CNH E805 Tier 3 User manual
Copyright 2006 CNH France S.A.
Printed in France
CNH Lep 9-42691EN September 2006
E805 Tier 3 Crawler Excavators
Table of Contents
DIVISION/SECTION SECTION NqREFERENCE Nq
1 GENERAL INFORMATION
Safety, general information and standard torque data .....................................1001 7-27691EN
General specifications and special torque setting............................................1002 9-94710EN
2ENGINE
Radiator and engine, removal and installation .................................................2001 9-94910EN
Engine specifications ............................................................................................. *
Disassembly and assembly of the engine.............................................................. *
3 FUEL SYSTEM
Fuel tank ..........................................................................................................3001 9-36821EN
Fuel engine system................................................................................................ *
4 ELECTRICAL SYSTEM
Electrical system, electrical and electronic troubleshooting.............................4001 9-94700EN
Inspection and maintenance of batteries and connecting a booster battery....4002 9-36830EN
Main and engine electronic control boxes........................................................4003 9-94510EN
5 UNDERCARRIAGE
Removal and installation of tracks ...................................................................5001 9-36860EN
Rollers..............................................................................................................5003 9-36881EN
Sprocket ...........................................................................................................5004 9-36890EN
Idler wheel and tension shock absorber ..........................................................5005 9-94350EN
6 DRIVE TRAIN
Drive motor and final drive transmission removal and installation ...................6001 9-36980EN
Drive motor and final drive transmission disassembly and assembly ..............6002 9-40351EN
Swing reduction gear, removal and installation................................................6003 9-36991EN
Swing reduction gear, disassembly and assembly...........................................6004 9-42631EN
7 UNDERCARRIAGE HYDRAULICS
8 UPPERSTRUCTURE HYDRAULICS
Depressurising and decontaminating the hydraulic system, use of the
vacuum pump and bleeding the components ..............................................8000 9-94430EN
Specifications, troubleshooting, checks and hydraulic pressure settings.........8001 9-94740EN
Hydraulic reservoir removal and installation ....................................................8002 9-94490EN
Main and pilot pumps, removal and installation ...............................................8003 9-40771EN
Main hydraulic control valve, removal and installation .....................................8004 9-94501EN
Attachment cylinders, removal and installation ................................................8005 7-27792EN
Hydraulic swivel, removal and installation........................................................8006 9-94600EN
Pilot blocs, removal and installation .................................................................8007 9-94520EN
Swing motor, removal and installation..............................................................8008 9-94420EN
Main hydraulic pump, disassembly and assembly ...........................................8010 9-94590EN
Main hydraulic control valve, disassembly and assembly ................................8011 9-94781EN
Attachment cylinders, disassembly and assembly...........................................8012 9-40941EN
Hand control levers, disassembly and assembly .............................................8013 9-94630EN
Foot control levers, disassembly and assembly...............................................8014 9-40992EN
Six-solenoid valves, disassembly and assembly..............................................8015 9-42521EN
Caution valve, disassembly and assembly.......................................................8016 9-94531EN
Safety valve......................................................................................................8017 9-42770EN
Hydraulic swivel, disassembly and assembly...................................................8018 9-42511EN
Swing motor, disassembly and assembly ........................................................8019 9-42530EN
Hydraulic functions...........................................................................................8020 9-94720EN
Lep 9-42691EN Edition 09-06
DIVISION/SECTION SECTION N° REFERENCE N°
Fan motor, removal and installation .................................................................8022 9-94660EN
Fan motor, disassembly and assembly ............................................................8023 9-94670EN
Fan pump, removal, disassembly, assembly and installation ...........................8024 9-94680EN
Hydraulic component functions........................................................................8030 9-94130EN
9 UPPERSTRUCTURE
Upperstructure, turntable and counterweight...................................................9002 9-42551EN
Boom, dipper and bucket .................................................................................9003 9-42621EN
Seat and seat belt ............................................................................................9004 9-40960EN
Cab and cab equipment...................................................................................9005 9-94650EN
Air conditioning troubleshooting.......................................................................9006 7-xxxxxFR
Air conditioning unit disassembly and assembly..............................................9007 9-94640EN
Air conditioning servicing .................................................................................9008 7-xxxxxFR
Air conditioning components............................................................................9009 7-xxxxxFR
Removal and installation attachment, counterweight and side fram ................9010 9-94730EN
Large format hydraulic schematic .................................................................Pocket 87520431
Large format electrical schematic ................................................................. Pocket 9-93930
* 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.
