 1) Insert washer (110), spring (114), washer (110) and snap ring (145) in that order into cylinder block (104).

114

2) Place cylinder block (104) on the press bench.

104 WARNING When mounting snap ring (145), if the tip of the pliers slips out of the hole of snap ring (145), snap ring (145) could jump out.

SM2564

NOTE: press force of spring (114) is 1128N (254 lbs) or more. Protect by covering cylinder block (104) with a vinyl sheet so the contact surface with timing plate (109) of cylinder block (104) does not get damaged.

109

3) Place holder (M) on washer (110), and while clamping with the press, fit snap ring (145) in the snap ring groove of cylinder block (104) with the snap ring pliers.

145 104 SM2565

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Copyright © New Holland TRAVEL DEVICE

9.

E135B

Assembling hydraulic motor 1) Put three rollers (151) into the holes of cylinder block (104) and place washers (111) and thrust balls (108) on them. 2) Fit nine piston assy to retainer plate (107). 3) Fit retainer plate (107) and 9 piston assy to cylinder block (104).

NOTE: match retainer plate (107) with the spherical part of thrust ball (108) and install them.

151 4) Assemble cylinder block (104) fitted with swash plate (103), thrust ball (108), washer (111),retainer plate (107), piston assy (105), (106) and roller (151), to shaft (102) that is placed level. (to make a hydraulic motor assy).

104 SM2566

105,106

107 108 111 104(151) SM2567

5) Installing cylinder block (104) into shaft (102). NOTE: install cylinder bock (104) into the spline of shaft (102) by aligning the spine hole with the spline of shaft (102).

104 SM2568

6) After installing cylinder block (104), turn it by hand and make sure that it fits properly. If not, inspect it. NOTE: cylinder block (104) is not flattered after installing it. If cylinder block (104) is flattered, thrust ball (108) is separated and GM motor does not rotate normally.

104

102 SM2569

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TRAVEL DEVICE

10. Installing parking brake.

115 NOTE: immerse friction plate (115) in hydraulic oil before fitting it.

104

1) Assemble separator plate (116) into the inner groove of spindle (2) that houses cylinder block (104). 2) Assemble three friction plates (115) and separator plates (116), by turns, into the outer groove of cylinder block (104) and into the inner groove of spindle (2). On that occasion, fix the friction plates first and then the separator plates.

SM2570

3) Fit O-rings (135), (139) to the O-ring grooves of piston (112). In that case, coat Orings (135), (139) with a thin film of grease. 4) Fitting piston (112) into spindle (2). NOTE: - if it is hard to fit the piston (112) into the spindle (2) due to the resistance of O-rings (135),(139), lightly tap the end face of the piston (112), using a plastic mallet. - Take care so as not to score the O-rings when installing the piston (112).

112 (135,139) 2 SM2571

11. Attaching two-speed spool. 1) Insert spring (366) and spool (363) into rear flange (301). 2) Fit O-ring (359) to plug (357). NOTE: apply grease to O-ring (359). 3) Attach plug (357) to rear flange (301). 4) Temporarily tighten plug (357) into rear flange (301) by hexagon wrench.

366 (363)

SM2572

357

301

SM2573

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Copyright © New Holland TRAVEL DEVICE

E135B

12. Attaching ball check part. 1) Fit two O-rings (358) to two plugs (352). NOTE: apply grease to O-ring (358). 2) Insert steel ball (353) into rear flange (301).

353 SM2574

3) Temporarily tighten plugs (352) into rear flange (301) by hexagon wrench.

352

301 SM2575

13. Attaching piston. 1) Fit two O-rings (383) to two plugs (380). NOTE: apply grease to O-ring (383). 2) Insert piston (381) into rear flange (301).

381 SM2528

3) Temporarily tighten plugs (380) into rear flange (301) by hexagon wrench.

301

380 SM2576

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TRAVEL DEVICE

14. Assembling brake valve parts in rear flange. 1) Insert spool (323) into rear flange (301).

301

NOTE: apply hydraulic fluid to spool (323) and insert it into rear flange (301). To insert spool (323), align the hole of rear flange (301) with spool shaft center so as to prevent the inner surface of rear flange (301) and the outer surface of spool (323) from being damaged due to interference. Otherwise internal leaks will occur after reassembly, resulting in performance deterioration of GM motor.

323 SM2577

2) Fit two O-rings (336) to two plugs (324). NOTE: apply grease to O-ring (336). 3) Attach washer (325) (2 pcs) and spring (328) (2 pcs) to plug (324) (2 pcs).

336

324 SM2578

4) Attach plug (324) (2 pcs) to rear flange (301). NOTE: when attach plug (324) to rear flange (301), insert carefully so as not to deform spring (328). 5) Temporarily tighten plug (324) (2 pcs) into rear flange (301).

SM2579

15. Assembling rear flange mounted parts. 1) Apply hydraulic fluid to ball bearing (150), and fit it into rear flange (301). 2) Insert two parallel pins (341) into the pin holes of rear flange (301). 3) Apply grease to the mating face of timing plate (109) in contact with rear flange (301) of timing plate (109).

150

SM2580

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Copyright © New Holland TRAVEL DEVICE

E135B

4) Fit timing plate (109) on rear flange (301) using parallel pins (341) as the guide. NOTE: fitting of timing plate (109) is carried out until timing plate (109) adheres to rear flange (301). Adhesion prevents from dropping timing plate (109) from rear flange (301) when mounting rear flange (301) on spindle (2).

109 SM2581

5) Mount ten springs (113) on the hole of rear flange (301).

113

NOTE: apply grease to springs (113) in order to prevent from dropping springs (113) from rear flange (301).

SM2582

16. Assembling rear flange. 1) Fit O-rings (32), (33) (2pcs) in the O-ring grooves of spindle (2).

32 33 NOTE: fit O-ring (32) without applying grease. If reassembled with grease applied, the grease may bleed from mating face of rear flange (301) and spindle (2) when GM motor is running. 2) Put 1.0 liters of hydraulic fluid in spindle (2). 3) Install rear flange (301) on spindle (2) so that two parallel pins (34) on spindle (2) enter the pin holes in rear flange (301). 4) Temporarily tighten hexagon socket bolts (343) (10 pcs) into spindle (2) by hexagon wrench.

SM2521

301

SM2583

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TRAVEL DEVICE

17. Tightening bolts. 1) Tighten hexagon socket bolt (343) (10 pcs) with the specified torque. : 102±15.7 Nm (75±11 lbf ft)

343 SM2584

2) Tighten plugs (324) with the specified torque. : 441±39.2 Nm (325±29 lbf ft)

SM2585

3) Tighten plugs (380) with the specified torque. : 58.8±9.8 Nm (43±7 lbf ft)

SM2586

4) Tighten plugs (352) with the specified torque.

