New holland e115sr crawler excavator service repair manual

INTRODUCTION

E115SR E135SR WORKSHOP MANUAL ENGLISH Print No. 604.13.426

Edition: 03/2005 English - Printed in Italy Printed by Studio ti - 20005

0-1

INTRODUCTION

AVOID ACCIDENTS Most accidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the failure of some individuals to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs.

Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation.

Carefully read indications, cautions and safety warning quoted in the “SAFETY RULES� section.

A careful operator is the best insurance against an accident.

The complete observance of one simple rule would prevent many thousand serious injuries each year.

That rule is: Never attempt to clean, oil or adjust a machine while it is in motion.

S

ATTENTION

On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/ or repairing.

If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment.

COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION

MACHINERY S.p.A. Product Support - Documentation Centre Strada di Settimo, 323 - 10099 - S. Mauro T.SE (TO) ITALY

All rights reserved. Reproduction of text and illustrations in whole or in part, is strictly prohibited.

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INDEX

INDEX SPECIFICATIONS Section 1 - Outline Section 2 - Specification Section 3 - Attachment dimension

MAINTENANCE Section 11 - Tools Section 12 - Standard maintenance time schedule Section 13 - Maintenance standard and test procedure

SYSTEM Section 21 - Mechatro control system Section 22 - Hydraulic system Section 23 - Electric system Section 24 - Components system Section 25 - Air-conditioner system

DISASSEMBLING Section 31 - Disassembling and assembling Section 32 - Attachment Section 33 - Upper structure Section 34 - Travel system

TROUBLESHOOTING Section 41 - Troubleshooting (mechatro control) Section 42 - Troubleshooting (Hydraulic) Section 43 - Troubleshooting (Electric) Section 44 - Troubleshooting (Engine)

ENGINE Section 51 - Engine

OPT Section 63 - Mounting the breaker and nibbler & breaker

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SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

YY

S

WARNING

5.

YY

The proper and safe lubrication and maintenance for this machine, recommended by Distributor, 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.

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 components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components.

Weight of components table is shown in the section; SPECIFICATIONS.

YY

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 level, hard 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.

0-6

S

WARNING

YY

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.

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 20 kg (45 lbs) 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.

The following is a list of basic precautions that must always be observed.

1.

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.

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

SAFETY PRECAUTIONS Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

greater if the machine has just been stopped because fluids can be hot.

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. Reinstall 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.

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.

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 cardboard 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.

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E115SR E135SR SECTION 1

OUTLINE

TABLE OF CONTENTS 1. General precautions for repairs .............................................................................. 1-1 1.1 Preparation before disassembling ................................................................................................... 1-1 1.2 Safety in disassembling and assembling ......................................................................................... 1-1 1.3 Disassembling and assembling hydraulic equipment ...................................................................... 1-1 1.4 Electrical equipment ....................................................................................................................... 1-2 1.5 Hydraulic parts ................................................................................................................................ 1-3 1.6 Welding repair ................................................................................................................................. 1-3 1.7 Environmental measure ................................................................................................................... 1-3

2. International unit conversion system ...................................................................... 1-4

1. GENERAL PRECAUTIONS FOR REPAIRS 3) Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine.

4) Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency.

5) Choose a hard, level and safe place, and place the attachment on the ground securely.

6) Use a lifter such as a crane to remove heavy parts (23 kg [50 lbs] or more) from the machine.

7) Use proper tools, and replace or repair defective tools.

8) Support the machine and attachment with supports or blocks if the work is performed in the lifted condition.

1.1

PREPARATION BEFORE DISASSEMBLING (1) Understanding operating procedure Read OPERATION & MAINTENANCE 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, if any 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) 1) 2) 3)

Arrangement and cleaning in service shop Tools required for repair work.

Prepare space to place the disassembled parts.

Prepare oil containers for spilling oil etc.

1.2

SAFETY IN DISASSEMBLING AND ASSEMBLING 1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses.

2) Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary meeting before starting work.

1.3

(1) 1)

2) 3) 4)

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT Removing hydraulic equipment Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter.

Carefully drain oil of the removed pipes into a containers without spilling on the floor.

Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion.

Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear oil before placing it on the workbench.

(2) Disassembling hydraulic equipment 1) Do not disassemble, reassemble or modify the hydraulic equipment without the permission of the manufacturer, who is not responsible for the performance and function of the product after reassembling.

2) When disassembling and reassembling for unavoidable reason, refer the work to qualified personnel who have the specific knowledge or completed the parts service training.

3) Provide matching marks to facilitate reassembling work.

4) Before starting the work, read the manual of disassembling procedure, if it is provided, and decide whether the work can be performed by yourself.

5) Use the special jig and tools without fail if they are

1-1

specified.

6) If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause.

7) Place the removed parts in order and attach tags to facilitate the reassembling.

8) Note the location and quantity of parts commonly applied to multiple locations.

(3) Inspecting parts 1) Ensure that the disassembled parts are free from seizure, interference and uneven contact.

2) Measure and record wear condition of parts and clearance.

3) If the problem is found in a part, repair or replace it with a new one.

(4) Reassembling hydraulic equipment 1) Turn ON the ventilation fan or open windows to maintain good ventilation prior to starting the cleaning of parts.

2) Perform rough and finish cleaning before assembling.

3) Remove washing oil by air and apply clean hydraulic or gear oil for assembling.

4) Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease in advance.

5) Remove dirt and moisture from and perform degreasing on the surface where liquid gasket to be applied.

6) Remove rust preventive agent from the new parts before use.

7) Fit bearings, bushings and oil seals using special jigs.

8) Assemble the parts utilizing matching marks.

9) Ensure all the parts are completely assembled after the work.

(5) Installing hydraulic equipment 1) Ensure hydraulic oil and lubricant are properly supplied.

2) Perform air bleeding when: a. Hydraulic oil changed b. Parts of suction side piping replaced c. Hydraulic pump installed d. Slewing motor installed e. Travel motor installed f. Hydraulic cylinder installed

WARNING Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air bleeding will result in damage to the equipment.

3)

4)

Perform air bleeding of the hydraulic pump and slewing motor after loosening the upper drain plug, starting the engine and keep it in low idle condition. Complete the air bleeding when seeping of hydraulic oil is recognized, and tightly plug.

Perform air bleeding of the travel motor and the hydraulic cylinders by running the engine for more than 5 minutes at low speed without load.

WARNING Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance.

5) 6)

Perform air bleeding of pilot line by performing a series of digging, slewing and travel.

Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if necessary.

Checking hydraulic oil level Level gauge

1.4

Oil level lines (Level located between the two lines shows appropriate amount of oil)

ELECTRICAL EQUIPMENT

(1) Do not disassemble electrical equipment.

(2) Handle it carefully not to drop and give a shock.

(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) Connect the connector and ensure it is completely locked.

1-2

(6) Turn the key OFF prior to touching the terminal of starter or generator.

used depending on the working pressure even the size of fitting and the total length of the hose is same.

• Tighten the fitting at the specified torque. Ensure no kink, tension, interference nor oil leakage is recognized.

(7) Remove the ground (earth) terminal of battery when handling tools around the battery or its relay.

(8) Do not splash water on the electrical equipment and connectors during machine washing.

(9) 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.

WARNING Battery electrolyte is hazardous.

