New Holland E27BSR TIER 4 User manual

www.newhollandconstruction.com
Issued 01Sep 08
S5PV0020E01 EN-US
E27BSR
TIER 4
COMPACT CRAWLER
EXCAVATOR
SERVICE
MANUAL

SERVICE MANUAL
E27BSR
COMPACT CRAWLER EXCAVATOR
TIER 4
Service Manual Number S5PV0020E01 EN-US
Issued 09-2008
Find manuals at https://best-manuals.com

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer
Revision History
Issue Issue Date Applicable Machine Remarks
First Edition Issued 09-2008 E27BSR COMPACT CRAWLER EXCAVATOR
Issued 09-2008
Book/Form Number 5-16520 EN-US
Copyright © 2008. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PV0020E01
Find manuals at https://best-manuals.com

I
Issued 09-2008 Bur
E27BSR SERVICE MANUAL
TABLE OF CONTENTS
SECTION 1
SAFETY AND GENERAL INFORMATION
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-16540 EN-US
CHAPTER 1
GENERAL PRECAUTIONS FOR MAKING REPAIRS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-16550 EN-US
CHAPTER 2
SPECIFICATIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-16560 EN-US
CHAPTER 3
ATTACHMENT DIMENSIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: 5-16570 EN-US
SECTION 2
MAINTENANCE
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-16580 EN-US
CHAPTER 1
TOOLS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-16590 EN-US
CHAPTER 2
STANDARD MAINTENANCE TIME TABLE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-16600 EN-US
CHAPTER 3
MAINTENANCE STANDARD AND TEST PROCEDURE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: 5-16610 EN-US
SECTION 3
SYSTEMS
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-16620 EN-US
CHAPTER 1
HYDRAULIC SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-16630 EN-US
CHAPTER 2
ELECTRICAL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-16640 EN-US
CHAPTER 3
COMPONENT SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: 5-16650 EN-US
SECTION 4
DISASSEMBLY AND ASSEMBLY
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: 5-16660 EN-US
CHAPTER 1
ATTACHMENTS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: 5-16670 EN-US
CHAPTER 2
UPPER STRUCTURE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: 5-16680 EN-US
5-16520 EN-US
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E27BSR
II Issued 09-2008 Bur 5-16520 EN-US
CHAPTER 3
TRAVEL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Book/Form Number: 5-16690 EN-US
SECTION 5
TROUBLESHOOTING
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
Book/Form Number: 5-16700 EN-US
CHAPTER 1
TROUBLESHOOTING (HYDRAULIC SYSTEM)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Book/Form Number: 5-16710 EN-US
CHAPTER 2
TROUBLESHOOTING (ELECTRICAL SYSTEM)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Book/Form Number: 5-16720 EN-US
CHAPTER 3
TROUBLESHOOTING (ENGINE)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Book/Form Number: 5-16730 EN-US
SECTION 6
ENGINE
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
Book/Form Number: 5-16740 EN-US
CHAPTER 1
ENGINE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Book/Form Number: 5-16750 EN-US
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SAFETY
0-III
5-16270 NA Issued 09-2008 Bur
GENERAL SAFETY INFORMATION
1. Most accidents, which occur during operation,
are due to neglect of precautionary measures
and safety rules. Sufficient care should be taken
to avoid these accidents. Erroneous operation,
lubrication or maintenance services are very
dangerous and may cause injury or death of
personnel. Therefore all precautionary
measures, NOTES, DANGERS, WARNINGS
and CAUTIONS contained in the manual and on
the machine should be read and understood by
all personnel before starting any work with or on
the machine.
2. Operation, inspection, and maintenance should
be carefully carried out, and safety must be given
the first priority. Messages of safety are indicated
with marks. The safety information contained in
the manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
3. Messages of safety appear in the manual and on
the machine : All messages of safety are
identified by either word of DANGER, WARNING
and CAUTION.
DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury and is represented as follows:
WARNING- Indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury and is represented as
follows:
CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also be used to
alert against possible damage to the machine
and its components and is represented as
follows:
4. It is very difficult to forecast every danger that
may occur during operation. However, safety can
be ensured by fully understanding proper
operating procedures for this machine according
to methods recommended by Manufacturer.
5. While operating the machine, be sure to perform
work with great care, so as not to damage the
machine, or allow accidents to occur.
6. Continue studying the manual until all Safety,
Operation and Maintenance procedures are
completely understood by all persons working
with the machine.
WARNING
Do not operate or perform any maintenance on this
machine until all instructions found in the
OPERATOR’S MANUAL and this MANUAL have been
thoroughly read and understood.
Improper operation or maintenance of this machine
may cause accidents and could result in serious
injury or death.
Always keep the manual in storage.
If it is missing or damaged, place an order with an
authorized our Distributor for a replacement.
If you have any questions, please consult an
authorized our Distributor.
DANGER
WARNING
CAUTION
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0-IV Issued 09-2008 Bur 5-16270 NA
SAFETY PRECAUTIONS
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it
important to use caution when performing service
work. A knowledge of the system and or components
is important before the removal or disassembly of
any component.
Because of the size of some of the machine compo-
nents, the serviceman or mechanic should check the
weights noted in this manual. Use proper lifting proce-
dures when removing any components. Weight of
components table is shown in the section ; SPECIFI-
CATIONS.
The following is a list of basic precautions that must
always be observed.
1. Read and understand all Warning plates and
decal on the machine before Operating,
Maintaining or Repairing this machine.
2. Always wear protective glasses and protective
shoes when working around machines. In
particular, wear protective glasses when using
hammers, punches or drifts on any part of the
machine or attachments. Use welders gloves,
hood/goggles, apron and the protective clothing
appropriate to the welding job being performed.
Do not wear loose fitting or torn clothing.
Remove all rings from fingers, loose jewelry,
confine long hair and loose clothing before
working on this machinery.
3. Disconnect the battery and hang a Do Not
Operate tag in the Operators Compartment.
Remove ignition keys.
4. If possible, make all repairs with the machine
parked on a firm level surface. Block the machine