352

: 12.3±2.4 Nm (9±2 lbf ft)

SM2587

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E135B

5) Tighten plugs (357) with the specified torque. : 98.1±19.6 Nm (72±14 lbf ft)

357 SM2588

18. Attaching relief valve assembly. 1) Attach relief valve assembly (203 others) (2 pcs) to rear flange (301).

203 SM2589

2) Tighten relief valve assembly (203 others) (2pcs) with the specified torque. : 98.1±19.6 Nm (72±14 lbf ft)

SM2590

19. Assembling 2nd stage planetary gears. 1) The workbench is rotated and the reduction gears side is turned upward. 2) Attach sun gear 2 (8) to carrier 2 (7). 3) Fasten three eyebolts to the tapped holes of carrier 2 (7). Place a wire sling and hook in the eyebolts, place carrier 2 assembly slowly in hub (1).

8 7 9 1

NOTE: when inserting carrier assembly 2, take care so as not to damage internal teeth of hub (1) by the edge of planetary gears 2 (9). SM2508

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TRAVEL DEVICE

NOTE: place carrier 2 (7) so that planetary gears 2 (9) should be located as the illustration on the left.

*

* Piping port ** Hole of 1st-2nd speed piston

**

SM2591

20. Attaching coupling. 1) Attach coupling (15) to shaft (102).

15

SM2507

21. Assembling 1st stage planetary gears. 1) Place carrier assembly 1, slowly in hub (1).

5 NOTE: when inserting carrier assembly 1, take care so as not to damage internal teeth of hub (1) by the edge of planetary gears 1 (5).

1

SM2592

2) Insert sun gear 1 (4) with aligning spline portion to coupling (15) first, then gear portion second.

4

NOTE: if the gear portion of sun gear 1 (4) does not engage with planetary gears 1 (5), lift carrier assembly 1 until the spline of sun gear 2 (8) is disengaged. Insert sun gear 1 (4) first, then engage the spline of sun gear 2 (8).

SM2505

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E135B

3) Place thrust plate (13) on carrier 1 (3).

13

SM2504

22. Assembling cover. 1) Apply "Loctite #515" to the mating surface of hub (1) for cover (14).

1

NOTE: "Loctite #515" should be applied around the mating surface without discontinuation.

SM2593

2) Fasten two eyebolts (A) to the tapped holes (PF1/2) of cover (14). Place a wire sling and hook in the eyebolts, place cover (14) on hub (1) with aligning the position of bolt holes.

A 14

SM2594

3) Apply "Loctite #242" to hexagon socket bolt (35) (12 pcs). Tighten hexagon socket bolts (35) (12 pcs) with the specified torque.

35 : 66.7±3.9 Nm (49±3 lbf ft)

SM2595

W3-2-39

Copyright © New Holland E135B

TRAVEL DEVICE

23. Filling lubrication oil. 1) Fill gear oil (lubrication oil) into the filling port. NOTE: supply 2.1 liters of gear oil Ambra Hypoide 90 - API GL 5

SM2596

2) Attach plugs (30) to ports of cover (14), tighten them with the specified torque. : 98.1±19.6 Nm (72±14 lbf ft)

14 24. Removing reassembled GM motor from the workbench. 1) Turn the workbench upside down. (The motor side of GM motor is turned up.) 2) Remove the bolts securing GM motor to the workbench. 3) Fasten two eyebolts M16 to spindle (2). 4) Place a wire sling and hook in the eyebolts, remove GM motor from the workbench with the crane.

W3-2-40

30

SM2597

Copyright © New Holland TRAVEL DEVICE

E135B

MAINTENANCE STANDARD Part maintenance standard 1.

Replace all seals Seal parts (O-ring, oil seal floating seal) should be replaced once disassembled even though no damage is observed.

2.

Maintenance criteria for wearing parts. 1) Replace any parts if they have severe damage on appearance. 2) Replace any parts if they have the following abnormalities. No. 1

PARTS HUB

TROUBLE

REFERENCE ALLOWANVALUE CE VALUE

• Severe damage on appearance. • Pitting on ring gear teeth.

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Clearance 0.05 mm (0.002")

Clearance 0.15 mm (0.006")

-

-

-

-

• Abnormal wear such as scoring. 2

SPINDLE

• Severe damage on appearance. • Abnormal wear such as scoring.

3,7 others

CARRIER ASSY

• Abnormal wear such as scoring.

4

SUN GEAR 1 SUN

• Pitting on ring gear teeth.

8

GEAR 2 PLANETARY

• Flaking on the outer race for needle roller bearing.

5

GEAR 1 PLANETARY

9

GEAR 2

24

ANGULAR BALL BEARING • Dent, flaking or uneven wear on contact surface.

301

REAR FLANGE

• Many scratch on sliding surfaces between spool (323) and piston (381).

102

SHAFT

• Abnormal wear on contact surface between oil seal (132). • Abnormal wear on spline.

103

SWASH PLATE

104

CYLINDER BLOCK

• Mark of sticking. • Abnormal wear on spline. • Abnormal wear on bore surface. • Scratch or uneven wear on sliding surface with timing plate (109).

105

PISTON ASSY

106

PISTON SHOE

107

RETAINER PLATE

• Abnormal clearance in the axial direction between piston (105) and shoe (106). • Abnormal wear on shoe (106). • Uneven wear on sliding surface with shoe (106). • Scratch or uneven wear on sliding surface with thrust ball (108).

108

THRUST BALL

• Uneven wear on sliding surface with retainer plate (107).

109

TIMING PLATE

• Sticking or uneven wear on sliding surface.

115

FRICTION PLATE

• Uneven wear on both contact surface.

116

MAITING PLATE

• Specified torque cannot be obtained. • Mark of sticking.

105

PISTON

• Scratch on sliding surface.

W3-2-41

-

-

Braking torque 206Nm (152 lbf ft) or over

Braking torque 206Nm (152 lbf ft) or over

-

-

Copyright © New Holland E135B

TRAVEL DEVICE

No. 149

PARTS

TROUBLE

BALL BEARING

• Dent, flaking or uneven wear on contact surface.

PISTON SHOE

• Uneven wear on both sliding surface.

150 161 162 323

• Abnormal wear on shoe (162). SPOOL

363

• Abnormal and uneven wear on the outer circumference.

REFERENCE ALLOWANVALUE CE VALUE -

-

-

-

-

-

-

-

• Severe scratch on the circumference. 381

PISTON

• Severe scratch on the circumference.

W3-2-42

Copyright © New Holland TRAVEL DEVICE

E135B

SPROCKET

PITCH

86.69 mm (3.413 in)

NUMBER OF TEETH

21

ROLLER DIA.