Battery electrolyte is dilute sulfuric acid. Exposure of skin or eyes to this liquid will cause burning or loss of eyesight. If the exposure occurs, take the following emergency measures and seek the advice of a medical specialist.

• When skin exposed: Wash with water and soap sufficiently.

• When eyes exposed: Immediately wash away with city water continuously for more than 10 minutes.

• When a large amount of the liquid flows out: Neutralize with sodium bicarbonate or wash away with city water.

• When swallowed: Drink a large amount of milk or water.

• When clothes exposed: Immediately undress and wash.

1.5 HYDRAULIC PARTS 1)

O-ring • 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.

2) Flexible hose (F hose) • Use the appropriate parts. Different parts are

1.6 WELDING 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.

1.7 ENVIRONMENTAL MEASURE (1) Run the engine at the place that is sufficiently ventilated.

(2) Industrial waste disposal Dispose of the following parts according to the relevant regulations: Waste oil and waste container Battery (3) Precautions for handling hydraulic oil Exposure of eyes to hydraulic oil will cause inflammation. Wear protective glasses before handling to avoid an accident. If an eye is exposed to the oil, take the following emergency measures: • When an eye exposed: Immediately wash away with city water sufficiently till stimulative feeling vanishes.

• When swallowed: Do not let vomit, and receive medical treatment immediately.

• When skin exposed: Wash with water and soap sufficiently.

(4) Others Use replacement parts and lubricants authorized as the Distributor genuine parts.

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2.

INTERNATIONAL UNIT CONVERSION SYSTEM (4) Derived Units bearing Peculiar Designations

Introduction Although this manual uses the JIS unit system.

If you need SI unit, refer to following international system of units.

Given hereinunder are an excerpt of the units that are related to this manual : 1. Etymology of SI Units French : Le Système International d’ Unitès English : International System of Units 2. Construction of SI Unit System

Table 2-4 QUANTITIES Frequency Force Pressure, Stress Energy Work, Quantity of heat Power Motive power, Electric power Charge, Quantity of electricity Potential Voltage, Electromotive force Quantity of static electricity Capacitance Electric resistance Celcius temperature Illuminance

Basic units Table 2-1

SI unit system

SI units

Supplementary units Table 2-2

Derived units of basic units Table 2-3

Derived units

Derived units bearing peculiar designations Table 2-4

Prefixes of SI (n-th power of 10, where n is an integral) Table 2- 5

(1) Basic Units Table 2-1 QUANTITIES DESIGNATION Length Meter Mass Kilogram Time Second Current Ampere Thermodynamic Kelvin temperature Gram molecule Mol Luminous intensity Candela (2) Supplementary Units Table 2-2 QUANTITIES DESIGNATION Plane angle Radian Solid angle Steradian

Hertz Newton Pascal

m kg s A K mol cd

SIGN

rad sr

SIGN

J

1J=1Nym

Watt

W

1W=1J/s

Coulomb

C

1C=1A・s

Volt

V

1V=1J/C (1W/A)

Farad

F

1F=1C/V

Ohm

Ω

1Ω=1V/A

Celcius degree or degree lux

℃ X

m2 m3 m/s m/s2 kg/m3

※1

1-4

1. X=1 m/m2

POWER 109 106 103 102 10 10－1 10－2 10－3 10－6 10－9 10－12

(6) Unit Conversion Table Table 2-6 QUANTITIES JIS SI Mass kg kg Force kgf 10N Torque kgfym 10Nym Pressure kgf/cm2 0.1MPa Motive power PS 0.7355kW Revolution rpm min－1

SIGN

DERIVED UNIT

Hz 1Hz=1s-1 N 1N=1kgfym/s2 Pa 1Pa=1N/m2

Joule

(5) Prefixes of SI Table 2-5 PREFIX DESIGNATION SIGN GigaG MegaM Kilok Hectoh Decada Decid Centic Millim Microμ Nanon Picop

SIGN

(3) Derived Units of Basic Units Table 2-3 QUANTITIES DESIGNATION Area Square meter Volume Cubic meter Velocity Meter per second Acceleration Meter per second / second Density Kilogram per cubic meter

DESIGNATION

Units that are allowed to use

REMARKS 9.807N 9.807Nym 0.098MPa r/min

※1

E115SR E135SR SECTION 2

SPECIFICATIONS

TABLE OF CONTENTS 1. Name of components .............................................................................................. 2-1 2. General dimension .................................................................................................. 2-2 2.1 4.6m (15’1”) boom ........................................................................................................................... 2-2 2.2 4.26m (14’) boom ............................................................................................................................ 2-2

3. Weight of components ............................................................................................ 2-3 4. Transportation dimension and weight ..................................................................... 2-4 5. Specifications and performance ........................................................................... 2-12 5.1 Speed and climbing capability ....................................................................................................... 2-12 5.2 Engine ........................................................................................................................................... 2-12 5.3 Hydraulic components ................................................................................................................... 2-12 5.4 Weight ........................................................................................................................................... 2-12

6. Type of crawler ...................................................................................................... 2-14 7. Type of bucket ....................................................................................................... 2-16 8. Combinations of attachment ................................................................................. 2-17 9. Engine specification .............................................................................................. 2-18 9.1 Specifications ................................................................................................................................ 2-18 9.2 Engine characteristic curve (isuzu BB 4BG1T) .............................................................................. 2-20

1.

NAME OF COMPONENTS

2-1

2. GENERAL DIMENSION 2.1 E135SR (LC) 3 4.6m (15′1″) Boom+2.45m (8′) Arm+0.5m (0.65cuyyd) Bucket+600mm (23.6″) Shoe

*Marked dimensions do not include height of shoe lug.

2.2 E135SRL 3 4.6m (15′1″) Boom+2.45m (8′) Arm+0.5m (0.65cuyyd) Bucket+700mm (28″) Shoe

*Marked dimensions do not include height of shoe lug.

2.3 E115SR 3 4.26m (14′) Boom+2.2m (7′3″) Arm+0.45m (0.59cuyyd) Bucket+600mm (23.6″) Shoe

*Marked dimensions do not include height of shoe lug.

2-2

3. WEIGHT OF COMPONENTS Item Machine complete

Model

E135SR 13,700(30,200)

1. Upper frame assy (including the following :) 1.1 Counterweight Counterweight (Add-on) 1.2 Cab 1.3 Engine ※ 1.4 Hydraulic oil tank ※ 1.5 Fuel tank ※ 1.6 Slewing motor (including reduction unit) 1.7 Control valve 1.8 Boom cylinder ※ 1.9 Pin (2pcs. for mounting boom) 1.10 Pump ※ 1.11 Radiator ※ 2. Lower frame assy (including the following :)

7,330(16,160) 3,490(7,690) 600(1,320) 210(460) 368(810) 91(200) 53(116) 110(240) 122(270) 107(235)×2 37(82) 95(210) 77(170) 4,450(9,810)

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

149(330) 144(320)×2 8(18)×2 27(60)×12 70(150)×2 57(125)×2 36(79)×2 30(66) ― 870(1,920)×2 730(1,610)×2 290(640)×2

Slewing bearing Travel motor (including reduction unit) Upper roller Lower roller Front idler Track tension adjuster Sprocket Swivel joint Track link with 700mm (28in) shoes assy Track link with 600mm (24in) shoes assy Track link with 500mm (20in) shoes assy 2.9.1 Track link assy 2.10 Dozer blade (OPT) 2.11 Dozer blade cylinder (OPT) ※ 3. Attachment 3.1 Bucket assy 3.2 Arm assy (including the following :) 3.2.1 Arm 3.2.2 Bucket cylinder ※ 3.2.3 Idler link 3.2.4 Bucket link 3.2.5 Attachement pin 3.3 Boom assy (Including the following :) 3.3.1 Boom 3.3.2 Arm cylinder ※ 3.3.3 Pin (Mounting arm・Mounting arm cylinder) 4. Lubricant and water (including the following :) 4.1 Hydraulic oil 4.2 Engine oil 4.3 Fuel + water NOTE : Numerical values marked ※ indicate the dry weight.

