Part of the New Holland Repair Manuals.
Within the hour you could be reading a code off the multi display or hanging a gauge on a pump port. You want factory numbers on the bench before you touch a relief adjuster. This book has them for the New Holland E135BSR ROPS Tier III crawler excavator.
It is Print No. 84396007A, Edition 09/2010, in English. The specification chapter covers the E135BSRLC from serial YH06-08001, market NHK-EUR. It includes the mechatro control system, hydraulic circuit diagrams, a seven-sheet electric circuit diagram, the pump, valve, swing and travel motor chapters, the undercarriage and two troubleshooting chapters. The complete Mitsubishi D04FR-TAA engine manual is bound in.
The book gives the tank capacities, the swing and travel motor pressures and the torque figures you need at the bench. You buy it once and it stays with this machine for good.
What's Inside This New Holland E135BSR Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction and Outline | 1-21 | Safety Precautions, Repair Preparations, Hydraulic Equipment Handling, Electrical Equipment Handling, International Units |
| Specifications | 22-51 | Machine Dimensions, Component Weights, Transportation Dimensions, Performance Specifications, Crawler Shoes, Bucket Types, Working Ranges |
| Tools | 52-73 | Fastener Torques, Hose and Fitting Torques, Plugs, Special Tools, Counterweight Lifting Jig, Engine Mounting Pedestal, Track Spring Jig |
| Standard Maintenance Time Table | 74-87 | Standard Work Times for Attachments, Cab and Guards, Swing Frame, Travel, Electrical Equipment and Engine |
| Maintenance Standard and Test Procedure | 88-113 | Performance Standards, Engine Speed Measurement, Hydraulic Pressure Adjustment, Travel and Swing Performance, Cylinder Times, Controller Output Adjustment |
| Mechatro Control System | 114-185 | Unload Valve Control, Pump Flow Control, Boom and Arm Confluence, Swing Priority, Travel Straight Control, Multi Display, Self Diagnosis |
| Hydraulic System | 186-219 | Hydraulic Schematics, Neutral, Travel, Bucket, Boom, Swing and Arm Circuits, Pressure Releasing Circuit |
| Electric System | 220-273 | Electric Circuit Diagrams, Electrical Equipment List, Instrument Panel, Controller Installation, Upper, Engine and Cab Harnesses |
| Components System | 274-391 | Hydraulic Pump and Regulator, Control Valve, Pilot Valves, Swing Motor, Travel Motor, Swivel Joint, Cylinders |
| Air-Conditioner System | 392-441 | HVAC Air Cycle, Components and Piping, Cooling Circuit, Unit Disassembly, Refrigerant Charging, Wiring Diagrams, Troubleshooting |
| Cab Interference Prevention System | 442-465 | Height and Depth Limits, Angle Sensors, Adjustment Procedures, Offset Limitation, Release Connector, Electrical Inspection |
| Attachments | 466-503 | Attachment Removal and Installation, Bucket, Arm and Boom Removal, Cylinder Disassembly and Assembly, Cylinder Troubleshooting |
| Upper Structure | 504-687 | Cab and Guards, Fuel and Hydraulic Tanks, Pump Installation, Counterweight, Radiator and Oil Cooler, Pump Repair, Swing Motor and Swivel Joint |
| Travel System | 688-791 | Crawler, Upper and Lower Rollers, Front Idler, Sprocket, Travel Motor, Swing Bearing, Maintenance Standards and Troubleshooting |
| Troubleshooting by Error Codes | 792-851 | Failure Classification, Controller Fuse Checks, Error Code Tables, Pressure Sensor, Proportional Valve, Solenoid and Speed Sensor Faults, CAN Communication |
| Troubleshooting by Trouble Diagnosis Mode | 852-861 | Unload System, Pump System, Travel Straight and Engine System Diagnosis, Diagnosis Remedies, Engine ECU |
| Mitsubishi D04FR-TAA Engine: General and Service Data | 862-907 | Engine Manual Introduction, Safety Cautions, System Flow Diagrams, Serial Number Location, Main Specifications, Service Data, Tightening Torques, Service Tools |
| Engine Overhaul: Disassembly, Inspection and Reassembly | 908-973 | Overhaul Timing, Compression Pressure Testing, Engine Disassembly, Crankshaft Inspection, Cylinder Head and Valve Repair, Reassembly |
| Engine Fuel, Lubrication, Cooling and Inlet/Exhaust | 974-1007 | Fuel Pump, Common Rail, Oil Filter and Cooler, Oil Pump, Water Pump and Thermostat, Inlet System, Exhaust Manifold |
| Engine Electrical System and Adjustment | 1008-1047 | Starter, Alternator, ECU Replacement, Sensors, Valve Clearance Adjustment, Belt Tension, Break-In Operation, Performance Testing |
| Engine Troubleshooting | 1048-1085 | Diagnosis Codes, Scan Tester Operation, Engine Status, Freeze Data, Troubleshooting Charts, Sensor and Wiring Inspection |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fully equipped weight | 14,700 kg (32,410 lbs) | p. 31 |
| Swing speed | 11.5 min-1 {rpm} | p. 31 |