ø53.797 mm (2.1180 in)

PITCH DIA.

581.67 mm (22.900 in)

SPECIFICATION

Unit: mm (in)

B

171.45 (6.750) 86.69 ) (3.4130

R

(1

26 ) R 236 0

(*)

C

P.C.D 58 (22.9 1.67 )

A

.

(1 R26 .02 36 )

R

2.5 (0.0984)

8.25(0.3248)

SM2643

(*) Induction hardening on two dotted line IMPORTANT: consult NEW HOLLAND KOBELCO for any inquiries concerning welding procedures.

Unit: mm (in) No.

A

NAME

O.D. of sprocket

B

Width of sprocket teeth

C

O.D. of bottom

sprocket

STANDARD VALUE

REPAIRAB LELEVEL

SERVICE LIMIT

REMEDY

ø 594±2 (23.4±0.79)

ø 586 (23.1)

ø 584 (23.0)

Reinforcement weld, repair or replace.

54 (2.13)

52 (2.05)

Replace.

ø 516 (20.3)

ø 514 (20.2)

Reinforcement weld, repair or replace.

61+1 -3 (2.40+0.039 ) -0.118 ø 524.7 (20.66)

W3-2-43

Copyright © New Holland E135B

TRAVEL DEVICE

TOOL TABLE Ref.

A

Name

Drawing

Long eye bolt

SM2598

D

Retainer metal

SM2599

G

Press fit jig for main bearing SM2600

I

Floating seal fitting tool SM2601

W3-2-44

Copyright © New Holland TRAVEL DEVICE

Ref.

J

Name

E135B

Drawing

Floating seal fitting tool

SM2602

K

Floating seal fitting tool SM2603

L

Press fit jig for oil seal

SM2604

M

Retainer metal

SM2605

W3-2-45

Copyright © New Holland E135B

Ref.

N

TRAVEL DEVICE

Name

Drawing

Inserting jig for lock washer

SM2606

W3-2-46

Copyright © New Holland SWIVEL JOINT

E135B

REMOVAL AND INSTALLATION OF SWIVEL JOINT WARNING Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself. Preparation 1.

Park the machine on a firm, level surface.

2.

Cut-off the engine. Actuate the manual and pedal pilot valves to release any residual pressure from inside the hydraulic system. Press the valve located on the hydraulic oil tank to release any residual pressure present inside the tank itself.

3.

Remove hydraulic oil tank cap.

Removal NOTE: Attach labels or tags to hoses and adapters, to aid in assembly. 1.

Remove tubes (2 and 8) (PF1). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf•ft)

Remove tube (5 and 6) (PF1/2). : 27 mm : 78.5 ±5 Nm (57.9 ± 3.7 lbf•ft)

2.

3.

4.

Remove tubes (3 and 4) (PF1/4). : 19 mm : 29.4 ±5 Nm (21.7 ± 3.7 lbf•ft)

Remove tubes (1 and 7) (PF1). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf•ft)

60

W3-3-1

Copyright © New Holland E135B

5.

SWIVEL JOINT

Remove drain hose (2).



: 27 mm : 78.5 ±5 Nm (57.9 ± 3.7 lbf•ft) 6.



Remove hoses (4 and 6). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf•ft)

7.



Remove hoses (1 and 3). : 36 mm : 177 ±18 Nm (130.5 ± 13 lbf•ft)

8.

Remove hose (5). : 19 mm : 29.4 ±5 Nm (21.7 ± 3.7 lbf•ft)

  

60

9.

Loosen the stop nut (7) M20 of swivel joint and remove the screw (8) M24x140.





: 36 mm : 120 ±12 Nm (88 ±9 lbf•ft)

60

10. Remove drain hose (10).

10

: 19 mm : 29 Nm (21 lbf•ft)

SM2648

W3-3-2

Copyright © New Holland SWIVEL JOINT

E135B

11. Remove six screws (2) M10x25.



: 19 mm : 14.7 Nm (10.8 lbf•ft)



12. Remove clip (1). : 6.8 Nm (5.0 lbf•ft)



13. Remove seal (4).

 60

14. Attach eye bolt (5), lift it up temporarily, and remove three screws (6) M12x40. : 19 mm : 110 ±11 Nm (81.1 ±8.1 lbf•ft)



NOTE: swivel joint mass: 25 kg (55 lbs). Swivel joint mass: 65 kg (143 lbs) (Version with blade).



60

Installation NOTE: refer to “Removal” section above for wrench sizes and tightening torque. 1.

Proceed with the re-installation of the centre joint following the operation in reversed order with respect to the removal.

NOTE: swivel joint mass: 25 kg (55 lbs). Swivel joint mass: 65 kg (143 lbs) (Version with blade).

W3-3-3

Copyright © New Holland E135B

SWIVEL JOINT

SWIVEL JOINT DISASSEMBLY AND ASSEMBLY

G

G 5

6 Section G - G

SM2649

1 2 3 4 5 6

-

Body Stem Thrust plate Cover Seal assy Seal ring (Q.ty 5)

7 8

- O-Ring - Socket Bolt M8 x 20 (Q.ty 2) 30.4 Nm (22.4 lbf ft) 9 - Socket Bolt M8 x 30 (Q.ty 4) 30.4 Nm (22.4 lbf ft) 12 - Plug 13 - O-Ring (Q.ty 2)

W3-3-4

Copyright © New Holland SWIVEL JOINT

E135B

VERSION EQUIPPED WITH BLADE

12

2

13 1

6 7 11 8

3

9

4

SM2608

1 2 3 4 6

-

Body Stem Thrust plate Cover Seal ring (Q.ty 8)

7 8

- O-Ring - Socket Bolt M8 x 20 (Q.ty 2) 30.4 Nm (22.4 lbf ft) 9 - Socket Bolt M8 x 30 (Q.ty 4) 30.4 Nm (22.4 lbf ft) 11 - Plug PT 3/8 (Q.ty 2) 12 - Plug PT 1/8 13 - O-Ring (Q.ty 2)

W3-3-5

Copyright © New Holland E135B

SWIVEL JOINT

Disassembly The part numbers used in this disassembly procedure correspond to those of a construction drawing in the figure on page W3-3-4. 1. Mark cover (4) and body (1) with matching marks for convenient reassembly. 2.



  

Place a 'V' (A) block on a work bench, place a swivel joint set on the side, fix it and loosen socket bolt (9) by means of a pipe and wrench. Alternately, the swivel joint may be fixed by holding stem (2) in a vise.



$

: 6 mm

60

3.

Remove cover (4) from body (1) and draw out O-Ring (7) from cover (4).





60

4.

Loosen socket bolt (8) fastening thrust plate (3), in the same manner as the removing of the above-mentioned cover (4).

