CNH E805 Tier 3 Manual

Crawler excavators

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DIVISION/SECTION

GENERAL INFORMATION

Safety, general information and standard torque data .....................................1001

General specifications and special torque setting............................................1002

ENGINE

Radiator and engine, removal and installation .................................................2001

Engine specifications ............................................................................................. *

Disassembly and assembly of the engine.............................................................. *

FUEL SYSTEM

Fuel tank ..........................................................................................................3001

Fuel engine system................................................................................................ *

ELECTRICAL SYSTEM

Electrical system, electrical and electronic troubleshooting.............................4001

Inspection and maintenance of batteries and connecting a booster battery....4002

Main and engine electronic control boxes........................................................4003

UNDERCARRIAGE

Removal and installation of tracks ...................................................................5001

Rollers..............................................................................................................5003

Sprocket ...........................................................................................................5004

Idler wheel and tension shock absorber ..........................................................5005

DRIVE TRAIN

Drive motor and final drive transmission removal and installation ...................6001

Drive motor and final drive transmission disassembly and assembly ..............6002

Swing reduction gear, removal and installation................................................6003

Swing reduction gear, disassembly and assembly...........................................6004

UNDERCARRIAGE HYDRAULICS

UPPERSTRUCTURE HYDRAULICS

Depressurising and decontaminating the hydraulic system, use of the

vacuum pump and bleeding the components ..............................................8000

Specifications, troubleshooting, checks and hydraulic pressure settings.........8001

Hydraulic reservoir removal and installation ....................................................8002

Main and pilot pumps, removal and installation ...............................................8003

Main hydraulic control valve, removal and installation .....................................8004

Attachment cylinders, removal and installation ................................................8005

Hydraulic swivel, removal and installation........................................................8006

Pilot blocs, removal and installation .................................................................8007

Swing motor, removal and installation..............................................................8008

Main hydraulic pump, disassembly and assembly ...........................................8010

Main hydraulic control valve, disassembly and assembly ................................8011

Attachment cylinders, disassembly and assembly...........................................8012

Hand control levers, disassembly and assembly .............................................8013

Foot control levers, disassembly and assembly ...............................................8014

Six-solenoid valves, disassembly and assembly..............................................8015

Caution valve, disassembly and assembly.......................................................8016

Safety valve......................................................................................................8017

Hydraulic swivel, disassembly and assembly...................................................8018

Swing motor, disassembly and assembly ........................................................8019

Hydraulic functions...........................................................................................8020