The description of the models shown in this manual has been made in
accordance with the technical specifications known as of the date of
design of this document.
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1001-2
Lep 9-94880EN Issued 06-06
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.
!
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1001-3
Lep 9-94880EN Issued 06-06
GENERAL INFORMATION
Cleanning
Clean all metal parts except bearings, in a suitable
cleaning solvent or by steam cleaning. Do not use
caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with
compressed air. Clean bearings in a suitable cleaning
solvent, dry the bearings completely and put oil on
the bearings.
Inspection
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for
indications of wear, pitting and the replacement of
parts necessary to prevent early failures.
Bearings
Check bearings for easy action. If bearings have a
loose fit or rough action replace the bearing. Wash
bearings with a suitable cleaning solvent and permit
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR.
Needle bearings
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position put
petroleum jelly on the inside and outside diameter of
the bearings.
Gears
Check all gears for wear and damage. Replace gears
that have wear or damage.
Oil seals, O-rings and gaskets
Always install new oil seals, O-rings and gaskets. Put
petroleum jelly on seals and O-rings.
Shafts
Check all shafts that have wear or damage. Check
the bearing and oil seal surfaces of the shafts for
damage.
Service parts
Always install genuine NEW HOLLAND service parts.
When ordering refer to the Parts Catalog for the
correct part number of the genuine NEW HOLLAND
replacement items. Failures due to the use of other
than genuine NEW HOLLAND replacement parts are
not covered by warranty.
Lubrication
Only use the oils and lubricants specified in the
Operator’s or Service Manuals. Failures due to the
use of non-specified oils and lubricants are not
covered by warranty.
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1001-4
Lep 9-94880EN Issued 06-06
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
manual.
Put the warning tag shown below on the key for the
keyswitch when servicing or repairing the machine.
One warning tag is supplied with each machine.
Additional tags Part Number 331-4614 are available
from your service parts supplier
.
WARNING: Read the operator’s manual to
familiarize yourself with the correct control
functions.
!
WARNING: Operate the machine and
equipment controls from the seat position
only. Any other method could result in
serious injury.
!
WARNING: This is a one man machine, no
riders allowed.
!
WARNING: Before starting engine, study
Operator’s Manual safety messages. Read
all safety signs on machine. Clear the area of
other persons. Learn and practice safe use
of controls before operating.
It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service and to observe
pertinent laws and regulations. Operator’s
and Service Manuals may be obtained from
your NEW HOLLAND dealer.
!
WARNING: If you wear clothing that is too
loose or do not use the correct safety
equipment for your job, you can be injured.
Always wear clothing that will not catch on
objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
gloves and reflector clothing.
!
WARNING: When working in the area of the
fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
!
WARNING: When doing checks and tests
on the equipment hydraulics, follow the
procedures as they are written. DO NOT
change the procedure.
!
WARNING: When putting the hydraulic
cylinders on this machine through the
necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.
!
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1001-5
Lep 9-94880EN Issued 06-06
WARNING: Use insulated gloves or mittens
when working with hot parts.
!
WARNING: Lower all attachments to the
ground or use stands to safely support the
attachments before you do any maintenance
or service.
!
WARNING: Pin sized and smaller streams
of hydraulic oil under pressure can penetrate
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
immediately. Maintain all hoses and tubes in
good condition. Make sure all connections
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
damaged. DO NOT use your hand to check
for leaks, use a piece of cardboard or wood.
!
WARNING: When removing hardened pins
such as a pivot pin, or a hardened shaft, use
a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
steel head hammer.
!
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
!
WARNING: Use suitable floor (service)
jacks or chain hoist to raise wheels or tracks
off the floor. Always block machine in place
with suitable safety stands.
!
WARNING: When servicing or repairing the
machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
grease, tools, etc. Use an oil absorbing
material and/or shop cloths as required. Use
safe practices at all times.
!
WARNING: Some components of this
machine are very heavy. Use suitable lifting
equipment or additional help as instructed in
this Service Manual.
!
WARNING: Engine exhaust fumes can
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
fumes from the area with an exhaust pipe
extension. Open the doors and get outside
air into the area.
!
WARNING: When the battery electrolyte is
frozen, the battery can explode if (1), you try
to charge the battery, or (2), you try to jump
start and run the engine. To prevent the
battery electrolyte from freezing, try to keep
the battery at full charge. If you do not follow
these instructions, you or others in the area
can be injured.
!