  

- When removing thrust plate (3) by fixing body (1), support stem (2) so it may not fall down. : 6 mm



60

W3-3-6

Copyright © New Holland SWIVEL JOINT

5.

Place body (1) on a 'V' (A)-block. Put a wooden block against stem (2) via the body so about half of the stem is covered by the wooden block (B) and knock it out using a mallet. By hitting out the stem over about 1/2 from the body, it can be easily pulled out by hand.

E135B

%

 

$

6.

60

Remove the O-rings (13).

( NOTE: Make sure the body (1) is not scored from the tip of the spatula (E). 7.



Remove the seal rings (6) by means of a spatula (E).

60

8.

Disassembling of the seal assy (5) (for version without blade only). Take off the slip rings (B) and (C) of the seals assy (5) by means of pin of screwdriver (A) and remove them from the grooves (D). The figure SM2652 on side shows the use of only one pin of screwdriver, but by using two screwdriver pins, these can be extracted with more sureness.

C

B

NOTE: Make sure the body (1) is not scored from the screwdriver (A).

1 A 5 D

SM2652

W3-3-7

Copyright © New Holland E135B

SWIVEL JOINT

Assembly

%

Prior to assembly, clean each parts (excluding the O- Ring and slipper ring), and arrange in the sequence of assembly. 1. Make sure that oil and grease remains have been completely removed. 2.

Apply grease on the groove, then insert the seal rings (6) by slightly-distorting the shape as shown in figure SM0904. Also, after inserting all of the seals, be certain that these are installed in the seal groove by use of the spatula.

3.

Apply hydraulic oil to O-ring (13) thinly and insert it into O-ring groove. Check the twist of Oring.

4.

Assembling of the seals ring (5) (for version without blade only). Slipper ring (B) is assembled, after first inserting the backup ring (C), by slightly-distorting the shape as shown in figure SM0904.

5.

Lightly coat the outer circumference of stem (2) and the inner surface of body (1) with grease or vaseline and slowly insert stem (2) into body (1).

NOTE: If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly. The clearance between body (1) and stem (2) is about 0.1 mm. Push stem straight along the shaft center.

60

2

13 5

6

1 SM2653

W3-3-8

Copyright © New Holland SWIVEL JOINT

6.

While holding stem (2) and body (1), match the hole of thrust plate (3) and the stem (2) hole.

7.

Next, after removing any oil from the thread of socket bolt (8), coat it with Loctite 242 and tighten to stem (2).

E135B







: 6 mm : 30.4 Nm (22.4 lbf•ft)

60

8.

After installing O-Ring (7) to cover (4) and aligning the matching marks of the cover (4) and body (1), coat socket bolt (9) with Loctite 242 and tighten it which will then complete assembly.



$  

: 6 mm : 30.4 Nm (22.4 lbf•ft)

60

W3-3-9

Copyright © New Holland E135B

SWIVEL JOINT

MAINTENANCE STANDARD

Allowable Limit (basis of judgment)

Item Sliding surface and sealed parts Sliding surface exception sealed parts Body, Stem Sliding surface ring

Cover

Sliding surface ring

Scored or something hurt it.

Remedy Replace

1.

Scored more than 0.1 mm.

Replace

2.

Scored less than 0.1 mm.

Repair with oil stone

1.

Wear more than 0.5 mm deep.

Replace

2.

Wear less than 0.5 mm deep.

Repair

3.

Scored less than 0.5 mm and able to repair.

Repair

1.

Wear more than 0.5 mm.

Replace

2.

Wear less than 0.5 mm.

Repair

3.

Scored less than 0.5 mm and able to repair.

Repair

1.

Protruded excessively from seal groove.

Replace (with back-up ring)

60

2.

Slipper ring narrower than 1.5 mm of seal groove, or narrower than back-up ring.

Replace (with back-up ring)

Slipper ring

PPPD[

60

3.

Worn unevenly more than 0.5 mm.

PPPD[

Replace (with back-up ring)

60

W3-3-10

Copyright © New Holland SWIVEL JOINT

E135B

Inspection after assembly After completion of assembly, inspection for oil leakage, pressure resistance, etc., using a device as shown in the figure on right. 1. High pressure port (A, B, C, D and F port). Install a directional valve (8) and pressure gauge (1) to the stem side port and body side port respectively, and while watching the pressure gauge (for high pressure) installed on the body side and also by regulating high pressure relief valve (7), gradually increase the pressure. When the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) and lock in the hydraulic oil in the swivel. At this time, keep stop valve (6) on the low pressure relief valve side closed for, at least, 3 minutes and check for any distortions, breakages or loosening. During the first minute, check for oil leakages and, in case of pressure drop, this shoul be the 10% of the pressure trapped. This check should be performed on each circuit. 2.

Low pressure port (E port). Similar to the high pressure port, install a directional valve and pressure gauge on each port of the stem side and body side. Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure) connected to the body side and also by regulating low pressure relief valve (5), gradually increase the pressure and check for outside leakage with a color check at a pressure of 0.49 MPa.







 







 60

123456789-

W3-3-11

Pressure Gauge Swivel Joint Stop Valve Hydraulic source Relief Valve for low pressure Stop Valve Relief Valve for high pressure Directional Valve Piping, etc.

Copyright © New Holland E135B

SWIVEL JOINT

NOTES:

W3-3-12

Copyright © New Holland TRACK ADJUSTER

E135B

REMOVAL AND INSTALLATION OF TRACK ADJUSTER (WITH FRONT IDLER) Before removing the track adjuster, the tracks and the front idler must be removed first. For removal and installation of the tracks and the front idler, refer to applicable removal/installation sections. In this section, the procedure starts on the premise that the tracks and the front idler have already been removed. Removal NOTE: Track adjuster assembly weight: 132.5 kg (292 lbs).

WARNING Be sure cables are anchored and the anchor point is strong enough to handle the expected load. Keep exposed personnel clear of anchor point and cables or chain. 1.

After swinging superstructure to 90° related to machine longitudinal centerline for easier access to track components, remove the front idler and track adjuster assembly from track frame by prying it out, using a pry bar shown in figure.

60

Installation WARNING Be sure cables are anchored and the anchor point is strong enough to handle the expected load. Keep exposed personnel clear of anchor point and cables or chain. 1.

As shown in figure, install the front idler and track adjuster into spring guide on track frame.

60

W3-4-1

Copyright © New Holland E135B

TRACK ADJUSTER

DISASSEMBLY AND ASSEMBLY TRACK ADJUSTER Disassembly Track Adjuster Be sure to thoroughly read "Precautions for Disassembly and Assembly" on page W1-1-1 before starting the disassembly work.