CNH

E805 Tier 3 Crawler Excavators

Table of Contents

Lep 9-42691EN

SECTION Nq

REFERENCE Nq

7-27691EN

9-94710EN

9-94910EN

9-36821EN

9-94700EN

9-36830EN

9-94510EN

9-36860EN

9-36881EN

9-36890EN

9-94350EN

9-36980EN

9-40351EN

9-36991EN

9-42631EN

9-94430EN

9-94740EN

9-94490EN

9-40771EN

9-94501EN

7-27792EN

9-94600EN

9-94520EN

9-94420EN

9-94590EN

9-94781EN

9-40941EN

9-94630EN

9-40992EN

9-42521EN

9-94531EN

9-42770EN

9-42511EN

9-42530EN

9-94720EN

Printed in France

September 2006

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Page 1 E805 Tier 3 Crawler Excavators Table of Contents DIVISION/SECTION SECTION Nq REFERENCE Nq GENERAL INFORMATION Safety, general information and standard torque data ........1001 7-27691EN General specifications and special torque setting..........1002 9-94710EN ENGINE Radiator and engine, removal and installation ..........2001 9-94910EN Engine specifications .....................
Page 2 * Consult the Engine Service Manual Sections to be distributed at a later date NOTE: CNH Company reserves the right to make changes in the specifi- cation and design of the machine without prior notice and without incur- ring any obligation to modify units previously sold.
Page 3 Section 1001 SAFETY, GENERAL INFORMATION AND TORQUE SPECIFICATIONS Copyright ” 2006 CNH France S.A. Printed in France Lep 9-94880EN June 2006 Find manuals at https://best-manuals.com...
Page 4 1001-2 TABLE OF CONTENTS GENERAL INFORMATION ............................3 SAFETY..................................4 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS................6 WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message that follows, as there is a risk of serious injury. Lep 9-94880EN Issued 06-06 Find manuals at https://best-manuals.com...
Page 5 1001-3 GENERAL INFORMATION Cleanning Gears Clean all metal parts except bearings, in a suitable Check all gears for wear and damage. Replace gears cleaning solvent or by steam cleaning. Do not use that have wear or damage. caustic soda for steam cleaning. After cleaning, dry Oil seals, O-rings and gaskets and put oil on all parts.
Page 6 1001-4 SAFETY This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death. To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the WARNING: Before starting engine, study manual.
Page 7 1001-5 WARNING: When servicing or repairing the WARNING: Use insulated gloves or mittens machine, keep the shop floor and operator’s when working with hot parts. compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use WARNING: Lower all attachments to the safe practices at all times.
Page 8 1001-6 STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS Tightening of cap screws, nuts Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the order of tightening. JS00481A Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or suitable cleaning solvent and dried.
Page 9 Section 1002 SPECIFICATIONS AND SPECIAL TORQUE SETTINGS Copyright ” 2006 CNH France S.A. Printed in France Lep 9-94870EN June 2006 Find manuals at https://best-manuals.com...
Page 10: Table Of Contents
1002-2 TABLE OF CONTENTS WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this symbol, carefully read the message which follows. Your safety depends on it. TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE....................3 FLUIDS AND LUBRICANTS .............................
Page 11: Type, Serial Number And Year Of Manufacture Of The Machine
1002-3 TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE When ordering parts, obtaining information or assistance, always supply your NEW HOLLAND service specialist with the type and serial number of your machine or accessories. Write the following in the spaces below: the type, serial number and year of manufacture of your machine, accesso- ries and the serial numbers of the various hydraulic and mechanical components.
Page 12: Fluids And Lubricants
1002-4 FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application. WARNING: The conditions of use for individual fluids and lubricants must be respected. Hydraulic fluid AMBRA hydraulic fluid is specially designed for high pressure applications and for the NEW HOLLAND hydraulic system.
Page 13 1002-5 Engine Oil AMBRA MASTERGOLD HSP is recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions. If the AMBRA MASTERGOLD HSP cannot be obtained, use the oil corresponding to one of the fol- lowing categories: (SAE 15W-40 - NH 330 H - API CH-4 - ACEA E5) AMBRA...