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1001-6
Lep 9-94880EN Issued 06-06
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. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then
tighten.
Torque table
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20
Cap Screw
Spanner
[mm] 10 13 17 19 22 24 27 30
[in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18
Tightening
torque
[Nm] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2
[lb-ft] 5.1 14.5 28.9 43.4 72.3 115.7 144.6 217
Socket
Head Cap
Screw
Spanner
[mm] 5 6 8101214 1417
[in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67
Tightening
torque
[Nm] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2
[lb-ft] 6.5 15.9 31.1 57.9 86.9 130.2 181 253.2
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1002-2
Lep 9-94870EN Issued 06-06
TABLE OF CONTENTS
TYPE, SERIAL NUMBER
AND YEAR OF MANUFACTURE OF THE MACHINE..............................................................................................3
FLUIDS AND LUBRICANTS .....................................................................................................................................4
SPECIFICATIONS.....................................................................................................................................................8
COMPONENT WEIGHT..........................................................................................................................................16
DIMENSIONS AND WEAR LIMIT OF THE TRACK ASSEMBLY ...........................................................................18
DIMENSIONS AND WEAR LIMITS OF ATTACHEMENT MOBILE JOINTS ..........................................................23
SHIMS FOR ADJUSTING ATTACHMENT GAPS...................................................................................................28
SPECIAL TORQUE SETTINGS ..............................................................................................................................29
MACHINE OVERALL DIMENSIONS.......................................................................................................................32
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.
!
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1002-3
Lep 9-94870EN Issued 06-06
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.
Engine
CT04D014B
Make and type ............................. ISUZU AH-6WG1X
Serial number .............................................................
Machine
CD00K015N
(1) Type .............................................................................
(2) Serial number..............................................................
(3) Year of manufacture....................................................
Serial numbers of the components
Hydraulic pump............................................................................................................................................................
Swing reduction gear...................................................................................................................................................
Travel reduction gears .................................................................................................................................................
Control valve................................................................................................................................................................
1
3
2
1002-4
Lep 9-94870EN Issued 06-06
FLUIDS AND LUBRICANTS
Lubricants must have the correct properties for each application.
Hydraulic fluid
AMBRA hydraulic fluid is specially designed for high pressure applications and for the NEW HOLLAND hydraulic
system. The type of fluid to be used depends on the ambient temperature.
Temperate climates: -20°C to +40°C (-4° to 104° F)
AMBRA HYDROSYSTEM 46 HV (NH 646 H - ISO VG 46 - DIN 51524 PART 3 category HVLP)
Hot climates: 0qC to +50qC (32° to 122° F)
AMBRA HYDROSYSTEM 68 HV (NH 668 HV - ISO VG 68 - DIN 51524 PART 3 category HVLP)
Cold climates: -25qC to +20qC (-13° to 68° F)
AMBRA HYDROSYSTEM 32 (NH 632 - ISO VG 32 - DIN 51524 PART 2)
Biodegradable fluid: -30qC to +40qC (-22° to 104° F)
This yellow-coloured fluid is miscible with standard fluid. If used to change standard fluid, it is advisable to drain the
circuit completely before refilling with this fluid.
AMBRA HYDROSYSTEM 46 BIO-S (NH 646 BS - ISO VG 46 - DIN 51524 PART 2)
Transmission component oil
Extreme pressure oil used for enclosed transmission components.
AMBRA HYPOIDE 90 (SAE 80W-90 - NH 520 A - API GL5 - MIL-L-2105 D - ZF TE-ML 05A)
Grease
AMBRA GR 75 MD (NH 720 A - NLGI 2 - Multipurpose grease with molybdenum disulphide).
AMBRA GR9 (NH 710 A - NLGI 2 - Extreme Pressure multipurpose grease).
AMBRA GR EXP (NH 587/GR - NLGI 2 - Extreme Pressure multipurpose grease).
WARNING: The conditions of use for individual fluids and lubricants must be respected.
!
1002-5
Lep 9-94870EN Issued 06-06
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
Oil viscosity / Oil range
CT02M001
1) With mineral base
(2) With semi-synthetic base
(3) With synthetic base
3
3
1
2
2
1002-6
Lep 9-94870EN Issued 06-06
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.
In cold weather (below -7°C), a mixture of fuels No. 1-D and No. 2-D is approved as a temporary measure. Consult
your fuel supplier or your NEW HOLLAND service specialist.
If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause
power loss or will prevent the engine from starting.