so it does not roll while working on or under the
machine. Hang a Do Not Operate tag in the
Operators Compartment.
5. Do not work on any machine that is supported
only by lift, jacks or a hoist. Always use blocks or
jack stands, capable of supporting the machine,
before performing any disassembly.
6. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
7. Lower the bucket, dozer, or other attachments to
the ground before performing any work on the
machine. If this cannot be done, make sure the
bucket, dozer, ripper or other attachment is
blocked correctly to prevent it from dropping
unexpectedly.
8. Use steps and grab handles when mounting or
dismounting a machine. Clean any mud or debris
from steps, walkways or work platforms before
using. Always face to the machine when using
steps, ladders and walkways. When it is not
possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
perform safe repair operations.
9. To avoid back injury, use a hoist when lifting
components which weigh 20kg (45lbs) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting
operation.
10. To avoid burns, be alert for hot parts on
machines which have just been stopped and hot
fluids in lines, tubes and compartments.
11. Be careful when removing cover plates.
Gradually back off the last two capscrews or nuts
located at opposite ends of the cover or device
and carefully pry cover loose to relieve any
spring or other pressure, before removing the
last two capscrews or nuts completely.
12. Be careful when removing filler caps, breathers
and plugs on the machine. Hold a rag over the
cap or plug to prevent being sprayed or splashed
by liquids under pressure. The danger is even
greater if the machine has just been stopped
because fluids can be hot.
WARNING
The proper and safe lubrication and maintenance for
this machine, recommended by Manufacturer, are
outlined in the OPERATOR’S MANUAL for the
machine.
Improper performance of lubrication or maintenance
procedures are dangerous and could result in injury
or death. Read and understand the MANUAL before
performing any lubrication or maintenance.
WARNING
Do not operate this machine unless you have read
and understand the instructions in the OPERATOR’S
MANUAL. Improper machine operation is dangerous
and could result in injury or death.
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SAFETY
0-V
5-16270 NA Issued 09-2008 Bur
13. Always use the proper tools that are in good
condition and that are suited for the job at hand.
Be sure you understand how to use them before
performing any service work.
14. Install all fasteners with the same part number.
Do not use a lesser quality fastener if
replacements are necessary.
15. Repairs which require welding should be
performed only with the benefit of the appropriate
reference information and by personnel
adequately trained and knowledgeable in
welding procedures. Determine type of metal
being welded and select correct welding
procedure and electrodes, rods or wire to provide
a weld metal strength equivalent at least to that
of the parent metal. Make sure to disconnect
battery before any welding procedures are
attempted.
16. Do not damage wiring during removal
operations. Reinstall the wiring so it is not
damaged nor will be damaged in operation of the
machine by contacting sharp corners, or by
rubbing against some object or hot surface. Do
not connect wiring to a line containing fluid.
17. Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution and replace the guard or
shield after repair is completed.
18. The maintenance and repair work while holding
the bucket raised is dangerous due to the
possibility of a falling attachment. Don’t fail to
lower the attachment and place the bucket to the
ground before starting the work.
19. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Very small (pinhole) leaks can
result in a high velocity oil stream that will be
invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use card-
board or paper to locate pinhole leaks.
20. Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat,
vibration or rubbing against other parts during
operation. Shields that protect against oil spray
onto hot exhaust components in event of a line,
tube or seal failure must be installed correctly.
21. Do not operate a machine if any rotating part is
damaged or contacts any other part during
operation. Any high speed rotating component
that has been damaged or altered should be
checked for balance before reusing.
22. Be careful when servicing or separating the
tracks (crawlers). Chips can fly when removing
or installing a track (crawlers) pin. Wear safety
glasses and long sleeve protective clothing.
Tracks (crawlers) can unroll very quickly when
separated. Keep away from front and rear of
machine. The machine can move unexpectedly
when both tracks (crawlers) are disengaged from
the sprockets. Block the machine to prevent it
from moving.
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0-VI Issued 09-2008 Bur 5-16270 NA
NOTE:
This Manual is prepared as a technical material in
which the information necessary for the maintenance
and repairing services of our hydraulic excavators
are collected, and is categorized into 6 Sections,
Safety and General Information, Maintenance,
System, Disassembly, Troubleshooting, and Engine.
The Section Safety and General information
describes the specifications for entire machine
and material, which are instructive for
replacement and repairing of attachments.
The Section Maintenance describes the material,
which is helpful for maintenance service and
adjustments for entire machine.
The Section System describes the operating
system like hydraulic system, electric system,
components, and so on.
The Section Disassembly describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
The Section Troubleshooting describes how to
find the fault equipment.
The Section Engine describes the engines
making use of the "Service Manual" provided by
the suppliers.
This Manual may be properly revised due to the
improvement of products, modification of
specifications, etc. And there are cases where the
system on actual machine and a part of the contents
of this manual may differ due to the variations of
specification by countries. For the section in which
the description is hardly understood, contact our
distributor.
The number is assigned to every part handled in this
Manual on account of the description, but the parts,
which cannot be supplied as service parts are
contained. Therefore, the order must be placed with
respective formal number with due confirmation on
the Parts Manual for applicable machine.
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SERVICE MANUAL - SECTION 1
SAFETY AND GENERAL
INFORMATION
Issued 09-2008
Book/Form Number 5-16540 EN-US
Copyright © 2008. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PV0020E01
E27BSR
COMPACT CRAWLER EXCAVATOR
TIER 4
Find manuals at https://best-manuals.com