Page 14 1002-6 Fuel Use fuel which is to ASTM (American Society for Testing and Materials) 975 standard. Use grade No. 2-D fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.
Page 15 1002-7 Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing. AMBRA AGRIFLU (NH 900 A) For areas where the temperature goes down to -38°C, mix 50/50 with water. IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the system.
Page 16: Specifications
1002-8 SPECIFICATIONS Main data Model name........................CX800 Hydraulic Excavator Operating weight ........................80300 kg (177031 lbs) Engine output ..........................397 kW / 1800 rpm Performance Standard weight..........................43.2 kN (9711 lbf) Swing speed ...............................6.4 Tr/min. Travel speed......................Low Speed 2.9 km/h (1.80 mph) ..........................
Page 17 1002-9 Engine Name ..............................ISUZU, 6WG1X Type: 4-cycle, water-cooled, overhead camshaft, common rail injection (electric control), with air-cooling type inter-cooler turbo with air-cooling. No. of cylinders - bore x stroke ..............6-dia. 147 mm x 154 mm (5.78 x 6.06 in) Displacement.............................15.7 L (4.15 gal) Compression ratio ..............................16 Rated output ........................
Page 18 1002-10 Operating devices Operator's seat Location; left side Structure; low frequency air suspension with helical springs and double acting hydraulic damper. Smooth and round shape design cab, fabricated by press work Safety glass for all windows. Levers and pedals For travel use; levers and pedals (hydraulic pilot type) (2) For operating machine use;...
Page 19 1002-11 Hydraulic system Hydraulic pump drive system, directly coupled to the engine (no transmission) Main pump Manufacturer ............................Kawasaki Pump type ..................double variable displacement piston pump Displacement ...................... 278 cm (16.96 cu in) X 2 /rev Rated operating pressure ....................31.4 MPa (4555 psi) Maximum operating pressure .....................34.3 MPa (4975 psi) Input revolution speed........................1850 min-1 Maximum flow ................
Page 20 1002-12 Rotating Joint Operating pressure High pressure passage (ABCD)..................34.4 MPa (4989 psi) Drain port (E) ..........................1.0 MPa (145 psi) Pilot port (F) ..........................3.9 MPa (566 psi) Hydrostatic test pressure High pressure passage (ABCD)..................51.5 MPa (7470 psi) Drain port (E) ........................2.0 MPa (290 psi) Pilot port (F) ..........................
Page 21 1002-13 Digging force (New JIS) Bucket digging force (Standard power boost) Standard ........................... 430 kN (96667 lbf) Power boost ..........................470 kN (105660 lbf) Arm (dipper) digging force (Standard boom specifications) Standard 2.98 m arm ........................... 317 kN (71264 lbf) Power boost 2.98 m arm ...........................
Page 22 1002-14 Work Unit Model; backhoe attachment Capacity / dimensions / working dimensions Boom length (Standard boom spec.) ....................... 7700 mm Boom length (Mass boom spec.) ......................6580 mm Standard boom Mass boom Standard arm Long arm Super long (3.66 m) (4.44 m) arm (5.62 m) Arm length...
Page 23 1002-15 Reference Values Numerical values for performance may change without notice due to product improvement. Reference Items Conditions values Idling 900 ± 10 Mode: H Engine speed (min Maximum without load 1870 ± 10 Standard 31.4 ± 1.0 Main Relief Boosting 34.3 ±...
Page 24: Component Weight
1002-16 COMPONENT WEIGHT Major component weight 700-3-01-00-45A Weight information is approximate 1) Overhall machine ......................80000 kg (176369 lbs) 2) Machine without attachment .................... 63000 kg (138891lbs) 3) Upperstructure assembly ....................25200 kg (55556 lbs) 4) Counterweight ........................12500 kg (27560 lbs) 5) Side Frame 650 mm (25.6 in) (47 shoe) ................
Page 25 1002-17 Other component weight Engine ........................Approximately 1214 kg (2676 lbs) Air cleaner ............................40.3 kg (89 lbs) Hydraulic pump........................... 300 kg (661lbs) Attachment control valve ........................430 kg (948 lbs) Swing motor and reduction gear assembly (2) ................487 kg (1074 lbs) Travel motor and reduction gear assembly ..................