470(1,040) 57(125)×2 1,920(4,230) 380(840) 580(1,280) 374(820) 90(198) 12(26)×2 43(95) 36(79) 940(2,070) 740(1,630) 149(330) 29(64) 310(680) 138(304) 11(24) 139(310) + 18(40) 2-3

E135SRLC [E135SRL] 13,900(30,640) [15,700(34,610)] ← ← ← ← ← ← ← ← ← ← ← ← ← 4,650(10,250) [6,750(14,880)] ← ← 8(18)×4 27(60)×14 ← ← ← ← [1,340 (2,950)]×2 915(2,020)×2 ── 300(660)×2 [465(1,040)]×2 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

Unit : kg (lbs) E115SR 11,900(26,230) 6,080(13,400) 2,340(5,160) ← ← 363(800) ← ← ← 114(251) 84(235)×2 ← ← 65(143) 4,140(9,130) ← ← 8(18)×2 27(60)×12 ← ← ← ← ― 760(1,670)×2 680(1,500)×2 270(590)×2 ← ← 1,680(3,700) 340(750) 490(1,080) 300(660) 87(190) ← 35(77) 24(52) 850(1,870) 680(1,500) 128(280) 27(59) ← ← ← ←

4.

TRANSPORTATION DIMENSION AND WEIGHT

E135SR(LC) E135SRL ● OVERALL DIMENSIONS Model

Item

OF A STD COMPLETE MACHINE ON A TRAILER E135SR

Shoe & Width mm(ft-in)

E135SRLC

600mm (24″) 2,590 (8′6″)

E135SRL 800mm (32″) 2,790 (9′2″)

Weight

kg(lbs)

13,700 (30,200)

13,900 (30,600)

16,000 (35,300) * LC SPEC. ** L SPEC.

● OVERALL

DIMENSIONS OF WITHOUT ARM AND BUCKET Type A : Shoe width

Combination

Without Arm and Bucket

STD LC

mm (ft-in) 600 (24″) 600 (24″)

L : Length H : Height mm (ft-in) mm (ft-in) 6,510 (21′4″) 2,740 (8′12″) 6,590 (21′7″) 2,940 (9′8″)

L

800 (32″)

6,620 (21′9″)

↑

W : Width Weight mm (ft-in) kg (lbs) 2,590 (8′6″) 12,720 (28,000) 2,840 (9′4″) 12,920 (28,500) ↑

14,920 (32,900)

** L SPEC.

● OVERALL

DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET Type A : Shoe width

Combination

Without Arm and Bucket

STD LC

mm (ft-in) 600 (24″) 600 (24″)

L : Length H : Height mm (ft-in) mm (ft-in) 3,570 (11′9″) 2,740 (8′12″) 3,740 (12′3″) 2,940 (9′8″)

L

800 (32″)

3,800 (12′6″)

** L SPEC.

2-4

↑

W : Width Weight mm (ft-in) kg (lbs) 2,590 (8′6″) 11,780 (26,000) 2,840 (9′4″) 11,980 (26,400) ↑

13,980 (30,800)

● OVERALL

DIMENSIONS OF BOOM Type

4.6m (15ft-1in) Boom

Item Length×Height×Width L×H×W

m(ft-in)

4.76×1.39×0.57 (15′7″×4′7″×1′10″)

Weight

kg (lbs)

940 (2,080)

● OVERALL

DIMENSIONS OF ARM+BUCKET Type

3

2.45m (8ft) Arm+0.5m (0.65cu･yd) Bucket

Item Length×Height×Width L×H×W

m(ft-in)

4.36×0.81×1.00 (14′4″×2′8″×3′3″)

Weight

kg (lbs)

970(2,140)

● OVERALL

DIMENSIONS OF ARM Type

2.45m (8ft) Arm

Item Length×Height×Width L×H×W

m(ft-in)

3.20×0.61×0.37 (10′6″×2′×1′3″)

Weight

kg (lbs)

580(1,280)

2-5

● OVERALL

DIMENSIONS OF BUCKET

Type Length× Height×Width L×H×W m (ft-in)

Weight kg (lbs) Bucket capacity 3 m (cu･yd)

Hoe bucket 1.19×1.07×0.70 (3′11×3′6″×2′4″)

1.19×1.07×0.70 (3′11×3′6×2′4″)

1.19×1.07×0.80 (3′11″×3′6″×2′7″)

1.19×1.07×0.90 (3′11″×3′6″×2′11″)

280 (620)

300 (660)

340 (750)

350 (770)

0.24 (0.31)

0.31 (0.41)

0.38 (0.50)

0.45 (0.59)

V-bucket

Slope finishing bucket

Type

Hoe bucket

Length× 1.19×1.07×1.00 1.19×1.07×1.10 1.25×0.65×1.79 Height×Width (3′ 11″ ×3′ 6″ ×3′ 3″ ) (3′ 11″ ×3′ 6″ ×3′ 7″ ) (4′ 1″×2′2″×5′10″) L×H×W m (ft-in)

Weight kg (lbs) Bucket capacity 3 m (cu･yd)

z Hoe bucket

1.01×0.79×1.80 (3′4″×2′7″×5′11″)

380 (840)

400 (880)

290 (640)

550 (1,210)

STD 0.50 (0.65)

0.57 (0.75)

0.46 (0.60)

0.52 (0.68)

z V-bucket

z Slope finishing bucket

2-6

E115SR ● OVERALL

DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER

Width

mm(ft-in)

Weight

● OVERALL

4.26m (14ft) Boom+2.2m (7ft-3in) Arm+ 3 0.45m (0.59cu･yd) Bucket+600mm (23.6in) Shoes

Type

Item

2,590 (8′6″)

kg(lbs)

11,900 (26,230)

DIMENSIONS OF WITHOUT ARM AND BUCKET Type A : Shoe width mm (ft-in)

Combination

L : Length mm (ft-in)

H : Height mm (ft-in)

W : Width mm (ft-in)

Weight kg (lbs)

Without arm and

600 (24″)

6,030 (19′9″)

2,740 (9′)

2,590 (8′6″) 11,070 (24,400)

bucket

500 (20″)

6,030 (19′9″)

2,740 (9′)

2,490 (8′2″) 10,990 (24,200)

● OVERALL

DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET

Combination

Type A : Shoe width mm (ft-in)

L : Length mm (ft-in)

H : Height mm (ft-in)

W : Width mm (ft-in)

Weight kg (lbs)

Without boom, arm

600 (24″)

3,320 (10′11″)

2,740 (9′)

2,590 (8′6″) 10,220 (22,500)

and bucket

500 (20″)

3,320 (10′11″)

2,740 (9′)

2,490 (8′2″) 10,140 (22,400)