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer
Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 09-2008 E27BSR 5-16540

I
SECTION 1 - SAFETY AND GENERAL INFORMATION
SECTION 1
SAFETY AND GENERAL INFORMATION
SECTION TABLE OF CONTENTS
CHAPTER 1
GENERAL PRECAUTIONS FOR MAKING REPAIRS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
GENERAL PRECAUTIONS FOR MAKING REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
INTERNATIONAL UNIT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
CHAPTER 2
SPECIFICATIONS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CHAPTER 3
ATTACHMENT DIMENSIONS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ATTACHMENT DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
5-16540 EN-US

NOTES
SECTION 1 - SAFETY AND GENERAL INFORMATION
II Issued 09-2008 Bur 5-16540 EN-US

CHAPTER 1
SECTION 1 - SAFETY AND GENERAL INFORMATION
GENERAL PRECAUTIONS FOR
MAKING REPAIRS
Issued 09-2008
Book/Form Number 5-16550 EN-US
Copyright © 2008. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PV0020E01
E27BSR
COMPACT CRAWLER EXCAVATOR
TIER 4

CHAPTER 1 - GENERAL PRECAUTIONS FOR MAKING REPAIRS
SECTION 1 - SAFETY AND GENERAL INFORMATION
1-II Issued 09-2008 Bur 5-16550 EN-US
CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer
Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 09-2008 E27BSR 5-16550

1-1
Issued 09-2008 Bur
SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1
GENERAL PRECAUTIONS FOR MAKING REPAIRS
TABLE OF CONTENTS
GENERAL PRECAUTIONS FOR MAKING REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Preparation Before Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safety When Disassembling And Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Disassembling and Assembling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Removing Hydraulic Equipment Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Disassembling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Inspecting Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Assembling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installing Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hydraulic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Weld Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Environmental Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
INTERNATIONAL UNIT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
5-16550 EN-US