Page 26: Dimensions And Wear Limit Of The Track Assembly
1002-18 DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY Sprocket Dimensions 800-6-10-00-11A1 Dimension Mark Standard Limit Standard Ø b Limit Standard Ø c Limit Standard Ø d Limit Standard 46.7 Limit 51.7 Standard 260.35 Limit Gauge [Unit: mm] 800-6-10-03-14A Lep 9-94870EN Issued 06-06...
Page 27 1002-19 Idler wheel Dimensions Dimension Mark Standard Ø a Limit Standard 22.5 Limit 25.5 Standard Limit Standard Ø d (shaft) Limit Standard Ø d (bushing) Limit Standard e (bushing) Limit 109.5 Standard 21.6 Limit 700-6-10-00-10B Gauge Unit in mm [Unit: mm] 800-6-10-03-14B Lep 9-94870EN Issued 06-06...
Page 28 1002-20 Upper roller Dimensions Dimension Mark Standard Ø a Limit Standard Limit Standard Limit 800.6.10.00.11C Gauge Unit in mm [Unit: mm] 800-6-10-03-14C Lep 9-94870EN Issued 06-06...
Page 29 1002-21 Lower roller Dimensions 700-6-10-00-10D Dimension Dimension Mark Mark Standard Standard 115.4 Ø a Ø e (bushing) Limit Limit 116.4 Standard Standard Limit Limit 112.5 Standard Standard Limit Limit 31.5 Standard Ø e (Shaft) Limit Gauge Unit in mm 800-6-10-03-14D Lep 9-94870EN Issued 06-06...
Page 30 1002-22 Track c’ d’ e’ f’ (4 pieces) 800-6-10-00-11E-1 Dimension Dimension Mark Mark Standard 70.5 Standard Ø c’ (bushing) Limit 42.5 Limit 85.5 Standard Standard 55.65 Ø d’ (bushing) Limit Limit Standard Standard 55.65 Ø c (bushing) Ø e’ (Pin) Limit 85.5 Limit...
Page 31: Dimensions And Wear Limits Of Attachement Mobile Joints
1002-23 DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS CRIL06C002 1. Boom foot/Frame 700-1-06-02-05JA Dimension Mark Standard 1110 a (frame) Limit 1118 Standard 1106 b boom) Limit 1103 Standard 4 to 6.5 c (clearance) Limit Shim adjustment Standard Ø d (shaft) Limit Standard Ø...
Page 32 1002-24 2. Boom cylinder foot/Frame 700-1-06-02-05A Dimension Mark Standard a (boom) Limit Standard b (cylinder) Limit Standard 1 to 3.5 c (clearance) Limit Shim adjustment Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit 131.5 3. Boom cylinder head/Boom CRPH06C001A Mark Dimension mm...
Page 33 1002-25 4. Dipper cylinder foot/Boom Dimension Mark Standard a (boom) Limit Standard b (cylinder) Limit Standard 0.5 to 3 c (clearance) Limit Shim adjustment Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit 131.5 CS01B525 5. Boom/Dipper Dimension Mark Standard a (boom) Limit...
Page 34 1002-26 7. Bucket cylinder foot/Dipper Dimension Mark Standard a (dipper) Limit Standard b (cylinder) Limit Standard 0.5 to 3 c (clearance) Limit Shim adjustment Standard Ø d (shaft) Limit Standard Ø e (bushing) Limit 131.5 800-6-10-00-11NB 8. Connecting rod/Dipper Mark Dimension mm Standard Limit...
Page 35 1002-27 10. Connecting rod/Compensator/Bucket cylinder head Mark Dimension mm Standard Limit Standard Limit Standard 1 to 1.5 c (clearance) Limit Shim adjustment Standard d (link) Limit Standard e (cylinder) Limit Standard 1 to 2 f (clearance) Limit Shim adjustment Standard Ø...
Page 36: Shims For Adjusting Attachment Gaps
1002-28 SHIMS FOR ADJUSTING ATTACHMENT GAPS For boom foot O.D I.D 000-6-10-02-02A Part No. I.D. O.D. Shim Material Thickness KNV1132 SPHC KRV2390 SPHC KBV1441 SPHC KBV1748 SPHC KSV1805 SPHC 000-6-10-02-02B Part No. I.D. O.D. Shim Material Thickness KSV1930 Urethone KSV11380 Urethone KSV1931 Urethone...
Page 37: Special Torque Settings
1002-29 SPECIAL TORQUE SETTINGS Component Screw Wrench (mm) Torque setting Travel motor and reduction gear assembly 1307-1526 Nm (964 - 1125 lb-ft) Sprocket 1307-1526 Nm (964 - 1125 lb-ft) Idler wheel Upper roller 521-608 Nm (384-448 lb-ft) Lower roller 1307-1526 Nm (964-1125 lb-ft) Chain guide 1307-1526 Nm (964-1125 lb-ft) Track pad...
Page 38 1002-30 12 13 700-2-01-00-15A 700-2-01-01-44AA Lep 9-94870EN Issued 06-06...
Page 39 1002-31 12 13 14 3-29-1- Lep 9-94870EN Issued 06-06...
Page 40: Machine Overall Dimensions
1002-32 MACHINE OVERALL DIMENSIONS NOTE: Numeral values may be changed without notice due to desing alterations or other reasons. The values in the diagram include the lug height of shoe (50 mm) () Show the smallest dimension in the transport. (1) Counterweight dimension Standard arm (3.66 m) 800-1-01-01-58A...
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CNH E805 Tier 3 Manual

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