Conditions applicable to Diesel fuel
The diesel fuel used must:
- be free from even minute dust particles,
- have the correct viscosity,
- have a high cetane number,
- present great fluidity at low temperatures,
- have low sulphur content,
- have very little residual carbon.
Recommendations applicable to Diesel fuel
- JIS (Japanese Industrial Standard) : No. 2
- DIN (Deutsche Industrie Normen) : DIN 51601
- SAE (Society of Automotive Engineers) Based on SAE-J-313C: No. 2-D
- BS (British Standard) Based on BS/2869-1970: Class A-1
IMPORTANT : Using any other fuel will reduce the operating performance of the engine.
Using fuels other than those recommended can damage the fuel injection pump, the injector and other parts of the
fuel supply system and the engine. NEW HOLLAND disowns any responsibility concerning this kind of dam-
age, which is not covered by the guarantee. To avoid any damage to the engine fuel supply system, you are rec-
ommended to take the following safety messages into account:
- Certain fuel suppliers mix used engine oil with diesel fuel. Certain manufacturers of large engines allow them to
do this. In all cases, for your engine, never use diesel fuel contaminated by engine oil. In addition to damaging the
engine, this fuel can actually adversely affect the correct purification of exhaust gases. Before using any diesel fuel,
ask the supplier if this fuel has been mixed with engine oil.
IMPORTANT : For correct use of fuel additives consult your supplier or your NEW HOLLAND service specialist. Do
not inject fuel oil or gasoline, both fuels can damage the engine.
IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of con-
densation.
Fuel storage
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be
traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain
off water and impurities regularly.
1002-7
Lep 9-94870EN Issued 06-06
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.
Environment
Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Contact your local ecological recycling centre or your NEW HOLLAND service specialist to obtain information on
the correct method of disposing of these lubricants.
1002-8
Lep 9-94870EN Issued 06-06
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)
.................................................................................................................................High Speed 4.2 km/h (2.60 mph)
Maximum drawbar pull ................................................................................................................. 564kN (126792 lbf)
Grade ability ................................................................................................................................................70% (35°)
Ground pressure...................................................................................... 110 kPa (650 mm (25.59 in) grouser shoe)
Complete machine dimensions
Main body dimensions
Main body length ........................................................................................................................7460 mm (293.69 in)
Main body width.....................................4360 mm (171.65 in) (Grouser shoe retracted width: 4250 mm (167.32 in))
Upper swing body width .............................................................................................................4250 mm (167.32 in)
Cab width......................................................................................................................................1000 mm (39.36 in)
Main body height ........................................................................................................................3880 mm (152.75 in)
Tail swing radius .........................................................................................................................4300 mm (169.29 in)
Distance of rear swing body .......................................................................................................4280 mm (168.50 in)
Ground clearance for upperstructure............................................................................................1590 mm (62.59 in)
Center-to-center of wheels .........................................................................................................5070 mm (199.60 in)
Overall track length.....................................................................................................................6360 mm (250.39 in)
Maximum track width........................ 4100 mm (161.41 in) (Retracted width in transporting style: 3480 mm (137 in)
Center-to-center for track............3450 mm (135.82 in) (Retracted width in transporting style: 2830 mm) (111.41 in)
Width of track shoe......................................... 650 mm (25.59 in) (Optional: 750 mm (29.52 in), 900 mm) (35.43 in)
Minimum ground clearance ..................................................................890 mm (35.03in) (To bottom of lower frame)
Standard
arm
(3.66 m)
(12 ft 0.09 in)
Long
arm
(4.44 m)
(14 ft 6.79 in)
Super
Long arm
(5.62 m)
(18 ft 5.25 in)
Mass
Digging arm
(2.98 m)
(9 ft 9.31in)
Length 14360 mm
(565.35 in)
14320 mm
(523.77 in)
13830 mm
(544.48 in)
13230 mm
(520.86 in)
Width 4360 mm
(171.65 in)
4360 mm
(171.65in)
4360 mm
(171.65 in)
4360 mm
(171.65 in)
Height 4810 mm
(189.36 in)
5000 mm
(196.84 in)
6300 mm
(248.03 in)
5050mm
(198.81in)
1002-9
Lep 9-94870EN Issued 06-06
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 ...................................................................................................................... 345 ± 7.0 kW / 1850 min-1
Maximum torque.............................................................................................. 2250 N•m (1659.51 lb-ft) / 1500 min-1
Engine dimensions (LxWxH) ............................................................. 1462x1017x1422 mm (57.55 x40.03x55.98 in)
Oil pan ............................................................................................................................... All direction 35°, inclinable
Oil pan capacity ........................................ Maximum: 52 L (13.73 gal) Minimum: 37 L (9.77 gal) (excluding oil filter)
Direction of rotation ............................................................................... Right (viewed from fan side); compliant with
Starter, reduction type ................................................................................................................................24 V, 7 kW
Alternator, AC type ..................................................................................................................................... 24 V, 50 A
Battery .................................................................................................................................. 2x 12V/24V,140 Ah/5 Hr
Cooling system