2-7

● OVERALL

DIMENSIONS OF BOOM Type

4.26m (14ft) Boom

Item Length×Height×Width L×H×W

m(ft-in)

4.42×1.33×0.57 (14′6″×4′4″×1′10″)

Weight

kg (lbs)

790 (1,740)

● OVERALL

DIMENSIONS OF ARM+BUCKET Type

3

2.2m (7ft-3in) Arm+0.45m (0.59cu･yd) Bucket

Item Length×Height×Width L×H×W

m(ft-in)

4.07×0.79×0.95 (13′4″×2′7″×3′1″)

Weight

kg (lbs)

820(1,810)

● OVERALL

DIMENSIONS OF ARM Type

2.2m (7ft-3in) Arm

Item Length×Height×Width L×H×W

m(ft-in)

2.93×0.59×0.35 (9′7″×1′11″×1′2″)

Weight

kg (lbs)

480(1,060)

2-8

● OVERALL

DIMENSIONS OF BUCKET

Type Length× Height×Width L×H×W m (ft-in)

Weight kg (lbs) Bucket capacity 3 m (cu･yd)

Hoe bucket 1.35×0.60×0.46 (4′5″×2′×1′6″)

1.19×1.03×0.60 (3′11″×3′5″×2′)

210 (460)

260 (570)

280(620)

320 (705)

0.17 (0.22)

0.23 (0.30)

0.30 (0.39)

0.37 (0.48)

V-bucket

Slope finishing bucket

Type Length× Height×Width L×H×W m (ft-in)

Weight kg (lbs) Bucket capacity 3 m (cu･yd) z Hoe bucket

Hoe bucket

1.19×1.03×0.70 1.19×1.03×0.80 (3′11″×3′5″×2′4″) (3′11″×3′5″×2′7″)

1.19×1.03×0.95 (4′5″×2′×3′1″)

1.19×1.03×1.00 (4′5″×2′×3′3″)

350 (770)

370 (820)

280(620)

480(1,060)

STD 0.45(0.59)

0.51(0.67)

0.46(0.60)

0.40 (0.52)

z V-bucket

1.29×0.64×1.81 0.99×0.73×1.60 (4′3″×2′1″×5′11″) (3′3″×2′5″×5′3″)

z Slope finishing bucket

2-9

E135SR L DOZER ● OVERALL DIMENSIONS

● DOZER

OF A COMPLETE MACHINE

SPECIFICATIONS

E135SR L

E135SRLC

R1,630mm (5´4˝ )

R1,730mm (5´8˝ )

Width [600mm (23. 6˝ ) shoe only]

2,590mm (8´6˝ )

2,590mm (8´6˝ )

Height

570mm (1´10˝ )

570mm (1´10˝ )

Weight

470kg (1,040 lb)

480kg (1,060 lb)

2

Length

ITEM (From the center of the arm fixing pin to the tip of the blade)

2

Set Pressure of Main Relief Valve

210kgf/cm (2,990psi)

210kgf/cm (2,990psi)

Set pressure of Overload Relief Valve

280kgf/cm (3,980psi)

2

280kgf/cm (3,980psi)

2-10

2

E115SR ● OVERALL

● DOZER

Length

DIMENSIONS A COMPLETE MACHINE

SPECIFICATIONS

ITEM (From the center of the arm fixing pin to the tip of the blade)

E115SR R1,630mm (5´4˝ )

Width [600mm (23. 6˝ ) shoe only]

2,590mm (8´6˝ )

Height

570mm (1´10˝ )

Weight

455kg (1,000 lb) 2

Set Pressure of Main Relief Valve

210kgf/cm (2,990pis)

Set pressure Of Overload Relief Valve

280kgf/cm (3,980pis)

2

2-11

5. SPECIFICATIONS AND PERFORMANCE E135SR(LC) E135SRL 5.1 SPEED AND GRADEABILITY Model

E135SR(LC), E135SRL

Item Swing speed

11.7rpm km/h (mph)

Travel speed (1-speed/2-speed) Gradeability

2.8 / 5.1 (1.7 / 3.2)

%(degree)

70 (35)

5.2 ENGINE Engine model Type

ISUZU BB－4BG1T Water-cooled, 4-cycle direct injection, turbo charged engine 4－105mm×125mm (4.13in×4.92in)

Number of cylinders－Bore×Stroke Total displacement

4,329cc (264cu･in)

Rated output / Rotation speed

62.5kW (85PS) / 2,050rpm

Maximum torque / Rotation speed

32.4kgf･m (235 lbf･ft) / 1,600rpm

Starter

24V / 4.5kW

Alternator

24V / 50A

5.3 HYDRAULIC COMPONENTS Hydraulic pump

Variable displacement axial piston + gear pump

Hydraulic motor (swing)

Axial piston motor

Hydraulic motor (travel)

2-speed axial piston motor

Control valve

6-spool control valve

Cylinder (Boom, Arm, and Bucket)

Double action cylinder

Oil cooler

Air-cooled type

Unit : kg (lbs)

5.4 WEIGHT E135SR

E135SRLC

E135SRL

Fully equipped weight

13,700 (30,200)

13,900 (30,640)

15,700 (34,610)

Upper structure

7,330 (16,160)

7,330 (16,160)

7,330 (16,160)

4,450 (9,810)

4,650 (10,250)

6,750 (14,880)

Lower machinery Attachment

〔Boom+2.45m(8ft) Arm+0.5m3(0.65cu･yd)Bucket〕

With 600mm (24in) shoe With 600mm (24in) shoe With 700mm (28in) shoe

1,920 (4,230)

2-12

1,920 (4,230)

1,920 (4,230)

E115SR 5.5 SPEED AND CLIMBING CAPABILITY Model Item

E115SR

Swing speed

11.4rpm km/h (mph)

TRAVEL SPEED (1-speed/2-speed)

Gradeability

3.5 / 6.0 (2.2 / 3.7)

%(degree)

70 (35)

5.6 ENGINE Engine model Type

ISUZU BB－4BG1T Water-cooled 4-cycle direct injection turbo charger engine 4－105mm×125mm (4.13in×4.92in)

Number of cylinders－Bore×Stroke Total displacement

4,329cc (264cu･in)

Rated output / Rotation speed

58.8kW (80PS) / 2,050rpm

Maximum torque / Rotation speed

30.0kgf･m (217 lbf･ft) / 1,600rpm

Starter

24V / 4.5kW

Alternator

24V / 30A

5.7 HYDRAULIC COMPONENTS Hydraulic pump

Variable displacement axial piston + gear pump

Hydraulic motor (swing)

Axial piston motor

Hydraulic motor (travel)

2-speed axial piston motor

Control valve

6-spool control valve

Cylinder (Boom, Arm, and Bucket)

Double action cylinder

Oil cooler

Air-cooled type

Unit: kg (lbs)

5.8 WEIGHT E115SR Fully equipped weight

11,900 (26,230)

Upper structure

6,080 (13,400)

Lower machinery

4,140 (9,130) With 600mm (24in) shoe

〔With grouser shoe〕

Attachment

1,680 (3,700)

〔Boom+2.2m(7ft-3in) Arm+0.45m3(0.59cu･yd)Bucket〕

2-13

6. TYPE OF CRAWLER E135SR(LC) E135SRL Shape Grouser shoe

44 links

Shoe width mm (in)

Overall width of crawler mm (ft-in)

Ground pressure 2 kgf /cm (psi)

500 (20)

2,490 (8′2″)

0.43 (6.12)

600 (24)

2,590 (8′6″)

0.36 (5.1)

700 (28)

2,690 (9′0″)

0.32 (4.49)

800 (32)

2,790 (9′2″)

0.30 (4.3)

500 (20)

2,490 (8′2″)

0.44 (6.26)

500 (20)

2,490 (8′2″)

0.43 (6.12)

800 (32)

2,790 (9′2″)

0.28 (3.98)

Rubber pad shoe

44 links Flat shoe

44 links Triangle shoe

44 links

NOTE : Use grouser shoes 500mm (20in) or 600mm (24in) on rough ground (areas covered with rocks and gravel). If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.) damage.