$

Be sure to use special tool (A) (380001029) for assembly / disassembly of the track adjuster. WARNING Prevent personal injury. The spring force of the track adjuster is extremely large. Thoroughly inspect the special tool for any damage. Carefully perform assembly work referring to the procedure below.

1.

Place a jack on the bottom of the track spring holder assembly (380001029).

2.

Loosen four nuts to remove the plate (A1).

60

: 46 mm

A1

SM2122

NOTE: track adjuster weight: 58.5 kg (129 lbs). 3.

Draw out piston (6) from grease cylinder (3) of the idler adjuster assy.

4.

Removing oil seal (8), seal (7) from grease cylinder (3).

1

4

5

2

3

8

7 6 9

10 SM2609

W3-4-2

Copyright © New Holland TRACK ADJUSTER

5.

E135B

Connect the track adjuster to a hoist using a lifting strap. Set the idler adjuster assy on the stand of the jig (A) (380001029), with its bracket side facing up. Remove the lifting strap.

SM2656

6.

Fit retainer plate (A1) tighten holding-down nuts alternately.

4

: 46 mm

5

A1

SM1820

7.

Press spring (2) lifting it with jack so that spring pin (4) can be removed. Loosen nut (5) and remove it.

2

: 85 mm

SM1821

W3-4-3

Copyright © New Holland E135B

8.

TRACK ADJUSTER

Allow the hydraulic jack to retract slowly till the spring is extended to its free length. Remove the retainer plate and take off bracket (1) and the cover (10). : 46 mm

1

10 SM2655

9.

Hook lifting eye nut (W) on grease cylinder (3) top end and hoist it. Then, remove the set of grease cylinder (3) and spring (2) using crane.

W 3

Free lenght of the spring: 427 mm (16.81 in)

2

SM1819

W3-4-4

Copyright © New Holland TRACK ADJUSTER

E135B

Assembly 1.

Insert grease cylinder (3) into spring (2) and attach lifting eye nut (W) to screw on the top end of the grease cylinder (3). Lift the grease cylinder by crane and place it in the center of the jig stand upright (380001029).

1

4

5

2

3

8

7 6 9

10 SM2609

W 3

2

SM1822

2.

3.

Install bracket (1) and the cover (10) on top of spring (2). Center the rod of grease cylinder (3) and the hole in bracket (1). Attach the retainer plate (A1) and its nuts. Fasten nuts evenly all around, and fix the idler adjuster assy to the jig body (380001029).

1 4 5

By means of a hydraulic jack compress spring (2) to the set length and screw nut (5) on the grease cylinder (3).

10

Set length of the spring: 354.8 mm (13.97 in) 4.

A1

Tighten nut (5) till the holes for spring pin (4) are aligned. Then fit spring pin (4). : 46 mm : 85 mm

3 2 SM2610

W3-4-5

Copyright © New Holland E135B

5.

TRACK ADJUSTER

Remove idler adjuster assy from jig (380001029).

NOTE: track adjuster weight:58.5 kg (129 lbs).

60

6.

Apply grease on the oil seal (8) and seal (7), then fit on the grease cylinder (3).

7.

Fill up grease in cylinder (3), remove the grease nipple from piston (6) in order to discharge the inside air, and press in the piston by hand. Direct grease nipple hole downward to make air discharge easier.

8.

Tighten grease nipple (X) to piston (6). : 19 mm : 58.8 ± 9.6 Nm (43.4 ± 7 lbf•ft)

3

8

7 6

X SM2612

W3-4-6

Copyright © New Holland TRACK ADJUSTER

E135B

MAINTENANCE STANDARD

Ref.

Item

Standard value

A

Installed length of spring

354.8 mm (14.0 in)

B

Free length of spring

Approx. 427 mm (16.8 in)

C

Stroke

39.4 mm (1.55 in)

D

Set length

686 mm (27.0 in)

E

Outside view of piston

Neither scoring nor rusting

F

Tightening torque of grease nipple

58.8 ± 9.6 Nm (43.3 ± 7 lbf•ft)

E

X

aa

C

F

A,B D X ｡ 35

8

7

1

Detail aa Section X - X SM2611

W3-4-7

Copyright © New Holland E135B

TRACK ADJUSTER

TOOL TABLE

TOOL NO.

DESCRIPTION

380001029

Jig stand track adjuster

FIGURE

SM2131

W3-4-8

Copyright © New Holland FRONT IDLER

E135B

DISASSEMBLY AND ASSEMBLY FRONT IDLER ASSY Disassembly NOTE: mass of front idler assembly with bracket: 74 kg (163 lbs). 1.

   

Remove plug (8) on the side of collar (3) to drain oil. : 5 mm

    60

2.



To remove pin (5) apply pin push bar (A) to the top of pin, and push out striking bar lightly by hammer.

$

60

Put idler on repair stand. Apply push-out jig on shaft (B), push out shaft (6) with collar (3), then remove collar (3).





3.



% 





60

* : Push with press

W3-5-1

Copyright © New Holland E135B

If removal of collar (3) on the opposite side is required, turn over front idler and proceed with the procedure described in the previous step.





4.

FRONT IDLER

% 



60

* : Push with press 5.

With idler (1) mounted on the stand, tap bushing (C) lightly by hammer, while placing the bushing drawing rod against the end face of bushing (2) evenly all round, till it comes out.

6.

Take out floating seals (4) from idler (1), collar (3). If you intend to re-use floating seals (4), confirm that there is no scoring and rusting on the contact surface and store the floating seals in pairs by placing card board between the sealing faces.

7.

Separate O-Ring (7) from shaft (6).



&



60

W3-5-2

Copyright © New Holland FRONT IDLER

E135B

Assembly Align inner hole of idler (1) and bushing (2) and press fit it vertically with jig (D) and press, so that bushing is correctly press-fitted into the idler.





'



1.



60

* : Push with press 2.

Fit O-Ring (7) to O-Ring groove on shaft (6).

3.

Press fit the O-Ring installed side of shaft (6) into collar (3), and drive pin (5).

4.

Fit the half of floating seal (4) on each side of collar (3) and idler (1).

   

60

5.

6.

Install idler (1) on the shaft (6) with the floating seal (4) fitted into shaft (6) with the toward collar (3).

 

Fit floating seal (4) on the other side of idler (1).



60

7.

8.

Fit the half of floating seal (4) on the other collar (3), press fit it in shaft (6), and drive pin (5) in with hammer. Fill in 200 cm³ (12.2 cu·in) of engine oil API-CD # 30 through the plug hole of collar (3), wind seal tape and tighten plug (8).