1-2 Issued 09-2008 Bur 5-16550 EN-US
CHAPTER 1 - GENERAL PRECAUTIONS FOR MAKING REPAIRS
SECTION 1 - SAFETY AND GENERAL INFORMATION
NOTES

CHAPTER 1 - GENERAL PRECAUTIONS FOR MAKING REPAIRS
1-3
5-16550 EN-US Issued 09-2008 Bur
SECTION 1 - SAFETY AND GENERAL INFORMATION
GENERAL PRECAUTIONS FOR MAKING REPAIRS
PREPARATION BEFORE DISASSEMBLING
1. Understanding operating procedure
Read OPERATOR’S MANUAL carefully to
understand the operating procedure.
2. Cleaning machines
Remove soil, mud, and dust from the machine
before carrying it into the service shop to prevent
loss of work efficiency, damage of parts, and
difficulty in rust prevention and dust protection
while reassembling.
3. Inspecting machines
Identify the parts to be disassembled before
starting work, determine the disassembling
procedure by yourself considering the workshop
situations etc., and request procurement of
necessary parts in advance.
4. Recording
Record the following items for communication
and prevention of recurring malfunction.
1) Inspection date and place
2) Model name, applicable machine number, and
hour meter read
3) Trouble condition, place and cause.
4) Visible oil leakage, water leakage and damage
5) Clogging of filters, oil level, oil quality, oil
contamination and loosening of connections
6) Result of consideration if any problem exists
based on the operation rate per month
calculated from hour meter indication after
the last inspection date.
5. Arrangement and cleaning in service shop
1) Tools required for repair work.
2) Prepare space to place the disassembled
parts.
3) Prepare oil containers for draining oil etc.
SAFETY WHEN DISASSEMBLING AND
ASSEMBLING
Safety
1. Wear appropriate clothing, safety shoes, safety
helmet, goggles, and clothes with long sleeves.
2. Attach "Don’t operate" tag to control lever, and
begin a meeting before starting the work.
3. Before starting inspection and maintenance stop
the engine to prevent operator from being caught
in machine.
4. 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.
5. Choose a hard, level and safe place, and put
attachment on the ground securely.
6. Use hoist, etc. to remove parts of heavy weight
(20kg [45 pounds] or more).
7. Use proper tools, and replace or repair defective
tools.
8. Support the machine and attachment with
supports or blocks if the work is prtformed in the
lifted condition.
DISASSEMBLING AND ASSEMBLING
HYDRAULIC EQUIPMENT
Removing Hydraulic Equipment Assembly
1. Before disconnecting pipes, release the pressure
of hydraulic oil tank, or open the cover on the
return side to tank, and take out the filter.
2. Drain the oil in the removed pipes into containers
to prevent the oil from spilling on the ground.
3. Appy plugs or caps to pipe ends to prevent oil
leaking, entry of dust, etc.
4. Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil and
gear oil before placing them on working bench.
Disassembling Hydraulic Equipment
1. Do not disassemble , assemble or modify the
hydraulic equipment without the permission of
the manufacturer, who is not responsible for the
performance and functon of the product after
modification.
2. If it is unavoidably necessary to disassemble and
modify, it should be carried out by experts or
personnel qualified through service training.
3. Make match mark on parts for reassembling.
4. Before disassembling, read Disassembling
Instruction in advance, and determine if the
disassembly and assembly are permitted or not.
5. For parts which are required to use jig and tools,
don’t fail to use the specified jig and tools.
6. For parts which can not be removed in the
specified procedure, never force removal. First
check for the cause.
7. The removed parts should be put in order and
tagged so as to install on proper places without
confusion.