2-14

E115SR Shape Grouser shoe

Shoe width mm (in)

Overall width of crawler mm (ft-in)

Ground pressure 2 kgf /cm (psi)

500 (20)

2,490 (8′2″)

0.41 (5.83)

600 (24)

2,590 (8′6″)

0.34 (4.8)

700 (28)

2,690 (9′0″)

0.31 (4.41)

500 (20)

2,490 (8′2″)

0.43 (6.12)

500 (20)

2,490 (8′2″)

0.42 (5.97)

800 (32)

2,790 (9′2″)

0.27 (3.84)

41 links Rubber pad shoe

41 links Flat shoe

41 links Triangle shoe

41 links

NOTE : Use grouser shoes 500mm (20in) or 600mm (24in) on rough ground (areas covered with rocks and gravel). If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.) damage.

2-15

7.

TYPE OF BUCKET

E135SR L – E135SR LC Hoe bucket

Heaped capacity m3(cu･yd)

0.24(0.31) 0.31(0.41) 0.38(0.50) 0.45(0.59) STD 0.50(0.65) 0.57(0.75) 0.70(0.92)

Struck m3(cu･yd)

0.20 (0.26) 0.23 (0.3) 0.28 (0.37) 0.35 (0.46) 0.38 (0.50) 0.43 (0.56) 0.50 (0.65)

Availability Outer width mm (ft-in) Number of W or W/O of face With side Without side tooth side cutter shovel cutter cutter

600 (2′) 700 (2′4″) 800 (2′7″) 900 (2′11″) 1,000 (3′3″) 1,100 (3′7″) ──

500 (1′8″) 600 (2′) 700 (2′4″) 800 (2′7″) 900 (2′11″) 1,000 (3′3″) 1,150 (3′9″)

3

W

YES

3

W

YES

4

W

YES

4

W

YES

5

W

YES

5

W

YES

5

W/O

YES

Weight kg (lbs)

280 (620) 330 (660) 340 (750) 350 (770) 380 (840) 400 (880) 400 (880)

E115SR Hoe bucket

Heaped capacity m3(cu･yd)

0.17(0.22) 0.23(0.30) 0.30(0.39) 0.37(0.48) STD 0.45(0.59) 0.51(0.67)

Struck m3(cu･yd)

0.13 (0.17) 0.19 (0.25) 0.22 (0.29) 0.27 (0.35) 0.39 (0.51) 0.35 (0.46)

Availability Outer width mm (ft-in) Number of W or W/O of face With side Without side tooth side cutter shovel cutter cutter

── 600 (2′) 700 (2′4″) 800 (2′7″) 950 (3′1″) 1,000 (3′3″)

2-16

450 (1′6″) 500 (1′8″) 600 (2′) 700 (2′4″) 850 (2′9″) 900 (2′11″)

3

W/O

YES

3

W

YES

3

W

YES

4

W

YES

4

W

YES

5

W

YES

Weight kg (lbs)

210 (460) 260 (570) 280 (620) 320 (705) 350 (770) 370 (820)

8.

COMBINATIONS OF ATTACHMENT

E135SR L – E135SR LC Hoe bucket

Heaped capacity m3(cu･yd)

0.24(0.31) 0.31(0.41) 0.38(0.50) 0.45(0.59) STD 0.50(0.65) 0.57(0.75) 0.70(0.929

Struck m3(cu･yd)

Applicable Arm 2.1m (6′11″) Arm

2.45m (8′) Arm

2.95m (9′8″) Arm

○

○

○

○

○

○

○

○

◎

○

○

△

○

◎

×

◎

△

×

△

×

×

1.9m (6′3″) Arm

2.2m (7′3″) Arm

2.7m (8′10″) Arm

○

○

○

○

○

○

○

○

○

○

○

◎

○

◎

△

◎

△

×

0.20 (0.26) 0.23 (0.3) 0.28 (0.37) 0.35 (0.46) 0.38 (0.50) 0.43 (0.56) 0.50 (0.65)

E115SR Hoe bucket

Heaped capacity m3(cu･yd)

0.17(0.22) 0.23(0.30) 0.30(0.39) 0.37(0.48) STD 0.45(0.59) 0.51(0.67)

Struck m3(cu･yd)

Applicable Arm

0.13 (0.17) 0.19 (0.25) 0.22 (0.29) 0.27 (0.35) 0.39 (0.51) 0.35 (0.46)

NOTE : ◎ Standard combination ○ General operation : Excavation or loading of sand, gravel, and clay △ Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel) × Prohibited combination : There are problems from the view points of strength and stability. z Use the attachments recommended by the Dealer. Reinforcement of arm allows to use it as nibbler and breaker.

The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibility z When bucket marked by △ has been attached or nibbler has been attached on long arm, the specified stability may not be obtained. So add weight 600kg (1,320 lbs) in add-on type as required.

If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and bucket may occur.

2-17

9.

ENGINE SPECIFICATION

9.1 SPECIFICATIONS

Model

E135SR

E115SR

ISUZU BB－4BG1T

ISUZU BB－4BG1T

Diesel, 4-cycle water-cooled, in-line, direct injection, turbo charger

Diesel, 4-cycle water-cooled, in-line, direct injection, turbo charger

4×105(4.13)×125(4.92)

←

4,329(264)

←

18.0

←

kW (PS) at rpm

62.5 (85) at 2,050

58.8 (80) at 2,050

kgfym (lbfyft) at rpm

32.4 (235) at 1,600

30.0 (217) at 1,600

Engine model Type Number of cylinder－ Bore×Stroke

mm (in)

Total displacement

cc (cu･in)

Compression ratio Rated out put Maximum torque High idling

rpm

2,310±20

←

Low idling

rpm

1,000±20

←

kgf/cm2(psi)

185(2,630)

←

82 / 95(180 / 203)

←

1－3－4－2

←

31(440) at 200

←

──

──

9°±1°before top dead point

←

Injection valve opening pressure Thermostat action Start/Full open

℃(° F)

Firing order Compression pressure

kgf/cm2 (psi) at rpm

Lubrication oil pressure Fuel injection timing

Valve clearance

Intake valve Exhaust valve

Starter capacity Generator capacity (Alternator)

Dry weight Fuel consumption ratio

Open

Close

0.4mm (0.016″) in cold condition 0.4mm (0.016″) in cold condition

19°before top dead point 57°before bottom dead point

47°after bottom dead point 15°after top dead point

V×kW

24×4.5

←

V×A

24×50

24×30

∅550 (21.7in) suction type 8 fans, V-belt drive, pulley ratio Crank / Fan= 0.89

∅550 (21.7in) suction type 6 fans, V-belt drive, pulley ratio Crank / Fan= 0.98

Max. 13(3.4), Min. 11(2.9)