 



: 5 mm NOTE: after installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating seal and plug (8) and that idler (1) rotates smoothly. 60

W3-5-3

Copyright © New Holland E135B

FRONT IDLER

MAINTENANCE STANDARD Front idler

 &

'

%

$

(

)

60

Unit: mm (in) No. A

ITEM Dia. of idler projection

STANDARD VALUE

ALLOWABLE LIMIT

SERVICE LIMIT

-

-

ø 496 (19.5)

B

Tread dia.

ø 456 (18.0)

ø 450 (17.7)

ø 448 (17.6)

C

Flange width

68 ± 1 (2.677±0.04)

63 (2.48)

60 (2.36)

D

Clearance between shaft and bushing

E

F

Interference between idler and bushing

Nominal size

Clearance

Fit

Fit

ø 60 (2.36220)

0.03 (0.00118) 0.06 (0.00236)

Clearance 1.5 (0.059)

Clearance 2.0 (0.079)

Nominal size

Interference

Fit

Fit

ø 64 (2.51969)

0.03 (0.00118) 0

Interference 0

Clearance 0.01 (0.0004)

REMEDY Replace

Replace bushing

Oil

Engine oil: API grade CD #30; Q.ty: 200 cm3 (12.2cu•in)

Refill

Idler rotation

Rotates smoothly by hand

Reassemble

W3-5-4

Copyright © New Holland FRONT IDLER

E135B

TOOL TABLE Unit: mm (in) NAME

DRAWING

A

30 (1.18)

15 (0.591)

No.

Pin (5) striking jig

15 (0.591)

105 (4.13)

59 (2.32)

SM2659

300 (11.8) B

Shaft (6) push out jig

16 (0.630)

SM2660

300 (11.8)

C

Bushing (2) drawing rod

Bushing (2) press fitting jig

75 (2.95)

D

55 (2.17)

70 (2.76)

20 (0.787)

SM2661

60 -0.030 -0.060 (2.36 -0.001 -0.002 )

W3-5-5

SM2662

Copyright © New Holland E135B

FRONT IDLER

NOTES:

W3-5-6

Copyright © New Holland UPPER AND LOWER ROLLER

E135B

REMOVAL AND INSTALLATION OF UPPER ROLLER Removal

WARNING Do not loosen valve (1) quickly or loosen it too much as high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2).

IMPORTANT: when gravel or mud is packed between sprockets and tracks, remove it before loosening.

1.

60

Loosen valve (1) to drain grease. : 19 mm

 

60

WARNING



Insert a piece of non-sliding rag between track frame (5) and hydraulic jack to prevent that the latter slides.

2.

Lift track chains (3) with the hydraulic jack to a height sufficient to remove upper roller (4).

 60

3.

Insert a wooden block between tracks (3) and track frame (5).



 W3-6-1

60

Copyright © New Holland E135B

4.

UPPER AND LOWER ROLLER

Loosen and remove the nut (3); remove the washer (4) and the screw M20 (2).

3

4

: 30 mm

5.

Remove the upper roller complete with support (1) extracting the shaft from the collar of the lower frame.

1

2 NOTE: upper roller mass: 9 kg (20 lbs).

SM2664

Installation 1.

Prior to the installation, check that the roller turns freely by hand and there are no leaks.

3

4

2

NOTE: upper roller mass: 9 kg (20 lbs).

2.

Insert the roller (1) until the collar contacts the support.

3.

Position the support roller directing the mark of bevel (S) on the shaft end, upward.

4.

Insert the screw M20 (2), the washer (4), the nut (3) and tighten it to the specified torque.

S

1

: 30 mm : 570 ± 30 Nm (420 ± 22 lbf•ft)

5.

SM2672

Remove the wooden blocks and the hydraulic jack.

60

W3-6-2

Copyright © New Holland UPPER AND LOWER ROLLER

6.

E135B

Tighten valve (1). : 19 mm : 58.8 ± 9.6 Nm (43.3 ± 7 lbf•ft)

7.

Supply grease to valve (1) tension.

to adjust tracks

Track sag specifications (A): 320 ÷ 350 mm (12.60 ÷ 13.78 in)

NOTE: check track sag after thoroughly removing soil stuck on the track area by washing.

 

60

60

W3-6-3

Copyright © New Holland E135B

UPPER AND LOWER ROLLER

REMOVAL AND INSTALLATION OF LOWER ROLLER Removal 1.

Remove the roller guard and loosen bolts (5). : 24 mm



60

2.

Lift the one side of the track frame high enough to remove the lower roller. Insert wooden blocks under track frame (2).

 60

WARNING Do not loosen valve (3) quickly or loosen it too much as high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (3). Never loosen grease fitting (4).

60

3.

Loosen valve (3) to drain grease enough to permit the roller removal. : 19 mm

  W3-6-4

60

Copyright © New Holland UPPER AND LOWER ROLLER

4.

E135B

Securely hold the lower roller using a fork lift. Remove lower roller (1).

NOTE: lower roller mass: 26 kg (57.3 lbs).

 60

Installation 1.

Securely hold the lower roller using a fork lift. Put lower rollers (1) on the tracks as illustration.





60

2.

Lower track frame (2) enough to allow bolts (4) to be installed into track frame (2).





60

3.

Align tapped holes in track frame (2). Tighten bolts M16x75 (4). : 24 mm : 320 ± 30 Nm (236 ± 22 lbf•ft)



60

W3-6-5

Copyright © New Holland E135B

4.

UPPER AND LOWER ROLLER

Tighten valve (1). : 19 mm : 58.8 ± 9.6 Nm (43.3 ± 7 lbf•ft)

5.

Supply grease to valve (3) throught nipple (4) to adjust tracks tension. Track sag specifications (A): 320 ÷ 350 mm (12.60 ÷ 13.78 in)

NOTE: check track sag after thoroughly removing soil stuck on the track area by washing.

 

60

60

W3-6-6

Copyright © New Holland UPPER AND LOWER ROLLER

E135B

DISASSEMBLY & ASSEMBLY OF THE UPPER ROLLER

1

3

5

10

7

4

6 12

2

9

11

8 SM2613

123456-

Roller Shaft Floating seal Plug Thrust washer Cover

7 - Screw M8 x 20 (Q.tà 2) 8 - O-ring 9 - Bushing 10 - Lock plate 11 - Collar 12 - Snap ring

W3-6-7

Copyright © New Holland E135B

UPPER AND LOWER ROLLER

Disassembly Be sure to thoroughly read "Precautions for Disassembly and Assembly" on page W1-1-1 before starting the disassembly work.

12

4

8 7

1.

6

Remove plug (4) and drain out oil.

5

10

: 6 mm

1 2.

Mount upper roller assy on the support (A) and remove snap ring (12) using snap ring pliers.

3.

Take off cover (6) upwards.

4.

Separate O-Ring (8) from cover (6).

A 5.

Unscrew the two screws (7), remove lock plate (10) and draw out thrust washer (5), from the roller (1). : 12 mm SM2614

6.