| Travel speed (1-speed/2-speed) | 3.4 / 5.6 km/h (2.1 / 3.5 mile/h) | p. 31 |
| Gradeability | 70 % (35 degree) | p. 31 |
| Engine model | MITSUBISHI D04FR-74kW | p. 31 |
| Total displacement | 4.249 L (259.27 cu-in) | p. 31 |
| Maximum torque / engine speed | 375 N-m (277 lbf-ft) / 1,600 min-1 | p. 31 |
| High idling | 2,220 ~ 2,260 min-1 | p. 35 |
| Low idling | 995 ~ 1,035 min-1 | p. 35 |
| Engine oil, full level | 17.5 L (4.62 gal) | p. 35 |
| Fuel tank capacity | 200 L (53 gal) | p. 521 |
| Hydraulic tank capacity | 146 L (39 gal) | p. 524 |
| Coolant volume of engine body | 6 L (1.6 gal) | p. 543 |
| Coolant capacity of radiator | 6.6 L (1.7 gal) | p. 543 |
| Swing reduction unit oil | 1.65 L (0.44 gal) | p. 340 |
| Travel reduction unit oil | 2.1 L (0.55 gal) | p. 352 |
| Swing hydraulic motor rated pressure | 28.0 MPa (4060 psi) | p. 340 |
| Travel hydraulic motor system pressure | 34.32 MPa (4976 psi) | p. 352 |
| Travel parking brake release pressure | 0.76 MPa (110 psi) | p. 352 |
| Swing motor unit capscrews M20X55 torque | 539 N-m (400 lbf-ft) | p. 560 |
New Holland E135BSR Common Problems This Manual Covers
Hydraulic pump oil flow is extremely low and no delivery pressure is available
The pump troubleshooting table blames this on a regulator that is out of order, and the remedy is to repair the regulator. The table sits in the hydraulic pump part of the Upper Structure chapter, and the Components System chapter describes the hydraulic pump and its regulator.
Manual Section: 33. Upper Structure - Hydraulic pump - Troubleshooting p. 578Travel motor does not start even though pressure is okay
When pressure checks out but the travel motor will not turn, the manual points to a blocked orifice in the parking brake passage. The remedy is to clean the foreign material out of that orifice. The specs list parking brake release pressure at 0.76 MPa (110 psi). The table is in the travel motor troubleshooting of the Travel System chapter.
Manual Section: 34. Travel System - Travel motor - Troubleshooting p. 788Error code A035 is displayed but the machine operates normally
Table 46-2 says A035 is not normal output, but the machine still runs normally. The cause is a missed unload valve adjustment. The remedy is to carry out the unload valve adjustment, called C adjustment in the book. The table is in the Troubleshooting by Error Codes chapter, and unload valve control is described in the Mechatro Control System chapter.
Manual Section: 46. Trouble Shooting (by Error Codes) - Table 46-2 p. 800Engine stops with Mitsubishi diagnosis code P0606
P0606 is the supervision code, and its control action is engine stop. The ECU has found an abnormality through its own self-diagnosis, and the listed inspection is to replace the ECU. The engine troubleshooting section also explains scan tester operation and freeze data. Follow the ECU replacement steps in the engine electrical section so the new unit goes in correctly.
Manual Section: Mitsubishi D04FR-TAA engine - Troubleshooting p. 1070Frequently Asked Questions
Which New Holland excavator does this service manual cover?
It covers the E135BSR ROPS Tier III crawler excavator, Print No. 84396007A, Edition 09/2010, in English. The specification chapter is written for the E135BSRLC from serial YH06-08001, market NHK-EUR. No upper serial limit is printed, so check your plate against that starting number. p. 23
What engine and displacement does the manual list?
The engine is a Mitsubishi D04FR with a total displacement of 4.249 L (259.27 cu-in). Maximum torque is 375 N-m (277 lbf-ft) at 1,600 min-1. The complete Mitsubishi D04FR-TAA service manual is bound in. It covers overhaul, fuel, lubrication, cooling, electrical and engine troubleshooting. p. 31
What are the fuel and hydraulic tank capacities on the New Holland E135BSR?
The fuel tank holds 200 L (53 gal) and the hydraulic tank holds 146 L (39 gal). p. 521
What operating weight and travel speeds are printed?
The fully equipped weight is 14,700 kg (32,410 lbs). Travel speed is 3.4 / 5.6 km/h (2.1 / 3.5 mile/h) in 1-speed and 2-speed. Swing speed is 11.5 min-1 {rpm} and gradeability is 70 % (35 degree). p. 31
Does the manual include electrical and hydraulic diagrams and error codes?
Yes. The hydraulic chapter has circuit diagrams for the standard circuit plus the nibbler and breaker option. The electric chapter opens with a seven-sheet electric circuit diagram. The error code chapter lists machine codes such as B013, disconnection of the boom up pressure sensor. F031 covers failure of output transistor OFF and GND short of travel 1-2 speed SOL valve. The engine section has its own diagnosis codes and charts. p. 222
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