←

368(811)

←

224±7％ (164±7%)

←

Cooling fan drive method Engine oil quantity (Oil pan only)

Valve clearance

(gal) kg (lbs) g/kW･h (g/PS･h)

Allowable inclination Dimension (L×W×H) Rotating direction

Front / Rear and Right / Left : 35° mm (in)

900×690×865 (34.4in×27.2in×34.1in)

860×670×850 (33.9in×26.4in×33.5in)

Counterclockwise seeing from flywheel side

2-18

E135SR

E135SRLC

E135SRL

9.2 ENGINE CHARACTERISTIC CURVE (ISUZU BB－4BG1T) Condition to be measured : With fan and generator Without muffler and air cleaner 1

313±20.0Nym /About1600min－ 1 (31.9±2.0kgfym /About1600min－ )

(Nym) (kgfym) 330 (33) 310

SHAFT TORQUE 290 (PS) (kW) 80

270

SHAFT OUTPUT

TORQUE

(29) (27)

1

62.5±1.8kW/2050min－ 1 (85±2.5PS/2050min－ )

(100)

(80)

(31) SHAFT

SHAFT OUTPUT

60

(60) 40 (40) 20

1

2350±20min－

(20)

0

(g/kWyh) (g/PSyh) 280 (210) 260 1

224.0±7%/kW yh /2050min－

240 220

FUEL CONSUMPTION RATE 1000

1500

2000 ENGINE SPEED (min－1)

Fuel consumption volume = Fuel consumption rate ×kw×Load factor (α) 0.835×1000 =

224g/kw･h ×62.5kw×α 0.835×1000

(190) FUEL

CONSUMPTION

(170) RATE (150) SFC (130)

200 2500

Fuel consumption volume = Fuel consumption rate ×PS×Load factor 0.835×1000 or (α) 164g/PS･h 0.835×1000 = ×85PS×α

=16.7α･ /h

α：Standard load factor (0.70～0.80) Fuel consumption in regular operation (load factor：0.70～0.80) 11.7～13.4 /h 2-19

E115SR 9.3 ENGINE CHARACTERISTIC CURVE (ISUZU BB－4BG1T) Condition to be measured : With fan and generator Without muffler and air cleaner 1

300±20.0Nym /About1600min－ 1 (30.6±2.0kgfym /About1600min－ )

(Nym) (kgfym) 330 (33) 310

SHAFT TORQUE

290 (PS) (kW) 80

270

SHAFT OUTPUT

TORQUE

(29) (27)

1

58.7±1.8kW/2050min－ 1 (79.8±2.5PS/2050min－ )

(100)

(80)

(31) SHAFT

60

SHAFT OUTPUT

(60) 40 (40) 20 2350±20min－

(20)

1

0

224.0±7%/kW yh /2050min－

(g/kWyh) (g/PSyh) 280 (210)

1

260 240

FUEL CONSUMPTION RATE

1000

1500

2000

ENGINE SPEED

Fuel consumption volume = Fuel consumption rate ×kw×Load factor (α) 0.835×1000 =

224g/kw･h ×58.7kw×α 0.835×1000

220

(190) FUEL

CONSUMPTION

(170) RATE (150) SFC (130)

200 2500

(min－1) Fuel consumption volume = Fuel consumption rate ×PS×Load factor 0.835×1000 or (α) 164g/PS･h 0.835×1000 = ×79.8PS×α

=15.7α･ /h

α：Standard load factor (0.70～0.80) Fuel consumption in regular operation (load factor：0.70～0.80) 11.0～12.6 /h 2-20

E115SR E135SR SECTION 3

ATTACHMENT DIMENSIONS

TABLE OF CONTENTS 1. Boom ...................................................................................................................... 3-1 1.1 Boom dimensional drawing ............................................................................................................. 3-1 1.2 Boom maintenance standard ........................................................................................................... 3-2

2. Arm ......................................................................................................................... 3-4 2.1 Arm dimensional drawing ................................................................................................................ 3-4 2.2 Arm maintenance standard ............................................................................................................. 3-5

3. Bucket ..................................................................................................................... 3-7 3.1 Hoe bucket ...................................................................................................................................... 3-7 3.2 Special bucket ................................................................................................................................. 3-9 3.3 Detail dimensional drawing of lug section ...................................................................................... 3-11 3.4 Detail dimensional drawing of boss section ................................................................................... 3-13

4. Dozer .................................................................................................................... 3-14 4.1 Dozer dimensional drawing ........................................................................................................... 3-14 4.2 Dozer maintenance standard ........................................................................................................ 3-15

1.

BOOM

1.1 BOOM DIMENSIONAL DRAWING I

d3

C

B C H

G C

B

d1

E

F

D

B

A I

J

d2

d4

SECTION

SECTION

BB

Fig. 1-1

CC

Boom dimensional drawing Table 1-1

No.

NAME

A Boom length

Unit : mm (ft-in)

E135SR(LC) E135SRL

E115SR

4,600 (15´1˝ )

4,260 (13´12˝ )

B Boom foot width

574 (1´10.6˝ )

574 (1´10.6˝ )

C Boom end inner width

274 (10.8˝ )

232 (9.13˝ )

D Boom end outer width

386 (1´3.2˝ )

376 (1´2.8˝ )

E Height of boom cylinder rod pin

961 (3´1.8˝ )

919 (3´0.2˝ )

1,084.5 (3´7˝ )

1,037.5 (3´5˝ )

F Height of arm cylinder (head side) pin G Distance between pins of boss

R2,024 (6´8˝ )

R1,960 (6´5˝ )

H Distance between pins of bracket

R2,303 (7´7˝ )

R2,129.5 (6´12˝ )

I Arm cylinder (head side) inner width

108 (4.25˝ )

108 (4.25˝ )

J Outer width of bracket on the arm cylinder (rod side) mounting section

400 (1´3.7˝ )

400 (1´3.7˝ )

d1 Boom foot pin dia.

∅70 (2.76˝ )

∅70 (2.76˝ )

d2 Boom cylinder (rod side) pin dia.

∅80 (3.15˝ )

∅75 (2.95˝ )

d3 Pin dia. of arm end.

∅70 (2.76˝ )

∅70 (2.76˝ )

d4 Arm cylinder (head side) pin dia.

∅70 (2.76˝ )

∅70 (2.76˝ )

3-1

1.2 BOOM MAINTENANCE STANDARD (1) Clearance of pin and bushing on boom section D

B

C

Fig. 1-2

1) E135SR L E135SR LC Sym -bol A

Boom foot

B

Boom cylinder (Head side)

C

Boom cylinder (Rod side)

D

Arm cylinder (Head side)

2) E115SR Sym -bol

Clearance of pin and bushing on boom section

Table 1-2 (1/2) Standard value

Item

A

Boom foot

B

Boom cylinder (Head side)

C

Boom cylinder (Rod side)

D

Arm cylinder (Head side)

Unit : mm (in) Clearance

Bushing Pin Pin dia.