Put the extrusion jig (B) against the end face of shaft (2) and push shaft with collar (11) for floating seal (3), using a press or hammer.

B

2 3 11

A

SM2615

W3-6-8

Copyright © New Holland UPPER AND LOWER ROLLER

7.

E135B

Take out floating seal (3) from roller (1).

3

1

SM2616

8.

Remove from collar (11), floating seal (3) that is located on the side from which shaft (2) was disparted.

2 IMPORTANT: collar (11) is press fitted into shaft (2) by means of press.Therefore do not disassemble it.

3 11

SM2617

9.

Since the bushing is thin, machine it on a lathe or scrape it off, exercise care so as not to damage the bore of roller (1). If the bushing is not worn much, mount upper roller (1) on jig stand jig (A), insert jig extrusion jig (C) into the end face of bushing (9) and push it out with a press.

C

9 1

A

SM2618

W3-6-9

Copyright © New Holland E135B

UPPER AND LOWER ROLLER

Assembly 1.

Assembly of the upper roller is done in the reverse order of disassembly.

2.

Place upper roller (1) on the top end face of stand jig (A), with its floating seal setting side facing down.

D

Confirm that the outer surface of bushing (9) is not seized and coat the outer surface of the inserting side of the bushing, with molybdenum disulfide grease.

9

3.

4.

1

Put extrusion jig (D) into bushing (9) and press it in, using the bore of the bushing and the bore of the roller as guides.

A IMPORTANT: if you fail in this operation by pressing the bushing unevenly, the bushing (9) is distorted and gets unserviceable. In that case, do not re-use the bushing as it may develop malfunctioning after assembly.

SM2619

IMPORTANT: for handling of floating seal (3), refer to the section "Precautions for floating seal handling" on page W1-1-3.

2 5.

Two floating seals (3) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1). - Prior to placing floating seal (3) in, apply engine oil lightly to seal surface.

3 11

SM2617

3

1

SM2616

W3-6-10

Copyright © New Holland UPPER AND LOWER ROLLER

6.

Coat shaft (2) with a thin film of oil and insert it into upper roller (1).

E135B

 2

1

SM2620

7.

Mount roller (1) on the support (A), mount the thrust washer (5), then install the lock plate (10) and the screw (7). Bend both ends of lock plate (10) by 90° to contact flats of screw heads (7). : 12 mm

4

: 30 ± 4 Nm (22.1 ± 2.95 lbf•ft)

7

8

10 8.

12

6 5

Fit O-Ring (8) to the groove of cover (6).

1 NOTE: apply grease to O-Ring.

9.

Install the cover (6) into roller (1) and fix snap ring (12) using snap ring pliers. : 19 mm : 132.5 ± 10.5 Nm (97.7 ± 7.7 lbf•ft)

A

SM2614

W3-6-11

Copyright © New Holland E135B

UPPER AND LOWER ROLLER

10. Fill in 34 cm3 (1.92 cu•in) of engine oil API grade CD #30 through the plug hole (4).

11. Wind seal tape around plug (4) and tighten it to the specified torque. : 6 mm

4

: 12 ± 2 Nm (8.85 ± 1.47 lbf•ft) NOTE: after assembling the upper roller, confirm that oil is not leaking from it and that it rotates smoothly by.

A

SM2621

W3-6-12

Copyright © New Holland UPPER AND LOWER ROLLER

E135B

A

E

D

F

UPPER ROLLER MAINTENANCE STANDARD

B

C

SM2677

Unit: mm (in) No.

ITEM

STANDARD VALUE

ALLOWABLE SERVICE LIMIT LIMIT

A

Diameter

ø 99 (3.90)

ø 95 (3.74)

ø 91.5 (3.60)

B

Width

140 (5.51)

-

-

C

Installing length

60

-

-

(1.5748 +0.00098)

-

-

40+0.025 -0

D

Shaft dia.

E

Clearance Nominal size between shaft and ø 40 (1.5748) bushing

Clearance

Fit

Fit

0.365 (0.01437) 0.287 (0.0113)

Clearance 0.7 (0.028)

Clearance 1.0 (0.039)

Interference Nominal size between roller and ø 47 (1.8504) bushing

Interference

Fit

Fit

0.170 (0.00669) 0.07 (0.00275)

Interference 0

Clearance 0.01 (0.0004)

F

ø

REMEDY Replace

Replace bushing

Oil

Engine oil: API grade CD #30; Q.ty: 34 cm3 (1.92 cu•in)

Refill

Roller rotation

Rotates smoothly by hand

Reassemble

W3-6-13

Copyright © New Holland E135B

UPPER AND LOWER ROLLER

TOOL TABLE FOR UPPER ROLLER Unit: mm (in) Ref.

Name

Drawing

+

+ 0.04

85 1 (3.35

A

)

Support jig

160 (6.30)

100 (3.94)

SM2622

B

30 (1.18)

38 (1.50)

Shaft extruding jig

Bushing extruding jig 60 (2.36)

0

0

40 -0.025 0 (1.57-0.001)

C

45 -0.025 0 (1.77-0.001)

59 (2.32)

SM2674

30 (1.18)

130 (5.12)

Bushing fixing jig

0

0

40 -0.025

(1.57-0.001)

D

57 (2.24)

SM2675

40 (1.57) 80 (3.15) SM2676

W3-6-14

Copyright © New Holland UPPER AND LOWER ROLLER

E135B

DISASSEMBLY & ASSEMBLY OF THE LOWER ROLLER

5

2

6

5

4

7

8

3

1

2

SM2623

1234-

Plug Collar (Q.ty 2) Pin (Q.ty 2) O-Ring (Q.ty 2)

5678-

W3-6-15

Floating Seal (Q.ty 2) Bushing (Q.ty 2) Roller Axle

Copyright © New Holland E135B

UPPER AND LOWER ROLLER

Disassembly Be sure to thoroughly read “Precautions for Disassembly and Assembly” on page W1-1-1 before starting the disassembly work.

3

1.

2

Prepare an oil container beforehand. Remove plug (1) and drain out oil [approx. 190 cm3 (11.59 cu.in)]. Remove pins (3) from collars (2).

1

: 8 mm : 8 mm

NOTE: mass of the lower roller 26 kg (57.3 lbs). 2.

SM3002

Put lower roller on jig (A) for repair stand so that the shaft (8) is perpendicularly located, apply push-out jig (B) on shaft end on upper side, and push shaft (8) until the O-ring (4) separate from collar (2) with press or mallet.

B 4 2

3.

Take out collar (2) and remove the O-ring (4) from the shaft (8).

4.

In addition, push out and remove shaft (8) together with the lower collar (2) from the roller (7).