Fan drive system ..................................................................................................................................hydraulic drive
Fan type..................................................................... diameter 1016 mm (40 in), suction type-6blades, resin & steel
Radiator capacity...........................................................................................................................................205.7kW
Fin type ...........................................................................................................................................................wavy
Fin space.......................................................................................................................................2.0 mm (0.07 in)
Oil cooler capacity ........................................................................................................................................174.4 kW
Fin type ........................................................................................................................................................... plate
Fin space.......................................................................................................................................3.0 mm (0.11 in)
Inter-cooler capacity .......................................................................................................................................63.3 kW
Fin type ....................................................................................................................................... triangular straight
Fin space.......................................................................................................................................2.0 mm (0.07 in)
Fuel cooler capacity........................................................................................................................................3.58 kW
Fin type ...........................................................................................................................................................wavy
Fin space.......................................................................................................................................2.0 mm (0.07 in)
Coolant capacity .............................................................................................................36 L (9.51 gal) (engine only)
Capacity of coolant and lubricants
Coolant .............................................................................................................................................108 L (28.53 gal)
Fuel.................................................................................................................................................900 L (237.75 gal)
Lubricant for engine............................................................................................................................52 L (13.73 gal)
Lubricant for travel reduction gear (per side).....................................................................................13.8 L (3.64 gal)
Lubricant for swing reduction gear (per side) ......................................................................................4.7 L (1.24 gal)
Hydraulic oil ....................................................................................................................................720 L (190.20 gal)
Capacity of hydraulic oil tank ............................................................................................................310 L (81.89 gal)
Hydraulic oil filter
Suction filter (inside tank) ............................................................................................................................ 150 mesh
Return filter (inside tank) .................................................................................................................................10 m m
Nephron filter (inside housing)...........................................................................................................................1 m m
Pilot line filter (inside housing).........................................................................................................................10 m m
1002-10
Lep 9-94870EN Issued 06-06
Operating devices
Operator's seat
Location; left side
Structure; low frequency air suspension with helical springs and double acting hydraulic damper.
Cab
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; levers (hydraulic pilot type) (2)
Instruments and switches
Work mode switchover; 4 modes (heavy digging, standard, finishing and auto)
Travel speed switchover; Low Speed / High Speed panel switch
One-touch idle; Knob switch type
Monitor device
Machine status display (full-dot liquid crystal)
Travel speed selection status; Low Speed / High Speed
Work mode selection status; H/S/L/A
Auto idle selection status; ON/OFF
Instruments (full-dot liquid crystal, except for hour meter)
Fuel gauge; bar graph indicator
Engine coolant temperature gauge; bar graph indicator
Hydraulic oil temperature gauge; bar graph indicator
Hour meter; digital type
Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm
Lighting
Horn; electric horn (2)
Other
Wiper with intermittent function (1)
Window washer fluid (1)
Air conditioner (1)
Rear view mirror (right-hand side) (1)
DC converter (1)
High dump
Over heat* Battery charge* Faulty electrical system*
Refill fuel* Engine oil pressure* Refill coolant*
Engine preheat Auto warm-up Air cleaner*
Idling Service interval Digging power up
Working light House: 24V, 70W (1)
Boom: 24V, 70W (1)
Cab: 24V, 70W (2)
Interior light 24V, 10W (1)
1002-11
Lep 9-94870EN Issued 06-06
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 cm3 (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 ............................................................................... 514.3 L/min (135.86 gpm) X 2 at 1850 min-1
Input horsepower .................................................................................................................................310.7 kW
Shaft input horsepower ................................................................................................. 314.3 kW at 1850 min-1
Shaft input torque....................................................................................... 1622 N•m (1197 lb-ft) at 1850 min-1
Pilot pump
Pump type ........................................................................................................................................Gear pump
Displacement ..................................................................................................................15 cm3 (0.91 cu in)/rev
Operating pressure ..................................................................... 4.4 MPa (638.16 psi) to 4.6 MPa (667.17 psi)