Standard Repairable i.d. dia. tolerance tolerance value level 0 +0.231 +0.291 (0) (+0.0091) (+0.0115) －0.030 +0.160 +0.160 ∅70 (－0.0012) (+0.0063) (+0.0063) +0.030 +0.180 (2.7559) (+0.0012) (+0.0071) 0 +0.070 More than (0) (+0.0028) 1.2 +0.180 +0.030 +0.180 (0.05) (+0.0012) (+0.0071) (+0.0071) ∅80 +0.100 0 +0.070 (3.1496) (+0.0039) (+0.0028) (0) +0.030 +0.180 (+0.0012) (+0.0071) ∅70 0 +0.070 (2.7559) (0) (+0.0028)

Table 1-2 (2/2)

Service Remedy limit

2.0 (0.08)

Replace bushing or pin

Unit : mm (in)

Standard value Item

A

Clearance

Bushing Pin Pin dia.

Standard Repairable i.d. dia. tolerance tolerance value level 0 +0.231 +0.261 (0) (+0.0091) (+0.0103) －0.030 +0.160 +0.160 (－0.0012) (+0.0063) (+0.0063) ∅70 (2.7559) +0.030 +0.180 (+0.0012) (+0.0071) 0 +0.070 More than (0) (+0.0028) 1.2 +0.180 +0.030 +0.180 (0.05) (+0.0012) (+0.0071) (+0.0071) ∅75 +0.100 0 +0.070 (2.9528) (+0.0039) (+0.0028) (0) +0.030 +0.180 (+0.0012) (+0.0071) ∅70 0 +0.070 (2.7559) (0) (+0.0028)

3-2

Service Remedy limit

2.0 (0.08)

Replace bushing or pin

(2) Clearance in thrust direction on the boom cylinder installation section

A

B

C

C

A

B D

L3 X X

D

L3’

L3

L4

4 SECTION

※

DD

3

SECTION X

X

L1

CC X

L2

L2

1 SECTION

2

AA

2 SECTION

Fig. 1-3

BB

Clearance in thrust direction on the boom cylinder installation section

E135SR L EVOLUTION E135SR LC EVOLUTION E115SR EVOLUTION Table 1-3 Unit : mm (in) Shim adjusting clearance Length under Basic size pin neck (Total of both sides) SecItem Remedy tion Sym Standard Repairable Service Size No. Length -bol value level limit A Boom foot B C D

Boom Upper frame

Boom cylinder Boom cylinder (Head side)

Upper frame

Boom cylinder Boom cylinder (Rod side)

Boom

Arm cylinder

Boom cylinder

(Head side)

Boom

L1 L2 L3

574 (22.6)

1.0 (0.04)

1.5 (0.06)

1

716 (28.2)

0.6～1.0 94 (3.70) (0.02～0.04)

2.0 (0.08)

2.5 (0.10)

2

180 (7.09)

80 (3.15)

2.5 (0.10)

3.0 ※ (0.12) 3

597 (23.5)

100 (3.94)

2.0 (0.08)

2.5 (0.10)

212 (8.35)

581 (22.9)

0.6 (0.02) or less

90 (3.54)

0.6～2.0 (0.02～0.08) L3’ 400 (15.7)

L4

0.6～1.0 (0.02～0.04) 108 (4.25)

4

Shim adjustment

However the mark ※ shows the length specified in the figure because it has no neck length.

3-3

2.

ARM

2.1 ARM DIMENSIONAL DRAWING

B

G

E F

D

A

R

Ⅰ

C

B

D2

A POINT B POINT

O

d2

d1 SECTION

AA

N

D4 d4

Q M SECTION

Ⅰ

BB

Arm dimensional drawing Table 2-1

NAME

C Arm length Distance between pins A point D of boss and bracket B point D1 I.D of boss D2 I.D of boss D4 I.D of boss Distance between of boss and E bracket F Distance between of boss and boss Height between pins of boss and G bracket Height between pins A point H of boss and bracket B point J Arm top end width (with bushing) K Boss width

H

P

Fig. 2-1

No.

H

2.95m arm Spec.

d3

VEIW

H

D

L

J K

d5

D1

H

A

E135SR LC E135SR L 2.95m (9´8˝ ) Long

2950 (9´8˝ ) R660 (26.2˝ ) R674 (26.5˝ ) ∅80 (3.15˝ ) ∅75 (2.95˝ ) ∅150 (5.91˝ ) R1820 (5´12˝ ) R350 (13.8˝ ) 456.5 (18.0˝ ) 258.5 (10.3˝ ) 150 (5.91˝ ) 250 (9.84˝ ) 232 (9.13˝ )

E115SR

No.

Unit : mm (ft-in) NAME

STD

STD

2450 (8´ )

2200 (7´3˝ )

R638.5 (25.1˝ )

R626.5 (24.7˝ )

←

∅75 (2.95˝ )

O Bracket inner width

←

←

P Idler link dimension

←

←

←

R1815.5 (5´11˝ )

L Arm link section boss width M Boss width N Bracket inner width

Q Bucket link dimension Height between pins of boss and R center

←

←

d1 Pin dia.

←

442 (17.4˝ )

d2 Pin dia.

246.5 (9.70˝ )

244 (9.61˝ )

← ←

216 (8.50˝ ) 198 (7.80˝ )

d3 Pin dia. d4 Pin dia. d5 Pin dia.

3-4

E135SR LC E135SR L 2.95m (9´8˝ ) Long

244 (9.61˝ 268 (9.37˝ 108 (4.25˝ 98 (3.86˝ 501 (19.7˝ 482 (19.0˝ 20 (0.79˝ ∅65 (2.56˝ ∅60 (2.36˝ ∅70 (2.76˝ ∅70 (2.76˝ ∅60 (2.36˝

) ) ) ) ) ) ) ) ) ) ) )

STD

← ← ← ← ← ← ← ←

E115SR STD 210 (8.27˝ 226 (8.90˝ 108 (4.25˝ 98 (3.86˝

) ) ) )

← 468 (18.4˝ ) 15 (0.59˝ ) ∅60 (2.36˝ )

←

←

←

←

←

←

←

←

2.2 ARM MAINTENANCE STANDARD (1) Clearance of pin and bushing

E

D,D’

B

F

A

C Fig. 2-2 1) E135SR L E135SR LC Sym -bol

Item

A Arm point Bucket link

B (Bucket connection)

Pin dia.

G Clearance of pin and bushing on arm section

Table 2-2 (1/2) Standard value Pin dia. tolerance

(2.5591)

－0.020 (－0.0008) －0.080 (－0.0031)

∅60

0 (0) －0.060 (－0.0024)

∅65

Idler link C (Arm connection) Bucket link D (Idler link connection)

Bushing i.d. tolerance ＋0.228 (＋0.0090) ＋0.168 (＋0.0066) ＋0.234 (＋0.0092) ＋0.171 (＋0.0067) ＋0.246 (＋0.0097) ＋0.187 (＋0.0073) ＋0.236 (＋0.0093) ＋0.180 (＋0.0071)

Bucket cylinder (2.3622) D’ (Rod side) Bucket cylinder E (Bottom side) Arm cylinder F (Rod side) G Arm foot

＋0.030 (＋0.0012) 0 (0)

∅70 (2.7559)

2) E115SR Sym -bol

Item

Pin dia.