1-4 Issued 09-2008 Bur 5-16550 EN-US
CHAPTER 1 - GENERAL PRECAUTIONS FOR MAKING REPAIRS
SECTION 1 - SAFETY AND GENERAL INFORMATION
8. For common parts, pay attention to the quantity
and places.
Inspecting Parts
1. Check that the disassembled parts are free from
adherence, interference and uneven working
face.
2. Measure the wear of parts and clearance, and
record the measured values.
3. If an problem is detected, repair or replace the
parts.
Assembling Hydraulic Equipment
1. During the parts cleaning, ventilate the room.
2. Before assembly, clean parts roughly first, and
then completely.
3. Remove adhering oil by compressed air, and
apply hydraulic oil or gear oil, and then assemble
them.
4. Replace the removed O-ring, backup rings and
oil seal with new ones, and apply grease oil on
them before assembling.
5. Remove dirt and water on the surface on which
liquid sealant are applied, degrease them, and
apply liquid sealant on them.
6. Before assembling, remove rust preventives on
new parts.
7. Use special tools to fit bearings, bushing and oil
seal.
8. Assemble the parts utilizing the matching marks.
9. After completion, check that all the parts are
completely assembled after the work.
Installing Hydraulic Equipment
1. Confirm hydraulic oil and lubrication oil.
2. Air release is required in the following cases ;
A. Change of hydraulic oil
B. Replacement of parts on suction pipe side
C. Removing and attaching hydraulic pump
D. Removing and attaching swing motor
E. Removing and attaching travel motor
F. Removing and attaching hydraulic cylinder
WARNING: If hydraulic oil and lubricating oil are not
filled and also air bleed is not performed, the hydraulic
equipment may be damaged.
3. 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, tighten plug
securely.
4. 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.
NOTE: For cylinder, don’t move it to the stroke end
at beginning.
5. Air in pilot circuit can be bleed out by only
operating digging, swing and traveling motions
thoroughly.
6. Check hydraulic oil level.
Move attachments to hydraulic oil check position,
and check hydraulic oil level of tank. Refill oil if
the oil level is lower than the specified level.
How to check oil level of hydraulic oil tank
GRAPHIC_ID Figure 1
ELECTRICAL EQUIPMENT
1. Do not disassemble the electrical equipment.
2. Handle equipment with care so as not to drop it
or bump it.
3. Turn the key OFF prior to connecting and
disconnecting work.
4. Disconnect the connector by holding it and
pressing the lock. Do not pull the wire to apply
force to the caulking portion.
5. Check that connector is connected and locked
completely.
6. Engine key off before removing and connecting
connector.
7. Turn the key OFF prior to touching the terminal of
starter or generator.
8. Remove battery ground (earth) terminal before
beginning work close to battery and battery relay
with tools.
9. Wash machine with care so as not to splash
water on electrical equipment and connector.
10. Check for moisture adhesion inside the
waterproof connector after pulling it out, since it
is hard to remove moisture from the connector.
If moisture adhesion is found, dry it completely
before the connection..
LEVEL GAUGE
Oil level of hydraulic oil tank.
If the indicator is within
level marks, the oil quantity
is acceptable.
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CHAPTER 1 - GENERAL PRECAUTIONS FOR MAKING REPAIRS
1-5
5-16550 EN-US Issued 09-2008 Bur
SECTION 1 - SAFETY AND GENERAL INFORMATION
HYDRAULIC PARTS
O-ring
Ensure O-rings have elasticity and are not
damaged before use.
Use the appropriate O-rings. O-rings are made of
various kinds of materials having different
hardness to apply to a variety of parts, such as
the part for moving or fixed portion, subjected to
high pressure, and exposed to corrosive fluid,
even if the size is same.
Fit the O-rings without distortion and bend.
Always handle floating seals as a pair.
Flexible hose (F hose)
Even if the connector and length of hose are the
same, the parts differ according to the
withstanding pressure. Use proper parts.
Tighten it to the specified torque, and check that
it is free from twist, over tension, interference,
and oil leak.
WELD REPAIR
1. Refer repair welding to qualified personnel
according to the appropriate procedure.
2. Disconnect the ground (earth) cable of the
battery before starting the repair.
Failure to do so will cause damage to the
electrical equipment.
3. Move away the articles in advance that may
cause fire if exposed to sparks.
4. Before starting the repair of the attachment, do
not fail to cover the plated surface of the piston
rod with flameproof sheet to prevent it from being
exposed to sparks.
ENVIRONMENTAL ISSUES
1. Engine should be started and operated in the
place where air can be sufficiently ventilated.
2. Waste disposal
The following parts follows the regulation.
Waste oil, waste container and battery
3. Precautions for handling hydraulic oil
Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
When it was swallowed ;
Don’t force him to vomit it, but immediately
receive medical treatment.
When it has adhered on skin ;
Wash with soap and water.
4. Others
For spare parts, grease and oil, use
manufacturer’s genuine parts and lubricants.
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.
1. When it has adhered on skin ;
Wash with soap and water.
2. When it has got in eyes ;
Wash in water for 10 minutes or more
immediately.
3. When it has spilled out in large quantity ;
Use sodium bicarbonate to neutralize, or
wash away with water.
4. When it was swallowed ;
Drink milk or water.
5. When it has adhered on clothes ;
Wash it immediately.