Maximum flow ....................................................................27.8 L/min (7.34 gpm) (at 1850 min-1) (1850 rpm-1)
Input horsepower .....................................................................................................................................3.6 kW
Control characteristics; simultaneous output control of overall, negative control, electric horse power control
Control Valve
Model; 4-spool section: integrated (1) or 5-spool section: integrated (1)
Operation method; hydraulic pilot method: travel, swing and operating machine
Maximum flow ..............................................................................................................514.3 L / min (135.86 gpm)
Set pressure of main relief valve ......................standard; 31.4 MPa (4554 psi), power boost 34.3 MPa (4975 psi)
Set pressure of overload relief valve ................................................................. 36.3 MPa (5265 psi) at 20 L / min
Functions
Straight travel circuit
Boom UP / 2-speed internal confluence for Arm
Boom/arm load holding circuit
Boom down regenerative circuit
Arm IN forced regenerative circuit
Boom up priority (speed restriction of bucket)
Boom up priority (Speed restriction of swing)
Swing priority (Speed restriction of arm)
Bucket 2-speed internal confluence
Resevbe 2-speed internal confluence
Hydraulic Cylinders
Boom cylinder (2)
Inner diameter of tube x rod diameter x stroke .................................................................... 200x140x1893 mm
Arm (dipper) cylinder
Inner diameter of tube x rod diameter x stroke .................................................................... 215x150x2290 mm
Bucket cylinder (Standard boom specifications)
Inner diameter of tube x rod diameter x stroke .................................................................... 190x130x1555 mm
Bucket cylinder (Mass boom specifications)
Inner diameter of tube x rod diameter x stroke .................................................................... 215x150x1520 mm
1002-12
Lep 9-94870EN Issued 06-06
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) .......................................................................................................................... 5.9 MPa (856 psi)
Flow
High pressure passage (ABCD).........................................................................................500 L/min (132 gpm)
Drain port (E) ......................................................................................................................50 L/min (13.2 gpm)
Pilot port (F) .....................................................................................................................27.8 L/min (7.34 gpm)
Number of revolutions ............................................................................................................................... 15 min-1
Torque, when pressurizing 2 ports ............................................................................................196 N m (145 lb-ft)
Port A; forward right ...................................................................................................................SAE 6000 psi 11/4
Port B; forward left......................................................................................................................SAE 6000 psi 11/4
Port C; backward right................................................................................................................SAE 6000 psi 11/4
Port D; backward left ..................................................................................................................SAE 6000 psi 11/4
Port E; drain port .............................................................................................................................. G3/4-A Class
Port F; pilot port ................................................................................................................................ G1/4-A Class
Solenoid Valve
Maximum flow .............................................................. P -> B: 30 L / min (7.92 gpm) Other: 5 L / min (1.32 gpm)
Rated pressure..........................................................................................................................4.41 MPa (640 psi)
Operating voltage ............................................................................................................................. DC 20 to 32 V
Current .............................................................................................................................. 13.0 W (at 24 V, 20× C)
Hand control valve
Manufacturer ............................................................................................................................................Kawasaki
Operating pressure ...................................................................................................................3.92 MPa (569 psi)
Secondary pressure, primary short type................................................................. 0.49 ± 0.1 to 2.89 ± 0.15 MPa
Operating angle
Ports 1, 3..............................................................................................................................................19 ± 1.9×
Ports 2, 4..............................................................................................................................................25 ± 2.5×
Operating torque
Port 1 ..........................................................................................................0.58 to 2.03 N m (0.42 to 1.49 lb-ft)
Port 3 ..........................................................................................................0.47 to 1.92 N m (0.34 to 1.41 lb-ft)
Ports 2, 4..................................................................................................... 0.71 to 2.30 N m (0.52 to 1.69 lb-ft)
Foot control valve
Manufacturer ............................................................................................................................................Kawasaki
Operating pressure ...................................................................................................................3.92 MPa (569 psi)
Secondary pressure; primary short type................................................................... 0.49 ± 0.1 to 2.89: 0.15 MPa
Operating angle.....................................................................................................................................12.4 ± 0.3×
Operating torque
Valve..............................................................................................................4.16 to 9.03 N m (3.06 to 19.90 lb-ft)
Damper ........................................................................................4.90 ± 0.98 Nm (3.61 ±0.72 Ib-ft) at 0.0275 m/s
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