＋0.231 (＋0.0091) ＋0.160 (＋0.0063)

Pin dia. tolerance －0.020 (－0.0008) －0.080 (－0.0031)

Bucket link B (Bucket connection) ∅60 (2.3622)

connection)

0 (0) －0.060 (－0.0024)

Bushing i.d. tolerance ＋0.228 (＋0.0090) ＋0.168 (＋0.0066) ＋0.234 (＋0.0092) ＋0.171 (＋0.0067) ＋0.246 (＋0.0097) ＋0.187 (＋0.0073) ＋0.236 (＋0.0093) ＋0.180 (＋0.0071)

Bucket cylinder D’ (Rod side) Bucket cylinder E (Bottom side) Arm cylinder F (Rod side) G Arm foot

Standard Repairable Service Remedy level value limit ＋0.308 (＋0.0121) ＋0.188 (＋0.0074) ＋0.314 (＋0.1236) ＋0.191 (＋0.0075) ＋0.306 (＋0.0120) ＋0.187 (＋0.0073) ＋0.296 (＋0.0117) ＋0.180 (＋0.0071) ＋0.240 (＋0.0094) ＋0.100 (＋0.0039)

＋0.030 (＋0.0012) 0 (0)

∅70 (2.7559)

±0.020 (±0.0008)

＋0.180 (＋0.0071) ＋0.100 (＋0.0039)

＋0.231 (＋0.0091) ＋0.160 (＋0.0063)

1.2 (0.45)

2.0 (0.08)

Replace bushing or pin

＋0.180 (＋0.0071) ＋0.070 (＋0.0028) ＋0.251 (＋0.0099) ＋0.140 (＋0.0055)

Table 2-2 (2/2) Standard value

A Arm point

Idler link C (Arm connection) Bucket link D (Idler link

±0.020 (±0.0008)

＋0.180 (＋0.0071) ＋0.100 (＋0.0039)

Unit : mm (in) Clearance

Unit : mm (in) Clearance

Standard Repairable Service Remedy level value limit ＋0.288 (＋0.0113) ＋0.188 (＋0.0074) ＋0.294 (＋0.0116) ＋0.191 (＋0.0075) ＋0.306 (＋0.0120) ＋0.187 (＋0.0073) ＋0.296 (＋0.0117) ＋0.180 (＋0.0071) ＋0.240 (＋0.0094) ＋0.100 (＋0.0039) ＋0.180 (＋0.0071) ＋0.070 (＋0.0028) ＋0.251 (＋0.0099 ＋0.140 (＋0.0055)

3-5

1.2 (0.45)

2.0 (0.08)

Replace bushing or pin

(2) Clearance of arm and cylinder installing sections in thrust direction D D’ C B

E F E

B

A

F

C

A

G X3

L1

1 AA

SECTION

X4’ L4’ 4

2 BB

Fig. 2-3

C

D

E F G

SECTION

Item

X7

FF

L7 7

SECTION

DD, D’ D’

GG

Arm Bucket

Table 2-3 Shim adjusting clearance Basic size (Total of both sides) No. L1

Link side Bucket link L2 Bucket Arm Idler link L3 (Arm connection) Link side Bucket link side Link L4 connection Idler link side Bucket Rod side cyinder L4’ connection Bucket link side Bucket Bottom side cylinder L5 Arm (Bottom side) Arm cylinder Rod side L6 (Rod side) Arm Arm foot

SECTION

Clearance of arm and cylinder installing sections in thrust direction

Bucket link

B

EE

Arm Boom

L7 L7’

E135SR

E115SR

250 (9.84) 251 (9.88) 250 (9.84) 252 (9.92) 244 (9.61)

216 (8.50) 218 (8.58) 216 (8.50) 218 (8.58) 210 (8.27)

― 2.44 (9.61)

― 226 (8.90)

― 90 (3.54) 98 (3.86) 90 (3.54) 98 (3.86) 100 (3.94) 108 (4.25) 268 (10.6) 274 (10.8)

― ←

Standard value

Repairable Service level limit

0.6～1.0 (0.02～0.0 4)

1.2 (0.05)

0.5 (0.02) or less

1.0 (0.04)

0.6～1.0 (0.02～0.0 4)

1.2 (0.05)

Unit : mm (in) Length under pin neck No.

E135SR

E115SR

※391 (15.4)

※351 (13.8)

※328 (12.9)

※310 (12.2)

5

※196 (7.72)

※184 (7.24)

6

※212 (8.35)

←

7

※386 (15.2)

←

1 2 2.0 (0.08)

3

4

← ← ← ←

0.6～2.0 (0.02～0.0 8)

2.0 (0.08)

0.5 (0.02) or less

1.0 (0.04)

2.5 (0.10)

← 226 (8.90) 232 (9.13)

2.0 (0.08)

Note : The mark ※ shows the length from the under head to the center of pin hole.

3-6

Remedy

SECTION

Arm point

SECTION

CC

L4

X4

L2

Section

6 X6 L6

3

SECTION X2

5 X5 L5

L3

Shim adjustment

X1

A

G

D D’

3.

BUCKET

3.1 HOE BUCKET (1) Hoe bucket dimensional drawing G

E d2

D

A d1 I H F

B

I0

Bushing out dia.

C Fig. 3-1

Hoe bucket dimensional drawing Table 3-1

No. A B C D E F

NAME Distance between pin and bracket Distance between bucket pin and tooth end Inner width of bucket top end Inner width of lug Inner width of bracket Outer width of side cutter

No. G H I I0 d1 d2

NAME Outer width of bucket bottom Bucket outer width of front side Pitch between teeth Pitch between teeth Outer width of bushing Pin dia.

(2) Hoe bucket dimensional table 1) E135SR L E135SR LC

Table 3-2 (1/2)

Type

Hoe bucket 〔 STD〕

Capacity

A B

Unit : mm (ft-in)

0.50m3 (0.65cuyyd) 370 (14.6˝ ) R1,225 (4´ )

0.24m3 (0.31cuyyd)

0.31m3 (0.41cuyyd)

0.38m3 (0.50cuyyd)

0.45m3 (0.59cuyyd)

0.57m3 (0.75cuyyd)

0.70m3 (0.92cuyyd)

←

←

←

←

←

←

←

←

←

←

←

←

C

862 (33.9˝ )

D

324 (12.8˝ )

←

←

←

←

←

←

E

252 (9.92˝ )

←

←

←

←

←

←

F

1,000 (3´3˝ )

462 (18.2˝ )

562 (22.1˝ )

662 (26.1˝ )

772 (30.4˝ )

962 (37.9˝ )

593 (23.3˝ )

700 (27.6˝ )

800 (31.5˝ )

910 (35.8˝ ) 1,100 (3´7˝ )

1,112 (3´8˝ )

―

G

739 (29.1˝ )

383 (15.1˝ )

439 (17.3˝ )

539 (21.2˝ )

649 (25.6˝ )

H

900 (35.4˝ )

500 (19.7˝ )

600 (23.6˝ )

700 (27.6˝ )

810 (31.9˝ ) 1,000 (3´3˝ )

I

193.5 (7.62˝ )

187 (7.36˝ )

237 (9.33˝ )

191 (7.52˝ )

228 (8.98˝ )

218.5 (8.60˝ )

256 (10.1˝ )

I0

193.5 (7.62˝ )

187 (7.36˝ )

237 (9.33˝ )

191 (7.52˝ )

228 (8.98˝ )

218.5 (8.60˝ )

256 (10.1˝ )

839 (33.0˝ )

989 (38.9˝ ) 1,150 (3´9˝ )

d1

∅80 (3.15˝ )

←

←

←

←

←

←

d2

∅65 (2.56˝ )

←

←

←

←

←

←

3-7

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