7 8 A

NOTE: the shaft (8) extrusion operation may cause the remaining lube oil to flow out. Prepare an oil container beforehand. 5.

SM3001

Remove floating seal (5) from collar (2).

5

2

SM3003

W3-6-16

Copyright © New Holland UPPER AND LOWER ROLLER

6.

E135B

Remove floating seal (5) from roller (7).

5

7

SM3004

7.

Removing bushing (6). Since thickness of bushing (6) is thin [thickness is 3.3 mm (0.130 in)], remove it through lathe or strip it with care, in order not to damage inner hole of roller. When the wear of bushing is not large, place upper roller (7) on jig (A) for repair stand and apply the end of push-out jig (C) on the end face of bushing (6), and push it out striking it with mallet.

IMPORTANT: hammer the inside surface of roller lightly so as not to damage the surface. Put the extrusion jig (C) uniformly over the circumference of bushing (6) and extrude it perpendicularly little by little.

W3-6-17

C 7

6 A SM3005

Copyright © New Holland E135B

UPPER AND LOWER ROLLER

Assembly 1.

Grease O-ring (4) and install it to groove on shaft (8).

8

4

NOTE: replace O-ring with new one without fail at reassembling.

SM3006

2.

Fit bushing (6) into jig (D), align inner hole of roller (7) and bushing (6) and press fit it vertically into the idler, using a press with a 5 ton (11000 lbs) load.

D

6

NOTE: apply molybdenum disulfide grease on press fit section of bushing, and press fit it in ordinary temperature.

SM3007

3.

Fit O-ring (4) to the one side of shaft (8) mating pin hole of collar (2) on which floating seal (5) is fit with pin hole of shaft (8) in advance. Use the press of capacity 17 ton (37500 lbs) or more.

NOTE: care should be taken not to damage O-ring (4) while press-fitting collar (2) to shaft (8).

2 5 4 8 SM3008

4.

Press-fit pin (3) to pin hole on aligning pin holes of shaft (8) and collar (2).

3 8

5

W3-6-18

4

2 SM3010

Copyright © New Holland UPPER AND LOWER ROLLER

5.

E135B

Fit floating seals (5) to inner holes on both ends of roller (1).

NOTE: check that the seal surface is free from flaws, rusts, etc. before reusing the floating seal.

7 5

8 6.

Insert roller (7) from the side where collar (2), is not press-fitted to the shaft (8).

2

SM3011

NOTE: replace O-ring (4) with new one without fail at reassembling. 7.

Grease O-ring (4) and install it to groove on shaft (8).

2

4 8.

Press-fit collar (2) to shaft (8).

NOTE: press-fit collar (2) on aligning pin (3) hole.

8

9.

Press-fit pin (3) to pin hole on aligning pin holes of shaft (8) and collar (2).

10. Fill in 190 cm3 (11.59 cu.in) of oil "VEEDOL 903 S3-30" or engine oil API grade CD #30 . SM3012

11. Installing plug (1) and tighten it to the specified torque. ·: 6 mm

1

: 12 ± 2 Nm (8.8 ± 1 lbf ft)

2

SM3013

W3-6-19

Copyright © New Holland E135B

UPPER AND LOWER ROLLER

LOWER ROLLER MAINTENANCE STANDARD

206 0,90 (8.110 0.035)

E

D

C

B

A

C

SM3014

Unit: mm (in) No.

ITEM

STANDARD VALUE

ALLOWABLE SERVICE LIMIT LIMIT

A

Diameter of flange ø 170 (6.693)

B

Treat diameter

ø 140 (5.512)

ø 132 (5.20)

ø 126 (4.96)

C

Flange width

18 (0.708)

14 (0.551)

11 (0.433)

50+0.0 -0.10

-

D

Shaft dia.

E

Clearance Nominal size Clearance between shaft and ø 50 (1.96850) 0.350 bushing (0.01378) 0.450 (0.01771)

F

ø

(1.9685 - 0.00394)

Interference Nominal size Interference between roller and ø 57 (2.24409) 0.115 bushing (0.00453) 0.035 (0.00138)

-

-

-

Fit

Fit

Clearance 0.7 (0.0276)

Clearance 1.0 (0.0394)

Fit

Fit

Interference 0

Clearance 0.01 (0.0004)

REMEDY Replace

Replace bushing

Oil

Engine oil: VEEDOL 903 S3-30 API grade CD #30; Q.ty: 190 cm3 (11.59 cu•in)

Refill

Roller rotation

Rotates smoothly by hand

Reassemble

W3-6-20

Copyright © New Holland UPPER AND LOWER ROLLER

E135B

TOOL TABLE FOR LOWER ROLLER Unit: mm (in) Ref.

Name

Drawing

110 (4.33)

A

Support jig

290 (11.40)

140 (5.51)

SM2626

B

Shaft extruding jig

49 (1.93)

270(10.6)

SM3009

C

Bushing extruding jig

16 (0.630)

200 (7.87)

SM3015

Bushing fixing jig

52 (2.05)

D

77 (3.03)

70 (2.76)

50 +0.1 0 (1.97 +0.004 ) 0

W3-6-21

SM3016

Copyright © New Holland E135B

UPPER AND LOWER ROLLER

NOTES:

W3-6-22

Copyright © New Holland TRACKS

E135B

REMOVAL AND INSTALLATION OF TRACKS Removal

WARNING Do not loosen valve (1) quickly on loosen too much since high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2).

60

1.

Move the tracks so that master pin (3) is positioned over front idler (4). Put a wooden block under track shoes (5), as shown.







60

2.

To loosen the track tension, slowly turn valve (1) counterclockwise one turn; grease will escape from grease outlet. : 19 mm

 

W3-7-1

60

Copyright © New Holland E135B

TRACKS

WARNING The front idler may jump out of position due to strong spring force when the tracks is disconnected. Especially, the strong spring force is always applied to the bolt part of the rod. If the rod and/or the bolt are damaged, metal fragments may fly off when the tracks is disconnected.

60

3.

Remove master pin (3) by using a special tool.



A: 380001008 B: 380001936 C: 380001935 D: 380001807 E: 380001937 G: 380001019 3: MASTER PIN

60

' &

*

%



(

$ 60

4.

Slowly drive the machine in reverse until the whole length of the removing track comes on the ground.

60

5.

Rotate the upperstructure 90 degrees toward the removing track side, perpendicular to the tracks. Operate the boom and arm so that the angle between them is 90 to 110 degrees. Lower the boom with the bucket rolled-in to jack up the machine as illustrated.

ƒƒ

60

W3-7-2

Copyright © New Holland TRACKS

E135B

Installation 1.

Jack up the machine and put the track under the lower roller. Be sure to position the track in correct direction, as illustrated.

;