NEW HOLLAND KOBELCO E485 WORKSHOP MANUAL – PDF DOWNLOAD

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NEW HOLLAND KOBELCO E485 WORKSHOP MANUAL

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NEW HOLLAND KOBELCO E485 WORKSHOP MANUAL – PDF DOWNLOAD:

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NEW HOLLAND KOBELCO E485 WORKSHOP MANUAL

• GENERALITIES Read the Operation and Maintenance Instruction Manual carefully before starting, operating, maintaining, fuelling or servicing the machine. 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.
• 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. It is fundamental that all machine operators know very well the meaning of each safety plate as this considerably decreases operating hazards and accidents.
• 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. 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. 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. 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.
• 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 Do not leave the machine until it has come to a complete stop. Always check height, width and weight limitations which may be encountered in the working site and ensure the machine does not exceed them. Assess exact paths of gas ducts, water mains, telephone lines, sewers, overhead and underground electric lines and all other possible obstacles. 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. Never exceed machine lifting capacity. Remain within the limits shown in the loading capacity chart which located on the machine. 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. 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.
• Obey all hand signals, safety indications and signs. 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. Ensure that nobody is within the excavator operating area before starting the machine, swinging the upper structure or moving in any direction. Adjust all rear-view mirrors for maximum visibility of the area behind the machine. Ensure that engine speed is appropriate to the job to be carried out.
• If any hydraulic control or system exhibits erratic performance or responds abnormally, have the machine checked for air in the system. 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. 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. Keep the operator’s compartment free of foreign objects, especially if not firmly secured. Never use the S1-2 E485 GENERALITIES machine to transport objects, unless proper securing points are provided. 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. 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. When backing, always look to where the machine is to be moved. 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. Always give way to loaded machines. Maintain a clear vision of the surroundings of the travel or work area at all times. Keep cab windows clean and repaired. 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. Always wear heavy gloves when handling chains or cables. Chains and cables should be securely anchored using suitable hooks. Anchor points should be strong enough to withstand the expected load. Keep anyone clear of anchor points and cables or chains. Do not pull or tow unless the operator’s compartments of the machines involved are 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. 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. Do not operate the machine until this condition is corrected. Regularly check all exhaust system components, as exhaust fumes are toxic for the operator. 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.
• 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. Do not operate the machine if you are extremely tired or feel ill. Be especially careful towards the end of the working shift. Where removable counterweights are provided, do not operate the machine if they have been removed. 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. Also, get to know load limits of the ground and paving type of the ramps you are to work on.
• 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. Whenever possible, avoid crossing over obstacles such as very rough terrain, rocks, logs, steps, ditches, railroad tracks.
• When obstructions must be crossed, do so with extreme care and at a square angle, if possible. Slow down. Ease up to the break-over point, pass the balance point slowly and ease down the other side also using the attachment, if necessary.
• To overcome deep trenches or sinking ground, place the machine perpendicular to the obstacle, drastically reduce ground speed and start crossing using also the attachment if necessary, only after assessing that ground conditions allow the traverse safely and without risks.
• 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.
• 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.
• Avoid faggots, 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. 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.
• 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) E485 S1-3 GENERALITIES and large roots (which may act as a leverage under the machine when up-rooted and cause the unit to overturn).
• Position the machine dependent upon the loading and unloading areas in order to swing leftwards to load to obtain best visibility. 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). 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. Ensure the truck driver is in a safe place before loading the truck.

TABLE OF CONTENTS:

NEW HOLLAND KOBELCO E485 WORKSHOP MANUAL

OPERATIONAL PRINCIPAL:
Section 1 GENERAL
Group 1 Specifications T1-1
Group 2 Component Layout T1-2
Section 2 SYSTEM
Group 1 Mechatro Control System T2-1
Group 2 Mechatro Controller T2-2
Group 3 Hydraulic System T2-3
Group 4 Electrical System T2-4
Section 3 COMPONENT OPERATION
Group 1 Hydraulic Pump Assy T3-1
Group 2 Pilot Valve T3-2
Group 3 Control Valve T3-3
Group 4 Swing Device T3-4
Group 5 Travel Device T3-5
Group 6 Swivel Joint T3-6
Group 7 Cylinders T3-7
Group 8 Air Conditioner T3-8
Group 9 Attachment Automatic Lubrication System T3-9
MANUAL INDEX
Section 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction T4-1
Group 2 Standard Performances T4-2
Group 3 Test Procedures T4-3
Group 4 Mechatro Controller Adjustment T4-4
OPERATIONAL PERFORMANCE TEST
Pag
Section 1 GENERALITIES S1
Section 2 SAFETY PRECAUTIONS S2
Section 3 SAFETY PLATES S3
SAFETY PRECAUTIONS
TROUBLESHOOTING
Section 5 TROUBLESHOOTING
Group 1 Mechatro Control T5-1
Group 2 Hydraulic System T5-2
Group 3 Electrical System T5-3
Group 4 Engine T5-4

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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